INTRODUCTION

National Thermal Power Corporation, NTPC, Indias largest power producing company, was set
up in 1975 to accelerate Indias power development in India. It is emerging as a diversified
power producing company with presence in the entire value chain of the power generation
business. Apart from the power generation, which is the mainstay of the company, NTPC has
already ventured into consultancy, power trading, ash utilisation, and coal mining. NTPC is
ranked 341st in the 2010, Forbes Global 2000 ranking of the Worlds largest companies. NTPC
became a Maharatna company in May 2010, one of the only five companies to be awarded with
this status.
With a current generating capacity of 37,514 MW by 16 coal based and 7 gas based stations,
located across the country, NTPC has embarked on plans to become a 75,000 MW company by
2017 and 1,28,000 MW by the year 2032. The capacity will have a diversified fuel mix
comprising of 56% coal, 16% gas, 11% Nuclear and 17% Renewable Energy Sources (RES)
including hydro. By 2032, non fossil fuel based generation capacity shall make up nearly 28% of
NTPCs portfolio.
At NTPC, People before the Plant Load Factor is the main mantra that guides all HR related
policies. NTPC has been awarded No. 1, Best Workplace in India among large organisations and
the best PSU for the year 2010, by the Great Places to Work Institute, India Chapter in
collaboration with The Economic Times.
The concept of Corporate Social Responsibility is deeply ingrained in NTPCs culture. Through
its expansive CSR initiatives, NTPC strives to develop mutual trust with the communities that
surround its power stations.

UNIQUE FEATURES OF NTPC SIMHADRI

The Simhadri Power Project is the first coastal coal fired thermal power project of
NTPC.
The biggest intake well in the country has been installed inside the Bay of Bengal to

1
 draw seawater for use in CW system as make up water.
Four natural draft-cooling towers of 165 meters height each are the biggest in Asia and
sixth largest in world.
Man-Machine (MMI) systems using monitors for operating the plant
Process Analysis Diagnosis and Optimization (PADO) system is used in plant operation
Flame analysis is done here
Acoustic pyrometers for boiler mapping
DDCMIS (Distributed Digital Control & Management Information System)
Totally loaded floating foundations for all major equipment including Turbo generators
Using INERGEN gas (eco-friendly) for the first time for protection from fire
Crowning NTPCS superlative saga of power, Simhadri Thermal Power Project comes alive on
the power map of the country with the synchronization of the first 500MW Unit. Racing against
time in project implementation, the Simhadri Thermal Power Project has set a new benchmark
for green-field project of this size and earned the distinction of being the only power project of
this size in the country to commission the 500MW unit in a record time of 39 months from the
date of main plant order, a feat that will probably remain unsurpassed. Spread over an area of
3,384 acres near Paravada in Visakhapatnam District of Andhra Pradesh, the 1000MW Simhadri
Thermal Power Project has two units of 500MW capacity each. The entire power generated from
this station will be supplied to Andhra Pradesh. The erstwhile Andhra Pradesh State Electricity
Board had signed a Power Purchase Agreement with NTPC on February 4, 1997. The Simhadri
Power Project will provide a bountiful power to Andhra Pradesh, the land of myriad
opportunities. Commissioning of the Simhadri Project is one step ahead . Generation of reliable
and quality power in large quantities from this station will forever keep Andhra Pradesh forging
ahead in the country as well as globally.

The Project name Simhadri comes from Simhachalam, the hill top temple of Lord Varaha
Lakshminarasimha Swamy, which is 16km from Visakhapatnam. The project was originally
conceived by the erstwhile Andhra Pradesh State Electricity Board, which submitted a feasibility
report to the CEA in March 1994. Subsequently, the Government of Andhra Pradesh entrusted
the project to NTPC. After completing the topographical survey, geo-technical investigation,
demography and socio-economic surveys, NTPC obtained techno-economic clearance from the
CEA in September 1996. The Public Investment Board of Government of India gave its approval
in February 1997. The Cabinet Committee on Economic Affairs accorded approval for the
project in July 1997.

2
A CHALLENGE TURNS INTO MEGA REALITY, A DREAM COME TRUE
Setting up of the Simhadri Thermal Power Project, a fast-track project, has been a daunting task.
A total of 3,384 acres of land has been acquired for construction of this project. A great deal of
courage to take bold decision, transform concepts into real tasks, sound material, contractual,
financial and man power management helped in commissioning the project well ahead of
schedule. For achieving speedy implementation, NTPC adopted a unique packaging concept at
the project. The entire works were executed under 13 packages as compared to earlier concept of
45 to 48 packages. The main plant turnkey contract was awarded to Bharat Heavy Electricals
Ltd., in November 1998. The scope of the main plant turnkey contract includes design,
manufacturing, engineering, civil construction, erection, testing and commissioning.
The massive task of installation of the project started with site leveling works on December 6,
1998. The site leveling involved massive earth filling to the tune of more than 82 lakh cubic
meter, which was completed in 16 months against a schedule of 17 months. This is the first
coastal-based green-field project, where additional works were required to be done due to
massive earth filling and deeper foundations as well as preparing of structural designs that were
suited for high wind zone and saline atmosphere to give protection for various structures, piping
and equipment. The entire construction, erection and commissioning works have been executed
ensuring quality and efficiency. As the works progressed, the project has set new benchmarks in
project implementation by achieving several major milestones well ahead of schedule. One of the
major milestone achievements is Unit-1 boiler light upon November 6, 2001 in 351/2 months,
which is a national record. The biggest intake well has been constructed offshore of the Bay of
Bengal for drawing sea water for using in the CW system for condenser cooling as make up
water. A 275-metre tall chimney, which has been built for wide dispersal of flue gases, is now
towering over the area. Two natural draft-cooling towers with a height of 165metres, which are
the biggest in Asia and the sixth biggest in the world, have been constructed. Synchronization of
the first 500MW Unit in a record time of 39 months is a challenge turned into mega reality
through hard work, innovation, determination and courage of the entire NTPC team. Today, the
project stands as a mammoth power complex.

3
FACTS ABOUT NTPC SIMHADRI
Govt..... approved date : 24.07.1997
Plant Capacity : 2000 MW
Plant Configuration : 4x500 MW
Land Availability : 3384.24 acres (land)
Internal Assistance : 32.011 billion euros (JBIC)
Approved Investment: Rs 3650.79 crore
Associated Transmission System : Being executed by APSEB

PROJECT PROFILE
Approved capacity : 2000MW(4x500MW)
Location : Paravada Mandal, Visakhapatnam, A.P.
Project cost : Rs 3,650.79 crore.
Source of finance : JBIC Loan and internal resources.
Fuel Requirement : 5.04 Million Tonnes of coal per annum
Mode of Transportation : By rail
Sweet Water Requirement : 600 cubic meters per hour
Source : Yeleru Canal
Seawater Requirement : 9,100 cubic meters per hour
Source : Bay of Bengal
Main Plant Turnkey package : Awarded to BHEL on November 23rd, 1998.
Evacuation : Through 400kv system of AP TRANSCO 400kv
Double circuit Vizag-Vemagiri- Nunna line. 400kv Double
Circuit Vizag- Khammam line 400kv Double circuit
Khammam- Hyderabad. 400kv Double circuit Vizag-
Gajuwaka(PGCIL) line.
Commissioning Schedule : 500MW unit-1 March 2002 Synchronised on February
22, 2002 ahead of schedule. : 500MW unit-11

