satyendra ' s report

8/3/2019 Satyendra ' s Report

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Galgotias College of Engineering and TechnologyDepartment of Mechanical Engineering

INDUSTRIAL TRAINING REPORT ON

N.T.P.C. POWER STATION,DADRI

Submitted by

SATYENDRA KUMAR SINGH

Roll no 0809740081

(Session 2010-11)

Under the guidance of

SH.M.K SHARMA

in partial fulfillment of

Degree Requirements as per GBTU Syllabus for the award of

Bachelor of Technology (Mechanical Engineering)Batch of 2008-12

Gautam Budha Technical University,

Lucknow


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ACKNOWLEDGMENTS

I am very much thankful to N.T.P.C. POWER PLANT,DADRI for

giving me such an excellent opportunity to be trained under experts of

your company.I specially convey my thanks to SH.M.K SHARMA

and other members of ring plant for their guidance during my training.

Again I want to say thanks to H.O.D(mechanical engineering) and

other professors for creating a learning environment and supportingthe students to deliver their best performance.

SATYENDRA KUMAR SINGH


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ABSTRACT

To meet the power demand of the country, it is required to set up new

projects, time to time so that demand and generation gap may be

narrowed but most important is to full utilization of existing capacity.This may be possible only by increasing the reliability, availability

and maintainability of power generating units and by operating theunits at its full capacity.This vocational training report is concerned with the overall

operation of the plant, machines used in the plant, water treatment in

the plant & thermodynamic cycles used in the NTPC, Dadri PowerPlant


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TABLE OF CONTENTS

LIST OF FIGURES

1. BRYATON CYCLE

1.1 SCHEMTIC FIGURE

1.2 P-V DIAGRAM

1.3 T-S DIAGRAM

2. RANKINE CYCLE

2.1 SCHEMTIC FIGURE

2.2 T-S DIAGRAM

3. INDUSTRIAL COOLING TOWERS.

4. AIR FLOW GENERATION METHOD COOLING TOWER

4.1 FORCED DRAFT COOLING TOWER4.2 FORCED DRAFT COUNTER FLOW PAKAGE TYPE COOLING TOWER

5. CROSS FLOW DESIGN TYPE

6. COUNTER FLOW DESIGN TYPE

7. STEAM LOCOMOTIVE BOILER.

LIST OF SYMBOLS

1. P- Pressure

2. V-Volume

3. T-Temperature

4. S-Entropy

5. q in- heat supplied

6. q out-heat rejected


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INDEX1. TITLE PAGE

2. ACKNOWLEDGEMENT

3. CERTIFICATE

4. LIST OF FIGURES

5. LIST OF SYMBOLS

6. ABSTRACT

7. INTRODUCTION

8. OVERVIEW

9. STATION AT GLANCE

10. INTRODUCTION TO GAS POWER PLANT

10.1Equipment.

10.2 Application.

11. COMBINED CYCLE

11.1 BRAYTON CYCLE

11.2 RANKINE CYCLE12. FUELS

13. INDUSTRIAL COOLING TOWER

13.1 NATURAL DRAFT

13.2 MECHANICAL DRAFT

13.3 INDUCED DRAFT

13.4 FORCED DRAFT

14. CROSS FLOW

15. COUNTER FLOW

15.1 COMMAN IN BOTH DESIGNS

16. BOILER16.1 POT OR HAYCOCK BOILER

16.2 FIRE TUBE BOILER

16.3 WATER TUBE BOILER

16.4 FLASH BOILER

17. CONTROLLING DRAUGHT

17.1 INDUCED DRAUGHT

17.2 FORCED DRAUGHT

17.3 BALANCED DRAUGHT

18. SAFETY

19. TYPES OF SAFETY19.1 NORMATIVE SAFETY

19.2 SUBSTANTIVE SAFETY

19.3 PERCIEVED SAFETY

20. SAFETY MEASURES

21. 5S (METHODOLOGY)

21.1 SORTING (SEIRI)21.2 STRAIGHTENING OR SETTING IN ORDER / STABILIZE (SEITON)

21.3 SWEEPING OR SHINING OR CLEANLINESS / SYSTEMATIC

CLEANING (SEISO)

21.4 STANDARDIZING (SEIKETSU)

21.5 SUSTAINING THE DISCIPLINE OR SELF-DISCIPLINE (SHITSUKE)


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7.INTRODUCTION

NTPC DADRI GAS POWER PLANTNational Thermal Power corporation Limited

National Capital Power Station -- Dadri P.O. Vidyut Nagar, District Gautam Budh -

Nagar - 201 008 (UP).

