Ntpc LNCT training report (autosaved)

Industrial Training Report
Department of Electronics and Telecommunication Engineering, Lakshmi Narain College of Technology, Bhopal
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Chapter 1
Introduction

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Chapter 1
Introduction
NTPC is the largest thermal power generating company of India. A Public sector
company wholly owned by government of India. It was incorporated in the year 1975 to
accelerate power development in the country. Within a span of 30 years, NTPC has
emerged as a truly national power company, with power generating facilities in all the
major regions of the country. NTPC contributes 28.5% of the country’s entire power
generation and hence today lights up every fourth bulb in the country. It is the third
largest Maharatna company of India after Coal India LTD and ONGC.
With ambitious growth plans to become a 56000MW power company by 2017, NTPC the
largest power utility of India has already diversified into hydro sector. 18 NTPC stations
have already been accredited with the ISO 14001 certification. In keeping with its well
focused environment protection policy, NTPC has set up a “Centre for Power Efficiency
and Environmental protection” (CENPEEP) which functions as a resource centre for
development and dissemination of latest technologies in environmental management.
In a remarkable achievement, the recently conducted Business Today –Hewitt Associate
Best Employers survey 2003 ranked NTPC the 3rd best among major companies in India.
1.1 Company Profile
NTPC, Kahalgaon super thermal power project is one of the most prestigious flagships of
NTPC striving ahead to bridge the country generation gap especially in the north region.
Kahalgaon Super Thermal Power Station (KhSTPP) is located in Kahalgaon in Bhagalpur
district of Bihar. It has secured ISO 14001 and ISO 9002 certificate in the field of
environment and power generation but also in various other fields. On September 2002 it
made glorious achievement by ensuring production up to 2340 MW. In 2007 total
production of , Kahalgaon became 4260MW by adding 2 units of each 500MW. Now,
NTPC , Kahalgaon is the largest power plant of India. It has won number of awards from

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government of India for proper utilization and consumption and has bagged the safety
awards presented by U.S.A. and British safety council.
1.1.1 Objectives
NTPC plans to broad base generation mix by evaluating conventional and alternate
sources of energy to ensure long run competitiveness and mitigate fuel risks.
1.1.2 Vision
“To provide green power through locally available resources at affordable price,
promoting clean energy”
1.1.3 Coal Source Of NTPC, , Kahalgaon
Eastern Coalfields Ltd (ECL) mines at piparwar mines north karanpura (Jharkhand)
1.1.4 Fuel Oil Source
Indian oil corporation ltd. (IOCL), COLD (customer operated lubricant and oil deposit)
at Jayant.
1.1.5 Water Source
Ganga river
1.1.6 Beneficiary States
Bihar, West Bengal,.Nepal
1.1.7 International Assistance
USSR and World Bank under time slice loan.
Table 1.1 Units Commissioned
1. Unit 1 210MW October 1987
2. Unit 2 210MW July 1988
3. Unit 3 210MW February 1989

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4. Unit 4 210MW December 1989
5. Unit 5 500MW March 1990
6. Unit 6 500MW February 1991
7. Unit 7 500MW 1998

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Chapter 2
Services and Major Functions Of The
Organization

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Chapter 2
Services and Major Functions of the Organization
NTPC is proud of the fact that it has successfully explored more than one way to
generate power. Other than thermal power, it operates in hydro and gas regions too. As a
natural progression of its in-depth understanding of the power sector and formidable
track record, NTPC has now ventured into three related fields namely Consultancy for
the power sector, setting up a training institute for the same and R&D.
2.1 Consultancy
The Consultancy Wing of NTPC, with an ISO 9001:2000 accreditation, undertakes all the
previous Consultancy and turnkey project contracts for Domestic and International
clients in the different phases of Power plants With the string of achievements behind it,
NTPC has emerged as the acknowledged leader in engineering, construction, O&M,
RLA/R&M and management of power projects.
As a result of the phenomenal success achieved by NTPC in executing its own power
projects, many utilities from India and abroad started approaching NTPC to gain from
the rich experience gained by NTPC. With this in view NTPC formally established its
Consultancy Wing in 1989.
Since then NTPC Consultancy has secured 490 orders from Domestic & International
Clients.
NTPC is registered as a consultant with several leading international development and
financial institutions such as The World Bank, The Asian Development Bank, The
African Development Bank and UNDP.
NTPC's vast pool of technically qualified and managerial manpower is well supported by
excellent infrastructure and knowledge management facilities to deliver the client time
bound, qualitative and cost effective solution meeting the global standards.
At NTPC, we offer consultancy services related to infrastructure sector business such as:

