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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.
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