NTPC DADRI

SUMMER TRAINING
ENERGY EFFICINECY AND MAINTENANCE
GROUP
KULDEEP KUMAR
ENERGY ENGG.
MANIT BHOPAL
SCH.NO- 081113223




SUMMLk 1kAINING N1C DADkI
Indias largest power company, NTPC was set up in 1975 to accelerate
power development in India. NTPC is emerging as a diversified power
mafor 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 utili:ation and coal mining. NTPC ranked 317th in the 2009,
Forbes Global 2000 ranking of the Worlds biggest companies. The
total installed capacity of the company is 30, 144 MW (including JJs)
with 15 coal based and 7 gas based stations, located across the country.
In addition under JJs, 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
profects, expansion of existing stations, foint ventures, subsidiaries and
takeover.

National Capital Power Station Dadri
The National Capital Power Station [NCPS] has the distinction of being
the countrys only three in one profect , 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.J.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-J 490 MW has been declared w.e.f
31.01.2010. Also work for Stage-II UNIT-JI 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 stations capacity
allocation is mainly concentrated innorthern 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 Gha:iabad The station has the unique distinction of having
Asias 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






Plant discription
Address NTPC-Dadri,Vidyut Nagar-201 008,Dist. Gautam Budhnagar,Uttar Pradesh

Telephone 2671284

Fax 2672330

Approved
capacity

817MW
Location

Distt. Gautam Budhnagar, Uttar Pradesh
Gas Source

HBJ Pipe line/ 3 MMSCMD (APM Gas)
Alternate Fuel: HSD
BeneIiciary
States
U.P.,Uttrakhand,Rajasthan,Delhi,Punjab,Haryana,HP,J&K,Chandigarh,Railw
ays
Approved Cost Rs.960.35crores(02.11.94)

Unit Sizes 4 GTX 130.19 MW 2 STX 154.51 MW
Units
Commissioned
GT-I- 130.19 MW May 1992
GT II- 130.19 MW June1992
GT III-130.19 MW August1992
GT IV-130.19 MW December1992
ST-I- 154.51 MW August 1996
ST-II- 154.51 MW April 1997





ENERGY CONSERVATION IN CONVENTIONAL
THERMAL POWER PLANT

Potential to improve the energy eIIiciency and conservation in power
plant-
With the help oI some modernization and renovation oI running power p
lant we can improve energy eIIiciency and conservation Ior any power
plant as given Iollowing-
1. Try to operate plants and equipments at raped capacity.
2. Cary out routine and preventive maintenance.
3. Energy eIIicient lighting system to be provided Ior all location.
4. Ensure proper working oI de-aerating equipment , and condenser
evacuation system.
5. Reduce hot water wastage.
6. Stop steam leakage. Steam leakage Irom a 3mm-diameter hole on a
pipeline carrying steam at 7kg/cm
2
would waste 32 kilolitres oI
Iuel oil per year.
7. Inspection, repair and replacement oI insulation. Heat loss Irom a
Iurnace wall 115mm thick at 650
o
C amounting to 2650 kcal/m
2
/hr
can be cut down to 850kcal/m
2
/hr by using 65 mm thick insulation
on the wall.
8. Variable Irequency drives should be used Ior speed control in the
raw coal Ieeders, large boiler combustion Ians with variable Ilow.
9. Cooling tower Ian motors to be replaced with high eIIiciency
motors.
10. Utilize waste heat Irom Iurnace Ilue gases Ior preheating oI
combustion air and boiler Ieed water. Evergy 22 dergee c rise in
combustion air temperature results in 1 saving oI Iuel.
11. Improve Iurnace burner design, comhution control and
instrumentation.
12. Control excess air in Iurnaces. 1 reduction in excess
oxygen in stack gas reduces 1 Iuel consumption.
13. Check inIiltration oI air and ensure a slight positive pressure
in the Iurnace combustion chamber.
14. Reduce heat losses Irom through Iurnace opening.
15. Use only treated water in boiler. A
scale
Iormation oI 1mm
thickness on the waterside would increase Iuel consumption by 5
to 8.
16. Remove sot deposits when Ilue gas temperature rises 40
0
C
above the normal. A coating oI 3mm thick soot on the heat transIer
surIace can cause an increase in Iuel consumption by 2.
17. Recover heat Irom heat condensate. For every 6
0
C rise in
boiler Ieed water temperature through condensate return, there is
1 saving in Iuel.
18. Replacement oI ineIIicient aluminium or Iabricated steel Ians
with molded aeroIoil designs FRP Ians reduces energy
consumption.
19. Replacement the wooden blade driIt eliminators with cellular
PVC driIt eliminators reduces the driIt losses and Ian power saving
oI 10.
20. Install automatic on- oII switches on cooling tower Ians.
21. Reduces Ilue gas temperature. II exit temperature is in the
range oI 175 degree c to 260 degree c, a 20degree reduction in Ilue
gas temperature may improve boiler eIIiciency by 1.