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 Fossil fuel based thermal power plants
 Combined cycle power plants
 Cogeneration plants
 Water supply and treatment
 Environment engineering and management
An entire gamut of services is offered in the areas mentioned above. These are:
 Owner's Engineer Services
 Lender's Engineer Services
 Environment Engineering and Management
 Procurement Services
 Project Management
 Quality Assurance and Inspection Services
 Materials Management
 Construction Management, Erection and Commissioning
 Financial Systems and Modeling
 Operation and Maintenance
 Restoration, Efficiency Improvement and Renovation and Modernization
 HRD and Training
 Research and Development
 Information Technology
 Management Consultancy
 Commercial Consultancy
2.2 International Marketing

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Towards the end of last century, many countries started structural changes in their
infrastructure sectors. Many countries decided to un-bundle their hitherto government
controlled power sector. Further, in order to meet the growing demand for power,
privatization of power projects emerged as the most outstanding choice. These actions of
many progressive governments resulted in a number of opportunities for private players
in power sector. These include development of power projects as Independent Power
Producers (IPP).
Keeping its proactive tradition, NTPC launched a separate International Marketing to
meet the varied needs of IPPs and other International clients who are looking for a world
class service in power sector. The International Marketing is fully backed by NTPC’s
three decades of experience and expertise. The Marketing is especially tuned to meet the
requirements of International clients in terms of quick response, flexible service options
and to deliver value for money.
Fig. 2.1 Consultancy Services

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2.2.1 NETRA (NTPC Energy Technology Research Alliance)
NTPC is a technology driven company and is fully aligned to the needs of adapting to
emerging technologies and upgrading the technologies through R&D. The company is
particularly sensitive to R&D and paradigm shift which it can make. Towards this, NTPC
has a multi-pronged approach. NETRA (NTPC Energy Technology Research Alliance)
has come into existence in 2009 after merging of R&D center (Established in 1981) and
Energy Technologies.
The focus areas are: Climate change, waste management, new & renewable energy,
efficiency improvement and cost reduction besides providing scientific support to NTPC
and external utilities for improving availability, reliability and efficiency.
The focus is on developing cutting edge technologies by carrying out applied research
which will manifest into cost reduction and environment protection. NETRA is
networked with Institutes/organizations for research related to development of cost
economic technologies in the field of Climate change, New & Renewable energy,
efficiency & reliability enhancement of thermal power generation and CO2
mitigation/fixation. It is also in the dialogue with many International
institutes/organizations for networking in these areas.
Initiatives are taken to develop technologies for reducing forced outages, installing
intelligent online monitoring of critical components, understanding the likely damages
due to corrosion and providing appropriate solutions etc. Effort is being made for
reducing cost of generation by either increasing the overhaul cycle or reducing overhaul
duration through correct and proper health assessment of critical components,
developing diagnostic tools and ensures environmental & safety compliances. The prime
thrust is towards clean and economic power generation. The Patents have been filed in
the areas of climate change, waste management etc.
Research Advisory Council (RAC) comprising of eminent scientists and experts from
India and abroad has been constituted to steer NETRA for high end research. In-house

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Scientific Advisory Council (SAC) has also been constituted to provide directions
improving plant performance & reducing cost of generation.
The key expertise lies in providing scientific support to stations for improving their life,
performance and developing technologies for clean & economic power generation for the
sustainable growth of power sector.
NETRA is a Member of IEA GHG R&D Program France, IERE Japan & CSLF France.
NETRA is National Boiler Board Certified RLA Agency.
2.3 Power Management Institute
NTPC runs a state-of-the-art Power Management Institute (PMI), at NOIDA. PMI has
over the years trained a large number of professionals from NTPC, State Electricity
Boards and other power utilities in the country. Also, participants in PMI programmes
have come from various South Asian and Middle Eastern countries.
With a wide range of expertise and experience acquired over the years, PMI offers
programme in the following categories:
 Enhancing General Management Competence and Skills: The programmes
included in this category develop the knowledge, attitude, behaviour and skills of
the participants from the perspective of general management of the enterprise.
 Enhancing Technical Expertise: These programmes are designed to impart
emerging technologies and practices that augment technical skills and
competencies.
 Upgrading Functional Skills: The programmes in this category cater to the
functional areas of the organization like HR, Finance, Materials, Contracts etc
 Managing Information Technology: IT enablement is a key determinant of
organization success and these programmes provide the required knowledge and
skills.
 Induction Level Training Programmes: A key area of expertise is the Induction
level training programme for newly recruited executive trainees in Engineering,
Chemistry, IT, Finance and Human Resources

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 Employee Development Programmes: Programmes are conducted for the
Supervisors and Workmen of our Corporate Centre Office in the areas of
powerplant familiarization, attitude, quality, finance and IT.