NTPC was set up in the central sector in the 1975.Only PSU to achieve excellent rating in

respect of MOU targets signed with Govt. of India each year. NTPC Dadri station has also

bagged ISO14001 certification. Today NTPC contributes more than 3 / 5th of the total powergeneration in India.

Approved capacity: 817MW Gas Source: HBJ Pipe line/ 3 MMSCMD (APM Gas) Alternate Fuel: HSD Water Source: Upper Ganga Canal BeneficiaryStates

U.P.,Uttrakhand,Rajasthan,Delhi,Punjab,Haryana,HP,J&K,Chandigarh,Railways

Approved Cost: Rs.960.35 crores (02.11.94) Unit Sizes : 4 GTX 130.19 MW + 2 STX 154.51 MW

Units Commissioned :GT-I- 130.19 MW May 1992

GT II- 130.19 MW June1992

GT III-130.19 MWAugust1992

GT IV-130.19 MW December1992

ST-I- 154.51 MW August 1996

ST-II- 154.51 MW April 1997


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8.OVERVIEW

NTPC was set up in the central sector in the 1975 in response to widening demand & supply

gap with the main objective of planning, promoting & organizing an integrated development

to thermal power in India. Ever since its inception, NTPC has never looked back and the

corporation is treading steps of success one after the other. The only PSU to have achieved

excellent rating in respect of MOU targets signed with Govt. of India each year. NTPC is

poised to become a 40,000 MW gint corporation by the end of XI plan i.e. 2012 AD. Lighting

up one fourth of the nation,NTPC has an installed capacity of 19,291 MW from its

commitment to provide quality power; all the operating stations ofNTPC located in the

National and Korba station have also bagged ISO 14001 certification. Capital Region &

western haveacquired ISO 9002 certification. The service groups like Engineering,

Contracts, materials and operation Services have also bagged the ISO 9001 certification.

NTPC Dari, Ramagundam, Vindhyachal.

9.STATION AT GLANCE

NTPC dadri is model project of NTPC. also it tit the best project of NTPC also known as

NCPS ( National capital power station ).Situated 60 kames away from Delhi in the District of

gautam budh Nagar, Uttar Pradesh. The station has an installed capacity of1669 MW of

power 840 MW from Coal based units and 829MW Gas Based Station. The station is

excelling in performance ever since itscommercial operation. consistentlyin receipts

ofmeritorious projectivity awards, the coal based units of the station stood first in the country

in terms of PLF for the financial year19992000 bygenerating an all time national high PLF

of 96.12% with the mostmodernO & M Practices. NTPC Dadri iscommitted to generated

clean and green Power. The Station alsohouses the first HVDC station of the country (GEP

project) inassociation with centrefor power efficiency and Environmentprotection (CENEEP)

NTPC& USAUID. The station hasbagged ISO 14001 & ISO 9002 certification during the

financialyear 19992000, certified by Agency of International repute M/sDNV Netherlands

M/s DNV Germany respectively.


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10.INTRODUCTION TO GAS POWER PLANTS

The development of the sector in the country, sinceindependence has been predominantly

through the StateElectricity Boards. In order to supplement the effects of the states in

accelerating power development and topromote power development on a regional basis to

enable the optimum utilisation of energy resources, the Government of India decided to take

up a programme of establishment of large hydro and thermal power stations in the central sec

torn a regional basis. With this in view, the Government set up the National Thermal Power

Corporation Ltd., in November1975 with the objective of planning, construction,

commissioning, operation and maintenance of Super Thermal and Gas Based Power projects

in the country. The availability of gas in a large quantity in western offshore region has

opened an opportunity to use the gas for power generation, which is uneconomical way and

quicker method of augmenting power generating capacity by natural gas as fuel in combined

cycle power plant in a power deficit country like ours.

NTPC to take up the construction of Kawas, Auraiya, Anta, Dadri and Gandhar Gas Power

Project along the HBJ Gaspipe line.

