Lok Sabha Question No. 5391 (UNSTARRED), answered on 2025-04-03
Subject: Audit of NTPC's Thermal Power Plants
Ministry: POWER
Asked by: Shri Rahul Gandhi

## GOVERNMENT OF INDIA MINISTRY OF POWER

## LOK SABHA UNSTARRED QUESTION NO.5391 ANSWERED ON 03.04.2025

## AUDIT OF NTPC'S THERMAL POWER PLANTS

5391.  SHRI RAHUL GANDHI:

Will the Minister of POWER be pleased to state:

- (a) whether  the  Government  has  conducted  any  audit  of  NTPC's  thermal  power plants over 25 years old and if so, the details thereof, State-wise;

(b) whether  the  Government  has  taken  any  initiatives  for  the  renovation  and modernization of NTPC's Feroze Gandhi Unchahar Power Station at Raebareli and if so, the details thereof;

- (c) the details of the measures taken by the Government to improve the operational efficiency at the Feroze Gandhi Unchahar Power Station at Raebareli; and
- (d) the  details  of  the  measures  taken  by  the  Government  to  improve  safety  and institutional accountability at the Unchahar Power Station in the aftermath of the boiler explosion in 2017?

## A N S W E R

## THE MINISTER OF STATE IN THE MINISTRY OF POWER

(SHRI SHRIPAD NAIK)

(a): In compliance to the Hon'ble National Green Tribunal's Order dated 22.12.2020, a Safety Audit Committee was constituted by Central Electricity Authority (CEA)under Ministry  of  Power,  comprising  of  representatives  from  Central  Electricity  Authority (CEA), Ministry of Coal, Central Boiler Board (CBB), Director General Fire Safety (DGFS), Oil Industry Safety Directorate (OISD), NTPC Ltd., NLC India Limited (NLCIL) and Bharat Heavy Electrical Limited (BHEL).

The  committee  had  conducted  the  physical  audit  of  Farakka  Super  Thermal Power Station of NTPC Limited situated in the state of West Bengal from 24.11.2021 to 25.11.2021  and  given  their  recommendations  on  safety  concerns  in  thermal  power plants. The recommendations of the safety audit committee were shared by NTPC Ltd. among their stations and the recommendations are being complied with.

(b) : As per Section 7 of  Electricity  Act,  2003,    setting  up  of  a  power  plant  is  a  delicensed  activity  in  the  country.  Any  generating  company  may  establish,  operate  and maintain a generating station without requiring a license under Electricity Act, 2003 if it complies with the technical standards relating to connectivity with the grid. Carrying out  renovation  &  modernization  (R&M)  works  in  thermal  units  are  decided  by  Power generating utilities/companies on their own based on techno-economic and environmental reasons.

The details of major upgradation/ replacement work executed by NTPC Ltd. at Feroze Gandhi Unchahar Power Station are as under:-

1. Replacement  of  Low-Pressure  Heaters,  some  parts  of  High  Pressure  By  Pass system, DC Charges, Coal handling plants HP travelling trippers, Turbine related valves, Boiler Feed Pump, Condensate Extraction Pump, Condenser Tubes of Unit #1 Condenser, Scrapper conveyor of Bottom ash hopper.
2. R&M  of control & Power cables and Electrostatic Precipitators (ESPs), Refurbishment of cooling tower, Residual Life Assessment study of critical piping & hangers,  Conversion  of  open  channel  ash  water  flow  to  closed  pipe  corridor flow, Renovation of fire fighting system.
3. (c) : The following measures have been/are being taken by NTPC Ltd. for improving the operational efficiency at the Feroze Gandhi Unchahar Power Station at Raebareli:
- 1) Unit parameters are being monitored offline/online for any deviation with respect to design performance.
- 2) Preventive  maintenance  of  critical  equipment  related  to  Boiler,  TG  and  other systems.
- 3) Benchmarking of unit performance parameters.
- 4) Overhauling  of  units  is  being  done  regularly  and  during  overhauling,  Critical systems and equipment related to Boiler, TG(Turbine-Generator) and BoP (Balance of Plants) are inspected, repaired and replaced as per the requirement.

