REGIONAL LEARNING INSTITUTE

(RLI) SIPAT
े ीय ानाजन सं ान, सीपत

CASE STUDY
PUBLICATION
A compilation of Case Studies of implemented
solutions in NTPC
Volume II
JULY 2020

REGIONAL LEARNING INSTITUTE (RLI), NTPC SIPAT

UJJAWALNAGAR, BILASPUR, CHHATTISGARH-495555
E-mail ID - [email protected]
 I N D E X

MESSAGES FROM
(1) RED, WR-II 01
(2) ED, SIPAT 02
(3) GM (O&M), SIPAT 03
PREFACE 04

01) FAILURE OF 400 KV DISC STRING INSULATORS 05

02) REDUCTION IN EROSION OF BOILER TUBES IN 10
LTRH COIL
03) REDUCTION OF APC BY MAINTAINING BOILER 15
DRUM LEVEL BY SCOOP CONTROL IN 200MW
BOILER
04) UNIT#2 HIGH MOISTURE CONTENT IN MAIN OIL 19
TANK
05) MODIFICATION OF MIXING SPHERE STRAINER 22
(START UP SYSTEM)
06) FREQUENT DE-LINKING OF HP TURBINE 25
CONTROL VALVE IN 660MW
07) DDCMIS TIMER BASED INSTRUMENT AIR AUTO 29
DRAINS
08) DM MAKE UP TO VACUUM PUMP SEPARATOR 32
MAKE UP
09) SACW TO ACW INTERCONNECTION 34
10) ROLE OF HR PROFESSIONAL DURING THE 36
SERVICE & AFTER THE SERVICE OF AN EMPLOYEE
 SIPAT

MESSAGE FROM
RED (WR-II)
I am very happy to learn that the second their workplace. I am also very happy to
edition of the “Case Study Digital note that this second compilation has
Booklet” of Regional Learning Institute got enriched with contributions not only
(RLI) Sipat is ready for release. from Sipat but also from other projects
Knowledge is one of the most important of NTPC.
strategic resources for any organization I appreciate RLI-Sipat for its endeavour
and sharing of knowledge is of utmost and I hope, they will keep coming
importance for the organization to with more such novel initiatives to
succeed. This compilation of case help actualise the vision of making
studies is truly an effort in creating an NTPC a“Learning Organisation”.
“Intellectual Capital” for our
organization. Case studies not only give
a platform to the contributors to share
Vinod Choudhary
their professional experiences but also
provide opportunities to the readers to RED (WR-II)
learn and implement the solutions at

01
 SIPAT
MESSAGE FROM
ED SIPAT
I am very pleased to note that RLI Sipat problems encountered and solved
is ready to release the second edition of somewhere in the company thereby
Case Study digital booklet containing preventing the effort of reinventing the
ten case studies collected from all over wheel.   It also provides a great platform
NTPC. to the contributing employees to share
During the Covid 19 pandemic, digital their professional stories with a large
platforms for learning have created a cross section of people across the
silent learning revolution. These case company. I compliment team RLI Sipat
studies have been collected and for this great effort in Knowledge
compiled during the lockdown period, Management and wish that this
utilizing such digital platforms, which is publication flourishes and becomes
a great way of gathering and richer with time.
disseminating knowledge in these
challenging times.
Padmakumar Rajasekharan
Case study compilation helps our
employees in learning the solutions of 
ED, SIPAT

02
 SIPAT
MESSAGE FROM
GM (O&M) SIPAT
I am delighted to learn that RLI Sipat documented, it becomes a great
has come up with the second edition treasure of learning. There was great
of Case Study Booklet. NTPC operates need to do something in this direction
and maintains a large fleet of and I am happy that our RLI has
equipment, which are handled by started this endeavor.
different employees spread across the I thank and complement team RLI
company. Many problems are faced in Sipat for this effort. I wish that this
the equipment and systems series becomes reference document
particularly during initial stabilization for all our new joining ETs, colleagues
period. The employees who handle who join new department on job
and solve such issues move on to new rotation and all those who face new
projects or to new roles in due course challenges in equipment and systems
of time. In that case, the knowledge and are looking for solutions.
about the problem and the solution
goes away with the person. If such Ghanshyam  Prajapati
experiences are captured and GM (O&M),  SIPAT

