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OPERATION MANAGEMENT

Instructions/Guidelines/Circulars
Doc:Ref.No OS/OPN/1 (Revised)
Date: 20.02.2007

OPERATION SERVICES

NTPC Ltd.
EOC, Noida

LIST OF CONTENTS
S.No.

Description

1.0

Introduction

2.0

Objective of Operation management

3.0

Performance Evaluation Matrix

4.0

Definitions

5.0

Calculation of Operational Parameters

6.0

Monitoring System
Station
Regional OS
Corporate OS

7.0

Reporting and Logging System


Station
Regional OS
Corporate OS

8.0

Function of different departments


Station
Regional OS
Corporate OS

9.0

Operation Review Team (ORT )

10.0

Regional Operation Performance Review ( ROPR)

11.0

Technical Audit

12.0

Technical Compliance System

13.0

Recommissioning

14.0

Maintenance Management System

15.0

Energy and Efficiency Management System

16.0

Protection & Interlock system

S.No.

Description

17.0

Unit Tripping

Page No.

Page No.

18.0

Documents

19.0

Preservation & Disposal of Log Book/Log Sheet/Charts


/DAS Printouts

20.0

Emergency instructions

21.0

Study Team & Knowledge Team

22.0

Housekeeping

23.0

Safety

24.0

Training & Development

25.0

Annexure (Formats)

LIST OF ANNEXURE
Annexure No.
Annexure-I

Description
Format for Action plan matrix for ROPR

Page
No.

Annexure No.

Description

Annexure-II

Technical Audit Plant Areas

Annexure-III

Format for reporting the findings of Technical


Audit

Annexure-IV
Annexure-V

Format for action plan / implementation on


findings of Technical Audit
Master list of Technical Compliance Documents

Annexure-VI

Format for Unit Trip report (Coal station)

Annexure-VII

Format for Unit Trip report (Gas station)

Annexure-VIII

Outage Codes for Coal Fired station

Annexure-IX

Outage Codes for Gas Fired station

Annexure-X

Model emergency Instructions for Total Power


Failure
Model Emergency Instructions for Fire in Mill

Annexure-XI
Annexure-XII

Model Emergency Instructions for Fire in Air


Preheater

Annexure-XIII

Model Emergency Instructions for Fire in Main


Oil Tank

Annexure-XIV
Annexure-XV

Instructions on Milling System shutdown &


isolation and some shutdown of more frequent
types.
Format for Monthly report of Coal Station

Annexure-XVI

Format for ORT

Annexure-XVII

Format for Exception Report of ORT

Annexure-XVIII

Templates for ROPR

Annexure-XIX

Technical Audit Checklists

Annexure-XX

Daily Flash report

Annexure-XXI

Report For Major Happenings

Annexure-XXII

Daily Detailed Report

Page
No.

Annexure No.

Description

Annexure-XXIII

Report On Make-Up Water & Specific Chemical


Consumption

Annexure-XXIV

Raw And Filtered Water Analysis

Annexure-XXV

Clarified Water Analysis

Annexure-XXVI

Performance Data PT Plant

Annexure-XXVII

Softened Water Analysis

Annexure-XXVIII

Performance Data Softening Plant For CW


System

Annexure-XXIX

Circulating Water Analysis

Annexure-XXX

Circulating Water Performance Data

Annexure-XXXI

DM Plant Performance Data

Annexure-XXXII

Condensate Polishing Plant Performance Data

Annexure-XXXIII

Steam-Water Analysis

Annexure-XXXIV

Chemical Consumption Data - Main Plant/ETP

Annexure-XXXV

Coal As Received Analysis (Joint Coal)

Annexure-XXXVI

Coal As Fired Analysis

Annexure-XXXVII

Fly Ash And Bottom Ash Analysis (Dry Basis)

Annexure-XXXVIII

Natural Gas/Naphtha Analysis

Annexure-XXXIX

Turbine Lubricating/Governing Oil Analysis

Annexure-XXXX

Coal Fineness

Annexure-XXXXI

Mill Rejects (Dry Basis)

Annexure-XXXXII

Flue Gas (By Orsat Or Portable Gas Analyzer) &


Hydrogen Gas Analysis

Annexure- XXXXIII

Chlorinators

Page
No.

Annexure No.

Description

Annexure- XXXXIV

Critical Parameters Deviation Record

Annexure- XXXXV

Page
No.

Model Start up checklist of 500 MW Boiler &


Aux.
Model Start up checklist of 500 MW Turbo
Generator & Aux.

Annexure- XXXXVI
Annexure-XXXXVII
Annexure-XXXXVIII
Annexure-XXXXIX

Model Recommissioning checklist of Main


Turbine (500 MW)
Model Recommissioning checklist of air
preheater
Operation Philosophy of Coal Handling Plant

LIST OF DIAGRAM/FLOW DIAGRAM


S.N

Description

Ideal AG/DC Plot against Average Frequency

System for Action plan Generation, Monitoring and Control

Design Change Request

ORT Process Flow Chart

Page
No.

ROPR Process

Operation division Documentation System

Flow Chart of activities in LMI preparation & implementation

Permissible eat rate deterioration between Overhaul to


Overhaul
Planning process of Unit Overhaul

1.0

INTRODUCTION

NTPC, since its inception, had recognised the need of acquiring professionalism in the
management of power industry to ensure safe and reliable operation of stations with sustained
performance, thus providing reliable service to customers. In this process, all possible efforts
have been made to standardize all systems of Operation Management. An effective system
known as "Operation Management System" has been developed to achieve uniform
implementation of the systems throughout all NTPC stations. Implementation of these
systems have paid rich dividends in the form high Plant Load Factor and high Availability
Factor on sustained basis. This also resulted in commissioning of units on or ahead of
schedule. Corporate Operation Services issued operating instructions and the different

communications, as OPERATION MANAGEMENT, instructions /Guidelines /Circulars in


1992.
Since the last decade, the Government of India (GOI) has been vigorously taking up the issue
of Power Sector reforms and initiated number of efforts in this direction. The introduction of
ABT and some other simultaneous developments have caused a sea change in the Grid
management in the country. ABT envisages shifting from PLF based to Availability based
tariff and also introduces a powerful mechanism called "UI Management" for regulation of
grid. The changed scenario enforces the Merit order operation of the grid and the stations.
Considering the above reforms, need has been felt to revise the OPERATION
MANAGEMENT, instructions /Guidelines /Circulars.
Presently focus is given on the following Operation matrix:
01. ABT Compliance
02. MOU Targets Actualisation
03. Efficiency Enhancement
04. Forced outage Reduction
05. Maintenance Quality improvement
06. Preparedness for Overhaul
07. System Compliance
08. Zero Accidents & Zero Fire target
09. Total Quality Management
10. Environment & Ash utilisation
The Operation Management Instructions/Guidelines/Circulars" has been revised accordingly
and the above Operation matrix has been covered in the revised Operation Management
System Manual.
The following aspects are also covered in the revised Operation Management System
Manual.
1. Definitions
2. Objective of Operation Management

3. Role of Individuals in Operation Monitoring of plant performances in Stations, Regional


OS & Corporate OS.
4. Monitoring system in Stations, Regional OS & Corporate OS.
5. Reporting & Logging system in Stations.
6. Functioning of ROPR
7. Functioning of ORT
8. Methodology of Technical Audit
9. Technical Compliance System
10. House keeping of the Station.
11. Guidelines for preservation & disposal of charts, log sheets, DAS printout, Log book.
12. Knowledge Team and their responsibilities.
13. Essential Documents
14. Formats for different reports used in Stations, Operation Services etc.

2.0

OBJECTIVES OF OPERATION MANAGEMENT

The Objectives of Operation Management are described under different Operational


Matrix constituents as follows:
A. MOU TARGETS ACTUALISATION:
Objectives:
1. To ensure safe, reliable and commercially viable operation of units with sustained
performance in order to actualize all MOU targets.
B. ABT COMPLIANCE:
Objectives:
1. To operate the stations at maximum capability (Maximise DC).
2.

Achieve maximum generation w.r.t. DC (limited to 101% of DC over the day)

3. To ensure optimum UI management.


In order to achieve the above objectives, the following are required:

a) To maximize declared capability within the ambit of CERC regulations.


b) To put all out efforts to generate optimally looking into the frequency trends.
c) To analyse the performance of station generation for the previous day block by block and
to discuss in daily plant meetings regarding the shortcomings in generation in each block.
d) To monitor carefully the generation in their shifts as per the guidelines given by CERC.
i.e 105% of DC in each time block & 101% of DC averaged over the day.
e) To operate station at 105% DC when the frequency is less than 49.5 Hz, gradually
reducing to SG from 49.5 Hz to 50 Hz and as per schedule between frequency 50.0 Hz to
Break Even Frequency (BEF-frequency at which UI rate is = marginal variable cost).
f) Above BEF station shall reduce the load progressively and generation level shall be kept
lower than the schedule considering technical minimum (Refer Ideal AG / DC plot
against frequency).
g) To give importance for optimum UI management vis--vis MOU targets. Detailed breakup of the negative UI incurred has to be made for analysis & for improving UI quality.
h) To monitor UI Quality closely with the help of scatter diagram on daily basis and it is to
be discussed in the daily meeting. This will facilitate maximizing / optimizing generation
at appropriate frequency time blocks.
i) To be aware about the load shedding pattern and techniques adopted by the various
beneficiary states to control the grid frequency. This shall require close co-ordination of
the RCC with the respective SLDCs / RLDCs.
Diagram

Id e a l A G /D C p lo t a g a in s t A ve ra g e F re q u e n c y :
(S G = 9 0 % D C )
110

AG/DC (%)

100
B E F , 50.3Hz

90

80

A G /D C (% )

A G /S G (% )
70

48

4 8 .5

49

4 9 .5

50

5 0 .5

A v . F re q u e n c y (H z )

51

5 1 .5

Notes: AG should scatter close to the purple trace


SG is arbitrarily assumed to be 90% of DC for illustration purposes
Y-axis corresponds to AG/DC, to left of 50Hz axis
and to AG/SG to the right of 50Hz axis
Technical Minimum assumed to be 80% of DC

B. EFFICIENCY ENHANCEMENT*:
Objectives:
1. To operate the plant and accessories at optimum efficiencies.
2. To operate the plant at minimum oil consumption, auxiliary consumption and make
up water consumption.
3. To operate the units at rated parameters.
4. To achieve optimum water chemistry parameters.
In order to achieve the above objectives, the following are required:
a) To gear up the Station EEMG cell to meet the operational requirements in the changed
operation scenario. EEMG department must play a vital & proactive role to enhance
marginal contribution.
b) To work on Energy Balance method and identify areas for Heat Rate improvement.

c) To involve effectively by EEMG department in every station in identifying the areas of


loss by way of various tests and prepare an action plan to achieve high efficiency near the
PG test /Design values. Deviations from actual & design is to be monitored and any help
in this regard to be referred to Region & Corporate OS on weekly basis.
d) To implement the action plan of the efficiency tests, conducted by site, OS & CENPEEP.
e) To ensure the testing of water chemistry, as envisaged and implementation of the
recommendations.
* Please refer to efficiency management document for more details
C. FORCED OUTAGE REDUCTION:
Objectives:
1. To operate the units at maximum availability.
2. To achieve zero forced outage.
3. To achieve minimum partial loading (less than 0.5%) by ensuring maximum
equipment availability.
In order to achieve the above objectives, the following are required:
a) To analyse systematically and comprehensively for identifying the root cause of unit
tripping and to eliminate them at the earliest. The learning should be blended with good
future improvement strategies to avoid the recurrence.
b) To identify all possible causes of multiple units tripping and formulate action plans to
eliminate them.
c) To maintain a database of unit parameters, equipment history, failures and major
incidents for reference.
d) To analyse properly major incidents, equipment failures and monitor the implementation
of action plans.
e) To contain station outage and partial loading within the targeted limits, more proactive /
innovative approach, actions & strategy are required like detailed scope of work for
overhauls, improved quality of overhauls etc.
f) To analyse tube failures properly, which is the major contributor of forced outage. Root
cause analysis for all tube leakages, followed by action plan is essential to eliminate the
tube leakage of a unit between two consecutive overhauls.
g) To analyse unexpected failure of Capital Equipments properly. All maintenance-incharges are to be geared up to eliminate them at the earliest by using the latest
monitoring/maintenance tools and techniques.

h) To shift the focus from conventional preventive to Knowledge-based Reliability Centered


maintenance practices. RCM concept is to be rolled out in all NTPC stations within a time
frame through the involvement of Regional teams.
D. MAINTENANCE QUALITY IMPROVEMENT AND PREPAREDNESS FOR
OVERHAUL:
Objectives:
1. To ensure no forced outage from overhaul to overhaul.
2. To ensure timely completion of overhaul.
3. To ensure overhauling of unit as per Rolling plan.
To ensure Overhauling quality of the units, the following operations are required
a) To reduce the forced outage and to ensure the quality of Overhauling, a rolling plan shall
be prepared. Scope of work of overhauling due for next two to three years need to be
worked out and all preparation must be made accordingly. The scope of work as well as
other associated activities shall be reviewed six monthly and action plan is to be worked
out to achieve timely completion of overhauls with quality of work to ensure reliability of
units operation.
b) To review the scope of work of unit overhaul based on feed back from area engineers/
operation engineers as per equipment maintenance requirements.
c) To adhere with the Overhauling schedule to bring back the unit within the schedule time
without compromising quality.
d) To analyse any outage after overhauling critically and to take necessary measures to
avoid such occurrences in future.
e) To arrange frequent workshops to review the forced Outages after overhaul. The
department concerned of stations shall have to explain the reasons for outage in the
workshop.
f) To prepare a comprehensive documentation and grouping of similar trips in each and
every field. This analysis has to be used while preparing the check list for next
overhauling.
g) To ensure timely availability of all material required for overhauls and accordingly the
scope of work, procurement action may be taken well in advance.

h) To award works contracts for unit overhauls covering total scope of work well in
advance.
i) To select the vendors/agencies for the overhauls and other maintenance jobs carefully to
ensure the quality of overhauls. Maintenance and FQA department is to focus more on
quality to achieve low forced outage and partial loading on account of equipments.
j) To advise Contracting agencies to ensure work execution under qualified engineers and
quality team.
E. SYSTEM COMPLIANCE:
Objectives:
1. To ensure the compliance of all systems, as envisaged.
To ensure the system compliance the Following operations are required.
a) To comply with all statutory requirements/licenses.
b) To comply with the protection and interlock system and to ensure all protections are in
service.
c) To comply with the all testing of Boiler, Turbine , Generator &

equipments, as

envisaged.
d) To ensure the availability and compliance of standard recommissioning check lists of all
equipment & systems.
e) To Prepare Technical Compliance documents and ensure their implementation.
f) To ensure proper documentation and record keeping for important documents.
g) To ensure efficient up-keep of instrumentation, auto loops, annunciation system,
protections and interlocks.
h) To ensure systemic monitoring and reporting system.
i) To ensure availability of operating instructions, check list. System manuals etc.
j) To comply with FGMO strictly by all stations.
F. ZERO ACCIDENT & ZERO FIRE:
Objectives:
1. To ensure no human accident
2. To ensure no equipment damage
To achieve zero accident & zero fire, the following operations are required:
a) To ensure availability of fire fighting/ safety equipments/ systems and protections

b) To ensure proper house keeping of the station.


c) To conduct the testing of tools & tackles timely.
d) To maintain healthiness of protection and interlock systems.
e) To conduct important testing like over speed test of Turbine & TDBFP etc..
f) To check structures & Machine foundation, as envisaged.
g) To ensure compliance to all statutory requirement/ license
h) To comply strictly with WOC/PTW system.
i) To carry out maintenance work as per standard checklist.
G. TOTAL QUALITY MANAGEMENT (TQM)
Objectives:
1. To ensure TQM activities are used for performance improvement and cost
reduction
To achieve that, the following operations are required:
a) To use various TQM tools like Six Sigma, Benchmarking etc. as important vehicles for
generation of new ideas, performance optimisation and cost reduction in running stations.
b) To identify the best practices and six sigma projects by the stations those are in line with
operation matrix.
H. ENVIRONMENT & ASH UTILISATION:
Objectives:
1. To ensure compliance of all environmental statutory requirements.
2. To ensure maximum Ash utilization
I. O&M COST REDUCTION:
Objectives:
1. To make an action plan to reduce inventory in line with norms.
2. To optimize O&M cost to ensure that cost remains within norms.
J. OTHERS:
1. To ensure that State of the art technologies are implemented in NTPC stations.
2. Restructuring of Regional Operation Services.

3. Modernization of Corporate OS Control Room to ensure automatic data capturing and


report generation.
4. To implement SMART (Strategic Monitoring Assistance Remote Terminus) in NTPC
stations.
5. To create Knowledge Teams of experts in various fields to get prompt help in case of
urgent need.
6. To maintain a healthy working environment.
7. Institution Building: To ensure proper training and development of O&M personnel.

3.0

PERFORMANCE EVALUATION MATRIX

3.1
Sl.
No.
1.

OPERATION AND MAINTENANCE INDEX


Constituents
Measure

The system of evaluating stations covering the whole gamut of Operations was started
recently. The main parameters (for coal stations) are as given below:

2
3

Unplanned Generation Cumulative Forced Outage till previous month


Loss
Cumulative Partial outage till previous month
( Excluding coal supply and grid constraints)
Energy Sent Out (AG) Cumulative AG/DC on bar
Quality of UI
Cumulative AG/DC when frequency less than
49.5 Hz.
Cumulative AG/DC when frequency greater
than BEF
Adherence to Planned Variance of actual commencement date w.r.t
maintenance schedule
and duration
Variance in duration from original agreed
duration and scope

Quality of Overhauls

Boiler Tube leakage after overhaul


Forced + Partial Outages after Overhaul
Heat Rate recovery after Overhaul

No. of Outages

Unplanned outages/unit/month
Repetitive outages/unit

3.2
Sl.
No.
1

Constituents
Heat Rate

Measure
Cumulative Variance from (MOU)

2
3

APC
Sp.Oil Consumption

Operation
and R&M-Cumulative variance from MOU
Maintenance Cost
Emp. Cost cumulative variance from MOU
Over Head cumulative variance from MOU
Profit without UI
Profit-cumulative variance from MOU
ROCE-cumulative variance from MOU
R&M
Budget-cumulative variance from MOU
Inventory
Spares-% cumulative variance from MOU

6
7

%
%
%
%
%
No.
of
Days
No.
of
days
No.
%
Kcal/
Kwh
No.
No.

COST OPTIMISATION INDEX

Cumulative Variance from design

Units

Cumulative Variance from (MOU)


Cumulative Variance from (MOU)

Units
Kcal/
kwh
Kcal/
kwh
%
ml/
kwh
%
%
%
%
%
%
Rs.
Crore

3.3
Sl.
No.
1
2

THRUST AREAS INDEX


Constituents
Ash Utilisation
Environment

Measure
Cumulative variance from MOU
Achievements of MOU Target
Any consent order pending
Emission within limits
Effluents within control
No. of issues pending with SPCB
No. of fatal accidents/year
No. of no-fatal accidents/year
Efficiency tests as per schedule
Energy audits as per schedule
Monthly report through OPPMS
Usage of Anurakshan
Quality of preparedness
Liquidation of problems/issues

Safety

Efficiency

IT

ROPR

Timely submission of Within specific days


results of evaluation
matrix

NOTE: These parameters are subject to modification from time to time.

Units
%

No.
No.

4.0 DEFINITIONS
ITEM
Availability

Availability Factor on
bar
Availability
Factor
(Machine)
Auxiliary
Power
Consumption (APC)

DEFINITION
Availability in relation to thermal generating stations for any
period means the average of the daily average declared
capacities (DCs) for all the days during that period expressed
as a percentage of the installed capacity minus normative
Auxiliary power consumption in MW.
Availability Factor on bar of a unit is the percentage ratio of
running hours and the total hours for a given period of time.
Machine Availability Factor of a unit is the percentage ratio of
running hours (including shutdown as per RLDC and
shutdown due to fuel constraints) and the total hours for a
given period of time.
In relation to any period, means the ratio, expressed as a
parentage, of energy in KWh generated at Generator terminals
minus energy in KWh delivered at the generating station
switchyard to gross energy in KWh generated at the Generator
terminals.
Actual sent out (Ex-bus) generation of station.

Actual Generation ex
bus (AG)
Black Start Procedure
The procedure necessary to recover from a partial or a total
blackout.
Benchmarking
The process of comparing performance with other
organizations, identifying comparatively high performance
organizations, and learning what it is they do that allows them
to achieve that high level of performance.
Break Even Frequency
The frequency at which UI rate =Marginal variable cost.
CEA
CERC
Installed Declared
Capacity (Max DC)
Declared Capacity (DC)
Commercial Operation
Date (COD)
Computerized
Maintenance
Management System
Condition Based
Maintenance

The Central Electricity Authority.


The Central Electricity Regulatory Commission.
In relation to any period or time block, means the maximum
capability of the generating station to deliver ex-bus MWh
declared by the generating station.
In relation to any period or time block, means the capability of
the generating station to deliver ex-bus MWh declared by the
generating station.
In relation to a Unit means date by which the Maximum
Continuous Rating (MCR) o installed capacity is
demonstrated through a successful trial run.
A computerized system to assist with the effective and
efficient management of maintenance activities through the
application of computer technology.
An equipment maintenance strategy based on measuring the
condition of equipment in order to assess whether it will fail
during some future period, and then taking appropriate action
to avoid the consequences of that failure.

ITEM
Condition Monitoring
Demand
Despatch Schedule
Drawal Schedule
Downtime
Disaster Management
Plan
Dry Flue gas loss
Demonstrated Capacity

Ex-Power Plant
Economic Life

Expert System
Emergency Instructions
Forced Outage
Frequency Variation
Index (FVI)
Free Governor Mode of
Operation (FGMO)
Gross Generation
Governor Droop

Gross Calorific Value

DEFINITION
The use of specialist equipment to measure the condition of
equipment.
The demand of Active power MW and reactive power MVAR
of electricity unless otherwise stated.
The ex-power plant net MW and MWH output of a generating
station, schedule to be exported to the Grid from time to time.
The ex-power plant, MW that a State is scheduled to receive
from the Inter State Generating Station (ISGS) including
bilateral exchanges from time to time.
The time that an item of equipment is out of service, as a
result of equipment failure.
Action plan to provide the maximum practicable protection
for equipments, personnel in the event of crisis or natural
disasters like earthquakes, floods, fire, man made disaster etc.
This is the heat loss from the boiler in the dry component of
gases to the stack.
In relation to a unit, the electric output at generator terminals
demonstrated at rated parameters during performance
acceptance tests as per international codes such as
ASME,PTC etc. after successful trial operation including
stabilization.
Net MW/MWH output of a generating station, after deducting
auxiliary power consumption & transmission losses.
The total length of time that an asset is expected to remain
actively in service before it is expected that it would be
cheaper to replace the equipment rather than continuing to
maintain it.
A software based system, which makes or evaluates decisions
based on rules established within the software. Typically it s
used for fault diagnosis.
Standing instructions to be carried out by each engineer &
each operator during emergencies like grid failure, hydrogen
leakage, fire etc.
An outage of a Generating unit due to fault or other reasons,
which has not been planned. It is expressed as the percentage
ratio of duration of unit forced outage and reference period.
A performance index representing the degree of frequency
variation, from the nominal value of 50.00 Hz, over a
specified period of time
Operation of Unit with Turbine Governor modulation in
action with respect to grid frequency.
Total electrical output from the generator terminal.
In relation to the operation of the governor of a Generating
unit, the percentage drop in system frequency which would
cause the Generating Unit under free governor action to
change its output from zero to full load.
The heat produced in Kcal by complete combustion of one kg

(GCV)

ITEM

Gross Heat Rate (GHR)


Heat Balance Diagram
Inventory Control
Installed Capacity
Loading Factor (LF)
Life Cycle Costing
Maximum Continuous
Rating (MCR)
Make up water
consumption
Maintenance Schedule
Mean Time Between
Failures (MTBF)
Mean Time To Repair
(MTTR)
Modification
Multiple Unit Tripping
Net Generation
Net Heat Rate(NHR)
Nozzle Governing
Operation &
Maintenance Cost
(O&M Cost)
Operation Co-ordination
Committee (OCC)
Outage Code

DEFINITION
of solid fuel or liquid fuel or one standard meter of gaseous
fuel, as the case may be.
The heat energy in Kcal input required to generate one KWh
of electrical energy at generator terminal
A diagram expressing temperature, pressure, enthalpy and
flow values throughout the cycle for a given set of conditions.
To maintain an optimum level of inventory which will
commensurate with the service level and optimize inventory
turn over.
In relation to a generating unit means the rated capacity or the
contracted capacity as the case may be.
It is the percentage ratio of Plant Load Factor and Availability
Factor on bar.
A process of estimating and assessing the total costs of
ownership, operation and maintenance of an item of
equipment during its projected equipment life.
In relation to a unit means the maximum continuous output at
the rated generator terminals, guaranteed by the manufacturers
at rated parameters.
It is the percentage ratio of DM water consumption and MCR
capacity of boiler.
A list of planned maintenance tasks to be performed during a
given time period, together with the expected start times and
durations of each tasks.
It is equal to the total equipment uptime in a given time
period, divided by the number of failures in that period. ( A
measure of reliability)
It is equal to the total equipment downtime in a given time
period, divided by the number of failures in that period. (A
measure of maintainability).
Any activity carried out on an asset which increases the
capability of that asset to perform its required function.
Outage of more than one unit simultaneously due to any fault
Total electric output at switchyard. It is the difference
between electrical generator output and the auxiliary output.
The heat energy in Kcal, input to a generating unit to deliver
one KWh at the switchyard.
Each governor valve controls a separate group of 1st stage
nozzles. It minimizes throttling loss at part load
In relation to a period means the expenditure incurred in
operation & maintenance of the generating station including
manpower, spares, consumables, insurance & overheads.
A committee of REB with members from all the constituents
which decides the operational aspects of the Regional Grid
A code typically given against an outage of unit, which
indicates the cause of failure.

ITEM
Operating Hours
Outage recurrence
Overall Plant Efficiency
Plant Load Factor (PLF)

Partial Loading
Planned Maintenance

Planned Outage
Predictive Maintenance

Preventive Maintenance
Protective Device
Permit To Work (PTW)
Performance Parameters

Regional Electricity
Board (REB)
Regional Load Dispatch
Centre (RLDC)
Reliability Centred
Maintenance (RCM)
Re-commissioning
Checklist

DEFINITION
The length of time that an item of equipment is actually
operating.
Outage of same unit over the period for same nature of fault.
It is the ratioo0f electrical energy sent out to the heat supplied
to steam in boiler.
In relation to a given period, is expressed as the percentage of
total KWh generated at generator terminals to installed
capacity, expressed in KW multiplied by number of hours in
that period.
It is the percentage by which unit runs at reduced load. It is
equal to (100- Loading Factor,%)
Any maintenance activity for which a pre-determined job
procedures has been documented, for which all labour,
materials, tools, and equipment required to carry out the task
have been estimated, and their availability assured before
commencement of the task.
It is expressed as the percentage ratio of duration of unit
planned outage and reference period. To convert any Forced
outage to Planned Outage needs approval of Corporate OS.
An equipment maintenance strategy based on measuring the
condition of equipment in order to assess whether it will fail
during some future period, and then taking appropriate action
to avoid the consequences of that failure.
An equipment strategy based on replacing, overhauling or
remanufacturing an item at a fixed interval, regardless of its
condition at the time.
Devices and assets intended to eliminate or reduce the
consequences of equipment failure.
The prime document used by the maintenance unction to
manage maintenance tasks.
Those variables in a cycle which can be measured or
calculated which are indicative of the level of performance of
a component or system.
A board constituted by resolution of Central Government for a
specified region for facilitating the integrated operation of th
power system in that region.
The center so designed for a specified region where the
operation of the power system in that region and the
integration of the power system with other regions and areas
are coordinated.
A structured process developed to determine the equipment
maintenance strategies required for any physical asset to
ensure that it continues to fulfill its intended functions in its
present operating context.
List of checks, which are adhered for every equipment during
the trial run and re-commission for safe and trouble free

ITEM
Sent Out Capability
(SOC)
Schedule Generation
(SG)
Specific Oil
Consumption
Specific Coal
Consumption
Spinning Reserve

Safety Consequences
Spares Parts
Development

Technical Co-ordination
Committee (TCC)
Total Productive
Maintenance (TPM)
Throttle Governing
Unscheduled
Interchange (UI)
Unit Tripping
Utilization
Unburnt carbon loss
Variable Pressure
Operation
Valves Wide Open
Work Order Card
Wet Flue gas loss

DEFINITION
operation of the equipment.
Sent out capability of a generating station means the
capability to deliver ex-bus MHh based on which availability
shall be worked out.
Ex bus scheduling in MW as given by RLDC to the
generating station.
It is the consumption of oil (ml) per KWh generation.
It is the consumption of coal (Kg) per KWh generation.
Part loaded generating capacity with some reserve margin that
is synchronsed to the system and is ready o provide increased
generation at short notice pursuant to dispatch instruction or
instantaneously in response to a frequency drop.
A failure has safety consequences if it causes a loss of
function or other damage that could hurt or kill someone.
To develop spare parts to be used as a substitutes for original
spares supplied by the original manufacturer/supplier and to
make necessary arrangements for manufacturing them from
local sources and also to locate alternative sources of supply
for assuring adequate competition and availability.
The committee set up by REB to coordinate the technical and
commercial aspects of the operation of the Regional grid.
A management program emphasizing production operator
involvement in equipment maintenance and continuous
improvement approaches.
All first stage nozzles are in common annulus and are
subjected to the same amount of throttling.
Variation in actual generation and the schedule generation
Outage of a unit due to actuation of any protection or the
outage of unit during emergency condition.
The proportion of available time that an item of equipment is
operating.
This loss is due to amount of carbon, which remains as a
residue in the ash from boiler.
An operating method in which the load is changed by varying
throttle pressure in lieu of changing valve position.
The turbine control valve setting which corresponds to all
turbine control valves fully open.
The prime document raised by Operation department
requesting the initiation of maintenance task.
This is the heat loss from the boiler in the flue gas due to
water vapor present as moisture & hydrogen in coal.

5.0 CALCULATION OF OPERATIONAL PARAMETERS


1. PLANT LOAD FACTOR (PLF):
a)Plant Load Factor for the Unit (%):
Gross Generation (MU) of a Unit over a reference period
PLF (Unit) = ------------------------------------------------------------------------------ x 100
Rated Gen. Capacity (MW/1000) of Unit x 24 x No. of days for ref. Period
b)Plant Load Factor for the Stage I (%):
Sum of Gross Generation (MU) of Stage-I units over a ref. period
PLF (Stg-I) = ------------------------------------------------------------------------------ x 100
Rated Gen. Capacity (MW/1000) of Stg-I x 24 x No. of days for ref. Period
c)Plant Load Factor for the Stage-II (%):
Sum of Gross Generation (MU) of Stage-II units over a ref. period
PLF (Stg-II) = ----------------------------------------------------------------------------- x 100
Rated Gen. Capacity (MW/1000) of Stg-II x 24 x No. of days for ref. Period
d)Plant Load Factor for the Station (%):
Sum of Gross Generation (MU) of all Units over a reference period
PLF (Station)=----------------------------------------------------------------------------- x 100
Rated Gen. Capacity (MW/1000) of all Units x 24 x No. of days for ref. period
2. AVAILABILITY FACTOR ON BAR:
a)Availability Factor on bar for the Unit (%)
Operating Hours of the unit over the reference period
A.V.F (On bar) = -------------------------------------------------------------------- x 100
Total hours in the reference period
b)Availability Factor on bar for Stage-I Units, (AVFs1) (%)

Sum of the Availability Factor of Stage-I Units


A.V.F (On bar) = -------------------------------------------------------------

Number of units of the Stage-I (N1)


c)Availability Factor on bar for Stage-II Units, (AVFs2) (%)

Sum of the Availability Factor of Stage-II Units


A.V.F (On bar) = ------------------------------------------------------------Number of units of the Stage-II (N2)
d)Availability Factor on bar for Station, (AVFs) (%)

AVFs1 x N1 x C1 + AVFs2 x N2 x C2
A.V.F (On bar) = -----------------------------------------------N1 x C1 + N2 x C2
Where,
AVFs1 , AVFs2 =Availability Factor On bar,(%) of Stage I & Stage-II respectively
N1 , N2 =
Number of Units of Stage I & Stage-II respectively
C1 , C2 = Capacity (MW) of units of Stage I & Stage-II respectively
3. MACHINE AVAILABILITY:
a) Machine Availability Factor for the Unit (%)
Sum of Operating Hours & outage hours due to fuel & grid
restriction of unit over the reference period
A.V.F (M/C) = ---------------------------------------------------------------------------- x 100
Total hours in the reference period
b) Machine Availability Factor for Stage-I Units (%)
This can be calculated sane way as shown in 2b)
c) Machine Availability Factor for Stage-II Units (%)
This can be calculated sane way as shown in 2c)
d) Machine Availability Factor for Station (%)

This can be calculated same way as shown in 2d)


4. AVAILABILITY BASED ON DC:
In relation to a thermal generating station Availability for any period means the average of
the daily average declared capacities (DCs) for all the days during that period expressed as a
percentage of installed capacity of the generating station minus normative auxiliary
consumption. Availability shall be computed in accordance with the following formula:
Availability = 10000

N
i=1

DCi / { N x IC x (100-AUXn)} %

Where,
I.C = Installed Capacity of the station in MW
DCi = Average declared capacity for the ith day of the period in MW.
N = Number of days during the period
AUXn = Normative Auxiliary power consumption as a percentage of gross generation
5. LOADING FACTOR,(%):
Loading Factor (%) of Unit or Stage-I/II or Station:
Plant load Factor of Unit or Stage-I/II or Station (%)
Loading Factor = -------------------------------------------------------------------- x 100
Availability Factor on bar of Unit or Stage-I/II or Station (%)
6. PARTIAL LOADING:
Partial Loading of Unit or Stage-I/II or Station:
Partial Loading,(%) = (100 - Loading Factor in %)
EQUIPMENT PARTIAL LOADING,(%)
Equipment Partial Loading (%)of Unit, Stage-I/II or Station:
Loss of Generation of Unit, Stage-I/II or Station in MU for the ref. period
=----------------------------------------------------------------------------------------- x 100
Total rated Generation (MU) of Unit, Stage or Station for the ref. Period
excluding outage hours
7. GROSS HEAT RATE:

Gross Heat rate (Kcal/KWh) of the Unit, Stage-I/II, and Station is expressed as
follows:
Average GCV for the ref. Period (Kcal/Kg) x Total Coal Cons. (Kg) for ref. period
= ----------------------------------------------------------------------------------------------------Total Generation for the ref. Period (KWh)
Gross Heat rate (Kcal/KWh) of the Unit can also be expressed as follows:
Gross Turbine Heat Rate (Kcal/Kwh)
= ------------------------------------------------ x 100
Boiler Efficiency (%)
Where,

Heat input to Turbine (Kcal)


Gross Turbine Heat Rate = ----------------------------------------Generation at Generator terminal
Heat input to Turbine = [ Main Steam flow (Kg) x (Enthalpy at HP Turbine inlet

Enthalpy of FW at ECO inlet) + CRH Steam flow (Kg) x (Enthalpy at IP Turbine inlet Enthalpy at HP Turbine exhaust) + Super heater spray flow (Kg) x (Enthalpy at HP
Turbine inlet Enthalpy of S/H spray) + Reheat spray flow (Kg) x (Enthalpy at IP
Turbine inlet Enthalpy of R/H spray)]
Where, unit of enthalpy of steam and water is Kcal/Kg
Net Heat rate (Kcal/KWh) of the Unit, Stage-I/II, and Station is expressed as
follows
=

Gross Heat Rate (Kcal/KWh)


---------------------------------------- x 100
(100- APC in %)

The monthly / yearly average Gross Heat Rate shall be calculated by weighted average as
per the following formula
GHRi x KWhi
= ----------------------KWhi
Where,
GHRi = Gross Heat Rate (Kcal/KWh) of the ith day
KWhi = Generation (KWh) of the ith day