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2.3.1 Installed Capacity
Present installed capacity of NTPC is 43,128 MW (including 5,974 MW through JVs)
comprising of 38 NTPC Stations (17 Coal based stations, 7 combined cycle gas/liquid
fuel based stations), 7 Joint Venture stations (6 coal based and one gas based) and 7
renewable energy projects.
Table 2.1 Installed Capacity
NO. OF PLANTS CAPACITY (MW)
NTPC Owned
Coal 17 33,015
Gas/Liquid Fuel 7 4,044
Renewable energy
projects
7 95
Total 31 37,154
Owned By JVs
Coal & Gas 7 5,974
Total 38 43,128

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Table 2.2 Regional Spread of Generating Facilities
REGION COAL GAS Renewable TOTAL
Northern 9,015 2,334 20 11,369
Western 10,840 1,313 50 12,203
Southern 4,600 370 15 4,975
Eastern 8,560 - 10 8,570
JVs 4,034 1,967 - 6,001
Total 37,049 5,984 95 43,128
Table2.3 Coal Based Power Stations
COAL BASED(Owned
by NTPC)
STATE
COMMISSIONED
CAPACITY(MW)
1. Singrauli Uttar Pradesh 2,000
2. Korba Chhattisgarh 2,600
3. Ramagundam Andhra Pradesh 2,600

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4. Farakka West Bengal 2,100
5. Vindhyachal Madhya Pradesh 4,260
6. Rihand Uttar Pradesh 3,000
7. Kahalgaon Bihar 2,340
8. Dadri Uttar Pradesh 1,820
9. Talcher Kaniha Orissa 3,000
10. Feroze Gandhi, Unchahar Uttar Pradesh 1,050
11. Talcher Thermal Orissa 460
12. Simhadri Andhra Pradesh 2,000
13. Tanda Uttar Pradesh 440
14. Badarpur Delhi 705
15. Sipat Chhattisgarh 2,980
16. Mauda Maharashta 1,000
17. Barh Bihar 660
Total 33,015
Fig 2.2 Installed Capacity

Department of Electronics and Telecommunication
2.4 Renewable Energy
Renewable energy (RE) is being perceived as an alternative source of energy for “Energy
Security” and subsequently “Energy Independence” by 2020. Renewable energy technologies
provide not only electricity but offer
2.4.1 Portfolio of Renewable Power
NTPC has also formulated its business plan of capacity addition of about 1,000 MW thru
renewable resources by 2017. In this endeavour, NTPC has already commissioned
PV Projects and another 15 MW Solar PV and 8 MW Small Hydro Projects are under
implementation
ment of Electronics and Telecommunication Engineering, Lakshmi Narain College of Technology, Bhopal
provide not only electricity but offer an environmentally clean and low noise source of power.
Portfolio of Renewable Power
renewable resources by 2017. In this endeavour, NTPC has already commissioned
Narain College of Technology, Bhopal
15
an environmentally clean and low noise source of power.
renewable resources by 2017. In this endeavour, NTPC has already commissioned 95 MW Solar

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CHAPTER 3
Brief about the Annual Report and
Organisational Policies

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Chapter 3
Brief about the Annual Report and Organisational Policies
3.1 Annual Report
Figure 3.1 depicts the annual report of NTPC in previous two years
Fig 3.1 Annual Report of NTPC

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3.2 Organizational Policies
There are a range of policies undertaken by NTPC
Fig. 3.2 Vision, Mission and Core Values of NTPC

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3.1.1 Environment Policy & Environment Management System
For NTPC, the journey extends much beyond generating power. Right from its inception,
the company had a well defined environment policy. More than just generating power, it
is committed to sustainable growth of power. They are as follows:
 National Environment Policy: The Ministry of Environment and Forests and
the Ministry of Power and NTPC were involved in preparing the draft
Environment Policy (NEP) which was later approved by the Union Cabinet in
May 2006. Since its inception NTPC has been at the forefront of Environment
management. In November 1995, NTPC brought out a comprehensive document
entitled ‘NTPC Environment Policy and Environment Management System.
Amongst the guiding principles adopted in the document are the company's pro-
active approach to environment, optimum utilization of equipment, adoption of
latest technologies and continual environment improvement. The policy also
envisages efficient utilization of resources, thereby minimizing waste, maximizing
ash utilization and ensuring a green belt all around the plant for maintaining
ecological balance.
 Environment Management, Occupational Health and Safety Systems:
NTPC has actively gone for adoption of the best international practices on
environment, occupational health and safety areas. The organisation has pursued
the Environmental Management System (EMS) ISO 14001 and the Occupational
Health and Safety Assessment System OHSAS 18001 at its different
establishments. As a result of pursuing these practices, all NTPC power stations
have been certified for ISO 14001 & OHSAS 18001 by reputed national and
international certifying agencies.
 Pollution Control Systems: While deciding the appropriate technology for its
projects, NTPC integrates many environmental provisions into the plant design. In
order to ensure that NTPC complies with all the stipulated environment norms,
following state-of-the-art pollution control systems / devices have been installed
to control air and water pollution:
 Electrostatic Precipitators