03
 SIPAT
PREFACE
We are delighted to bring before you
this second Case Study publication of
RLI Sipat (July 2020 Edition). As We may also bring out some editions
promised during the first publication, dedicated to some specific domain like
we have expanded the gamut of cases HR, Finance, C&M, and Project
this year by inviting case studies from Management etc.
across the company. We received very As you would notice, we have tried to
encouraging response and this keep the case format short and crisp for
compilation consists of ten selected easy readability. If you find a case
case studies from the responses worth implementing at your place, you
received from colleagues across the may always contact the author(s) for
company. more details.
When we published our last booklet, With deep sense of gratitude to all
we were apprehensive about sustaining authors, our senior executives, fellow
this effort. We were not sure whether a colleagues at RLI Sipat and Diploma
steady flow of new cases would be Trainees of Sipat who have
coming from employees to sustain a contributed, guided and helped us, we
regular publication. I am happy to are happy to give away this publication
share with you that not only we got to you.
cases for this edition; we are now We would keenly look forward to your
receiving cases for the next edition as feedback, suggestions and new case
well. studies. You may send them to
Another change in this edition is that [email protected]
last year we had only O&M case studies.
This time we have included one case Stay safe and keep sharing,
study from HR domain also. Going With best wishes and Warm Regards,
forward we would like to make this A K Tripathi
publication even more diverse, more AGM, RLI SIPAT
interesting and more attractive.

04
CASE#1
FAILURE OF 400 KV DISC
STRING INSULATORS
Name of the author
Balai Chandra Kar, Emp No 100630,
Sr. Manager (Operation), NTPC Sipat
Background of the case
This case relates to failure/bursting of 400KV
string insulators of NTPC Vindhyachal. There
was an incident of bursting of one string insulator
leading to multiple tripping of generating and
transmission circuit. Bursting of Disc insulator
strings had never happened before in NTPC. So
it was suspected that this failure of Disc Insulator
had occurred due to extraneous reasons like
lightning, over voltages or pollution led flash over.
Further to this, there were 02 more incidents of
400 KV Disc Insulators failure/bursting leading to
multiple generating units tripping as well as
secondary damages to the nearby equipment's.
This has led to rethinking and paved the way for
root cause analysis.

What was done

IR, PI, KI, Tan delta, Capacitance Measurement
and High voltage test were carried out on the
400KV disc insulators. Thereafter the same disc
insulators were dipped in water for 24Hr and
again all the above tests were repeated.

05
 Results were surprising. Deviation in IR and
capacitance were there which indicate varied
voltage variation along the string i.e. uneven
voltage stress on the discs of the string.
Capacitance values of insulators after 24Hr of
wetting got changed indicates porosity in the
insulating material.
Based on these test results, it was apprehended
that more insulator disc which were in service
would be defective.
To ascertain the above conclusions ONLINE PID
Testing was carried out on the charged 400KV
Strings of Switchyard. PID (Punctured Insulator
detection ) Test- is used for detecting leakage in
the defective insulator in the string, the
equipment is moved across each disc of the
string and it records the electric field intensity
surrounding each disc. The electric field
decreases considerably in front of defective disc
insulator.
The PID test results of the 400KV Disc Insulators
of NTPC Vindhyachal Switchyard revealed that
approx 60% of the in-service strings were
defective (Total were 20,000 Disc)
Further detailed failure analysis was done at
BHEL works too. Based on the above analysis
and results, BHEL agreed to replace the
entire lot of disc insulators free of cost due to
the reason that there was some quality issue
in the complete lot.

06
Fig. PID Equipment is moved across the string to
measure electric field

Fig. Healthy Insulator

07 Fig. Faulty Insulator

Parallel action done to carry out the thermo vision
scanning (Infra-Red energy radiating out from the
Heat energy) of the in-service insulator strings.

Below results of thermo vision scanning was

in line with approximate PID Results.

Thermo vision scanning of insulators shows

temperature variation along the string, higher
temperature indicates faulty disc in correlation
with PID test result.
Thermo vision scanning can provide early
signs of insulator failure.

08
Major learning
Before installation of the Insulator Disc, every
disc should be put on IR Test and there should
not be appreciable variation in the values
otherwise it may leads to variation in the voltage
stresses across the discs in the string leading to
creation of high voltage stress at some disc which
eventually lead to failure. Before installation IR
Testing will ensure equalized voltage grading.
After installation and charging of these Discs in
the switchyard, PID Testing of complete string
insulators of Switchyard will ensure no
manufacturing and material defects. If any such
defects are there it will be noticed at the early
stage and rectification will ensure no forged
outage /no multiple trippings in Switchyard.
After Commissioning of Disc Insulators PID
Testing of switchyard will ensure healthiness.

In-service disc Insulators should be monitored

through PID and thermography. They can provide
early sign of failure and may avoid catastrophic
bursting of Disc Insulators.

