JUNE - JULY

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2017

Summer Training Report – NTPC Faridabad

SUBMITTED BY:

………………………
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INDEX

1. Acknowledgements
2. About the company
a. Evolution of NTPC
b. NTPC group
c. Installed Capacity
d. NTPC Strategies
e. NTPC Faridabad
f. International Cell
g. NTPC Operations
3. Gas to Electricity Conversion
4. Automation and Control
a. Control and Monitoring Mechanisms
b. Pressure Control
c. Temperature Control
d. Flow Control
e. Control Valves
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ACKNOWLEDGEMENTS

I would firstly wish to thank Mrs. ……………………………. for allowing me to

undergo summer training at NTPC Faridabad , all of the HR team of the Institute

for their continued guidance. I would also wish to convey my warm regards to Mr.

……….. and Mr. …………….. for providing me with all the knowledge database

that I needed for this report.

I would also like to thank Mr. ……………… , TPO – …………………….

…………, for providing me this wonderful opportunity to work with the NTPC

family
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ABOUT THE COMPANY

Corporate Vision:
“A world class integrated power major, powering India’s growth, with increasing global
presence”

Core Values:

B-Business Ethics
C-Customer Focus
O-Organizational & Professional pride
M-Mutual Respect and Trust
I- Innovation & Speed
T-Total quality for Excellence

NTPC Limited is the largest thermal power generating company of India. A public sector
company, it was incorporated in the year 1975 to accelerate power development in the country as
a wholly owned company of the Government of India. At present, Government of India holds
89.5% of the total equity shares of the company and the balance 10.5% is held by FIIs, Domestic
Banks, Public and others. Within a span of 31 years, NTPC has emerged as a truly national
power company, with power generating facilities in all the major regions of the country.
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NTPC’s core business is engineering, construction and operation of power generating plants. It
also provides consultancy in the area of power plant constructions and power generation to
companies in India and abroad. As on date the installed capacity of NTPC is 27,904 MW through
its 15 coal based (22,895 MW), 7 gas based (3,955 MW) and 4 Joint Venture Projects (1,054
MW). NTPC acquired 50% equity of the SAIL Power Supply Corporation Ltd. (SPSCL). This
JV company operates the captive power plants of Durgapur (120 MW), Rourkela (120 MW) and
Bhilai (74 MW). NTPC also has 28.33% stake in Ratnagiri Gas & Power Private Limited
(RGPPL) a joint venture company between NTPC, GAIL, Indian Financial Institutions and
Maharashtra SEB Holding Co. Ltd.

NTPC’s share on 31 Mar 2007 in the total installed capacity of the country was 20.18% and it
contributed 28.50% of the total power generation of the country during 2006-07.
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EVOLUTION OF NTPC

NTPC was set up in 1975 with 100% ownership by the Government of

1975 India. In the last 30 years, NTPC has grown into the largest power
utility in India.

In 1997, Government of India granted NTPC status of “Navratna’ being

1997 one of the nine jewels of India, enhancing the powers to the Board of
Directors.

NTPC became a listed company with majority Government ownership

of 89.5%.
2004
NTPC becomes third largest by Market Capitalisation of listed
companies

The company rechristened as NTPC Limited in line with its changing

2005 business portfolio and transform itself from a thermal power utility to
an integrated power utility.

NTPC is the largest power utility in India, accounting for about 20% of
India’s installed capacity.
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NTPC GROUP

NTPC Limited

Subsidiaries

NTPC Vidyut Vyapar NTPC Electric Supply Pipavav Power NTPC Hydro
Nigam Limited Co. Limited Development Co. Ltd Limited
100% 100% 100% 100%

Joint Ventures

NTPC-SAIL Power Bhilai Electric Supply NTPC Alstom Power Utility Powertech
Company Pvt. Limited Co. Pvt. Limited Services Pvt. Limited Limited
50% 50% 50% 50%