4
 December 2002
Beneficiary State : Andhra Pradesh

AN OVERVIEW OF THERMAL POWER PLANT

Conversion of Chemical Energy to Electrical Energy

Initially the coal is brought through railway wagons from Talcher Coal Fields and is unloaded at
the Track Hopper in the coal handling plant where the Paddle Feeder which feeds the coal onto
the conveyer belts. The conveyer belts take the coal through metal detectors and magnetic
separators and to remove any unwanted material in the coal. The coal is then crushed in the
crushers to the size of 20mm. From there, the coal is fed to the coal bunkers at the boilers. There
are 18 sets of coal bunkers (Nine for each boiler).
From the bunkers, coal is passed into the coal mills, where pulverised coal is made into fine
powder. From here, coal is mixed with air and is forced into the boiler from four sides with the

5
help of forced drought fans. Inside the boiler, coal is fired and a ball of fire is formed. This is a
water tube boiler so demineralised water flows through economiser, boiler drum and goes to the
ring header and there it is divided to all four sides through tubes inside the boiler to the furnace
and heat is transferred converting water into steam. This steam and water mixture is again taken
to the boiler drum where the steam is separated and passed through super heater and is first
passed through the HP Turbine and then after reheating, it is passed through IP Turbine and then
through LP Turbine. Water flows through the same path. All the turbines are mounted on the
same shaft and are mechanically coupled to the generator. The generator converts the mechanical
energy to electricity.
The steam after passing through the LP Turbine is then fed to the condenser where it is
condensed using the sea-water. The condensate is stored in the Condensate Storage Tank. The
condensed water is passed through economiser and is finally fed to the boiler. The sea-water is
used for the cooling purpose in cooling towers.
Flue gases from the furnace are extracted by the induced draught fan. The flue gases emit their
heat energy to various super heater, air pre heaters and economiser and finally pass through the
ESP where the ash particles are collected and mixed with water to form slurry and is pumped to
ash pond.
This is the process of conversion of thermal energy into electrical energy, which is employed at
NTPC Simhadri.

PARTS OF THE POWER PLANT VISITED

COAL HANDLING PLANT In a coal based thermal power plant, the initial process in
the power generation is Coal Handling. The huge amount of coal is usually supplied through
railways. A railway sliding line is taken into the power station and the coal is delivered in the
stack yard. The coal is unloaded from the point of delivery by means of wagon tippler. It is rack
and pinion type. The coal is taken from the unloading site to dead storage by belt conveyors. The
belt delivers the coal to the pent house and further moves to transfer point.
The transfer points are used to transfer coal to the next belt. The belt elevates the coal to breaker
house. It consists of a rotary machine, which rotates the coal and separates the light dust from it
by the action of gravity and transfers this dust to the reject bin house through belt.

6
The belt further elevates the coal to the transfer point and it reaches the crusher through belt. In
the crusher a high-speed 3-phase induction motor is used to crush the coal to a size of 20-25mm
so as to be suitable for milling system. Coal rises from crusher house and reaches the dead
storage by passing through another transfer point.
In NTPC SIMHADRI the coal handling process is described below: The major supply of coal to
the plant is from Talcher and IB Valley coal mines in Orissa. Coal is also imported from
Indonesia as and when required. The average consumption of coal is 380 tonnes per hr. per boiler
of 500MW i.e., approximately 9120 tonnes per day per boiler.
The coal is unloaded at track hoppers from the train and from the hoppers the coal is dragged on
to the conveyer belts using paddle feeders. Metal detectors are used to separate various metal
parts, which are present in the coal, while passing through the conveyor belt and for such
operations inline magnetic separators and suspended magnets are also used. The coal is
transferred to the crushers where the coal of 250mm size is crushed into 20mmsize. From the
crusher house, the coal is transferred to coal stack yard and the bunkers as per requirements
through conveyer belt. Transfer Points (TP) are used at various places in the coal handling plant
for transferring coal from one conveyer to the other which works through the flap gates.

MAIN PARTS OF A COAL HANDLING PLANT

Stack Yard: There is a need for storing of coal required for ten to fifteen days of consumption
to meet any exigencies. So the stack yard is the place where the coal is stored after crushing in to
20mm size. In this stack yard there is a stacker-cum-reclaimer which reclaims the stored coal to
the bunkers in emergency situations through conveyors. This machine consists of bucket wheel
which is rotated by using squirrel cage motors. While in motion, it collects the coal from the yard
and transfers it on to the boom conveyor, which is then transferred to the bunker. It works on the
basis of three motions namely long travel motion, slew motion and luff motion. Long travel drive
consists of eight DC motors for the forward and backward movement each with rating of 7.5
KW. Separately excited slew drive consists of four motors for the slew movement. Pulleys with
pressurized oil cylinders are used for luff motion
STACKER-CUM-RECLAIMER

7
Used to store coal in the stack yard and also to reclaim from the stock yard to conveyer belt.
Wagon Trippler:

Coal from the coal

wagons is unloaded in the
coal handling plant. This
unloading is done by the
Tipplers. This coal is
transported up to the raw
coal bunkers with the help
of conveyor belts.

8
TRACK HOPPER :

coal from the train is

unloaded by removing the
gates of the wagon and it is
collected in under ground and
then it is sent to crusher
houses.

Crusher House:

After hand picking

foreign material, coal is
transported to the Crush
house by conveyor belts
where it is crushed to
small pieces of about 20
mm diameter. The crushed coal is then transported to the store yard. Coal is transported to bowl
mills by coal feeders.
Magnetic separator:

These are used to separate the

ferrous impurities from the

9
coal.
Metal Detector: The transmitter consists of a high frequency oscillator, which produces
oscillations of 1500 Hz at 15V. The receiver receives this frequency signal if there is any
presence of metal in the coal. Then this frequency is disturbed and a tripping signal is send to
relay to stop the conveyor belt.
PADDLE FEEDER used to pour coal on to the conveyer belt.

Conveyer belt

10
AIR PRE HEATER (APH)
The purpose of the air pre-heater is to recover the heat from the boiler flue gas which increases
the thermal efficiency of the boiler by reducing the useful heat lost in the flue gas. As a
consequence, the flue gases are also sent to the flue gas stack or chimney at a lower temperature,
allowing simplified design of the ducting and the flue gas stack. It also allows control over the
temperature of gases leaving the stack (to meet emissions regulations, for example).
Types: There are two types of air pre-heaters for use in steam generators in thermal power
stations: One is a tubular type built into the boiler flue gas ducting and the other is a regenerative
air pre-heater. These may be arranged so the gas flows horizontally or vertically across the axis
of rotation. Another type of air pre-heater is the regenerator used in iron or glass manufacture
Figure: AIR PRE HEATER (APH)

11
Regenerative air pre-heaters: In this design the whole air pre-heater casing is supported
on the boiler supporting structure itself with necessary expansion joints in the ducting. The
vertical rotor is supported on thrust bearings at the lower end and has an oil bath lubrication,
cooled by water circulating in coils inside the oil bath. This arrangement is for cooling the lower
end of the shaft, as this end of the vertical rotor is on the hot end of the ducting. The top end of
the rotor has a simple roller bearing to hold the shaft in a vertical position. The rotor is built up
on the vertical shaft with radial supports and cages for holding the baskets in position. Radial and
circumferential seal plates are also provided to avoid leakages of gases or air between the sectors
or between the duct and the casing while in rotation. For on line cleaning of the deposits from the
baskets steam jets are provided such that the blown out dust and ash are collected at the bottom
ash hopper of the air pre-heater. This dust hopper is connected for emptying along with the main
dust hoppers or the dust collectors. The rotor is turned by an air driven motor and gearing and is
required to be started before starting the boiler and also to be kept in rotation for some time after
the booker is stopped, to avoid uneven expansion and contraction resulting in wrapping or
cracking of the rotor. The station air is generally totally dry (dry air is required for
instrumentation), so the air used to drive the rotor is injected with oil to lubricate the air motor.
Safety protected inspection windows are provided for viewing the pre- heaters internal operation
under all operating conditions. The baskets are in the sector housings provided on the rotor and
are renewable. The life of the baskets depends on the ash abrasiveness and corrosiveness of the
boiler outlet gases.