09
CASE#2
REDUCTION IN EROSION
OF BOILER TUBES IN LTRH
COILS 
Name of the author
Rishabh Kapoor, Emp No.102242,
Manager (BMD), NTPC Sipat
Background of the Case
Boiler Tube Failures are the major contributor of
the Total Force Outage in a Coal Fired Power
Plant. Failure of tubes in boiler of the power
plants may occur due to various reasons. These
include failures due to creep, corrosion, erosion,
overheating, weld joint failures and a host of
other reasons.
Stage-1 (3X660 MW) Units at NTPC Sipat were
commissioned in Year 2012. Since inception tube
failures in these boilers created trouble for O&M.
Being a new technology and new design, we
faced few surprises during overhauling as well.
LTRH (Low Temperature Reheater) are
Reheaters located in 2nd Pass in the furnace.
Reheater being a low pressure zone, the
designed thickness of the tubes are less. The
size of the LTRH Tubes installed in our Boiler is
OD 63.5 MM X THK 3.4 MM.

10
Total 10 No. of Boiler Tube Failures have
occurred in the LTRH Area in the Last 5 Financial
Years. Failure mechanism of these failures were
either Flue Gas Erosion or Fly Ash Erosion.

What was done

1. CLIT WELDING NEAR HANGER CLAMPS
Gaps were there in between Hanger Tubes and
LTRH coils, which resulted in reduction in
thickness of LTRH tubes and even leads to boiler
tube failure. Small clits have been welded
between Hanger and LTRH coil clamps to
prevent fly ash erosion.

11
2. CHICKEN WIRE MESH INSTALLATION
NEAR HANGER 1
Heavy erosion was observed in LTRH coils near
Hanger 1 Front and Rear which resulted in many
boiler tube failures as well. To stream-line the
Flue Gas Flow and to avoid Flue Gas Erosion,
Chicken Wire Mesh were installed near Hanger 1
Coils.

3. SHIELDING NEAR HANGERS AND PROFILE

SHILEDINGS IN INNER AND OUTER BENDS
To avoid erosion near Hanger Coils, Small
shields were installed near Hanger Tubes.
Erosion was also observed in LTRH Bends near
Corner side. To avoid Boiler Tube Failures and to
increase the life of the tubes, Inner and Outer
Profile Shield Bends were installed in Corner
Bend Tubes in all 3 LTRH Coils

12
4. COIL GAPPING AND INSPECTION &
ALIGNMENT OF ALL 111 LTRH COILS IN ALL
3 BANKS DURING OVERHAUL
Our aim is to run the Boiler from Overhaul to
Overhaul without any Tube Failure. To ensure no
failure in LTRH coils, inspection of all 111 Coils
(ALL 3 BANKS) is being carried out by gapping
using INFLATABLE JACKS.
The defective tubes with low thickness readings
are being replaced and Shieldings are also
installed as per the requirements.

13
MAJOR LEARNING
1. LTRH Tubes being of low thickness (3.4 MM),
need proper Inspection and Shielding during
each opportunity shutdown. Otherwise these
tubes may fail repeatedly.
2. Shields of Extreme 10 Coils in LHS & RHS of
all 3 Banks to be replaced in very Overhaul.
3. No gaps to be left in between Hanger Tubes
and LTRH Coils, If left the flue gas will erode
the LTRH Coil and this will lead to Boiler Tube
Failure.
4. Alignment of ALL Coils to be checked during
each Opportunity Shutdown. Any misaligned
tube if comes in the path of flue gas may lead
to a Boiler Tube Failure.

14
CASE#3
REDUCTION OF APC BY
MAINTAINING BOILER
DRUM LEVEL BY SCOOP
CONTROL IN 200MW
BOILER
Name of the author
Baburao Sharad Tembhurne, Emp No: 020573
Manager (Stores), NTPC Sipat
Background of the Case
Driven by cost reduction, emission minimization
and our commitment to provide quality electric
power in most efficient manner at optimal costs,
NTPC Limited has always emphasised the need,
importance and opportunity to initiate energy
conservation measures. While exploring the
possibilities for low cost easy to implement
modification or process development resulting in
Auxiliary Power Consumption (APC) reduction,
we came across the idea of reducing differential
pressure across Feed Regulating Station of
boiler to avoid unnecessary throttling losses and
work done by BFP. Stage I of KSTPS Korba
comprised of 3X200 MW (CE design BHEL
supplied) boilers are equipped with 09 numbers
(6 running & 3 standby) Weir make 3.5 MW BFPs
supplying about 320 T/HR feed water at 180 KSC
each drawing 2.7 - 2.9 MW pumping power.

