MANUFACTURING PROCESS, WITH DETAILS OF RAW MATERIALS,

INTERMEDIATE AND FINISHED PRODUCTS

BRIEF DESCRIPTION OF PLANT PROCESS

Salient Features

1. Project : Faridabad Gas Power Project

2. Location : Village Mujedi, P. O. Neemka, Faridabad.
State Haryana
3. Plant Capacity : 432 MW
4. Plant Configuration : Gas Turbine 1 - 138 MW
Gas Turbine 2 - 138 MW
Steam Turbine - 156 MW
5. Mode of Operation : Base Load
6. Fuel : Natural Gas
7. Alternate Fuel : Naphtha
8. Average Gas : 2 million cubic meters per day
requirement
9. Fuel Source : HBJ pipe line ( through GAIL )
10. Cooling water : Rampur Distributory
source
11. Naphtha Storage : 2 tanks of 8000 Kl. Capacity each.
12. Power Evacuation : 2X220 KV Double circuit lines to220 KV BBMB
sub-station at Samaipur ( Ballabgarh )
2X220 KV Double Circuit lines to 220 KV HVPN
sub-station at Palla ( Faridabad )

NTPC-Faridabad is a power (electricity) generating company with installed plant

capacity of 432 MW. The plant configuration is as under:

Gas Turbine -1 138 MW

Gas Turbine -2 138 MW
Steam Turbine 156 MW

The mode of operation is “Base Load”. Natural Gas is used as main fuel.
Naphtha is used as alternate fuel. Average gas requirement is two million cubic
meters per day. Gas Authority of India Ltd. supplies Natural Gas to the plant
through their H.B.J. Gas pipeline. The electricity generated is supplied to the
state of Haryana.
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MAIN PLANT:
NTPC-Faridabad is a Gas based Combined Cycle Power Plant. It has two gas
turbines of 138 MW each. Natural Gas, when fired in combustion chamber, runs
gas turbine. Exhaust gases from gas turbines go to two Heat Recovery Steam
Generator of 277 t/hr each. Superheated steam generated in these generators is
used to run steam turbine coupled with Power Generator to get 156 MW. In
addition to these, we have various other auxiliaries; mentioned hereunder.

DM PLANT:

DM Plant has been installed to provide de-mineralized water for steam

generation & equipment cooling. It has two streams of 100 m3/hr each. Effluents
generated are neutralized in the neutralization pit before discharging to Central
Monitoring Basin.

COOLING TOWER:

Induced Draft Cooling Tower of 29000-m3/hr capacity has been built to cool the
hot water coming out of condenser of steam turbine. It is capable to reduce
water temperature by 110C.

STORAGE RESERVOIR:

Raw water drawn from Rampur Distributory of Gurgaon Canal is stored in two
reservoirs of 45000 m3 each.

C.W. SOFTENING PLANT:

Raw Water Softening Plant of capacity 630 m3/hr has been provided. The raw
water received is treated in clarifier, then passed through sand filter and stilling
chamber. The pH value of soft water is maintained throughout. The water from
cooling water-softening system is fed into basin of cooling tower.

FIRE WATER PUMP HOUSE:

As a part of integrated fire fighting system, firewater pump house has also been
built which houses following equipment:

A] Hydrant System:
Motor driven pumps = 03 Nos.
Diesel driven pumps = 02 Nos.
B] Spray System:
Motor driven pumps = 02 Nos.
Diesel driven pumps = 02 Nos.
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C] Jockey pumps: Motor driven = 02 Nos. (common for Hydrant
 & Spray system)
D] Compressors: Motor driven = 02 Nos. (for hydro-pneumatic
tank)
This pump house remains operational round-the-clock.

EFFLUENT TREATMENT PLANT:

To handle and treat all effluents, an Effluent Treatment Plant has been designed
to treat following liquid effluents.

Regeneration waste water from DM Plant;

• Waste water from Raw Water Pre-treatment Plant;

• Sludge generated from Cooling Water Softening Plant;
• Boiler blow down
• Cooling Tower blow down
• Dirty water from various sources

After treatment water is taken to the Central Monitoring Basin. The treated
effluents meet the parameters of Water (Prevention and Control of Pollution) Act
1974. Then they are discharged to the canal.

C.W. CHLORINATION PLANT:

NTPC-Faridabad has a Chlorination Plant involving state-of-art technology for

on-line Chlorination of circulating water. It protects the water of cooling tower
against bacteriological contamination. It has also in-built chlorine leak detection
system. To control and contain leakage of chlorine, a Chlorine absorption tower
has been provided.