NTPC Tamilnadu PTC India Limited Ratnagiri Gas &

Energy Co. Limited 8% Power Private Ltd
50% 28.33%
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INSTALLED CAPACITY

AN OVERVIEW

Commissioned
Projects No. of Projects Capacity
(MW)
NTPC OWNED
COAL 15 22,895
GAS/LIQ. FUEL 07 3,955
TOTAL 22 26,850
OWNED BY JVCs
Coal 3 314*
Gas/LIQ. FUEL 1 740**
GRAND TOTAL 26 27,904
* Captive Power Plant under JVs with SAIL
** Power Plant under JV with GAIL, FIs & MSEB

PROJECT PROFILE
Coal Based Power Stations

Commissioned
Coal based State Capacity
(MW)
1. Singrauli Uttar Pradesh 2,000
2. Korba Chattisgarh 2,100
3. Ramagundam Andhra Pradesh 2,600
4. Farakka West Bengal 1,600
5. Vindhyachal Madhya Pradesh 3,260
6. Rihand Uttar Pradesh 2,000
7. Kahalgaon Bihar 1,340
8. NTCPP Uttar Pradesh 840
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9. Talcher Kaniha Orissa 3,000
10. Unchahar Uttar Pradesh 1,050
11. Talcher Thermal Orissa 460
12. Simhadri Andhra Pradesh 1,000
13. Tanda Uttar Pradesh 440
14. Badarpur Delhi 705
15. Sipat Chattisgarh 500
Total (Coal) 22,895

Gas/Liq. Fuel Based Power Stations

Commissioned
Gas based State Capacity
(MW)
16. Anta Rajasthan 413
17. Auraiya Uttar Pradesh 652
18. Kawas Gujarat 645
19. Dadri Uttar Pradesh 817
20. Jhanor-Gandhar Gujarat 648
Rajiv Gandhi CCPP
21. Kerala 350
Kayamkulam
22. Faridabad Haryana 430
Total (Gas) 3,955

Power Plants with Joint Ventures

Commissioned
Coal Based State Fuel Capacity
(MW)
23. Durgapur West Bengal Coal 120
24. Rourkela Orissa Coal 120
25. Bhilai Chhattisgarh Coal 74
26. RGPPL Maharastra Naptha/LNG 740
Total(JV) 1054
Grand Total (Coal + Gas + JV) 27,904
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Projects Under Implementation

Additional
Capacity Under
Coal / Hydro State Fuel
Implementation
(MW)
Kahalgaon
500
1. Stage II (Phase I) (Phase Bihar Coal
500
II)
1980
2. Sipat (Stage I) (Stage II) Chhattisgarh Coal
500
3. Barh Bihar Coal 1980

Bhilai (Exp. Power

4. Chhattisgarh Coal 500
Project-JV with SAIL)

5. Korba (Stage III) Chhattisgarh Coal 500

6. Farakka (Stage III) West Bengal Coal 500

7. NCTPP (Stage II) Uttar Pradesh Coal 980

Andhra
8. Simhadri (Stage II) Coal 1000
Pradesh
Himachal
9. Koldam (HEPP) Hydro 800
Pradesh

10. Loharinag Pala (HEPP) Uttarakhand Hydro 600

Tapovan Vishnugad
11. Uttarakhand Hydro 520
(HEPP)
Total (Coal + Hydro) 10,860
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NTPC STRATEGIES

Sustainable
Development

Maintain
Nurturing sector
Human Leadership
Resource position
through

STRATEGIES
- NTPC

Technology Further
initiatives enhance
fuel security

Exploit new
business
opportunities

Technological Initiatives

 Introduction of steam generators (boilers) of the size of 800 MW

 Integrated Gasification Combined Cycle (IGCC) Technology
 Launch of Energy Technology Center -A new initiative for development of
technologies with focus on fundamental R&D
 The company sets aside upto 0.5% of the profits for R&D
 Roadmap developed for adopting ‘Clean Development
 Mechanism’ to help get / earn ‘Certified Emission Reduction
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Corporate Social Responsibility