15
What was done
To ensure proper flow from BFP discharge header
to boiler drum, a pressure difference of 8 KSC is
maintained across the feed regulating station
(refer Fig. 1). Thus BFP has to discharge at 8 KSC
higher than drum pressure. This gives rise to
requirement of throttling of feed regulating station
control valve and additional pumping power. This
throttling loss and additional pumping power can
altogether be reduced if pressure difference
between BFP discharge and boiler drum is
reduced.

Fig. 1 Scheme for Feed Water Flow

Fig. 2 Boiler Level Control

16
Under strict monitoring of experienced Operation
executives in one unit, all relevant data and
observations were recorded, analyzed, compared
and differential pressure was reduced to 4.0 KSC
in steps. At this 4.0 KSC differential pressure
(DP) across feed regulating station, substantial
saving potential of >100KW pumping power per
pump was observed.
Encouraged by this huge saving potential we
changed drum level control philosophy from DP
control to SCOOP control, controlled from DAS
(refer Fig. 2). Hence DP is reduced to the value
of 0.4 KSC eliminating complete throttling and
pumping power loss resulting in reduction of
auxiliary power consumption by approximately
150 KW per pump. This was implemented in one
unit and kept under observation.

Major Learning
There is an urgent need to reduce APC of old
running units and it is possible by brainstorming
and small modifications. Changing over from DP
control to Scoop control is one such modification.
Drum level, feed-water flow, metal temperatures,
requirement of super heater, Reheater spray and
actual flow, metal temperature excursion, BFP
discharge pressure and pumping power are still
monitored. All the boiler parameters were
observed normal with reduction of auxiliary power
consumption (APC) by approximately 150 KW
per pump (300 KW per unit).

17
Also during planned shut down for unit
overhauling, no unpredicted adverse effect was
observed. Hence all the units of KSTPS were
planned to run with feed regulating station control
valve full open under scoop control. This simple
modification and no cost process improvement
resulted in savings of around 21,600 KWH per
day amounting to approximately Rs 9 million
when annualized at current sales price. Also this
has let our earth remain cleaner and greener as
emission of GHG will reduce by 6300 tons.

18
CASE#4
HIGH MOISTURE CONTENT
IN MOT (MAIN OIL TANK)
Name of the authors
1. Saurabh Soni, Emp. No. 103647
Manager (Operation), NTPC Dadri
2. Ketam Kritesh, Emp. No. 075089
Manager (Operation), NTPC Unchahar

Background of the Case

NTPC Sipat Unit#2 was running at full load
since 04.08.2018 (After overhaul)
It was observed that Hydrogen gas dew point
started deteriorating on a continuous basis
after 16.08.2018. It came down to -4.0 deg.
compared to the normal running value of -20
deg.
To improve the H2 Dew point, various actions
were taken. They were as follows:

What was done

Hydrogen purging was performed on a shift-
wise basis but no improvement was observed.
And this led to increased Hydrogen
consumption of 14-15 cylinders daily.
Performance of Hydrogen Dryer was
monitored. It was drained manually on regular
basis (to remove, if any moisture
accumulated). Working of H2 driers were
found OK.

19
 Oil sampling was performed at MOT tank, seal
oil cooler inlet & outlet, MOT cooler inlet &
outlet and it was found that moisture content in
the Lub-oil was on much higher side (of about
5000ppm range), which was way beyond its
normal range of <100 ppm.
MOT centrifuging was started immediately to
reduce the moisture content and seal steam
pressure of the main turbine also reduced to
100 mmwc. Further, to rule-out any cooler
leakage, one by one MOT and seal oil cooler
changeover were done. No Significant
improvement was seen in the H2 dew point as
well as MOT Moisture levels didn’t come
down.
After these activities MOT Moisture content did
not improve much.
Main turbine seal steam pressure was
reduced (as one could feel high seal steam
pressure at the end seals of LPT in local) and
its leak-off steam lines were checked.
Finally, Upon local round it was found that
GSC discharge pipes were cold and both the
GSC fans were not giving discharge in the
atmosphere. This was because of the fact that
the GSC header was filled with water.
Further analyzing the situation, the drains in the
line of GSC exhaust to fans were opened and the
draining was carried out.

20
Just after this activity, GSC fans started taking
proper suction and within 24 hours MOT moisture
came down within limits (<100ppm).

Major learning
1. Drain of GSC header to be connected to
hydrasyl tank so that no water accumulation
takes place.
2. "GSC level high" alarm to be provided in LVS.
3. Temperature transmitter should be provided at
GSC fans discharge (as in MOT VEF
discharge line).