Note: For detailed calculation of Heat Rate, refer Efficiency Manual


8. SPECIFIC OIL CONSUMPTION (ml/KWh):
Specific Oil Consumption (ml/KWh )of Unit, Stage-I/II, and Station is expressed as follows:
Oil Consumption (KL ) for the reference period
= --------------------------------------------------------------------------------------------------Total gross generation (MU) of the Unit, Stage-I/II, Station for the reference period
9. SPECIFIC COAL CONSUMPTION (Kg/KWh):
Specific Coal Consumption (Kg/KWh) of Unit, Stage-I/II, and Station is expressed as
follows:
Coal Consumption (MT) for the reference period
= --------------------------------------------------------------------------------------------------Total gross gen. (MU) of the Unit, Stage-I/II, Station for the reference period x1000
10. AUXILIARY POWER CONSUMPTION,(%):
Aux. Power Consumption (%) of Unit, Stage-I/II, and Station is expressed as follows:
Aux. Power Consumption (MU ) for the reference period
= -----------------------------------------------------------------------------------------------*100
Total gross generation (MU) of the Unit, Stage-I/II, Station for the reference period
11. MAKE UP WATER CONSUMPTION ,% MCR:
Make up water consumption (% MCR) of Unit, Stage-I/II, and Station is expressed as
follows:
Make up water consumption ( MT) for the reference period
= -----------------------------------------------------------------------------------------------*10000
Total MCR capacity of boiler (MT/hrs) of Unit, Stage-I/II, Station x Ref. Period (hrs) x
A.V.F on bar of Unit, Stage-I/II, Station(%)
12. PLANNED OUTAGE:
a) Planned for the Unit (%)
Planned Outage Hours of the unit over the reference period
Planned Outage (%)= ------------------------------------------------------------------- x 100
Total hours in the reference period

b) Planned Outage for Stage-I Units, P1 (%)


Sum of the Planned Outage (%) of Stage-I Units
Planned Outage (%) = ------------------------------------------------------------Number of units of the Stage-I (N1)
c) Planned Outage Stage-II Units, P2 (%)
Sum of the Planned Outage (%) of Stage-II Units
Planned Outage (%) = ------------------------------------------------------------Number of units of the Stage-II (N2)
d) Planned Outage for Station, (%)
P1 x N1 x C1 + P2 x N2 x C2
Planned Outage(%) = -----------------------------------------------N1 x C1 + N2 x C2
Where,
P1 , P2 =Planned Outage(%) of Stage I & Stage-II respectively
N1 , N2 =
Number of Units of Stage I & Stage-II respectively
C1 , C2 = Capacity (MW) of units of Stage I & Stage-II respectively
13. FORCED OUTAGE
a) Forced Outage for the Unit (%)
Forced Outage Hours of the unit over the reference period
Forced Outage (%)= ------------------------------------------------------------------- x 100
Total hours in the reference period
b) Forced Outage for Stage-I Units, F1 (%)
Sum of the Forced Outage (%) of Stage-I Units
Forced Outage (%) = ------------------------------------------------------------Number of units of the Stage-I (N1)
c) Forced Outage for Stage-II Units, F2 (%)
Sum of the Forced Outage (%) of Stage-II Units

Forced Outage (%) = ------------------------------------------------------------Number of units of the Stage-II (N2)


d) Forced Outage for Station, (%)
F1 x N1 x C1 + F2 x N2 x C2
Forced Outage (%) = -----------------------------------------------N1 x C1 + N2 x C2
Where,
F1 , F2 = Forced Outage(%) of Stage I & Stage-II respectively
N1 , N2 =
Number of Units of Stage I & Stage-II respectively
C1 , C2 = Capacity (MW) of units of Stage I & Stage-II respectively
14. OUTAGE DUE TO COAL:
a) Forced Outage (F.O) due to coal for the Unit (%)

F.O (coal) (%)=

F.O (coal) Hours of the unit over the reference period


----------------------------------------------------------------- x 100
Total hours in the reference period

b) F.O (coal) for Stage-I Units, F1c (%)


Sum of the F.O (coal) (%) of Stage-I Units
F.O (coal) (%) = ------------------------------------------------------------Number of units of the Stage-I (N1)
c) F.O (coal) for Stage-II Units, F2c (%)

F.O (coal) (%) =

Sum of the F.O (coal) (%) of Stage-II Units


------------------------------------------------------------Number of units of the Stage-II (N2)

d) F.O (coal) for Station, (%)


F1c x N1 x C1 + F2c x N2 x C2
F.O (coal) (%) = -----------------------------------------------N1 x C1 + N2 x C2

Where,
F1c , F2c = F.O (coal) (%) of Stage I & Stage-II respectively
N1 , N2 =
Number of Units of Stage I & Stage-II respectively
C1 , C2 = Capacity (MW) of units of Stage I & Stage-II respectively
15. OUTAGE DUE TO GRID RESTRICTION:

a) Forced Outage (F.O) for the Unit (%)


F.O (Grid) Hours of the unit over the reference period
F.O (Grid) (%)= ------------------------------------------------------------------- x 100
Total hours in the reference period
b) F.O (Grid) for Stage-I Units, F1g (%)

Sum of the F.O (Grid) (%) of Stage-I Units


F.O (Grid) (%) = ------------------------------------------------------------Number of units of the Stage-I (N1)
c) F.O (Grid) for Stage-II Units, F2 (%)
Sum of the F.O (Grid) (%) of Stage-II Units
F.O (Grid) (%) = ------------------------------------------------------------Number of units of the Stage-II (N2)
d) F.O (Grid) for Station, (%)

F.O (Grid) (%) =

F1g x N1 x C1 + F2g x N2 x C2
-----------------------------------------------N1 x C1 + N2 x C2

Where,
F1g , F2g = F.O (Grid) (%) of Stage I & Stage-II respectively
N1 , N2 =
Number of Units of Stage I & Stage-II respectively
C1 , C2 = Capacity (MW) of units of Stage I & Stage-II respectively

6.0

MONITORING SYSTEM

Daily monitoring of plant performance is given a very high importance by top executives
starting from Managers to Director (Operations). Monitoring and reporting is to be carried
out systematically and interfaced properly so that the instructions issued reaches to the
concerned working engineers and are reported back for their compliance.
Generally, the executives at following level are doing monitoring of plant performance:
STATION LEVEL

REGIONAL LEVEL

CORPORATE LEVEL

Head of the station

ED (Region)

D(O)

Head of O&M

Group Heads of Regional ED(OS)


OS

Head of Operation

HOD-Control Room

Head of Maintenance

All Group
Heads
Corporate OS
HOD-Fuel Management

Head of Fuel Management

of

HOD-Control Room

Head of EEMG
Head of MTP
Head of Chemistry
Shift Charge Engineers
The following parameters are to be monitored at all levels by different groups:
Sl
No.
1.

Issues

Parameters to be monitored

AB T
Gap Generation schedule Vs actual generation
analysis
Shortfall in declared DC against possible DC on daily basis
Shortfall in actual generation w.r.t 101% of declared DC
Generation bottleneck upto 105% of DC
Opportunity matrix for UI Analysis
Timely communication with RLDC during outage and restoration of unit

Sl
No.
2.
3.

Issues

Parameters to be monitored

Shortfall in MOU target w.r.t generation, availability, heat rate etc.


MOU
Targets Gap
Analysis
Efficiency
Heat Rate of the units, Specific Oil consumption, Aux Power
monitoring
Gap Analysis Consumption etc.
Operational parameters affecting unit efficiency. Operation of equipments
at rated parameters.
Timely execution of all efficiency tests

4.

Implementation of the recommendations of the efficiency tests. (At


running condition, short shutdown & overhaul)

F or c e d
Outage Gap Major reasons for loss in Availability factor
Analysis
Unit tripping , its analysis ,implementation of the recommendations

Multiple unit tripping, its analysis and implementation of action plan to


prevent recurrence
Implementation of the recommendations of Operation Services, Engg. and
various committees
Time taken for unit start up & difficulties experienced
Quality of Maintenance covered under forced outage
Proper follow up of re-commissioning checklist

5.

Updating of re-commissioning checklists as per experience based on last


outages

Maintenance
Quality of Maintenance covered under forced & planned outage
Quality
Improvement
Duration of Maintenance covered under planned & forced outage
Quality compliance as per guidelines/standard checklists
Updating of checklists based on last overhaul or outages.

Re-commissioning activities of equipments and unit after overhaul


Identification of Major failure/incident after overhaul

Sl
No.
6.

Issues

Parameters to be monitored

Preparedness
for Overhaul Availability of spares & consumables ,finalisation of contracts
Scope of work for forthcoming overhaul
Testing of tools & tackles

7.
8.

Overhauling
cost
Maintenance
Management
System:

Availability of Bar chart, Engg. declaration, recommissioning checklists


Overhauling Cost
Availability of equipments and status of reserve auxiliaries
Healthiness of instruments (Control Room, Local field devices, On line
Analysers etc.)
Monitoring of Equipments where repeated failures occurring
Strict Compliance to PTW / WOC system
Healthiness of OLMS : (On Line Maintenance Management system )

9.

System
Compliance
Status:

Condition monitoring of equipment


Implementation of Technical Compliance System
Periodic checking
availability

of protections and interlock system to ensure

Equipment Testing / change over schedule


Compliance to environment regulation and requirements
Implementation of recommendations of O&M Conference / Work shops
/Various committees etc
Compliance of Statutory requirements/ license
Compliance of Ash dyke inspection schedule
Compliance with Energy conservation norms

10.

Safety:

Monitoring of environmental parameter emission and meteorological data


Availability of fire fighting equipments/ systems and protection
Adequacy of fire fighting pump pressure at furthest & highest point

Sl
No.

Issues

Parameters to be monitored
Healthiness of all mulsifier systems on auto (Transformers, MOT etc)
Cleanliness of the units including hazardous and non hazardous waste
disposal
Testing of Tools & Tackles
Over speed test of Turbine & TDBFP
Compliance to all statutory requirement/ license
Healthiness of structures & Machine foundation
Monitoring of hydrogen generation plant

11.
12.
13.
14.

Fuel
Oil
Status of fuel oil consumption and stock
status
Coal status
Status of coal consumption and stock
Water status
CW forebay level, raw water consumption & availability
Chemistry
Quality of make-up water and clarified water
Consumption and stock of chemicals
Timely execution of all tests & samplings
Monitoring of results of all chemical tests. Chemical regimes of boiler
water & steam.
Lubrication report

15.

Operation:

Corrosion, scale formation, deposition in equipments


Boiler light up, Turbine rolling, Synchronisation of units as per standard
start up curves/procedures
Operation of unit with all protections in service
Availability checking of standby equipments & testing of equipments
Operation of unit and equipments at rated parameters
Proper isolation of equipments for issuing permit
Immediate reporting of any defect via WOC
Compliance of the recommendations of Chemistry, Efficiency &
Maintenance group

Sl
No.

Issues

16.

Environment
&
Ash Compliance to Environmental norms, % of ash utilisation
unitlisation:
R&M related R&M related activities
activities
Others
Benchmark with other projects

17.
18.

Parameters to be monitored
Activities of all three shifts for providing decision support to shift charge
engineers

Status of Computerization
Implementation status of SMART ( Strategic Monitoring Assistance
Remote Terminus)
Cost reduction by different productive means
Implementation of ISO standards
Availability of trained manpower
Training of employees
Proper dissemination of knowledge & Creation of Knowledge Team
Proper co-ordination with all maintenance groups in site
Proper coordination with RLDC, Corporate OS, Regional OS

19.

Documentati
on:

Proper Data entry in the Operational Parameter performance monitoring


System (OPPMS) for generating MIS
Availability of documents related for emergencies like Grid
Failure,Hydrogen gas leakage,Leakage of turbine oil,Failure of D.C
supply, Failure of instrument Air,Fire & Accidents.
Availability of system manuals, write up, technical papers etc.
Availability of standard checklists, Recommissioning checklists etc.

7.0

REPORTING AND LOGGING SYSTEM

STATION LEVEL:
REPORTING TO HEAD OF STATION/ HEAD OF O&M
1. Head of the station and Head of O&M are briefed by the shift charge engineer in the
morning about the performance of the station.
2. Head of Energy & Efficiency monitoring group (EEMG) gives a report in which a brief
explanation of the performance deviations w.r.t set norms and target are provided at 9.30
Hrs daily.
3. Head of the station takes half an hour meeting in the morning where he discusses the
performance , plant problems, gap analysis with respect to generation,101% generation of
declared capability, units capability of 105% generation of declared capability for some
blocks with senior executives consisting of:
a)

Head of O&M

b)

Head of Operation

c)

Head of EEMG

d)

Head of Maintenance

e)

Head of Maintenance Planning

f)

Head of Chemistry

4. The decisions taken during the meeting by GM are conveyed to respective sections for
implementation and non-compliance of the instructions are informed by Head of EEMG
to GM, where upon GM may take necessary action.
5. GM attends daily planning meeting occasionally.
A) ENERGY & EFFICIENCY MONITORING GROUP (EEMG):
The following reports are generated by station Energy & Efficiency Monitoring group.
EEMG department informs the concerned department for taking corrective actions.
Reports:
1. Heat Rate deviation of all units on daily basis
2. Efficiency test reports
3. ABT Gap analysis report
4. Other Commercial report
5. Parameters defect list

6. Daily Flash Report to Corporate OS


7. Report for Major Happenings to Corporate OS
8. Reports for ROPR to Corporate OS
9. Daily detailed report
10. Monthly report
11. Annual Report
12. Unit Trip Report
13. Critical Parameters deviation report
14. Other reports
Note : Format for Monthly Report for Coal station is given in annexure- XV
Format for daily Flash report is given in Annexure-XX
Report for major happening is given in Annexure-XXI
Daily Detailed Report is given in Annexure-XXII
B) CHEMISTRY DEPARTMENT:
The following reports are generated by station chemistry department. Chemistry department
informs the concerned department for taking corrective actions.
1. Report on Make up water consumption.
2. Report on Chemical consumption.
3. Report of steam/water chemical Regimes.
4. Report on analysis of Coal.
5. Report on analysis unburnt carbon in Ash.
6. Report on Coal mill fineness.
7. Report on analysis of Turbine lubricating oil/ FRF.
8. Report on analysis of Raw water, Clarified water, soft water, and cooling water.
9. Report on analysis of Flue Gas.
10. Report on analysis of Hydrogen Gas.
11. Report on Effluent water quality.
12. Report on Environment monitoring.
Note:Testing frequencies shall be as per Code of practice on power plant chemistrydocument no. COS-ISO-00-OGN/OPS/CHEM/015 Rev. No. : 0 October 2003.
Note; Refer Annexure-XXIII to XXXIII for the required formats.
C) OPERATION SHIFT PERSONNEL:
During the shift the following personnel write the log book/log sheet.

a)

Shift Charge Engineer.

b)

Assistant Shift Charge Engineer.

c)

Unit Controller.

d)

Desk Engineer

These officers will not duplicate the recording of events.


a) Shift Charge Engineer - Shift Charge Engineer logs important parameters and important
station happenings.
b) Assistant Shift Charge Engineer - ASCE records happenings in more detail in their
respective areas.
c) Unit Controller- Unit Controller writes happenings and performance details with respect
to his own unit.
d) Desk Engineers - Desk Engineers fill log sheet of concerned desk & writes logbook in
Boiler/Turbine/Generator area in detail.
Operation desk engineers will take out the print out of all process parameters on two
hourly basis and will scrutiny them to determine any deviations in the parameters and will
take necessary actions accordingly.
In addition to logging of the events, the above officers will also record important
information about the station equipment and unit in the check list.
During shut down of unit, parameters are to be monitored till the turbine temperature
comes down to 120 deg C and also during start up of the unit parameters are to be
monitored continuously till the stabilisation of the unit.
D) CHP & MGR DEPARTMENT:
The following reports are generated by station CHP & MGR department
Reports:
1. Availability of coal
2. Availability of equipments
3. MGR Rack status
4. Other reports

8.0 FUNCTIONS OF DIFFERENT DEPARTMENTS


STATION
A) ENERGY AND EFFICIENCY MONITORING GROUP (EEMG):
EEMG is the focal point of monitoring the systems in a plant and would interface information
& action. EEMG keeps Head of Station & Head of O&M continuously informed. EEMG
highlights system deficiencies & improvements required.
Requirement for EEMG Cell
1. It is to be ensured that Head of EEMG Cell should have handled shift operation as Shift
chare engineer or Unit Control Engineer and should have the Mechanical background.
2. Other executives in EEMG Cell also should have Mechanical background with M Tech
and the experience of shift operation.
3. Executive strength will vary depending upon the size of the plant.
FUNCTIONS OF EEMG:
1. Data collection, compilation & record keeping.
2. Preparation of daily & monthly performance reports.
3. Investigation of unit outages, major happenings.
4. Compilation of code of practice for emergencies.
5. Co-ordinate operation requirements with maintenance.
6. Assess and up date the knowledge & competency of operation staff through Training Cell
and coordinate training needs.
7. Prepare check lists, log sheets, log books etc.
8. Perform efficiency tests periodically.
9. Interact with OS department in respect of O&M problems of station.
10. Combustion monitoring &control.
11. Checking oft all instruments for healthiness & calibration.
12. Monitor consumption of coal and oil, coordinating calibration of coal feeders, belt
weighers, integrators, flow meters and energy meters for accurate measurement.
13. Coordinate for preparing & monitoring the Availability Schedule of the units.
14. Provide MIS support to top management on ABT calculations & commercial aspects.
15. Provide statutory data to various government agencies as per corporate directive.

16. Coordinate with REB and CEA boards.


17. Conduct unit tripping analysis
18. Coordinate coal survey/audit.
19. Perform efficiency tests before & after Overhaul and ensure the implementation of the
recommendations.
20. Coordinate for carrying out PG tests.
21. Ensure the implementation of POG recommendations.
22. Perform Efficiency tests in association with CENPEEP.
23. Implement State of the art technologies.
24. Highlight Generation deviation, Heat Rate deviation, Temperature excursion etc. in Daily
Planning Meeting.
25. Obtain boiler license, hydrogen plant license and high pressure vessel license from
various licensing authorities.
26. Analyse data with respect to declared capacity, schedule and frequency.
27. Provide details of losses/gains on day to basis in line with ABT norms in the Daily
Planning meeting.
28. Liaison with RHQ, Corporate OS and Commercial department, RLDC,REB and CERC.
CENTRE FOR ENERGY EFFICIENT TECHNOLOGY & ENERGY
MANAGEMENT (CEETEM )
1. Coordinate energy audit and energy balance of plant and equipment.
2. Monitor plant equipment for energy conservation purpose.
3. Coordinate technological promotion of non-conventional sources of energy.
4. Ensure implementation of statutory requirements of energy conservation measures.
5. Coordinate the energy conservation awareness program.
6. Introduce energy efficient devices in place of old and obsolete technology.
7. Ensure monitoring of coal-oil-water-steam and electricity for purposes of energy
conservation.
B) FUNCTIONS OF OPERATION
The responsibility of each of the operation staff shall be defined and clear cut instructions
issued for:
1. Analysis of DC,SG & AG
2. Analysis of reason for shortfall in declared DC against possible DC on daily basis
3. Analysis of reason for shortfall in actual DC w.r.t 101% of declared DC.

4. Analysis of reason for shortfall in unit capability (105%)


5. Efficient, safe, reliable operation of units.
6. High availability and dispatch as per ABT schedule.
7. Normal running, emergency handling and lining up activities of the Unit.
8. Checking of important protections, availability of emergency system supply /equipment
and reserve auxiliaries.
9. Boiler light up, Turbine rolling, Synchronisation of units as per procedures & curves.
10. Operational planning for unit start up and shutdown.
11. Coordination with Maintenance teams for emergency and for planned and breakdown
maintenance.
12. Coordination with MTP, EEMG and CHP.
13. Safety of men and equipment.
14. Data entry in the Operational Parameter performance monitoring System (OPPMS) for
generating MIS.
15.

Clear cut instructions shall also be issued for emergencies like:


a)

Grid Failure.

b)

Hydrogen gas leakage

c)

Leakage of turbine oil.

d)

Failure of D.C supply.

e)

Failure of instrument Air.

f)

Fire & Accidents.

FUNCTIONS OF SHIFT CHARGE ENGINEER


Shift Charge Engineers (SCE) shall carry out the following functions:
1. SCE ensures commercially efficient, safe, reliable and profitable operation of plant.
2. SCE ensure high availability and dispatch as per ABT schedule.
3. Coordinate with maintenance teams for emergency and for planned and breakdown
maintenance.
4. Coordinate with MTP, EEMG and CHP to ensure seamless operation of the power plant.
5. SCE manages real time coordination with RLDC and OS Control room to maximize
commercial profit of the station.

6. SCE Communicates instructions to Unit Controllers and Desk engineers relating to


generation, efficiency, emergency happenings, outages, light up & synchronization of unit
and permits to be issued.
7. SCE issues Hot Permit where there is possibility of fire.
8. SCE participates in the Daily Planning Meeting and highlights operational issues.
9. SCE monitors the compliance of daily change over schedule & availability checking
of emergency equipments like Turbine LOP, DC, LOP,DG set etc.
10. SCE participates in the Overhauling meeting .
11. SCE scrutinizes Walk Down Check Lists of various areas where abnormality is noted
down such as abnormal sounds, abnormal temperatures, abnormal vibrations or any
possible safety hazards.
12. SCE reports major happenings to Head of Station, Head of O&M, Head of Operation etc.
in each shift.
13. SCE monitors stack emissions and maintaining pollution free environment at plant.
14. SCE prepares Daily Generation Report.
FUNCTIONS OF GENERAL SHIFT OPERATIONS
General Shift Engineers shall carry out the following functions:
1. Monitor the hydrogen plant operations.
2. Monitor inventory of hydrogen cylinders, carbon di-oxide cylinders, nitrogen cylinders.
3. Coordinate with shift charge engineer for routine operations and trouble shooting.
4. Assist the shift operation engineers during emergencies, unit start up & planned
shutdown.
5. Monitor the operation of dirty/clean turbine transfer oil pump & also transferring oil to
MOTs.
6. Ensure adherence to safety, environment and other statutory norms.
7. Monitor housekeeping.
8. Coordinate for commissioning of R&M packages/new system.
9. Coordinate the overspeed testing of Main Turbine & TDBFPs.
10. Ensure the healthiness of ESP systems, soot blower systems.
11. Monitors the operation of On Load Condenser Cleaning system.
12. Assist in isolation of interconnected systems for issuing PTWs.
13. Monitor the unloading of fuel oil.

14. Monitoring the Air Conditioning System.


15. Monitor ISO related activities and documentation (Recommissioning & different check
lists).
C) FUNCTIONS OF CHEMISTRY DEPT.
Chemistry department shall carry out following functions:
1. The information regarding water, steam, oil, flue gas, bottom/fly ash, coal, CPU,
stator water, hydrogen purity etc., shall be reported to Shift charge engineer of each
unit for taking necessary action on the basis of advice given by the chemist.
2. Chemist will sent all observations and his instructions/recommendations with regard
to followings reports through LAN system and hard copies. Special/ emergency report
or advice shall be given on phone to respective units.
a)

Daily report on Steam-water cycle parameters*.

b)

Generator hydrogen purity, dew point.

c)

Stator water analysis.

d)

Flue gas analysis.

e)

Lubricating oil/FRF analysis.

f)

Coal as fired, Coal mill fineness/ mill rejects, bottom/fly ash analysis.

g)

Dissolved gas analysis.

h)

CPU operation

3. Monitoring of chemical parameters in the power station and ensuring they are within the
limit.
4. Fugitive emission monitoring and meteorological data monitoring.
5. Combustion monitoring, lub oil quality monitoring.
6. Water Treatment Plant (WTP) operation- PT plant, DM plant, Softening plant, and
Chlorination plant.
7. Monitoring the healthiness of instruments (Chemical Lab).
8. Monitoring the healthiness of on-line chemical analyzers of the units.
9. Monitoring of corrosion, scale formation, deposition, and biofouling in CW system.
10. Monitoring the stock/consumption of chemicals.

11. Daily check on the DM water and chemical consumption. Reasons for high make up
water and chemical consumption to be highlighted.
12. Check quality of make-up water and clarified water.
13. Interactions with Shift charge engineer to ensure that instructions issued by Chemistry
department have been carried out.
14. Give a check to all test results once in a day.
15. Operation of Condensate Polishing Units.
16. Check quality of lay-up solution for boiler/feed/condensate during preservation.
D) FUNCTIONS OF ELECTRICAL MAINTENANCE:
Electrical Maintenance department shall carry out following functions:
1. Ensure high availability of all electrical equipment and systems in the power plant
2. Minimise cost of maintenance of the plant and optimise equipment life cycle cost.
3. Supervision of maintenance measures in electrical maintenance and ensuring quality of
maintenance.
4. Ensure availability of spares and other infrastructure for maintenance.
5. Minimise response time to the Operation department for handling routing day to
problems.
6. Ensure compliance with safety and statutory requirements.
7. Ensure compliance of all electrical testing.
8. Optimise Mean Time between Failure (MTBF) and Mean Time to Repair(MTTR)
9. Plan resource requirements-manpower, materials and contracts.
10. Coordination with R&M for equipment upgradation and coordination with OS and
Engineering.
11. Identification of root cause of problems and repair/modification of the system to avoid
recurrence.
12. Maintain equipment wise records and documentation e.g failure history.
13. Ensure compliance with safety requirements.
14. Ensure maintenance and health of the Fire Protection systems.
15. Record keeping of equipment history.

E) FUNCTIONS OF MECHANICAL MAINTENANCE


Mechanical Maintenance department shall carry out following functions:
1. Ensure high availability of all mechanical equipment and systems in the power plant
2. Minimise cost of maintenance of the plant and optimise equipment life cycle cost.
3. Supervision of maintenance measures in mechanical maintenance and ensuring quality of
maintenance.
4. Ensure availability of spares and other infrastructure for maintenance.
5. Minimise response time to the Operation department for handling routing day to
problems.
6. Ensure compliance with safety and statutory requirements.
7. Ensure compliance of all testing of tools & tackles and equpments.
8. Optimise Mean Time between Failure (MTBF) and Mean Time to Repair(MTTR)
9. Plan resource requirements-manpower, materials and contracts.
10. Cordination with R&M for equipment upgradation and coordination with OS and
Engineering.
11. Identification of root cause of problems and repair/modification of the system to avoid
recurrence.
12. Maintain equipment wise records and documentation e.g failure history.
13. Ensure compliance with safety requirements.
14. Ensure compliance with statutory requirements like insurance, industry acts and ISO.
15. Ensure maintenance and health of the Fire Protection systems.
16. Record keeping of equipment history.
17. Reclamation of spare parts.

F) FUNCTIONS OF C&I MAINTENANCE


C&I department shall carry out following functions:
1. Ensure high availability of all C&I systems.
2. Minimise cost of maintenance and optimise equipment lifecycle cost.
3. Supervision of maintenance measures in C&I.
4. Ensuring healthiness of C&I Lab instruments and compliance of all tests.
5. Minimise response time to the Operation.

6. Optimise Mean time Between Failure (MTBF) and Mean Time To Repair (MTTR)
7. Network with other C&I maintenance teams in the plant and at other locations to capture
learning.
8. Coordination with shift operations for ensuring efficient plant operations.
9. Coordination with R&M for equipment upgradation.
10. Ensure compliance with ISO.
11. Ensure safety of people & equipment involved in maintenance procedures.
G) FUNCTIONS OF MAINTENANCE PLANNING DEPARTMENT
Maintenance Planning department shall carry out following functions:
1. Formulate plant maintenance policy and strategy to serve corporate objectives.
2. Coordinate maintenance planning activity at the plant.
3. Ensure cost efficiency and bring about cost reduction in the plant through spare parts cost
reduction, inventory control and planning.
4. Ensure adherence to safety, environment, energy conservation and regulatory norms.
5. Benchmark with other projects to find areas for improvement.
6. Ensure timely availability of materials, tools and tackles for overhauling and breakdowns.
7. Monitor the preparedness through OPI.
8. Coordinate meeting with all maintenance departments for job and material planning on
daily basis for overhauling.
9. Prepare annual and 5 year rolling plan of overhauls and pre-overhauling preparations for
material and contracts.
10. Forced shutdown planning and coordination
11. Monitoring of job progress and preparation of MIS on major equipment history,
performance and failure analysis
12. Spare parts development.
13. PTW system management.
14. Maintain record of documentation including drawings of the parts to be developed.
15. Condition monitoring of the plant equipment and maintaining records thereof.
SPARE PARTS PLANNING AND DEVELOPMENT:

Ensure cost efficiency and bring about cost reduction in the plant through spare parts cost
reduction, inventory control and planning.

Coordinate development of spare parts as per the SPD policy.

Ensure timely availability of materials, tools and tackles for overhauling and breakdowns.

Financial budgeting for O&M departments including annual plans for contract jobs and
material.

Planning and coordinating requirement of critical spares and contracts for various
maintenance activities.

Review and control indents for all operations and maintenance spares.

LONG TERM STORAGE OF POWER PLANT AND EQUIPMENTS:


A lot of high value critical spares are being procured by all operating stations to be used
during shutdown/overhaul periods. It is essential that all theses spares, which are procured are
stored and preserved in a proper way for ready and purposeful use to meet station's
requirement. The implementation of storage and preservation instructions is to be monitored
for adherence. Further, the following need to be implemented strictly:
1. Storage and preservation instructions given by manufacturers /suppliers shall be fully
followed and any revisions in their instructions/recommendations shall also be followed
if and when revised.
2. Spares should be kept in special categorized stores as envisaged.
3. Periodic inspection of these stores in regard to the adherence to storage and preservation
instructions are to be ensured.
4. To check the implementation of all the storage and preservation procedures, audit is to be
carried out to ensure the compliance of the procedural requirements.

H) FUNCTIONS OF FUEL MANAGEMENT GROUP:


Fuel Management department shall carry out following functions:
1. Ensure continuous supply of fuel by coordination with Coal companies, Railways etc.
2. Effective Operation of CHP & MGR.
3. Feeding of cleansed coal to bunker in required quantity.
4. Ensure Safety & housekeeping of coal handling plant and MGR.
5. Maintain Fuel inventory.
6. Management of coal stock yard.

7. Ensure preventive measures for fire hazards


8. Ensure the availability of equipments
9. Ensure the availability of protection and interlock system.
10. Ensure high conveyor utilisation factor.
11. Optimisation of operation of CHP conveyor system
The main functions of MGR Operation at NTPC are:
1.

Movement of empty and loaded trains between loading station near coal mines to unloading
station at NPTC safely.

2.

Monitors closely the running timings of a rake.

3.

Ensuring the availability of empties at loading station.

4.

Ensuring the unloading of wagons safely in the least possible time.

5.

Maintaining of statistics of coal receipt on hourly basis for management feed back.

6.

Co-ordination with Indian Railways for receipt of coal through railway wagons during
emergencies.

7.

Movement of oil rakes and other stores consignment to the unloading sites and clearing the
empties to exchange yard.

8.

Co-ordination with maintenance wing of MGR department for keeping the rolling stock, track
and signal system in healthy condition for safe working of trains.

9.

Co-ordination with coal coordination wing for day to day planning of train movement to the
different loading points on the feed back of availability of coal.

10.

Co-ordination with coal handling plant for early clearance of the coal from track hopper and
enabling CHP to plan for stocking of the coal during excess receipt and reclaiming during
shortfall.

12.

Co-ordination with main plant operation to enable them to plan for generation.

13.

Co-ordination with C&I department for weight bridge calibration for correct weighment.

14.

Co-ordination with Chemistry department for quality check.

I) FUNCTIONS OF R&M
R&M department shall carry out following functions:
1. Identify renovation and modernisation projects and prepare proposals in association with
the concerned departments and put up for approval.

2. Prepare estimate and specifications for various phases of the project.


3. Coordinate with OS, Engg and corporate R&M for approval.
4. Prepare discussion and proposal documents for NTPC board and CEA.
5. Prepare budget for R&M project.
6. Provide MIS support to OS for monitoring R&M implementation and providing
information to CERC.
7. Monitor projects under implementation.
8. Provide MIS support for the capitalization of implemented proposals.
J) FUNCTIONS OF O&M CIVIL DEPARTMENT:
O&M Civil department shall carry out following functions:
1. Carry out regular inspection and maintenance of all structures, machine foundations,
sanitation and horticulture work.
2. Carry out regular inspection and maintenance for any water seepage.
3. Ensure regular maintenance of ash dyke/mound
4. Ensure healthiness of plant drainage systems
5. Ensure measures for preventing flood.
6. Coordinate coal stack verification.
K) FUNCTIONS OF ENVIRONMENT MONITORING GROUP (EMG):
Environment Monitoring Group (EMG) shall carry out following functions:
1. Ensure monitoring of and compliance with environment norms.
2. Analyse deviation in environmental parameters, if any and take corrective actions.
3. Conduct programs on environment training
4. Implement ash water re-circulation, ash pond reclamation etc.
5. Ensure compliance with air and water consents
6. Manage regular and timely compliance of solid waste management, sanitary waste
management and authorization for handling hazardous and biomedical waste.
7. Ensure compliance with MOEF and ISO.
8. Cordinate environmental and scientific studies.
9. Cordination with external agencies and statutory authorities.

L) FUNCTIONS OF ASH UTILISATION GROUP:


Ash Utilisation Group shall carry out following functions:
1. Ensure Ash utilization as per MOU targets.
2. Optimise cost of ash utilisation
3. Marketing of ash and ash based products in different sectors.
4. R&D and product development of ash based products.
5. Coordinate with Corporate and External agencies.
M) FUNCTIONS OF EDP AND COMMUNICATION
EDP Group shall carry out following functions in O&M area:
1. Ensure implementation of the IT strategy at Operation & Maintenance area.
2. Ensure operation of SMART ( Strategic Monitoring Assistance Remote Terminus)
3. Ensure healthy operation of software implemented in O&M.
4. Ensure healthiness of SATCOM and EPABX.
5. Increase computer literacy level of O&M personnel by organising IT training.
FUNCTIONS OF REGIONAL OPERATION SERVICES
All activities of Operation Services revolve around following key parameters:
1. Generation Control
Generation scheduling & coordination with external agencies
2. Operation Support
Support stations in terms of monitoring, expert assistance, developing initiatives,
implementing initiatives.
3. Maintenance Management
Assist in Maintenance development & implementation of new initiatives
4. System & Compliance
Develop and update systems and ensure compliance.
5. O&M Budgeting and Monitoring
Collate and review O&M budgets
6. R&M Planning
Plan and monitor Renovation & Modernisation initiatives.
7. Project Support

Support project activities like Commissioning, Stabilisation, PG test, Equipment


finalisation.
Regional Operation Services shall carry out following functions:
1. Discuss with all stations regarding major issues on daily basis.
2. Discuss the different O&M issues of the plants in the daily morning meeting at the
Regional Head Quarter.
3. Conduct ORT and follow up the action plan
4. Participate in PRT.
5. Analyse the trip reports of the units and follow up the implementation of the
Site/Corporate OS Trip Committee recommendations.
6. Analyse the major failures of equipment/boiler tube failure of the units and follow
up the implementation of the action plan
7. Analyse any deviation in the generation of the units & load flow in all the
transmission lines of the stations in the Control room.
8. Carry out ABT Gap analysis of all stations and follow up the action plan
9. Carry out MOU Target Gap analysis of all stations(Operational & Financial) and
follow up the action plan
10. Carry out Forced outage gap analysis and follow up the action plan
11. Participate actively in the progress of unit overhauls and extending help.
12. Monitor the progress of new projects.
13. Conduct of Efficiency tests of the station and follow up the implementation of the
site/Corporate OS/CENPEEP recommendations
14. Co-ordinate with RLDC for fixing the load schedule of all plants of the region.
15. Co-ordinate with state /statutory authorities.
16. Attend OCC meeting highlighting operational issues.
17. Participate in the Efficiency tests, PG tests etc conducted by CENPEEP.
18. Participate in Technical Audit/Technical Compliance audit of the stations.
Please refer to the latest OS restructuring guidelines for more details.

FUNCTIONS OF CORPORATE OS
All activities of Operation Services revolve around following key parameters:
1. Generation Control
Generation scheduling & coordination with external agencies
2. Operation Support
Support stations in terms of monitoring, expert assistance, developing initiatives,
implementing initiatives.
3. Maintenance Management
Assist in Maintenance development & implementation of new initiatives
4. System & Compliance
Develop and update systems and ensure compliance.
5. O&M Budgeting and Monitoring
Collate and review O&M budgets
6. R&M Planning
Plan and monitor Renovation & Modernisation initiatives.
7. Project Support
Support project activities like Commissioning, Stabilisation, PG test, Equipment
finalisation.
Role of Operation services is as follows:
01. Provide technical support to NTPC Power Stations.
02. Work out technical solution for identified problems.
03. Collect information regarding proven solution & best practices and provide to the rest of
the stations.
04. Analyse the feasibility of adopting state of the art technology, new technologies and
implement in the stations.
05. Ensure that systems envisaged are developed, implemented and complied by the stations.
06. Monitor various performance parameters of the station to meet all corporate information
needs.
07. Develop systems, standards & policy, guidelines under Technical Compliance system.
08. Assist NTPC stations in R&M activities.
09. Carry out ABT Gap analysis of all stations and follow up the action plan

10. Carry out MOU Target Gap analysis of all stations(Operational & Financial) and follow
up the action plan
11. Carry out Forced outage gap analysis and follow up the action plan
12. Assist the station in trouble shooting.
13. Analyse the Trip reports.
14. Prepare Overhauling scheduling
15. Participate actively in the overhauling activities of the units.
16. Develop Overhaul guidelines & supervision
17. Develop new maintenance strategies.
18. Assist stations in commissioning/stabilisation activities
19. Ensure compliance of safety, environmental, statutory requirement/license.
20. Conduct periodic Technical Audit
21. Coordinate PG tests.
22. Initiatives for efficiency improvement
23. Develop efficiency and cost improvement solutions.
24. Provide necessary Management information to Director (Operations)
25. Provide necessary information to external agencies like Ministry, CERC, CEA etc.
26. Coordinate with regulatory interface activities.
27. Review budget & expenditure monitoring
28. Develop new inventory and procurement strategies.
29. Drive for implementation of new initiatives at stations.
30. Improve data capture to include component / activity level data.
31. Coordination for fuel.
32. Initiatives for safety activities
33. Provide required input to Corporate Engineering, Quality Assurance etc.
34. Provide required feedback to the Commercial department for fixation of tariff.
35. Provide required feedback to Consultancy department.