FANS :
Forced Draft Fans:
The FD fans are used to feed the coal into the boiler by mixing air. There are two fans
per boiler. These are called Forced Draft Fans because irrespective of conditions, they always
forced the air at a constant rate into the boiler. The capacity of the fan is 246 m3/s.
Induced Draft Fans:
The Induced Draft Fans are used to remove the air along with the flue gases and ash and
finally sent out through the chimney after removing the ash content. They are called induced
fans because their working is dependent on the availability of the air inside the boiler. The speed
of the ID fan is controlled through the VFD control of the synchronous motor driving the ID fan.
Primary Air Fans:
The Primary Air Fan is used to suck the atmospheric air and feed it to the boiler and is the
main source of air. There are two fans per boiler. They are of vertical, suction and horizontal

12
delivery type.

BOILER FEED WATER PUMP

A Boiler feed water pump is a specific type of pump used to pump feed water into a steam boiler.
The water may be freshly supplied or returning condensate produced as a result of the
condensation of the steam produced by the boiler. These pumps are normally high pressure units
that use suction from a condensate return system and can be of the centrifugal pump type or
positive displacement type. Feed water pumps range in size up to many horsepower and the
electric motor is usually separated from the pump body by some form of mechanical coupling.
Large industrial condensate pumps may also serve as the feed water pump. In either case, to
force the water into the boiler, the pump must generate sufficient pressure to overcome the steam
pressure developed by the boiler. This is usually accomplished through the use of a centrifugal
pump. Feed water pumps usually run intermittently and are controlled by a float switch or other
similar level-sensing device energizing the pump when it detects a lowered liquid level in the
boiler. The pump then runs until the level in the boiler is substantially increased. Some pumps
contain a two-stage switch. As liquid lowers to the trigger point of the first stage, the pump is
activated. If the liquid continues to drop (perhaps because the pump has failed, its supply has
been cut off or exhausted or its discharge is blocked), the second stage will be triggered. This
stage may switch off the boiler equipment (preventing the boiler from running dry and
overheating), trigger an alarm, or both.
BOILER
A boiler is a closed vessel in which water or fluid is heated. The heated or vaporized fluid exits
the boiler for use in various processes or heating applications.

13
Fire tube boilers:
Here water partially
fills a boiler barrel
with a small volume
left above to
accommodate the
steam. The heat
source is inside a
furnace or a fire-box
that has to be kept
permanently
surrounded by the
water in order to
maintain the
temperature of the heating surface just below the boiling point. The furnace can be situated at
one of the fire tube which lengthens the path of hot gases, thus augmenting the heating surface
which can be further increased by making the gases reversed direction through a second parallel
tube or bundle of multiple tubes (two-pass or return flue boiler). Alternatively the gases may be
taken along the sides and then beneath the boiler through flues. In the case of a locomotive boiler
a boiler barrel extends from the fire box and the hot gases passes through a bundle of fire tubes
inside the barrel which greatly increases the heating surface compared to a single tube and
further improves heat transfer. Fire tube boilers usually have a comparatively low rate of steam
production, but high steam storage capacity. Fire tube boilers mostly burn solid fuels, but are
readily adaptable to those of liquid or gas variety. Water tube boilers: In this type the water
tubes are arranged inside a furnace in a number of possible configurations. Often the water tubes
connect large drums; the lower half portion of the drum contains water and the upper half
contains steam. In other cases such as mono-tube boilers, water is circulated by a pump through a
succession of coils. This type generally gives high steam production rates, but less storage

14
capacity than the above. Water tube boilers can be designed to exploit any heat source including
nuclear fission and are generally preferred in high-pressure applications, since the high-pressure
water or steam is contained within narrow pipes which can withstand the pressure within a
thinner wall.

COOLING TOWER

15
 No. of NDCTs: 04
Height of NDCT: 165 mtrs
Bottom diameter: 100 mtrs
Top diameter: 70 mtrs
Total no of Racker columns :88 per NDCT
Shell thickness :300-350 mm
SPLASH TYPE FILLS used for to increase the surface area of the water particles so
that heat transfer will be more.

16
ELECTROSTATIC PRECIPITATOR
The electrostatic precipitators (ESP) are extensively used in the thermal power plant or steam
power plant for removal of fly ash from the electric utility boiler emissions. The use of
electrostatic precipitators is growing rapidly because of the new strict air code and environmental
laws. An electrostatic precipitators can be designed to operate at any desired efficiency for use as
primary collector or a supplementary unit to cyclone collector. It is often considered worthwhile
to retain an existing cyclone collector as primary collector in the case where the fly-ash
collection efficiencies must be upgraded especially where there is a large amount of unburnt
carbon in the fly-ash. Because the presence of large quantities of the carbon in the gas can
adversely affect the efficiency of the electrostatic Precipitator. Supplying high voltage between
the Collecting Electrode and Discharge Electrode generates a Corona Discharge that produces
minus ions. The electrically charged dusts are attracted towards the Collecting Electrodes by an

17
electrostatic force. The dust is discharged in the hopper by flushing using a spray washing
system. The dusts inside the hopper are discharged and transported by ash handling system

TURBINE
A steam turbine is a mechanical device that extracts thermal energy from pressurized steam, and
converts it into useful mechanical work.
Non-condensing or back pressure turbines are mostly widely used for process steam applications.
The exhaust pressure is controlled by a regulating valve to suit the needs of the process steam
pressure. These are commonly found at refineries, district heating units, pulp and paper plants
and desalination facilities where large amounts of low pressure process steam are available.

HIGH PRESSURE TURBINE

18
Condensing turbines are most commonly found in electrical power plants. These turbines exhaust
steam in a partially condensed state, typically of a quality near 90%, at a pressure well below
atmospheric to a condenser. Reheat turbines are also used almost exclusively in electrical power
plants. In a reheat turbine, steam flow exits from a high pressure section of the turbine and is
returned to the boiler where additional superheat is added. The steam then goes back into an
intermediate pressure section of the turbine and continues expansion.

INTERMEDIATE PRESSURE TURBINE

Extracting type turbines are common in all applications. In an extracting type turbine, steam is
released from various stages of the turbine and used for industrial process needs or sent to boiler

19
feed water heaters to improve overall cycle efficiency. Extraction flows may be controlled with a
valve or left uncontrolled. Induction turbines introduce low pressure steam at an intermediate
stage to produce additional power.

Principle of operation
An ideal steam turbine is considered to be an isentropic process or constant entropy process, in
which the entropy of the steam entering the turbine is equal to the entropy of the steam leaving
the turbine. No steam turbine is truly Isentropic, however, with typical isentropic efficiencies
ranging from 20%-90% based on the application of the turbine. The interior of the turbine is

20
comprised of several sets of blades or buckets as they are more commonly referred to. One set of
stationary blades is connected to the casing and one set of rotating blades is connected to the
shaft. The sets intermesh with certain minimum clearances, with the size and configuration of
sets varying to efficiently exploit the expansion of steam at each stage.
GENERATOR
500 MW THDF 115/59 TG: TECHNICAL SPECIFICATION
UNIT 1 TYPE: TG-HW-0500-2 SL.NO: 10526-P-129-01
UNIT 2 TYPE: TG-HW-0500-2 SL.NO: 10527-P-129-01

21
GENERATOR : 500 MW, 588 MVA, 16.2 kA,
: 21 kV, 0.85 PF(lag),
FREQUENCY : 50Hz
H2 PRESSURE : 3.5 BAR.
EXCITATION : 340 V, 4040 A.
CRITICAL SPEEDS : 864, 1806, 2388 RPM