Drains
Figure: Drawing of GSC drains

21
CASE#5
MODIFICATION OF MIXING
SPHERE STRAINER (START
UP SYSTEM)
Name of the authors
1. Sanket Basu, Emp. No. 104977
Asst. Manager (Operation), NTPC Gadarwara
2. Prasanjit Roy, Emp. No. 100101
Sr. Manager (Mech. Maint.), NTPC Gadarwara

Background of the Case

On 30.07.2018, i n Gadarwara Super Thermal
Project, Unit-1 Boiler Mixing sphere routine
inspection was done by BHEL and NTPC
Commissioning Team. On inspection, Mixing
sphere strainer top plate found dislodged
condition. which is bolted with strainer with 2
bolts, out of which 1 bolt is found connected with
top plate and 2nd bolt found missing. Also,
strainer 3 out of 4 bolts were found broken and
missing (through which it is connected with main
body of mixing sphere). The strainer found in
upside down condition and one bolt was found
connected with strainer body along with
connector. Another strainer connected to mixing
sphere inlet from eco inlet was found okay. It was
concluded that the main reason due to which
strainer bolts and top plate bolts broken is axial
thrust and transverse thrust acting on strainer.

22
The axial thrust is due to water coming from
Separator Storage tank and transverse thrust is
due to water coming from ECO inlet (feed water).

What was done

After the incident, case was referred to BHEL
Trichy. On 06.08.2018, BHEL Trichy sent one
representative with modified strainer drawing
where it is decided that all bolted parts are to be
replaced by welding. Also it was decided to do a
Boroscopic Inspection.
Modification done in Mixing Sphere Strainer
Top plate was replaced by another plate of
same material and thickness. Holes were done
in top plate of same size which was present in
strainer (10 mm).
Mixing sphere strainer side bolt holding plates
were removed and strainer parts were welded.
Two stiffener plates are welded in cross to
give support to Top plate.
Two semi-circular ring plates are provided,
whose one end is welded with strainer open
part and another end welded with main body
of mixing sphere.

Fig. Modified Strainer

23
Major learning
It is clearly understandable that the design of
mixing sphere strainers was not right as the
bolted assembly was not able to withstand the
thrust acting on it. The other strainer at inlet to
mixing sphere from eco inlet was pre welded
only. So it should be checked in every upcoming
or commissioned supercritical boiler with such
start up systems and get it modified. This will help
in saving the failure of capital equipment. After
modification in both Unit#1 and Unit#2 no
problem has been found with the new design.

24
CASE#6
FREQUENT DE-LINKING
OF HP TURBINE CONTROL
VALVE IN 660MW
Name of the author
Abhishek A Katware, Emp. No. 101722
Manager (MM - TMD), NTPC Sipat

Background of the case

In 660MW units at Sipat, frequent de-linking of
HP Control valves is observed. Above 630MW,
HPCV#3 starts opening gradually and at loads
above 660MW, HPCV#3 is almost 100% open.
There is continuous change of load from 630-
660MW. Hence HPCV#3 also opens/closes
intermittently. This increases the chances of
coupling de-linking. HPCV delinking leads to
restricted steam supply to HP turbine and
consequently unit load decreases and turbine
vibration
increases due
to disturbance
in steam whirl.
Eventually this
de-linking
leads to unit
stoppage.

25
What was done
ISSUE:-
The shearing of cylindrical locking pin ( dia 6
mm ) of coupling spherical nut observed even
after material improvement.
The shearing of pin results in free rotational
relative motion between valve spindle and the
nut.
This free rotational motion due to shearing of
pin results in unscrewing of spindle and
subsequent de-linking.
In some cases, the threaded portion of the
spindle was intact even after pin shear. This is
possible only when the pin got sheared and
spindle unscrewed due to rotation of spindle.
Solution:-
Increase of pin diameter from 6mm to 8mm.
Additional pin in coupling through threaded
portion.
Increasing diameter of threaded portion.
SUGGESTED MODIFICATION :-
Installing a locking plate at the coupling position
to restrict possibility of unscrewing of valve
spindle from coupling spherical nut even if the
lock pin gets sheared.
The suggested locking arrangement shall not
hamper the normal operation of the valves and
can be removed & restored back in future if
required.