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 Flue Gas Stacks
 Low-NOX Burners
 Neutralisation Pits
 Coal Settling Pits / Oil Settling Pits
 DE & DS Systems Cooling Tower
 Ash Dykes & Ash Disposal Systems
 Ash Water Recycling System
 Dry Ash Extraction System (DAES)
 Liquid Waste Treatment Plants & Management System
 Sewage Treatment Plants & Facilities
 Environmental Institutional Set-up
Following are the additional measures taken by NTPC in the area of Environment
Management:
 Environment Management During Operation Phase
 Monitoring of Environmental Parameters
 On-Line Data Base Management
 Environment Review
 Upgradation & Retrofitting of Pollution Control Systems
 Resources Conservation
 Waste Management

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 Municipal Waste Management
 Hazardous Waste Management
 Bio-Medical Waste Management
 Land Use / Bio-diversity
 Reclamation of Abandoned Ash ponds
 Green Belts, Aforestation & Energy Plantations
The NTPC is not just the leading power generating company in the country. It is also one
of the topmost public sector undertakings which have been playing a dynamic role in
transforming the lives of the people in various regions locating its projects. Its sustained
work for the resettlement and rehabilitation of the affected people as also the community
development programmes in the adjoining villages is a testimony to the deep
commitment of NTPC to its corporate social responsibility. In the process, NTPC
projects have helped in imparting high growth to the local village economy, apart from
improving the standard of living of the project affected persons and the villagers. NTPC’s
CSR programmes have been continuously improving upon the resettlement and
rehabilitation work through a process of consultations with the affected people and
various non-government organizations.

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Fig 3.3 Sustainable Policy

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Chapter 4
Different Departments and Close
Relationships

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Chapter 4
Different Departments and Close Relationships
NTPC being the largest power plant of India has several departments which are
interrelated to each other. All these departments act together to perform all the
functions of the organization.
4.1 Departments of NTPC
NTPC has several departments, nearly 45 departments in all. They are as follows:
 GM Cell
 Vigilance cell
 TSD
 Field Energy
 Planning & System
 Business & Excellence
 Safety
 Field Quality & Assurance
 Info Tech Department
 EMG Department
 AVD Department
 Project
 CCD Department
 C& I Erection
 Commissioning
 Town Administration
 C&M Department
 Purchase
 Stores
 Contract Cell
 F&A

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 Human Resources
 EDC Department
 Hospital
 Operation & Maintenance Department
 Research & Management Department
 EEMG Department
 Operation Department
 O&M Civil
 Chemistry
 MTP Department
 Maintenance
 BMD Department
 ASH Handling
 Central Workshop
 Auto Base
 MM-TMD
 MM-TMD-OS
 EMD
 C&I- Maintenance
 FM
 CHP
 Merry Go Round
4.2 Subsidiaries & Joint Ventures
The names of Joint Ventures/Subsidiaries and their areas of operation/business are given
below:

26
Table 4.1 Joint Ventures
S.No.
Company Name
(Incorporated on)
Promoters
Equity holding
Capacity
(MW)
Objective
Power Generation
1.
NTPC-SAIL
Power Company
Pvt. Ltd.
(08.02.1999)
NTPC-50%
SAIL-50%
814
To operate & maintain the
Captive power plants of
Durgapur, Rourkela &
Bhillai
2.
Aravali Power
Company Private
Ltd.
(21.12.2006)
NTPC-50%
IPGCL-25%
HPGCL-25%
1500
To set up & operate 3X500
MW Indira Gandhi Super
Thermal Power Project at
Jhajjar, Haryana.
3.
NTPC Tamil
Nadu Energy
Company Ltd.
(23.05.2003)
NTPC-50%
TNEB-50%
1500
MW Coal based power
project at Vallur, Tamil
Nadu
4.
Meja Urja Nigam
Private Ltd.
(02.04.2008)
NTPC-50%
UPRVUNL-50%
1320
MW power project at Meja
Tehsil in Allahabad district
in UP
6.
Ratnagiri Gas and
Power Pvt. Ltd.
(08.07.2005)
NTPC & GAIL -
32.47% each ,
IFIs-18.13%
MSEB Holding
Co.-16.93%
1967
To own & operate the
assets of erstwhile Dabhol
power plant in Ratnagiri
1967 MW and 5 MMTPA
LNG Re-gasification

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terminal
7.
Trincomalee
Power Co. Ltd.
(26.09.2011)
NTPC-50%
Ceylon
Electricity Board-
50%
500
For setting up 2X250 MW
coal based power plant in
Trincomalee Region in Sri
Lanka
8.
Bangladesh-
India Friendship
Power Company
Pvt. Ltd.
(31.10.2012)
NTPC-50%
Bangladesh
Power
Development
Board- 50%
1320
Setting up and
implementing coal based
Power plant (s) in
Bangladesh
9.
Anushakti
Vidhyut Nigam
Ltd.
(27.11.2010)
NTPC – 49 %
NPCIL – 51 %
-
Development of nuclear
power projects in the
country.
10.
Pan Asian
Renewables Pvt.
Ltd.
(14.10.11)
NTPC-50%
ADB-25%
Kyuden-25%
-
Development of 500 MW
of Renewable Power
generation resources in
India.
Power Equipment Manufacturing
11.
NTPC BHEL
Power Projects Pvt
Ltd.
(28.04.2008)
NTPC-50%
BHEL-50%
To take up EPC contracts and
manufacturing of equipments for
power plants and other infrastructure
projects in India & abroad
12. BF-NTPC Energy NTPC-49% To initially take up manufacturing of