Please refer to the latest OS restructuring guidelines for more details.

F
E
E
D
B
A
C
K

FROM:

Prepare ORT Agenda &


forward to station 5 days

OS Control Room
Performance report of all
NTPC stations.

Feed back about major


incidents / issues of NTPC
stns. for the month & any
specific issue related to the
station.

OS Specialist Groups

various Action Plans/

Updated status of

Updated status of various


Regional HQs
Action Plans/ issues
raised in ORT.

Updated status of various


Action Plans/ issues
Updated
status
of
raised in ORT.
various Action Plans/
issues raised in ORT and
Guidelines/
policy
issues, if any.

CORPORATE CENTRE
OS ENGG. C&M FMG

INPUTS

PREPARATION
(By Regional OS Team
consisting 3-4 members)

NTPC

Discuss performance / feedback of


NTPC stations and Guidelines, policy
matters, if any.

Discuss with Head of Station, Head of O&M,


Group Heads etc. regarding Target setting,

Check personally the systems/ aspects


mentioned specifically in ORT format.

Conduct Tech. Audit of Maint. System,Safety


system & two other areas every month.

Visit various plant locations & verify eqpt.


Healthiness, Safety, Housekeeping etc.

Collect: Tube failure details / POG & other


committee reports and Action Plan Analyse

Collect: Outage/Trip Reports & status of


Action Plan Analyse / Verify

Collect: Updated status of all action plans


mentioned in ORT format Analyse / Verify

Finalise Action Plans for all issues


discussed. Review the status of earlier

Discuss other issues as per Agenda.

Discuss findings of ORT Team during


site visits & audits.

Discuss safety issues, O&M / Critical


issues and O&M Cost Reduction.

Review Planned Maint. preparation &


adequacy of scope of work.

Discuss strategies for achieving less


than 1% Forced Outage.

Discuss Tube failure/Eqpt.failure with


OS / R&D reports and Action Plan.

Identify /discuss constraints for full


load gen. and prepare Action Plan.

Collect: ORT related report from various


depts.- Analyse / Verify
Collect: Efficiency Reports, reports regarding
planned maint. prepardness - Analyse

Review Monthly/yearly Perf.of the stn.


Focus on Forced Outage, Partial
Loading,
Efficiency,
Commercial
aspects etc. Prepare Action Plan

Collect: Monthly Performance Reports from


station O&E dept. - Analyse

ORT MEETING
Chaired by GM (Station)
(Before 10th of every month).

ORT PROCESS FLOW CHART


PRE-ORT
(By ORT team, at site 3 days before ORT meeting)
Methodology: Data collection, discussion, site visits..

9.0 OPERATION REVIEW TEAM (ORT)

Regular Monitoring of
Action Plans and
highlighting of
exceptions by ORT
Coordinator.

Implementation of
Action plans at Station,
Regional and Corporate
levels. levels.

Due diligence of ORT


reports and Action plans
at station, RHQ and CC.

Put up Exception report


of ORTs of all stations
to ED (OS) and D (O)
by COS before 17TH.

(next day).

Preparation
and
forwarding of exception
report to Regional ED
and Corporate OS

Preparation & Issue of


ORT minutes on station
LAN (next day) and
distribution to other
stations, Regions & CC
(by ORT coordinator).

POST-ORT
(Preparation of Minutes,
Follow up of action plans

GUIDELINES FOR CONDUCTING ORT:


A.
CONSTITUTION OF ORT TEAM:
Constitution of ORT Team (Regional OS) for the month consisting of 3 or more members
Information to Site regarding Agenda in advance
B.

CAPTURING OF INFORMATION BY ORT TEAM:

a) Monthly performance data of NTPC units


b) Major failures of NTPC units during the last month
c) Critical analysis of Station issues by Corporate OS Specialist groups
d) Status of Action plan of Technical audit
e) Status of Action plan of Peer Committee or any other committee
f) Issues from various sources like Ministry, CERC, different committees etc. to make an
action plan
g) Status of different issues pending with various department of Corporate Centre.
h) Identification of specific area of Technical audit to be deliberated in ORT.
C.

VISIT OF ORT TEAM:

Visit of ORT Team to Site 2 to 3 days before the date of conductance of ORT.
D.

ACTIVITIES BEFORE CONDUCTANCE OF ORT

a) Meeting with Head of Station/O&M & apprising different issues


b) Analysis of Station monthly reports with respect to targets Vs performance, reason for
shortfall, constraints, deviation.
c) Collection of information from different departments as defined in ORT report and
analyze for any deviation
d) Random inspection of different areas of the plant for any discrepancy
e) Inspection of the safety systems as per ORT format & generation of exception.
f) Technical audit of the specific area as identified.
E.

CONDUCTANCE OF ORT
a) Discussion & Analysis of all the issues as defined in ORT
b) Discussion of the issues already identified by ORT Team
c) Discussion of the problem of station faced during the last month
d) Review of action plan of Technical Audit & other audits.

e) Discussion of the deviation as highlighted by different groups of the station.


f)

Making action plan of all the issues as discussed in ORT.

g) A standard format containing the startup data, various hold-ups, constraints, delays
and issues encountered during every unit synchronization. shall be monitored in ORT
F.

EXCEPTION REPORT OF ORT

Exception report is to be prepared as per the structure given & sent to Corporate OS at next
day of conducting ORT
G.

INPUT TO MANAGEMENT

The Corporate O&C group will generate the summary of the Exception report of ORT in will
forward to Director (Operations)
H.

ORT REPORT

The minutes of ORT meeting is to be prepared as per structure given & to be put in LAN at
the next day of conducting ORT
I.

ANALYSIS OF ORT REPORT

Each Corporate OS Specialist Group will analyse the concerned issues from ORT report and
will make an action plan.
J.

REVIEW OF ORT

Director (Operations) will take the review of the major issues of the Exception of ORT
reports during the last week of every month

10.0 REGIONAL OPERATION PERFORMANCE REVIEW (ROPR)


ROPR is a platform for exchanging of ideas and experiences amongst all the stations
regarding O&M aspects of stations .In view of the increasing number of units, quarterly
regional review of stations has assumed more significance. Director (Operations) takes
review of stations of region on quarterly basis.
.
The forum of ROPR is to be used for focused discussions with concentration on areas of
concern.
All ROPR templates are to be filled on regular basis by the stations. The templates and the
status of action plan is to be continuously monitored through ORT.
Discussions will be concentrated on the following aspects:
1. ABT GAP ANALYSIS
2. MOU TARGET GAP ANALYSIS
3. FORCED OUTAGE TARGET GAP ANALYSIS
4. PLANNED OUTAGES
5. MAINTENANCE QUALITY IMPROVEMENT
6. OVERHAUL PREPAREDNESS
7. EFFICIENCY GAP ANALYSIS
8. SAFETY GAP ANALYSIS
9. SYSTEM COMPLIANCE STATUS
10. R & M
11. ENVIRONMENT& ASH UTILISATION
12. TQM
13. INTERVENTION REQUIRED FROM CORPORATE CENTRE
14. MISCELLANEOUS

Note: Templates for ROPR are attached in the Annexure-I.

ROPR- PROCESS
AGENDA TEMPLATE

INPUT:

REG. OS AND
STATIONS

ED (REGION)

NEXT ROPR
PEER
PARTICIPATION -

INPUT:

CORP. OS

ROPR : CHAIRED
BY D(O)

ACTION
POINTS: REG. OS

AGM(O&M)s FROM
OTHER STATIONS
(AS REQUIRED)

ED (RHQ)/
ED (OS)

EXCEPTION
REPORT

ACTION POINTS FROM OTHER


ROPRs

ORT COORDINATOR
FOR CENTRALIZED
ACTION POINTS

MONITORING
IN ORT

SYSTEM FOR ACTION PLAN GENERATION, MONITORING AND CONTROL

Issue Author- Action Plan Source

Issue Owner
Conformance

Tech Audit Report


ORT meeting
MCM

ATR Vetting by
Author

Non Conformance
OS

R&M Review Meeting


Enquiry Comm Report-Accident
Pear Comm. Report

STA

D(O) Comments on various Report

FMG

TQM

Specific Issues
with action
plan

EN
R&D
AUD+ENV

Respective Group Head

OS

ED(Reg) Review meeting


Enquiry Comm report- Accident
D(O) visit to Stn
ROPR Mtg.
RMC

Regional ORT Coordinator

ED(Reg) Visit to stn

Action Completed
Review
by GM Stn (ORT)
Action plan (N-1)

Regional ORT
Coordinator
shall be
Custodian of all
Review
meetings

(N+ 0.5) Month

Exception Report to ED(Regn)


Action
Completed
Action Pending

(N+1) Month

Exception Report to ED(OS)

Review by ED(OS) of pending


Exception Report of (N-1)

Action
Completed
Action Pending

(N+2) Month
ROPR Agenda

ROPR Review

Review Mtg by CMD/Directors


Enquiry Comm report-Fire

Action Pending

Review month=N

Review by ED(Rgn)
Action plan of exception report
(N-1)

CUSTODIAN: REGIONAL ORT CORD.

CENPEEP

CENTRALISED ACTION PLAN DATA BASE FOR REGION-

ECM

Action Pending

Action
Completed

REGIONAL OPERATION PERFORMANCE REVIEW (ROPR)


The process of ROPR is as follows:
S.N
1
2

Description
Filling up of standard templates with back up
data, action plans etc, wherever applicable.
Compilation of the data from stations, its
scrutiny and forwarding to Corp. OS on a
monthly basis.

Responsibility

Stations
Regional OS

Preparation of the presentation material based


on the data received from RHQs (for the review
period), further clarifications, if any and expert
opinion of OS Specialist groups.

Corporate OS

ROPR chaired by D (O): Review and


discussions
Finalisation of Record notes of the discussionwithin 4 days of ROPR
Distribution of Record notes of the discussion.
Preparation of detailed Action plan based on the
Record notes, in the prescribed format-within
15 days of finalisation of Record notes.

All concerned

5
6
7

Regional & Corp. OS


Regional OS
Stations

Scrutiny of the action plans and forwarding to


Corp. OS.

Regional OS

Regular review of the action plans (along with


previous / other Regional reviews) in ORT.

Station GMs

10

Follow up of the Action plan points and


highlighting of exceptions to the appropriate
level (ED-Region/ ED-OS).

ORT coordinator-RHQ

11

Review by ED-Region/ ED-OS based on the


nature of the exceptions.
Put up the pending exceptions to the next
ROPR. Close the feedback loop for the
completed action points.

Regional OS /
Corporate OS
ORT coordinator-RHQ

12

11.0 TECHNICAL AUDIT


Technical Audit of NTPC stations shall bring out problems in equipments and deviations in
systems and processes, a time bound corrective action plan depicting responsibility and
implementation of the same to achieve reduced forced outage, optimized O&M cost, quality
maintenance & overhauling, efficiency enhancement and full system compliance leading to
safe, efficient & reliable power generation.
OBJECTIVES OF TECHNICAL AUDIT
The Objectives of Technical Audit are described under different Operational Matrix as
follows:

MOU TARGET GAP ANALYSIS & ABT GAP ANALYSIS:

A.

Objectives:
1. To identify the reasons for not meeting MOU target, if any with respect to generation,
heat rate etc. and make an action plan.
2.

To identify the reasons for not achieving 80% installed DC, if any and make an
action plan.

3. To identify the reasons for not achieving 101% of actual DC and make an action plan.
4. To identify the reasons for not attaining 105% of actual DC for some blocks (during
low frequency) and make an action plan.
5.

To study the actual generation pattern and to monitor UI Quality closely with the
help of scatter diagram to find any deviation.

6. To find out he reasons for negative UI and an action plan o reduce it


B. EFFICIENCY MONITORING GAP ANALYSIS:
Objectives:
1. To determine the reasons for not achieving Design/PG test heat rate and make an action
plan.
2. To identify the parameters, which are affecting the efficiency of the nits and make an
action plan to rectify them.
3. To check that all efficiency tests, as envisaged are carried out as per schedule.

4. To check that recommendations of the efficiency test are implemented.


5. To check that proper efficiency monitoring system is followed.
6. To identify the reasons for high oil consumption and make an action plan to reduce it.
7. To identify the reasons for high auxiliary power consumption and make an action plan to
reduce it.
8. To identify the reasons for make up water consumption and make an action plan to reduce
it.
9. To check the healthiness of protection & interlock system. To identify the reasons for
bypassing the protection, if any.
10. To check that units are running at rated parameters.
K. FORCED OUTAGE GAP ANALYSIS:
Objectives:
1. To ensure the root cause of unit tripping are identified and measures have taken to
eliminate them.
2. To check the implementation status of the action plan to eliminate multiple unit tripping
3. To check the implementation status of the action plan to eliminate recurrence of unit
tripping
4. To check the implementation status of the recommendations of Tube leakage committees.
5. To analyse unexpected failure of Capital Equipments properly.
L. MAINTENANCE QUALITY IMPROVEMENT AND PREPAREDNESS FOR
OVERHAUL:
Objectives:
1. To ensure no forced outage from overhaul to overhaul.
2. To ensure timely completion of overhaul.
3. To ensure overhauling of unit as per Rolling plan.
4. To identify the reasons for any outage after overhaul.
5. To ensure timely availability of all material required for overhauls and accordingly the
scope of work, procurement action are taken well in advance
6. To ensure the active participation of FQA department
7. To ensure awarding of contracts for unit overhauls covering total scope of work well in
advance.

M. SYSTEM COMPLIANCE:
Objectives:
1. To ensure the compliance of all statutory requirements/licenses.
2. To ensure the compliance of the protection and interlock system and to ensure all
protections are in service.
3. To check that

with the all efficiency testings of Boiler, Turbine , Generator &

equipments are as per schedule.


4. To ensure the availability and compliance of standard recommissioning check lists of all
equipment & systems.
5. To ensure the implementation of Technical Compliance documents and LMI
6. To ensure proper documentation and record keeping for important documents.
7. To ensure efficient up-keep of instrumentation, auto loops, annunciation system,
protections and interlocks.
N. ZERO ACCIDENT & ZERO FIRE:
Objectives:
1. To ensure no human accident
2. To ensure no equipment damage
3. To ensure availability of fire fighting/ safety equipments/ systems and protections
4. To ensure proper house keeping of the station.
5. To ensure the timely conductance of the testing of tools & tackles.
6. To ensure the healthiness of protection and interlock systems.
7. To ensure the conductance of important testing like overspeeding test of Turbine &
TDBFP etc.
8. To ensure the checking structures & Machine foundation, as envisaged.
9. To ensure the compliance to all statutory requirement/ license
O. TOTAL QUALITY MANAGEMENT (TQM)
Objectives:
2. To ensure TQM activities ( TQM Tools like Six Sigma, Benchmarking) are used for
performance improvement and cost reduction

P. ENVIRONMENT ,ASH UTILISATION:


Objectives:
1. To ensure compliance of all environmental statutory requirements.
2. To ensure maximum Ash utilization
Q. O&M COST:
Objectives:
1. To check the different measures to reduce inventory in line with norms.
2. To check the different measures to reduce O&M cost to ensure that cost remains within
norms.

AUDIT OF POWER PLANTS - PROCESS FLOW CHART


SELECT THE STATION TO BE AUDITED
(AS PER ANNUAL PLAN OR MANAGEMENT RQMT.)

INTIMATE O&M HEAD ABOUT


AUDIT SCHEDULE AND SCOPE

FINALISE AUDIT TEAM (NOMINATED BY


EACH GROUP & APPROVED BY HOD (OS)

OBTAIN CONFIRMATION OF AUDIT


SCHEDULE FROM STATION

CONDUCT TECHNICAL AUDIT AS PER


THE SCHEDULE AND AS PER GENERAL
GUIDELINES FOR CONDUCTING AUDIT
DISCUSS MAJOR OBSERVATIONS WITH STATION
PERSONNEL AT THE END OF AUDIT

PREPARE DETAILED REPORT AND SEND TO STATION


AND OTHERS AS PER DISTRIBUTION LIST

GET THE ACTION PLAN


PREPARED BY THE STATION

MONITOR IMPLEMENTATION OF
THE ACTION PLAN REGULARLY

LIQUIDATE ALL ACTION POINTS. CARRY


OVER INCOMPLETE ISSUES TO NEXT AUDIT

NOTE: HOD of the group responsible for the ORT of the concerned station will be
responsible for the conductance of the Technical Audit and further monitoring.
REF: Procedure P-015 of Divisional Manual (COS).

SCOPE
Technical Audits will be carried out by Operation Services and will monitor the following: a)

f)
g)

All relevant statutory requirements that apply to the plant areas listed in
Appendix A of this document.
All Procedures and Instructions issued by Corporate Operation Services
Division and other Corporate Functions which are applicable to Plant O&M
functions.
The approved recommendations contained in Enquiry Committee Reports,
Investigation Reports, Trip Analysis Reports and O&E inspections.
All Technical Compliance documents, within the formal Operation and
Maintenance Management Systems.
O&M problems including major repetitive failures and maintenance
preparedness of the station
Performance and outage analysis
Healthiness of the equipment.

h)
i)
j)
k)

O&M cost reduction measures


Safety aspects of Plant & Equipments
Commercial aspects of unit operation
Plant efficiency deviations and corrective actions taken.

l)

Any other areas, at the discretion of the Management.

b)

c)
d)
e)

The Technical Audit should be able to bring out / deliver the following points

Identification of instances where based on site observation and study of O&M


parameters, vigilant O&M staff had averted a major failure / outage / tripping.
Reasons, analysis and learnings thereof to be recorded and circulated for the
benefit of other stations.

Identification of specific training needs of individuals to dovetail with the


overall OS strategy to develop pools of specialized maintenance expertise in
selected area through discussions with O&M staff during audit.

Learnings from the station which can be circulated to other stations.

The Technical Audit team should be able to do identification of repeated trips and failures of
components along with corrective action. It should also find out

Instances where operation & maintenance staff failed to arrive at


recommendations to prevent forced outages

No. of incidences or occasions when the unit operation continued even with
known problems.
Full load generation constraints, partial loading and the reasons thereof.

QUALITIES OF TECHNICAL AUDITOR


a. He must be well experienced in power station operation and maintenance procedures.
b. He should be diplomatic, unbiased, patient, communicative, and should propagate good
practices.
c. He should not feel / show triumph on finding discrepancies and should not criticise
people, but point out discrepancies in the system / equipments.
d. He should have a strong analytical and data crunching abilities.
e. He should develop a good feel of various parametric numbers and using them along with
clinical correlation of any tangible / intangible symptoms and identify possible root
causes and corrective actions thereof.
SYSTEM FOR TECHNICAL AUDIT
1. Site to be audited shall be selected, as per the Annual Plan finalized at the beginning of
each financial year, or as per the requirements of the management.
2. The Frequency of Audit of each station shall be once a year or as decided by the
management.
3. Head of O&M of the site shall be informed with a copy to GM (site) & ED (Region),
about the audit schedule and scope.
4. Nominations of team members from the concerned HODs shall be sought by the
Operation & Commissioning group. If required team members can also be drawn from
respective regional headquarters / other stations. In special cases team members can be
taken from other Corporate / regional functions such as Engg. , finance etc. The audit
team shall be assisted by each area representative of site during conductance of audit.
5. The team leader will be nominated by the management.
6. Station may request Corporate OS for minor rescheduling of audit to cater for special
exigencies to ED (OS) / GM (OS), the competent authority to approve such minor

changes in schedule. Any long term deferment from the schedule or cancellation of audit
plan will have to be approved by Director (O).
7. In case no acknowledgment is received from site, confirmation of the schedule shall be
sought from site, at least one week in advance.
8. The audit team shall be briefed about the methodology of the Audit, use of check list, the
area of concern requiring special attention emerging from ORT, Trip Analysis and major
failures by the Team Leader. A meeting shall be held before the departure for audit
where above points shall be discussed.
9. Confirmation of the program shall be given to Head of O&M of the site, on Phone /
SATCOM or E-mail, one day before leaving for the audit.
10. The findings of the audit shall be summarized in a given format.
11. Critical Issues and areas requiring top management attention shall be identified. An action
plan to resolve the issues should be made with defined responsibility and target dates.
This shall be discussed in the closing meeting and shall be flagged to D(O) & Head of OS
immediately.
12. On returning back, final report including executive summary shall be made by the team
leader, in association with other team members within two weeks

of reporting at the

headquarters.
13. The report shall be sent to Head of O&M of the site for making action plan, and copies
shall be sent to the Regional ED, Head of OS, Head of the Project and Head of Regional
OS. A copy shall be given to the ORT coordinator for necessary follow-up.
14. An action plan is to be prepared for the non conformities raised during the audit by the
station within two weeks of the receipt of the Audit report. The action plan should fix the
responsibilities and time frame for different proposed actions to rectify the audit findings.
The action plan should be made and put on Station LAN. Copies of the same should be
sent to Head of Corp. & Regional OS, ED of Region and the Team Leader of the Audit. A
copy shall be given to the ORT coordinator for necessary follow-up.
15. The action plan available on Station LAN should be updated by the concerned persons
every month. The updated status report should be sent to Head of Corp. OS and Head of
Region. A copy should be given to ORT coordinator for review during the ORT. A
database of the action Plan is to be maintained by the station.

16. The ORT Coordinator shall review the status of action plan every month and discuss the
points which are not complied. This should be recorded in the ORT minutes.
17. The head of OS shall review the action plan once in 4 months or as and when desired.
18. The MIS of audit to D (O) / Management should be in power point and should include the
following:
19. Executive Summary in line with the Targeted Operation Matrix. This will be made ready
by the Team Leader after the receipt of the action plan from the site.
20. Major areas requiring management action and intervention along with area of concern or
neglect.
21. Meeting of D(O), Corp. OS and GM station along with team for discussion on critical
issues to be scheduled if required
GENERAL GUIDELINES FOR CONDUCTING THE TECHNICAL AUDIT
Do not report unsubstantiated discrepancies, which may easily be challenged. For every
exception/discrepancy reported there should be objective evidence. This evidence should be
shown and explained to the representative of the auditee section. Detailed reference of
discrepancy should be given in the report (like exact area/location, equipment no./name,
WOC no., etc.)
Judicious selection of the representative samples on as wide a spectrum as time permits
should be done. Select samples on your own choosing and do not accept only those offered
by the auditee. Emphasis may be required in areas of concern.
Where irregularities are found, ask for further samples to be examined. Do not make a
judgment on the basis of a single finding or an isolated incident provided the implications of
any single incident / record are not crucial, report the finding as an observation / deviation.
Formal discrepancy should be reported on the basis of a fully representative sample where a
significant proportion of the sample taken was found to contain discrepancy.
Remember: nobody likes to be audited; nobody likes to be told about his mistakes; nobody
likes to be told how to run his Department. The auditor may face auditees who are secretly or
openly hostile and uncooperative. They may not accept objective evidence of discrepancies,
and may try to engage the auditor in an offensive and personal argument. They may also say,

we already know the problems, tell us about the solution ....

or come and solve the

problems.
Check Lists prepared by the specialist groups should be used extensively during the audit.
The check lists are available in appendix 6. Reference should also be made to sections 7.0 to
15.0 of this document which deal with some of the common systems, wherever applicable.
Maintenance System
Audit of the maintenance management system (e.g. Anurakshan) in service at the station
being audited should cover the points discussed below as envisaged in the particular system.
Study the Preventive Maintenance Schedules, to assess their adequacy as per O&M manuals,
guidelines, etc. If time does not permit a comprehensive assessment, at least check for
critical equipments and activities.
Random scrutiny of the Work Order Cards being returned to Maintenance Planning Section
should be done. As a minimum, check for the following:
1. Information regarding Manpower used, Time taken, Spares/Consumables used,
special tools/tackles used and details of work done.
2. All the activities listed in the WOCs have been executed.
3. Any request for replanning a job should be accompanied by the reason for the
same, verify that these jobs are actually re-planned.
4. Wherever possible, relevant values/readings should be mentioned.
5. Verify whether equipment history is being maintained and how quickly it can be
retrieved.
Audit of Anurakshan should also include
1.

Status of full availability

2.

No. of bugs identified / corrected

3.

User friendliness and seamless connectivity to other related management


system.

4.

Matrix of all available attributes and its use in the particular site. (Refer
appendix 5)

Permit to work (PTW) system


Verify that PTW System is being followed to ensure safety of men and machines.
Random scrutiny of safety documents, like Permit to Work (PTW), Limited Work

Certificate (LWC), Restoration of Motive Power (ROMP) and Sanction for Test (SFT).
Random check for the isolation and locking for existing PTWs. The auditors should
check the adequacy and correctness of equipment labeling, usage of identification as well
as danger tags.
Inspection, measuring and test equipment (Lab equipment, calibration instruments,
multimeters, process instruments, etc. of C&I and Elect. Labs.)
Verify that the site has a documented procedure for calibration of these equipment
(including their list, frequency and methodology of calibration.). Verify at random the
availability of calibration records for these equipment. Exceptions, if any should be
recorded in the audit report.
Review all the records of repetitive failures and examine for quality of maintenance,
systemic failures etc. Also review the records of all equipment failures including
corrective actions and root cause.
Review records of all major failures and study their analysis. Study and review the status
of the action plan to prevent recurrence. Record deviations.
Operation System
Random scrutiny of Log Books and DAS/IS Logs may be done to review the operating
practices of an area. This should include, but not be limited to, assessing that the operating
regime, changeover schedule of equipment, operation of soot blowers & black-out /
emergency instructions. Check the present operating parameters for safety, efficiency &
correctness of values and analyse the reasons of deviations so as to bring out the actual
performance of the equipment / unit. The availability of other critical records may also be
checked for ensuring the system healthiness.
In addition the following should also be done

Audit time taken for restoration of units after trip / outage grading for safe
restoration and recommendation for improvements thereof.

Identification of parameters where sufficient improvement (stretched target


parameters) can be done so that excellence in O&M is achieved.

Analysis of plant performance to match with ABT policy. (DC, SG, AG and UI
optimisation).

Plant performance review with respect to stretched target operation

Partial Loss Review Analysis as brought out in ORT reports and checking the
efforts made by the stations to improve the loss due to partial loading.

Forced Outages since the last audit and their analysis. Action plan to achieve the
target of <1.0% in the financial year. Recommendations made by Corp. OS in the
annual trip analysis to be checked for compliance.

All instances of multi unit trippings to be analysed in detail and the efforts made
by the station to avoid recurrences to be checked

Data for Renovation & Modernisation (R&M)


During the Technical Audit the auditor must check the data available with O&E /
MTP and ORT minutes which would go as input for R&M. The relevance of this data
should also be checked and areas for which data is not available should be identified.
The audit should be able to deliver the following.

Identification of the equipments which are regularly becoming a constraint in


achieving the targeted performance parameters.

Equipments / Systems whose performance is becoming a constraint in meeting


statutory / safety norms.

Identification of weak areas which are likely to cause problem based on operators
gut feelings.

Identification of items / systems which are obsolete / nearing obsolescence.

Overhauling
Review a sample report of the recent overhauling, and study it for the following points.
Record deviations and action plan thereof.
1. Deviation in planned & actual activities in bar chart
2. Spares and consumables consumed
3. Tools and tackles used.
4. Proper record of necessary protocols.
5. Records of quality checks along with involvement of FQA.
6. Cost of overhauling, variance analysis and pay back period.
7. Improvements achieved after overhauling.
8. Delay analysis if any.
9. Critical Observations / lessons learnt

10. Focus in areas for improvement which can significantly either expand the
frequency of O/H or reduce the O/H period.
11. Identify all activities planned but not done during overhauling and time bound
action plan for undertaking the same.
12. Examine detailed breakup of cost of O/H.
Check the records of the system for identification of activities not possible during plant
operation or short shutdowns, and inclusion of these activities during overhauling.
The following points should also be seen / discussed during the audit
1. Adequacy of scope and preparedness / plan of previous years O/H and the next
two years O/H.
2. Analyse all O/H deferment and / or extension of overhauling. In case of extension
whether it was due to increase in scope of work or lack of planning or other
reasons.
3. List out all forced outages / causes of unit trips within 6 months of overhauling
and identify the reasons of outages with corrective action. Specific learnings to be
recorded and actions thereof may be taken appropriately.
Maintenance Preparedness
Assess the adequacy of documentation, maintenance tools and trained manpower. Study
the manpower deployment (executive and non executive), along with job distribution.
Inspect the records of receipt and maintenance of Drawings and Documents.
Study the shift maintenance log book for assessing promptness, skill and effectiveness of
attending to emergency jobs.
Check for the healthiness of the tools, tackles & lifting equipments. Also check randomly
the certificate issued by the competent authority.
Spares Availability
Identification of critical spares, their quality and spares having high failure rate along
with reasons for failure.
Verify availability of spares/service, by inspecting records of inventory, consumption of
spares and consumables, purchase indents and orders, etc. This should be done for at
least critical spares.

Examine the spares identified for spares pool within NTPC for the Station.
Check for storage condition and preservation of these spares.
Check for spares development programme at the station and audit the present and future
plans.
Healthiness of Installed Equipment
List out the equipment not in service.
Describe the reasons for not being in service.
Evaluate and bring out the effect / implication for the equipment not being in service.
Sites action plan.
Housekeeping
As a minimum check for the following:

Dust on the floor and the equipments, and inside the enclosures/tracks.

Spilled oil and garbage on the floor.

Spillage of fuel oil.

Water logging.

Presence of bird nests, particularly on the switchyard gantries, storage tank breather /
vents etc.

Check for any source of dust ingress and actions taken to suppress the same in plant
area.

Presence of disposable cups and foodstuffs on the floor and in the enclosures/racks.

O&M problems and action plan

Identification and prioritizing the O&M issues.

Action plan to resolve them as per priority

Implementation status of the action plan is also to be checked.

O&M Cost reduction measures

O&M cost details for last 3 years with cost centre wise breakup for ABC analysis to
identify areas of concern.

Cost reduction measures adopted at sites and the effect in actual cost reduction /
control.

Examine critically the long term strategies and plan for O&M cost reduction

Safety aspects of Plant and Equipments

Checking of records of compliance of applicable statutory safety regulations.

Check records to ascertain that disaster management plan is being actively


practiced.

Check whether safety appliances for safety of men are being used extensively.

Checking of equipments safety system healthiness and records thereof.

Special focus should be on fire hazard and corrective actions taken. Records of
fire calls may be checked.

MoU Targets
Check for all the MoU Targets. Record deviations and the recovery plan to achieve the
MOU Target.
Benchmarking
During the audit the following should also be addressed.

Identification of parameters which can be used as Benchmarks within NTPC.

Review of benchmarks targeted by the station in O&M areas and status of


achievement of the benchmarks.

General
Describe any other specific problem of the station; along with reasons, effect / implication
and sites action plan.
Inform the team leader regarding any major discrepancy, any controversial issue,
persistent non cooperation from the auditee or any necessary resource which is not being
provided to you.
Commercial aspects of operating in CERC / ABT Regime may also be examined.

Note:

1. Technical Audit areas are given in Annexure-II


2. Format for reporting the findings of Technical Audit is enclosed in Annexure-III
3. Format for Action plan/implementation on findings of Technical Audit is given
in Annexure-IV
4. Format for Technical Audit Checklists are given in Annexure-XIX

PEER AUDIT / REVIEW


Peer Review also will be conducted for selected stations every year by Corporate OS based
on the Performance, O&M problems, feed back from ORT / Technical Audit etc.

PEER AUDIT / REVIEW - PROCESS FLOW CHART

P
R
E
P
A
R
A
T
I
O
N

SELECT THE STATION TO BE REVIEWED:


Based on Performance parameters, O&M / Environment issues,
analysis of ORT/ Technical Audit, etc.
PREPARE SCOPE & SCHEDULE OF AUDIT
FINALISE AUDIT TEAM
Consisting of Specialist group members selected based on the issues
& approved by HOD (OS)
INTIMATE HEAD OF STATION
About the Schedule & Scope of Audit(minimum 1 week in advance)
OBTAIN CONFIRMATION
Of Audit Schedule from Station

COLLECT INFORMATION / FEEDBACK

About the issues mentioned in the Scope of audit, from CC / External agencies.

A
U
D
I
T

CONDUCT PEER AUDIT


As per the schedule and as per the general guidelines for
conducting audit. Analyse issues and highlight deviations.
DISCUSS MAJOR OBSERVATIONS
With station personnel at the end of the Audit and prepare a draft
Action Plan.
PUT UP MAJOR EXCEPTIONS & ACTION POINTS
To Top Management.

F
O
L
L
O
W
U
P

PREPARE DETAILED REPORT AND SEND TO STATION


And others as per distribution list.
GET THE ACTION PLAN PREPARED BY THE STATION
MONITOR IMPLEMENTATION OF THE ACTION PLAN
Regularly and give feed back to all concerned (ORT coordinator)
LIQUIDATE ALL ACTION POINTS
As per the Target dates. Highlight exceptions if any in forums like
ORT, D (O) Review etc.
PUT UP EXCEPTIONS TO TOP MANAGEMENT
PREPARE DETAILED REPORT AND SEND TO STATION
and others as per distribution list (within 2 weeks of completion of
the Audit)

12.0 TECHNICAL COMPLIANCE


Introduction:
In NTPC, the Technical Compliance System was introduced in October/November,1992 with
the help of a twining arrangement with National Power International (NPI),U.K. who had
developed this concept in their organisation over a period of 30 years to improve safety &
reliability of their power plants.
Technical Compliance System involves issuing of documents to the power stations pertaining
to statutory obligations, company's mandatory requirements and procedures and instructions
for safety, reliability and availability of various equipments/plants of a power station. With
the help of NPI, NTPC consultants, specialist groups and stations prepared technical
compliance documents and sent to the stations for the preparation of Location Management
Instructions (LMI) and their implementation.
OBJECTIVES OF TECHNICAL COMPLIANCE:
i)

To eliminate spurious trippings, thereby increasing availability of plant.

ii)

To

standardize

operating

procedures,

thereby

reducing

risk

of

misunderstanding or subjective interpretation of technical matters.


iii)

To increase awareness of sound O&M management practices to all personnel.

iv)

Better work environment / culture aimed at good efficient & safe O&M
practices.

v)

Proper testing of protective devices so that unit / equipment damage is


prevented.

vi)

Early decision making as all procedures are documented. This will save time
which otherwise would have been lost due to delayed decision.

vii)

To eliminate short cut / adhoc procedures for a perceived short term gain.

viii)

To establish systems and procedures to maintain technical integrity.

ix)

To develop a uniform system for various contingent situations so that


responsibility for actions to be taken in such situations is defined.

x)

To ensure a safe and accident free work atmosphere.

xi)

Fulfillment of statutory and mandatory standard of the state.

xii)

To do demonstrating to external organizations that the company has in place


sound management practices for the control of technical issues.

