Dhruv Batra(Ntpc Report)

8/12/2019 Dhruv Batra(Ntpc Report)

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REPORT ON

INDUSTRIAL TRAINING

AT

NTPC, Badarpur

Name Of Student : Dhruv Batra Name Of Supervisor : Mr. Manmohan Singh

Institute : JIIT Designation : Dy. Manager (HR-EDC)

Branch : DUALM-ECE Training Period : 23rdMay to 2ndJuly 2011

Roll No. : 08502934


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STUDENT DECLARATION

I hereby declare that this industrial training report titled REPORT ON INDUSTRIAL

TRAINING AT NTPC, Badarpur, submitted to Jaypee Institute of Information Technology

in partial fulfillment of the requirements for the award of B.Tech degree, is my original work

and not submitted for the award of any other degree/ diploma/ fellowship or other similar

titles or prizes.

Dhruv Batra

(Student of JIIT)


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CERTIFICATE


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ACKNOWLEDGEMENT

With profound respect and gratitude, I take this opportunity to convey my thanks to all

individuals who helped me complete my training.

I do extend my sincere thanks to Mrs. Rachana Singh for providing me this opportunity to be

a part of this esteemed organization.

I am extremely grateful to all the technical staff of BTPS/NTPC for their co-operation and

guidance that helped me a lot during the course of training. I have learnt a lot working under

them and I will always be indebted of them for this value addition in me.

I would also like to thank members of T&P cell and faculty of Electronics & Communication

department of JIIT for their guidance and support.


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CONTENTS

1) ABOUT THE ORGANISATION2) DESCRIPTION OF WORK CARRIED OUT3) THERMAL POWER PLANT BASICS AND OPERATIONS CARRIED OUT AT

PLANT

a) SITE LOCATION AND REQUIREMENTS OF PLANTb) WORKING CYCLE OF THERMAL POWER PLANT

COAL TO STEAM STEAM TO MECHANICAL POWER SWITCHING AND TRANSMISSION

c) INSTRUMENTATION USED AT PLANTd) SAFEGUARDS, INTERLOCKS AND PROTECTIONS USED AT PLANTe) WATER TREATMENTf) ROLE OF IT

4) CONCLUSIONS5)

REFERENCES


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1) ABOUT THE ORGANIZATION

NTPC, India's largest power company, was set up in 1975 to accelerate power development

in India. It is emerging as an Integrated Power Major, with a significant presence in the

entire value chain of power generation business.

NTPC ranked 341stin the 2010, Forbes Global 2000 ranking of the Worlds biggest

companies.

With a current generating capacity of 34,854 MW, NTPC has to become a 75 GW company

by the year 2017 and envisages to have an installed capacity of 128 GW by the year 2032

with a well diversified fuel mix comprising 56% coal, 16% gas, 11% nuclear energy, 9%

renewable energy and 8% hydro power based capacity.


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STRATEGIES

Looking at the opportunities coming its way, due to changes in the business environment,

NTPC made changes in its strategy and diversified in the business adjacencies along the

energy value chain. In its pursuit of diversification NTPC has developed strategic alliances

and joint ventures with leading national and international companies. NTPC has also made

long strides in developing its Ash Utilization business.

Nuclear Power: A Joint Venture Company "Anushakti Vidhyut Nigam Ltd." hasbeen formed (with 51% stake of NPCIL and 49% stake of NTPC) for

development of nuclear power projects in the country.

Coal Mining: In a major backward integration move to create fuel security, NTPChas ventured into coal mining business with an aim to meet about 20% of its coal

requirement from its captive mines by 2017. The Government of India has so far

allotted 7 coal blocks to NTPC, including 2 blocks to be developed through joint

venture route.

Power Trading: 'NTPC Vidyut Vyapar Nigam Ltd.' (NVVN), a wholly ownedsubsidiary was created for trading power leading to optimal utilization of NTPCs

assets. It is the second largest power trading company in the country. In order to

facilitate power trading in the country, National Power Exchange Ltd., a JV of

NTPC, NHPC, PFC and TCS has been formed for operating a Power Exchange.