26
27
Major Learning
Coupling of all HPCVs to be inspected during
every Unit overhauls and HPCV-3 coupling
inspection during opportunity shutdown
time>48 hrs .
During future unit overhauls, (i) Spindle thread
& spherical nut thread to be properly checked
for looseness, wear and damage and to both
stem & nut to be replaced with new one if
found defective, (ii) all the critical valve
clearance to be recorded and in case of slight
deviation also valve cone, barrel, guide bush,
gland bush etc to be replaced in order to
remove the chances of valve spindle swing.
Since the problem seems to be generic in
design, it is advised to replace stem (part no
4/1452386), sleeve bush (part no 5/1452386),
sleeve bush (part no 16/1453322) for HPCV-
3&4 every 04 years cycle and at every 06
years for HPCV-1&2, in order to remove the
chances of valve stem failure during unit
running.
Monitoring of HPT inlet pressure and response
to any significant deviation be taken up by
changing HPCV operation from Auto mode to
Manual mode to avoid intermittent operation,
thereby reducing tension on pin and
decreasing any chance of pin failure.

28
CASE#7
DDCMIS TIMER BASED
INSTRUMENT AIR AUTO
DRAINS
Name of the author
Sreenu Daravathu, Emp. No. 102000
Manager (C&I MAINT), NTPC Ramagundam

Background of the case

In Ramagundam Stage-1 Units, Instrument Air is
having heavy moisture due to poor performance
of instrument air driers and also drastic variation
in temperature of this geographic location leading
to instrument air becomes water, which in turn
leading to failure/Improper operation of
Pneumatic control valve, Pneumatic dampers etc
causing emergencies and non availability of a
equipment.
In Unit#3, there was more number of problems
related to pneumatic control valves, because this
is the last unit where moisture gets condense
and turns into water leading to failure of
pneumatic components. While attending the
problem, it was found that full of water coming
from instrument air line. The instrument air is
supplied from instrument air compressors which
were around 1km away from Stage-1 Units, there
it is having instrument air driers and auto drains.

29
What was done
Heavy moisture in instrument air is a repetitive
problem and damaging the all pneumatic
components/instruments like air pressure
regulators, E/P converters, pneumatic petitioners
and diaphragms. To come out of this problem it
was decided to install auto drains at different
locations of instrument air headers within the
units with zero investment and unique way.
Normally, unit Instrument air main header is
having tapings which will from sub instrument air
header at different locations of units like 0 mts,
5.5 mts etc, one such instruments air header may
feed instrument air supply to 3 to 4 pneumatic
control valves.
Our Idea is to install timer based auto drains at all
such instrument air headers of units in addition to
the auto drains at instrument air compressors, so
that any moisture/condensate water should drain
in auto just before entering into pneumatic
components. To implement this, it was decided
not to procure any moisture auto drains and use
available resources.
Implementation:
Finally after brain storming, it was decided to
install DCS timer based auto drain solenoids
Auto timer logic made in DDCMIS all
requirements listed out, i.e 4 number of spare
DO’s, 4 number of spare 24V DC solenoids,
one 230V AC to 24V DC converter, spare DCS
cables to local JB’s.

30
 24V DC solenoids installed at bottom of
instrument air header with proper isolation
valves and terminated to spare DO’s in
marshalling cabinet.
Based on timer, auto drain solenoids energise
and went out the moisture/water in instrument
air header then de energises. All these timings
can be change as per user requirements
based on instrument air moisture.
24V DC to the solenoids derived from
separate 230V AC panel lighting supply, such
that any disturbance in the field may not affect
24 VDC of DCS.

Major Learning
As main control loops of power plant are of
pneumatic type, the healthiness of pneumatic
components is at most important to avoid unit
emergencies and unit outage.
Moisture free instrument air is essential to
avoid all these problems. To get moisture free
instrument air, auto drains installed at every
instrument air header in individual units with
the help of 24V DC solenoids and timer logic
in DDCMIS.
As DDCMIS timer based auto drains is one
time job, it will work as long as our DDCMIS
exist.
The cost incurred for completion of this project
is zero, because we have utilized available
resources in a unique way such that it can
improve the availability, reliability and
performance of control system

31
CASE#8
DM MAKE UP TO VACUUM
PUMP SEPARATOR MAKE
UP
Name of the author
Yousuf Ali, Emp. No.009822,
Sr. Manager (Operation), NTPC Lara
Background of the case
Normal Barring gear stoppage time of main
turbine is approx. 10 days under natural cooling
form hot state after Unit shutdown, if
maintenance activity is needed to be performed
on main turbine which requires its barring gear
stoppage hence to reduce forced outage time
early stoppage of barring gear is required. For
this purpose, turbine forced cooling system has
been provided by OEM.
Vacuum Pumps are required to run during forced
air cooling system operation. Vacuum pumps
separator make up is having only one source as
per PID which is from CEP. Hence during this
period atleast one CEP is needed to be run for
vacuum pumps separator make up requirement.