EFFICIENCIES
AT FULL LOAD & AT 75% FULL LOAD : 98.63%
AT 50% FULL LOAD : 98.44%.
AT 25% FULL LOAD : 97.50%

HYDROGEN GAS COOLERS

4 SECTIONS EACH RATED FOR 25%.
GAS FLOW 33 CUM/SEC.
HEAT DISSIPATION PER COOLER 5050 KW
HOT / COLD GAS TEMP. 75.5 / 43.7 C
GAS PRESSURE DROP 620 Pa
COOLING WATER FLOW 114 dm3/S CW INLET / OUTLET TEMPS. 38.7/45.8 C
TUBES OF CuZn28Sn, FINS OF COPPER.
CONSTRUCTION

22
Stator: The generator has built in end shields bearings. Core suspension system using flat -
plate springs, keeps the stator body vibrations low and within acceptable limits. 21 springs are
provided at the machine bottom and at both its sides. Mild steel pressure plates and axial studs
keep core tight. Core ends are shielded from end leakage magnetic fluxes by H2 cooled
magnetic steel flux shields. Stator core is insulated from the frame except for one earthing core
bar. Stator core is cooled by H2 flow in radial ducts. All four cooler sections are vertically
mounted. A control valve on cold-water flow side, based on load, automatically adjusts cold
water flow. This ensures nearly uniform temperatures inside generator irrespective of loads.
Ring type double flow H2 shaft seals, with separate air and Hydrogen side oil flows, are reliable
and give low H2 gas consumption. Distortion free seal rings carriers are provided.
Rotor: Rotor shaft forging is single piece vacuum cast and then forged from low alloy steel to
achieve high electro-magnetic as well as mechanical properties. Both poles are provided with
cross pole slots for inertia equalization. Rotor is fitted with 18Mn -18Cr non-magnetic steel
retaining rings for winding retention. The rings are shrunk fitted and locked axially by snap
rings. Seating surfaces of rings and the shaft are silver coated. Class F layers electrically
insulate the rings from copper underneath. Axial flow multi- stage fans/compressors fitted on
shaft at turbine end. Copper forged field leads carry DC-rotor current from exciter to the rotor
coils.
TRANSFORMER
A transformer is an energy transfer device. It has an input side (primary) and an output side
(secondary). Electrical energy applied to the primary is converted to a magnetic field which in
turn, induces a current in the secondary which carries energy to the load connected to the
secondary. The energy applied to the primary must be in the form of a changing voltage which
creates a constantly changing current in the primary, since only a changing magnetic field will
produce a current in the secondary. A transformer consists of at least two sets of windings
wound on a single magnetic core. There are two main purposes for using transformers. The first
is to convert the energy on the primary side to a different voltage level on the secondary side.
This is accomplished by using differing turns counts on primary and secondary windings. The
voltage ratio is the same as the turns ratio. The second purpose is to isolate the energy source
from the destination, either for personal safety, or to allow a voltage offset between the source
and load. Transformers are generally divided into two main types. Power transformers are used

23
to convert voltages and provide operating power for electrical devices, while signal transformers
are used to transfer some type of useful information from one form or location to another.
Following are the Main Power transformers used in the Simhadri power plant.

Generator Transformer: There are two Generator Transformers one to each of the
Generator. This Generator Transformer is connected between generator and switch yard which
steps up 21 KV to 400 KV. It is connected in star-delta connection with the secondary star neutral
is solidly grounded.

Unit

Transformers: It is a transformer which steps down the voltage from 21 KV to 11 KV which

is supplied to the other auxiliaries. There are four Unit Transformers, two for each Generator.
There are two Unit Transformers are connected to Generator to supply auxiliary power to plant.
Each Transformer supplies to one 11KV switchgear. Four such switch gears are provided in the
station. Vacuum Circuit Breakers are used in the 11KV Switchgear for feeding power supply to
motor and transformers. Each Unit Transformer is connected in delta-star connection with star
side neutral resistively grounded. If fault occurs in one Unit Transformer then loads connected to
that transformer will change over to 400KV/11KV Standby Transformer .If there is a fault in one
unit the loads connected to that unit are fed by the 400KV/11KV Standby Transformer.

24
Standby Transformer: It is a transformer which steps down the voltage from 400 KV to 11
KV supply. There is only one Standby Transformer in the total plant. This transformer supplies
power to the unit switch gears whenever any one or both the Unit Transformers fail. Standby
Transformer is connected in star-star fashion with both primary and secondary neutrals being
solidly grounded.
SWITCHYARD
The place which is used for switching operation of power lines without changing the voltage
level is called as Switch yard. Here different connections are made between substations through
various transmission lines.

Figure: SWITCHYARD OF NTPC SIMHADRI

400KV Switch yard involves practical application of engineering sciences in the design of

25
individual items of equipment and of their disposition within a given site to achieve the most
flexible, reliable, economic and safe way of controlling and directing electrical power. The
voltage level employed is determined by the transmission capacity and the short circuit capacity
of the power system. Safety will always be paramount regardless of the layout chosen. The most
important is the consideration of maintenance and operation of the station and its equipment.
FACTORS AFFECTING THE DESIGN OF SWITCHING STATION:
System flexibility
System availability
Ease of maintenance
Configuration and location of site
Future equipment
Economics

Electrical power system can be divided into the following regions

1. GENERATING STATIONS
2. TRANSMISSION SYSTEMS
3. RECEIVING STATIONS
4. DISTRIBUTION SYSTEMS
5. LOAD POINTS
The switchgear in generating stations can be classified as
1. Main switchgear
2. Auxiliary switchgear
Main switchgear: comprises of circuit-breakers, isolators, bus bars, current transformers,
potential transformers, etc. in the main circuit of generator associated transformers of
transmission lines. It is generally of EHV and outdoor type.
Auxiliary switchgear: is generally indoor type and controls the various auxiliaries of the
generator, turbine, boiler and the station auxiliary. The functions of switch yard are as follows:
Main link between generating plant and transmission system which has a large influence over the
security of the supply. Switching ON/OFF reactive power control devices, which has effect on
quality of power.
SWITCHYARD IN NTPC, SIMAHADRI

26
In NTPC, Simhadri, the bus layout used is sectionalized one and half breaker scheme with four
buses. The equipment used in the feeders are identified by their respective symbols or numbers
as follows:
1. Breaker by 52
2. Isolator by 89
3. Earth Switch by E
4. Current Transformer by CT

27
5. Capacitive Voltage Transformer by CVT

28
The advantages of one and half breaker system are:

29
1. Great operation flexibility
2. High availability
3. Breaker fault on the bus bar side disconnects only one branch
4. Each main bus can be isolated at any time
5. All switching operations executed with circuit breakers
6. Change over switching is easy without isolators
7. Bus bar fault does not lead to feeder disconnection.

