INDUSTRIAL TRAINING

REPORT
ON
‘NTPC DADRI’
National Thermal Power Coropration
Limited
National Capital Power Station (NCPS)-
DADRI
P.O-Vidyut Nagar, Dist. Gautambudhnagar,
Uncha Amirpur, Uttar Pradesh 201008

“NTPC was set up in the central sector in the

1975. Only PSU to achieve excellent rating in
respect to MOU targets signed with Govt. of
India each year. NTPC DADRI station is also
bagged ISO 14001 certification.

pg. 1
Today NTPC contributes more than 3 / 5 th of
the total generating power station in India.
CONTANTS

S.NO. DESCRIPATIO PAGE NO.

N
(1) Over view of
NTPC
(2) Introduction
(3) National
Capital Power
Station - Solar
(4) National
Capital Power
Station HVDC
(5) National
Capital Power
Station - Coal
(6) National
Capital
Power

pg. 2
 Station - Gas
(7)
7.
INTRODUCTION
OF GAS POWER
PLANT

(8)
(9)
(10)
(11)
(12)
(13)
(14)
(15)

pg. 3
 (1) . Overview of NTPC

NTPC is India’s largest energy conglomerate with roots planted way back in 1975 to
accelerate power development in India. Since then it has established itself as the
dominant power major with presence in the entire value chain of the power generation
business. From fossil fuels it has forayed into generating electricity via hydro, nuclear
and renewable energy sources. This foray will play a major role in lowering its carbon
footprint by reducing green house gas emissions. To strengthen its core business, the
corporation has diversified into the fields of consultancy, power trading, training of power
professionals, rural electrification, ash utilisation and coal mining as well.

NTPC became a Maharatna company in May 2010, one of the only four companies to be
awarded this status. NTPC ranked 492nd  in the ‘2019, Forbes Global 2000’ ranking of the
World’s biggest companies.

Growth of NTPC installed capacity and generation

pg. 4
The total installed capacity of the company is 55,126 MW (including JVs) with 21 coal
based,  7 gas based stations, 2 Hydro based station and 1 Wind based station. 9 Joint
Venture stations are coal based and 11 Solar PV projects. The capacity will have a
diversified fuel mix and by 2032, non fossil fuel based generation capacity shall make up
nearly 30% of NTPC’s portfolio.

NTPC has been operating its plants at high efficiency levels. Although the company has
15.56% of the total national capacity, it contributes 22.74% of total power generation due
to its focus on high efficiency.

In October 2004, NTPC launched its Initial Public Offering (IPO) consisting of 5.25% as
fresh issue and 5.25% as offer for sale by the Government of India. NTPC thus became a
listed company in November 2004 with the Government holding 89.5% of the equity share
capital. In February 2010, the Shareholding of Government of India was reduced from
89.5% to 84.5% through a further public offer. Government of India has further divested
9.5% shares through OFS route in February 2013. With this, GOI's holding in NTPC has
reduced from 84.5% to 75%. The rest is held by Institutional Investors, banks and Public.
Presently, Government of India is holding in NTPC has reduced to 69.74%.

pg. 5
NTPC is not only the foremost power generator; it is also among the great places to work.
The company is guided by the “People before Plant Load Factor” mantra which is the
template for all its human resource related policies. In 2018, NTPC was recognized as
“Laureate” for consistently ranking among “Top 50 Best Companies to Work for in India”
for last 10 years in the Great Place to Work and Economic Times survey. Besides, NTPC
was also recognized as the best among PSUs and in Manufacturing.

(2). Introduction

2.1 Gas based power station

Sr. GAS BASED COMMISSIONED

STATE
No (Owned by NTPC) CAPACITY(MW)

1. Anta (WR) Rajasthan 419.33

2. Auraiya (NR) Uttar Pradesh 663.36

3. Kawas (WR) Gujarat 656.20

4. Dadri (DBF) Uttar Pradesh 829.78

5. Jhanor-Gandhar (WR) Gujarat 657.39

Rajiv Gandhi CCPP

6. Kerala 359.58
Kayamkulam (SR)

7. Faridabad (DBF) Haryana 431.59

Total 4,017.23

pg. 6
 2.2 Coal based power station
COAL
BASED(
Sr.
Owned COMMISSIONED
No STATE
by CAPACITY
.
JVs/Subs
idiaries)

