NTPC Ltd

India’s largest power company, NTPC was set up in 1975 to accelerate power
development in India. NTPC is emerging as a diversified power major with
presence in the entire value chain of the power generation business. Apart from
power generation, which is the mainstay of the company, NTPC has already
ventured into consultancy, power trading, ash utilization and coal mining. NTPC
ranked 317th in the ‘2009, Forbes Global 2000’ ranking of the World’s biggest
companies.
The total installed capacity of the company is 30, 144 MW (including JVs) with 15
coal based and 7 gas based stations, located across the country. In addition
under JVs, 3 stations are coal based & another station uses naptha/LNG as fuel.
By 2017, the power generation portfolio is expected to have a diversified fuel mix
with coal based capacity of around 53000 MW, 10000 MW through gas, 9000
MW through Hydro generation, about 2000 MW from nuclear sources and around
1000 MW from Renewable Energy Sources (RES). NTPC has adopted a multi-
pronged growth strategy which includes capacity addition through green field
projects, expansion of existing stations, joint ventures, subsidiaries and takeover
of stations.
National Capital Power Station Dadri

The National Capital Power Station [NCPS] has the distinction of being the
country's only three in one project ; consisting of Stage-I 840 MW; Stage-II
490MW ( and 490 MW under construction) of coal based units , 829 MW gas
based modules , and a 1,500 MW H.V.D.C. converter station {under the
operational control of P.G.C.I.L. since October '93}. The stage-II (490MW*2) coal
based units are scheduled in 2010 to meet the common wealth games power
requirement. The commercial operation of Stage-II Unit-V 490 MW has been
declared w.e.f 31.01.2010. Also work for Stage-II UNIT-VI 490MW is under full
swings. Besides the station has the largest switchyard in the country with a
power handling capacity of 4,500 MW
The station's capacity allocation is mainly concentrated in northern region of India
. Spread over 2,465 acres , the station is situated on the Dadri -Dhaulana road
[10 kms. off Dadri G.T. road , and 12 kms. off the National Highway # 24] . The
route from New Delhi to NCPS is 60 kms. long and is about 25 kms. from
Ghaziabad
The station has the unique distinction of having Asia's first 100 percent dry ash
extraction with transit ash storage silos and final storage place converted to an
green ash mound . An Ash Technology park has also been set up to
demonstrate the uses of ash which has become the point of attraction for the
visitors.
USES OF COAL ASH
Dadri ash have been successfully used in the following applications .

• LAND FILLS
• ROAD EMBANKMENTS
• ROAD CONSTRUCTION
• PORTLAND POZZOLONA CEMENT
• BUILDING PRODUCTS
• CONCRETE

Use of Dadri ash in above applications have resulted in saving in terms of money
, conservation of natural resources viz mother earth, lime stone, coal, sand,
energy, land and water apart from reduction in CO2 emission and thus
environment.
PRESENT SENARIO IN INDIA
• 65% of the total installed power generation is coal based.
• 230 - 250 million MT coal is being used every year.
• High ash contents vrying from 30 to 50%.
• 95 million MT ash generated every year.
• Ash generation likely to reach 170 million MT by 2010.
• Presently 65000 Acres of Land occupied by Ash Ponds.

The NCPS Dadri project has the unique distinction of having Asia's first 100
percent dry ash extraction with transit ash storage silos and final storage place
converted to an green ash mound.

Ash can be collected in following categories: -

 • DRY FLY ASH:-
Dry ash is collected from different rows of electrostatic precipitators. It is
available in two different grades of fineness in silos for use as resource material
by different users
• BOTTOM ASH:-
Bottom ash collected from bottom of boiler and transported to hydro bins and
then ash mound for use in Road Embankment.
• CONDITIONED FLY ASH: -
Conditioned fly ash is also available in Ash mound for use in Land fills and Ash
Building prod

NTPC - A trend setter in the country has set up 100 % dry ash extraction cum
disposal in the form os Ash Mound at NTPC Dadri .
Ash mound has come out as the most viable alternative for ash disposal in an
economic friendly way by minimum use of land and water.
ADVANTAGES OF ASH MOUND

• Less requirement of land only 1/3rd land requirement as compared to wet

disposal system.
• 375 acres of land is required as compared to 1000 acres for installed capacity
of 840 MW at Dadri.
• Only 1/50th water required in comparison to wet system
• Eliminates leaching effect.
• Separate storage of fly ash (PFA) and furnace bottom ash(FBA).
• Facilitates large scale utilization at later stage.
• The green ash mound can be used as a useful piece of land.