Power Distribution: NTPC Electric Supply Company Ltd. (NESCL), a whollyowned subsidiary of NTPC, was set up for distribution of power. NESCL is

actively engaged in Rajiv Gandhi Gramin Vidyutikaran Yojanaprogramme for

rural electrification.


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Equipment Manufacturing: Enormous growth in power sector necessitatesaugmentation of power equipment manufacturing capacity. NTPC has formed jvs

with BHEL and Bharat Forge Ltd. For power plant equipment manufacturing.

NTPC has also acquired stake in Transformers and Electricals Kerala Ltd. (TELK)

for manufacturing and repair of transformers.

ENVIRONMENT CONSIDERATION

While leading the nations power generation league, NTPC has remained committed to

the environment. It continues to take various pro-active measures for protection of the

environment and ecology around its projects.

NTPC was the first among power utilities in India to start Environment ImpactAssessment (EIA) studies and reinforced it with Periodic Environmental Audits

and Reviews.

Right from inception, the company had a well defined environment policy. Ash utilisation is one of the key concerns at NTPC. Towards the reduction of Greenhouse Gas (GHG) emission from Indian thermal

power plants, NTPC has been promoting and deploying efficient power generation

technologies and practices from design stage to operation stage and building local

institutional capacities for continuously striving for eco-friendly technologies.

Maintenance of ecological balance and a perfect environment byAfforestation hasbeen of utmost importance at NTPC.
http://www.ntpc.co.in/index.php?option=com_content&view=article&id=41&Itemid=97&lang=enhttp://www.ntpc.co.in/index.php?option=com_content&view=article&id=41&Itemid=97&lang=en


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NTPC BADARPUR

NTPC Badarpur is a thermal power plant and requires coal for power generation. Ownership

of BTPS was transferred to NTPC with effect from 01.06.2006 through GOIs Gazette

Notification.

The PLF of the power station improved from 31.94% at the time of the takeover to 86.46%

for the year 2007-08.

It receives coal from Coal India (Jharia Coal Fields) via Indian Railways. This coal has 35%

ash by weight. This plant uses Agra Canal for its water requirements. It has 5 independent

power generating units, three of 95 MW and two of 210 MW, totaling to 705 MW installed

capacity. Out of produced electricity, 9% is consumed by plant itself. Each unit has separate

boiler, turbines, generators, control and protection systems each feeding to common grid.

Electricity produced is provided to various distributors like NDPL, BSES etc. In peak seasons

plant may operate at 105% of production capacity, and if load is less then, plant has to

shutdown its appropriate units as electricity produced cannot be stored, and this is taken as

opportunity for maintenance and servicing of the non operating units.


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2) DESCRIPTION OF THE WORK CARRIED OUT

I was appointed to do six-week training at this esteemed organization from 23rd May to 2nd

July 2011 which gave me an opportunity to see the plant by myself and learn how electricity

is generated and helped me learn the principles and specifications involved.

Detailed working of a thermal power plant was taught on the first three days and plant visit

was arranged on the fourth day, later I was assigned to visit following divisions:

1. Control and instrumentation (C&I) Protection And Interlock Lab Pyrometer Lab Water Treatment Lab Turbine Safeguard Instrument Lab Furnace Safety Supervisory System(FSSS) Lab Electronics Lab

2. Information Technology (IT)

.


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3) THERMAL POWER PLANT BASICS AND OPERATIONS CARRIED

OUT AT PLANT

a) SITE LOCATION AND REQUIREMENTS

Selecting site for the plant is most crucial factor for its working.

Site area should be large enough considering both present and future capacityanticipated.

Site selection depends upon fuel used and its mode of delivery to the site, fuel storage,cooling towers, switchyards, store yards, workshops, railway sidings, water supply

access, transmission connection and surrounding area.

Modern power plants with heavy structures impose a heavy load on subsoil and hencemust be supported by suitable foundations.