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CATEGORIES OF TECHNICAL COMPLIANCE DOCUMENTS


Operation Directives (ODs)
These documents are the means by which the Director (Operation) communicates
specific instructions to Station Heads. Their implementation is mandatory and
authorisation will be required by the Director (Operation) before issue.
Operation Guidance Notes (OGNs)
Guidance Notes are the means by which the Director (Operation) provides advice and
guidance to Station Heads & EDs(Region). Their implementation will be mandatory,
if applicable to the station. These documents will require authorisation by the
Director (Operation) before issue.
Operation Information Notes (OINs)
This category of documentation provides Station Heads with information from
various sources relating to technical matters. Documentation within this category will
be authorised by ED(OS) / GM(OS) {when ED(OS) / GM(OS) are not in place then
AGM(OS)}. The information is to assist station staff and to be acted upon at the
discretion of the Station Head.
LOCATION MANAGEMENT INSTRUCTIONS (LMIS)
These documents are to be issued to Locations which may be derived from Operation
Directives, Operation Guidance Notes or Operation Information Notes and endorsed
by the Station Head to instruct his staff on station policy. He may also wish to
include, within his LMI system, other matters of Station Policy, which he wishes to
introduce, and which allows him to effectively discharge his managerial
responsibilities. The LMIs are mandatory documents and are site specific.
PREPARATION & IMPLEMENTATION OF LMIs (Refer Annexure)
The head of the Project shall nominate a TC Coordinator who can be drawn from a
department as per the discretion of the head of the project. He will also form a
working committee to assist the TC coordinator and to monitor the preparation and
implementation of the LMIs.
Preparation of LMIs

The TC Coordinator, on receipt of the TC documents, will hand over a copy of the
document to the working committee, which will find out the relevance of the
document to the station. If found relevant, he will then send another copy to the
concerned department for conversion to LMI. The working committee shall also find
out the interfacing departments if any and seek comments / assistance from such
departments to be included in the draft LMI. The working committee shall also
monitor the progress of the preparation of the LMI. The concerned HOD after being
satisfied with the draft LMI shall pass it back to the working committee / TC
coordinator. The latter shall then put the LMI in the approved format with a distinct
number and put it up for approval of the Head of the Project. Once approved the LMI
shall be multiplied and distributed as per the document distribution list. A copy of the
LMI should also be put on the stations LAN for easy access to all interested.
Implementation of the LMIs
The LMIs should be studied thoroughly by the working level executives, who in
consultation with their seniors and HODs, take suitable steps such that the provisions
of the LMI are implemented and records maintained, if required. HOD shall apprise
the Head of O&M about the status and necessity of the steps taken for the
implementation of the LMIs. Head of O&M is responsible for the implementation of
the LMIs.
After giving sufficient time for LMI implementation (at least 3 months) the
implementation of the same shall be audited first through internal audit and then
through external audit, as per the audit schedule already finalized. Points of nonconformity if found should be resolved and closed in the next audit.

(Refer

OGN/GEN/003 : Guidelines for Conducting Technical Compliance Audit within a


Station).

Steps for Effective Implementation of LMIs


Based on the feedback received at various workshops on TC implementation,
following steps are considered to be necessary for effective implementation of LMIs :

LMI preparation and implementation status must be reviewed and discussed at


stations at least twice in a month in a convenient forum which is chaired by
the Head of Project.

Individual departments must also organize a quarterly training for their


employees to increase the awareness about the provisions of various Location
Management Instructions (LMIs) and the practical benefits to the system after
their implementation.

There will be two audits each year. The station will conduct the first audit
internally by the end of first six months and a third party audit by a
neighboring station by the end of the year as a second audit.

Regional

Headquarter OS will issue a schedule for internal Technical Compliance audit


in consultation with the stations every year.

FLOWCHART OF ACTIVITIES IN LMI PREPARATION &


IMPLEMENTATION
Receipt of Technical Compliance
Documents by the stations

Need of LMIs through internal


resources

Finding out the relevance of the TC document to site / Identification of the department for
the preparation of the LMI by TC working committee
Sending the document to the respective department for preparing LMI draft based on the
TC document
Checking of the draft by the department head and other interfacing departments, if any

Finalisation of the draft LMI by the concerned department

Putting up for approval of the Head of the Project by TC coordinator

Multiplication of the final LMI and distribution as per the distribution list / putting the
LMI on LAN
Use of the LMI by the concerned department(s), thereby ensuring compliance of the same
and maintaining records, if required
Checking the compliance of the LMIs through bi-annual audits

Formulating action plan for correcting points of non-compliance, if any

Closing of the points of non-compliance in the next audit

Technical Compliance Audit: It is done to improve the safety of plant and maximise
reliability and availability of the plant.
OBJECTIVES OF TECHNICAL COMPLIANCE AUDIT
To monitor the technical, operational and maintenance implementation against statutory
and mandatory standard as specified in all documents.
To notify management where the required standards identified in (1) above have not been
established or maintained.
In case of non-compliance, to evolve solutions with station GM that would be adopted to
satisfy the requirement of the relevant directives.
To ensure that technical training is in line with relevant Operation Directive.
Report the finding of the audit to station.
Assist management in demonstrating to external organisations that the company has in
place sound management practices for the control of technical issues.
TECHNICAL COMPLIANCE AUDITOR
The Auditor Must:Be experienced in the operation and maintenance of Power Plant
Not be subject to line management control at any plant to be audited.
Always be impartial
Use objective evidence
Execute the audit as planned
Propagate good practices
Remember an auditor should seek and find FACTS not FAULTS
Note: Master List of Technical Compliance Documents is enclosed in Annexure-V

13.0 RECOMMISSIONING
01. Recommissioning team should be constituted, clearly indicating the responsibility of each
individual including the leader of the recommissioning group before start of overhaul..
02. The operation personnel connected with the unit should be included in the
recommissioning team.
03. Recommissioning team shall prepare a Recommissioning schedule in line with the maint.
bar chart and carry out the activities as per the schedule.
04. Recommissioning team should follow the standard check list of each equipment while
recommissioning the unit.
05. Recommissioning team should maintain the necessary protocol duly signed by all
concerned department while recommissioning the equipment/unit.
06. Recommissioning team should check the healthiness of all equipments and unit
protections.
07. Recommissioning team should ensure the safety of equipment/ personnel by adhering to
proper PTW system.
08. Recommissioning leader should highlight problems, planning and action plan related to
recommissioning activities in daily recommissioning meeting to ensure the completion of
recommissioning of unit within the stipulated time period.
09. Recommissioning team should ensure the healthiness of all auto loops, recorders,
indicators, annunciation system during recommissioning period.
10. Recommissioning team should carry out all testing during recommissioning and maintain
all test data for future reference.
11. Recommissioning Team should ensure that the concerned department has cleaned
respective area of the unit after overhaul.
12. The dissolution of Recommissioning Team will be decided by the Head of O&M, after
ensuring the unit is functioning properly at full load with all protections in service and all
equipments available.
Note:

i)
ii)
iii)

Model start up check list of 500 MW Boiler & Aux. is given in AnnexureXXXXV
Model start up check list of 500 MW Turbine & Aux. is given in
Annexure-XXXXVI
Model Recommissioning checklist of Main turbine (500 MW) is given in
Annexure-XXXXVII

iv)

14.0

Model Recommissioning checklist of Air Preheater is given in AnnexureXXXXVIII

MAINTENANCE MANAGEMENT SYSTEM

OVERHAULING
a) The objective of overhaul is to bring back the equipments to near its design parameters.
Keeping this in view, overhaul performance declaration of unit has been made to evaluate
the quality of overhaul. Two sets of readings, one before and one after the overhaul, of
the critical parameters along with the design value will help the maintenance and
operating engineers to review critically the improvement in the performance of the
equipment.
b) Heat Rate deterioration between two successive overhaul may be maximum 0.5% of Heat
Rate just after Overhaul as shown in the following figure.
c) The rolling plan for next two years is to be made by 15th March every year.
d) Overhauling planning must be started 18 months before overhaul
e) Engineering declaration must be sent to Corporate OS ,15 months before overhauling
f) Major contributor of forced outage is tube failure. Root cause analysis for all tube
leakages followed by action plan is essential by site to eliminate the tube leakage of an
unit between two consecutive overhauls.
g) A system should be made to ensure the availability of all required materials at site one
month before commencement of overhaul to avoid fire fighting
h) Monitor the preparedness for overhaul through Overhaul Preparedness index (OPI)*
i) During overhauling ,contractor should be asked to keep quality manpower and this clause
is to be incorporated in contract
j) Learnings after each overhaul to be deliberated among the Maintenance groups and
action plans to be formulated for avoiding repetition of similar mistakes in future. Further
comprehensive documentation to capture learnings to be made in each station and after
discussion in ROPR, the same should be rolled out automatically to all the stations.
k) Overhauling schedule to be adhered to and all out efforts to be made to bring back the
unit within the schedule time without compromising quality
l) The Operation personnel is to take part in Overhauling activities of the units like defects
identification/ liquidation,isolation & issuing permits,recommissioning etc.

Shift

Executives/ Supervisors are to join the Overhauling & Recommissioning group and
coordinate these jobs.
m) Preparing the defect list of all equipments prior to overhaul.
n) Strictly adhering to PTW system while issuing/taking permits.
o) Strictly following the panel locking system.
p) Shift Charge Engineer is to participate daily in the Overhauling meeting, where the
progress of overhauling of unit , permits to be issued and constraints are discussed.
q) Conductance of Efficiency tests of boiler & turbine before & after overhaul.
r) Each department should ensure the cleanliness of the respective area after equipment
overhaul.
* Please refer the document on Overhaul Preparedness Index.

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% H I R U H 2 Y H U K D X OL Q J

 

$ I WH U 2 Y H U K D X O

' H WH UL R U D WL R Q

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PLANNING PROCESS OF UNIT OVERHAUL

BILL
OF
MATL.

JOB
LIST

UNIT OUTAGE REPORT


1. Analyse of Unit outage/equipment failure
2. Reviw of re-commissioning check test
3. Action plan to avoid recurrence
4. Presentation (for failure) by the concerned dept.
5. Action for any deviation in duration of overhaul

JOB CLASSIFICATION

MAN POWER
PLANNING
MATERIAL
FROM CENTRAL
POOL
TENDERS &
CONTRACTS

RESOURCE
MOBILISATION

QUALITY CHECKS

INDENT
AND
FOLLOW-UP
PRE SHUT DOWN
PLANNING

PERT
NETWORK

PRE
OUTAGE
SURVEY

UNIT
OFF
LOAD

EXECUTION &
MONITORING

RECOMMISSIONING
CHECKS & TRIALRUN
MONITORING
SHEET

QUALITY CHECK
SHEET

SERVICING OF RIGGING
MATERIAL
SITE O/H

RECOMMISSIONING
CHECK SHEET

ISOLATION AND
RECOMMISSIONING
PLAN

UNIT
ON
BAR

WOC/PTW SYSTEM
a) Operation Engineers inform the Maintenance dept. as well as Maintenance Planning dept.
regarding the defects by issuing Work Order Cards with the help of Computer based
Maintenance Management system (OLMMS).
b) As per the priority, different types of WOCs are issued like E,A,B,C priority defect,
where E is the Emergency priority.
c) Operation engineers ensure the proper isolation of the equipments mechanically &
electrically. HT/LT breakers modules are totally isolated from live system and the key is
put in lock out boxes. Danger tags are displayed on isolated breakers and also at Control
panel breaker.
d) As per system requirement four types of PTW forms are issued by Operation Engineers to
Maintenance department like: PTW, ROMP, LWC, SAF.

15.0 ENERGY & EFFICIENCY MANAGEMENT SYSTEM


Efficient operation of a power station means more generation with same fuel input or same
generation with less fuel input.
Efficiency of a power station is generally expressed by using the term Heat Rate.
For a power station to implement an effective efficiency management system the following
aspects require attention:
1.

Design/technological upgradation : As there is a continuous technological


development, more efficient designs and upgraded technologies of main system and
equipments are being produced. Therefore, while setting up a new power station, it is
prudent to opt for a better design and upgraded technology suitable for the station in
consideration..

2.

Operational & monitoring aspects: A strict monitoring of heat rate and its
deviations is to be established.
a) Measurement: For proper monitoring of heat rate & its deviations, the primary
requirement is accurate measurement.
b) Efficiency Tests: Monitoring of heat rate should also comprise of carrying out
schedule performance test of boiler, turbine and other equipments like condenser,
heaters, turbine cylinders efficiency, cooling tower performance, air preheater
efficiency & seal leakages etc. Performance tests should also be carried out
before and after capital overhaul of a unit to take up major works during overhaul
and monitor improvement in performance after overhauling.
c) Operating parameters: In most cases, however, it is a better alternative to
operate the unit at near to its design parameters and record the deviations if any.
There are some parameters which are required to be monitored continuously, as
the heat rate deviation depends on deviation in these parameters. For all these
parameters, a target value of deviation should be fixed and action should be taken
whenever the deviation exceeds the target value. This should be done on day to
day basis.

d) Quality of Maintenance: Maintenance of the equipments also require due


attention for a efficiently running machine.
e) Knowledge: Awareness and knowledge upgradation in efficiency management
area is made a continuous process through trainings, workshops and seminars.
Energy Balance method is to be used for identifying areas for Heat Rate improvement for
bringing down nearer to design values
O&E department should involve effectively in every station in identifying the areas of
loss by way of various tests and prepare an action plan to achieve high efficiency near the
PG test values.
EFFICIENCY TEST:
Condenser
The following tests are carried out for condenser performance test.
a) Flood test : off line test is done to detect air ingress.
b) Steam pressurisation test : off line test is done to detect air ingress.
c) Helium leak detector : on line detection of air ingress to condenser .
d) On line Condenser performance test to determine TTD, Air Vapour depression, Loss in
Condenser back pressure due to CW inlet temperature, CW flow & due to Condenser
dirty tubes.
Turbine
The following tests are carried out for Turbine performance test.
a) Turbine cycle heat rate test
b) HP/IP Cylinder efficiency
c) Turbine Pressure survey
HP Heater:
The following tests are carried out for HP Heater performance test.
a) On line HP Heater performance test is carried out to determine Terminal Temperature
difference (TTD), Drip Cooling Approach (DCA).
LP Heater:
The following tests are carried out for LP Heater performance test.
a) On line LP Heater performance test is carried out to determine Terminal Temperature
difference (TTD), Drip Cooling Approach (DCA).

Deaerator:
The following test are carried out for Deaerator
a) Deaerator drop test is carried out to determine the water/steam leakage in the system.
Cooling Tower
a) Cooling Tower performance test is carried out to determine Range, Approach and
Capability of Cooling Tower
Boiler:
Boiler efficiency test is carried out to determine losses on different account e.g
a) Heat loss due to dry gas
b) Heat loss due to moisture in the fuel
c) Heat loss due to moisture of burning hydrogen
d) Heat loss due to unburnt carbon
e) Heat loss due to moisture in air
Mill
The following tests are carried out for air balancing through the discharge pipes of Mills.
a) Clean air flow test:
b) Dirty air flow test
APH
a) APH performance test is carried out to determine APH Gas Side efficiency , X Ratio to
determine the healthiness of APH baskets and system and Seal leakage to determine the
healthiness of APH seals.
Other Efficiency Tests
Site also carry out other efficiency test like oxygen survey in boiler to determine the air
ingress in the boiler system, TD BFP performance test, Fan efficiency test, Aux. Power
Consumption test etc.
SCHEDULE OF EFFICIENCY TEST
a) Efficiency test are carried out periodically
b) Pre and post overhaul performance test is carried out to determine the effectiveness of
Overhaul.

Monitoring of Heat Rate parameters is done by:


a) Daily meetings
b) ORT : monthly
c) ROPR-Quarterly
d) POG : periodically
In addition to carry out different efficiency tests & monitoring of unit parameters, EEMG
department is to fill up "Performance Monitoring Sheet" once in a week in each unit as per
the format, given in Annexure.
Note : Please refer Efficiency Manual for a) Methods of Efficiency tests, b) Calculation
of Efficiency test, c) Different result sheet, d) Reporting system for Efficiency test result,
e) Format for Action plan for any deviation in efficiency result and f) Efficiency Test
schedules.

16.0 PROTECTION & INTERLOCK SYSTEM


a) Checking of Protection, permissive, interlock and alarm system of the equipments, Boiler,
Turbine , Generator & switchyard are to be done during annual overhaul with necessary
protocols duly filled up by all concerned departments.
b) Healthiness of all annunciation system is to be checked periodically (with a minimum
frequency of once in a year).
c) In the event of failure of any protection system components like field device, relay system
I/O model, associated software, associated cabling etc, temporary bypassing of the
protection may be done with proper recording.
d) Bypassing of protection/permissive should be carried out with the approval of the Head of
O&M acting for the Station General Manager*.
e)

Whenever the bypassing of protection/permissive is undertaken, information relating to


the extent of the bypassing should be prominently displayed and operator notified to
ensure that any necessary measures are taken.

f)

Strict restraint shall be exercised when bypassing protection and every effort shall be
directed towards restoration of these protection devices at the earliest opportunity.

g) The records of bypassing any protection/permissive are to be maintained by Shift Incharge and following format should be filled up while bypassing & restoration of
protection.
h) Records pertaining to the bypassing and restoration shall be reviewed daily by the heads
of operation and maintenance and at least once in a month by the Station General
Manager
* Please refer to the Operation Directives, Unit Protection Devices (OD/OPS/SYST/007)
and Procedures for bypassing and normalizing of Protections (OD/OPS/SYST/005) for
details.

17.0 UNIT TRIPPING


Definition of Unit Tripping: Outage of Unit due to actuation of any protection device or
outage of Unit during emergency condition.
Tripping Report for the above outages are to be prepared.
Planned shutdown, outage due to grid restriction, outage due to fuel shortage are not
considered as tripping
Unit Tripping ReportTo know the actual cause of any unusual occurrences which leads to tripping of a unit in any
of our Power Stations & Sub-Station, it is very essential to analyse the same thoroughly and
the cause is attended immediately to avoid repetition of same type of problem. The analysis
of the tripping shall be done by senior level executives, consisting of Head of Operation,
C&I, EEMG and Electrical Maintenance departments expeditiously but not later than two
days from the date of tripping, in the format enclosed herewith. The analysis should be
reviewed by AGM (O&M) before it is put up to General Manager for approval. Duly
approved tripping analysis by GM of project should be forwarded to Corporate Operation
Services division for feed back and information, within three days of the tripping.
Tripping Report:
a) Detailed reports containing analysis of outage and back-up papers should be sent to
Corporate OS by station within 7 days of the trip.
b) The trip report should be analysed by Corporate OS Trip Committee within 7 days of
receipt and observations, if any, should be sent to the concerned stations within 7 days.
c) The station should make an action plan for the recommendations along with target date
and responsibility centre and send to Corporate OS within 7 days.
d) Trip committee recommendations should not be open ended. All trips wherein root cause
had been established should have a detailed action plan, responsibility centre and
schedule.
e) All preventive and corrective measures should be listed out to prevent recurrence of trips.
The compliance of such recommendations must be ensured by Corporate OS.

f) Technical audits/ ORTs must have a complimentary system to check compliance of the
recommendations.
g) Recommendations/ Action plans should also be sent to the concerned ORT coordinators
for follow up.
h) All trip reports should also indicate incidences of similar trips of the same unit/station.
Recurring trips and trips immediately after overhauls deserve special attention.
i) Stations should not send analysis reports, which do not establish the root cause.
j) Corporate OS Overhauling group and site MTP should take necessary inputs from
Tripping Analysis, Forced Outages and failures to incorporate in the overhauling
checklists to avoid failure of equipments after overhauling.
k) Trip committee's recommendations should be communicated to the concerned Corporate
OS Specialist Group for taking necessary action.
l) Restoration of unit should be as per standard procedures. Strict restraint shall be
excercised not to bypass any interlock/protection, OEM instructions etc. during
restoration. This aspect should be captured in ORT minutes and Technical audits.
m) Active monitoring of each station/unit wise needs to be done for targeted forced outage
not exceeding 1 %. ORT data should capture this on a reducing balance principle.
n) Typical unit outage details and similar occurrence of outage of a station along with the
recommendations should also be circulated to other stations and groups for proper sharing
knowledge and to take corrective action.
Note:
1.0

Site can change the Outage Code after getting proper approval from Corporate OS.

2.0

If planned shutdown is declared after any unit outage due to actuation of protection

or outage due to emergency condition, necessary approval is to be taken for changing the
code.
3.0

Format for Unit trip report for Coal & Gas Station are given in Annexure-VI & VII

4.0

Outage Codes for Coal stations & Gas Stations are given in Annexure-VIII & IX

OS OPERATION & EFFICIENCY DEPARTMENT


PROCESS FLOW CHART FOR TRIP ANALYSIS
TRIP REPORTS
OF NTPC UNITS

STATION TRIP
COMMITTEE (ANALYSIS)

HEAD OF STATION

REGIONAL OS

OBSERVATIONS

HEAD OF OS

(COPY IN CASE OF DELAY)

MIS
OS-O & C
TRIPS
DATA BANK
CORPORATE TRIP
COMMITTEE
(ANALYSIS)

TRIP ANALYSIS
BOOK (YEARLY)

TRIP REPORTS
FILE

18.0 ESSENTIAL DOCUMENTS


Site should ensure the availability of following documents:
01. Emergency instructions for:a) Grid failure (instructions for UCE, desk engineers, locations and
switchyard).
b)

Total AC failure of a unit.

c)

Total DC failure of a unit.

d)

Fire in Air heater.

e)

Fire in Mill.

f)

Fire in Main Oil Tank.

g)

Hydrogen gas leakage and Purging out of Hydrogen from Generator.

h)

Loss of instrument air.

02. Disaster Management Plan


03. Technical diary, Schematics diary and operation management book.
04. Integrated start-up procedure
05. System manuals for all areas of O&M
06. Recommissiong check list of all equipment.
07. Protocol of recommissioning of equipment,unit, protection, interlock system specifying
the custodian.
08. Equipment change over schedule.
09. Equipment lubrication schedule.
10. Record of routine checking of cable galleries (daily).
11. Schedule of ATT-Turbine oil injection & valves testing.
12. Schedule of overspeed test of main turbine & TDBFPs.
13. Operator walk down check list.
14. Records of routine testing details (schedule, result and method of rectifying any
abnormality) of emergency equipment like DC lube oil pump, DC JOP,DC Seal oil pump,
DC seal water pump, DG set, DC lighting etc.
15. Documents related to boiler license, hydrogen plant license and high pressure vessel
license.

19.0 PRESERVATION & DISPOSAL


SHEET/CHARTS/DAS PRINTOUTS

OF

LOG

BOOK/LOG

FEATURES OF LOG BOOK/LOG SHEET/CHARTS


The Log Books have the following features:
a)

Log books are bound for period of three months.

b)

One

side

of

the

log book

is

printed and

contains

important

data

of

station/equipment/system availability and C&I status and other side is meant for filling
up activities and other particulars.
c)

Log book contains Black out/ Emergency instructions along with individual
responsibilities.

Charts contain the following information:


a)

Signature with time, date at the beginning and at the end of the shift.

b)

At the time of tripping, time, date is specified in all UCB charts.

Preservation & disposal of log book/charts/DAS printouts


In view of standardising the Disposal system of used charts,the following guidelines shall be
followed:
01. All charts, DAS print outs are to be preserved from one annual overhaul to next annual
overhaul. All these records are kept in a file unit wise for easy retrieval.
02. During every tripping/failure/damage/unusual occurrence, the following relevant charts
for 30 minutes prior to the event and 15 minutes after the event are preserved along with
event analysis reports as a permanent record unit wise and should not be destroyed.
a.

Boiler
i)

Drum level

ii)

Boiler stop valve pressure

iii)

Main Steam & HRH steam temperatures before & after attemperation.

iv)

Boiler/Heating surfaces metal temperature

v)

Flue gas exit temperature

vi)

DM make up

vii)

Feed flow/steam flow

b.

Turbine
i)
ii)

Bearing temperatures,bearing drain oil temperature

iii)

Differential and overall expansions

iv)

TSE charts

v)

Axial shift charts

vi)

Lub oil temperature

vii)
c.

Vibration

Vacuum and LP casing temperature

Generator
i)
ii)

MVAR/power factor

iii)

Frequency chart

iv)

Hydrogen hot/cold gas temperature

v)

Hydrogen purity

vi)

Rotor temperature

vii)

Stator winding temperature

viii)

Stator water flow

ix)

Stator water conductivity

x)
d.

Load/voltage/current

Seal oil/gas differential pressure

Switchyard:
i)

Disturbance recorder (whenever grid disturbance take place)

03. Whenever 'DAS' is available


a)

Half an hour pre-trip logs

b)

15 minutes post trip logs

c)

sequence of events from DAS

04. The charts being preserved should contain the following information.
a) Signing of each chart everyday with time, data and shift in the beginning and end of shift.
b) Whenever tripping takes place, the time, date should be specified in all the UCB charts at
the time of tripping.
c) An absolute expansion chart of the turbine from hot tripped condition to room
temperature should be preserved as soon as such an opportunity is available after every
overhaul. These records should be preserved on a permanent basis and should be
available for all machines.

05. All parameters of an equipment corresponding to the maximum load on everyday basis
should be maintained as a permanent record..
06. SCE log books, UCE log books should be preserved as a permanent record whereas other
log books are preserved from one annual overhaul to next annual overhaul.
07. Deviations of critical parameters on daily basis along with details as given in format is to
be prepared and preserved as a permanent record.

20.0 EMERGENCY INSTRUCTIONS


01. Model Emergency instructions are provided to the stations. It is essential that Emergency
Instructions for stations may be reviewed and approved and should become standing
order. The emergency instructions once approved become part of the Log Book and
printed on the first page so that each desk /local operator has gone through the
instructions and understood the same.
02. The emergency instructions are also displayed at the locations.
03. Apart from Emergency Instructions, some important instructions are also displayed at
local like:

Change over of Turbine lub.oil filter, where mal operation can cause unit
tripping.

At the locations where human error might cause unit tripping.


The following Emergency Instructions are to be prepared:
SL

Description

1.

Black Out Conditions

2.

Fire in the Mill

3.

Fire in Air-Preheater

4.

Fire in Main Oil Tank

5.

Instructions on Milling System Shutdown and Isolation

6.

Failure of Total D.C Supply

7.

Hydrogen Gas Leakage

8.

Leakage of Turbine Oil

9.

Failure of Instrument Air

Note: Model emergency Instructions for Total Power Failure, Model Emergency
Instructions for Fire in Mill, Model Emergency Instructions for Fire in Air Preheater,
Model Emergency Instructions for Fire in Main Oil Tank, Instructions on Milling
System shutdown & isolation and some shutdown of more frequent types are given in
Annexure- X to XIV.

22. STUDY TEAM/KNOWLEDGE TEAM


Knowledge team is to strengthen skill base across the organisation.
Major functions of the Study team/Knowledge Team are as follows:
01. Study team/Knowledge Team shall be constituted for in-depth investigation of major
problems and issues.
02. The Study Team/Knowledge Team shall assist the specialist group in trouble shooting
whenever required and shall make concrete suggestions and recommendations for review
of concepts and specifications.
03. Study Team/Knowledge Team, if considered necessary, also shall interact with
professional and technical institutions and with outside experts.
04. The Study Team/Knowledge Team may co-opt representatives from power stations on
specific problems and issues.
05. The Study Team/Knowledge Team shall make presentation to the top level management
highlighting the achievements, constraints etc.
06. The Study Team/Knowledge Team shall standardize the different guidelines in the O&M
area.
07. Knowledge team will participate in Audit team
08. A pool of trained resources shall be maintained across region and stations, and the team is
to be picked up on a ( rolling basis) for every audit process.
Appropriate training /exposure shall be imparted to the members of this team.
Suitable mechanism is to be developed for collaborative work and knowledge flows.

22.

HOUSE KEEPING OF THE STATION

House keeping of the power plants is one of the most important precondition for ensuring the
efficient operation & maintenance of the units. It is, therefore, very important that a defined
House Keeping philosophy is adopted in the station to ensure that all the areas, equipments,
panels, walls, glasses etc. are totally kept cleaned and also the lighting system is maintained
in a most efficient condition for enabling the staff to work in a safe, healthy and acceptable
environment.
The House Keeping has been sub-divided into different categories as follows:
a) Sweeping of floors.
b)

Removal of cobwebs.

c)

Cleaning of drains.

d)

Cleaning of toilets, Bathrooms etc.

e)

Cleaning of equipments, desk, gauges etc.

f)

Cleaning of 6.6 KV & L.T switch gears.

g)

Cleaning of C&I panels.

h)

Cleaning of coal from the coal handling plant & mill rejects.

i)

Keeping of the working area clean.

j)

Removal of leaking lubrication oil.

k)

Lighting of the station.

l)

Cleaning of pipe lines.

m)

Cleaning of roof & structures.

n)

Cleaning of ducts & cable gallery.

The mode of house keeping for each category is discussed as below:


SWEEPING OF FLOORS:
It is suggested that the entire power station should be divided into a number of sections
for the purpose of sweeping.
The sections can be as follows:a)

Turbine '0'mts & 5 mts, level area.

b)

Turbine Floor & UCB area.

c)

Boiler '0' mts. Area.

d)

Boiler burner floor area.

e)

6.6 KV switch gear & LT switch gear rooms.

f)

Water treatment plant.

g)

Compressor room.

h)

Work-shop.

i)

Other miscellaneous areas.

j)

Deaerator, R.C.Feeder & Dozing floors.

Above areas will be got cleaned through contractor.


The railings, pipelines, glass windows and other places which do not pose operational or
safety hazards will be cleaned by the contractor.
Contractor should not be permitted for cleaning where cleaning can cause operation or safety
hazards, unless supervised by the concerned department.
The contract should include the following items of work:
a)

Sweeping, swabbing, operating vacuum cleaners, brushing etc.

b)

Disposal of the collected materials into dustbin.

c)

Disposal of materials from dust bin to waste collection centres.

d)

Final disposal of collected waste from central waste collection centres to dumping
grounds.

Cable gallery should be made pressurized to avoid dust ingress.


All cleaning contracts should be operated by Civil division.
S.C.E should certify the quality of work otherwise payments should be withheld.
Cleaning of ESP area, should be done by contractor.
REMOVAL OF COBWEBS:
a)

Cobwebs in all the areas will be cleaned by the contractor.

CLEANING OF DRAINS:
a)

All the drains would be cleaned through contractor.

b)

All the drain lines would be cleaned at least twice a month but if required may be
earlier.

CLEANING OF TOILETS, BATHROOMS ETC:

a)

Cleaning of desk, Gauges (Fixed on various equipments), Field switches, Junction


Boxes, Sight Glasses, Flow sight glasses for oil etc. will be carried out by the
technical helpers under the overall control of shift charge engineers.

b)

Equipment cleaning should be done through contract labour ,however for C&I panel
cleaning should be done through C&I department.

CLEANING OF 6.6 KV & L.T SWITCH GEARS:


a)

The cleaning (dust removal etc.) of 6.6 KV switch gear and all electrical protection
panels will be carried out by the technical helpers under the supervision of electrical
maintenance division for which one supervisor will be nominated.

b)

The cleaning will be done by means of vacuum cleaners and blowers.

CLEANING OF C&I PANELS:


This will be done in the same way as above, under the C&I division.
CLEANING OF COAL ACCUMULATED IN COAL HANDLING PLANT:
a)

The cleaning of spilled coal will be carried by a separate contractor.

b)

Mill rejects if any, would also be cleaned by the contractor if the quantity is huge,
otherwise it should be done departmentally through contract labour.

KEEPING OF THE WORKING AREA CLEAN:


a)

It is proposed that the maintenance staff after completing the maintenance work must
remove from the place of work:
1. All scrap material, oil drums etc.
2. Waste insulation material.
3. Cotton waste.
4. Other materials.

b)

This should be strictly ensured an implemented by the operation staff by not accepting
the work as completed till the above cleaning has been done.

c)

Compliance of the above will be accordingly entered in the permit book.

REMOVAL OF LEAKING LUBRICATING OIL:


a)

Any leakage of oil will be taken care by keeping a tray tin/container under the leaking
points and finally disposed off in a dirty oil drums.

b)

The work will be carried out by the lubricating cell under Maintenance Planning
Division.

c)

GM to take review of critical lub oil leaky points once in a week.

d)

A register will be maintained toward status of all leaky points and will be kept in SCE
room.

LIGHTING OF THE STATION:


a)

It is suggested that the entire plant should be divided into suitable nos. of sections,
each section will be attended intern by the electrical maintenance staff as routine.

b)

For the purpose of emergency requirements as skeleton staff should be kept in shift
also, who would assist the electrical maintenance, in case of need of such
maintenance, during the shift.

c)

The lighting staff should maintain a register in which total numbers of points in each
section and record of replacements should be recorded.

d)

A complaint register should be maintained in which the operation staff will record
their need for the lighting.

HOUSE KEEPING ORGANISATION:


a)

It is proposed that under civil maintenance division, one executive and two
supervisors may be provided to deal with the cleaning, to be carried out by the
contractor.

b)

Each discipline should have one supervisor for house keeping purpose.

c)

Shift charge engineer should be provided with two numbers of technical helpers for
each unit.

23.

SAFETY

The following actions are to be taken to ensure safety:


a)

Schedule and checking details of fire fighting system healthiness are to be ensured for
the Mulsifyres for transformers and oil tanks.

b)

Schedule and checking details of fire fighting system healthiness are to be ensured for
the Fire detection system.

c)

Adequacy of Fire water pressure at furthest & highest point is to be ensured.

d)

Adequacy and coverage of permit to work system usage of safety locks are to be
ensured.

e)

Proper testing of Tools & Tackles adhering to schedule.

f)

Proper identification/labeling of equipments/switch gear etc. are to be ensured

g)

Accepted rules, procedures and code of practice which are formulated with proper
regard to safety consideration must be strictly observed by all concerned.

h)

Adequate safety instructions are to be communicated to staff in proper time.

i)

Contracting agencies executing works should be made responsible through various


measures including appropriate provisions in the contract for discharging their safety
obligations.

j)

Periodic safety inspection of different work place by a competent team is to be ensured

k)

Awareness regarding Disaster Management Plan is to be ensured among all operational


personnel.

Note :In every station, a team of 4-5 persons from various departments should be made
responsible for safety aspects of the plant for a period of one month.
This group shall make a structured report on safety aspects. The new group would then study
the same & make further improvements in this regard.
DISASTER MANAGEMENT PLAN
Natural disasters, such as earthquakes, floods, fire, man-made disaster etc. are potential
hazards, for which we must prepare action plan. The objective is to provide the maximum
protection for equipments and personnel in the event of crisis.
In the objective the following priorities shall apply
1.

Protection of life.

2.

Prevention of injury.

3.

Ensuring electricity

4.

Protection of property, equipments.

5.

Protection of the campus for extended stay or evacuation


Like every other action plan, there must be a crisis plan. The Action plan must be
communicated to all staff and rehearsed from time to time.
When a crisis hits, there has to be a reporting process that moves it to the team leader in a
matter of minute.
The team leader then needs to activate the team, if necessary, as soon as possible.
Include different expertise in the crisis team.
Crisis team should not be saddled with other duties during a crisis. If the crisis is real,
then it ought to be their top & only priority.
Disaster management plan must contain the names of the team and their phone numbers.
Important: Disaster management plan must be updated every year.

PAINTING
Painting of structures shall be done with a particular frequency of the following structures:
a) TG Hall
b) Boiler
c) ESP
d) CHP
e) Bunker
f)
AHP
g) DM Plant
h) CW Pump House
i)
Compressor House
Painting of lines: Proper colour coding of pipe lines are required to facilitate easy
identification and isolation of line for issuing PTW/ Safe Maintenance.

24.0 TRAINING & DEVELOPMENT


01. To keep abreast of latest technology as well as to keep Operation & Maintenance
personnel afresh, training & refresher programs shall be given to Site and Corporate
personnel at the following Training Centres:
a)

Site Training Centre.

b)

Power Management Institute.

c)

Manufacturers works.

d)

200 / 500 Simulator training at NTPC, Korba.

e)

External Training Centres.

02. Continuous interaction shall be maintained among all levels of employees for
dissemination of knowledge, identification of training needs etc.

25.

ANNEXURE (FORMATS)

ANNEXURE-I

ACTION PLAN MATRIX

SOURCE REFERENCE:
DATE:
NAME OF THE CO-ORDINATOR:
S.N.