FEATURES OF ASH MOUND

• Ash mound covers area of 375 acres.

• Ultimate height 55 meters.
• Side slope 1:4 with haulage road at 15 m interval.
• Top most flat area 140 acres.
• Capacity of ash storage 53 million cum.
• Sufficient for running 840 MW for 40 years.
• Side slopes covered with green grass and plantations of trees .
• Beautiful green spot in the vicinity of power house.
National Capital Power Station - Coal
The coal-based station mainly meets power requirements of the National Capital
Region [NCR] , and the northern grid . With the World Bank funding component ,
the capital cost of the units is Rs. 16.69 billion . There are four 210 MW coal
based units. The units have a coal-fired boiler and a steam turbine each . The
boiler design is also suitable for 100% operations with heavy furnace oil firing .
For this , three storage tanks , each of capacity 15,000 kL , enough for 10 days
continuous oil firing requirements have been provided for the boilers .

Coal Source:
The coal is transported from the Piparwar block of mines of the North Karanpura
Coalfields of Bihar , over a distance of about 1,200 kms. , by the Indian Railways
bottom discharge , and Box 'N' type of wagons . The coal requirements for the
four units is 15,000 M.T. each day , 3.67 million tonnes annually . The station
has its' own 14 kms. Long rail track from the Dadri Railway Station , to the
site , and a 6 km in-plant track , on electric traction.

National Capital Power Station - Gas

The gas-based station at N.C.P.S. is the country's largest . It has two modules;
each module consists of two gas turbines of 130.19 MW each with one waste
heat recovery boiler and one steam turbine of 154.51 MW capacity . The power
from this plant is allocated to Uttar Pradesh , and also to Delhi , Punjab , Jammu
and Kashmir , Haryana , Himachal Pradesh and Rajasthan . The cost of gas
based modules is Rs. 9.75 billion , which includes a German K.f. W. funding .
The modules are fully commissioned . Gas turbines generate power at an
efficiency of about 32% only , and to utilize the rest of this energy , a combined
cycle system is adopted . The waste heat from the gas turbine exhaust is routed
through the waste heat recovery boiler , and the steam thus generated is utilized
in a conventional steam turbine to generate additional power . By this , the
overall efficiency of fuel heat utilization reaches to about 48% .

Gas Source:
The source of fuel for this plant is the reserves of South Bassein fields in South
Tapi and mid Tapi delta in the Arabian Sea . The natural gas from South Bassein
off shore fields is transported through a submarine pipeline to Hazira onshore
terminal and then through the 1,700 kms. Long Hazira-Bijapur pipeline via
Shahjanpur and Babrala , to the project . For the 829 MW project , the
requirement is 3.00 million cubic meters per day (yearly average). It would be
worthwhile to note that within a short span of less than 7 years , both the coal
and gas based power cycle units/modules have been commissioned in a project .
Both the projects have diverse modern technologies , with the latest process
controls .
HVDC
This is a technological accomplishment in power by NTPC . Commissioned in
December '90 , the system is the first commercial long distance HVDC link in
India , and also the largest in Asia . The basic objective of the HVDC link is to
transmit the power generated at the RhSTPP efficiently to the northern region ,
with significant reduction in transmission losses . It consists of two converter
stations - one located at Rihand (RhSTPP) acting as a rectifier , and the other at
Vidyutnagar (NCPP) as an inverter , involving a distance of about 900 kms. .
These stations are connected by a +/- 500 kV HVDC line for transmission of
1,500 MW power from Rihand to Vidyutnagar . The overall HVDC system
engineering was done by Asea Brown Boveri .