The power plant consists of gas turbine generating units waste heat recovery boilers, steam

turbo generator, ancillary electrical and mechanical equipments. The power generated at this

power station is fed over 220 KV AC transmission system associated with this project to

distribute the power in the various Regions. In the Power Sector, gas turbine drive generators

are used. Gas turbines range in size from less than 100 KW up to about140.000 KW. The gas

turbine has found increasing application due to the following potential advantages over

completive

10.1 Equipment.

Small size and weight per horsepower

Rapid loading capability

Self-contained packaged unit


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Moderate first cost

No cooling water required

Easy maintenance

High reliability

Waste heat available for combined cycle

10.2 Application.

Low Gestation Period

Low Pollution Hazards

The function of a gas turbine in a combined cycle power plant is

to drive a generator which produce electricity and to provide input steam from the cycle

11.COMBINED CYCLE

It integrates two power conversion cycles namely. Brayton Cycle (Gas Turbines) and

Rankine Cycle (Conventional steam power plant) with the principal objective of increasing

overall plant efficiency.

11.1 BRAYTON CYCLE

Gas Turbine plant-operate on Brayton Cycle in which air is compressed this compressed air is

heated in the combustor byburning fuel combustion produced is allowed to expand In the

Turbine and the turbine is coupled with the generator without losses the theoretical cycle

process is represented by 1 2 3 4. In the actual process losses do occur. Deviation from the

theoretical process, results from the fact that compression and expansion are not performed

isentropically but polytropically which is conditioned by heat dissipation (expansion) and

heat supply (Compression) caused by various flow and fraction of loses.


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Fig.1.1 Fig. 1.2 Fig. 1.3

11.2RANKINE CYCLE

The conversion of heat energy to mechanical energy with the aid of steam is carried out

through this cycle. In its simplest form the cycle works as follows (fig.2).The initial state of

the working fluid is water (point-3) which, at a certain temperature is compressed by a pump

(process 3-4) and fed to the boiler. In the boiler the compressed water is heated at constant

pressure (process 4-5-6-1). Modern steam power plants have steam temperature in the range

of 5000C to 5500C at the inlet of the turbine.


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Fig. 2.1

T-S DIAGRAM(Fig. 2.2)

12.FUELS

Gas turbines are capable of burning a range of fuels including naptha, distillates, crude oils

and natural gas. Selection of fuel (s) depends on several factors including fuel availability,

fuel cost and cleanliness of fuel.


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13.INDUSTRIAL COOLING TOWERS

Fig.3

Industrial cooling towers can be used to remove heat from various sources such as machinery

or heated process material. The primary use of large, industrial cooling towers is to remove

the heat absorbed in the circulating cooling water systems used in power plants, petroleum

refineries, petrochemical plants, natural processing plants, food processing plants, semi-

conductor plants, and for other industrial facilities such as in condensers of distillation

columns, for cooling liquid in crystallization, etc. The circulation rate of cooling water in a

typical 700 MW coal-fired power plant with a cooling tower amounts to about 71,600 cubic

metres an hour (315,000 U.S. gallons per minute) and the circulating water requires a supply

water make-up rate of perhaps 5 percent (i.e., 3,600 cubic metres an hour).

If that same plant had no cooling tower and used once-through cooling water, it would

require about 100,000 cubic metres an hour and that amount of water would have to be

continuously returned to the ocean, lake or river from which it was obtained and continuously

re-supplied to the plant. Furthermore, discharging large amounts of hot water may raise the

temperature of the receiving river or lake to an unacceptable level for the local ecosystem.

Elevated water temperatures can kill fish and other aquatic organisms (seethermal pollution).

A cooling tower serves to dissipate the heat into the atmosphere instead and wind and air

diffusion spreads the heat over a much larger area than hot water can distribute heat in a bodyof water. Some coal-fired and nuclear power plants located in coastal areas do make use of
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once-through ocean water. But even there, the offshore discharge water outlet requires very

careful design to avoid environmental problems.

Petroleum refineries also have very large cooling tower systems. A typical large refinery

processing 40,000 metric tonnes of crude oil per day (300,000 barrels (48,000 m3

) per day)

circulates about 80,000 cubic metres of water per hour through its cooling tower system.