Water supply is a major factor considered while selecting a site, water is required forsteam generation and for cooling purposes. Water needed for steam generation should

be of permissible quality for which water treatment plant is required and this adds up

to cost. Water for cooling purposes is required in significant amount, direct cooling

can be used if perennial river is located nearby site otherwise closed cooling system

involving cooling towers is used.

Plant should be located as near as possible to coal pit head or coal washeries so thattransportation cost is less and also mode and ease of transportation is to be

considered.

A route must be available for the transmission lines to the nearest grid system. Climatic conditions also play a significant role, tropical climate calls for special

attention to ventilation and cooling arrangements required for sensitive electronic


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equipments and, humid conditions create hindrance by causing corrosion of

insulations.

Proximity to airfields is studied so that chimney height does not create problems in airnavigation.

Personnel requirements will consist of both skilled and unskilled labour, thereforeprovisions for residential colonies with full amenities are to be thought of.

Disposal of effluents majorly flu gas, fly ash and chemically treated water from watertreatment plant are also to be considered. These affect marine life of rivers. Ash is

disposed by converting into slurry and then pumping it to waste lands, therefore large

amount of waste lands for effluent disposal are required.


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b) WORKING OF THERMAL POWER PLANT

Coal to steam

Fig. 1: coal to steam cycle

Coal from coal wagons is unloaded in coal handling plant. This coal is transported upto raw

coal bunkers with help of conveyor belts. Now coal is transported to bowl mills by coal

feeders where coal is pulverized to powder form with help of rollers.

Fig. 2: coal storage and transport with conveyor belts to mills


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Primary Air Fan (P.A. Fan) are used to transport and preheat pulverised coal to furnace.

P.A. Fan takes atmospheric air and sends it to air-preheaters for heating and to mill for

temperature control. Atmospheric air from Force Draft Fan (F.D. Fan) is heated in air heaters

and sent to furnace as combustion air. Air pre heaters raise the temperatures of primary and

secondary air by utilising heat from flue gas at low temperature, this increases efficiency.

Water from the boiler feed pump passes through economizer and reaches the boiler drum.

Boiler drum is at 80 m of height, 8 kg of pressure is developed. Water from drum passes

through down-comers and goes to bottom ring header from where it is divided to all four

sides of furnace. Due to heat and density difference the water rises up in water wall tubes (

which form the inner wall of the furnace), this water is partly converted to steam as it rises up

in the furnace, the steam is separated in boiler drum and is sent to super heaters while water

follows same path. Super heater is used to convert wet, saturated steam into dry steam. Super

heaters are a very beneficial part of the steam cycle, because dry steam contains

more thermal energy and increases the overall efficiency of the cycle. Not only that, dry

steam also is less likely to condense within the cylinders the casing of a steamturbine.Three

boiler super heaters are there : low temperature radiant super heaters,convection super

heaters and final super heaters.

Fig. 3 : furnace side at NTPC
http://www.wisegeek.com/what-is-a-turbine.htmhttp://www.wisegeek.com/what-is-convection.htmhttp://www.wisegeek.com/what-is-convection.htmhttp://www.wisegeek.com/what-is-a-turbine.htm


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Flue gas from furnace is extracted by induced draft fan which maintains balance draft in

furnace with force draft fan by creating vacuum. F.D. Fan creates pressure in furnace by

supplying air, the flue gasses are taken out due to pressure difference between furnace and the

atmosphere. These flue gasses emit their energy to various super heaters and finally pass

through air preheaters and goes to electrostatic precipitator consisting of electrically charged

plates which attract ash particles from flue gas and rest of flue gas is emitted out of the

chimney. Regular mechanical blows cause ash to fall in hopper at bottom of precipitator. The

ash collected is mixed with water to form slurry and is pumped to ash pond.

Steam to mechanical power

Fig. 4 : turbines and generator internal description

Superheated steam from boiler is passed to the turbines through stop valve (for emergency

shut off) and through control valves (for regulation of supply of steam) and governor driven


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from main turbine shaft operates the control valves according to speed of turbine required and

amount of electricity required.