The disadvantages are:

1. Three circuit breakers are required for two feeders.
2. Greater outlay for protection and auto-reclosure, as the middle breaker must respond
independently in the direction of both feeders (generally in India we use auto-reclosure system
for 1-phase only).
The various equipment used in the switch yard are
Busbar
Solid Core Post Insulator
Capacitor Voltage Transformers (CVT)
Current Transformers (CT)
Surge Arresters (SA)
Isolators and Earth switches
Circuit Breaker (CB)
Circuit Breaker (CB): Circuit Breaker makes or automatically breaks the electrical circuits under
loaded condition
On the basis of type of current they may be classified as
1. Ac circuit breakers 2. DC circuit breakers
However, most general way of classification of circuit breaker is on the basis of medium of arc
extinction such as
1. Air-break circuit breaker
2. Oil circuit breaker
3. Air-blast circuit breaker
4. SF6 circuit breaker
5. Vacuum circuit breaker
In NTPC all the breakers used in Switch yard are SF6 circuit breakers. Circuit breaker is an on

30
load switch. This is a form of switch gear by means of which the system may be safely and
efficiently controlled and regulated under both normal and abnormal operating conditions. In this
switch yard SF6 (sulphur hexafluoride) circuit breakers are used. The breaker is continuously
rated for 420kV, 2000A. The breaking capacity of the breakers is 40,000A.Each pole of the
breaker consists of the following two parts: Two interrupter units, a bell crank mechanism with
capacitors, support insulator column of three multistep insulators and an operating mechanism.
Operating rod which moves vertically inside the support insulator column. Transmits the motion
from operating mechanism to the interrupters.
Two interrupter units provide a double-break a feature for pole, the grading capacitor ensuring
uniform voltage distribution in open position. The double- break assembly and the column of
support insulators are filled with SF6 gas for arc-quenching and insulating purposes. The bell-
crank mechanism converts the vertical movement of operating rod into linear horizontal moving
parts of the interrupter unit. The operating rod is actuated by the vertically acting electro-
hydraulic operating mechanism. The corona rings are provided at the ends of the interrupters and
at the bottom of the bell crank mechanism. The support insulator column in fastened to
mechanism housing which, in turn, is mounted on the electro-hydraulic operating mechanism.
The coupling flange in the mechanism housing connects the piston rod of the operating
mechanism to the operating rod through the driving rod .The operating energy is produced by
compression of nitrogen in the accumulator, which mounted horizontally on the base unit of each
pole. A pressurized oil pipe runs from the accumulator to the operating mechanism of the
associative pole. Two more pipes run from the accumulator to the control unit ; one to the pump
and the other to the hydraulic monitoring unit the control unit accommodates the hydraulic pump
set, all the devices for electrical, hydraulic control and monitoring of the breaker and the
terminals
required .

SF6 CIRCUIT
BREAKER:

31
Advantages of SF6 breakers
1. Minimum current chopping tendency at low pressure and velocity
2. High dielectric strength
3. Outstanding arc quenching properties (small arcing times)
4. Not affected due to atmospheric conditions.

Isolators and Earth Switch: Isolators are disconnecting switches, which will operate under no-
load conditions and it is not designed to make a circuit under load or short- circuit conditions.
Earth Switch is connected between the line conductor and it is earthed. Normally it is open and it
is closed to discharge the voltage trapped on the isolated or disconnected line. When the line is
disconnected from the supply end there is some voltage on the line to which the capacitance
between the line and earth is charged. The Voltage is significant in HV systems. Before
commencement of maintenance work it is necessary that these voltages are discharged to earth
by closing the earthing switch. Normally, the earthing switches are mounted on the frame of the
isolator. Isolator cannot be opened unless the circuit breaker is opened and circuit breaker cannot
be closed unless the isolator is closed and these two are interlocked to serve the above functions.
Overhead Earth Wire: Protects the overhead transmission line from lightning strikes.
Reactive Power Control Devices: Controls the reactive power imbalance in the grid by switching
ON/OFF the Shunt Reactors, Shunt Capacitors, etc.
Current Limiting Reactors: Limits the Short Circuit Current in case of faulty conditions.
INSTRUMENT TRANSFORMERS
They are used to reduce the voltage/current levels which are being measured to easily
measurable levels.
Current Transformer: The primary winding of a current transformer is connected in series
with the circuit whose current is to be sensed and across the secondary of the current transformer,
the operating coil of the relay are connected. The C.T used in protection are usually primary bar
i.e these have one turn of primary winding i.e the conductor of the circuit itself forms the
primary of the current transformer. The voltage drop across primary terminals is very small and
the primary current is independent of the secondary current. The secondary currents are usually
designed for 1A or 5A.

32
Capacitive Voltage Transformer: Potential transformers are used for measuring high
voltages where as capacitance voltage transformers are used for measuring extra high voltages.
As conventional two winding transformers, the primary of the C.V.T is connected between phase
and ground while the secondary is connected to the voltage coil of the relay. The C.V.T generally
consists of a stack of series connected capacitor units and an auxiliary transformer. The no. of
stacks depends on the voltage transmitted. The secondary of a C.V.T is
SURGE ARRESTOR: The cause of over voltages in a system may be due to: 1. External
-- due to lightening 2. Internal -- due to switching operations
The high voltages are usually earthed using suitable arrestors. A meter is arranged to indicate the
number and the intensity of the surges.
ASH HANDLING PLANT
Clinker Grinder

33
FLY ASH

34
Waste management and Overview
Fly ash from power plant : Energy requirements for the developing countries in particular are
met from coal-based thermal power plants. The disposal of the increasing amounts of solid waste
from coal-fired thermal power plants is becoming a serious concern to the environmentalists.
Coal ash, 80% of which is very fine in nature and is thus known as fly ash is collected by
electrostatic precipitators in stacks. In India,nearly 90 mt of fly ash is generated per annum at
present and is largely responsible for environmental pollution. In developed countries like
Germany, 80% of the fly ash generated is being utilized, whereas in India only 3% is being
consumed.
COAL-based thermal power plants have been a major source of power generation in India,
where 75% of the total power obtained is from coal-based thermal power plants. The coal reserve
of India is about 200 billion tonnes (bt) and its annual production reaches 250 million tonnes
(mt) approximately. About 70% of this is used in the power sector. In India, unlike in most of the
developed countries, ash content in the coal used for power generation is 3040%. High ash coal
means more wear and tear of the plant and machinery, low thermal efficiency of the boiler,
slogging, choking and scaling of the furnace and most serious of them all, generation of a large

35
amount of fly ash. India ranks fourth in the world in the production of coal ash as by-product
waste after USSR, USA and China, in that order. Fly ash is defined in Cement and Concrete
Terminology (ACI Committee 116) as the finely divided residue resulting from the combustion
of ground or powdered coal, which is transported from the fire box through the boiler by flue
gases. Fly ash is fine glass powder, the particles of which are generally spherical in shape and
range in size from 0.5 to 100 m.
Effluent and disposal
Disposal and management of fly ash is a major problem in coal-fired thermal power plants. Fly
ash emissions from a variety of coal combustion units show a wide range of composition. All
elements below atomic number 92 are present in coal ash. A 500 MW thermal power
plant releases 200 mt SO2, 70 t NO2 and 500 t fly ash approximately every day. Particulate
matter (PM) considered as a source of air pollution constitutes fly ash. The fine particles of fly
ash reach the pulmonary region of the lungs and remain there for long periods of time; they
behave like cumulative poisons. The sub micron particles enter deeper into the lungs and are
deposited on the alveolar walls where the metals could be transferred to the blood plasma across
the cell membrane. The residual particles being silica (4073%) cause silicosis.

Fly ash can be disposed-off in a dry or wet state. Studies show that wet disposal of this waste
does not protect the environment from migration of metal into the soil. Heavy metals cannot be
degraded biologically into harmless products like other organic waste. Studies also show that
coal ash satisfies the criteria for landfill disposal, according to the Environmental Agency of
Japan. According to the hazardous waste management and handling rule of 1989, fly ash is
considered as non-hazardous. With the present practice of fly-ash disposal in ash ponds
(generally in the form of slurry), the total land required for ash disposal would be about 82,200
hectare by the year 2020 at an estimated 0.6 hectare per MW. Fly ash can be treated as a by-
product rather than waste.

During the last 30 years, extensive research has been carried out to utilize the fly ash in various
sectors, as this is not considered as hazardous waste4,5. Broadly, fly ash utilization programmes
can be viewed from two angles, i.e. mitigating environmental effects and addressing disposal
problems (low valuehigh volume utilization). Following are some of the potential areas of use

36
of fly ash.