Energy conservation in Electricity Transmission and Distribution-
Nearly all the modern and super capacity generating stations are located
Iar Irom the actual electricity load centres. Transmission oI generated
electrical power to load centres such as cities and large industries and
their Iurther distribution is carried out through transmission and
distribution losses. The EIIiciency oI transmission and distribution
network is improved by reducing T and D losses.

Reason oI T and D losses-
1. Some power is dissipated in transIormers while stepping up or
stepping down the voltage levels.
2. Some power is lost along the lines and cables in Iorm oI I
2
R
losses.
3. Corona losses
4. Losses occurring at various stages oI power transIormation and
loading oI transmission system aat 132 kv and above are
transmission losses, whereas losses occurring at 33kv and above
are transmission losses. The losses at 11kv and lower voltage
levels are termed distribution losses.


Normally transIormer losses are 0.5 oI total losses. The line
losses are nearly 2 Ior transmission voltage and 4 and 5
respectively Ior primary and secondary distribution system.
The transmission and distribution losses associated with the
operation oI network are classiIied as technical and non technical
losses-
Technical losses-
It depend oI load nature, system conIiguration , characterstics oI
equipment etc. it is due to unadequate sizing oI conductor
,lengthy transmission and distribution line ,unadequate reactive
compensation in the system. This is two types-
1-variable losses- these losses occur mainly in lines and cables and
in the current part oI transIormer(copper losses) and are
proportional to square carrying oI current that the particular
equipment carries .
2. Fixed losses- these losses occur mainly in the transIormer cores
and do not vary according to current. The level oI Iixed losses in a
transIormer is largely dependent on the quantity and quality oI
material.
Non technical losses-
The non technical losses are component oI distribution system
losses and are because oI unidentiIied and uncollected revenue,
arising Irom metering errors, shortIalls in billing and revenue
collection and consumer malpractices like such as meter
tampering, illegal connections.
Methods to improve the T and D losses-
There are some methods which are being used to optimize system
losses-
1. The installation oI static VAr controller in the transmission
system can reduce Tand D losses. Nearly 8 oI the losses take
place above 33KV level and rest do happen below 33kv level.
2. The use oI low loss transIormer( low constant or magnetizing
loss) Particurlarly in case distribution transIormer. A new
development is the amorphous core distribution transIormer
with very low constant losses(iron loss) but higher cost than
conventional units.
3. Re-conductor overhead line with large cross-sectional area
conductors, use oI lower resistence conductors such as all
aluminium alloy conductor.
4. Keeping the load on power and distribution transIormers with in
limits and shiIting oI distribution to load centre.
5. Installation oI cable oI large conductor size.
6. Use oI cables and conductors with lower dielectric losses
7. Use oI higher sub-transmission voltage and upgrading oI 11kv
network to 33 kv networks. Because power losse in
transmission line are inversely proportional to V
2
. Where V is
voltage at which power is being supplied.
We know that
Complex power
8. Installation oI swiched shunt capacitors banks Ior reactive
power compensation, either at substations or on the line .
9. Improving the eIIiciency oI insulator by providing the ring
guard method to keep maintain voltage at each insulator section
and improve the string eIIiciency
10. Reducing the corona losses by grading oI insulator,
increasing the distance b/w conductor , polished and smooth
conductor and increasing the radius oI conductors.