What was done

An additional source for Vacuum pump separator
make up has been provided from DM make up
pumps apart from existing source from CEP.

32
Since DM make up pumps are always in service
for makeup requirement of SG/TG ECW
overhead tanks & its discharge Header pressure
(4-5 Ksc) is approx. same header pressure after
Aux control valve provided in CEP dish line for
Vacuum pump separator make up. Hence it was
decided to connect DM make up line to separator
make up line with manual valve & NRV as shown
in below schematic. In this modification 25NB
interconnection along with manual globe has
been provided between DM make up line & CEP
discharge line after aux control valve at TG 9m.
After taking in service above modified scheme
various system parameters are kept under
observation & no abnormality & deviation has
been reported. DM make up pumps are running
normal & all parameters are within limits.

Major Learning
Due to above modifications following savings
were achieved in monetary term
APC saving of approx. 0.51 Lacs/day
achieved due to stoppage of CEP pump
during forced cooling.
Better Vacuum pump performance achieved
due to reduction of seal water temperature

33
SACW TO ACW
CASE#9

INTERCONNECTION
Name of the author
Yousuf Ali, Emp. No.009822,
Sr. Manager (Operation), NTPC Lara
Background of the case
After Unit shutdown, CW & ACW pumps were to
be kept in service for cooling requirement of Lub
oil & other SG/TG auxiliaries. When turbine is in
hot condition, normally it takes 10 days for
barring gear to be stopped after unit shutdown
when its HPT 1st stage temp comes below 50
deg as per TG manual. During this time when TG
is in Barring Gear, lub oil temp should be
maintained below 42 deg as per OEM
recommendations hence for this purpose CW &
ACW pumps were kept in service to cool DMCW
water which in turn maintains Lub oil temp Below
42 deg & for other SG/TG auxiliaries cooling load.

What was done

An interconnection has been provided between
SACW & ACW system. Since SACW is always in
service for IA/PA compressors & AC system & its
discharge Header pressure approx. 4-5Ksc same
as ACW discharge header pressure. Also SACW
pumps are taking suction from same forebay as
CW pumps thus having same temperature.
Hence it was decided to connect SACW supply &
return lines to ACW inlet & outlet header as

34
shown in scheme below. This has enabled us to
use SACW water as ACW water thus allowing
stoppage of both CW & ACW pumps which were
earlier needed to be kept in service for cooling
requirement of TG & SG auxiliaries. In this
modification 250 NB interconnection along with
butterfly valves has been provided between
SACW & ACW at TG bay C-row trussle. After
Taking in service above modified scheme various
system parameters are kept under observation &
no abnormality & deviation has been reported.
SACW system is running normal & all parameters
are within limits.

Major Learning
Due to above modifications following savings
were achieved in monetary terms (Approx 3.7
Lac/day)
1. APC saving- Due to stoppage of CW & ACW
pumps
2. Water saving- Due to no evaporation loss
through Cooling towers due to stoppage of CW
& ACW pumps
35
ROLE OF HR
CASE#10

PROFESSIONAL - DURING
THE SERVICE AND AFTER
THE SERVICE OF AN
EMPLOYEE
Name of the author
K Sreelatha, Emp. No. 006928,
AGM (HR), NTPC Sipat
Background of the case
Shri Devya Sahoo, joined NTPC as EET in 2011
and after regularization on 26.09.2012 posted to
Operation Department as Asst. Manager
(Operation) at Talcher Kaniha. In March 2013, he
was transferred to Business Excellence
department. He had been-suffering from stomach
cancer since December 2012 and had been
undergoing treatment at TATA Memorial Hospital,
Mumbai. During his treatment there, he suddenly
expired on 4.8.2013.
His family consists of
1. Mrs. Sabita Sahoo - 58 yrs - Mother
2. Mrs. Navya Sahoo - 26 yrs - Wife (Home
maker)
3. Master Priyam - 1 year 7 months - Son.
Further it is to mention that he lost his father at
very early age & his mother is dependent on him
as his elder brother is running a small shop at his