Fly ash bricks

The Central Fuel Research Institute, Dhanbad has developed a technology for the utilization of
fly ash for the manufacture of building bricks. Fly ash bricks have a number of advantages over
the conventional burnt clay bricks. Unglazed tiles for use on footpaths can also be made from it.
Awareness among the public is required and the Government has to provide special incentives
for this purpose.Fly ash in manufacture of cement Fly ash is suitable for use as pozzolana. In the
presence of moisture, it reacts chemically with calcium hydroxide at room temperature to form
compounds possessing cementitious properties. Fly ash has a high amount of silica and alumina
in reactive form. These reactive elements complement the hydration chemistry of cement. On
hydration, cement produces CSH gel and free lime, i.e. Ca(OH)2. The CSH gel binds the
aggregates together and strengthens the concrete. Water, sulphates and CO2 present in the
environment attack the free lime causing deterioration of the concrete. A cement technologists
observed that the reactive elements present in fly ash convert the problematic free lime into
durable concrete. The difference between fly ash and portland cement becomes apparent under a
microscope. Fly ash particles are almost totally spherical in shape, allowing them to flow and
blend freely in mixtures. This property make fly ash a desirable admixture for concrete
Fly ash in distemper
Distemper manufactured with fly ash as a replacement for white cement has been used in several
buildings in Neyveli, Tamil Nadu, in the interior surfaces and the performance is satisfactory.
The cost of production will only be 50% that of commercial distemper.

Fly ash-based ceramics

The National Metallurgical Laboratory, Jamshedpur has developed a process to produce ceramics
from fly ash having superior resistance to abrasion.

Fly ash as fertilizer

Fly ash provides the uptake of vital nutrients/minerals (Ca, Mg, Fe, Zn, Mo, S and Se) by crops
and vegetation, and can be considered as a potential growth improver. It serves as a good
fertilizer.

37
Fly ash in road construction
The use of fly ash in large quantities making the road base and surfacing can result in low value
high volume utilization.

ENVIRONMENT MANAGEMENT
Harmony between man and environment is the essence of healthy life and growth. Therefore,
maintenance of ecological balance and a pristine environment has been of utmost importance to
the Union Ministry of Power (MoP). NTPC being the leading organization under the ministry in
the areas of power generation, has been taking various measures discussed below for mitigation
of environment pollution due to power generation.

Environment Policy & Environment Management System

Driven by its commitment for sustainable growth of power, NTPC has evolved a well defined
environment management policy and sound environment practices for minimising environmental
impact arising out of setting up of power plants and preserving the natural ecology.

National Environment Policy: At the national level, the Ministry of Environment and Forests had
prepared a draft Environment Policy (NEP) and the Ministry of Power along with NTPC actively
participated in the deliberations of the draft NEP. The NEP 2006 has since been approved by the
Union Cabinet in May 2006.

NTPC Environment Policy: As early as 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 company's proactive approach to
environment, optimum utilisation of equipment, adoption of latest technologies and continual
environment improvement. The policy also envisages efficient utilisation of resources, thereby
minimising waste,maximising ash utilisation and providing green belt all around the plant for
maintaining ecological balance.

Environment Management, Occupational Health and Safety Systems: NTPC has actively gone

38
for adoption of best international practices on environment, occupational health and safety areas.
The organization 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 comply with all the stipulated
environment norms, various state-of-the-art pollution control systems / devices as discussed
below have been installed to control air and water pollution.
Electrostatic Precipitators: The ash left behind after combustion of coal is arrested in high
efficiency Electrostatic Precipitators (ESPs) and particulate emission is controlled well within the
stipulated norms. The ash collected in the ESPs is disposed to Ash Ponds in slurry form.
Flue Gas Stacks: Tall Flue Gas Stacks have been provided for wide dispersion of the gaseous
emissions (SOX, NOX etc) into the atmosphere. Low-NOX Burners: In gas based NTPC power
stations, NOx emissions are controlled by provision of Low-NOx Burners (dry or wet type) and
in coal fired stations, by adopting best combustion practices.
Neutralisation Pits: Neutralisation pits have been provided in the Water Treatment Plant (WTP)
for pH correction of the effluents before discharge into Effluent Treatment Plant (ETP) for
further treatment and use. Coal Settling Pits / Oil Settling Pits: In these Pits, coal dust and oil are
removed from the effluents emanating from the Coal Handling Plant (CHP), coal yard and
Fuel Oil Handling areas before discharge into ETP.
DE & DS Systems: Dust Extraction (DE) and Dust Suppression (DS) systems have been
installed in all coal fired power stations in NTPC to contain and extract the fugitive dust released
in the Coal Handling Plant (CHP).
Cooling Towers: Cooling Towers have been provided for cooling the hot Condenser cooling
water in closed cycle Condenser Cooling Water (CCW) Systems. This helps in reduction in
thermal pollution and conservation of fresh water.
Ash Dykes & Ash Disposal Systems: Ash ponds have been provided at all coal based stations
except Dadri where Dry Ash Disposal System has been provided. Ash Ponds have been divided

39
into lagoons and provided with garlanding arrangements for change over of the ash slurry feed
points for even filling of the pond and for effective settlement of the ash particles. Ash in slurry
form is discharged into the lagoons where ash particles get settled from the slurry and clear
effluent water is discharged from the ash pond. The discharged effluents conform to standards
specified and the same is regularly monitored. At its Dadri Power Station, NTPC has set up a
unique system for dry ash collection and disposal facility with Ash Mound formation. This has
been envisaged for the first time in Asia which has resulted in progressive development of green
belt besides far less requirement of land and less water requirement as compared to the wet ash
disposal system.
Ash Water Recycling System: Further, in a number of NTPC stations, as a proactive measure,
Ash Water Recycling System (AWRS) has been provided. In the AWRS, the effluent from ash
pond is circulated back to the station for further ash sluicing to the ash pond. This helps in
savings of fresh water requirements for transportation of ash from the plant. The ash water
recycling system has already been installed and is in operation at Ramagundam, Simhadri,
Rihand, Talcher Kaniha, Talcher Thermal, Kahalgaon, Korba and Vindhyachal. The scheme has
helped stations to save huge quantity of fresh water required as make-up water for disposal of
ash.

Dry Ash Extraction System (DAES): Dry ash has much higher utilization potential in ash based
products (such as bricks, aerated autoclaved concrete blocks, concrete, Portland pozzolana
cement, etc.). DAES has been installed at Unchahar, Dadri, Simhadri, Ramagundam, Singrauli,
Kahalgaon, Farakka, Talcher Thermal, Korba, Vindhyachal, Talcher Kaniha and BTPS.
Liquid Waste Treatment Plants & Management System: The objective of industrial liquid
effluent treatment plant (ETP) is to discharge lesser and cleaner effluent from the power plants to
meet environmental regulations. After primary treatment at the source of their generation, the
effluents are sent to the ETP for further treatment. The composite liquid effluent treatment plant
has been designed to treat all liquid effluents which originate within the power station e.g.
Water Treatment Plant (WTP), Condensate Polishing Unit (CPU) effluent, Coal Handling Plant
(CHP) effluent, floor washings, service water drains etc. The scheme involves collection of
various effluents and their appropriate treatment centrally and re-circulation of the treated
effluent for various plant uses.