The world's tallest cooling tower is the 200 metre tall cooling tower ofNiederaussem Power

Station

AIR FLOW GENERATION METHOD

Fig. 4.1 A forced draft cooling tower

Fig. 4.2:Forced draft counter flow package type cooling towers
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With respect to drawing air through the tower, there are three types of cooling towers:

13.1 Natural draft, which utilizes buoyancy via a tall chimney. Warm, moistair naturally rises due to the density differential to the dry, cooler outside air.

Warm moist is less dense than drier air at the same pressure. This moist air

buoyancy produces a current of air through the tower.

13.2 Mechanical draft: which uses power driven fan motors to force or draw airthrough the tower.

13.3Induced draft: A mechanical draft tower with a fan at the discharge whichpull air through tower. The fan induces hot moist air out the discharge. This

produces low entering and high exiting air velocities, reducing the possibility

ofrecirculation in which discharged air flows back into the air intake. This fan/fin

arrangement is also known as draw-through.

13.4Forced draft: A mechanical draft tower with a blower type fan at the intake.The fanforces air into the tower, creating high entering and low exiting air

velocities. The low exiting velocity is much more susceptible to recirculation.

With the fan on the air intake, the fan is more susceptible to complications due to

freezing conditions. Another disadvantage is that a forced draft design typically

requires more motor horsepower than an equivalent induced draft design. The

forced draft benefit is its ability to work with high static pressure. They can be

installed in more confined spaces and even in some indoor situations. This fan/fill

geometry is also known as blow-through.

Fan assisted natural draft. A hybrid type that appears like a natural draft though airflow is

assisted by a fan.

Hyperboloid cooling towers have become the design standard for all natural-draft cooling

towers because of their structural strength and minimum usage of material. The hyperboloid

shape also aids in accelerating the upward convective air flow, improving cooling efficiency.They are popularly associated with nuclear power plants. However, this association is
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misleading, as the same kind of cooling towers are often used at large coal-fired power plants

as well. Similarly, not all nuclear power plants have cooling towers, instead cooling their heat

exchangers with lake, river or ocean water.

14. CROSS FLOW

Cross flow is a design in which the air flow is directed perpendicular to the water flow (see

diagram below). Air flow enters one or more vertical faces of the cooling tower to meet the

fill material. Water flows (perpendicular to the air) through the fill by gravity. The air

continues through the fill and thus past the water flow into an open plenum area.

A distribution or hot water basin consisting of a deep pan with holes or nozzles in the bottom

is utilized in a cross flow tower. Gravity distributes the water through the nozzles uniformlyacross the fill material.

Fig 5.0


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15. COUNTER FLOW

In a counter flow design the air flow is directly opposite to the water flow. Air flow first

enters an open area beneath the fill media and is then drawn up vertically. The water is

sprayed through pressurized nozzles and flows downward through the fill, opposite to the air

flow.

Fig 6.0

15.1 Common to both designs:

The interaction of the air and water flow allows a partial equalization and evaporationof water.

The air, now saturated with water vapour, is discharged from the cooling tower. A collection or cold water basin is used to contain the water after its interaction with

the air flow.

Both cross flow and counter flow designs can be used in natural draft and mechanical draftcooling towers


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16. BOILER

Boilers can be classified into the following configurations:

16.1"Pot boiler" or "Haycock boiler": a primitive "kettle" where a fire heats apartially-filled water container from below. 18th century Haycock boilers generally

produced and stored large volumes of very low-pressure steam, often hardly above that of

the atmosphere. These could burn wood or most often, coal. Efficiency was very low.

16.2Fire-tube boiler. Here, water partially fills a boiler barrel with a small volume leftabove to accommodate the steam (steam space). This is the type of boiler used in nearly

all steam locomotives. The heat source is inside a furnace or firebox that has to be kept

permanently surrounded by the water in order to maintain the temperature of the heating

surface just below boiling point. The furnace can be situated at one end of a fire-tube

which lengthens the path of the hot gases, thus augmenting the heating surface which can

be further increased by making the gases reverse direction through a second parallel tube

or a bundle of multiple tubes (two-pass or return flue boiler); alternatively the gases may

be taken along the sides and then beneath the boiler through flues (3-pass boiler). In the

case of a locomotive-type boiler, a boiler barrel extends from the firebox and the hot

gases pass through a bundle of fire tubes inside the barrel which greatly increase the

heating surface compared to a single tube and further improve heat transfer. Fire-tube

boilers usually have a comparatively low rate of steam production, but high steam storagecapacity. Fire-tube boilers mostly burn solid fuels, but are readily adaptable to those of

the liquid or gas variety.