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Systems Ltd.
(19.06.2008)
Bharat Forge
Ltd.-51%
castings, forgings, fittings, high
pressure piping required for power
projects and other industries and
Balance of Plant (BOP) equipment
13.
Transformer &
Electricals Kerala
Ltd. (44.6% shares
acquired by NTPC
on 19.06.2009)
NTPC-44.6%
Govt. of Kerala-
55.39%
Banks-0.01%
For manufacturing and repair of high
voltage transformers and associated
equipment.
Power Services
14.
National Power
Exchange Ltd.
(11.12.2008)
NTPC - 16.67 %
NHPC - 16.67 %
PFC - 16.66 %
BSE - 16.66 %
TCS - 19.04 %
IFCI – 5.72 %
MEENAKSHI-
4.77%
DPSC - 3.81 %
To set up and operate power exchange.
Keeping in view the change in market
scenario and the fact that NTPC’s
objective of joining NPEX was not
achieved so far, NTPC Board in its
meeting held on November 7th, 2012,
approved the proposal of NTPC’s exit
from NPEX. The decision of NTPC to
exit from NPEX has been
communicated to other promoters of
NPEX.
15.
Utility Powertech
Ltd.
(23.11.1995)
NTPC-50%
Reliance
Infrastructure
Ltd.-50%
To take up assignments of
construction, erection and supervision
in power sector and other sectors in
India and abroad
16.
NTPC-Alstom
Power Services
NTPC-50%
Alstom Power
To take up Renovation &
Modernisation assignments of Power

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Private Ltd.
(27.09.1999)
50% Plants both in India & SAARC
countries
17.
National High
Power Test
Laboratory Private
Ltd.
(22.05.2009)
NTPC-20%
NHPC-20%
PGCIL-20%
DVC-20%
CPRI-20%
For setting up an online High Power
Test Laboratory for short-circuit test
facility in the country.
18.
Energy Efficiency
Services Ltd.
(10.12.2009)
NTPC-25%
PFC-25%
PGCIL-25%
REC-25%
To carry out and promote the business
of Energy Efficiency, Energy
Conservation and Climate Change.
Coal Mining
19.
International Coal
Ventures Pvt. Ltd.
(20.05.2009)
NTPC, RINL &
NMDC -14.28%
each
SAIL & CIL-
28.58% each
For sourcing coking coal and thermal
coal from abroad.
However, opportunities for
identification of thermal coal were
limited. Therefore NTPC decided to
opt out of this.
Permission from Ministry of Power
taken for opting out of JV.NTPC
Board has approved the proposal for
withdrawal from ICVL. Letter issued to
ICVL for withdrawal.
ICVL is in the process of obtaining
cabinet clearance on the same.

30
20.
NTPC-SCCL
Global Venture
Pvt. Ltd.
(30.07.2007)
NTPC-50%
Singareni
Collieries Co.
Ltd.-50%
To undertake the development and
O&M of coal blocks and integrated
coal based power projects in India and
overseas.
21.
CIL NTPC Urja
Pvt Ltd
(27.04.2010)
NTPC – 50%
CIL – 50%
Development, operation and
maintenance of coal blocks and
integrated coal based power plants.
Table 4.2 Subsidiaries
S.No.
Company Name
(Incorporated on)
Promoters
Equity
holding
Objective
Power Generation
1.
Bhartiya Rail Bijlee Company Ltd.
(22.11.2007)
NTPC-
74%
Indian
Railways-
26%
To set up a power plant
of 1000 MW to meet the
requirements of Railways.
2.
Kanti Bijlee Utpadan Nigam Ltd.
(06.09.2006)
NTPC-
65%
BSEB-35%
To take up and operate
Muzaffarpur Thermal
Plant in Bihar.
3.
NTPC Hydro Limited, a wholly-
owned subsidiary of NTPC
Limited, has been merged with the
NTPC-
100%
To set up hydro power
projects up to 250 MW
capacity. It has merged

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NTPC Limited, its Holding
Company
with NTPC.
Distribution
4.
NTPC Electric Supply Co. Ltd.
(21.08.2002)
NTPC-
100%
Distribution of power.
Trading
5.
NTPC Vidyut Vyapar Nigam Ltd.
(01.11.2002)
NTPC-
100%
Trading of power & Ash.