(d) : Government  investigated  the  cause  of  boiler  explosion  at  Unchahar  Power Station to improve safety and institutional accountability. To investigate the causes of the accident, six (06) nos. of enquiry committees were constituted. Reports submitted by these committees which inter-alia mentioned high ash build up and consequent tube failure  due  to  dislodging  of  this  build  up  ash  in  the  boiler  as  one  of  the  causes  of accident  in  the  boiler.  The  key  recommendations/findings  of  these  Committees  along with the actions taken thereon are given as under:

## Recommendations of the Committees:

1.    Accumulation  of  ash  should  be  controlled,  and  continuous  ash  removal  should  be ensured without blocking the furnace bottom opening and ash hopper.
2. All  Technical  considerations  of  plant  operating  conditions  should  be  part  of Standard Operating Procedures (SOPs).
3. The plant Engineers and operation general team should have adequate and relevant experience as per the duties.
4. Opening  of  manhole  doors/scaffold  doors  during  operation  is  not  resorted  and water injection for dislodging should be avoided.
5. Whenever people attend to any problem during boiler operation, there should be a clear checklist for safe practice.
6. The protocol  of  work  permit  for  carrying  out  any  activity  in  the  unit  should  be strictly adhered to.

## Action Taken by NTPC ltd:-

-  Operation guidance note was reviewed with additional points of safety and the same has been complied by all NTPC Stations.
-  NTPC executive trainees undergo 12 Months training at entry level covering all aspects of the power plant. Further, regular trainings are being conducted across all stations in respect of assigned duties.
-  International certification courses like NEBOSH-IGC  and NOSA  are being organized every year for employees for capability building.
-  Training program for contractors' employees are being conducted at all sites on regular basis covering all relevant topics on occupational health and safety.
-  Safety  behavior  index  has  been  introduced  in  the  Performance  Management System (PMS).
-  To strengthen the elements of Institutional Accountability internally, NTPC safety Framework was rolled out in 2021which is integrated with NTPC SAP system. The framework provides a consistent conceptual structure and serve as the guidance document to the various functions  and  roles.  It  contains  a  set  of  expectations that ensure that all efforts are aligned with the overall Policy and objectives of NTPC.  The  expectations  are  expressed  broadly  in  the  form  of  components  Safety Policy, Safety Risk Management, Safety Assurance and Safety Promotion.
-  Cross-functional  safety  task  force  for  operating  plants  and  under  construction projects are functional at all projects/stations to monitor and ensure safe working conditions.
-  For early detection of ash build up, cameras have been installed for monitoring by desk operator.
-  Internal  and  external  safety  audits  are  undertaken  by  NTPC  through  its  safety officers  at  regular  intervals  and  external  (third  party)  safety  audit  through reputed agencies from time to time.
-  Job Safety analysis has been made a part of permit to work system, and stations are strictly following it.
-  For  early  detection  and  mitigation  of  the  on-site  emergencies,  effective  control systems are provided at all operating stations.
-  Regular Mock drills are conducted to check the healthiness of the systems, and any abnormalities are immediately rectified.
-  Awareness program on disaster management plan are also conducted regularly.
-  To  inculcate  safety  culture,  various  messages/instructions  are  displayed  in  the form  of  posters/hoardings  at  various  vulnerable  locations  of  working  sites. Different competitions and campaigns on safety are also organized time to time to enhance the safety awareness of employees, contractors' workers and nearby villagers.
-  Regular Medical examinations are conducted to monitor the health condition of workers  at  workplace.  Safety  trainings  and  pep-talks  are  also  organized  for workers at sites to make them aware about the hazards at workplace.
-  Disaster management  plan and emergency action plans are prepared in consultation with district & state authorities and nearby industries to tackle any emergency situation.

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