The special features of this HVDC line are that the entire system can be
controlled either from RhSTPP or NCPP , depending on which station is selected
as the master . The system has been handed over to the Power Grid Corporation
of India , and is under their control since October 1993
DETAILS OF 220KV AND 400KV FEEDERS SOURCES

Sl.No. Line Name Capacity Remarks

1. Generator - 1 210 MW
Thermal Plant
2. Generator - 2 210 MW

3. Generator - 3 210 MW

4. Generator - 4 210 MW

5. Generator - 1 131 MW
Gas Plant
6. Generator - 2 131 MW

7. Generator - 3 131 MW

8. Generator - 4 131 MW

9. Generator – 5 (Steam) 146.5 MW

10. Generator – 6 (Steam) 146.5 MW

11. HVDC Feeder 1500 MW HVDC

TRANSMISSION LINES

Sl.No. Line Name Capacity States

1. Panipat - 1 500MW Haryana

2. Panipat - 2 600MW

3. Murad Nagar 500MW Utter Pradesh

4. Maler Kotla 500MW Puniab

5. Mandola - 1 750MW Delhi

6. Mandola - 2 750MW

7. Greator Noida 750MW Utter Pradesh

Delhi
8. Maharani Bagh 750MW
2.2 SUB-STATION EQUIPMENTS

1. Bus-bar

2. Circuit Breaker

3. Earth Switch

4. Inter Connecting Transformer (I.C.T.)

5. Current Transformer (C.T)

6. Capacitive Voltage Transformer (C.V.T.)

7. Lightning Arrester

8. Protection Relay

10. Power Line Carrier Communication (PLCC)

DADRI SWITCHYARD

Figure No. (5) Single line diagram for power flow

BUS BAR SCHEME FOR 220KV SWITCHYARD

Transfer Bus

Main Bus#1

Main Bus#2

Transfer Bus
Bus Coupler
Feeder Coupler

Figure No. (6) Double Main and transfer bus arrangement

BUS BAR SCHEME FOR 400KV SWITCHYARD

ICT Feeder

Bus#1

Bus#2

Feeder#1 Feeder#2

Figure No.(8) : 400kV switchyard single line diagram

CIRCUIT BREAKER

Types of breakers operational at NTPC Dadri Switchyard

(1) 400kV Air blast circuit breaker

(2) 220kV SF6 filled circuit breaker.
SPECIFICATION OF AIR BLAST CIRCUIT BREAKER

Type DLYF420 nc4

Normal Voltage 420KV

Normal Current 2000A

Trip coil voltage 220V dc

Close coil voltage 220V dc

Frequency 50HZ

Short time Current 40KA 3Sec.

Breaking Current Sym. 40KA

Asym. 48 KA

R I L at 50HZ 630KV

Voltage switching impulse 1050

Operating pressure 27-31 Kg

Mass 3850 Kg

Make Hindustan Brown Boveri

SPECIFICATION OF SF6 GAS CIRCUIT BREAKER

 SR. NO CIRCUIT BREAKER

1. CIRCUIT BREAKER TYPE ELF SL 4-1

2. SR. NUMBER 20000070

3. Month and year of Mfg. JANUARY - 2001

4. Voltage 245 KV

5. Normal current 1600/2500 AMP.

6. Lightning impulse with stand voltage 1050 KV

7. Switching impulse with stand voltage - KV

8. Short circuit breaking current 40 KA

9. Short time with stand current & duration 40 LA 1 Sec.

10. Line charging breaking current 125 AMP.

11. Operating sequence 0-0 3S - CO – 3Min- CO

12. First - pole - to - clear factor 1.3

13. Gas pressure SF6 at 200C (abs) 7.0 bar

14. Closing & opening device supply voltage 220 V DC

15. Auxiliary circuit supply voltage 240 V AC

16. Air pressure 20.5 bar

17. Frequency 50 Hz

18. Mass (approx) for 3 poles 4000 kg

INTERCONNECTING TRANSFORMER (ICT)

Power transformers are the backbone of the large grid. The power is generated
at the low voltage level and has to be carried to far away load centers. Typically
the power is generated at the Pit heads i.e power source like coal, water. It is
uneconomical carry the bulk power at low voltage levels. Depending upon the
requirement the voltage level is stepped upto the transmission level i.e 220 or
400kV. At higher voltages the transmission losses are less. Similarly at the
remote end the voltage is stepped down the distribution level. To accomplish the
task
Power transformers are installed and act as bi-directional element in the system.
At NTPC Dadri this task is carried out by bank of Single Phase 400/220kV
Interconnecting transformers. Autotransformers are used when transformation
ratio is between 1 and 2 and above 315MVA, due to size and weight constraints
all the transformers are single phases. Three such single phase transformers are
installed three phases to make One bank of transformer.
Three banks of transformers are installed to evacuate power from the 220kV
switchyard generated by 4X 210MW thermal Units.