ISSUE BRIEF

ACTION TO BE
TAKEN ACTIVITY
WISE

RESPONSIBILITY

TARGET
DATE

PRESENT
STATUS

ANNEXURE-II
TECHNICAL AUDIT PLANT AREAS
PLANT AREA 1 (TURBINE & AUXILIARIES)
1.0
1.1
1.1.1
1.1.2
1.1.3
1.1.4
1.1.5

Turbine
Main Turbine
TG Lubricating Oil System/Bearings
TG Rotors/Cylinders
Steam Chests / Valvegear /Governors
Turbine Supervisory Equipment
HP Steam Pipework

2.0

Feed & Condensate Heating System

2.1
2.2
2.3
2.4
2.5

Feed Water System


Boiler Feed Pump
Main Condenser / Ball Cleaning System
Air Evacuation System
Condensate System

3.0

Other Related Areas / Equipments

PLANT AREA 2 BOILER & AUXILIARIES


1.0

BOILER PLANT (GAS-SIDE)

1.1
1.2
1.3
1.4

Boiler Plant
Gas Passes
Fans and APH
Electro Static Precipitators

2.0

BOILER PLANT (WATER/STEAM SIDE)

2.1
2.2
1.2

Main Boiler (Water Circuit)


Main Boiler (Steam Circuit)
Auxiliary Steam Systems

3.0

Milling System

3.1
3.2

Mills (including mill reject system)


Feeders

4.0

Other Related Areas / Equipments

PLANT AREA 3 OFFSITES


1.0

FUEL MANAGEMENT

1.1

Coal Handling Plant

1.2
1.3
1.5

Coal Conveyors and Bunkers


Coal Storage
Fuel Oil Pumping and Storage

2.0

ASH PLANT

2.1
2.2
2.3
2.4

Ash Disposal Area


Ash Handling System
Dry ash System
Chimney

3.0

STATION AIR SYSTEMS

3.1
3.2

Compressed Air System


Air Conditioning System

4.0

CW PLANT

4.1
4.2
4.3
4.4
5.0
5.1
5.2

CW Pumps and other Equipments


CW Cooling Towers
CW Dosing Equipment
Clarified water System
CHEMICAL PLANT
Water Treatment Plant
Storage of Chemicals and Gases

6.0

Other Related Areas / Equipments

PLANT AREA 4 (ELECTRICAL SYSTEMS/GENERATORS)


1.0

GENERATORS

1.1
1.2
1.3

Stators and Rotors / Exciters


Stator Cooling system
Hydrogen System / Sealing Systems

2.0

ELECTRICAL SYSTEM

2.1
2.2
2.3
2.4
2.5
2.6
2.7
2.8
2.9
2.10

Switchgear
Transformers
Batteries, DC Systems & DG Sets etc.
Station Earthing Systems
Station Lightning Arrestors
H.T. Motors
Switchyards Equipments & PLCC
Relays and Protection
Cable Galleries and Fire fighting Equipments
Gas Turbine starting system

3.0

Other Related Areas / Equipments

PLANT AREA 5 C&I SYSTEMS


UPS
DDCMIS
Analysers
Lab
FSSS
Local instruments
Hp / LP Bypass
ATRS / ATT
Protections
Storage of C&I Items
PLANT AREA 6 GAS TURBINE
1.0
1.1
1.2
1.3
1.4
1.5
1.6

Gas Turbines
Compressors
Air Intake Systems
Fuel Burners / Combustion System (both liquid and gas)
Fuel Firing Systems (both liquid and gas)
WHRB
Other Related Areas / Equipments

PLANT AREA 7 (COMMON)


Fire Fighting System
Lifting Equipments & Lifts
Tools & Tackles
Workshop and Labs.
Environment Areas
Plant Communication System
Auxiliary Boiler
H2 Generation Plant

ANNEXURE-III

AREA: EFFICIENCY

Format for Reporting the Findings of Technical Audit


S.N

Deviations /
Non
Conformities
Number

Equipments / Subsystems Checked

Area Audited
Observations / Findings/deviations
(Technical / System Related)

The Non Conformities shall be given a unique no. e.g. <stn.><unit/common><year><area><no.>

ANNEXURE-IV

Format for Action Plan / Implementation on Findings of Technical Audit of <Station> from <
Sl. No. Deviations /
NC of Audit
(No.)

Observation /
Deviation

Action Plan for Remedial Action

1
2
3
4
5
6
7
8
9
10
The next Review of the action plan will be held on <date> at <venue>
The report is to be sent to Head of OS, Regional OS and put on station LAN

Responsibility

Target D

ANNEXURE-V
MASTER LIST OF TECHNICAL COMPLIANCE DOCUMENTS:
MASTER LIST OF DOCUMENTS
AND DRAWINGS
(Operation Services-ISO&TC Department)

S. N.

Document Title

1 Policy on Technical Management System

DOC.NO. : COS-ISO-00-TC/ML/001
REV.NO. : 31
PAGE NO.: Page 1 of 5
ISSUE DATE : 30.12.04

Document No.

Project

Latest Latest Rev.


Rev.No.
10-12-93 <2>

2 Operation Documentation System

All proj. as per Issue-1


distr. list
COS-ISO-00-OD/GEN/002
-doRev.2

3 Action on Receipt of Reports of Panels of Inquiry and Local Investigations

OD/GEN/003

-do-

Issue-1

22-06-94 <2>

4 Local Investigations Initiated by the Director(O)

OD/GEN/004

-do-

Issue-1

22-06-94 <2>

5 Plant Modifications

OD/GEN/006

-do-

Issue-1

15-03-94 <2>

6 Reporting Arrangements in the Event of a Serious Incident

OD/GEN/007

-do-

Issue-1

11-03-94 <2>

7 Chemical Control of the Water/Steam Circuits of Drum Type Boilers

OD/OPS/CHEM/001

-do-

Issue-1

13-02-95 <2>

8 Management of DC Supply System Failure

OD/OPS/ELEC/002

-do-

Issue-1

11-03-94 <2>

9 Testing of Electrical Protection

OD/OPS/ELEC/003

-do-

Issue-1

03-10-94 <2>

10 Capacity Testing of DC Batteries

OD/OPS/ELEC/004

-do-

Issue-1

17-11-95 <2>

11 High Pressure Pipe Support Systems

OD/OPS/MECH/002

-do-

Issue-1

01-09-94 <2>

12 Routine Inspection of Turbine Control Oil Pipework to Reduce Potential

OD/OPS/MECH/004

-do-

Issue-1

22-06-94 <2>

OD/OPS/MECH/007

-do-

Issue-1

11-03-94 <2>

OD/OPS/MECH/009

-do-

Issue-1

21-11-96 <2>

OD/OPS/SYST/001

-do-

Issue-1

10-12-93 <2>

16 Procedure for Testing and Maintenance to Avoid Excessive Overspeeding of OD/OPS/SYST/003

-do-

Issue-1

10-12-93 <2>

Prime Movers
17 Prevention of Air Heater Fires

OD/OPS/SYST/004

-do-

Issue-1

10-12-93 <2>

18 Procedures for Regulating Bypassing of Permissive and Protection

OD/OPS/SYST/005

-do-

Issue-1

28-09-94 <2>

19 Testing of the Turbine Protection Devices

OD/OPS/SYST/006

-do-

Issue-1

22-06-94 <2>

20 Unit Protection Devices

OD/OPS/SYST/007

-do-

Issue-1

22-06-94 <2>

21 The Safe Operation and Maintenance of Pulverised Fuel Plant

OD/OPS/SYST/009

-do-

Issue-1

11-10-94 <2>

22 Power Station Drainage

OGN/ENG/002

-do-

Issue-1

06-10-94 <2>

23 The Control of Environmental Pollution

OGN/ENV/001

-do-

Issue-1

22-11-96 <2>

24 Measurement of Particulate & Gaseous Emissions

OGN/ENV/002

-do-

Issue-1

13-02-95 <2>

25 The Control of Liqiud Effluents from Fossil Fuel Fired Stations

COS-ISO-00-OGN/ENV/008

-do-

Rev. 0

02-02-99 <1>

26 Monitoring of Ambient Air Quality.

COS-ISO-00-OGN/ENV/010

-do-

Rev.0

02-02-99 <1>

27 Technical Compliance within Operation Division.

OGN/GEN/001

-do-

Issue-1

11-03-94 <2>

28 Isolation for Plant Safety.

OGN/GEN/002

-do-

Issue-1

01-09-94 <2>

29 Guidelines for Internal Technical Compliance Audit within a Station.

COS-ISO-00-OGN/GEN/003

-do-

Rev.0

19-04-01

30 Handling of Electrostatic Sensitive Devices

OGN/OPS/C&I/003

-do-

Issue-1

21-11-96 <2>

31 The Operational and Safety aspects of the Chemical Cleaning of Thermal

COS-ISO-00OGN/OPS/CHEM/001
OGN/OPS/CHEM/002

-do-

Rev.0

31-12-99 <5>

-do-

Issue-1

11-10-94 <2>

Fire Risk
13 Turbine Generator Vibration Monitoring

14 Routine Inspn. of Fire Protection Devices & Systems to Reduce Potential


Fire Risk in BHEL Sets of KWU Design
15 Barring of Turbine Generators

<10>

Power Plant
32 Chemical Control of 500 MW KWU/BHEL Genarator Stator Primary Water
System

OD/GEN/001

09-06-99 <9>

33 Sample Preperation and Analysis of Coal

COS-ISO-00OGN/OPS/CHEM/006
OGN/OPS/CHEM/007

-do-

Rev.2

28-01-00 <5>

-do-

Issue-1

11-03-94 <2>

OGN/OPS/CHEM/009

-do-

Issue-1

04-08-97 <2>

36 Storage of the Water/Steam Circuits of Generating Plants

OGN/OPS/CHEM/010

-do-

Issue-1

28-08-94 <2>

37 The Sampling of Steam and Water for Chemical Monitoring and Analysis

-do-

Rev.0

03-08-99 <3>

-do-

Rev.0

05-11-98

39 Code of Practice for Power Plant Chemistry

COS-ISO-00OGN/OPS/CHEM/011
COS-ISO-00OGN/OPS/CHEM/014
COS-ISO-00-

-do-

Rev.0

30-10-03

40 Guidelines on Action to be taken in the Event of Condenser Tube Leakage

OGN/OPS/CHEM/015
COS-ISO-00-

-do-

Rev.0

19-09-04

41 Inspection and Maintenance Guidelines for Chimneys

OGN/OPS/CHEM/016
OGN/OPS/CIV/005

-do-

Issue-1

05-04-95 <2>

42 Inspection and Maintenance of Storm water drains

OGN/OPS/CIV/006

-do-

Issue-1

03-10-94 <2>

43 Inspection and Maintenance of Steel and Concrete Structures (Non

OGN/OPS/CIV/007

-do-

Issue-1

22-11-96 <2>

COS-ISO-00OGN/OPS/CIV/011
COS-ISO-00OGN/OPS/CIV/012
OGN/OPS/ELEC/001

-do-

Rev.0

04-10-99 <4>

-do-

Rev.0

04-10-99 <4>

-do-

Issue-1

11-03-94 <2>

47 Electrical Testing of Generator Rotor Winding Insulation

OGN/OPS/ELEC/004

-do-

Issue-1

03-10-94 <2>

48 Generator Rotor End Winding Retaining Rings

OGN/OPS/ELEC/005

-do-

Issue-1

11-03-94 <2>

49 Hand Held Insulated Tools for Live Working upto 1000 Volts

OGN/OPS/ELEC/006

-do-

Issue-1

21-11-96 <2>

50 Prevention and Detection of Generator Rotor Earthfaults

COS-ISO-00OGN/OPS/ELEC/007
OGN/OPS/ELEC/008

-do-

Rev.0

09-06-99 <9>

-do-

Issue-1

06-10-94 <2>

Hose Connections
52 Insulator Protection in Polluted Atmospheres

OGN/OPS/ELEC/009

-do-

Issue-1

02-01-97 <2>

53 Maintenance and Testing of Generator Exitation Control Systems

OGN/OPS/ELEC/010

-do-

Issue-1

21-11-96 <2>

54 The Maintenance of Generator Brushgear

OGN/OPS/ELEC/011

-do-

Issue-1

11-03-94 <2>

55 Shaft Voltages and Currents in Large Turbo-generators

OGN/OPS/ELEC/014

-do-

Issue-1

11-03-94 <2>

56 Operating Guidelines for Valve Regulated Lead Acid Batteries

-do-

Rev.0

17-10-00 <8>

57 The Use and Processing of Insulating Oil in Power Transformers

COS-ISO-00OGN/OPS/ELEC/015
OGN/OPS/ELEC/017

-do-

Issue-1

11-03-94 <2>

58 Pyrolytic Carbon Growth on Tapchanger and Off -circuit Tapping Switch

34 Safety Precautions and Opereating Procedures for the Unloading of Bulk


Acid and Caustic Soda
35 The Examination and Maintenance of Turbine Lubricating oil.

38 Coal as Fired sampling Procedure


<25>
<30>

Corrosive Atmosphere)
44 Manual for Inspection & Maintenance of Machine Foundations Including
Spring Supported Foundations
45 Guidelines for Inspection & Maintenance of Structures/Buildings in the
Vicinity of Corrosive Chemicals, Effluents and Fumes
46 Buchholtz Alarms in Transformers and Reactors

51 Inspection and Protection of Water Cooled Generator Stator Winding PTFE

OGN/OPS/ELEC/018

-do-

Issue-1

03-10-94 <2>

Contacts in Transformers
59 Dissolved Gas Analysis of Transformers and Reactors.

OGN/OPS/ELEC/019

-do-

Issue-1

11-03-94 <2>

60 Clean Conditions during Work of Generators

OGN/OPS/ELEC/020

-do-

Issue-1

25-02-94 <2>

61 Maintenance and Testing of Station Earthing Systems

OGN/OPS/ELEC/021

-do-

Issue-1

11-03-94 <2>

62 Negative Phase Sequence Alarms at Generating Stations

OGN/OPS/ELEC/023

-do-

Issue-1

03-10-94 <2>

63 High Current Busbar Systems Connected to Generators and Generator

COS-ISO-00OGN/OPS/ELEC/035
COS-ISO-00OGN/OPS/MECH/001

-do-

Rev.0

09-05-00 <9>

-do-

Rev.2

24-01-00 <9>

COS-ISO-00OGN/OPS/MECH/002
COS-ISO-00-

-do-

Rev.0

16-05-00 <9>

-do-

Rev.0

27-09-01

-do-

Rev.0

04-03-00 <6>

-do-

Issue-1

04-02-97 <2>

Transformers
64 The Examination, Maintenance, Safety & Handlimg Aspects of Phosphate
Ester Fire Resistant Hydraulic Fluids

65 Attemperator Spray Nozzles and Liners


66 Testing of Safety & Protective Device (KWU Turbine)

<12>

67 Boiler Header Ligament Cracking - Guidance on Inspection Policy


68 Boiler Header Ligament Cracking - Hydraulic Leak Testing during

OGN/OPS/MECH/003
COS-ISO-00OGN/OPS/MECH/004
OGN/OPS/MECH/005

Breakdown Repairs
69 Boiler Thermal Expansion Indicators and their Use

OGN/OPS/MECH/006

-do-

Issue-1

16-08-94 <2>

70 Operation Requirements for the Care & Maintenance of Large Butterfly

OGN/OPS/MECH/008

-do-

Issue-1

28-09-94 <2>

OGN/OPS/MECH/011

-do-

Issue-1

02-01-97 <2>

Valves in Cooling Water Systems


71 Control of PFA Agglomerate Emissions from Coal Fired Power Stations

72 Deaerator Storage Vessels; Reinspection and Monitoring Requirements

OGN/OPS/MECH/012

-do-

Issue-1

26-11-96 <2>

73 Inspection Requirements of Radial ID Fans of BHEL Make for 500 MW

COS-ISO-00OGN/OPS/MECH/013
OGN/OPS/MECH/014

-do-

Rev.0

04-10-99 <4>

-do-

Issue-1

03-10-94 <2>

OGN/OPS/MECH/016

-do-

Issue-1

11-10-94 <2>

OGN/OPS/MECH/017

-do-

Issue-1

10-10-94 <2>

OGN/OPS/MECH/021

-do-

Issue-1

21-11-96 <2>

OGN/OPS/MECH/023

-do-

Issue-1

03-10-94 <2>

OGN/OPS/MECH/026

-do-

Issue-1

04-02-97 <2>

COS-ISO-00OGN/OPS/MECH/031
OGN/OPS/PERF/002

-do-

Rev.0

31-03-00 <6>

-do-

Issue-1

07-12-96 <2>

-do-

Rev.0

04-10-99 <4>

83 Performance Monitoring of CW System

COS-ISO-00OGN/OPS/PERF/006
COS-ISO-00-

-do-

Rev.0

15-05-02

84 Ash Build up in Boiler Bottom Ash Hoppers

OGN/OPS/PERF/008
OGN/OPS/SYST/001

-do-

Issue-1

16-08-94 <2>

85 Fire Protection of NTPC Power Stations

COS-ISO-00-

-do-

Rev.0

19-04-01

86 Handling of Electrical Apparatus in Distress

OGN/OPS/SYST/002
OGN/OPS/SYST/003

-do-

Issue-1

22-11-96 <2>

-do-

Rev.0

17-01-01 <9>

-do-

Issue-1

07-12-94 <2>

-do-

Rev.0

09-06-99 <4>

-do-

Issue-1

21-11-96 <2>

Units
74 Fire Resistant Fluids for Control Systems-Avoidance of Mixing Natural &
Synthetic Based Fluids within the same Control System
75 Maintenance of the Integrity of Boiler Support Systems

76 Non-compatibility of Turbo Generator Lubricating/Control/Sealing Oils

Supplied by Different Oil Companies


77 Guidance for the Removal of Seized Studs by the Drilling/Bore Welding
System
78 Safety Precautions to be taken when Carrying out Insp. & Maint. on
Turbine Gen. Component which are not Completely Self Supporting
79 The Care and Maintenance of Pumps

80 Care and Maintenance of Turbine Plant Feed System


81 Performance Testing of Condenser Air Extraction Plant
82 Thermal Performance of Cooling Towers at NTPC Stations
<16>

<10>

87 Optimisation of Water Consumption in Ash Handling Systems


88 Long Retractable Soot Blower Operation

COS-ISO-00OGN/OPS/SYST/004
OGN/OPS/SYST/005

89 Prevention of Hydrogen Explosions due to Hydrogen Leak in Generator Bus COS-ISO-00Ducts


90 Operational Switching

OGN/OPS/SYST/006
OGN/OPS/SYST/007

91 Prevention of Damage to Generators due to Moisture in Hydrogen

OGN/OPS/SYST/009

-do-

Issue-1

16-08-94 <2>

92 Steam Purging

OGN/OPS/SYST/011

-do-

Issue-1

21-11-96 <2>

93 Switching of Power System Distribution Systems where Fault Level Ratings OGN/OPS/SYST/012
may be Exceeded
94 Care in Operation and Maintenance of Coal Handling Plant

-do-

Issue-1

22-09-94 <2>

OGN/OPS/SYST/013

-do-

Issue-1

07-12-96 <2>

95 Long Term Storage of Power Plant and Equipments : General

COS-ISO-00-

-do-

Rev.0

30-06-01

OGN/OPS/SYST/017
COS-ISO-00-

-do-

Rev.0

15-02-02

<11>

Considerations and Preservation

96 Quality Management in Maintenance / Overhauling

<14>

OGN/OPS/SYST/018

97 Boiler Access and Viewing Doors

OIN/ENG/001

-do-

Issue-1

11-10-94 <2>

98 Terms of Reference for Appointment of LNG Consultants

COS-ISO-00-OIN/GEN/001

-do-

Rev.0

02-02-99 <1>

99 Guidance for the Issue of LMIs as a Controlled Document

COS-ISO-00-OIN/GEN/002

-do-

Rev.0

20-08-99 <4>

100 Guidelines for Conducting Technical Audit

COS-ISO-00-OIN/GEN/004

-do-

Rev.0

20-07-04

101 Recommendations of Heads of C&I Meet (held at EOC, Noida on 26th and

COS-ISO-00-

-do-

Rev.0

30-01-03

102 Data Bank of Protections & Interlocks of Auxiliaries

OIN/OPS/C&I/001
COS-ISO-00-

-do-

Rev. 0

31-03-03

103 Data Bank on Problems and Solutions in C&I areas

OIN/OPS/C&I/002
COS-ISO-00-

-do-

Rev. 0

05-06-03

104 Recommendations of C&I HOD Workshop (held at PMI, Noida 3rd to 5th

OIN/OPS/C&I/003
COS-ISO-00-

-do-

Rev. 0

20-12-04

OIN/OPS/C&I/004
OIN/OPS/CHEM/002

-do-

Issue-1

06-10-94 <2>

-do-

Rev.0

13-04-00 <6>

-do-

Rev.0

24-10-00 <8>

<29>
<19>

27th November, 2002

<20>
<22>
<31>

November, 2004 )

105 The Control of Marine Fouling by Continuous Chlorination


106 Recommendations of Chemistry Workshop on Online Instruments (Held at
Dadri on 11th & 12th January 2000
107 Recommendations of Chemistry Workshop on Operational Problems of

COS-ISO-00OIN/OPS/CHEM/003
COS-ISO-00-

Condensate Polishing Unit held at Korba on 7 and 8 August 2000

OIN/OPS/CHEM/004
COS-ISO-00-

-do-

Rev.0

15-10-01

OIN/OPS/CHEM/005
COS-ISO-00-

-do-

Rev.0

24-01-02

110 Specifications for Water Treatment Chemicals

OIN/OPS/CHEM/006
COS-ISO-00-

-do-

Rev.0

21-02-02

111 Chemical Laboratory Instrument Specifications

OIN/OPS/CHEM/007
COS-ISO-00-

-do-

Rev.0

28-07-03

112 Data Bank of Water Analysis and Chemical Consumption

OIN/OPS/CHEM/008
COS-ISO-00-

-do-

Rev.0

04-11-03

113 Analytical Procedures for Raw Materials

OIN/OPS/CHEM/010
COS-ISO-00-

-do-

Rev.0

14-01-04

114 Data Bank of Water Analysis and Chemical Consumption for 2003-2004

OIN/OPS/CHEM/011
COS-ISO-00-

-do-

Rev.0

05-08-04

115 Recommendations of the Workshops on Cycle Chemistry and Condensate

OIN/OPS/CHEM/012
COS-ISO-00-

-do-

Rev.0

21-09-04

116 Manual on Sampling and Testing Procedures for Oils

OIN/OPS/CHEM/014
COS-ISO-00-

-do-

Rev.0

29-11-04

117 132 KV Earth Switch - Maintenance

OIN/OPS/CHEM/015
OIN/OPS/ELEC/001

-do-

Issue-1

02-01-97 <2>

118 132 KV R.C.P. Isolators Excluding Rolling Head Types - Maintenance

OIN/OPS/ELEC/002

-do-

Issue-1

21-11-96 <2>

119 Electrical Isolaton for Electrically Operated Valve Actuators

-do-

Rev.0

29-12-99 <5>

120 Data Bank of Transformers & Reactors failures

COS-ISO-00OIN/OPS/ELEC/003
COS-ISO-00-

-do-

Rev.0

27-03-02

121 Data Bank of Generator Failures

OIN/OPS/ELEC/005
COS-ISO-00-

-do-

Rev.0

16-04-02

122 Recommended Procedures to Assess the Quality of Insulation of Generator

OIN/OPS/ELEC/006
OIN/OPS/ELEC/007

-do-

Issue-1

03-10-94 <2>

COS-ISO-00-

-do-

Rev.0

20-03-03

124 Overfluxing of Generator Transformers

OIN/OPS/ELEC/008
OIN/OPS/ELEC/009

-do-

Issue-1

03-10-94 <2>

125 Transformer Oil/Water Coolers- Operation and Maintenance

OIN/OPS/ELEC/011

-do-

Issue-1

28-09-94 <2>

126 Ring Flux Testing of Generator Stator Cores

OIN/OPS/ELEC/012

-do-

Issue-1

11-03-94 <2>

127 Application of Condition Monitoring Package for the Detection of

108 Recommendations of Chemistry Workshop on Cooling Water Treatment

<13>

(held at Ramagundam on 18th and 19th August 2001)

109 Proceedings and Recommendations of 20th chemical Heads Meeting (held

<13>

at Dadri on 22nd and 23rd November 2001)

<14>
<23>
<25>
<27>
<29>
<30>

Polishers Conducted under EPRI Program 64

<31>

<15>
<15>

and Motor Stators


123 Data Bank of Transformers
<20>

OIN/OPS/ELEC/013

-do-

Issue-1

03-10-94 <2>

Overheating in Hydrogen Cooled Generators


128 Generator Stator Core Faults

OIN/OPS/ELEC/014

-do-

Issue-1

11-03-94 <2>

129 In Service Hydraulic Pressure Testing of Boilers and Other Pressurised

OIN/OPS/MECH/001

-do-

Issue-1

05-04-95 <2>

COS-ISO-00-

-do-

Rev.0

05-12-02

-do-

Rev.0

02-02-99 <1>

-do-

Issue-1

21-11-96 <2>

-do-

Rev.0

18-11-98

Components
130 Data Bank of Milling Plants
<18>

131 Prevention and Control of Boiler Tube Failures


132 The Specification & Inspection of Primary Flow Devices for Turbine Heat

Rate Testing
133 Recommendations of the Workshop on Maintenance Practices of KWU
Turbines Held on 19 and 20 August at Korba
134 Data Bank of Steam Condensers
<18>

OIN/OPS/MECH/002
COS-ISO-00OIN/OPS/MECH/004
OIN/OPS/MECH/010
COS-ISO-00OIN/OPS/MECH/018
COS-ISO-00-

-do-

Rev.0

14-11-02

135 Data Bank of Problems in Cooling Towers

OIN/OPS/MECH/019
COS-ISO-00-

-do-

Rev.0

23-05-03

136 Data Bank of KWU Turbine Problems & Failures

OIN/OPS/MECH/020
COS-ISO-00-

-do-

Rev.0

26-03-04

-do-

Rev.0

19-03-99 <1>

-do-

Rev.0

08-07-99 <3>

-do-

Rev.0

12-05-00 <6>

<21>
<28>

137 Proceedings of O&M Conference - 1999


138 Recommendations of the Technical Compliance Implementation

Workshop held at Ramagundam on 20 and 21 April 1999


139 Recommendation of International Conference on Power Plant Operation,
Efficiency and Environmental Protectiom

OIN/OPS/MECH/021
COS-ISO-00OIN/OPS/SYST/003
COS-ISO-00OIN/OPS/SYST/004
COS-ISO-00OIN/OPS/SYST/005

140 Recommendations of the Technical Compliance Implementation

-do-

Rev.0

21-11-00 <8>

-do-

Rev.0

27-02-01 <9>

-do-

Rev.0

25-07-01

OIN/OPS/SYST/008
COS-ISO-00-

-do-

Rev.0

28-01-02

OIN/OPS/SYST/009
COS-ISO-00-

-do-

Rev.0

02-05-02

OIN/OPS/SYST/010
COS-ISO-00-

-do-

Rev.0

22-07-02

146 Quality Management of C - Inspection of ABB Gas Turbine (13D2)

OIN/OPS/SYST/011
COS-ISO-00-

Anta

Rev.1

05-03-04

147 Quality Management of Major Inspection of MHI Gas Turbine (MW 701

OIN/OPS/SYST/012
COS-ISO-00-

Auraiya

Rev.0

09-04-03

All proj. as per Rev.0

12-02-03

Workshop held at Singrauli on 26 and 27September, 2000


141 Proceedings of Workshop on Fire Fighting system (held at PMI, Noida from
5th to 7th December 2000)
142 Recommendations of Workshop on Lifting Tools & Tackles including EOT
<12>
Cranes (held at PMI, Noida on 2nd and 3rd May 2001)
143 Recommendations of the 3rd Technical Compliance Implementation
<14>
Workshop held at Kawas on 21st and 22nd December, 2001
144 Maintenance Optimization through Predictive Maintenance
<16>

145 Recommendations of Workshop on "Spares Inventory & its Preservation"

<17>

held at Singrauli from 28th to 30th may 2002

<27>
<21>

D)

148 Recommendations of the 4th Technical Compliance Implementation

<19>

Workshop held at PMI, Noida on 18th and 19th December, 2002

149 Recommendations of the 1st Workshop on Condition Monitoring &

<19>

Predictive Maintenance held at PMI, Noida on 26th and 27th Nov., 2002

150 Quality Management of Major Inspection of Siemens (V 94.2) Dadri Gas

<24>

Turbine

151 Templates for Reliability Centered Maintenance (For Critical Equipments

<26>

in a Power Plant)

152 Quality Management of Major Inspection of GE (9171E) Kayamkulam Gas

<27>

Turbine

153 Recommendations of the 5th Technical Compliance Implementation

<27>

Workshop held at Talcher Thermal on 21st and 22nd January, 2004

COS-ISO-00OIN/OPS/SYST/006
COS-ISO-00OIN/OPS/SYST/007
COS-ISO-00-

OIN/OPS/SYST/014
COS-ISO-00OIN/OPS/SYST/015
COS-ISO-00-

distr. list
-do-

Rev.0

21-01-03

OIN/OPS/SYST/016
COS-ISO-00-

Dadri

Rev.0

30-09-03

OIN/OPS/SYST/018
COS-ISO-00-

All proj. as per Rev.0

14-11-03

OIN/OPS/SYST/019
COS-ISO-00-

distr. list
Kayamkulam Rev.0

30-12-03

OIN/OPS/SYST/020
COS-ISO-00-

All proj. as per Rev.0

18-03-04

OIN/OPS/SYST/021

distr. list

Note: 1) All documents issued before Nov.'98 are initial documents. Their first revision will be called Rev.2

ANNEXURE-VI
(COAL STATIONS)
UNIT TRIPPING REPORT
Unit No .
Report No..
1.
Date of tripping.

Station------------

Outage No. ..
Outage Code

2.

Time of tripping.

3.

Before unit tripping.


a)
Unit load.
b)
Mills in service.
c)
No. of oil guns in service (elevation).
d)
No. of BFPs.
e)
No. of CEPs.
f)
No. of ID fans.
g)
No. of FD fans.
h)
No. of PA fans.
i)
No. CC pumps
j)
No. of CW pumps.
k)
Any other information

4.

First up protection acted.

5.

Similar occurrences in last two financial years.


(Attach status of Recommendations/Action plan of the previous trips)

6.

Other relays/ protection acted.

7.

Supporting documents attached


(Minimum requirement: SOE ,PTL, Alarm Log)

8.

Any operation done prior to tripping :


(Please attach unit controllers observation).

9.

Analysis of tripping.

10.

Root Cause

11.

Remedial measures taken/ to be taken.

12.

Time/ Date of Boiler light up & synchronization.

13.

Date of completion of last Overhaul/Type of Overhaul

14.

Problems/Constranits faced during restoration

15.

Recommendations/Action Plan.

S.N. Recommendation

Action Plan

Resposibility

Schedule/Targe
t date

16. Any specific Learning/Feedback


17. Signature/Date
HOD (Operation)
HOD (O&M)
GM (Site)
ED (Region)
ED (OS)

HOD (Elect.)

HOD(C&I)

HOD(O&E)

ANNEXURE-VII
(GAS STATIONS)
UNIT TRIPPING REPORT
Unit No .
Report No..
1.
Date of tripping.
2.
3.
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)

Station------------

Outage No. ..
Outage Code

Time of tripping.
Before unit tripping.
Unit load.
Type of Fuel (Gas/Liquid/Naptha):
WHRB in service.
No. of HP BFPs.
No. of LP BFPs.
No. of CEPs.
No. of CW pumps.
No. of CT fans:
No. of LPBWCPs:
No. of HPBWCPs:
Any other information

4.

First up protection acted.

5.

Similar occurrences in last two financial years.


Attach status of Recommendations/Action plan of the previous trips)

6.

Other relays/ protection acted.

7.

Supporting documents attached


(Minimum requirement: SOE ,PTL, Alarm Log)

8.

Any operation done prior to tripping :


(Please attach unit controllers observation).

9.

Analysis of tripping.

10.

Root Cause

11.

Remedial measures taken/ to be taken.

12.

Time/ Date of Boiler light up (ST), GT starting & synchronization

13.

Date of completion of last Overhaul/Type of Overhaul

14.

Problems/Constranits faced during restoration

15.

Recommendations/Action Plan.

S.N. Recommendation

Action Plan

16.

Schedule/Targe
t date

Any specific Learning/Feedback

17.

Resposibility

Signature/Date

HOD (Operation)
HOD (O&M)
GM (Site)
ED (Region)
ED (OS)

HOD (Elect.)

HOD(C&I)

HOD(O&E)

ANNEXURE-VIII

TRIPPING CODES FOR COAL FIRED STATIONS


S.N

TRIPPING CAUSE

CODE

S.N

TRIPPING CAUSE

COD
E

1.

Boiler & Auxiliaries


Water Wall Tube Leakage
LTSH Tube Leakage
Economiser Tube Leakage
Superheater Tube Leakage
Reheater Tube Leakage
Steam cooled W/Wall Leakage
Leakage at various places
Clinkering/Slagging Problem
P.A.Fan Problem
I.D. Fan Problem
F.D. Fan Problem
Furnace Disturbance
Mill Problem
Poor Quality / Moist Coal
Feeder Problem
Oil Gun Problem
C.C. Pump Problem
APH Problem
Feed Regulating Station Problem
Attemperation Station Problem
M S Temperature Problem

2.

Turbine & Auxiliaries

01

02

05

03
0301
0302
0303
0304
0305
0306
0307
0308
0309

Offsite System & Aux.


Ash Handling System
DM Water Plant
Compressor System
Fuel Oil System
Fire Protection System
CW System

0201
0202
0203
0204
0205
0206
0207
0208
0209
0210
0211
0212
0213
0214
0215

C&I System

4.

Generator & Auxiliaries


Generator Stator Problem
Generator Rotor Problem
Seal Oil System Problem
AVR & Excitation System
Stator Cooling Water System
Gen./Field Breaker Problem
Hydrogen Cooling System
Gen. Slipring Brush Problem
Generator Bus Duct Problem

0101
0102
0103
0104
0105
0106
0107
0108
0109
0110
0111
0112
0113
0114
0115
0116
0117
0118
0119
0120
0121

Governing System Problem


ESV / MS / IV / CV Problem
Axial Shift High
Turbine Bearing Problem
Shaft Vibration High
Lub Oil System Problem
Control Oil System Problem
HP/LP Bypass System Problem
Differential Expansion Problem
TDBFP Problem
MDBFP Problem
CEP Problem
Vacuum System Problem
Aux. Steam System Problem
LP/HP Heater/Gland Cooler
Problem
Shaft Eccentricity High
Leak off Steam Problem
Water / Steam Leakages
Diff. Temperature Problem
Miscellaneous

5.

3.

04
0401
0402
0403
0404
0405
0406

0216
0217
0218
0219
0220

9.

No Demand

09

S.N

TRIPPING CAUSE

CODE

S.N

TRIPPING CAUSE

COD
E

Control Supply/Cable Fault


Maloperation Relays / Protection
ATRS Problem
DAS Problem
Transmitter Switches Problem
UPS System Problem
RTD/ Thermocouple Problem
Prot. Trip-No Estab. Reason
Control System Problem
FSSS Problem
EHC Problem
Card Failure

6.

Human Error
Operators Mistake
Maintenance Staffs Mistake
Contract Labours Mistake
Unidentified People Mistake

7.

Tr. Line/ Grid Disturbance


400/220/132 KV Line Trip Ext.
400/220/132
KV
Relay
Malfunction
400/220/132 KV Bkr/Isolator
Prob.
Line Capacity Inadequate
Problem in Shunt Reactor
Disturbance from PGCL Sw. Yd.
Blocking of HVDC
C.T./P.T. Problem
Shunt Reactor Problem
Isolator Problem
ICT Problem

8.

Coal Problems
Coal Shortage Mine Problem
Coal Shortage MGR Problem
CHP problem

0501
0502
0503
0504
0505
0506
0507
0508
0509
0510
0511
0512

06
0601
0602
0603
0604

07
0701
0702
0703
0704
0705
0706
0707
0708
0709
0710
0711

08
0801
0802
0803

REB/IOCC Message
System Frequency High

10. Planned Shutdown


Planned Overhaul only Boiler
Planned Overhaul Blr .& Turbine
Planned Overhaul Blr.,Turb. &
Gen.
Short S/D for all Area
S/D Blr. Certificate Renewal
S/D PG Test Preparation

11. Electrical System


415V Bus Problem
3.3/6.6/11 KV Bus Problem
Power Cable Fault
Control Cable Fault/Fuse Blown
GT/UAT/SAT Problem
Prot./Interlock/Relay Malfunction
D.C. System Problem
3.3/6.6/11 KV Breaker Problem
Maintenance Schedule
HT Motor Problem
LT Motor Problem
D.G. System Problem

12. Miscellaneous
Occurrence of Fire
Dewatering Problem
Others
Commercial Regulation

0901
0902

10
1001
1002
1003
1004
1005
1006

11
1101
1102
1103
1104
1105
1106
1107
1108
1109
1110
1111
1112

12
1201
1202
1203
1204

ANNEXURE-IX

TRIPPING CODES FOR GAS FIRED STATIONS


OUTAGE CODE FOR GAS STATIONS
S.N OUTAGE CAUSE
1. Gas Turbine & Auxiliaries

CODE
01

GT Governing System Problem


High Inlet Air Filter DP
GT Blade Problem
Exhaust High Temperature
ESV/CV Problem
CW Pump Problem
Disc. Cavity Temperature High
Fuel Changeover
Gas Leakage
GT Air Cooler Problem
Fouling of Compressor
Naptha / Liquid Fuel Leakage
High Vibration of GT
Blade path Temp. diff. of GT/Comp.
GT Combustion Chamber/Combustor Prob.
Gas Flame off/disturbed flame
GT L.O. System Problem
GT Control/Power Oil Sys. Prob.
Water Injection Sys. Prob.
Gas pressure low at GT inlet
Bleed Valve malfunctioning
GT Bearing Temperature high
GT speed measurement/monitor/sensor Prob.
GT shaft seal air diff. Pre. Prob.
Lub./Gen. Water Cooling Fans
Miscellaneous
3.