16.3 Water-tube boiler. In this type, the water tubes are arranged inside a furnace in a number

of possible configurations: often the water tubes connect large drums, the lower ones

containing water and the upper ones, steam and water; in other cases, such as a monotube

boiler, water is circulated by a pump through a succession of coils. This type generally gives
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high steam production rates, but less storage capacity than the above. Water tube boilers can

be designed to exploit any heat source and are generally preferred in high pressure

applications since the high pressure water/steam is contained within small diameter pipes

which can withstand the pressure with a thinner wall.

16.4Flash boiler. A specialized type of water-tube boiler.

1950s design steam locomotive boiler, from a Victorian Railways J class

Fig 7.0

Fire-tube boiler with Water-tube firebox. Sometimes the two above types have beencombined in the following manner: the firebox contains an assembly of water tubes,

called thermic siphons. The gases then pass through a conventional fire tube boiler.

Water-tube fireboxes were installed in many Hungarian locomotives, but have met withlittle success in other countries.

Sectional boiler. In a cast iron sectional boiler, sometimes called a "pork chop boiler"the water is contained inside cast iron sections. These sections are assembled on site to

create the finished boiler.
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17. CONTROLLING DRAUGHT

Most boilers now depend on mechanical draught equipment rather than natural draught. This

is because natural draught is subject to outside air conditions and temperature of flue gases

leaving the furnace, as well as the chimney height. All these factors make proper draught

hard to attain and therefore make mechanical draught equipment much more economical .

There are three types of mechanical draught:

17.1 Induced draught: This is obtained one of three ways, the first being the "stackeffect" of a heated chimney, in which the flue gas is less dense than the ambient air

surrounding the boiler. The denser column of ambient air forces combustion air into and

through the boiler. The second method is through use of a steam jet. The steam jet

oriented in the direction of flue gas flow induces flue gasses into the stack and allows fora greater flue gas velocity increasing the overall draught in the furnace. This method was

common on steam driven locomotives which could not have tall chimneys. The third

method is by simply using an induced draught fan (ID fan) which removes flue gases

from the furnace and forces the exhaust gas up the stack. Almost all induced draught

furnaces operate with a slightly negative pressure.

17.2 Forced draught: Draught is obtained by forcing air into the furnace by means ofa fan (FD fan) and ductwork. Air is often passed through an air heater; which, as the

name suggests, heats the air going into the furnace in order to increase the overall

efficiency of the boiler. Dampers are used to control the quantity of air admitted to the

furnace. Forced draught furnaces usually have a positive pressure.

17.3 Balanced draught: Balanced draught is obtained through use of both induced andforced draught. This is more common with larger boilers where the flue gases have to

travel a long distance through many boiler passes. The induced draught fan works in

conjunction with the forced draught fan allowing the furnace pressure to be maintained

slightly below atmospheric.

18. SAFETY

Safety is the state of being "safe" (from French sauf), the condition of being protected against

physical, social, spiritual, financial, political, emotional, occupational, psychological,

educational or other types or consequences of failure, damage, error, accidents, harm or any

other event which could be considered non-desirable. Safety can also be defined to be the
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control of recognized hazards to achieve an acceptable level of risk. This can take the form of

being protected from the event or from exposure to something that causes health or

economical losses. It can include protection of people or of possessions.

19. TYPES OF SAFETY

It is important to distinguish between products that meet standards, that are safe, and those

that merely feel safe. The highway safety community uses these terms.

19.1 NORMATIVE SAFETYNormative safety is a term used to describe products or designs that meet applicable design

standards and protection.

19.2 SUBSTANTIVE SAFETY

Substantive or objective safety means that the real-world safety history is favorable, whether

or not standards are met.

19.3 PERCEIVED SAFETYPerceived or subjective safety refers to the level of comfort of users. For example, traffic

signals are perceived as safe, yet under some circumstances, they can increase traffic crashesat an intersection. Traffic roundabouts have a generally favorable safety record, yet often

make drivers nervous.