Durgapur West
1. 120
(ER) Bengal

Rourkela
2 Orissa 120
(ER)

Bhilai Chhattisg
3 574
(WR) arh

Kanti
4 Bihar 610
(ER)

IGSTPP,
5 Jhajjar Haryana 1500
(NR)

Vallur Tamil
6 1500
(SR) Nadu

Nabinaga
r-
7 Bihar 500
BRBCL(E
R)

Meja
8 U.P. 660
(NR)

Total 5,584 MW

pg. 7
 2.4 Renewable Energy Projects
Solar Energy:
Sr. Capacity
Project State/UT
No. (MW)

1. Dadri Solar PV (DBF) Uttar Pradesh 5

Andaman &
2. Port Blair Solar PV (SR) 5
Nicobar Island

Ramagundam Solar PV
3. Telangana 10
(Phase -I) (SR)

Talcher Kaniha Solar PV

4. Odisha 10
(ER)

5. Faridabad Solar PV (DBF) Haryana 5

6. Unchahar Solar PV (NR) Uttar Pradesh 10

7. Rajgarh Solar PV (WR) Madhya Pradesh 50

8. Singrauli Solar PV (NR) Uttar Pradesh 15

Ananthapuram Solar PV
9. Andhra Pradesh 250
(SR)

10. Bhadla-Solar (WR) Rajasthan 260

11. Mandsaur-Solar PV (WR) Madhya Pradesh 250

Total 870

3.National Capital Power Station - Solar

The On-Grid type solar PV plant at NTPC Dadri,spread overb 27.400 Acre, has the 5MW
capacity.The commercial operation was started on 29th March 2013. It has 20,856 PV modules;
each PV module generating a power of 240.944W.One string consists of 24 PV modules and 18
such string connected in parallel to one SCB leading to power O/p of 104.087KW from one SCB.

pg. 8
5 nos SCBs are connected to one inverter. Total 10 nos. of inverters are installed giving total
solar power of 5.20435MW.

From solar generation to transmission one underground line has been laid having length
around 4.2 KM. at the end of the line one 7.5 MVA, 33/220 KV transformer has been installed at
switchyard of Dadri Gas. Here this incoming solar power is sent to 220 KV bus through SF-6
Circuit breaker and other electrical switchgears.

4.National Capital Power Station HVDC

This is a technological accomplishment in power by NTPC . Commissioned in December '90 ,
the system is the first commercial long distance HVDC link in India , and also the largest in Asia
. The basic objective of the HVDC link is to transmit the power generated at the RhSTPP
efficiently to the northern region , with significant reduction in transmission losses . It consists
of two converter stations - one located at Rihand (RhSTPP) acting as a rectifier , and the other at
Vidyutnagar (NCPP) as an inverter , involving a distance of about 900 kms. . These stations are
connected by a +/- 500 kV HVDC line for transmission of 1,500 MW power from Rihand to
Vidyutnagar . The overall HVDC system engineering was done by Asea Brown Boveri .

The special features of this HVDC line are that the entire system can be controlled either from
RhSTPP or NCPP , depending on which station is selected as the master . The system has been

pg. 9
handed over to the Power Grid Corporation of India , and is under their control since October
1993 .

5.National Capital Power Station - Coal

The coal-based station mainly meets power requirements of the National Capital Region
[NCR] , and the northern grid . With the World Bank funding component , the capital cost of the
units is Rs. 16.69 billion . There are four 210 MW coal based units. The units have a coal-fired
boiler and a steam turbine each . The boiler design is also suitable for 100% operations with
heavy furnace oil firing . For this , three storage tanks , each of capacity 15,000 kL , enough for
10 days continuous oil firing requirements have been provided for the boilers .

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

6.National Capital Power Station - Stage

II(2X490MW)
The stage-II (490MW*2) coal based units are scheduled in 2010 to meet the common wealth
games power requirement. The commercial operation of Stage-II Unit-V 490 MW has been
declared w.e.f 31.01.2010 00:00 Hrs. The commercial operation of Stage-II Unit-VI 490 MW has
been declared w.e.f 31.07.2010 00:00 Hrs by Shri Sushil Kumar Shinde honourable Minister of
Power .

pg. 10
 INTRODUCTION OF GAS POWER PLANT

6.National Capital Power Station - Gas

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

The source of fuel for this plant is the reserves of South Bassein fields in South Tapi and mid
Tapi delta in the Arabian Sea . The natural gas from South Bassein off shore fields is transported
through a submarine pipeline to Hazira onshore terminal and then through the 1,700 kms. Long
Hazira-Bijapur pipeline via Shahjanpur and Babrala , to the project . For the 829 MW project ,
the requirement is 3.00 million cubic meters per day (yearly average). It would be worthwhile to
note that within a short span of less than 7 years , both the coal and gas based power cycle
units/modules have been commissioned in a project . Both the projects have diverse modern
technologies , with the latest process controls .