CODE S.NOUTAGE CAUSE


21
2. WHRB & Auxiliaries
2101
2102
2103
2104
2105
2106
2107
2108
2109
2110
2111
2112
2113
2114
2115
2116
2117
2118
0119
0120
0121
0122
0123
0124
0125
0126

0107
0119
0120
0121
0131
0132
0133
0134
0135
0136
0137
0138
0139
0140
0141
0142
0143
0144
0145
0146
0147
0148
0149
0150

Turbine & Auxiliaries

02

Governing System problem


ESV/MS/IV/CV Problem
Turbo Max Problem
Axial Shift
Turbine Bearing Problem
Shaft Vibration High
Lub. oil System Problem
Control Oil System Problem
HP/LP Bypass System Problem
Differential Expansion Problem
HP/LP BFP Problem
CEP Problem
Vacuum System Problem
LP/HP Heater/Gland Cooler Prob.
Shaft Eccentricity High
Water Steam Leakage

0201
0202
0203
0204
0205
0206
0207
0208
0209
0211
0212
0213
0215
0216
0218

Leakage at various places


Feed Regulation Station Problem
Attemperation Station Problem
M.S. Temperature Problem
Condensate Pre heater Tube Leakage
HP Economizer-1 Tube Leakage
HP Economizer-2 Tube Leakage
WHRB Inlet/Diverter Damper
WHRB Blind Plate Problem
Gas Bypass Damper Problem
Seal air fan Problem
Duct Burner Problem
HP Super heater-1 Tube Leakage
HP super heater -2 Tube Leakage
HP Evaporator Tube Leakage
LP Super Heater Tube Leakage
LP Evaporator Tube Leakage
LP Economizer Tube Leakage
HP/LP Boiler Drum Level Problem
WHRB Expansion joint Problem
Exhaust Duct Leakage Problem
High Chemical parameters
Rain Damper exhaust/bypass stack
Miscellaneous

4. Generator & Auxiliaries


Generator Stator Problem
Generator Rotor Problem
Seal Oil System Problem
AVR & Excitation System
Stator Cooling Water System
Gen/Field Beaker Problem
Hydrogen Cooling System
Gen. Slipring Brush Problem
Generator Bus Duct Problem
Generator Protection System
Miscellaneous

03
0301
0302
0303
0304
0305
0306
0307
0308
0309
0310
0311

S.N OUTAGE CAUSE


Top/Bottom diff. Temp. High
Vacuum Pump Problem
Turbine & Auxiliaries

CODE S.NOUTAGE CAUSE


0219
0220

9.

0401
0402
0403
0404
0405
0406
0407
0408

Human Error

06

Operators Mistake
Maintenance Staffs mistake
Contract Labours mistake
Un-identified peoples mistake
Miscellaneous

7.

0221
0222
0223
0231
04

Liquid F/O handling & transfer sys.


DM Water Plant
Instrument Air Compressor System
Fuel Oil System
Fire Protection System
C.W. System
Plant Air Compressor System
Miscellaneous

5.

HP/IP/LP Rotor Failure


Aux. CW System Problem
Miscellaneous
GTs not available
Off-site System & Auxiliaries

0601
0602
0603
0604
0605

Gas Shortage Problem

08

Due to GAIL supply


Due to Gas reducing Stn./NTPC
Liquid Fuel System Problem
Miscellaneous
11. Planned Shut Down
Short S/D for all area
S/D WHRB Certificate Renewal
Planned Shut Down

0810
0811
0812
0813
10
1004
1005

CODE

6. C&I System

05

Control Supply/ Cable Fault


Mal-operation Relay/Protection
ATRS Problem
DAS Problem
Transmitter Switches
UPS System Problem
RTC/Thermocouple Problem
Prot. Trip-No Established reason
Control System Problem
EHC Problem
Card Failure
DDC MIS System
Field Instrument Problem
Miscellaneous
8. Tr. Line/Grid Disturbance

0501
0502
0503
0504
0505
0506
0507
0508
0509
0511
0512
0513
0514
0515
07

400/220/132 KV Line Trip Ext.


400/220/132 KV Relay Malfunction
400/220/132 KV Bkr/Isolator Problem
Line Capacity inadequate
Problem in Shunt Reactor
Disturbance from PGCL Sw. Yd.
Blocking of HVDC
C.T./P.T. Problem
Shunt Reactor Problem
Isolator Problem
ICT Problem
Grid Frequency Low
CVT Problem
Wave Trap Problem
Bus bar/coupler problem
LA Fault problem
Miscellaneous
10. No. Demand

0701
0703
0703
0704
0705
0706
0707
0708
0709
0710
0711
0712
0713
0714
0715
0716
0717
09

REB/ IOCC Message


System frequency high
Miscellaneous
12. Electrical System
415 V Bus Problem
3.3/6.6/11 KV Bus Problem
Electrical System

0901
0902
0903
11
1101
1102

S.N OUTAGE CAUSE


S/D-PG Test Preparation
Planned overhaul WHRB & GT
Planned Overhaul WHRB, GT, ST &
Gen.
S/D-only ST
Mandatory Inspection
Planned Overhaul only WHRB
Miscellaneous
13. Miscellaneous
Occurrence of Fire
De-watering Problem
Others
Commercial Regulation
RLA study

CODE S.NOUTAGE CAUSE


Power cable fault
1006
Control Cable Fault/Fuse Blown
1011
GT/UAT/SAT Problem
1012
Prot/Interlock/Relay Malfunction
D.C. System Problem
1013
3.3/6.6/11 KV Breaker Problem
1014
Maintenance Schedule
1015
HT Motor Problem
1016
LT Motor Problem
D.G. System Problem
Miscellaneous
12
14. Ambient Factor

CODE
1103
1104
1105
1106
1107
1108
1109
1110
1111
1112
1113
13

1201
1202
1203
1204
1205

1301
1302

Rain/ Fog/ Wind


Earth-quake /Cyclone

ANNEXURE-X
MODEL EMERGENCY INSTRUCTIONS FOR TOTAL POWER FAILURE
A.

TOTAL POWER FAILURE

1.

Total Power failure can take place only when


a)
All outgoing 400 KV/220 KV, whatever the case may be, trips on feeder
protections.
b)
400 KV/220 KV system trips on protections.
2.

During grid failure following operations are to be dealt with


a)
Starting of DC lub oil pump.
b)
Starting of DC seal oil pump.
c)
Switching on DC lighting.
d)
Ensure that APH Air motor rotates and APH is rotating, if APH is not
rotating by air motor, start manual rotation.
Starting of Diesel Generator Set.
Resumption of supply.
Normalisation of supply.
Purging of H2 from Generator in case Oil System fails.
Boiler and Turbine side operations.
Note: It is essential to ensure that always torch lights are readily available to meet such
emergencies.
Role of Shift Charge Engineer
1.

SCE should make himself available in his office or in a Control Room.

2.

Ensure from all Unit Controllers regarding running of D.C. oil pump, D.C. seal oil
pump, D.C. lighting and starting of DG sets.

3.

Ensure from 400 KV Control Room regarding start up power.

4.

Once power is restored, instruct C.W. pump house operator to start C.W. pumps,
ensure proper venting of the pumps, ensure starting of all cooling water pumps, DM
plants, DM make-up pumps, fuel oil pumps and compressor.

5.

Select unit for light up. Coordinate with DGM. (Operation.) and AGM (O&M).

6.

After all the steps from (2) to (5) are satisfied, make available in the unit which has
been lighted up first.

Imp: SCE will ensure that no unauthorized instructions and interference are made to his
executives during this emergency.
ACTIVITY 1 : EMERGENCY STATION LIGHTING
Responsibility: Generator Desk Engineer & Electrical Operator 6.6 KV

Act as follows:
1.

Emergency DC lighting should come automatically, but if it fails to come on auto, the
Operator / Engineer has to switch it on from the DC lighting panel.

2.

If the DC lighting does not come automatically the following procedures should be
followed.

After ascertaining that DC seal oil pump and DC lub oil pump has started, the Electrical
Engineer will go for operating DC emergency lights for Control Room.
The DC lighting in the zero meter area will be made on by 6.6 KV Electrical Operator in each
unit.
Once the AC supply is restored, then DC lighting is to be switched off.
ACTIVITY 2 : TURBINE LUB OIL PUMP OPERATION
Responsibility : Turbine Desk Engineer & Jr. Controller
Act as follows:
1.

Check that DC lub oil pump has started on auto and required minimum lub oil
pressure is available.

2.

In case DC lub oil pump does not start on auto the following actions have to be taken.

Turbine Engineer informs his Controller for starting DC lub oil pump from local (at 5.5 mts.).
If still the pump does not start, TG Oil Pump will be started on resumption of supply from
DG set.
If the DC pump fails to start and also DG set fails to start, then individual unit Electrical
Engineer has to go and check the battery output switch is ON and also the switch on
distribution board is ON.
In case EMCC can not be charged on DG set power, and also DC is not available in a
particular unit. DC supply has to be resumed from the other units where DC supply is
available.
If there is delay in starting of DG set or resumption of station supply, then break the vacuum
by opening vacuum breaker valve manually, generally vacuum is killed at speed below 2000
rpm.
3.

If DC lub oil pump is still running after resumption of supply, change over to
Auxiliary Oil Pump when station supply is restored or to TGOP when emergency
MCC supply is restored.

ACTIVITY 3 : SEAL OIL PUMP OPERATION


Responsibility: Electrical Engineer and Seal Oil Operator
Act as follows:
1.

Check that DC seal oil pump has started on auto.

2.

In case DC seal oil pump does not start on auto, then following action will be taken.

Start DC seal oil pump locally.


If still DC seal oil pump does not start, seal oil Operator will check whether Turbine Lub oil
pump (EBOP) is running.
If Turbine lub oil pump is running, then oil pressure of 1.75 Kg/Cm2 will be obtained in the
lub oil Header. So taking a seal oil to H2 differential pressure of 0.35 Kg/Cm2, H2 pressure
of 1.4 Kg/Cm2 can be maintained in the Generator.
Operator will rush for rectifying the fault in DC seal oil system.
If still DC seal oil pump does not start, AC seal oil pump will be started only after resumption
of supply from Control Room.
Change over, DC seal oil pump to AC seal oil pump, on availability of AC supply, if DC seal
oil pump is still running.
ACTIVITY 4 : DG SET OPERATION
Responsibility : Generator Engineer and Station Electrical Operator
Act as follows:
1.

Check that DG set has started on auto on loss of power. Generator desk engineer will
start the available DG set for remote operation from push button provided in CSSAEP
of UCB-I. In case, it fails to start on auto, close the breaker to E.M.C.C. after
ensuring that tie to E.M.C.C. has tripped.

2.

If, it does not start on auto, then it is to be started locally from DG set room. Station
Electrical Operator is responsible for starting DG set on manual.

3.

The generator desk Engineer - Unit-I will serve as the third man for starting DG set
from local in case he does not have any problem in his area.

4.

Before starting DG set from local, diesel oil level in the tank, water level in radiator,
and battery voltages (24V) are to be checked. All selector switch positions be kept in
local mode.

5.

Start DG set locally. Yellow lamp indication will be available in Generator desk
indicating DG set has started. While starting of DG set, if cranking is observed, start
the DG set again.
After 3 starts if the DG set fails to pick up speed, try starting the other DG set by
following the same procedure.

6.

Close incoming breaker to E.M.C.C. after ensuring tie-breaker from E.M.C.C. is


tripped. This operation is to be done by Electrical Engineer.

7.

If the breaker does not close from control room panel, it should be closed from
E.M.C.C. located at zero mts. So, the Electrical Engineer should rush there with LT
breaker handle, LT key etc.

8.

415 volts L.T. supply is restored to Emergency MCC.

ACTIVITY 5: HYDROGEN PURGING


Responsibility : Seal Oil Operator, Electrical Engineer and DM Plant Operator
Requirements :
1.

2 Nos. of Helpers

2.

Spanner (size 25-28) and key

3.

Availability of filled CO2 cylinders.

Case 1 :
1.

In case of DC or AC seal oil pump does not pick, then seal oil operator has to check
the running of Turbine lub oil pump (either EBOP or TGOP). If not running, then H2
purging should be started immediately.

2.

Seal oil operator will make ready the system for H2 purging.

3.

On receipt of information from Unit Controller / Electrical Engineer, H2 purging will


be started as follows:

Open H2 gas vent valve and start CO2 filling to generator.


H2 will start purging out.
Fill CO2 upto 95% purity. Measure purity by ORSAT Apparatus with the help of shift
chemist.
Start purging CO2 by air by opening CO2 vent valve and opening isolating valve of H2 feed
line to fill air from atmosphere.
Electrical Engineer / Unit Controller will guide the Junior Controller and Operator regarding
purging procedure.

Case 2 :
1.

If EBOP or TGOP is running, then H2 is to be vented till a H2 pressure of around 1.0


Kg/Cm2 is obtained.

2.

H2 venting is to be carried out by opening the H2 vent valve.

ACTIVITY-6 : IMPORTANT OPERATIONS ON BOILER SIDE


Responsibility : Boiler Desk Engineer and Jr. Controller
Help of respective area operator is to be taken wherever necessary.
Act as follows:
1.

a)
Check whether APH is rotating through Air motor. If not check for air
pressure and verify solenoid valve opening. If needed, open bypass of air solenoid
valve too, otherwise start manual operation for rotating APH.

Start APH motor on availability of supply from DG set.


2.

Confirm no fuel input to the Furnace by closing oil and ignitor valves (Burner Floor
Operator).

3.

Close CBD valve, if in open condition.

4.

Close soot blower isolating valve, if in service.

5.

Close all superheater attemperation valves.

6.

Close all reheater attemperation valves, if it is in service before the emergency.

7.

Ensure SCAPH steam inlet isolating valves are closed.

8.

Close all sampling line valves before sample coolers.

9.

Ensure that mill outlet valves are shut.

10.

Reset all fields manually (ESP Operator).

11.

Close PRDS min isolating valve and spray valve, if there is no requirement of aux.
steam.

12.

Start the scanner air fan after resumption of supply and open its discharge damper
manually.

Imp.:

Engineer (Off site) / Jr. Controller (Off site) will ensure that Diesel Fire Fighting
Pump is in service. If not, it is to be checked locally and to be started manually.

ACTIVITY-7 : IMPORTANT OPERATIONS ON TURBINE SIDE


Responsibility : Turbine Engineer, Jr. Controller
Act as follows:
1.

Close Hot well make up to condenser manually.

2.

Close main ejector steam valve and break vacuum by opening vacuum break valve at
less than 2000 rpm of Turbine speed. This may help in avoiding rupture of LPT
diaphragms.

3.

Close seal steam header valve from main steam and also ensure aux. steam supply to
seals is isolated when the vacuum drops to less than 100 mm of Hgc.

4.

Ensure HP / LP bypass line valves are closed and spray line valves are also shut off.

5.

ESV, CRV and CV closing to be ensured from Control Room.

6.

All extraction block valves have to be closed manually.

7.

Ensure that all NRVs of block valves have closed.

8.

All unit drains are to be kept closed, except extraction line and turbine casing drain,
manually.

9.

CRH line and HRH line drains are to be ensured for closing.

10.

In case DG set does not start and power supply is not restored from station
transformer, then hand turning of Turbine is required for uniform cooling of rotor.
The rotor should be rotated by handle intermittently, till supply is restored.

11.

Ensure that no drain is going to condenser.

12.

If condenser hot well level is high, drain to normal level.

13.

If L.T. supply is restored, the electrically operated valves which ever is required
should be operated from Control Room.

ACTIVITY-8 : IMPORTANT OPERATIONS ON SWITCHYARD SIDE


Responsibility : Switchyard Control Engineer
Act as follows:
1.

Quickly ascertain the cause or reason leading to grid failure.

2.

Identify fault initiation point whether it is inside the station or external.

3.

Send Jr. Controller to yard for visual inspection of Breakers, Transformers etc.

4.

Bring Auto transformers tap position to minimum.

5.

Keep in continuous touch with other SEBs.

6.

If 132 KV system is healthy and the fault in 400 KV external to station, establish
power supply through 132 KV System.

7.

When fault is cleared on 400 KV side, arrange for restoration of supply.

8.

When 400 KV bus is charged, 33 KV supply is to be restored through Tie transformer.

9.

Reset the Tie transformer incoming breaker to 33 KV system.

10.

Close 400 KV Breaker to Tie transformer 1 and 2 for idle charging.

11.

Close Tie transformer 1 incoming Breaker to 33 KV Section 1.

12.

Close Tie transformer 2 incoming Breaker to 33 KV Section 2.

13.

33 KV Bus-A and B is charged.


On availability of 33 KV supply, the Engineer will check that supply is restored as per
following priority.

Check that Station transformer are charged.


Inform Unit Controller and Shift Charge Engineer.
Normalise communication DC System.
Charge 415V switchyard MCC.
(Start one of the Air compressor for switchyard)
Normalise unit L.T. supply.
Normalise C.W. Switchgear.
Normalise W.T.P. Switchgear.
Normalise colony lighting.
Once L.T. supply is restored in unit control room, D.G. set can be stopped and kept on auto
standby, after confirming from all the units.
Note :
When total power failure occurs, Battery charger will trip and D.C. load will come on
batteries till DG set comes into services. If during that period D.C. voltage comes down,
Boost charger may be kept in service to boost up voltage after starting D.G. set and later on
only Float charger may be kept in service (Normal condition).
ACTIVITY-9 : NORMALISATION OF SUPPLY

Responsibility: Electrical Engineer, Electrical Operator 6.6 KV, WTP and 33 KV


Act as follows :
1.

Charge 6.6 KV Station Bus.

2.

Charge station L.T. Bus 1A, 1B, 2A, 2B from Control Room.

3.

Charge unit LT Bus and Emergency MCC from Control Room. Stop DG set if it is
running.

4.

Charge and normalize WTP 6.6 KV Bus.

5.

Charge C.W. Bus System.

6.

Charge C.T. LT MCC, AW/FF Raw Water M.C.C.

7.

Check that Air Compressor 6.6 KV system charged.

8.

Check that 415 V Air compressor supply is available and normalized.


Inform Shift Charge Engineer for starting the auxiliaries.

ACTIVITY-10 : RESTORATION OF OFF SITE SYSTEMS


Responsibility : Off Site Engineer Jr. Controller
Activities for starting the auxiliaries like CFW pumps, CW pumps, AW/FF pumps CT fans,
Raw water pumps, ARCW pumps, Ash Slurry pumps and Air compressors.
Act as follows :
1.

Operator (Raw Water Pump House) will start Raw Water pumps.

2.

Operator C.W. pump house will start the clarified water pumps.

3.

Operator / Jr. Controller will start the CW pumps, after ensuring that Unit condenser
inlet / outlet valves are open.

4.
air).

Operator / Jr. Controller will start the Air compressors (both plant air and instrument

5.

Jr. Controller (Turbine) will start ARCW pumps.

6.

Operator (CW fans) will start CT fans.

7.

Operator (Fly ash pump) will start the Fly ash pumps, HP and LP one by one.

8.

Operator (Ash Slurry) will start the slurry pumps, depending on slurry level in the pit.

9.

Operator (air conditioning) will start the Air-conditioning System.

10.

Operator will start the Ventilation System.

11.

Operator / Jr. Controller (Turbine) will start the Air Washer pumps and fans.

12.

Operator (Fuel oil pump house) will start one HSD and one HFO pumps.

13.

DM Plant Operator will start DM make up pumps.

Now after all these operations, unit is ready for start up operation. The subsequent operation
is as per Shift Charge Engineer / Sr. Superintendent (O).

ANNEXURE-XI
MODEL EMERGENCY INSTRUCTIONS FOR FIRE IN MILL
B.

FIRE IN THE MILL

Responsibility : Unit Controller, Boiler Desk Engineer, Boiler Controller & Mill Area
Operator
Fire in the mills can be classified into two categories
a)

Fire in Mill under Shutdown :


Isolate the mill totally from air side by closing mill cold / hot air dampers, PA Fan
isolating damper, PA Fan & mill seal air valves. Keep the Mill PF valves closed and
also reject doors closed.
Charge CO2 into the mill to extinguish the fire.
We can also charge high temp. steam wherever the system is provided.

Caution: Never use water or any other liquid, as it may crack the grinding elements.
b)

Fire in Running Mill :


Bring down the temperature by admitting cold air. Reduce the air flow and increase
the coal feed. When Mill outlet temperature starts dropping and fire in Mill is
extinguished. Normal fuel/air flow/temperature can be maintained.
If the fire is uncontrollable still, stop the mill immediately and follow the instruction
as in (a).

ANNEXURE-XII
MODEL EMERGENCY INSTRUCTIONS FOR FIRE IN AIR PREHEATER
C.

FIRE IN AIR-PREHEATER

Responsibility : Unit Controller, Boiler Engineer, Boiler Controller and Burner Floor
Operator
1.0 DETECTION
Early detection of air heater fire will help in reducing the damage and down time. An air
heater fire is indicated by one or more of the following symptoms:
a)

An alarm from the Infra Red Fire Detection System (IRDS), which can detect hot
spots very early.

b)

Abnormal or sudden rise in the temperature, mainly, gas outlet temperature. Once the
fire is established, all the terminal temperatures may go out of scale.

c)

An alarm indicating Air preheater gas outlet / Air outlet temperature high

d)

Stoppage or jamming of the air heater or hunting in the amperage.

e)

Visual indication at local.

f)

Sudden jamming of the dampers below.

2.0 DEALING WITH AIR HEATER FIRE


Any sign of an air heater fire should be dealt with very seriously. On receiving a suspicion of
air heater fire, start air heater soot blowers immediately (if not in progress already) and
inspect the air heater locally for any abnormality. If there is no sign of improvement and fire
is confirmed, then proceed as follows:a)

Trip the boiler and draft plant and close all the associated dampers, leaving the air
heater running

b)

Intimate fire tender

c)

Open fire water and water washing valves for extinguishing the fire.

d)

Admit fire water in the air side also, through the header, if provided; or with the help
of fire tender; through the manhole

e)

Continue to spray water until the rotor is completely cooled. Ensure that water

is

free to escape through drains.


f)

Keep the air heater running and open the inspection doors when safe to examine the
airheater

g ) Inspect the other air heaters also

Note:

While admitting fire water, bottom duct/hopper drains / manholes should be opened.
Dampers also can be slightly opened for the escape of water and steam.

The same procedure mentioned above is to be adopted, if the air heater is not rotating
also (jammed).

Soot blowing operation can be suspended during fire fighting.

Copious amount of water only and not other extinguishers like CO2, Halon etc. is
effective during air preheater fire.

3.0 REMEDIAL ACTIONS/ PRECAUTIONS


Air heater fires can be avoided if enough care is taken during overhaul,
recommissioning and operation of the plant. The precautions to be taken at various O&M
Stages are given below.
3.1

During Overhaul:
Water Washing of air heaters should be carried out in the hot condition after boiler
shutdown ie, when the flue gas temperature is between 200 to 150C.

Proper cleanliness of heating elements should be ensured after water washing. If any
basket is excessively fouled, it should be taken out and cleaned with water and steam.

Damaged or thinned out baskets should be replaced with new baskets.

Before loading new baskets into the air heater, they should be steam cleaned to
remove the preservative oil.

Usage of reconditioned/ reclaimed baskets

should be avoided.

Care should be taken to prevent the accumulation of ash on the heating elements
while duct cleaning etc.

If ash accumulation is observed on the heating elements, it should be removed by


water washing and the air heater should be sufficiently dried by running ID and FD
fans and charging SCAPH (about 75C), before starting oil firing.

3.2 During Recommissioning (Pre-light up)

Before light up, cleanliness of the air heater and removal of all foreign material
should be ensured. Necessary protocols to this effect should be signed by Boiler
Maintenance and Operation Department.

Air heater dampers should be commissioned and made available for operation.

Air heater oil carry over probes and inspection ports with lights (if provided) should
be made available for operation.

Air heater fire water should be charged up to the last valve.

Air heater soot blowers should be commissioned and kept ready for operation.

All oil burner valves should be checked for passing and any defective one should be
rectified.

Particular attention should be given to the cleanliness and maintenance of oil burners.
Guns should be flushed thoroughly and any leakage from the sprayer or flexible hose
should be attended.

All instruments related to combustion and air heaters must be ensured to be in perfect
working condition.

Infra red fire detection system or an alternative arrangement for detecting the fire at
an early stage should be available when the air heater is in service, particularly during
start - up activities.

Air heater interlocks and the functioning of the rotor stoppage alarm should be
checked before taking the air heater into service.

3.3 During Start up :

Necessary protocols, covering the aspects mentioned in 3.2 should be signed with the
concerned maintenance departments, before boiler light up.

Boiler cold start up check list should be signed and the deviations should be approved
by the competent authority.

During start up, start and keep all the air heaters in service, irrespective of the number
of fans being started.

Keep the air and flue gas dampers of the idle air heaters closed..

Charge SCAPHs as soon as the fans are started.

Ensure correct air flow at the time of purging and light up.

Maintain proper atomising medium pressure and oil pressure at the time of light up.

Maintain the required minimum oil temperature (>100C for HFO and LSHS).
During light up, check for proper combustion by observing the flame, exit of the
furnace section and the stack. Take corrective action in case of unstable flame or
black or white smoke leaving the chimney.
Air registers/ secondary air dampers of all oil guns in service should be ensured open.
In case of poor combustion of a particular burner, the reason should be identified and
corrected immediately. Burners, which are not proving should not be tried repeatedly.
Increase of firing rate and boiler pressurization shall be as per the rates prescribed
under start up procedures.

HFO/ LSHS shall be admitted into the furnace only when the furnace is sufficiently
warm.
Air heater soot blowing should be started immediately after boiler light up. Blowing
should be done with steam at proper pressure and temperature at least once in four
hours for each air heater (including the idle air heater). During light up, if availability
of the soot blower is lost, boiler pressurisation should be stopped and the boiler
should be boxed up.
Oil carry over probes should be inspected regularly during light up.
Air heaters should be inspected locally through the inspection port regularly.
While the boiler and air heaters are in service, all the instruments related to
combustion and air preheaters should be observed carefully and any sign of error in
the instrument should be attended immediately.
A close watch should be kept on the terminal temperatures of air heaters. Any
unusual increase in one or more of these should be investigated immediately.
The above precautions should be continued till oil support is completely removed and
temperatures have stabilised.
Soot blowing shall also be carried out before shutting down the boiler after a
significant period of oil firing.
5.4 During Shut down:
After the boiler is tripped and combustion chamber has been purged, all air heater
dampers should be tightly closed and air flow through the air heaters should be
avoided.
The creation of draft through the air heater is to be avoided. The air heater
temperature should be monitored regularly when the boiler is boxed up till the air
heater cools down.

ANNEXURE-XIII
MODEL EMERGENCY INSTRUCTIONS FOR FIRE IN MAIN OIL TANK
D.

FIRE IN MAIN OIL TANK

Responsibility : Unit Controller, Turbine and Generator Desk Engineer, Turbine


Controller and Seal Oil Operator.
Action :
1.

Oil fire around MOT should be controlled immediately by using fire extinguishers and
inform UCB.

2.

In case of MOT oil fire does not come under control, following action to be taken.

Unit Controller should trip the unit immediately and break the vacuum so that speed comes
down at the earliest.
Hydrogen in Generator is to be purged out immediately.
Stop the lub oil and seal oil pumps.
After controlling the fire in case oil is there in MOT lub oil and seal oil pumps are to be
started. Otherwise oil to be topped up in MOT and lub oil and seal oil pumps are to be
started.
ANNEXURE-XIV
E.

INSTRUCTIONS ON MILLING SYSTEM SHUTDOWN AND ISOLATION

A milling system in service is shutdown either to carry out some maintenance works on any
of the equipment or as a standby.
The isolation carried out
a)
Enables maintenance people to carry out their work.
b)
Ensures safety of the equipments.
SOME SHUT DOWNS OF MORE FREQUENT TYPE ARE LISTED BELOW.
1

SHUTDOWN TO CARRY OUT MILL INTERNAL INSPECTION ETC.

PA Fan isolating damper and seal air isolating valves are to be closed.
Keep Mill PF valves open.
Carry out Mill local run, if requested by Maintenance staff on opening of reject chamber
doors and then isolate supply for Mill Motor.
Isolate supply for PA fan also.

MILL:
Whenever a mill is shutdown to a normal standby condition normally no
isolation is carried out. Even then, ensure that
a)
Hot air damper is close fully.
b)
Cold air damper is open fully.
c)
PA fan van is in minimum position, wherever applicable.
Mill outlet temperature is to be observed regularly. If any rising trend is observed PA fan
isolating damper is to be closed.
2. SHUTDOWN TO CARRYOUT PA FAN BEARING INSPECTION
Isolate supply to PA fan.
Isolate the PA fan bearing cooling water.
Inform Mechanical Maintenance staff to get C&I connections like bearing temperature RTDs,
vibration pick ups and local temperature, gauges removed before opening bearings.
Carryout isolations listed under (1) for equipment safety.
Close PA fan isolating damper and PA seal air isolating valve if requested by Mechanical
Maintenance.
3.

SHUTDOWN TO ATTEND PA FAN CASING LEAKS

Close PA fan isolating damper.


Close PA fan seal air isolating valve.
Ensure isolations listed under (1) also.
Isolate supply for PA fan in case maintenance wants to work inside the PA fan casing.
4.

SHUTDOWN TO CLEAR CHOKING OF MILL REJECT GATES.

PA fan isolating damper is to be closed.


PA fan seal air isolating valve to be closed.
Keep Mill PF valves open.
Once Maintenance staff open the reject chamber doors, carry out Mill local run, if requested.
Isolate the supply for Mill motor is requested by Maintenance staff (want to go inside and
work).
Caution: Please normalize C&I bypassing immediately after Mill local run.
5.
SHUTDOWN TO ATTEND TO CLEAN OUT CONVEYOR / RC FEEDER
INSPECTION / RC FEEDER CALIBRATION ETC.
R.C. feeder is to be emptied before stopping the Milling system, by closing the bunker
gate. On closing bunker gate lower Secoal protection gets bypassed and feeder normally
trips on No coal on belt protection. If for any reason bunker gate opens or gets jammed,
feeder will trip on lower Secoal even though gate is closed. So ensure that Bunker gate
opens, is not bypassed. If so get lower Secoal protection bypassed by C&I.
After emptying the feeder and stopping the milling system, carryout following
isolation immediately:
Close PA Fan isolating damper & seal air valve.

Ensure conditions listed under (1).


Feeder front & rear door be kept open.
Keep Mill PF valves open, if still hot gases are found coming through the feeder to mill inlet
chute.
Isolate feeder supply depending upon the requirement or Maintenance person s request.
6.

SHUTDOWN AFTER COAL BUNKER EMPTYING

Ensure complete emptying of the bunker. After stopping the Milling system following
isolations are to be carried out immediately.
Close RC bunker gate.
Close PA fan isolating damper & seal air valve.
Feeder front & rear doors be kept open.
Keep PF valves open.
Note : In case bunker gate is not closing due to any defects isolations listed as (b), (c), (d) are
very important in addition a frequent check of RC feeder is essential to prevent any fire
hazard and subsequent damage to feeder.
8.
SHUTDOWN TO ATTEND LEAKAGE (COAL LEAKS, AIR LEAKS, OIL
LEAKS, PA FAN CASING LEAKS ETC.)
In good number of cases, to identify the leaking zone becomes difficult after stopping
the milling system. Hence it is essential to ensure that Maintenance staff has personally seen
the leakage with Milling system in service before stopping. Carry out the isolations suitable
for carrying out maintenance work. Also ensure conditions listed under (1).

ANNEXURE-XV
A. SAMPLE FORMAT FOR MONTHLY REPORT ( COAL STATION)
(To be prepared by site)

Performance for the month of ________________


Sl.
01
02
03

Description
Installed Capacity
One Hour Peak Load
Generator on Bar
Reserve Hours
Total Available Hours

04 Generation Targets
- ORT
- Budget
RE
05 Actual Generation
06 Plant Load Factor
07 Availability Factor
08 Loading Factor
09 Partial Loading
10 Aux. Power Consumptn.
11 Aux. Power Consumptn.
FUEL AND HEAT RATE DATA -SEPTEMBER2007
01. Coal consumption
02. Sp. coal consumption
03. Oil consumption
04. Sp. oil consumption
05. GCV of coal as fired
06. Avrg CV of oil
07. Unit Heat rate
08. Overall Efficiency
09. D.M. water : Make-Up
10. Outage Hours
- Planned
- Forced
- Grid (Disturbance)
- Coal supply
- Total
11. No. of Outages
- Planned
- Forced
- Grid (Disturbance)
- Coal supply
- Total

Unit
MW
MW
Hrs
Hrs
Hrs

MUs
MUs
MUs
%
%
%
%
MUs
%
MT
Kg/kwh
KL
ML/KWH
Kcal/Kg
Kcal/KL
Kcal/Kwh
%
MTs
% MCR
Hrs
Hrs
Hrs
Hrs
Hrs

(Nos)
(Nos)
(Nos)
(Nos)
(Nos)

Unit-I

Unit-II

Stage I

Unit-III

Unit-IV

12. No. of Tube leakage


13. (a) Generation loss due to Outages
- Planned
- Forced
- Grid (Reserve)
- Coal supply
Total :
(b) Generation loss due to Partial loading
Start-up/Stabilisation
Grid restriction
Poor coal quality
High Frequency
Coal supply problem
Station Problms
Total :

(Nos)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)

(c) Grand Total :

(MUs)

(d) Excess Gen. (-)

(MUs)

(d) Net Partial loss


14 Generation loss due to Grid
- Grid Backing Down Claimed

(MUs)
(MUs)
(MUs)

BREAK-UP OF GENERATION LOSS DUE TO STATION PROBLEMS


Description

Unit-I

Mill Air Preheater A outage


Main APH A Outage
Debris removal from Condenser
Condenser cleaning
CW forebay debries removal
Poor vacuum
Silica high
Shut-down activities
Load Optimisation
Commercial Regularisation
Mill Not available
Milling system
Bunkering Problem

15 Coal status :

Unit-II

Stage I

Unit-III

Unit-IV

Stage II

(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
Total :

- Opening Stock
- Receipt during Month (Provisional)

Unit
MT
MT

Station

- Total
Stage-1
Stage-2
Total

- Consumption

- Closing stock (Usable Stock) PSL

16 Energy Export
400 KV System

MUs
MUs
MUs
MUs
MUs

- HVDC - I
- HVDC - II
Total Energy Export
Construction power Consumption
Township Consumption
STAGE I
Decleared Capability
Schduled Generation
STAGE II
Decleared Capability
Schduled Generation
OIL STOCK / RECEIPT / CONSUMPTION
Sl
01

Item
HFO

Unit
(KL)

02

LDO (stg-1)
Stage II

MT
MT
MT
MT
MT
MT
MT

Opening Stock

MUs
MUs
Month

Year

%
MUs
%
MUs
Receipt

Consumption

Closing Stock

(KL)

Oil consumption Break-up


Sl. Description
01. HOT START UP
02. WARM START UP
03.COLD START UP
04. STABILISATION
05. GUN TESTING
06. SHUT DOWN ACTIVITY
07. ELECT TESTING
08. SAFETY VALVE FLOATING
09. 2 ND START UP
10. MILL SUPPORT
TOTAL

Unit
KL
KL
KL
KL
KL
KL
KL
KL
KL
KL
KL

Unit-I

UNIT RUNNING HOURS/GEN SINCE INCEPTION

Unit-II

Stage I

0.000

Unit-III

Unit-IV

Stage II

0.000

Station

0.000

Unit-I
Cummulative Generation
since First Synchronisation
Cumml. Hrs Generator on
Bar since First Synchronisation
Generation computed based
on Peak hour generation

Unit-II

MUs

Hrs

MUs
MUs
% PLF

OUTAGE REPORT
Unit /
Outage No

From
Hrs

To
Hrs

Duration
Hrs

Remarks

Stage I

Unit-III

Unit-IV

Stage II

Station

ANNEXURE-XVI
ORT EXCEPTION REPORT

ORT EXCEPTION REPORT


STATION:--------------------

NATIONAL THERMAL POWER C

Regional Operation S

..

Ref. No:

Sub: ORT Exception Report of ----------- (Name of station) for the month -------------- (Name 0f Month/Year)
Enclosed please find herewith the Exception report of ORT Meeting held at---(Name of station)---------- on ---(Date)--to review the performance of the station for the ----(Month)---- 2005.

This is for your information and necessary action please.


DISTRIBUTION:
Corporate centre / Regional HQ: Through NTPC
Intranet/e mail

1.0 STATION PERFORMANCE W.R.T. MOU TARGET (2005-2006):

1.1 VARIATION IN MOU TARGET WITH ACTION PLAN :


MOU
TARGET (R0)
(FINANCIAL
YEAR)
PARAMETERS

MOU TARGET (Fin. Yr.)