NAPHTHA STORAGE SYSTEM:

This system has two tanks of 8000 m3 each. This system involves unloading
from tankers and then transportation to storage tanks. It has all in-built system
for transfer of naphtha from tanks to gas turbines, also leak detection system
and protection against fire.

FIRE FIGHTING SYSTEM:

NTPC-Faridabad has full-fledged Fire Fighting System to safeguard against any

kind of eventuality. It has fire fighting hydrant system, which remains operational
round-the-clock. It has fully automatic system involving state-of-art technology to
fight against any kind of fire arising due to gas/naphtha leak. Also, there is
Natural Gas Leak Detection System, Naphtha Leak Detection System.
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MAJOR LEGAL SANCTIONS/CONSENTS:

NTPC-Faridabad has been granted following legal sanctions/ consents:

• Clearance by Ministry of Environment & Forest for setting up the plant;

• No Objection Certificate from Haryana State Pollution Control Board
(HSPCB);
• Consent Order for Water and Air, issued by HSPCB with time-to-time
renewal.
• Clearance for the Boilers operation from Chief Inspector of Boilers,
Haryana
• License for Naphtha/ Diesel storage from Chief Controller of Explosives,
Haryana
• Grant for discharge of effluents from Haryana State Pollution Control
Board
• Grant for emission of air pollutants from Haryana State Pollution Control
Board
• Factory Licence issued by Chief Inspector of Fctories , Haryana

SAFETY:

NTPC-Faridabad has also full-fledged safety department to ensure compliance

of safety norms inside and outside the plant. Safety trainings/workshops are
conducted from time-to-time to increase awareness among persons.

FIRE FIGHTING:

Fire Fighting activities are being controlled by Central Industrial Security Force
(CISF). They have trained manpower for this job. They conduct mock drills from
time-to-time to test soundness of their system in coordination with NTPC
operation & safety Department.

HUMAN RESOURCE:

Human Resource is the main strength of this medium industry. General Manager
is the head of the Unit. Predominantly; executives manning Operation,
Maintenance, Erection, and other technical sections are engineers. Executives
looking after Human Resource, Finance is professionals. Supervisors and
workmen are qualified personnel. Skill is further sharpened through training from
time-to-time.

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CONTRACTS & MATERIALS:

This department is responsible for arranging/ storing all raw materials, spares
and consumables required for generation of electricity.

MEDICAL CENTRE:

There is a Medical Centre located inside NTPC- Township where the injured and
sick persons are treated. It is under the charge of Chief Medical Officer (CMO).
Also one Asst. Chief Medical Officer is available on General duty. Also one nurse
is available during the day time and one compo under is on duty during night.
Further, an ambulance with driver is kept ready all the time. All other Medical
facilities are out sourced to Escorts- Faridabad.

Raw Materials Used

Water : From Rampur distributory canal

Natural gas : HBJ pipe line of GAIL (2mcm / day)

Alternate fuel : Naphtha (two tanks of 8000kl capacity)
to be used in emergency.

We also use small quantity of Chlorine, Acid and Alkali for treating the water and
water purification purposes.

There is no intermediate product and by product in the process

DETAILS OF CHEMICALS STORED IN THE FACTORY

Sl. No Description Storage Capacity

1 Hydrochloric Acid 100 KL

2 Alkali (NaOH) 100 KL

3 Sulphuric Acid 40 Kl

4 Naphtha 16000 KL (() 2Tanks

8000KL each)
5 Chlorine 10 Tonners connected
02 in service
6 Natural Gas No Storage

7 HSD 500KL
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 RISK ASSESSMENT AND HAZARD IDENTIFICATION

Major plant sections

Considering the power generation process at Faridabad Gas Power Project, the
following are the major plant sections :
• Main plant including gas and steam turbo-generators and their auxiliaries
• Waste heat recovery boilers and their auxiliaries.
• Central and local control rooms.
• LT and HT switch gear rooms.
• Cable galleries .
• PT & DM plants and chlorination units
• Gas receiving station and gas distribution piping network.
• Unit gas skids.
• Naphtha storage and distribution piping network.
• Black start DG set

Major hazard potential assessment

The major emergencies or disasters usually take place from one or any
combination of the following:
• Fast spreading fires
• Explosions
• Bursting of pipe lines or vessels
• Uncontrolled release of toxic / corrosive / flammable liquid
• Uncontrolled release of toxic / flammable gas .
• Structure collapse due to Natural disasters like earth quake, storm etc
• Sabotage and Terrorist attacks on installations
• Destructive trade union activities, strikes and mob violence etc

Depending upon the nature, scale, velocity and impact on environment, each of
these may constitute an emergency.