Steam from control valves enters into high pressure cylinder where it is passed through ring

of stationary blades. These act as nozzles and direct the steam to secondary ring of moving

blades mounted on disc secured to shaft so that steam helps move the shaft. Many such stages

are present in high pressure cylinder. Till steam reaches the end of high pressure cylinder,

some of its heat energy is exchanged to mechanical energy. Steam leaving high pressure

cylinder goes back to boiler for reheating and returns to intermediate pressure cylinder and

here it passes through another series of stationary and moving blades.

Fig. 5 : turbines and generators at NTPC, Badarpur for different units

Finally, the steam enters low pressure cylinders from center flowing outwards in opposite

direction through rows of turbine blades (double flow arrangement).

Turbine shaft rotates at 3,000 revolutions per minute necessary to generate 50 cycles per

second of alternating current from 2 pole generator.


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After extracting as much energy as possible from steam, it is exhausted to the condenser

consisting of large vessel containing many tubes. Cold water from cooling tower is passed

through these tubes so that steam condenses to water condensate, as water has much smaller

volume than steam therefore a vacuum is created in condenser.

From condenser, the condensate passes through low pressure heaters by extraction pump,

after which its pressure is increases to boiler pressure by boiler feed pump. It is passed

through feed heaters, de aerator and through economizer and finally to boiler for reconversion

to steam.

Indirect type of heat exchangers are used (shell and tube type). Economizer is used to preheat

the boiler feed water before it is introduced into the steam drum by recovering heat from the

flue gas leaving the boiler. The water is heated so as to increase the efficiency, less energy

from burning coal will be utilized to convert this water into steam. Water used for cooling

purposes is again passed through cooling towers where heat is removed by evaporation and

water is reused. De aerator is used to avoid air from mixing with steam.

Switching and transmission

Refer to figure below, moving turbine shaft produces electricity in stator windings of the

generator and this is fed through terminal connections to transformer (1) which steps up the

voltage. From here conductors carry it to series of three switches comprising an isolator (2),

circuit breaker (3), another isolator (4). From circuit breaker the current is taken to busbars

(5) common for all generators of different production units and then to another series of

switches (6)(7) and finally fed to grid (8).

Three wires are used in a three-phase system for large power transmission as it is cheaper

than two wire single-phase system (used in homes).


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Fig. 6 : from generator to grid

The center of power station is control room (9) where continuous monitoring of output of

electricity, supervising and controlling of plant and high voltage switch gear and directing

power to grid is carried out.

Fig. 7 : control room at NTPC, Badarpur


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c) INSTRUMENTATION USED IN PLANT

Temperature measurement instruments:

Liquid In Glass Thermometer : Mercury in the glass thermometer boils at 340 degreeCelsius which limits the range of temperature that can be measured. It is L shaped

thermometer which is designed to reach all inaccessible places.

Ultra Violet Censor (optical pyrometer) : This device is used in furnace and itmeasures the intensity of ultra violet rays there and according to the voltage wave

generated which directly indicates the temperature in the furnace.

Thermocouples : This device is based on seeback and peltier effect. It comprises oftwo junctions at different temperature. Then the emf is induced in the circuit due to

the flow of electrons. This is an important part in the plant.

RTD (Resistance Temperature Detector) : Its resistance increases with increase intemperature, and this changes the current in circuit, this change helps measure

temperature.

Mercury in steel : As temperature increases near bulb, the mercury vapours incapillary tube expand, C-tube within moves, by mechanical advantage pointer moves

and temperature is measured.


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Bimetallic temperature guage : Consists of two metals joined together at hot junction,one shrinks and other expands on increasing temperature, this deformation is

measured by help of mechanical advantage which then indicates change in

temperature.

Pressure measurement instruments:

Bourden tubes : The Bourdon Tube is a non liquid pressure measurement device. It iswidely used in applications where inexpensive static pressure

measurements are needed. A typical Bourdon tube contains a curved tube that is open

to external pressure input on one end and is coupled mechanically to an indicating

needle on the other end, as shown schematically below.