R1

R2
(Revision)

R3

R4

MOU
TARGET
Pro rata

ACT
UAL
TILL
Date

VARI
ATION

GENERATION-MU

PLANNED OUTAGE-%

FORCED OUTAGE-%

PARTIAL LOADING (%)

HEAT RATE-KCAL/KWH

SP. OIL-ML/KWH

AUX. POWER CONS.ml/kwh

INVENTORY-(Rs. Cr)
1.2 DETAILS OF MOU PARAMETERS

Description
Gross Gen.
(MU)

APR
Target
Actual
Deviation (+/-)

Planned
outage(%)

Target
Actual
Deviation (+/-)

Forced Outage
(%)

Target

MAY

JUN

JUL

AUG

SEP

OCT

NOV

DEC

Actual
Deviation (+/-)
Partial loading
(%)

Target
Actual
Deviation (+/-)

Aux. power
Con. (%)

Target
Actual
Deviation (+/-)

Specific Oil
Cons. (%)

Target
Actual
Deviation (+/-)

Heat
Rate(Kcal)

Target
Actual
Shortfall/
Excess

Inventory
(Rs.Cr)

Target
Actual
Deviation (+/-)

Note: The shortfall (-) & excess (+) in the above parameters should be highlighted in red & green colour respectively.
2.0 PERFORMANCE DETAILS

Apr
Gross Gen.

MU

Plant Load
Factor

Availability
Factor on bar
Machine
A.V.F

Total Partial
Loading

May

Jun

Jul

Aug

Sep

Oct

Nov

Dec

Jan

Feb

Equipment
Partial
Loading

Oil Cons.

KL

Sp. Oil Cons.


Coal Cons.

ml/kwh
MT

Sp. Coal cons.

kg/Kwh

DM Make up
Cons.

% of
MCR

No. of Outages

No.

No. of Tube
Lkg
Forced
Outage (
Incld. coal &
grid)
Forced
Outage due to
coal
Forced
Outage due to
grid
Forced
Outage
(Excld. coal &
grid)
Forced
Outage (due to
Tube Lkg)

No.

%
%
%

%
%

3.0 ABT ANALYSIS

3.1 ABT GAP ANALYSIS (FOR STATIONS UNDER ABT)

DC
installed
(A)

MONTH

DC
(bar)
%of
A

SG
%
of
DC
bar

AG %
of DC bar

DC (installed)-DC (bar) break up (%)

Planned

Forced

Equpt.

APRIL
MAY
JUNE
JULY
AUG
SEPT
OCT
NOV
DEC
JAN
FEB
MAR
CUM.
Note: The above table may be filled separately stage wise, where ABT is followed stage wise
3.2 ACTION PLAN FOR ANY DEVIATION IN ABT GAP ANALYSIS:

Issues

Reason for not achieving 80%


of installed DC
Reason for not achieving
101% of DC (Declared)

Reasons

Action Plan

Fuel
quality

Fuel
supply

Constraints for achieving 105% DC


*

Reason for Negative UI,if any

* Limited to 105% of the name plate rating of the machine


4.0 UNIT WISE AVAILBILITY LOSS BREAK UP (%) :
Month (Till)

July/05

S.N

Description

Unit-1
Month

1
2
3
4
5
5.1
5.2
5.3
5.4
5.5
5.6
5.7
5.8

PLANNED
GRID (Reserve)
GRID(Regulation)
FORCED Outage (Without Coal)
FORCED Outage (With Coal)
TUBE LEAKAGE
BOILER & AUX.
TURBINE & AUX.
ELECT.
C&I
HUMAN ERROR
BOP
GRID DISTURBANCE

Unit-2
Cum

Month

Cum

Unit-3
Month

Cum

Month

COAL
5.9

OTHERS

5.10
TOTAL
5.0 OUTAGE ANALYSIS & RESTORATION

5.1 DETAILS OF UNIT OUTAGES


Note: The following tables will contain all outages during the month.

S.N

Unit

Outage
No.

S.N

Unit

Outage
No.

Outage From
Date/
Time

Outage
Duration
(Hrs.)

Outage Category

Station Trip Committee Recommendations

Root Cause

Responsibility

5.2 DETAILS OF MULTIPLE UNIT TRIPPING:


S.N

Unit

Outage
No.

S.N

Unit

Outage
No.

From
Date/
Time

Outage
(Hrs.)

Recommendations /
Action plan

Category

Responsibility

Root Cause

Target Date

6.0 6TUBE
ANALYSIS

S.N

FAILURE

Unit

S.N

Outage
Time

Outage Date

Last O/H Date

Root cause of
failure
(As per central
committee)

Supplementary Jobs
Attended

Outage
Hours

Postponed

Location

Action Plan

7.0 PARTIAL LOADING

7.1 Partial Loading for the Month


September/05
S.N

Description

Unit-1
Month

Total (Equipment)

1.1

Boiler & Aux.-

1.2

Turbine & Aux.

1.3

Electrical

1.4

C&I

1.5

Balance of Plant

1.6

Others

Total (external)

Unit-2
Cum

Month

Cum

Unit-3
Month

Cum

Unit-4
Month

Cum

2.1

Coal Shortage

2.2

Coal Quality

2.3

Water Shortage

2.4

Grid Disturbance

Start up/ Stab./S/D

Regulation
Total

7.2 ACTION PLAN FOR REDUCING PARTIAL LOADING FOR THE MONTH
Sl.No

Unit

Reason for major Partial Loading

Corrective Action

8.0 EFFICIENCY

8.1 OVERVIEW OF EFFICIENCY GAP ANALYSIS -UNIT WISE


Note: Based on
Efficiency tests
conducted during the
month
Ma
y/0
5
Month

Uni
t

Design
Value

Actual
Value

Uni
t

May/05

BOILER
EFFICIENC
Y-%
(
UNCORREC
TED)

Design
Value

Actual
Value

Unit

May/05

TURBINE
HEAT
RATEKCAL/KWH

UNIT
HEAT
RATEKcal/Kwh)

Design
Value

8.2 ACTION PLAN FOR MAJOR HEAT RATE DEVIATIONS:

Unit

System/
Parameter

Loss
(Kcal/Kwh)

Major Causes of Heat


Rate deviation

Action plan

8.2 HEAT RATE DEVIATION-FOR


THE MONTH-Kcal/Kwh

PARAMETER

Unit-1

Unit-2

Unit-3

Unit-4

DESIGN HEAT RATE


COND. VACUUM
FW TEMP. AT ECO INLET
M.S PRESSURE
M.S TEMP.
HRH TEMP
SH SPRAY
RH SPRAY
HP TURBINE CYLINDER
EFFICIENCY
IP TURBINE CYLINDER
EFFICIENCY
MAKE UP WATER
DRY FLUE GAS LOSS
WET FLUE GAS LOSS
UNBURNT CARBON LOSS
OTHERS
TOTAL HEAT RATE
DEVIATION

8.3 ACTION PLAN FOR DEVIATION (IF ANY) IN APC

S.N

Heading

Reason for High APC

Unit-5

Unit-6

Unit-7

Unit No

Type
of Overhaul

SCHEDULE

II

III

9.2 PLANNED OUTAGES-QUALITY OF OVERHAULS


OUTAGES AFTER OVERHAUL

Unit

Date of Completion of last O/H

1
2
3
4
5
6
7

Unit
1
2
3

Major Equipments failures


after O/H

Duration &
Type of O/H

10.0 SAFETY GAP ANALYSIS


MAJOR DEVIATIONS (FOR THE MONTH):
A) ACCIDENTS:
Accidents
Unit /
Non
Off site
Fatal
fatal

Near
miss

Root cause

Station
B) FIRE INCIDENTS:
Unit /
Off site

No. of
fire
incidents

Root Cause

Station

C) FIRE PROTECTION SYSTEM AND T&P

Description

Unit/area

Any Major deviation in Fire Protection


System(including non availability of any
equipment)
Pending of T &P testing,
if any
Any abnormal operation duringthe
month

11.1 STATUS OF TECHNICAL AUDIT ACTION PLAN:

Status/Reason

Target
date

Audit/Date

Complied & Closed

Work in progress

Responsibility

Work in progress

Responsibility

11.2 STATUS OF ROPR ACTION PLAN

ROPR No./Date

Complied & Closed

12.0
SYSTE
M
HEAL
THIN
ESS

Sl.No
1
2

Unit

Protection

Out since
(Date)

Unit

Auto loop

Out since
(Date)

Unit

Equipment

Pending since
(Date)

Unit

Sl.No

Non-Availability
of EHC/Hydraulic Mode

Out since
(Date)

1
2

Sl.No
1
2

Sl.No
1
2

13 .0 O&M / CRITICAL ISSUES

13.1 SUMMARY OF O&M ISSUES

Area
Boiler &
Aux.

S.No.

1
2

Turbine &
Aux.

Brief description of the


problem

Problem
Initiated on
(Month/year)

Action taken /
to be taken

Electrical

1
2

C&I

2
BOP

1
2

Fuel
Management

1
2

Others

1
2

13.2 ACTION PLAN FOR LOW COAL STOCK (HAVING LESS THAN 10 DAYS STOCK)
Coal Stock
(Days)

Description of Problem

Action Plan for increasing Coal stock

13.3 MONITORING OF SPARE GENERATOR TRANSFORMERS

S.N

GT DETAILS *

PROJECT

UNIT

2
14.0 MISCELLANEOUS
14.1 STATION HIGHLIGHTS

14.2 STATUS OF R&M WORKS OF STATION


S.N

Description

Total no. of schemes


approved

Date of approval

Total approved cost

BE for Financial Year

Amount Spent till date

Cumulative amount
spent till date

No. of schemes planned


to be completed in FY

No. of schemes
completed in FY

Cumulative no. of
schemes completed

10

Action plan for


meeting shortfall

14.3 NEW POINTS DISCUSSED DURING ORT MEETING

Status

S.No

System

Description

S.No

Unit

Parameter

14.5 UNIT COMMISSIONING / TRIAL OPERATION ETC. ( IF ANY ) :


S.No

Description

Signature of ORT Coordinator (Regional OS)

ANNEXURE-XVII
SAMPLETEMPLATES FOR ROPR MAIN (COAL STATIONS)

Performance Highlights
ROPR Target Gap analysis
Forced Outage Gap analysis
ABT Gap Analysis
Efficiency Gap analysis
Overhaul Preparedness Index
Critical Issues
R&M
Safety
Fuel Status
Ash Utilisation
Environment
Financial Ratios

PERFORMANCE HIGHLIGHTS OF SR STATIONS


PARAMETER

DADRI (COAL)
MOU
ACTUAL

BADARPUR
MOU
ACTUAL

APR 06-JAN 07

GENERATION, MU
AVAILABILITY, %
PLF, %
LOADING FACTOR, %
PLANNED OUTAGE, %
FORCED OUTAGE, %
HEAT RATE,Kcal/kwh
APC, %
SP. OIL CONS,Ml/kwh
INVENTORY, Rs Cr.
PROFIT, Rs Cr
Margi.Contri., Rs. Cr
ROCE, %

NOTE: MOU target mentioned are pro rata targets


Financial parameters are without UI.

Up to Jan 07

ROPR TARGETS & STATUS: DADRI (COAL)


PARAMETER

MOU
TARGET

ROPR TARGET
(R0)
MU/ PLF

(R1)
MU/ PLF

ACTUAL
TILL
JAN07

STATION PROJECTION
PROGRAM
FOR BAL.
PERIOD

EXPECTED
AT FY END

GENERATION,
MU
FORCED
OUTAGE, %
EQPT
PARTIAL
LOADING, %
HEATRATE,
KCAL/ KWH

2005-06 Generation: Mu ( % PLF)


PROGRAM FOR BAL. PERIOD (BREAK UP)

ROPR TARGETS & STATUS: BADARPUR


PARAMETER

MOU
TARGET

ROPR TARGET
(R0)
MU/ PLF

(R1)
MU/ PLF

ACTUAL
TILL
JAN07

STATION PROJECTION
PROGRAM
FOR BAL.
PERIOD

EXPECTED
AT FY END

GENERATION,
MU
FORCED
OUTAGE, %
EQPT PARTIAL
LOADING, %
HEATRATE,
KCAL/ KWH

2005-06 Generation: Mu (

% PLF)

PROGRAM FOR BAL. PERIOD (BREAK UP)

FORCED OUTAGE-CATEGORY WISE (NO / %)

(Apr06-Jan07)

DADRI (COAL)
DESCRIPTION
FORCED OUTAGE
TUBE LEAKAGE
BOILER & AUX.
TURB & AUX.
ELECTRICAL
C&I
HUMAN ERROR
GRID FORCED/
HVDC
OTHERS
MULTIPLE TRIPS
MAJOR OUTAGES
(Duration >6 hrs)

NO

BADARPUR
NO

NTPC BEST
STATION

NO

MULTIPLE TRIPS: BADARPUR


DATE/
TIME

THE INCIDENT

WHAT WENT
WRONG

CORRECTIVE
ACTION

FORCED OUTAGES: DADRI (COAL)


SEP06-TILL DATE

S.N UNIT TRIP DATE/TIME DURATION

ROOT CAUSE

OUTAGE RECOMMEND
CODE
ATIONS

FORCED OUTAGES: DADRI (COAL)


SEP06-TILL DATE

S.N UNIT TRIP DATE/TIME DURATION

INCIDENT/ ROOT CAUSE

OUTAGE RECOMMEND
CODE
ATIONS

FORCED OUTAGES: BADARPUR


SEP06-TILL DATE

S.N UNIT TRIP DATE/TIME DURATION

INCIDENT/ ROOT CAUSE

OUTAGE RECOMMEND
CODE
ATIONS

10

FORCED OUTAGES AFTER OVERHAUL


BATH TUB
CURVES

QUALITY OF OVERHAULS
MAJOR REASONS
No of
Inad.
outage Inad. Inspecti Supervi Vendor Workm
Erectio Human
Chemi
s
Scope
on
sion quality ansip Spares
n
Error System Others stry

DADRI (COAL)
Outage within 3
months
Outage bet 3-6
months
Outage beyond 6
months

TO BE FILLED BY COS

BADARPUR
Outage within 3
months
Outage bet 3-6
months
Outage beyond 6
months
TOTAL

11

DC-SG-AG GAPS (UP TO JAN07)


DADRI (COAL)

Parameter

BADARPUR

DC installed (A)
DC (bar) % of A
SG % of DC bar
AG % of DC bar
DC installed- DC (bar) break up,
%
Planned outage
Forced outage
Equipment
Fuel Quality / supply
Others (Excess gen.)
AG <101/100.5%DC break up, %
Grid
Freq.>50 Hz or BEF
Equipment

12

Unit trip
ABT/ OPPORTUNITY MATRIX
POSSIBLE DC-ACTUAL DC GAPS (UP TO JAN07):
DADRI COAL: (Percentage & major reasons)
BADARPUR: (Percentage & major reasons)
OPERATION W.R.T. IDEAL GRAPH:

13

105% DC CAPABILITY-EXCEPTIONS
STATION

UNITS NOT CAPABILITY


CAPABLE
, MW

MAJOR
CONSTRAINTS

ACTION PLAN

DADRI
(COAL)

BADARPUR

ACTION PLAN DETAILS GIVEN IN EFFICIENCY SLIDES

14

DEVIATION IN OVERHAUL SCHEDULE/ DURATION


DEVIATION IN OH
SCHEDULE
STATION

UNIT

PLANNED

ACTUAL

DEVIATION IN OH
DURATION
REASON

PLANNED

ACTUAL

REASON

I
DADRI
COAL

II

III
IV
I
BADARPU
R

II
III
IV
V
15

16

DADRI (COAL) OPI PERFORMANCE:2006-07* O/H


UNI
T

OPI
NO

Target
score

OPI SCORE
ACHIEVED
(CUMULAT
IVE)

Status
TOTAL
SPRS

Receive
d

Balance

Total
Cont

Awarded

Balance

O/h sch
06-07

1
2
3
4

* Please furnish the final (at the time of o/h) scores of the units, which had completed overhauls
also.
17

DADRI (COAL) OPI PERFORMANCE:2007-08 O/H


UNI
T

OPI
NO

Target
score

OPI SCORE
ACHIEVED
(CUMULAT
IVE)

Status
TOTAL
SPRS

Receive
d

Balance

Total
Cont

Awarded

Balance

O/h sch
07-08

1
2
3
4

NOTE: in case of major deviation between Target and actual scores, recovery plan is to be given.
18

DADRI (COAL) OPI PERFORMANCE:2008-09 O/H


UNI
T

OPI
NO

Target
score

OPI SCORE
ACHIEVED
(CUMULAT
IVE)

Status
TOTAL
SPRS

Receive
d

Balance

Total
Cont

Awarded

Balance

1
2
3
4

19

O/h sch
08-09

BADARPUR OPI PERFORMANCE:2006-07* O/H

UNI
T

OPI
NO

Target
score

OPI SCORE
ACHIEVED
(CUMULAT
IVE)

Status
TOTAL
SPRS

Receive
d

Balance

Total
Cont

Awarded

Balance

O/h sch
06-07

1
2
3
4
5

* Please furnish the final (at the time of o/h) scores of the units, which had completed overhauls
also.
20

BADARPUR OPI PERFORMANCE:2007-08 O/H

UNI
T

OPI
NO

Target
score

OPI SCORE
ACHIEVED
(CUMULAT
IVE)

Status
TOTAL
SPRS

Receive
d

Balance

Total
Cont

Awarded

Balance

O/h sch
06-07

1
2
3
4
5
NOTE: in case of major deviation between Target and actual scores, recovery plan is to be given.
21

BADARPUR OPI PERFORMANCE:2008-09 O/H

UNI
T

OPI
NO

Target
score

OPI SCORE
ACHIEVED
(CUMULAT
IVE)

Status
TOTAL
SPRS

Receive
d

Balance

Total
Cont

Awarde d

Balance

O/h sch
06-07

1
2
3
4
5

22

CRITICAL
ISSUES

CRITICAL ISSUES DADRI (COAL)

S
N

Issues

Status

Target

1
2
3
4

Interventions, if any, required from CC:

23

CRITICAL ISSUES BADARPUR


SN

Issues

Status

Target

1
2
3
4

Interventions, if any, required from CC:

24

SAFETY
ISSUES

SAFETY ISSUES (2006-07 UPTO JAN)

STATION

NO OF ACCIDENTS
(UP TO JAN-07)
FATAL

NONFATAL

NO OF FIRE
INCIDENTS

NEAR
MISS

DADRI
(COAL)
BADARPUR
(ACTION PLAN SHALL BE GIVEN IN CASE OF MAJOR DEVIATIONS)

25

R&M STATUS (As on 31.01.07)


S.N

Description

Total no. of schemes


approved

Date of approval

3
4

Total approved cost


BE for Financial Year
RE for Financial Year
Amount Spent till date
Cumulative amount
spent till date
No. of schemes
planned
to be completed in FY

5
6
7

Cumulative no. of
schemes completed
Action plan for
meeting shortfall

BADARPUR

No. of schemes
completed in FY

DADRI (COAL)

10

26

FUEL STATUS
STATION

COAL STOCK(MT)
( Days)

MAJOR ISSUES

DADRI (COAL)
BADARPUR

FSA RELATED ISSUES, IF ANY:

27

ASH UTILIZATION (06-07)


STATION

ANNUAL
TARGET

PRORATA
TARGET

ACTUAL UP TO
JAN07
LMT

Till Jan07
SHORTFALL /
EXCESS
LMT

DADRI
(COAL)
BADARPUR

PROGRAM FOR BALANCE PERIOD &


RECOVERY PLAN
28

ENVIRONMENTAL ISSUES
(AS ON 31.01.07)
STATION

DESCRIPTION

STATUS

REMARKS

DADRI
(COAL0

(MAJOR ISSUES FROM ORT FORMAT)

29

ENVIRONMENTAL ISSUES
(AS ON 31.01.07)
STATION

DESCRIPTION

STATUS

REMARKS

BADARPUR

(MAJOR ISSUES FROM ORT FORMAT)

30

FINANCIAL RATIOS (UP TO JAN07)


STATION
DADRI (COAL)
BADARPUR

Ratio

MOU

Actual

MOU

Actual

A. Percentage of cost
of spares/ Total cost of
routine maintenance:
B. Percentage of cost
of spares/ Total cost of
overhaul:
C. Percentage of cost
of overhaul/ Total cost
of routine & overhaul
maintenance:
D. Percentage of
variable cost actually
incurred / Energy
charges from tariff:

31

Financial Parameters (Till Jan-07)


PARAMETER

DADRI (COAL)
MOU
2006-07

MOU Till
Jan 07

BADARPUR
Actual
Till
Jan07

MOU
2006-07

MOU
Till
Jan07

Actual
Till
Jan07

Marginal
Contribution (exl.
UI )
Rs. Cr
Profit*
Rs. Cr
ROCE*
%

* Excluding UI.

32

EFFICIENCY GAP ANALYSIS


EFFICIENCY OVERVIEW (STATION)
Unit

U-1

U-2

U-3

U-4

U-5

U-6

OH 2006-07
Boiler Efficiency Design (%)
Boiler Efficiency Expected
Boiler Efficiency Test
Boiler Efficiency Test
Corrected
Boiler Eff Deviation (%)
GTCHR Design (kcal/kWh)
GTCHR Test
GTCHR Test Corrected
GTCHR Deviation (kcal/kWh)
Unit H R Design (kcal/kWh)
Unit H R Expected
Unit H R Test Corrected
Unit HR Dev (kcal/kWh)
Accountable Deviation
Un Accountable Deviation
Post OH Target HR (06-07)
Post OH Target HR (07-08)
Post OH Target HR (08-09)

MAJOR LOSS & HEAT RECOVERY PLAN


HR Loss
OH 06-07
Accountable Losses
1

DFG Loss
Post OH loss

RH Spray
Post OH Loss

Condenser Loss
Post OH Loss

HP Turbine
Post OH loss

IP Turbine
Post OH loss

HP/IP Cyld. Lkg

Recovery

Un Accountable
Post OH losses

Cooling Towers
Post OH loss

ACTION PLAN EXCEPTION


SN Description / Unit
OH (06-07)

U-1

U-2

U-3

U-4

U-5

U-6

A) DFG Loss
1
Basket replacement
2

AH Seals

Sector Plate

Replacement of
expansion joints (37)
LRSB

B) RH Spray Loss
1

To contain metal
temperature

C) Condenser Loss
1

Condenser Cleaning

OLTC

D) Cooling Tower Loss


1

CT Revamping

ACTION PLAN EXCEPTION


SN Description / Unit
OH
E) HP Turbine Loss
1

HP rotor

Diaphragms

Inter stg / Inter Cylinder


seals
Tip/ Seals

F) IP Turbine Loss
1

IP rotor

Diaphragms

Inter stage / Cylinder seals

Tip Seals

G) Unaccountable Loss
1

HE Drain Valve

U-1

U-2

U-3

U-4

U-5

U-6

2
3

On Line Drain Temp.


Monitoring
Insulation survey

MATERIAL OVERVIEW
Description
AH baskets
AH Sector plates
Expansion Bellows
HPT/IPT rotor
Diaphragms (1,2,3) /
Inner casing (4,5,6)
Inter Cylinder Seals
Inter Stage Seals
Tip Seals
Cooling Tower
On line monitoring of
HE drain valve
HE drain valves

U-1

U-2

U-3

U-4

U-5

U-6

ANNEXURE-XVIII
SAMPLETEMPLATES FOR ROPR BACK UP (COAL STATIONS)

Slide 1

ROPR VI
NATIONAL CAPITAL REGION
(COAL STATIONS)

BACK UP SLIDES
1

Slide 2

MOU: Program for Balance Period: DADRI


(COAL)
Description
Till Jan'
07
Gross Gen. (MU)
Planned outage(%)
Forced Outage (%)

FEB

MAR

EXPECTED

MOU

Eqpt.Partial loading (%)

Aux. power Con. (%)


Specific Oil Cons. (%)
Heat Rate(Kcal)
Inventory (Rs.Cr)

Slide 3

MOU: Program for Balance Period: Badarpur


Description
Gross Gen. (MU)
Planned outage(%)
Forced Outage (%)

Till Jan'
07

FEB

MAR

EXPECTED

MOU

Eqpt.Partial loading (%)

Aux. power Con. (%)


Specific Oil Cons. (%)
Heat Rate(Kcal)
Inventory (Rs.Cr)

Slide 4

FORCED
OUTAGE

Forced Outage Up to Jan07: Dadri (coal)


Description
F/O (% )
Target < 1.0 %
No. of Outage
Unit
No. of Outage
Hours
% of total hrs
Major Reasons

Slide 5

TUBE LEAKAGE DETAILS: DADRI (COAL)


OUTAGE OUTAGE OUTAGE Last O/H
S.N UNIT
DATE
TIME
HIOURS
Date

Reference
Outage
Hours

CAUSE
Location *

Recomme
ndations

2
3
4
5
6
7
8

Slide 6

Forced Outage Up to Jan07: Badarpur


Description
F/O (% )
Target < 1.0 %
No. of Outage
Unit
No. of Outage
Hours
% of total hrs
Major Reasons

Slide 7

TUBE LEAKAGE DETAILS: BADRPUR


OUTAGE OUTAGE OUTAGE Last O/H
S.N UNIT
DATE
TIME
HIOURS
Date

Reference
Outage
Hours

CAUSE

Recomme
ndations

Location *

2
3
4
5
6
7
8

Slide 8

SCATTERED GRAPH: DADRI COAL -DEC06

Slide 9

SCATTERED GRAPH: DADRI COAL -JAN07

Slide 10

Opportunity Matrix: Dadri Coal


1. Freq< 50 Hz

MONTH

1.1.
Duratio
n
when
AG<SG,
%

1.2.
Durati
on
when
AG>S
G, %

2. Freq.> 50 Hz & < BEF

2.1.
Duratio
n
when
AG<SG,
%

2.2.
Duratio
n
when
AG=SG,
%

2.3.
Duratio
n
when
AG>SG,
%

3. Freq>BEF&<50.5 Hz

3.1.
Duration
when
AG<SG,
%

3.2.
Duration
when
AG>SG,
%

4. Freq.>50.5 Hz

4.1.
Duratio
n when
AG<SG,
%

4.2
Duration
when
AG>SG,
%

APRIL
MAY
JUNE
JULY
AUG
SEPT
OCT
NOV
DEC
JAN07

10

CUM.

Slide 11

SCATTERED GRAPH: BADARPUR-DEC06

11

Slide 12

SCATTERED GRAPH: BADARPUR-JAN07

12

Slide 13

Opportunity Matrix: Badarpur


1. Freq< 50 Hz

MONTH

1.1.
Duratio
n
when
AG<SG,
%

1.2.
Durati
on
when
AG>S
G, %

2. Freq.> 50 Hz & < BEF

2.1.
Duratio
n
when
AG<SG,
%

2.2.
Duratio
n
when
AG=SG,
%

2.3.
Duratio
n
when
AG>SG,
%

3. Freq>BEF&<50.5 Hz

3.1.
Duration
when
AG<SG,
%

4. Freq.>50.5 Hz

3.2.
Duration
when
AG>SG,
%

4.1.
Duratio
n when
AG<SG,
%

4.2
Duration
when
AG>SG,
%

APRIL
MAY
JUNE
JULY
AUG
SEPT
OCT
NOV
DEC
JAN07

13

CUM.

Slide 14

COAL STOCK DETAILS: DADRI (COAL)


Month

Coal
Recd

Percentage coal receipt w.r.t.


100% PLF 80% PLF Linkage CEA Target

FSA

Coal
Stock

April
May
June
July
Aug
Sep
Oct
Nov
Dec
Jan'
07
TOTAL

14

Slide 15

COAL STOCK DETAILS: BADARPUR


Month

Coal
Recd

Percentage coal receipt w.r.t.


100% PLF 80% PLF Linkage CEA Target

FSA

Coal
Stock

April
May
June
July
Aug
Sep
Oct
Nov
Dec
Jan'
07
TOTAL

15

Slide 16

DADRI (COAL) OPI PERFORMANCE:2006-07 O/H


Unit
#

OPI
NO

Critical
Spares
(Max-300

Non critical Consumables Contracts


T&P
Spares
(Max-150)
(Max-250) (Max-100)
(Max-200)

Overall
score%

1
2
3
4

Scores mentioned are cumulative scores


16

Slide 17

DADRI (COAL) SPARES OPI PERFORMANCE 2006-07


O/H
UNI
T

TOTAL CRITICALSPARES

PI
Raised

PE
Sent

PO
Placed

TOTAL NON CRITICALSPARES

Matl
recd

PI
Raised

PE
Sent

PO
Placed

Matl
recd

1
2
3
4

17

Slide 18

DADRI (COAL) OPI PERFORMANCE:2007-08 O/H


Unit
#

OPI
NO

Critical
Spares
(Max-300

Non critical
Spares
(Max-200)

Consumables
(Max-150)

Contracts
T&P
(Max-250) (Max-100)

Overall
score%

1
2
3
4

Scores mentioned are cumulative scores


18

Slide 19

DADRI (COAL) SPARES OPI PERFORMANCE 2007-08


O/H
UNI
T

TOTAL CRITICALSPARES

PI
Raised

PE
Sent

PO
Placed

TOTAL NON CRITICALSPARES

Matl
recd

PI
Raised

PE
Sent

PO
Placed

Matl
recd

1
2
3
4

19

Slide 20

DADRI (COAL) OPI PERFORMANCE:2008-09 O/H


Unit
#

OPI
NO

Critical
Spares
(Max-300

Non critical
Spares
(Max-200)

Consumables
(Max-150)

Contracts
T&P
(Max-250) (Max-100)

Overall
score%

1
2
3
4

Scores mentioned are cumulative scores


20

Slide 21

DADRI (COAL) SPARES OPI PERFORMANCE 2008-09


O/H
UNI
T

TOTAL CRITICALSPARES

PI
Raised

PE
Sent

PO
Placed

TOTAL NON CRITICALSPARES

Matl
recd

PI
Raised

PE
Sent

PO
Placed

Matl
recd

1
2
3
4

21

Slide 22

BADARPUR OPI PERFORMANCE:2006-07 O/H


Unit
#

OPI
NO

Critical
Spares
(Max-300

Non critical
Spares
(Max-200)

Consumables Contracts
T&P
(Max-150)
(Max-250) (Max-100)

Overall
score%

1
2
3
4
5

Scores mentioned are cumulative scores


22

Slide 23

BADARPUR SPARES OPI PERFORMANCE 2006-07


O/H
UNI
T

TOTAL CRITICALSPARES

PI
Raised

PE
Sent

PO
Placed

TOTAL NON CRITICALSPARES

Matl
recd

PI
Raised

PE
Sent

PO
Placed

Matl
recd

1
2
3
4
5

23

Slide 24

BADARPUR OPI PERFORMANCE:2007-08 O/H


Unit
#

OPI
NO

Critical
Spares
(Max-300

Non critical
Spares
(Max-200)

Consumables
(Max-150)

Contracts
(Max-250)

T&P
(Max-100)

Overall
score%

1
2
3
4
5

Scores mentioned are cumulative scores

24

Slide 25

BADARPUR SPARES OPI PERFORMANCE 2007-08


O/H
UNI
T

TOTAL CRITICALSPARES

PI
Raised

PE
Sent

PO
Placed

TOTAL NON CRITICALSPARES

Matl
recd

PI
Raised

PE
Sent

PO
Placed

Matl
recd

1
2
3
4
5

25

Slide 26

BADARPUR OPI PERFORMANCE:2008-09 O/H


Unit
#

OPI
NO

Critical
Spares
(Max-300

Non critical
Spares
(Max-200)

Consumables Contracts
T&P
(Max-150)
(Max-250) (Max-100)

Overall
score%

1
2
3
4
5

Scores mentioned are cumulative scores


26

Slide 27

BADARPUR SPARES OPI PERFORMANCE 2008-09


O/H
UNI
T

TOTAL CRITICALSPARES

PI
Raised

PE
Sent

PO
Placed

TOTAL NON CRITICALSPARES

Matl
recd

PI
Raised

PE
Sent

PO
Placed

Matl
recd

1
2
3
4
5

27

Slide 28

ASH UTILIZATION PLAN FOR BALANCE PERIOD (06-07)


STATION

ANNUAL
TARGET

Actual upto
Dec06

Bal.
LMT

Q4
LMT

Anticipated
06-07

DADRI COAL

LMT
%

LMT
%

LMT
%

BADARPUR

LMT
%

LMT
%

LMT
%

NCR

LMT
%

LMT
%

LMT
%

Recovery Plans shall be attached in case of major shortfall


28

Slide 29

8 YEAR ROLLING PLAN- DADRI COAL

29

Slide 30

8 YEAR ROLLING PLAN-BADARPUR

30

Slide 31

PERFORMANCE IMPROVEMENT PROJECTS: DADRI COAL


S.No.

Project Objective

Enabling
process
selected

Project
sponsor

Process
Owner

Team
members

Present status

31

Slide 32

PERFORMANCE IMPROVEMENT PROJECTS: BADARPUR


S.No.

Project Objective

Enabling
process
selected

Project
sponsor

Process
Owner

Team
members

Present status

32

ELECTRICAL: CHECK LIST FOR TECHNICAL AUDIT

ANNEXURE-XIX

COMMON ELECTRICAL AREAS


SN

2.0
SN

Check for the following

OBSERVATIONS
Status /Data
Description / Identification of panel including back opening panel
Material preservation system in store and their healthiness.
Spares for critical areas are available & advance planning for further
needs.
Painting of different equipment'
s
ESP Status: All Passes in service
How many fields are in Service?
Status of rapping (emitting &collecting) motors
Calibration testing of relays of switchgear
(TMCC, BMCC, BVDC, TVDC, EMCC etc.) and maintained
record properly.
Are all identified LMIs for electrical system approved and issued.
Is electrical equipment history available or not.(Testing as per
scheduled frequency)
Check records of lightening mast and other major equipment' earth
s
resistance.
Are CHP and Off site switchgear & protection relays put in PM
schedule
Check calibration records of electrical Laboratory standard meter,
measuring & Test equipments, from recognized institution.
Whether all cable entries are sealed
Relay testing status(Annually & Record the same)
Energy meter calibration
Indication lamps , meter and relays status of MCCs
Paging system status in all areas including off sites.

SWITCHYARD EQUIPMENTS
OBSERVATIONS
Status /Data
Whether Thermovision scanning is being done? Check scanning
data and date of attending hot spots.
House keeping of switchyard (400/220/33 kV) De-weeding done or
not. Tree cutting near fencing being done or not.
Are surge arresters being checked daily for counter reading and
leakage current? Is the leakage current with shunt being crosschecked monthly?
Check if earth resistance are checked half yearly and record are
maintained.
O/H of 400/220/132 KV Circuit breakers is to be done after 7-10
years of operation.(Depending upon performance.) Check Records
Switchyard Voltage (actual)
Condition of insulators
Cable trenches condition and proper drainage.

SN

OBSERVATIONS
Status /Data
Bay and Transformer identification provided or not
Disturbance recorders, Event loggers, Distance to fault locators etc.
are available and have been synchronized with master clock. Is GPS
commissioned or not.
Energy meter Accuracy class,
MAIN Meter----Date of calibration
CHECK Meter--Frequency of calibration
Check history of switchyard equipment failure.
Whether all main and tie breakers are kept closed in One and Half
breaker scheme.
Any special problem faced by site.
Water logging and proper drainage
Approachability for fire tender.
Oil level in HV bushing/CT/CVT
Isolators open and close operation being done locally or from
remote.
Availability and healthiness of all recording instruments in control
panel.
Smoke detector healthiness in switchyard control room.
Auto re-closer whether in service for all lines and working
satisfactory
A/C functioning satisfactorily
Checking of protection and relays of switchyard is to be done
regularly. Check Records.

GENERATOR AND AUXILLARIES

SN

J
K
L

OBSERVATIONS
Status /Data
Shaft earthing bushes were found connected and earth voltage is
being monitored weekly and value is within limit.
Stator winding temp. in different points.
Hydrogen & carbon dioxide (CO2) cylinder required / day
Exciter transformer any spare available or not
Fire extinguishers placed near generator
Condition of silica gel in (H2) drier and readiness of drier
RSO and ELCID test carried out in O/H schedule. Check Records
Sufficient nos. of H2 & CO2 connectors and cylinders available near
generator filling area.
(H2 Cylinder to be stored out side TG area)
Difference between Hydrogen dew point and cold gas temp.
(Should be more than 20 deg. C)
Excitation room physical condition and status of air conditioning.
Are blowers in thyristor panel running?
Gas trap- Whether any gas collected.
No. of H2 cylinders consumed/day
LLD (liquid level detector)- Whether any liquid collected

SN
M
N
O
P
Q
R

S
T
U
V
W
X
Y
A

OBSERVATIONS
Rotor winding temperature
Cooling water to hydrogen cooler
Inlet pressure
Inlet temperature
Outlet pressure
Outlet temperature
Hydrogen pressure and purity
Availability of both stator water pump motors
AC/DC Seal oil motors
Jacking oil Pumps motors
Barring gear motors
Stator water inlet temperature
Stator water inlet pressure
Stator water outlet temperature
Stator water outlet pressure
Sta. water cooler inlet temp.
Sta. water cooler outlet temp.
Sta. water cooler inlet pressure
Sta. water cooler outlet pressure
Seal oil system Exciter end pr. / Seal oil system Turbine end pr. /
Differential pressure (seal oil/H2)
Excitation system Auto/manual.
Dissolved oxygen in stator water.
Stator water conductivity.
Stator water Doppler flow test.
Stator core temp. Record exceptions.
Are cylinder identification by color.(CO2, H2, N2).
Any uncovered opening in the excitation panel.