7. INTRODUCTION OF GAS POWER PLANT

8.1 SALIENT FEATURES :

pg. 11
i) Type of Station : Combined Cycle Power Plant

ii) Station Capacity : 817 MW(2(131 x 2+146.5))130.5+154.51

iii) Fuel : Main - Natural Gas

Alternate fule - HSD

iv) Source, Gas Transportation : Hazira

Consumption : Through HBJ Pipe Line 4.0 MCMD

v) Cooling Water source : Upper Gange Canal Dehra

headwork. During closer of UGC

through network of tubewells.

vi) Startup Power : Black Start DG set 2.6 MVA

capacity.

vii) Heat rate- open cycle : 2692 Kw / Kwh

Combined cycle : 1748 Kw / Kwh

Specific Gas : Open cycle - 0.3167m3/ Kwh

Consumption : Combined Cycle - 0.205m3/ Kwh

viii) HP/LP bypass capacity : 100% MCR

(for steam turbine only)

ix) Efficiency

Open cycle : 32%

Combined cycle : 48.33%

Time required form barring

Speed to synchronisation : 4 min

Time required form synchronisation

To base load at normal Gradient : 16 min.

pg. 12
 At Fast Gradient : 9 min.

8.2 GAS TURBINE

Make : Siemens AG, Germany

Type : V94.2

Yr. Of Mfr. : 1990

Capacity : 131.3 MW

Gross Power : 284.2 MW at 27oC and 987 mbar

Turbine efficiency : 32.7%

Design inlet Temp : 1060oC

Rated Speed : 3000rpm

Critical Speed of turbine : 1750rpm

Self sustaining Speed : 2100rpm

Quantity of air reqd for cooling

And sealing : 50 Kg/Sec.

Type of tertiary blades of

Rotor disc. : Fir free roots.

Type of insuluting material : Mineral Wool

Type of Governing : Electrohydraulic

Starting Device i) Type : Starting Frequency converter

ii) Rated power : 2900 KW

Time from barring speed

To synchronisation : 4 min

Rates of loading.

Normal(MW/min) : 11

Fast(MW/min) : 30

pg. 13
Heat Rate of Gas turbine (Kcal/KWH) on Natural Gas firing.

Peak : 2674

100% : 2692

80% : 2789

60% : 2997

25% : 4408

Heat rate of Combined Cycle(Kcal/ KWH) on natural Gas

Firing.

Peak : 1724

100% : 1748

80% : 1796

60% : 1925

8.3 Gas turbine Inlet Temp. (deg C)

Peak : 1100

100% : 1060

80% : 942

60% : 826

25% : 625

Nox Emmission :

Premix Mode < 70 ppm

Noise level < 85 db(at 10.5 metre distance)

Main Fuel - Natural Gas

pg. 14
Alternate Fuel - HSD

8.4 GAS TURBINE COMPRESSOR

Manufacturer : siemens KWU

Type : Multistage axial flow.

No. of stages : 16

Guide Vane : 1) Variable type at the inlet of

Compressor.

2) Fixed type at the exit of the

compressor.

Compressor ratio : 10.2

Air flow rate(at 27oC) : 404 kg/Sec.

Compressor efficiency : 88.2%

No of bleeds : 2(after 5th & 10th stage)

Type of fixing of rotor disc. : Hirth serration.

Type of fixing of blades of rotor : Dove tail.

Type of fixing of rotor : Central bolt.

Compressor washing :

Method : Wet cleaning

Washing agent : Ardsox6322 orequiv.

Frequency : Depending on compressor

Efficiency.

Water tank capacity : 0.5 m3

Type of pump : KSB : MOVI

pg. 15
8.5 COMBUSTION CHAMBER

Type : Vertical Silo type.