20. SAFETY MEASURES

Safety measures are activities and precautions taken to improve safety, i.e. reduce risk related

to human health. Common safety measures include: Root cause analysis to identify causes of a system failure and correct

deficiencies.

Visual examination for dangerous situations such as emergency exits blockedbecause they are being used as storage areas.

Visual examination for flaws such as cracks, peeling, loose connections.

Chemical analysis X-ray analysis to see inside a sealed object such as a weld, a cement wall or an

airplane outer skin.
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Destructive testing of samples Stress testing subjects a person or product to stresses in excess of those the person or

product is designed to handle, to determining the "breaking point".

Safety margins/Safety factors. For instance, a product rated to never be required tohandle more than 200 pounds might be designed to fail under at least 400 pounds, a

safety factor of two. Higher numbers are used in more sensitive applications such as

medical or transit safety.

Implementation of standard protocols and procedures so that activities are conductedin a known way.

Training of employees, vendors, product users Instruction manuals explaining how to use a product or perform an activity Instructional videos demonstrating proper use of products Examination of activities by specialists to minimize physical stress or increase

productivity

Government regulation so suppliers know what standards their product is expected tomeet.

Industry regulation so suppliers know what level of quality is expected. Industryregulation is often imposed to avoid potential government regulation.

Self-imposed regulation of various types. Statements of Ethics by industry organizations or an individual company so its

employees know what is expected of them.

Drug testing of employees, etc. Physical examinations to determine whether a person has a physical condition that

would create a problem.

Periodic evaluations of employees, departments, etc. Geological surveys to determine whether land or water sources are polluted, how firm

the ground is at a potential building site, etc.

21. 5S (METHODOLOGY)

5S is the name of a workplace organization methodology that uses a list of five Japanese

words which are seiri, seiton, seiso, seiketsu and shitsuke. There are 5 primary phases of 5S:

sorting, straightening, systematic cleaning, standardizing, and sustaining.

21.1 SORTING (SEIRI)
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Eliminate all unnecessary tools, parts, and instructions. Go through all tools, materials, and soforth in the plant and work area. Keep only essential items and eliminate what is not required,

prioritizing things per requirements and keeping them in easily-accessible places. Everythingelse is stored or discarded.

21.2 STRAIGHTENING OR SETTING IN ORDER / STABILIZE (SEITON)

There should be a place for everything and everything should be in its place. The place foreach item should be clearly labeled or demarcated. Items should be arranged in a manner that

promotes efficient work flow, with equipment used most often being the most easilyaccessible. Workers should not have to bend repetitively to access materials. Each tool, part,

supply, or piece of equipment should be kept close to where it will be used in other words,straightening the flow path. Seiton is one of the features that distinguishes 5S from

"standardized cleanup". This phase can also be referred to as Simplifying.

21.3 SWEEPING OR SHINING OR CLEANLINESS / SYSTEMATIC CLEANING

(SEISO)

Clean the workspace and all equipment, and keep it clean, tidy and organized. At the end of

each shift, clean the work area and be sure everything is restored to its place. This makes it

easy to know what goes where and ensures that everything is where it belongs. Spills, leaks,

and other messes also then become a visual signal for equipment or process steps that need

attention. A key point is that maintaining cleanliness should be part of the daily worknot anoccasional activity initiated when things get too messy.

21.4 STANDARDIZING (SEIKETSU)

Work practices should be consistent and standardized. All work stations for a particular job

should be identical. All employees doing the same job should be able to work in any station

with the same tools that are in the same location in every station. Everyone should know

exactly what his or her responsibilities are for adhering to the first 3 S's.

21.5 SUSTAINING THE DISCIPLINE OR SELF-DISCIPLINE (SHITSUKE)

Maintain and review standards. Once the previous 4 S's have been established, they becomethe new way to operate. Maintain focus on this new way and do not allow a gradual decline

back to the old ways. While thinking about the new way, also be thinking about yet betterways. When an issue arises such as a suggested improvement,

a new way of working, a new tool or a new output requirement, review the first 4 S's

and make changes as appropriate.


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. REFERENCES

1. www.google.com.

2 .R.S.Khurmitext book.

3. NTPC brochure.
http://www.google.com/http://www.google.com/


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satyendra ' s report

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