MANUFACTURING PROCESS, WITH DETAILS OF RAW MATERIALS, INTERMEDIATE AND FINISHED PRODUCTS

BRIEF DESCRIPTION OF PLANT PROCESS Salient Features 1. 2. 3. 4. 5. 6. 7. 8. Project Location : : Faridabad Gas Power Project Village Mujedi, P. O. Neemka, Faridabad. State Haryana 432 MW Gas Turbine 1 - 138 MW Gas Turbine 2 138 MW Steam Turbine - 156 MW Base Load Natural Gas Naphtha 2 million cubic meters per day HBJ pipe line ( through GAIL ) Rampur Distributory 2 tanks of 8000 Kl. Capacity each. 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 )

Plant Capacity : Plant Configuration : : : : : : : : :

Mode of Operation Fuel Alternate Fuel Average Gas requirement 9. Fuel Source 10. Cooling water source 11. Naphtha Storage 12. Power Evacuation

NTPC-Faridabad is a power (electricity) generating company with installed plant capacity of 432 MW. The plant configuration is as under: Gas Turbine -1 Gas Turbine -2 Steam Turbine 138 MW 138 MW 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. 3 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] B] Hydrant System: Motor driven pumps = 03 Nos. Diesel driven pumps = 02 Nos. Spray System: Motor driven pumps = 02 Nos. Diesel driven pumps = 02 Nos. 4 Motor driven = 02 Nos. (common for Hydrant

C]

Jockey pumps:

D]

& Spray system) 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. 5

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. 6

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 Natural gas Alternate fuel : : : From Rampur distributory canal HBJ pipe line of GAIL (2mcm / day) 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 1 2 3 4 5 6 7 Description Hydrochloric Acid Alkali (NaOH) Sulphuric Acid Naphtha Chlorine Natural Gas HSD Storage Capacity 100 KL 100 KL 40 Kl 16000 KL (() 2Tanks 8000KL each) 10 Tonners connected 02 in service No Storage 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) 9 • Explosion hazard : a) b) c) d) • Naphtha storage tanks, Gas and naphtha piping network, GAIL terminal 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

10 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 11

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.

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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 12 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.

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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. 14 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.

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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.

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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. 15

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.

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