 As a responsible corporate citizen NTPC has taken up number of CSR initiatives

 NTPC Foundation formed to address Social issues at national level
 NTPC has framed Corporate Social Responsibility Guidelines committing up to
0.5% of net profit annually for Community Welfare Measures on perennial basis
 The welfare of project affected persons and the local population around NTPC
projects are taken care of through well drawn Rehabilitation and Resettlement
policies
 The company has also taken up distributed generation for remote rural areas

NTPC Faridabad has been doing development work in the nearby villages of Mujedi
under the guidance of Mrs. Manjula Sengupta with an annual budget of Rs Ten lacs.

Environment Management

 All stations of NTPC are ISO 14001 certified

 Various groups to care of environmental issues
 The Environment Management Group
 Ash Utilisation Division
 Afforestation Group
 Centre for Power Efficiency & Environment Protection
 Group on Clean Development Mechanism

NTPC is the second largest owner of trees in the country after the Forest department

Partnering government in various initiatives

 Consultant role to modernize and improvise several plants across the country
 Disseminate technologies to other players in the sector
 Consultant role “Partnership in Excellence” Programme for improvement of PLF of
15 Power Stations of SEBs.
 Rural Electrification work under Rajiv Gandhi Grameen Vidyutikaran Yojana
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NTPC FARIDABAD PLANT

Location Village – Mujedi,P.O. Neemka,Dist.

Faridabad,Haryana
Govt. approved date 25.07.1997

Plant Capacity 430MW (Nominal)

Plant Configuration 2(GT)+1ST

GT-143 MW, ST-144MW

Land Availability Available

Fuel Used Gas and Naptha

Gas Source HBJ Pipeline

Water Source Rampur distributories of Gurgaon canal

Financing OECF, Japan

Project Cost Rs.1163.60 Cr. (IV Qtr.96)

Beneficiary States Haryana (100%)

Commissioning Date GT-I : June 1999

GT-II : October 1999
ST : July 2000

International Assistance OECF

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NTPC INTERNATIONAL CELL

Keeping its proactive tradition, NTPC launched a separate International Cell to meet the varied
needs of IPPs ( Independent Power Producers) and other International clients who are looking for
a world class service in power sector. The Cell is especially tuned to meet the requirements of
International clients in terms of quick response, flexible service options and to deliver value for
money.

Pursuing Business Opportunities in:

• Sri Lanka
• Saudi Arabia
• UAE
• Iran
• Jordan
• Bahrain
• Egypt
• Malaysia
• Indonesia
• Vietnam
• Thailand
• Sudan
• Nigeria
• Yemen
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NTPC OPERATIONS
The operating performance of NTPC has been
considerably above the national average. The
availability factor for coal stations has increased
from 85.03 % in 1997-98 to 90.09 % in 2006-07,
which compares favourably with international
standards. The PLF has increased from 75.2% in
1997-98 to 89.4% during the year 2006-07 which is
the highest since the inception of NTPC.

It may be seen from the table below that while the installed capacity has increased by 56.40% in
the last nine years, the employee strength went up by only 3.34%

1997-
Description Unit 2006-07 % of increase
98
Installed Capacity MW 16,847 26,350 56.40
Generation MUs 97,609 1,88,674 93.29
No. of employees No. 23,585 24,375 3.34
Generation/employee MUs 4.14 7.74 86.95
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ECOLOGICAL MONITORING PROGRAMME

NTPC has undertaken a comprehensive Ecological Monitoring Programme through Satellite

Imagery Studies covering an area of about 25 Kms radius around some of its major plants. The
studies have been conducted through National Remote Sensing Agency (NRSA), Hyderabad at
its power stations at Ramagundam, Farakka, Korba, Vindhyachal, Rihand and Singrauli. These
studies have revealed significant environmental gains in the vicinity areas of the project as a
result of pursuing sound environment management practices. Some of these important gains
which have been noticed are increase in dense forest area, increase in agriculture area, increase
in average rainfall, decrease in waste land etc. In general, the studies, as such, have revealed that
there is no significant adverse impact on the ecology due to the project activities in any of these
stations. Such studies conducted from time to time around a power project have established
comprehensive environment status at various post operational stages of the project.