40
NTPC has implemented such systems in a number of its power stations such as Ramagundam,
Simhadri, Kayamkulam, Singrauli, Rihand, Vindhyachal, Korba, Jhanor Gandhar, Faridabad,
Farakka, Kahalgaon and Talcher Kaniha. These plants have helped to control quality and
quantity of the effluents discharged from the stations.
Sewage Treatment Plants & Facilities: Sewage Treatment Plants (STPs) sewage treatment
facilities have been provided at all NTPC stations to take care of Sewage Effluent from Plant and
township areas. In a number of NTPC projects modern type STPs with Clarifloculators,
Mechanical Agitators, sludge drying beds, Gas Collection Chambers etc have been provided to
improve the effluent quality. The effluent quality is monitored regularly and treated effluent
conforming to the prescribed limit is discharged from the station. At several stations, treated
effluents of STPs are being used for horticulture purpose.
Environmental Institutional Set-up
Realizing the importance of protection of the environment with speedy development of the
power sector, the company has constituted different groups at project, regional and Corporate
Centre level to carry out specific environment related functions. The Environment Management
Group, Ash Utilisation Group and Centre for Power Efficiency & Environment Protection
(CENPEEP) function from the Corporate Centre and initiate measures to mitigate the impact of
power project implementation on the environment and preserve ecology in the vicinity of the
projects. Environment Management and Ash Utilisation Groups established at each station, look
after various environmental issues of the individual station. Environment Management During
Operation Phase NTPC's environment friendly approach to power has already begun to show
results in conservation of natural resources such as water and fuel (coal, oil & gas) as well as
control of environmental pollution. As already mentioned earlier, NTPC has chalked out a set of
well defined activities that are envisaged right from the project conceptualisation stage so that
during the entire life cycle of the power plant, NTPC is fully compliant with various environment
regulations and a pristine environment and ecological balance is maintained in and around its
power station and townships. Following is brief description of some of the measures taken
during the operation phase of the stations.
Performance enhancement and up-gradation measures are undertaken by the organisation during
the post operational stage of the stations. These activities have greatly helped to minimise the
impact on environment and preserve the ecology in and around its power projects. These

41
measures have been enumerated as follows.
Monitoring of Environmental Parameters: A broad based Environment Monitoring Programme
has been formulated and implemented in NTPC. All pollutants discharged from the power plant
such as stack emission, ash pond effluent, main plant effluent, domestic effluent and Condenser
Cooling Water (CCW) effluent are monitored at the stipulated frequency at the source itself and
at the points of discharge. In addition to the above, ambient air, surface water and ground water
quality in and around NTPC plants are regularly monitored to assess any adverse impacts as a
result of operation of the power plant.
On-Line Data Base Management: In order to have better control on pollution and to achieve
effective environment management in and around NTPC stations, it is imperative to have an on-
line, reliable and efficient environment information system on the plant operational and
environmental performance parameters at all three levels i.e generating Stations, Regional
Headquarters and Corporate Centre. In consideration of the above, a computerized programme,
namely "Paryavaran Monitoring System" - PMS, which could provide reliable storage, prompt
and accurate flow of information on environmental performance of Stations was developed and
installed in NTPC. This software facilitates direct transfer of environment reports and other
environment related information from stations to the Regional Headquarters and Corporate
Centre. The PMS has already been implemented at Corporate Centre, the Regional Headquarters
and most of the Stations. This system has helped in achieving continuous improvement in
NTPCs environment performance through improved monitoring and reporting system by using
the trend analysis and advanced data management techniques.
Environment Reviews: To maintain constant vigil on environmental compliance,Environmental
Reviews are carried out at all operating stations and remedial measures have been taken
wherever necessary. As a feedback and follow-up of these Environmental Reviews, a number of
retrofit and up-gradation measures have been undertaken at different stations. Such periodic
Environmental Reviews and extensive monitoring of the facilities carried out at all stations have
helped in compliance with the environmental norms and timely renewal of the Air and Water
Consents.
Upgradation & Retrofitting of Pollution Control Systems: In order to keep pace with the
changing norms and ensure compliance with statutory requirements in the field of pollution
control, NTPC keeps an open mind for Renovation and Modernisation (R & M) and Retrofitting

42
and Upgradation of pollution monitoring and control facilities in its existing stations. It is
important to mention that such modifications/retrofit programs not only helped in betterment of
environment but also in resource conservation.
High efficiency Electro-Static Precipitators (ESPs) of the order of 99.5% and above have been
provided at NTPC stations for control of stack particulate emissions. However, the ESPs of a
number of stations were built prior to the promulgation of the Environment (Protection) Act,
1986 and notification of emission control standards under this Act. Remedial measures have
already been taken up and implemented to improve the efficiency of the existing ESPs at various
NTPC stations. ESP performance enhancement programme by adopting advanced
microprocessor based Electrostatic Precipitator Management System (EPMS) was installed at its
power stations at Singrauli, Ramagundam, Korba, Farakka, Rihand, Vindhyachal and Unchahar.
Additional ESPs were retrofitted in the older power stations, namely at Badarpur and Talcher
Thermal. As a result of the above retrofits, the emission of Suspended Particulate Matter (SPM)
has been brought down appreciably at the above stations and is maintained within the present
statutory limit of 150 mg/Nm3. In new projects, the ESPs have been designed for a maximum
permissible outlet dust emission of 50 mg/Nm3 to meet the likely stringent emission norms in
the near future.
Resources Conservation
With better awareness and appreciation towards ecology and environment, the organization is
continually looking for innovative and cost effective solutions to conserve natural resources and
reduce wastes. Some of the measures include:
a) Reduction in land requirements for main plant and ash disposal areas in newer units.
b) Capacity addition in old plants, within existing land.
c) Reduction in water requirement for main plant and ash disposal areas through recycle &
reuse of water.
d) Efficient use of Fuel (Coal, Natural gas and Fuel oil) and Reduction in fuel requirement
through more efficient combustion and adoption of state-of-the-art technologies such as
super critical boilers.
Waste Management
Various types of wastes such as Municipal or domestic wastes, hazardous wastes,Bio-Medical
wastes get generated in power plant areas, plant hospital and the townships of projects. The

43
wastes generated are a number of solid and hazardous wastes like used oils & waste oils, grease,
lead acid batteries, other lead bearing wastes (such as garkets etc.), oil & clarifier sludge, used
resin, used photochemicals, asbestos packing, e-waste, metal scrap, C&I wastes, electricial scrap,
empty cylinders (refillable), paper, rubber products, canteen (bio-degradable) wastes, buidling
material wastes, silica gel, glass wool, fused lamps & tubes, fire resistant fluids etc. These wastes
fall either under hazardous wastes category or non-hazardous wastes category as per
classification given in Government of Indias notification on Hazardous Wastes (Management
and Handling) Rules 1989 (as amended on 06.01.2000 & 20.05.2003). Handling and
management of these wastes in NTPC stations have been discussed below.
Municipal Waste Management: Domestic or municipal waste is generated in households at
townships. This waste is segregated into bio-degradable and non-biodegradable wastes at source
itself in different coloured containers and thereafter the two types are disposed separately. Bio-
degradable waste is spread uniformly in identified low lying areas and thereafter it is covered
with soil for use later as manure after composting. The segregated non bio-degradable waste is
disposed off separately in other identified low lying areas and is spread out uniformly.
Hazardous Waste Management: NTPC being a proactive organization, the handling and disposal
of hazardous wastes are done as per the Hazardous Wastes (Management & Handling) Rules
1989 (as amended in 2003) guidelines issued by Government of India for the treatment, storage
and disposal of hazardous wastes.Scientific study on management and handling of hazardous
wastes was carried out at a few NTPC stations to adopt the best practices so that there is a
complete compliance with statutory requirements. In NTPC sataione, the Hazardous Wastes
(Recyclable) are sold / auctioned to registered recyclers / refiners. The other hazardous wastes
such as the activated carbon resins, used drums (hazardous) chromium (Cr-III electrolytes, used
petro-chemicals, asbestos packings, used torch batteries, ribbon, toners / cartridges, mixed wastes
(waste oil, water & cotton) filters, earth contaminated with synthetic oil (FQF) glass used &
sodium silicate, lamps & tubes etc. fall under the category of Hazardous Wastes (Non-
Recyclable). These wastes are small in quantity and are stored in properly identified locations.
As per the notification, hazardous wastes (non-recyclable) are to be sent to State Pollution
Control Board (SPCB) approved common treatment storage and disposal facility (TSDF). Bio-
Medical Waste Management: Hospital (or Bio-medical) wastes get generated from hospitals and
they include urine bags, human anatomical wastes, plaster of paris waste, empty plastic bottles of