Pressure transmitters : are used and they can be used for digital means of monitoringas with being ON is referred as high and being OFF is as low.

All the monitored data is converted to either Current or Voltage parameter.

The Plant standard for current and voltage are as under

Voltage :010 V

Current :420 mA

Accuracy of such systems is very high .


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Flow measurement instruments

Rotameter : Is a device that measures the flow rate of liquid or gas in a closed tube. Venurimeters / Orifice meters Massflow meters ( oil level ) Ultrasonic Flow meters Magnetic Flowmeter


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d) SAFEGUARDS, INTERLOCKS AND PROTECTIONS

Furnace Safety and Supervisory System

This has the responsibility of starting fire in the furnace to enable the burning of coal.

For first stage coal burners are in the front and rear of the furnace and for the second and

third stage corner firing is employed. Unburnt coal is removed using forced draft or

induced draft fan. The temperature inside the boiler is 1100 degree Celsius and its height

is 18 to 40 m. It is made up of mild steel. An ultra violet sensor is employed in furnace to

measure the intensity of ultra violet rays inside the furnace and according to it a signal in

the same order of same mv is generated which directly indicates the temperature of the

furnace. For firing the furnace a 10 KV spark plug is operated for ten seconds over a

spray of diesel fuel and pre-heater air along each of the feeder-mills. The furnace has six

feeder mills each separated by warm air pipes fed from forced draft fans. In first stage

indirect firing is employed that is feeder mills are not fed directly from coal but are fed

from three feeders but are fed from pulverized coalbunkers. The furnace can operate on

the minimum feed from three feeders but under not circumstances should any one be left

out under operation, to prevent creation of high cpressure with in the furnace, which

threatens to blast it.

Turbine safeguarding

Turbine safeguarding is ensured by continuously monitoring

Axle shift Eccentricity Vibrations


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Interlocking and protections

It is basically interconnecting two or more equipments so that if one equipments fails other

one can perform the tasks. This type of interdependence is also created so that equipments

connected together are started and shut down in the specific sequence to avoid damage.

For protection of equipments tripping are provided for all the equipments. Interlocking and

protection systems are used in plant at -

Furnace : Pressure is continuously monitored inside the furnace, if vacuum inside ishigh than particular value, there will be incomplete combustion of coal and furnace

may collapse, therefore to prevent any mishap, unit trips at certain pressure.

Boiler : If I.D. Fan of a unit trips because of some problem, other fans also trip,turbine and generator also trips, whole unit is tripped by interlocking.

Water drum : Water in drum is to kept till certain level, if water exceeds then flowdown valve opens, and if level further increases then, whole unit tripped.

Fans : These have 6.6 kV motors, temperature of bearings required for free movementincreases because of friction, and these need to be cooled down with oil. As

temperature increase is sensed by temperature sensing instruments, pump is started to

provide oil for cooling, but if this pump fails to start and temperature further increases

at the bearings then, because of interlocking whole unit is tripped for safety. Fans are

always started in unloaded condition. When fans are started, discharge damper gates

and ducts are closed then ducts are opened by interlocking.

Turbines : Emergency stop valves are present for all turbines. Axil shift andeccentricity of rotors in turbines are continuously monitored, if exceed particular

value then turbine is tripped, and by interlocking boiler for that unit is tripped


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Condenser : Particular value of vacuum is to be maintained inside condenser, ifexceeds that value then unit trips.

Chimney: Flue gas going out must have temperature of 130 C. If temperature is morethen safety system alarm goes off, it may be due to deposition of soot onto water wall

tubes and super heater which causes improper exchange of heat, then soot has to be

cleaned by soot blower. If temperature is less than also system alarm goes off, as

sulphur in flue gas may precipitate to inner walls of chimney and on mixing with rain

water can form sulphuric acid which may damage the chimney.

Low and high limits are set for each control system, at low warning occur and at high tripping

occur. 256 protection points are critical and all protections are regularly checked and there is

continuous display of all data being monitored.