USE OF WASTE PRODUCTS & SERVICES -ASH

UTILIZATION

Ash is the main solid waste which is put into use for various products and services. NTPC has
adopted user friendly policy guidelines on ash utilisation.
In order to motivate entrepreneurs to come forward with ash utilisation schemes, NTPC offers
several facilities and incentives. These include free issue of all types of ash viz. Dry Fly Ash /
Pond Ash / Bottom Ash and infrastructure facilities, wherever feasible. Necessary help and
assistance is also offered to facilitate procurement of land, supply of electricity etc from
Government Authorities. Necessary techno-managerial assistance is given wherever considered
necessary. Besides, NTPC uses only ash based bricks and Fly Ash portland pozzolana cement
(FAPPC) in most of its construction activities. Demonstration projects are taken up in areas of
Agriculture, Building materials, Mine filling etc. The utilisation of ash and ash based products is
progressively increasing as a result of the concrete efforts of these groups.
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LINE DIAGRAM SHOWING GAS TO ELECTRICITY

CONVERSION AT FARIDABAD GAS POWER PLANT

NTPC Faridabad has Two Gas Turbines manufactured by Seimens and One Steam
Turbine from BHEL
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AUTOMATION AND CONTROL SYSTEM

AUTOMATION: THE DEFINITION

The word automation is widely used today in relation to various types of applications, such as
office automation, plant or process automation.

This subsection presents the application of a control system for the automation of a process /
plant, such as a power station. In this last application, the automation actively controls the plant
during the three main phases of operation: plant start-up, power generation in stable or put
During plant start-up and shut-down, sequence controllers as well as long range modulating
controllers in or out of operation every piece of the plant, at the correct time and in coordinated
modes, taking into account safety as well as overstressing limits.

During stable generation of power, the modulating portion of the automation system keeps the
actual generated power value within the limits of the desired load demand.

During major load changes, the automation system automatically redefines new set points and
switches ON or OFF process pieces, to automatically bring the individual processes in an
optimally coordinated way to the new desired load demand. This load transfer is executed
according to pre- programmed adaptively controlled load gradients and in a safe way.
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AUTOMATION: THE BENEFITS

The main benefits of plant automation are to increase overall plant availability and efficiency.
The increase of these two factors is achieved through a series of features summarized as follows:

 Optimisation of house load consumption during plant start- up, shut-down

and operation, via:

 Faster plant start-up through elimination of control errors creating delays.

 Faster sequence of control actions compared to manual ones. Figures 1 shows the
sequence of a rapid restart using automation for a typical coal-fired station. Even a
well- trained operator crew would probably not be able to bring the plant to full load
in the same time without considerable risks.
 Co-ordination of house load to the generated power output.

 Ensure and maintain plant operation, even in case of disturbances in the

control system, via:

 Coordinated ON / OFF and modulating control switchover capability from a sub

process to a redundant one.
 Prevent sub-process and process tripping chain reaction following a process
component trip.

 Reduce plant / process shutdown time for repair and maintenance as well
as repair costs, via:

 Protection of individual process components against overstress (in a stable or unstable

plant operation).
 Bringing processes in a safe stage of operation, where process components are
protected against overstress
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PROCESS STRUCTURE

Analysis of processes in Power Stations and Industry advocates the advisability of dividing the
complex overall process into individual sub-processes having distinctly defined functions. This
division of the process in clearly defined groups, termed as FUNCTIONAL GROUPS, results in
a hierarchical process structure. While the hierarchical structure is governed in the horizontal
direction by the number of drives (motorised valves, fans, dampers, pumps, etc.) in other words
the size of the process; in the vertical direction, there is a distinction made between three
fundamental levels, these being the: -

 Drive Level
 Function Group Level
 Unit Level.