36
native place and financially not so stable.
After this disaster in the family, with the tears
filled eyes, father of the young window
approached HR to help his daughter. At that
juncture, all of us started realising that because of
the sudden demise of the bread winner, the
entire family was on roads.
How to Help this family out from this crisis ..?
Mean while we received a request from Mrs.
Navya, spouse of Late Sh. Devya Sahoo to
consider her request on sympathetic grounds for
granting benefits under NTPC Employees Family
Economic Rehabilitation Scheme (NEFERS).
As per sub clause no.3.1 of NEFERS read with
sub clause no.4.1 the benefits under the scheme
will cover all regular employees and will be
admissible in case of death, permanent & total
disablement provided the employee had
completed one year of service at the time of
death/disablement.
But Sh. Devya has rendered service of 10
months 7 days i.e short of just 53 days for
completion of one year. To say that the eligibility
criteria is not getting fulfilled to grant benefits
under NEFERS to Mrs. Navya.
What was done
Interpretation line with Objective/Philosophy
of the Policy(NEFERS)
Objective of this policy is to provide monetary
benefit and support to an employee in case of his
Permanent Total Disablement, and to his family in
case of his death, provided the Permanent Total
disablement/death, as the case may be,

37
 takes place while the employee is in service of
the Company.
Quote: Payment of Gratuity Act, 1972, Section
4 (1), Conditions of Gratuity:
"Gratuity shall be payable to an employee on
termination of his employment after he/She
has rendered continuous service for not less
than 5 Years. The condition of completion of 5
years shall not be necessary where the
termination of employment is due to death or
disablement of the employee"
Further in the said act it is elaborated under
Subsection (1) of Section 4 that Permanent
employees are not entitled to payment of Gratuity
for the years in which they remained absent
without leave and had actually worked for less
than 240 days due to absence without leave.
Interpreting the above, if the employee has
rendered more than 240 days of service in an
year including sanctioned leave & Holidays, then
it can be rounded off to 1 Completed Year of
Service.
Taking cue from the above mentioned clauses of
Payment of Gratuity Act, 1972, a proposal was
prepared with the following Justification:
The spouse of Late Sh. Devya is otherwise
eligible for the benefits of the ERS scheme
except for rendering of one year of service by Sh.
Devya as a regular employee and the beneficiary
is ready to deposit required amounts (PF- Rs.
96,662.00, Gratuity- Rs.1,05,895.00 and Group
lnsurance- Rs.1 ,70,000.00)

38
It may be pointed out that, generally in legal
parlance for purposes like calculation of gratuity
there exists relaxation in the eligibility criteria in
case of Death / Permanent Disablement &
service of 240 Days & more in an year is
reckoned as 1 year of Complete Service.
The death of Sh. Sahoo was sudden, premature
& untimely. Since he was the only earning
member of his family which consists-of an old
woman, young widow, and an infant son, his
death has left his family bereft of any means for
earning livelihood.
Sh Devya had rendered service of 10 months 7
days i.e short of just 53 days for completion of 1
Year.
Hence on humanitarian grounds if the eligibility
condition of completion of one year service as
mentioned at sub clause no 4.16 the scheme is
relaxed so as to extend the benefit under
NEFERS to Mrs Navya Sahoo it shall provide
monetary benefit and support to the bereaved
family.
Accordingly the approval of the competent
Authority was obtained & the benefits under
NEFERS were granted to the dependent mother
& Spouse Mrs. Navya Sahoo, 50% share each.
As on today, Mrs. Navya, spouse of Late Sh.
Devya Sahoo & his old widowed mother are
getting a decent amount every month to lead
their lives & expressed their indebtedness to
NTPC.

39
To conclude, as a HR professional, in alignment
with the Philosophy of the Policy, interpretation is
to be done so as to extend the benefit to the real
needy.

Major Learning
Even the service of 240 days (including
leave/Paid/Closed Holidays) is reckoned as
one year on humanitarion grounds.
The death of Sh.Sahoo was sudden, premature
& untimely. Since he was the only earning
member of his family which consists-of an old
woman, young widow ,and an infant son, his
death has left his family bereft of any means for
earning livelihood.
Hence on humanitarian grounds the eligibility
condition of completion of one year service as
mentioned at sub clause no 4.16 of the scheme
was relaxed so as to extend the benefit under
ERS to Mrs. Navya Sahoo which shall provide
monetary benefit and support to the bereaved
family.
As per clause no. 13 of NEFERS, CMD is the
competent authority to amend, add delete ,
review or discontinue the Scheme at any time.
We forwarded the proposal approval was
accorded, advising us to give 50% benefit to his
mother also.
Behind the screen: HOHR personally went to
CC to explain the case to Top Management &
the hardship of the bereaved family.

40
CASE STUDY PUBLICATION
Compiled and Published by
REGIONAL LEARNING INSTITUTE(RLI)
NTPC SIPAT
Ujjwal Nagar, Bilaspur,Chhattisgarh
Pin Code:-495555
Email:- [email protected]