Some of the instrument uses for protection are -

Relay : It is a protective device. It can detect wrong condition in electrical circuits byconstantly measuring the electrical quantities flowing under normal and faulty

conditions. Some of the electrical quantities are voltage, current, phase angle and

velocity.

Fuses : It is a short piece of metal inserted in the circuit, which melts when heavycurrent flows through it and thus breaks the circuit.

Miniature Circuit Breaker : They are used with combination of the control circuits toenable the staring of plant and distributors and protect the circuit in case of a fault. It

consists of current carrying contacts, one movable and other fixed. When a fault

occurs the contacts separate and is stuck between them. There are three types :

Manual Trip Thermal Trip Short Circuit Trip


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High Tension Control Circuit : For high tension system the control system are excitedby separate D.C supply. For starting the circuit conditions should be in series with the

starting coil of the equipment to energize it. Because if even a single condition is not

true then system will not start.

Low Tension Control Circuit : For low tension system the control circuits are directlyexcited from the 0.415 KV A.C supply. The same circuit achieves both excitation and

tripping. Hence the tripping coil is provided for emergency tripping if the

interconnection fails.


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e) WATER TREATMENT

Yamuna water in Agra canal is used by the plant, this water has to be cleaned, demineralized

and deoxygenated before using.

Clarifier removes big particles, then leaching powder and various filters are used to remove

small suspended particles and micro organisms. After this water is fed to cation exchanger to

remove cations, degasser removes gasses produced after reactions and at last water is fed to

anion and mixed bed exchanger to finally get demineralized water.

Many problems are imposed if raw water is not treated such as resistance to passage of heat,

corrosion of water tubes, foaming.

For improving quality of water and removing cations and anions, chlorine and other chemical

raisins are used in cycles so that they do not react among themselves.

This water undergoes ph analyzing, Na analyzing, silica analyzing and conductivity tests

before being fed to boiler drum and condenser. Conductivity tests tell about the presence of

cations and anions. Each unit has separate analyzers.


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f) ROLE OF IT IN PLANT MANAGEMENT

1. Development, Implementation, Maintenance & Support for Local Applications.2. Planning , Procurement & Maintenance of IT Infrastructure ( pcs, Printers, Servers

& Network LAN,WAN etc)

3. ERP Support & developing interface modules to supplement ERP.4. SW Customization & support for BTPS Applications to other projects.

Enterprise Resources Planning (ERP) Modules

Maintenance Management- PM Finance Management- FI Materials Management- MM Human Resource Management- HR Operations Management- OPN Employee Self service- ESS


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Plant Load & Unit Trip SMS Alert

Each of 5 energy meters continously monitor working of all 5 units separately, if problem in

any unit occurs then SMS alert is given to all employees of NTPC, Badarpur


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Communication Infrastructure

Fiber Optic (5km) & 15 km UTP based LAN covering all buildings in BTPS @ 500nodes.

Nortel L3 core switch, BS 1648, 425, 3510, 325. 400 pcs & 8 Windows /Linux Servers. Siemens Telephone exchange of 2000 lines. 2 Mbps WL link to CSES- Noida, 2 mbps MPLS to data center & 2 mbps LC to

Scope complex. 60 mbps Motorola WL link. CISCO Routers.

Internet & e-mail thru secured NTPC Network. Video Conferencing to Scope & Noida. NTPC is among very few companies in India to have its own Enterprise-wide

Satellite /MW based communication Network.


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4) CONCLUSIONS

Through this training I was able to gain new insights and more comprehensive understanding

about the real industry working condition and practice.

All of this valuable experience and knowledge that I have gained were not only acquired

through the direct involvement in task given but also through other aspect of the training such

as work observation, interaction with employees of the company and students of different

institutes. As a result of this, now I am more confident to enter the industry and build my

future career.


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5) REFERENCES

1. Self notes made while attending training classes.2. Power plant familiarization manual.3. Manual give by IT Department.4. Previous years reports from seniors.

Dhruv Batra(Ntpc Report)

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