Dadri ash have been successIully used in the Iollowing applications.
LAND FILLS
ROAD EMBANKMENTS
ROAD CONSTRUCTION
PORTLAND POZZOLONA CEMENT
BUILDING PRODUCTS
CONCRETE
Use oI Dadri ash in above applications have resulted in saving in terms
oI money , conservation oI natural resources viz mother earth, lime
stone, coal, sand, energy, land and water apart Irom reduction in CO2
emission and thus
environment.
PRESENT SENARIO IN INDIA
65 oI the total installed power generation is coal based.
230 - 250 million MT coal is being used every year.
High ash contents vrying Irom 30 to 50.
95 million MT ash generated every year.
Ash generation likely to reach 170 million MT by 2010.
Presently 65000 Acres oI Land occupied by Ash Ponds.
The NCPS Dadri project has the unique distinction oI having Asia's Iirst
100 percent dry ash extraction with transit ash storage silos and Iinal
storage place converted to an green ash mound. Ash can be collected in
Iollowing categories:-



DRY FLY ASH:-
Dry ash is collected Irom diIIerent rows oI electrostatic
precipitators. It is available in two diIIerent grades oI Iineness in silos
Ior use as resource material by diIIerent users.

BOTTOM ASH:-
Bottom ash collected Irom bottom oI boiler and
transported to hydro bins and then ash mound Ior use in Road
Embankment.

CONDITIONED FLY ASH: -
Conditioned Ily ash is also available in Ash
mound Ior use in Land Iills and Ash Building product.NTPC- A trend
setter in the country has set up 100 dry ash extraction cum disposal in
the Iorm os Ash Mound at NTPC Dadri .Ash mound has come out as the
most viable alternative Ior ash disposal in an economic Iriendly way by
minimum use oI land and water.

ADVANTAGES OF ASH MOUND

Less requirement oI land only 1/3rd land requirement as compared to
wet
disposal system.
375 acres oI land is required as compared to 1000 acres Ior installed
capacity
oI 840 MW at Dadri.
Only 1/50th water required in comparison to wet system
Eliminates leaching eIIect.
Separate storage oI Ily ash (PFA) and Iurnace bottom ash(FBA).
Facilitates large scale utilization at later stage.
The green ash mound can be used as a useIul piece oI land.

FEATURES OF ASH MOUND
Ash mound covers area oI 375 acres.
Ultimate height 55 meters.
Side slope 1:4 with haulage road at 15 m interval.
Top most Ilat area 140 acres.
Capacity oI ash storage 53 million cum.
SuIIicient Ior running 840 MW Ior 40 years.
Side slopes covered with green grass and plantations oI trees .
BeautiIul green spot in the vicinity oI power house.


National Capital Power Station - Coal
The coal-based station mainly meets power requirements oI the National
Capital Region |NCR| , and the northern grid . With the World Bank
Iunding component , the capital cost oI the units is Rs. 16.69 billion .
There are Iour 210 MW coal based units. The units have a coal-Iired
boiler and a steam turbine each . The boiler design is also suitable Ior
100 operations with heavy Iurnace oil Iiring . For this , three storage
tanks , each oI capacity 15,000 kL , enough Ior 10 days continuous oil
Iiring requirements have been provided Ior the boilers .

Coal Source:
The coal is transported Irom the Piparwar block oI mines oI the North
Karanpura CoalIields oI Bihar , over a distance oI about 1,200 kms. , by
the Indian Railways bottom discharge , and Box 'N' type oI wagons .
The coal requirements Ior the Iour units is 15,000 M.T. each day , 3.67
million tonnes annually . The station has its' own 14 kms. Long rail track
Irom 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 oI two gas turbines oI 130.19 MW each
with one waste heat recovery boiler and one steam turbine oI 154.51
MW capacity . The power Irom this plant is allocated to Uttar Pradesh ,
and also to Delhi , Punjab , Jammu and Kashmir , Haryana , Himachal
Pradesh and Rajasthan . The cost oI gas based modules is Rs. 9.75
billion , which includes a German K.I. W. Iunding . The modules are
Iully commissioned . Gas turbines generate power at an eIIiciency oI
about 32 only , and to utilize the rest oI this energy , a combined
cycle system is adopted . The waste heat Irom 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 eIIiciency oI Iuel heat utilization
reaches to about 48 .