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Chapter 5
Organizational Structures

33
Chapter 5
OrganizationalStructures
Fig 5.1 Organizational Structure of NTPC

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Chapter 6
Process Flow

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Chapter 6
Process Flow
Following processes take place during power generation in NTPC
6.1 Generation of Coal to Electricity
Electricity generation takes place in following three broad steps
6.1.1 Coal to Steam
A modern boiler pulverizes coal at rate up to 200 tones per hour. From the coal store,
fuel is carried on a conveyor belt and discharged by means of coal tipper into the bunker.
It thus falls, perhaps through a weather, into the coal pulverizing mill, where it is ground
to a power as fine as flour. The mill usually consists of a round metal table on which large
steel rollers or balls that crushes it.
Fig 6.1 Boiler Parts
Air is drawn from the top of the boiler house by the forced draught fan and passed
through the air pre heaters, to the hot air duct. From here some of the air passes directly
to the burners and the remainder is taken through the primary air fan to the pulverizing
mill, where it is mixed with the powdered coal, blowing it along pipes to the burners of
the furnace. Here it mixes with the rest of the air and burns the condensate in the

36
economizer and then pass through the air pre heaters, to the electrostatic precipitator.
Finally they are drawn by the induced draught fan into the main flue and to the chimney.
The electrostatic precipitator consists of metal plates, which are electrically charged. Dust
and grit in the flue gasses are attracted on to these plates, so that they do not pass up the
chimney to pollute the atmosphere. Regular mechanical hammer blows cause the
accumulation of ash, dust and grit to fall to the bottom of the precipitator where they
collect in a hopper for disposal. Additional accumulation is also collected in the hoppers
beneath the furnace. The ash is either sold for use in road and building constructions or
piped as slurry.
Fig 6.2 Coal to Electricity
6.1.2 Steam to Mechanical Power
As from the fig. it is clear that a steam pipe (1) conveys steam to the turbine through a
stop valve and through control valves (2) that automatically regulate the supply of steam
to the turbine. Stop valve and control valve are located in a steam chest and a governer
(3) driven from the main turbine shaft (4), operates the control valve to regulate the
amount or steam used.
Steam from the control valve enters the high pressure cylinder of the turbine where it
passes through a ring of stationary blade (5) fixed to the cylinder wall (6). These act as

Department of Electronics and Telecommunication
nozzles and direct the steam onto a second ring of moving blades (7) mounted on a disc
secured to turbine shaft. This second ring turns shaft as a result of the force of steam.
The stationary and moving blades together constitute a `stage` of the turbine and in
practice many stages are necessary so that the cylinder contains no. of rings of s
blades with rings of moving blades arranged between them. The steam passes through
each stage in turn until it reaches the end of the high
some of its heat energy is changed into mechanical energy. The steam l
pressure cylinder goes back to the boiler from reheating (8) and return by a further pipe
(9) to the I.P. cylinder. Here it passes through another series of stationary and moving
blades. Finally the steam enters to L.P. cylinder. As the steam g
drive the turbine, its temperature and pressure falls and it expands. Because of this
expansion the blades are much larger and longer towards the low
turbine. The turbine shaft usually rotates at 3000r.p.m.
When as much energy as possible has been extracted from the steam it is exhausted
directly to the condenser. The condenser consists of a large vessel containing some 20000
tubes, each about 25mm in diameter. Cold water from the cooling towers is circulated
through these tubes and as the steam from the turbine passes around them it is rapidly
condensed into water-condensate. Because water has a much smaller comparatively
volume then steam, a vacuum is created in the condenser. This allows the steam to be
used down to pressure below that of normal atmosphere and more energy can be utilized.
From the condenser, the extraction pump pumps the condensate through low pressure
ment of Electronics and Telecommunication Engineering, Lakshmi Narain College of Technology, Bhopal
ecured to turbine shaft. This second ring turns shaft as a result of the force of steam.
practice many stages are necessary so that the cylinder contains no. of rings of s
each stage in turn until it reaches the end of the high-pressure cylinder and in its passage
some of its heat energy is changed into mechanical energy. The steam l
blades. Finally the steam enters to L.P. cylinder. As the steam gives up its heat energy to
expansion the blades are much larger and longer towards the low-pressure ends of the
turbine. The turbine shaft usually rotates at 3000r.p.m.
Fig 6.3 Steam to Mechanical Power
condensate. Because water has a much smaller comparatively
d down to pressure below that of normal atmosphere and more energy can be utilized.
Narain College of Technology, Bhopal
37
ecured to turbine shaft. This second ring turns shaft as a result of the force of steam.
practice many stages are necessary so that the cylinder contains no. of rings of stationary
pressure cylinder and in its passage
some of its heat energy is changed into mechanical energy. The steam leaving high-
ives up its heat energy to
pressure ends of the
condensate. Because water has a much smaller comparatively
d down to pressure below that of normal atmosphere and more energy can be utilized.

38
feed heaters. It further passes through feed heaters to the economizer and the boiler for
re conversion into steam.
A power station generating 2000MW of electricity requires about 227500m3 of water per
hour for cooling purpose. Where cooling towers are used, about one hundredth part of
the cooling water evaporates and a certain amount is returned to its source to carry away
any impurities that collect. Most of it however is re circulated.
Fig 6.4 Various Steps
6.1.3 Mechanical Power to Electricity
The power generated by the turbine is given to generator, which is coupled with shaft of
turbine. Generator converts this power into electricity by the rule of Mutual Induction.
The electricity produced by the generator is given to the switchyard, which collects,
control and finally distribute it through long transformers and cables.