44
water & glucose, blood & chemical mixed cotton, blood & urines tubes etc. these wastes are
segregated and are placed in buckets of different colours as per the notification for Bio-Medical
Waste (Management & Handling) Rules. The segregated bio-medical wastes are either disposed
through the SPCB approved agency or they are treated in autoclaves
before disposal into bio-medical waste disposal pits. The treated bio-medical waste is spread
uniformly and covered with 10 cm thick soil in bio-medical waste disposal Pits.
Land Use / Bio-diversity As a policy, NTPC lays special emphasis on land use and Bio-diversity
by way of development of green belts, energy plantations, reclamation of abandoned Ash Ponds
and EIA and ecological monitoring in the project areas and its surroundings. Reclamation of
Abandoned Ash ponds: The reclamation of abandoned ash pond sites is a challenging task.
NTPC has reclaimed temporary ash disposal areas at some of its projects namely Ramagundam,
Talcher Thermal, Rihand, Singrauli and Unchahar through plantation and converted these sites
into lush green environments. Extensive plantations have also been undertaken on dry ash mound
at NTPC-Dadri. It is planned to reclaim all the abandoned ash disposal areas by plantation.
Green Belts, Afforestation & Energy Plantations: Whats more, in a concerted bid to counter the
growing ecological threat, NTPC is undertaking afforestation programmes covering vast areas of
land in and around its projects. Appropriate afforestation programmes for plant, township and
green belt areas of the project have been implemented at all projects. In order to enhance green
cover in the areas around our projects, as a responsible corporate citizen, NTPC till date has
planted more than 18 million trees at its projects throughout the country. The afforestation has
not only contributed to the aesthetics but also has been serving as a 'sink' for the pollutants
released from the station and thereby protecting the quality of ecology and environment in and
around the projects. Thrust has also been given to bio-diesel plantation and around 4.8 lakh
energy plants including Pongamia and Jatropha have already been planted. A pilot project for
extraction of seeds from these bio-diesel plants has also been set up.
Ecological Monitoring & Scientific Studies
NTPC has been a leader in the industrial sector of India in undertaking scientific studies related
to thermal power generation. NTPC has pioneered several scientific studies in collaboration with
national/ international institutions to develop an environmental database e.g. Detailed Geo-
hydrological Studies to understand the impact of ash pond leachate on ground water and
Ecological Impacts Monitoring through Remote Sensing Data have been carried out at its

45
operating stations as discussed below.
Environment Impact Asssement Studies: Environmental Impact Assessment (EIA) Studies are
inevitably undertaken to evaluate potential negative impacts as well as to formulate
Environmental Management Plans to overcome the identified impacts. Based on the
recommendations of Environmental Impact Assessment Study and Environmental Management
Plan (EMP) and the conditions stipulated in the clearances from Ministry of Environment and
Forests and State Pollution Control Boards, These studies consists of impact assessment in the
area of the land use, water use, socio-economic aspects, soil, hydrology, water quality,
meteorology, air quality, terrestrial and aquatic ecology and noise. These studies are conducted
before starting the construction as well as after operation of the plant and gives comprehensive
status of the environment as existed before construction as well as in the post operational stages
of the project. The EIA involves stage-by-stage evaluation of various parameters which affect the
environment. Based on EIA study, wherever required, specific scientific studies are also
conducted to scientifically assess the likely impact of the pollutants on the sensitive flora and
fauna in the surroundings, as also, to take preventive and mitigatory measures, wherever
required. Apart from project specific EIA studies, Regional Environmental Assessment studies
have been conducted for Integrated Development of Singrauli, Korba and Ramagundam areas.
Such studies are of first of their kind in India and probably very few such studies have been
undertaken in other countries.
Socio-economic Studies: Detailed socio-economic studies are undertaken to establish the socio-
economic status of project affected persons and rehabilitation and resettlement plans are drawn in
consultation with the state government.Rehabilitation and resettlement options include land for
land (subject to availability), limited jobs with NTPC and contractors and self employment
schemes. In addition, NTPC also undertakes community development activities in the
surrounding villages.
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

46
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.
Geo-hydrological Studies: NTPC has conducted several geo-hydrological studies of the ash
disposal areas at its projects (Singrauli, Rihand, Vindhyachal, Korba, Farakka and Talcher)
through reputed institutions like Indian Institutes of Technology, Roorkee; Indian Institutes of
Technology, Mumbai, Centre for Studies on Man and Environment, Calcutta. All these studies
conclude that the leaching of heavy metals from ash occurs only under pH 4 or below. In
practice, the pH of the ash water is either neutral or alkaline (7 or above) and hence the leaching
of heavy metals is highly unlikely.
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.
Advanced / Eco-friendly Technologies
NTPC has gained expertise in operation and management of 200 MW and 500 MW Units
installed at different Stations all over the country and is looking ahead for higher capacity Unit
sizes with super critical steam parameters for higher efficiencies and for associated
environmental gains. At Sipat, higher capacity Units of size of 660 MW and advanced Steam
Generators employing super critical steam parameters have already been implemented as a green

47
field project. Higher efficiency Combined Cycle Gas Power Plants are already under operation at
all gas-based power projects in NTPC. Advanced clean coal technologies such as Integrated
Gasification Combined Cycle (IGCC) have higher efficiencies of the order of 45% as compared
to about 38% for conventional plants. NTPC has initiated a techno-economic study under
USDOE / USAID for setting up a commercial scale demonstration power plant by using IGCC
technology. These plants can use low grade coals and have higher efficiency as compared to
conventional plants. With the massive expansion of power generation, there is also growing
awareness among all concerned to keep the pollution under control and preserve the health and
quality of the natural environment in the vicinity of the power stations. NTPC is committed to
provide affordable and sustainable power in increasingly larger quantity. NTPC is conscious of
its role in the national endeavour of mitigating energy poverty, heralding economic prosperity
and thereby contributing towards Indias emergence as a major global economy.
CONCLUSION
The past month of our training has been very instructive for us. NTPC Simhadri has offered us
ample opportunities to learn and develop ourselves in many areas. We gained a lot of practical
knowledge, especially about how the Switch yard functions as the final controlling unit of the
generation process.
A comprehensive training about thermal power generation proved to be all the more enriching
and at the same time enjoyable because we had a detailed course on Power Supply Systems in
our Second Year Second Semester. Thus, our freshly garnered knowledge about Power
Generation and High Voltage transmission underwent a thorough brush-up with crucial practical
inputs.
A thermal power plant is a multifaceted enterprise and encompasses various departments with
employees of various academic backgrounds working collectively so that the nation stays lit-up.
Being students of Electrical Engineering, we were naturally over-enthusiastic about those
departments that concern our stream viz. the 400 kV Switch yard, the ESP, the high and low
voltage switch gears and the Generating, Unit and Standby Transformers. We visited these
departments over longer durations and had the opportunity to closely observe and monitor the
various ongoing processes in these departments. We learned in detail how the Switch yard
performs complex switching operations to transmit power over transmission lines to the grid
while maintaining a constant voltage. Additionally, we also visited the Electrostatic Precipitator

48
and watched readings being taken about the quality of exhaust gases and subsequently realized
the importance of this unit and its relevance in the modern day environmentally conscious
society. Our guide helped us immensely in this know and provided us with invaluable knowledge
regarding the working of various units.

49