To the Drive Level, the lowest level, belong the individual process equipment and associated
electrical drives.

The Function Group is that part of the process that fulfils a particular defined task e.g., Induced
Draft Control, Feed Water Control, Blooming Mill Control, etc. Thus at the time of planning it is
necessary to identify each function group in a clear manner by assigning it to a particular process
activity. Each function group contains a combination of its associated individual equipment
drives. The drive levels are subordinate to this level. The function groups are combined to obtain
the overall process control function at the Unit Level.

The above three levels are defined with regard to the process and not from the control point of
view.
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CONTROL SYSTEM STRUCTURE

The primary requirement to be fulfilled by any control system architecture is that it be capable of
being organized and implemented on true process-oriented lines. In other words, the control
system structure should map on to the hierarchy process structure.

BHEL’s PROCONTROL P®, a microprocessor based intelligent remote multiplexing system,

meets this requirement completely.

SYSTEM OVERVIEW

The control and automation system used here is a micro based intelligent multiplexing system
This system, designed on a modular basis, allows to tighten the scope of control hardware to the
particular control strategy and operating requirements of the process

Regardless of the type and extent of process to control provides system uniformity and integrity
for:

 Signal conditioning and transmission

 Modulating controls
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CONTROL AND MONITORING MECHANISMS

There are basically two types of Problems faced in a Power Plant

 Metallurgical
 Mechanical

Mechanical Problemcan be related to Turbines that is the max speed permissible for a turbine is
3000 rpm , so speed should be monitored and maintained at that level
Metallurgical Problem can be view as the max Inlet Temperature for Turbile is 1060 oC so
temperature should be below the limit.

Monitoring of all the parameters is necessary for the safety of both:

 Employees
 Machines

So the Parameters to be monitored are :

 Speed
 Temperature
 Current
 Voltage
 Pressure
 Eccentricity
 Flow of Gases
 Vaccum Pressure
 Valves
 Level
 Vibration
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PRESSURE MONITORING
Pressure can be monitored by three types of basic mechanisms

 Switches
 Gauges
 Transmitter type

For gauges we use Bourden tubes : The Bourdon Tube is a non liquid pressure measurement
device. It is widely used in applications where inexpensive static pressure measurements are
needed.

A typical Bourdon tube contains a curved tube that is open to external pressure input on one end
and is coupled mechanically to an indicating needle on the other end, as shown schematically
below.

Typical Bourdon Tube Pressure Gages

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Transmitter types use transducers (electrical to electrical normally) they are used where
continuous monitoring is required
Normally capacitive transducers are used

For Switches pressure swithes are used and they can be used for digital means of monitoring as
swith being ON is referred as high and being OFF is as low.

All the monitored data is converted to either Current or Voltage parameter.

The Plant standard for current and voltage are as under

 Voltage : 0 – 10 Volts range

 Current : 4 – 20 milliAmperes

We use 4mA as the lower value so as to check for disturbances and wire breaks.

Accuracy of such systems is very high .

ACCURACY : + - 0.1 %
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The whole system used is SCADA based

ANALOG INPUT MICRO

INPUT 4-20 mA
MODULE PROCESSOR

ALARM

We use DDCMIC control for this process.

Programmable Logic Circuits ( PLCs) are used in the process as they are the heardt of
Instrumentation .

Pressure
Electricity Start
HL switch
Level low AND
Pressure in line Level High
LL switch
High level
pump Electricity Stop
Pressure OR

Electricity

BASIC PRESSURE CONTROL MECHANISM

Hence PLC selection depends upon the Criticality of the Process

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TEMPERATURE MONITORING
We can use Thernocouples or RTDs for temperature monitoring
Normally RTDs are used for low temperatures.