39
Fig 6.5 Thermal Power Plant
6.2 Raw Water to Demineralized Water
As the water is the basic requirement of the plant so initially water is treated in order to
remove scales, corrosion and priming foaming problems.
Water treatment process done in two sections:
1. Pretreatment Section :- Pretreatment plant remove the suspended solids such as
clay, slit, organic and inorganic matter, plants and other microscopic organism by
passing water in aerator, clarifier, filter bed.
2. Demineralization Section: - Pretreated water is now feed into DM plant in which
dissolved solids are removed (cations & anions) by passing pretreated water in
activated carbon filter. Cation exchanger, degassed water storage tank, anion
exchanger and then to mixed bed.

40
Fig 6.4 DM Water Plant

41
Chapter 7
Assignment Completed During Training

42
Chapter 7
Assignment Completed During Training
Several assignments were also given during the training period to understand the
importance and functioning of the control and instrumentation department. For safe &
efficient operation of power plant, it is of paramount importance to monitor all power
plant parameter such as: temperature, pressure, flow, level, etc. In a power plant control
& instrumentation is synonymous to the nerves & brain of human being. All the
parameters is measured and communicated to control room. The processing is done in
control room and commands were given to field control drives to attain the desire plant
conditions. In Vindhyachal advanced distributed digital control, monitoring and
information sys (DDCMIS) has been provided.
The assignment given to us are as follows which will be described later on
 Study of FCX-A Series Transmitter
 Study of Dead Weight Tester
 Study of various measuring instruments for flow and level.
 Study of closed loop control system.
8.1 Study of FCX-A Series Transmitter
The FCX-A Series transmitter which is available as an analog or smart type, detects the
differential pressure or pressure of various fluids, converts it into a current of 4 to 20 mA
DC & transmits it. All the adjustment function is incorporated in the transmission unit
for making adjustments easy & exact. In the smart type, transmitter setting as range &
damping time constant etc can be changed from HHC (Hand Held Communicator).
Operating principle is shown in the block diagram below. The input pressure is changed
into an electrostatic capacitance in the detecting unit. The change proportional to the
pressure which undergoes amplification & signal conditioning in transmission unit & it
then gives output as current of range 4 to 20 mA. Diaphragm & Sensor Unit is called

43
detecting unit & measuring circuit & operational amplification unit togetherly are called as
transmission unit.
Fig 7.1 Block Diagram Of Operating Principle
8.2 Study of Dead Weight Tester
Dead weight tester is an apparatus to check the accuracy of the instrument . It takes into
account all the parameters like sensitivity linearity accuracy etc. Piston/Cylinder on left
hand connection & Gauge stand on right hand connection. Bench should be 0.9m high.
OPERATION
 Load the weight carrier with the weight equivalent to the desired pressure
 Fill & apply pressure until piston rises & head is floating weights should be rotated
by hand.
If there were no leaks, the piston head would float for many minutes. After the test is
finished stop weights rotating, wing backs the screw pump & opens the valves. Now
residual pressure is relieved.
PISTON/CYLINDER

44
Pressure is force per unit area. Dead weight pressure testers use measurements of force &
area to produce pressure to calibrate instruments with great accuracy. Force is delivered
from weight & area.
If Area = 1/8 in sq.
Weight=12.5 pound
Pressure=100 lb/in2
Piston, cylinder & weights together are called DEAD WEIGHT BALANCE.
Effective area is the average of piston & cylinder area.
There is small gap between piston & cylinder i.e. when the piston rotates in the cylinder
pressure medium forms a bearing eliminating friction & metallic contacts between the
two. If the gap is too small, piston will not spin at low pressure but it will spin if gap is
medium. If the gap is too large there will be leakage between the two.
PERFORMANCE depends on the accuracy with which the piston & cylinder are
manufactured. They are generally made of tool steel.
In air heaters, made of high chromium steel, as the moisture corrosion doesn’t affect
them.
WEIGHTS
Weights are manufactured of Martens tic stainless steel. Piston weights are manufactured
to give appropriate force when subject to gravitational acceleration (9.80665 m/sec2) &
in air of density 1.2 kg/m3.
ACCURACY
An unknown area can be known by connecting them hydraulically under pressure.
Pressure of system = WD/AD = WK/AK
AD – UNKNOWN PRESSURE
AK – KNOWN PRESSURE
These are calculated on account of fact that effective area or piston/cylinder increases