No of combustion chamber : 2

No of burner per combustion chamber: 8

No of ignitors : 8

Combustion efficiency : 99.8%

Ignitor voltage : 5000 V (A.C.)

No of bricks(Tiles)

In combustion chambers : 360

8.6 STEAM TURBINE

GENERAL

Manufacturer : BHEL
Capacity : 146.5 MW
Type : Two Cylinder
Condensing Reaction
No of Stages HP : 2 x 22
LP : 2x7
Type of governing : Throttle
Mode of operation : Sliding pressure
Type of gland sealing : Labyrinth type sealing.
LP/ HP cylinder : Double flow, Horizontally split
NO of shells HP : 2
No of shells LP : 3
Turbine inlet pressure : 61.75 bar
Turbine inlet temp. : 528.6oC
Turbine exhaust pressure : 0.1122 bar
No load steam flow : 16 t/hr.
Steam flow at rated condition :
HP : 451.8 t/hr.
LP : 537.8 t/hr.
Make up water : 3%

pg. 16
 Exhaust steam flow to condenser : 527.9 t/hr.
Condenser Exhaust steam temp. : 47.7 oC
Critical speed : 1900 rpm
Type of Turning Gear : Hydraulic
Turning Speed : 48 rpm
Coasting down time with Vac : 60 min
Without Vac : 15 min
Governing System : Electrohydraulic
Max Noise level : 85 db
HP/ LP bypass : 115 db
No of Stop valves HP : 2
LP : 2
No of control valves HP : 2
HP : 2
Type of valves : Combined stop & control Valves.

No of Bearings : 3 including combined

Thrust & journal bearing
Type of thrust Brg : Tilting pad type
Type of Journal Brg : Supported by spherical block
Overspeed Trip
Type : Eccentric bolts movement
No of bolts : 2
Insulation of Turbine : Spray type rock wool
Density of insulation(Kg/m3) : 220
Thermal Conduction(W/mk) : 0.086
Surface temp. of insulation : 65oC at 45oC ambient temperature

Rotational Inertia

First cylinder rotor 904.72 kg m2

Second cylinder rotor 9558.04 kg m2

Weights

First cylinder, top half outer casing 13.2 Mg

Second cylinder, top half inner casing 5.5 Mg
Second cylinder, top half outer casing 20.9 Mg
Second cylinder inner casing I with stationary
Blade carrier. Stage 1-4 5.2 Mg
Second cylinder, inner casing II with top half
Stationary blade rings, stage 5-7 and diffusers 1.6 Mg
First cylinder rotor complete with blading 13.0 Mg
Second cylinder rotor complete with blading 46.3 Mg

Combined main stop and control valve, complete

Without bend and pipe section 9.0 Mg
Combined induction steam stop and control valve
Complete. Without bend and pipe section 5.9 Mg

9. GENERATOR AND AUXILLARIES

GENERATOR (STEAM TURBINE - 1 &2)

01. Make : BHEL, HYDRABAD

02. Type : THRI-1000-36P

pg. 17
 03 C ode : VDE 530, IEC 34
04 Type of Cooling : HYDROGEN
05 RATING :
a) Rated Output : 193.1 MVA
b) Active Power : 154.5 MW
c) Terminal Voltage : 10.5 KV + 10%
d) Rated Speed : 3000 RPM (50 Hz.)
e) Power Factor : 0.8 (LAG)
f) Rated Current : 10618 Amp.
06 Insulation Class : F
07 Phase Connection : YY(2 path per Phase)
08 H2 Pressure : 3.0 Bar
09 Field Current at : 2362/802 Amp
Full load/ No load
10 Rated Field Voltage : 272 Volts
11. Contineous permitted : 8% of rated current
unbalance current
12. Generator efficiency at : 98.75%
full load
13. Generator reactive : 146.2 MVAR (over excitation)
capability
14. Generator losses at : 2094 KW
full load
15. Stator winding resistance : .0005845 ohm at 20 deg.C.
between phases
16. Rotor winding resistance : .08529 ohm at 20 deg.C.
17. Nos. Terminals : 6(3 phases, 3 Neutral)

SLIP RING/ CARBON BRUSHES :

01 Nos of brushes : 30 at +ve side

a) Slipring : 30 at -ve side
02 Rotor grounding : 4 Nos.
Brush dimension
A) Slipring : 64 x 32 x 32
b) Grounding : 20 x 8 x 32

CRITICAL SPEED ET.