Hazard potential of various plant sections

• Fire hazard :
a) Cable galleries and cables trays
b) Diesel oil tank, Transformer oil
c) Naphtha storage area
d) Gas handling station at GAIL terminal
e) Gas skids
 f) Turbine hall.
g)
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• Explosion hazard :

a) Naphtha storage tanks,

b) Gas and naphtha piping network,
c) GAIL terminal
d) Transformers.

• Bursting of pipe lines / vessels :

a) Water and steam pipes due to high pressure,

b) Gas & oil lines due to high pressure and temperature.

• Release of gases :

a) Chlorine in PT, CW Chlorination units,

b) Natural gas from gas receiving station, gas skids and pipe lines.

• Release of liquid:

a) Chemical tanks in DM plant,

b) Fuel oil from oil storage tanks.
c) Lubricating oil from turbines and generators

• Natural disasters

a) Structure collapse may occur due to natural disasters like earth

quake or storm

• Sabotage and Terrorist attacks

a) Depending upon the location of sabotage and terrorist attacks

emergencies may have the aforesaid risk potential

• Destructive trade union activities, strikes and mob violence etc

a) Depending upon the situation the emergencies arising out of

above factors may have the aforesaid risk potential
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Risk assessment and Environment impact assessment

• There is less probability of fire in cable galleries, cable trays, transformer

oil, turbine areas, naphtha storage area and gas handling system as
adequate detection, manual and automatic fire fighting arrangement have
been made and those are checked at fixed intervals.

• There is very less probability of bursting of pipes as they are made of

sound construction and every year all the Waste Heat Recovery Boiler
and its accessories are checked by chief inspector of boiler and certificate
is issued by him about sound condition. Till date there is no such fracture
of pipes.

• There is also very less probability of explosion in naphtha storage area,

gas and oil line system as adequate detection and protection is in built
with the system. Every year the chief control of explosive renews the
explosive certificate issued by him about sound condition.

• There is less possibility of major emergency on account of release of

hazardous chemicals as we are not storing such chemicals in large
quantities and adequate inbuilt protection has been provided. Also
sufficient care is taken while handling these chemicals.

• The probability of sabotage and terrorist attacks and also the possibilities
of destruction by union activities / strikes and mob violence is very less as
the plant is protected by a boundary wall and watch towers are
constructed at four corners of the boundary wall. These are manned
round the clock by CISF personnel. CISF personnel are also deployed at
vulnerable locations of the plant. Visitors are screened by CISF personnel
and photo passes are issued to them.

• Possibility of collapse of tall structure is almost nil as all safety factors

have been taken during design and erection of the structures

Environment impact assessment

• There is very thin population around the plant.

• There is no built up area very near the plant. So effect of fire in such area
is almost nil.
• Possibility of contaminating drains, crops, water supplies and natural
water is almost nil. To handle and treat all effluent treatment plant has
been installed liquid effluents.
• There is no radio active source in the plant area

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THE PREVENTIVE MEASURES AND PLANS REFLECTING THE

FACTORY SAFETY STATUS CURRENTLY IN FORCE / PRACTICE.

1. Safety precautions and preventive measures

Safety precautions and preventive measures are documented in book form

for all type of major activities.
Like
• Electrical, mechanical safety rules.
• Safety rules for construction
• NTPC safety management.
• Local Management Instructions (LMI) for majority of activities
• Start up and Shut down procedures
• Emergency operating procedures during total power failure
• Procedures for charging liquid fuel system
• Procedure for charging fuel gas system
• Naphtha handling and storage procedures

2. Other safety measures

• All the pipes carrying steam, oil , water, gas are identified by different
colors.
 Steam – insulated with aluminum sheet cover.
 Water – green
 Oil- brown
 Compressed air- blue
 Fire hydrant – red
• Permit to work system is strictly followed with lock out boxes as per CEGB
pattern of U.K
• Safety audit of station is done very year by other project representatives
of NTPC.
• All the break down / periodic maintenance are done under the strict
supervision of qualified officers. The job quality is checked by field quality
assurance department after thorough checking and testing.
• Personal protective equipment like – safety shoes, gum boot & safety
helmet are given to every employee every year.
 • Plastic overhaul suit with face mask, rubber hand gloves , dust mask, ear
plugs, safety goggles, safety belt, Breathing apparatus set etc. are also
used by employees when required.
• Installation is certified under ISO – 9001. The systems being followed are
as per this standard
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• FGPP is also certified under ISO – 14001. Environment management
systems confirm to this standard.
• Certification under Occupational Health and Safety Management System
(OHSAS – 18001 ) is also done.