45
with pressure. Accuracy takes into account the buoyancy of weights in air & buoyancy of
parts of piston immersed in liquid.
8.3 Study Of Closed Loop Control System
The CLCS shall interact with its MS function blocks and shall perform close loop control
and information function. The sys shall accept the execute commands from CRT/Key
boards and hard wired A/M station located in unit control room and make available data
for display to CRT and printing on printers. All the control loops of one unit are
implemented in 17 functional groups. Each functional group consists of an independent
& dedicated controller along with associated hardware.
The functional requirements of the control are as under
 Co-coordinated Control system (CCS).
 Automatic boiler Controls.
 Balance of Plant Control.
8.3 Study of Piping of Transmitter for Flow and Level Measuring
Devices
All primary measuring instruments are installed include: temperature sensing element/
wells/ cold junction compensation boxes, Flow sensing elements (orifice plates, flow
nozzles etc), electronic transmitter, flue gas analysis instruments, Vibration Monitoring
System, local indicators, process actuator switches, electro/ pneumatic converters, coal
bunker level indicating system.
The secondary instruments like recorders. Indicators, analyzer monitors, integrators and
electrical meters etc. are mounted on control panels to provide maximum accessibility,
optimum operability. The instruments are arranged such that, failure of any device will
not cause any malfunction towards operation.
 Flow measurement (in case of gas): Place the transmitter above the differential
pressure source.

46
 Flow measurement (in case of liquids): Place the transmitter below the
differential pressure source. Make the piping so that the gas in the impulse pipe is
not delivered to the transmitter& incorporate gas reservoirs as required.
 Flow measurement (in case of steam): Set the two condensers at the same
height near the process tap. Fill the line between the condensers & the transmitter
with the condensed water.
 Pressure measurement (in case of liquid): Zero point can be checked with a
manifold valve installed.
 Pressure measurement (in case of gas): Mount the transmitter above the
process pipes preventing the moisture from entering the inside if the transmitter.
 Level measurement in case of wet leg: For measurement, connect the highest
liquid level tapping of the tank with the low-pressure side of the transmitter, and
the lowest liquid level tapping of tank with the high-pressure side of the
transmitter.
 In case of dry leg: For an open tank, leave the low-pressure side of the
transmitter open to atmosphere

47
CHAPTER 8
Conclusion

48
Chapter 8
Conclusion
The training session was very educational and informative. Being a MAHARATNA
company, NTPC have good harmonic relationship and co-ordination between the staff
members. As the vocational training seem laborious job to get in touch with the activities.
It was nobility of people to provide the information and required theoretical background
at their continuous job hour. Most of the equipments were technically strong for huge
production. Doing training in NTPC, I hope it would be useful in my future not only in
academic but also in professional carrier. Electricity is much more than just another
commodity. It is the life-blood of the economy and our quality of life. Failure to meet the
expectations of society for universally available low-cost power is simply not an option.
As the world moves into the digital age, our dependency on power quality will grow
accordingly. The infrastructure of our power delivery system and the strategies and
policies of our insurers must keep pace with escalating demand. Unfortunately, with the
regulators driving toward retail competition, the utility business priority is competitiveness
(and related cost-cutting) and not reliability.

49
Chapter 9
Problems & Difficulties Encountered &
Guidelines for Betterment & Suggestions

50
Chapter 9
Problems & Difficulties Encountered & Guidelines for
Betterment & Suggestions
Being the largest power plant of India, NTPC still is facing several issues and difficulties
related to coal supply, electricity and safety issues. These problems are as follows:
 The country’s largest power utility is seeking coal concessions abroad as domestic
sources are not able to meet its growing demand. Indian coal also has high ash
content, which reduces the efficiency of power plants (restricting the power that
can be generated from one tonne of coal). Domestic coal, however, is 30-40%
cheaper than imports, depending on the quality.
 NTPC is facing problems in awarding an equipment contract. The equipment will
help NTPC improve plant efficiency and achieve economies of scale. By 2032,
about half the country’s generation capacity is expected to be coal-based. To
mitigate the shortfall, India is planning to set up a bulk of its capacity on
supercritical and advanced ultra-supercritical equipment, which are more efficient.
NTPC requires an acre of land per megawatt.
 NTPC is also facing severe problems on the norms of start-up electricity. This
electricity to start the whole plant is provided by the state government after lots of
efforts.
 Water scarcity due to shortage of rain has also been encountered as one of the
biggest problem of NTPC plant. The water providing source Rihand Dam had
dried up due to shortage of rain and thereby hinders the production of electricity.
 Several safety issues have also been recorded in past in NTPC, Vindhyachal plant
despite of the Safety Department present in the plant.

51
These problems however cannot be resolved completely but however can be sorted to a
certain extent by following ways:
 NTPC must try to acquire the lands surrounding its area by giving the rural proper
jobs and penalties so that they may be able to get equipment contracts easily.
 Water shortage can be sorted if NTPC has its own storage tanks and even if they
recycle and use the water.
 Electricity can be easily resolved by its good relationship with the state
government which provide them electricity to start the plant and further for any
other requirements.
 Coal problems can be sorted by the bulk storage of coal when available and to be
used during its shortage specially during monsoon season.

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