Thermocoupkle selection depends upon two factors:

 Temperature Range
 Accuracy Required

Normally used Thermocouple is K Type Thermocouple:

Chromel (Nickel-Chromium Alloy) / Alumel (Nickel-Aluminium Alloy)

This is the most commonly used general purpose thermocouple. It is inexpensive and, owing
to its popularity, available in a wide variety of probes. They are available in the −200 °C to
+1200 °C range. Sensitivity is approximately 41 µV/°C.

RTDs are also used but not in protection systems due to vibrational errors.

We pass a constant curre t through the RTD. So that if R changes then the Voltage also changes

RTDs used in Industries are Pt100 and Pt1000

Pt100 : 0 0C – 100 Ω ( 1 Ω = 2.5 0C )

Pt1000 : 0 0C - 1000Ω
Pt1000 is used for higher accuracy

The gauges used for Temperature measurements are mercury filled Temperature gauges.

For Analog medium thermocouples are used

And for Digital medium Switches are used which are basically mercury switches.
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FLOW MEASUREMENT

Flow measurement does not signify much and is measured just for metering purposes and for
monitoring the processes

ROTAMETERS:
A Rotameter is a device that measures the flow rate of liquid or gas in a closed tube. It is
occasionally misspelled as 'rotometer'.

It belongs to a class of meters called variable area meters, which measure flow rate by allowing
the cross sectional area the fluid travels through to vary, causing some measurable effect.

A rotameter consists of a tapered tube, typically made of glass, with a float inside that is pushed
up by flow and pulled down by gravity. At a higher flow rate more area (between the float and
the tube) is needed to accommodate the flow, so the float rises. Floats are made in many different
shapes, with spheres and spherical ellipses being the most common. The float is shaped so that it
rotates axially as the fluid passes. This allows you to tell if the float is stuck since it will only
rotate if it is not.

For Digital measurements Flap system is used.

For Analog measurements we can use the following methods :

 Flowmeters
 Venurimeters / Orifice meters
 Turbines
 Massflow meters ( oil level )
 Ultrasonic Flow meters
 Magnetic Flowmeter ( water level )
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Selection of flow meter depends upon the purpose , accuracy and liquid to be measured so
different types of meters used.
Turbine type are the simplest of all.
They work on the principle that on each rotation of the turbine a pulse is generated and that pulse
is counted to get the flow rate.

VENTURIMETERS :

Referring to the diagram, using Bernoulli's equation in the special case of incompressible fluids
(such as the approximation of a water jet), the theoretical pressure drop at the constriction would
be given by (ρ/2)(v22 - v12).

And we know that rate of flow is given by:

Flow = k √ (D.P)
Where DP is Differential Presure or the Pressure Drop.
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CONTROL VALVES

A valve is a device that regulates the flow of substances (either gases, fluidized solids, slurries,
or liquids) by opening, closing, or partially obstructing various passageways. Valves are
technically pipe fittings, but usually are discussed separately.

Valves are used in a variety of applications including industrial, military, commercial,

residential, transportation. Plumbing valves are the most obvious in everyday life, but many
more are used.

Some valves are driven by pressure only, they are mainly used for safety purposes in steam
engines and domestic heating or cooking appliances. Others are used in a controlled way, like in
Otto cycle engines driven by a camshaft, where they play a major role in engine cycle control.

Many valves are controlled manually with a handle attached to the valve stem. If the handle is
turned a quarter of a full turn (90°) between operating positions, the valve is called a quarter-turn
valve. Butterfly valves, ball valves, and plug valves are often quarter-turn valves. Valves can
also be controlled by devices called actuators attached to the stem. They can be
electromechanical actuators such as an electric motor or solenoid, pneumatic actuators which
are controlled by air pressure, or hydraulic actuators which are controlled by the pressure of a
liquid such as oil or water.

So there are basically three types of valves that are used in power industries besides the handle
valves. They are :
 Pneumatic Valves – they are air or gas controlled which is compressed to turn or move
them
 Hydraulic valves – they utilize oil in place of Air as oil has better compression
 Motorised valves – these valves are controlled by electric motors
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