5 Inspection procedure

• Daily visual inspection of all the equipment and meter readings are
recorded by area operators daily in each shift.
• Shutdown maintenance inspection is done vigorously.
• Electrical testing is done after every shut down, break down and routine
maintenance.
• After every shut down maintenance all area and equipments are
thoroughly checked by maintenance personnel.
• Testing of pressure vessels are done by competent mechanical
maintenance engineer group.
• Pressure pipes are tested by mechanical engineers in the presence of
Chief inspector of boiler or his representative and take the certificate of
safe condition.
• At the time of commissioning, all the interlocks and protections, tripping
circuit, safety alarm circuit are tested and records are kept.
• All the lifting tools & tackles, hoists tested every year after preventive
maintenance.
• All the fire fighting and alarm system are on auto and during mock
demonstration these are checked.
• Smoke detection systems are checked by maintenance and operation
group.
• Fixed fire fighting systems are checked jointly by operation, safety and fire
groups.
• Chlorination system healthiness is checked monthly by operation, safety
and fire groups

6. Safeguard of DM plant.

• In acid, alkali tanks area all safety measures have been taken to avoid
disaster.
• Contents of the tanks are marked clearly.
 • Said areas are carpeted with acid/alkali proof bricks and separate soaking
pits around the tanks are also provided to hold the total volume of acid /
alkali in case of total drain of acid / alkali, to avoid spreading.
• Drains are provided to drain the spilled acid / alkali to neutralization pits
which have capacity of more than total capacity of acid / alkali tanks.

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• Shower both platform and eye wash basins are provided in the vicinity of
tanks.
• Acid fumes extraction fans are provided to remove the fumes from
working area.
• Safety instructions are displayed what to do in case of emergency.

7. Naphtha tanks and associated installation

• Storage area is isolated, segregated and located at a safe distance from

the main plant
• Entire area is fenced and entry of persons is restricted to only authorized
persons.
• Entry to naphtha storage area is allowed after thorough checking by CISF
security.
• Entire installation is paved so that no grass grows there. Therefore the
chances of fire is almost nil.
• No vehicles are allowed inside the storage installation. Emergency
vehicles such as fire tenders and fire jeeps are allowed with spark
arresters only.
• Following fire detection and protection following measures are taken.
 Naphtha gas leak detection system is installed in handling area for
timely detection of leakage
 All electrical fittings are flame / explosion proof and are approved type.
 Auto water sprinkler system is installed for equipments and storage
tanks which operate automatically.
 Automatic foam flooding system is provided for storage tanks.
 Entire installation, storage and handling area is covered by fire
hydrants and fire water monitors are always under charged condition.
 One number hose house is there inside the installation for emergency
use.
 First aid fire fighting equipments are also placed inside the installation
in sufficient quantity.
• Preventative as well as breakdown maintenance is carried out by
experienced and qualified personnel with non sparking tools only.
• Safety instructions do’s and don’t are displayed at all location of the
installation.
 • Spill retention dyke walls are constructed for storage tanks as per
Petroleum Protection Act .
• Level indicators are installed in storage tank for spill control.
• Installation is inspected and certificate of compliance (explosive license) is
issued by explosive department and renewed every year by them.
• As all precautionary safe guards as mentioned above are taken, the
chances of disaster in this area is very less.
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8. Safe guards for chlorination plant

• Chlorine leak detectors are provided for sensing and giving alarm in case
of chlorine leakage from toners or manifold.
• Neutralization pit with lime solution is provided for neutralization of leaking
gas
• Ventilation fans are provided at low level
• An automatic functioning scrubber system is provided to neutralize any
chlorine leak from the connected toner and the manifold.
• Chlorination plant is open from all sides and covered by roof only
• Breathing apparatus and emergency leak sealing kit is provided for
emergency use.
• Employees are trained to use breathing apparatus and sealing kit.
• Monthly checking of detection, protection and control system is carried out
jointly by Safety, fire and O&M groups
• Safety instructions do’s and don’ts are displayed prominently in the area.
• Disaster Management Plan is prepared and mock drills are conducted
once in six months

9. Specific gas detection system

• Leak detectors are provided for natural gas at gas receiving station, unit
gas skids and combustion chambers of gas turbines.
• Naphtha leak detectors are installed for naphtha handling and storage
areas
• Chlorine gas leak detectors are installed in chlorination plants.