Gas Source:
The source oI Iuel Ior this plant is the reserves oI South Bassein Iields in
South Tapi and mid Tapi delta in the Arabian Sea . The natural gas Irom
South Bassein oII shore Iields 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 oI 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( high voltage D.C current)
This is a technological accomplishment in power by NTPC .
Commissioned in December '90 , the system is the Iirst commercial long
distance HVDC link in India , and also the largest in Asia . The basic
objective oI the HVDC link is to transmit the power generated at the
RhSTPP eIIiciently to the northern region , with signiIicant reduction in
transmission losses . It consists oI two converter stations - one located at
Rihand (RhSTPP) acting as a rectiIier , and the other at
Vidyutnagar (NCPP) as an inverter , involving a distance oI about 900
kms. . These stations are connected by a /- 500 kV HVDC line Ior
transmission oI 1,500 MW power Irom Rihand to Vidyutnagar . The
overall HVDC system engineeringwas done by Asea Brown Boveri .
. The special Ieatures oI this HVDC line are that the entire system can be
controlled either Irom RhSTPP or NCPP , depending on which station is
selected as the master . The system has been handed over to the Power
Grid Corporation oI India , and is under their control since October 1993
.




SUB-STATION EQUIPMENTS
1. Bus-bar
2. Circuit Breaker
3. Earth Switch
4. Inter Connecting TransIormer (I.C.T.)
5. Current TransIormer (C.T
6. Capacitive Voltage TransIormer (C.V.T.)
7. Lightning Arrester
8. Protection Relay
10. Power Line Carrier Communication (PLCC)














CIRCUIT BREAKER
Types oI breakers operational at NTPC Dadri Switchyard

(1) 400kV Air blast circuit breaker
(2) 220kV SF6 Iilled circuit breaker






SLClllCA1lCn Cl Sl6 CAS Cl8Cul1 88LAkL8










PROTECTION RELAYS
Relay is a device that detects the Iault mostly in the high voltage circuits
and initiates the operation oI the circuit breaker to isolate the deIective
section Irom the rest oI the circuit. Whenever Iault occurs on the power
system, the relay detects that Iault and closes the trip coil circuit. This
results in the opening oI the circuit breaker, which disconnects the Iaulty
circuit. Thus the relay ensures the PURPOSE OF PROTECTIVE
RELAYING .The capital investment involved in a power system Ior the
generation, transmission and distribution oI 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 eIIiciency, but also that it
is protected Irom accidents. The normal path oI the electric current is
Irom the power source through copper conductors in the generators,
transIormers and transmission lines to the load and it is conIined to this
path by insulation. The insulation however may be broken
down, either by the eIIect oI temperature and age or by a physical
accident, so that the current then Iollows an abnormal path generally
known as a short circuit or Iault. Whenever this occur the destructive
capabilities oI the enormous energy in the power system may cause
expensive damage to the equipment, severe drop in the voltage and loss
oI revenue due to interruption oI service. Such Iaults may be made in
Irequent by good design oI the power apparatus and lines and
saIety oI the circuit equipment Irom damage, which the Iault may cause
the provision oI protective devices, such as surge diverters and ground
Iault neutralizers, but a certain number will occur inevitably due to
lightening and unIoreseen accidental conditions.
The purpose oI protective relays and relaying systems is to operate
correct circuit breaker so as to disconnect only the Iaulty equipment
Irom the system as quickly as possible, thus minimizing the trouble and
damage caused by Iaults when they do occurs. With all other equipment
it is only possible to mitigate the eIIects oI short circuit by disconnecting
the equipment as quickly as possible, so that the destructive eIIects oI
the energy into the Iault may be minimized.


UNDER VOLTAGE RELAY
Under voltage protection is provide Ior AC circuits, busbar, transIormer,
motor, rectiIier etc. Such protection is given by means oI under voltage
relay. The relay coil is energized by voltage to be measured either
directly or via a voltage transIormer.
OVER CURRENT RELAY
II a short circuit occurs the circuit impedance is reduced to a low value
and thereIore a Iault is accompanied by a large current, Over current
protection is that protection in which the relay pickup when the
magnitude oI 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 oI CTs.
EARTH FAULT RELAY
Earth Iault protection responds to single line to ground Iault and double
line to ground Iaults. The current coil oI the earth Iault relay is
connected either in neutral to ground relay CT circuit. Core balance Cts
are used Ior earth Iault
protection.
DIFFERENTIAL RELAY
DiIIerential protection responds to vector diIIerence between two or
more similar quantities. In circulating current diIIerential protections
CTs are connected on either side oI the protected equipments. During
the internal Iaults the diIIerence oI secondary current Ilow through the
relay coil. DiIIerential protection is used Ior protection oI large
transIormer, generator, motors Ieeders and busbars.