All these transformers are star- star connected transformers with neutral solidly
grounded. A third winding called tertiary winding at much lower voltage i.e 33kV,
is also provide and is connected in delta to facilitate the flow of third harmonic
current to reduce the distortion in the output voltage.
To reduce the overall size of the transformer, the transformer is provided with Oil
forced and Air forced type cooling at its 100% rating. However, to save the
energy, the cooling system is controlled by the temperature of the winding.
The transformers are also equipped with On Load Tap Changer to meet the
change in voltage variation. Typically the Tap changer provides variation
between ± 10% of the nominal voltage i.e. 400kV with a variation of 0.5% at each
tap.

6.1 SPECIFICATIONS
Make CROMPTON GREAVES Ltd.
No. 3
Rating 167*3 = 500 MVA
 Tap 17
No load Voltage KV (HV 400/√3
side)
No load Voltage KV (IV side) 220/√3
No load Voltage KV (LV side) 33 KV
Line current Amp. (HV side) 289.25 , 433.88 , 723.13
Line current Amp. (IV side) 525.91, 788.87, 1314.78
Line current Amp. (LV side) 1688.48
Connection symbol YNaOd11 for 3 phase bank
Type of cooling ONAN / ONAF / OFAF
Frequency 50 Hz
Insulation level (HV) 1450kV
Insulation level (IV) 630kV
Insulation level (LV) 250kV
Temperature rise oil deg. c 350 above ambient

PROTECTION RELAYS
Relay is a device that detects the fault mostly in the high voltage circuits and
initiates the operation of the circuit breaker to isolate the defective section from
the rest of the circuit. Whenever fault occurs on the power system, the relay
detects that fault and closes the trip coil circuit. This results in the opening of the
circuit breaker, which disconnects the faulty circuit. Thus the relay ensures the
safety of the circuit equipment from damage, which the fault may cause.
PURPOSE OF PROTECTIVE RELAYING
The capital investment involved in a power system for the generation,
transmission and distribution of electrical power is so great that the proper
precautions must be taken to ensure that the equipment not only operates as
nearly as possible to peak efficiency, but also that it is protected from accidents.
The normal path of the electric current is from the power source through copper
conductors in the generators, transformers and transmission lines to the load and
it is confined to this path by insulation. The insulation however may be broken
down, either by the effect of temperature and age or by a physical accident, so
that the current then follows an abnormal path generally known as a short circuit
or fault. Whenever this occur the destructive capabilities of the enormous energy
in the power system may cause expensive damage to the equipment, severe
drop in the voltage and loss of revenue due to interruption of service. Such faults
may be made in frequent by good design of the power apparatus and lines and
the provision of protective devices, such as surge diverters and ground fault
neutralizers, but a certain number will occur inevitably due to lightening and
unforeseen accidental conditions.
The purpose of protective relays and relaying systems is to operate correct circuit
breaker so as to disconnect only the faulty equipment from the system as quickly
as possible, thus minimizing the trouble and damage caused by faults when they
do occurs. With all other equipment it is only possible to mitigate the effects of
short circuit by disconnecting the equipment as quickly as possible, so that the destructive
effects of the energy into the fault may be minimized.
UNDER VOLTAGE RELAY
Under voltage protection is provide for AC circuits, busbar, transformer, motor,
rectifier etc. Such protection is given by means of under voltage relay. The relay
coil is energized by voltage to be measured either directly or via a voltage
transformer.
9.3 OVER CURRENT RELAY
If a short circuit occurs the circuit impedance is reduced to a low value and
therefore a fault is accompanied by a large current, Over current protection is
that protection in which the relay pickup when the magnitude of current exceeds
the pickup level. The basic element in over current protection is an over current
relay. The over current relays are connected to the system normally by means of
CTs.

9.4 EARTH FAULT RELAY

Earth fault protection responds to single line to ground fault and double line to
ground faults. The current coil of the earth fault relay is connected either in
neutral to ground relay CT circuit. Core balance Cts are used for earth fault
protection.

9.5 DIFFERENTIAL RELAY

Differential protection responds to vector difference between two or more similar
quantities. In circulating current differential protections CTs are connected on
either side of the protected equipments. During the internal faults the difference
of secondary current flow through the relay coil. Differential protection is used for
protection of large transformer, generator, motors feeders and busbars.
t