01 First critical speed : 1425
02 Second critical speed : 3906

MATERIAL

Rotor Shift : 26 Ni Cr. Mo VII5

Material of retaining : x 8 Cr. Mn N 1818 IK
Forgings
Material of Rotor wedge : Cu Ni 2 Si

EXCITATION SYSTEM(ST)

01 Make : BHEL
02 Type : Thyrister controlled/ static
Range of voltage -

pg. 18
 a) In auto : 90 to 110%
b) In manual : 75% of No load field current to 110%
of full load field current.
04 Frequency range of operation : 47 to 52 Hz.
Response Time
- Rated current : 2855 Amp.
- Rated Voltage : 350 V
- Ceiling current rating : 4728 Amp.
- Ceiling Voltage rate : 566 V for 10 Sec.
- Limitors in services : Rotor current limitor 2362 Amp. Stator
current limiter 10618 Amp. Under
excitation limiter (91.6 MVAR at rated
Voltage) power system stablizer.

10.EXCITATION TRANSFORMER

Manufacturer : BHEL
Type : Dry cast resin
Capacity : 2300 KVA
Voltage : 10.5 KV/0.460 KV
Current HV/LV : 126.5 A/2886.8 A
Percentage Impedance : 7.2 + 10%
Vector Group : Dy.5.
Insulation level : 75 KVP, 25 KV rms
Type of cooling : Natural with additional (AF) forced
Cooling also.
Class of insulation : F
Degree of Protection : IP20

11.GAS SYSTEM DATA

Volume of Hydrogen : 55 m3
Space in Generator
Cooling gas Flow : 24 m3/sec
Purity of H2 required : >98%
Leakage of H2 by volume : 12m3
Per day at rated H2 pr.
Cold Gas Temp.(Rated) : 42 deg.C.
Max. hot gas temp.(before cooler): 75 deg.C
Max. cold gas temp. After cooler : 55 deg.C

12.GENERATOR (GAS TURBINE)

Make : Siemens, Germany

Type : TLRI-108/ 41
Aparent Power : 165.5 MVA
Active power : 132.4 MW
Current : 9101 Amp.
Voltage : 10.5 KV + 1.05 KV
Speed : 300 rpm/ 50 Hz
Power Factor : 0.8
Contineous Unbalance : 10%
Current
Inner Connection of stator : YY/48
Winding /slots
- Rated field voltage : 441 V
Nos. of Terminals

pg. 19
 Brought out : 6(3 phase, 3 Neutral)
- Type of Cooling : Air Cooled in close cycle air in cooled
through water
Generator Rotor Winding : 0.0005061 ohm at 20 Deg.C
Resistance between phases
Generator Rotor Winding resistance : 0.368 ohm at 20 deg.C
Generator Air Volume : 60 m3

13.TORQUES, CRITICAL SPEED ETC. :

01. Max. short circuit torque : 5032 Knm.

At line to line single phase
Short circuit

02 Moment of intertie of : 5500 Kg. M3

generator rotor shaft

03. First critical speed of rotor : 1146 rpm

04 Second critical speed of rotor : 3372 rpm

15.WEIGHTS & MATERIAL DETAILS

01. Inner frames with core : 126200 kg.

02. Outlet casing upper part : 15400 kg.

03. Outer casing lower Part : 38300 kg.

04 Rotor : 40100 kg.

05. Generator total wt. : 220000 kg.

16.STATIC FREQUENCY CONVERTOR

Rating : 2.9 MW

Manufacturer : AEG Germany

A030- Eprom programme : GKA 301.3

Version

pg. 20
Thyristers : 12 No. T1580 N3600 TOC

Fuses LCC : 12 No. 12.5

BODKC6URB73TTC

MCC : 12 Nos 12.5

: BODKC6CURB73TTC

Changeover device : GKU 400.2

Programme version

Maximum dragging with SFC : 1050 rpm.

Washing speed : 650 rpm.

DC circuit current : 2020 Amps.

At maximum speed

A.C.voltage : 0 to 1300 Volts

Frequency variation : 0 to 36 Hz.

17.SFC TRANSFORMER DATA

1600 KVA, 6.6 KV/ 1.3 KV; %Imp-6, Vector Group DY5, 50 Hz

Air cooled dry type cast resign. Insulation class B/F IP00

pg. 21
pg. 22
 Thank you

pg. 23