Status /Data

PROTECTIONS

SN

OBSERVATIONS
Relay testing frequency
Refer records
All protection in service?
LIST OF PROTECTION
Generator differential
Generator transformer diff.
Gen transformer E/F.
Gen over fluxing
Gen loss of excitation.
Gen over voltage.
Reverse power protection.
Back up impedance.
G.T. stand by E/F.
G.T. restricted E/F.
Overhang diff.
Negative phase sequence.
Pole slipping.
Under frequency.
O/L.
LBB Protection.

Status /Data

SN

OBSERVATIONS

Status /Data

GT/UAT fire protection.


GT/UAT pressure relief.
GT/UAT Buchholtz relay.
UAT diff.
GT/UAT winding temp
GT/UAT oil temp.
UAT back up over current.
2nd stage rotor E/F.
Excitation system trouble.
Stage 1&2 GT diff.
Gen inter- turn fault protection.
bb) Stator water flow low.
cc) Stator water through bushing low.
5.0 D.C. SYSTEM & DG SET.
SN

OBSERVATIONS
Smoke and gas detection sensor in battery room installed or not.
Trial run of DC auxiliaries is being taken - daily/ weekly /
fortnightly to ensure healthiness.
Check level of electrolyte, Vent plug cleanliness(no clogging)
Support insulators(no cracks)
Any metallic structure was found above the battery bank.
Missing/Bypass cell/cells
Check for Earth fault in DC board.
1) Voltage between P/E and N/E
No of feeder having E/F
Battery rooms are clean and ventilation system working or not.
Battery terminals properly coated.
Capacity test of battery done or not if so value.
Wash Basin in battery Room.
Record of cell voltage and sp. gravity of cell on random.
PM of DCDB done or not
Trickle /Boost charger are in service.
Trial run of DG set
Sp gravity of battery
Auto start of DG set
Diesel level
Battery charger condition
Sulphation of battery terminal/vent plug
Frequency of trail start

6.0

CABLE GALLARIES

Status /Data

SN
1)
2)
3)
4)
5)
6)
7)
7.0
SN
1)
2)
3)
4)

OBSERVATIONS

Status /Data

Illumination
Water logging /dripping
Cable sealing /cable dressing
Smoke detectors in service
Dressing of cables
Water sprinklers in service
Testing of Fire Protection system. Check records
MOTORS
OBSERVATIONS

Status /Data

Both / Double Earth of motor properly connected.


HT motor failure list
Major reasons of failure
Preventive maint. records
All T& P and testing equipment, available for any type of
maintenance.
TRANSFORMER

SN

OBSERVATIONS
Condition of silica gel, regeneration required or not?
Condition of HT bushings and oil level
Mulsifyre system in service? System kept in auto or manual
Arrangement for transformer removal / replacement of available or
not
Protective wall around deluge valve available or not
Any transformer kept as spare
Direction of rotation of oil cooler fans and oil pumps to all
transformers to be marked
Condition of transformer marshalling box
Transformer overhauling may be considered after 7-10 years
depending upon performance.
Shorting between two sections of tank with flexible to ensure proper
continuity
Double earthing of the transformer tank to be ensured
Whether all protections are in service
NGR (Neutral Grounding Resistance) resistance is being checked or
not
Oil test status: BDV/PPM/tan delta/ acidity/resistivity and any
abnormality
DGA results and any abnormality. When next due.
Status of cooling fans & pumps
Any abnormality in annual test results
Oil leakage in transformer / HT bushing and Conservator
Whether tap changer (on load / off load) is being operated.
Winding temp.(local/remote)

Status /Data

Condition of drain pit.


PLCC
SN
1
2
3

Status /Data
OBSERVATIONS
TX/RX level from panel mounted meter
Whether code sent and received counter reading being recorded
regularly
Whether signal to noise level being recorded regularly

CHP
SN
1
2
3

Status /Data

OBSERVATIONS
Availability of Pull cord of conveyors
Availability of Zero speed switch
Effectiveness of MD, MS & ILMS

OFF SITES
SN
1

Status /Data

OBSERVATIONS
Indication lamps on HT and LT switchgears.

System and Safety points in Hydrogen generation plant

Preventive maintenance of HT and LT switchgear and bus bars are


as per schedule.
Emergency push buttons are in service or not.

C&I :CHECK LIST FOR TECHNICAL AUDIT


CONTROL LOOPS
S No

Description

Systems control loops not in service/auto.

Reasons for not being in service.

Effect/implication for not being in service/auto.

Status/Reason

Remark

Runbacks not in service.

Status/Reason

Remark

HOUSE KEEPING
S No
1.
2.
3.

Description
General House Keeping.
Field Instruments.
Field JBs
Glanding.

Cable routing.
Panel sealing, cleanliness
Loose connections
Identification of JB s connected with protection signals
leading to unit outage with prominent mark.

4.

MAINTENANCE PREPAREDNESS
S No
1.
2.
3.

Description
Status/Reason
Availability of spares/service/service support.
Identification of critical spares and spares having high
failure rate along with reasons for failure.
Adequacy of documentation, maintenance tools (Hardware
and software), trained manpower for the following
Preventive Maintenance
Card repairs
Development/modification of displays and functions
Development/modification of application software.
Advance diagnostics based on knowledge about operating
system
and assembly languages and its adequacy

Remark

C&I LABORATORY
S No
1.

Description
Work being done in the lab. Check records

2.
3.

Any work/spares being pending in the lab. for long


Availability of calibration records for lab equipment verify
at random.
Also check
Equipments are tagged with suitable indicator for their
calibration status
Calibration of equipment from a recognized standard lab at
prescribed interval are being done.
Inspection, measuring and testing equipment are
safeguarded from adjustments, which would invalidate
the calibration s settings (like sealing of potentiometer
/ switch with paint).
When any measuring or test equipment is found to be out of
calibration, the validity of any tests and inspection carried
out using this equipment is reviewed for the suitability
based on the identified measurement requirement and
required accuracy
The environmental conditions are suitable for the
calibrations, inspection, measurements and tests being
carried out.
The handling, preservation and storage of inspection,
measuring and test equipment is such that the accuracy and

5
6

Status/Reason

Remark

S No
7

Description
Status/Reason
fitness for use are maintained
Station practice for repair of assemblies (In house /Vendor).

Remark

MAINTENANCE OF RECORDS
S No
1
2
3
4
5
6
7
8
9

Description
Status/Reason
Consumption of spares and consumables
Inventory status
Receipt of drawings and documents
Shift C&I log book (Monitoring of healthiness of redundant
C&I equipment and emergency job response).
Initial commissioning and testing records and date
Table of adjustments for control loops
Records of the present response of the control system on
actual load variations
Preventive maintenance schedules and records
Protocols of protection testing

Remark

OVERHAULING
S No
1
2
3
4
5

Description
Report of previous overhauling.
Major activities, along with the manpower for each activity
Spares and consumables consumed
Tools and tackles used
Identification of activities not possible during plant
operation or short shutdowns. To ensure inclusion in the
overhauling activities

Status/Reason

Remark

Status/Reason

Remark

Status/Reason

Remark

MONITORING & AVAILABILITY


S No
1
2
3

Description
Quality of instrument air, practice for maintenance
condition of filter regulator
SWAS availability.
Power supplies/UPS availability and maintenance checks
being done

ANNUNCIATION SYSTEM
S No
1
2

Description
Identification of the reason for the persistent alarms.
Healthiness of the system and all the bulbs.

ENVIRONMENTAL CONDITION

S No
1
2
3

Description
Temperature, humidity and dust
Maintenance of records
Monitored by whom.

Status/Reason

Remark

Status/Reason

Remark

Status/Reason

Remark

GENERAL MONITORING
S No
1
2
3
4
5
6
7
8

Description
Random comparison between two indications of the same
parameter.
Accuracy checks of the important temperature points and
calibration of protection devices.
Status of on-line instruments for the environmental
monitoring
Opacity/smoke density monitors.
Practice adopted for making modifications in schemes, set
points etc.
Scanner removal, airflow, cleanliness of scanner pipe,
indication in UCB.
Weigh bridge, belt weighers healthiness
Checking of off site Instruments of CT/CW, DM Plant,
CHP, AHPs etc as per guidelines
Review of protections type regarding cable routing of
protection channel.

MISC (Any other specific problem of the plant)


S No

Description

OPERATION: CHECKLIST FOR TECHNICAL AUDIT


STATION:
UNIT:

DATE:

AVAILABILITY OF IMPORTANT DOCUMENTS


S.N.

Description

1.

Emergency instructions for:Grid failure (instructions for UCE, desk engineers,


locations and switchyard).
Total AC failure of a unit.
Total DC failure of a unit.
Fire in air heater, mill or Main Oil Tank.
Purging out of Hydrogen from Generator.
Loss of instrument air.
(With proper display at log books/location)

2.

Disaster Management Plan (Adequacy, usefulness &


updation)

3.

Technical diary, Schematics diary and operation


management book.

4.

Operating instructions, standard checklists for start up &


shut down for all major equipments & systems.

5.

Integrated start-up & shutdown procedures.

6.

Operational records preservation


Log books
Log sheets
Trend records/DAS/Computer reports

SYSTEM HEALTHINESS:

Status

Remarks

S.N.

Description

1.

Status

Remarks

Availability of protections. If any protection is bypassed,

Status

Remarks

action plan for normalisation should be indicated.


2.

Procedure for bypassing/restoration of protection (check


adequacy and implementation w.r.t. LMI).

3.

Method and frequency of checking Protections and


Interlocks (check compliance as per LMI).

4.

Equipments non-availability:- Status, method of


monitoring and action plan for restoration.

5.

Availability/usage of auto loops;- Reasons for nonavailability /no usage and action plan for improvement.

6.

Availability and healthiness of annunciation system:Method of checking (including switchyard annunciation).

7.

Availability and performance of recorders, indicators,


hydrasteps etc.

8.

Availability and usage of ATRS, ATT, CMC etc.

9.

Availability and usage of SADC, burner tilt, ERVS, soot


blowers etc.

10.

Availability & usage of SGC evacuation system, SGC Oil


system, SLC Drain system etc.

11.

Availability of ESP fields & Rapping motors

12.

Availability & usage of Condensate Polishing Unit

13.

Equipments erected, but not in use.

ROUTINE TESTING, SCHEDULED CHANGEOVERS ETC:


S.N.

Description

S.N.

Description

Status

1.

Remarks

Routine testing details of emergency equipments like DC

Status

Remarks

lube oil pump, DC JOP, DC seal oil pump, DC Scanner


Fan, DC seal water pump, DG set, Diesel Fire water
pump/booster pump, DC lighting etc.

(Schedule, result

and method of rectifying any abnormality). Recording of


testing result like discharge pressure of DC LOP & DC
SOP etc. Auto starting of Fire fighting pumps.
2.

Equipment changeover schedule and its implementation.


Recording the implementation status in log books.

3.

Schedule for ATT (for protective devices & stop/control


valves) and its implementation (Turbine oil injection,
valves testing etc.).Recording of the observation of ATT

4.

Status of actual over speed test of main turbine and TD


BFPs.

5.

Record of routine checking of cable galleries (daily).

MONITORING:
S.N.

Description

1.

Availability and filling up of local log sheets.


- Details of cross checking by UCE/SCE.

2.

Availability and filling-up of UCB log sheets.

3.

Adequacy and completeness of data in log books (should


cover recording of major parameters and deviations w.r.t.
loading, Sp. Oil consumption, Aux. Power consumption
etc.) of SCE/UCE/desk engineer etc. check for counter
signature by superior at random.

4.

Availability of updated chemical analysis book, with


details of water analysis, oil analysis, PF fineness
analysis, coal analysis and unburnt analysis, flue gas
oxygen analysis. Compliance of the instructions of the

S.N.

Description

Status

Remarks

Status

Remarks

chemist and the record of final result.


5.

Regular monitoring of systems like SADC, burner tilt etc.

6.

Details of monitoring of boiler tube metal temperature and


furnace temp.

7.

Start-up monitoring. Record of boiler start-up and turbine


rolling parameters for each start-up. Availability and
usage of start-up check lists.

8.

Routine checking & cleaning of oil guns

9.

Monitoring of Heat Rate related parameters


Main Steam Pressure
Main Steam/HRH Steam temperature
Condenser vacuum
Feed Water temperature before ECO
Turbine 1st stage pressure
CW Inlet temperature
Air heater inlet temperature
Air heater outlet temp.
Unburnt carbon in bottom ash and fly ash.
Mill rejects.
HP heaters availability.
Make-up water consumption.
(Details of identification, defect raising and follow-up).

10.

Healthiness of parameters like Hydrogen purity & dew


point etc.

11.

Availability and usage of operator walk down check lists


(boiler).

ANALYSIS:
S.N.

Description

S.N.

Description

Status

1.

Remarks

Analyzing major parameters for any deviation w.r.t rated

Status

Remarks

Status

Remarks

value.
2.

Scanning of Operating parameters for correctness


(validation).

3.

Analyse the chemical regime in boiler water & steam w.r.t


silica, condensate, phosphate, pH values etc.

4.

Detailed analysis of unit tripping and implementation of


recommendations.

5.

Analyse the trips of repetitive nature

6.

Analysis of abnormal operating conditions and


precautions taken.

7.

POG/other

committee

recommendations

and

their

implementation.
OVERHAUL AND RECOMMISSIONING:
S.N.

Description

1.

Constitution of recommissioning teams with office order,


clearly indicating responsibility.

2.

Availability and usage of recommissioning checklists and


other protocols.

3.

Details of protections and interlocks checking during


overhauls.

4.

Adequacy of defects identification prior to overhauls.

SAFETY:
S.N.

Description

1.

Schedule and checking details of fire fighting system


healthiness:
Fire fighting safety equipments.

Mulsifyres for transformers, oil tanks, cable galleries.


Fire detection system.
Fire water pressure.
2.

Adequacy and coverage of permit to work system usage


of safety locks. Usage of Hot permit.

3.

Proper identification/ labeling of equipments/ switch gear


etc.

4.

Adequacy of carbon di oxide stock in CO2 rack

5.

Healthiness of dewatering pumps

6.

Awareness regarding Disaster Management Plan.

7.

Awareness and usage of Technical compliance system,

IMPLEMENTATION OF OLMMS:
S.N.

Description

1.

PTW system.

2.

Status

Remarks

Work-order card system.

ENVIRONMENT:
S.N.

Description

1.

Availability and usage of Effluent treatment plant

2.

Status

Remarks

Availability and usage of Ash water re-circulation

Status

Remarks

system.
3.

Availability of Opacity meter

4.

Any non-compliance in environmental indicator like


SPM, Ash pond effluent TSS, CW diff. temp etc.

HOUSEKEEPING:
S.N.

Description

1.

Physical verification.
Boiler
Turbine
Switchyard
Off-sites

MISCELLANEOUS:
Any other specific technical problem being faced by station (w.r.t full load, reliability,
efficiency), its reasons & actions taken thereof
S.N.

Description

Status

Remarks

1.

BALANCE OF PLANT : CHECK LIST FOR TECHNICAL AUDIT


Sl. No.
Description
1.0
ASH HANDLING SYSTEM
1.1
Bottom Ash (BA) Handling System
1.1.1 To check working / availability of the following
Scraper Conveyor
Clinker grinder
Seal Overflow system
Trench Nozzle Condition
Gate Sealing System
Availability of sight glasses, gate opening system for
isolation of hoppers and spare unit assembly
1.1.2 Any major O&M Problem
S.C. Jamming during normal operation/soot blowing
operation
C.G. Jamming during normal operation/soot blowing
operation
Any other equipment problem.
1.2
Fly Ash (FA) Handling System
1.2.1 Type - Flushing Apparatus/Feeder Ejector/or any other
type
1.2.2 To Check working of
Flushing System
Nozzles in ESP / APH / Economiser Hoppers
Water sealing system

Status

Remarks

Sl. No.

1.2.3
1.2.4
1.3.
1.4
1.4.1

1.4.2
1.5.0
1.6.0

1.6.1
1.7.0
1.7.1

1.8

Description
Adequacy of Water Supply
Trench condition
Any chockage problem / Field outage problem
Any major O&M problem
BA/FA ash slurry conveying - Satisfactory /
Unsatisfactory
Dry fly ash extraction & handling system
To Check working of
No. of streams & Capacity
No. of Vacuum pumps & capacity
No. of transfer air compressor & capacity
No. of instrument air compressor
Buffer hopper & silos - for fly ash storage
Compressor driers working
Air Lock / Blow tank system
Working of various types of pumps
PLCC operation
O & M problems
Overall Plant Healthiness / house keeping
Ash Slurry Disposal System
No. of Pumps installed/Available in each series
No. of series installed/available
Booster Pumps installed / available in each series
(wherever applicable)
Any O&M problem
Ash Dyke Status
To check for the following
Physical condition of Ash Dyke
Total area of ash dykes
Available capacity of Ash Dyke
Any Ash Dyke raising done ?
Any Ash Dyke breach occurred in the past. If yes, give
details.
No. of ash slurry disposal lines installed/ available
Length of each ash slurry disposal lines
Condition of Ash Disposal lines.
Maintenance Practices adopted for Ash Disposal.
Any other problem in Ash Disposal
Ash Water System
No. of HP/LP/SW Pumps
installed/available.

Status

Remarks

Sl. No.

1.9
1.9.1

2.0
2.1
2.2
2.3
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
2.14
2.15
2.16
2.17
2.18
2.19
2.20
2.21
2.22

Description
Any O&M problem in HP/LP/Seal water
pumps.
Ash Water recirculation system
Check for the following
Daily running hours of operation
Availability of recirculation pumps / population
P. L. C. C. System
Any other O&M problems
COOLING TOWERS
Whether plant is operated in open cycle/Hybrid/closed
cycle (CW system)
Operation of CT s
- Intermittent / continuous
Type of CT
- Induced Draught / Natural
Draught
Condition of Mech. Equipments - CT Fans/gear
boxes/motors
Availability of CT Fans - No installed/available.
Overall Physical condition of CT structures RCC /
Metallic
Whether spray nozzles are intact and without choking
Condition of splash bars/ fills and drift eliminators
Design range (Difference between cold water temperature
and actual wet bulb temperature of air)
Actual value of range being achieved at full load
Approach (Difference between hot water temperature and
cold water temperature
Condition of cold water basin - Clean/Full of mud
Any O&M problem in CT s/CT pumps (if provided)
CT Pumps Installed/available Make/Type/Head/Capacity/KW
Whether chlorination of cooling water is done
Whether algae growth is there on CT structures, hot water
basin, cold water basin, cold water basin
Whether all cell doors are in place and properly closed
Whether sides of CT s are free of vegetation growth and
buildings/ structures
Whether water distribution (droplet formation) below
nozzles is proper
Whether overflow takes place from CTs
No of CW/ CT pumps required to run at full load of the
unit

Status

Remarks

Sl. No.

3.0
3.1

3.2

4.0

Description
as per design
actual
COMPRESSED AIR SYSTEM
Plant Air Compressors - Installed/available
Compressor running as per design / actual
Discharge air pressure
Air line leakage
Instrument Air Compressor - Installed/available
Compressor running as per design / actual
Discharge air pressure
Check air line for leakage / presence of moisture
Dew point of instrument air
Drier condition satisfactory / unsatisfactory
ALL OTHER PUMPS (MISC.)
Type/Make
No Installed/available
Head/Capacity/KW rating
Any major O&M problem

5.0

FIRE DETECTION AND FIRE FIGHTING SYSTEM

S.N.
A

ITEM DESCRIPTION
Fire Water Pump House
No. of Electric motor driven Hydrant
Pumps installed
No. of Hydrant Pumps available for service
No. of diesel engine driven hydrant pumps
installed
No. of diesel engine driven hydrant pumps
available for service
No. of electric Booster pumps installed
No. of electric Booster pumps available
No. of spray Pumps installed
No. of spray Pumps available for service
No. of make up make up fire water pumps
installed / available
No. of diesel engine driven spray pumps
installed
No. of diesel engine driven spray pumps
installed
No. of Diesel Booster pumps installed /
available
Source of fire water (Raw water, clarified

DATA

Status

Remarks

S.N.

ITEM DESCRIPTION
DATA
water etc)
Arrangement of fire water (i.e. whether
pumps are taking suction from some
channel, CW forebay, overground tank etc.)
No. of hydrant valves in service / installed
Whether fire water hydrant & spray headers
are kept charged & pressurized all the time
No. of pumps kept running continuously
Whether diesel pumps start on auto
Hydrant pressure at the highest point
Hydrant pressure at the farthest
21(a) Whether all hydrant and spray headers/
loops are in service or some are isolated
(b) If isolated, reason for the same
22
Whether hydrant & spray headers are over
ground or under ground
23
Type &pipe used(MS/CI)
24
Cases of pipe leakages, if any
Check joint inspection reports & find
recurring problems if any.
B
Transformers
1
List of transformers provided with
emulsifier system
2
List of transformers not provided with
emulsifier system
3
List of transformers where emulsifier
system is functioning on auto
4
Type of detectors provided on transformers
5
Whether deluge valves of transformers are
of water/water or water/air type
6
Whether soak oil pit is available for
transformers
7
Frequency of checking of spray system of
transformers
C
Cable Galleries
1(a) Whether cable galleries are provided with
water spray system
1(b) If provided (i) type of system (TES/Open
nozzle) (ii) is it available for service
2
Type of fire/smoke detection system
provided in cable galleries (LHS Cable,
photo-electric) ionization type smoke
detectors etc.)
3
Whether cable fire sealing is done at cable
entry points
4
Whether inter-unit fire wall is provided
D
Conveyor Galleries & CHP
1
Whether conveyor galleries & TP s are

S.N.
2
3
4
5
6
7
8
E
1
2
3
4
5
6
7
F
1

2
3
4
5

ITEM DESCRIPTION
DATA
provided with fire detection & fire fighting
(spray) system
If so, details of the system provided
Whether cables are run inside conveyor
gallery or outside conveyor gallery
Whether cable trays in CHP are vertical or
horizontal
Whether fire hydrants are provided in
transfer points, crusher house, conveyor
galleries
Check availability of fire water
Protection against moving fires (IRD)
provided or not
Details of Fire Fighting System of coal
stockyard
Fuel Oil Tanks & FOPH
Whether foam system provided for oil tanks
Whether spray system also provided for oil
tanks
Whether any detection system provided for
oil tanks
Whether fire detection and fire fighting
system is provided in FOPH
Whether above mentioned system are in
service
Type of foam used
Frequency of choking of foam system
Details of Miscellaneous FPS
Details of fire detection and fire fighting
systems provided in the following areas MOT
Generator Hydrogen seal oil system
Valve room
Control Room
Control eqpt. Room
Battery room
Switchyard control room
CHP control room
LT/HT switchgear rooms of main plant &
station Aux.
Availability of fire hydrants in various
areas of the plant
Availability of fire houses various areas of
the plant
Availability of ire extinguishers various
areas of the plant
No. of working fire tenders available in
plant

S.N.
6
7
8
6.0

ITEM DESCRIPTION
Whether fire alarm and annunciation panel
is in working order
Whether repeater panel in fire station is in
working order
Major problems faced & deficiencies in fire
detection and fire fighting system

DATA

Coal Handling Plant

S.N. ITEM DESCRIPTION


DATA
Capacity of CHP in MT/Hr.
Various sources of coal and grades of coal being
received
Method of unloading coal, i.e., by wagon tippler/
manual/ track hopper etc.
Whether coal is received by road also
Average amount of coal received per month
Conveyor Nos. from which stones are picked up
Average amount of stone picked from coal per
month
Whether conveyor belts are of FR( fire retardant )
type
Major problems faced in conveyor and drive
systems
Average life of Coal Crusher hammers
Major problems faced in crushing system
Major problems faced in vibrating feeders/vibrating
grizzly feeders
Major problems faced in trippers
Major problems faced in Wagon Tipplers
Average tippling rate achieved with Wagon
Tipplers
Coal stock as on date
Average loading of conveyor belts in MT/Hr (
Total coal bunkered in a month/ total running hours
of bunkers conveyors )
Condition of gear boxes, fluid couplings (oil
leakage, sound etc.)
Generation loss due to CHP in the year
Man power for operation and maintenance of CHP
(a) No. of dozers procured (b) No. of dozers in
working order
Type of dust extraction and dust suppression
system & its availability
(a) Size of coal received (b) Size of crushed coal
(a) No. of belt weighers installed (b) No. of belt
weighers in working order (c) Last calibration done
Whether wagon weighment system is available on

S.N. ITEM DESCRIPTION


wagon tippler
Whether in-motion weigh bridge is installed and
available
Problems faced in Coal Bunkers
No. & capacity of coal bunkers
Capacity of coal stockyard
List of major problems & constraints being faced in
CHP
Availability of critical spares like conveyor belts,
crusher hammers, idlers, pulleys etc.
Condition of pulleys, idlers, their bearings
Availability of hold-backs of gear boxes & brakes
(a) No. of magnetic separators installed (b) No. of
magnetic separators in service
(a) No. of magnetic pulleys installed (b) No. of
magnetic pulleys in service
Whether flap gates are motorised and in service
Whether coal spillage from transfer chutes, skirt
boards etc is common in most of the TPs and
crusher house
Whether side walkways of conveyor galleries,
conveyor tunnels are in general filled with spilled
coal
(a) No. of metal detectors installed (b) No. of metal
detectors in service
Availability/ stock position of protection switches
like pull cord switches, belt sway switches, zero
speed switches
Problems faced in Stacker Reclaimer
Whether any fires exist in stockyard

DATA

STEAM TURBINE : CHECK LIST FOR TECHNICAL AUDIT


A.

MAIN TURBINE

Sl.
No.

Description

1.

Status /
Data

Remarks

Governing system
Hunting if any
Availability of operating modes
(EHC/Hydraulic/Hydro Mechanical)
Any restriction in control valve/stop valve opening
Transient speed rise during full load throw off
Condition of main steam/hot reheat line strainers

Rise in HP exhaust temperature during hot trip outs

Failures observed in extraction bellows

HP/LP Bypass System


Performance is OK or not and it is available on auto
Fast opening mode available or not
Failure of any component observed.

Gland Steam System


Performance of gland steam supply & leak off valves
Check for alarming levels of gland steam leak off i.e.
opening of gland steam leak off bypass & control
valve together
Warm up drain /manual drain condition

Attainability of target condenser vacuum & load


restriction if any due to condenser vacuum

7
8

Availability of ATRS & ATT and scrutinise records to


verify regular operation
Scrutinise one or two start up procedure carried in the
last six months for rolling procedure followed
including quality of steam

Availability and cross checking of SLC of turbine

10

Oil/steam/water leakage source if any

Sl. No.
Description
11
Overhauling Records

Status

Remarks

Availability of protocols
Work content
Involvement of FQA
Check for liabilities of a particular overhaul and its
liquidation in the next overhaul. Also to check the
procedure followed for such activities
Equipment performance improvement
12

MTP and O&E


Trend plotting of critical parameters
Turbine overspeed records
Turbine efficiency & pressure survey records
Equipment efficiency records
Gain in efficiency after O/H (Compare pre & post O/H
efficiencies)

13
B

Any other observations/site feed back


LUBE OIL & CONTROL FLUID SYSTEM

Sl. No.
Description
1
Main oil pump suction Pr/discharge Pr.
2

Oil vapour extraction fan availability & performance

Centrifuge
availability & performance & operating records
oil samples results testing and reporting procedure
Pipe line connection in place & reasons for selection of
particular schemes.
Selection of mode of operation

Main oil tank


Level indicators
Thrust brg. filter choking
Healthiness of fire protection
Vapour exhauster
Drain line connection & operation to dirty oil tank &
centrifuge
Lighting
Exhaust fan

CFT room

Status

Remarks

Sl. No.

Description

Accumulators

Status

Remarks

Status

Remarks

Adequacy of pressure/time
Failure if any
Level indicator
Oil heater av
Oil heater oil level
Lighting
Exhaust fan
6

Sampling & analysis of MOT oil and FRF oil


Last sample tested by internally/external/R&D
Analysis record keeping and action as per recommendation
Any deviation in report

Availability of stand by of
FRF pump
Auxiliary oil pump

Oil and FRF consumption target & achieved

Availability of central oil purification system

10

Availability of standby oil cooler & performance of other


coolers (oil temperature control on auto or manual)

11

Lub oil consumption (frequency of oil topping/ Equip.)


history

12

Thrust brg. Filter (chocking/frequency)

C
REGENERATIVE SYSTEM
Description
Sl. No.
1
Availability & Performance of
HP heaters
LP heaters
Cause of deviation in performance
Drip pumps/drip cascading of heaters
Vacuum pumps/ejectors
Condenser on load tube cleaning system availability of
records of operating hours & balls consumption
Condenser vacuum survey and causes of bad performance
HP heater bypass protection on high-high level

Sl. No.

Description
No. of tubes plugged in heaters & condenser

Status

Remarks

Status

Remarks

Status

Remarks

Status

Remarks

Functioning of extraction NRV s


2

Deficiencies observed in heaters & condenser if any


during site performance tests & actions taken by site
Heater - TTD,DCA
Condenser - TTD

Source of steam to
TDBFP
Deaerator

Condenser back washing frequency & effects

Vacuum pumps availability and performance

Performance of Plate Heat Exchangers

BOILER FEED PUMPS

Sl. No.
Description
1
Availability of standby BFP (Remote manual/auto)
2

BFP performance w.r.t. flow vs rpm curve

Speed control (auto/manual)

Review of vibration & temperatures of bearings

Performance of hydraulic coupling

Performance of recirculation valve

Failure of mechanical seals

Availability of spare cartridge

Performance of booster pumps

10

Performance of lube oil & working oil coolers

CONDENSATE EXTRACTION PUMP

Sl. No.
Description
1
Availability of standby
2

No. of pumps operating vis--vis load

Performance of pumps & availability of spares

F
CW SYSTEM
Sl. No.
Description
1
CW pump availability

Sl. No.
Description
2
CW pump sealing arrangement (normal/deviated)
3

Remarks

Status

Remarks

Status

Remarks

Working of condenser CW inlet/outlet butterfly valves

Status

Condenser priming system working & frequency of


operation

G
GENERAL
Sl. No.
Description
1
Any additional observation on equipments/systems
2

Lighting

DC Lighting status and checking

Cleaning

Ventilation

Preservation of spares of capital/insurance nature like


turbine rotors/bearings/spare pump modules

Availability of critical spares such as rotors, bearings &


valves

Structure healthiness

Implementation status of LMI s issued in turbine area.

10

Checking overhauling records

11

Repetitive nature of failures and corrective actions taken

12

Trending of consumption of lub oil, DM make up and H2


consumption

STORE PRESERVATION & INVENTORY CONTROL

Sl. No.
Description
1
Check for store-preservation guidelines availability and
formation of stores preservation cell. Check codification
of stores material as per NTPC policy
2

Sample check for stacking and allocation of spares bin as


per NTPC store system

Check for adequacy of covered space for keeping the


spares

Check for adequacy of handling equipments, lifting tool


and tackles

Check adequacy of fire fighting system and availability in


gas cylinder store, spare stores and oil & chemical stores

Sl. No.
Description
6
Checks for availability of first aid box and water shower
7

Status

Remarks

Check availability of hot and cold room for storing


relevant material

Check formation of inventory control cell and steps taken


by station in controlling inventory level

Check preservation and stocking of boiler tubes and


headers

10

Check preservation of turbine, generator, rotors, journals


and their rotation once in six months

11

Transformer & winding coils : To be kept in up-right


condition and periodic check as per manufacture
guidelines

12

RESINS : To be kept in plastic drum under moist


condition and to be checked for moisture once in a month

13

CHEMICALS : All chemical to be kept inside the store


with proper ventilation

CHEMISTRY : CHECK LIST FOR TECHNICAL AUDIT


STATION:

PERIOD OF AUDIT:

PT PLANT
Sl. No.
Description
CHEMICAL HOUSE (For Clarification units in Water
1.1
treatment and CW treatment system)
To check the condition/availability of dosing system
a) Alum
b) Lime
c) Coagulant Aid
Tanks
Agitator
Level indicator
Pumps

Status

Remarks

Sl. No.

Description

Storage area

Lifting & weighing arrangement


1.2

CHLORINATION PLANT
To check working/availability of
a) CW Plant
b) Pretreatment Plant
Chlorinator
Evaporators
Hoist for cylinders
Safety arrangements
(Leak arresting kit, mask, Breathing
apparatus, Absorption tower
Leak detectors
Alarms/control panel
Exhaust Fans
Display of safety Instructions

1.3

CLARIFLOCULATORS
To check the condition/availability
a) CW system
b) Pre treatment
c) DM system
Aeration Tower
Flash Mixer
Flow Meter
Bridge
Flocculating Agitator
De-sludging facility
Launders
Leakage/painting
Clarifier Performance

1.4

FILTERATION PLANTS
To check the condition/availability
a) Gravity Filters
b) Pressure filter

Status

Remarks

Sl. No.

Filter Media

Description

Status

Remarks

Status

Remarks

Backwash frequency
Back wash water quantity
Level indicator
Filter blowers / pumps for backwash
Filter water pumps
Working of instruments
Backwash water quantity
Filter water quality
Topping up of filter media during last one year
.

2.0

DM PLANT

Sl. No.
Description
To check inspection report, media condition, level of
2.1
media, test reports
ACF
WAC
SAC
WBA
SBA
MB
Spare resin availability
Spare resin storage condition
De-gasser Blower condition
Regeneration levels employed
Cation
Anion
Output quantity/quality
Cation
Anion
Degasser
MB

Sl. No.

Description
DM Water consumption, MT
% Make-up

2.2

Control Room
To check the condition/availability
Integrators
Conductivity Meters
pH meters
Silica Analyzers
Alarms
Mimic
Other Instrumentation

2.3

Regeneration system
To check the condition/availability
Storage tanks (Acid/Alkali)
Fume absorbers for acid storage tanks
Alkali filter
Alkali Heating system
Unloading system (Acid/alkali)
Acid & alkali metering pumps
Ejector system
Condition of pipes and vessels
Flushing arrangement
Shower/Eye Washer
Exhaust Fans

2.4

Neutralization/effluent disposal system


EDP availability
Neutralization pit condition
pH meter

2.5

DM Water storage tanks


To check the availability /condition : Tank nos
Level indicators
CO2 breathers
Over flow seal

Status

Remarks

Sl. No.

Inspection of Tanks

Description

Status

Remarks

Status

Remarks

Status

Remarks

Status

Remarks

Conductivity monitor in make up lines


3.0
SOFTENING PLANT
Sl. No.
Description
3.1
Type of plant , condition & performance
a) Lime softening
b) Ion exchange
Condition
Performance
3.2

Control room
To check the working/availability
Integrators
Hardness indicators
Flow meters
Recorders
Other Instrumentation

3.3

Regeneration system
To check the condition/availability
Salt lagoons
Salt/ Lime storage
Regeneration Levels/OBR
Concrete structure
Steel structure

CW CHEMICAL TREATMENT AND ITS EFFICACY


Sl. No.

COC

Description

Chemical in use
LI/RI
5.0

GENERATOR STATOR COOLING SYSTEM

Sl. No.
Description
5.1
Testings (frequency/analysis)
pH

Sl. No.

Conductivity

Description

Status

Remarks

Status

Remarks

Status

Remarks

Dissolved oxygen
Copper
Iron
Availability of SPU/Alkalizer
Make up quantity/quality
6.0
GENERATOR HYDROGEN COOLING
Sl. No.
Description
6.1
Testing (frequency/analysis)
Purity
Moisture/Dew Point
7.0
CONDENSATE POLISHING UNITS
Sl. No.
Description
7.1
CPU Operation
To check Availability
No. of days in Operation in a month in:
Hydrogen cycle
Ammonia cycle
7.2

Testing (frequency/analysis)
pH
Conductivity/Cation Conductivity
Chlorides
Sodium
Silica
Copper
Iron
Crud

7.3

Regeneration system
To check the condition/availability
Storage vessels
Alkali filters
Alkali heaters
Regeneration vessels

Sl. No.

Pumps

Description

Status

Remarks

Status

Remarks

Status

Remarks

Status

Remarks

Air blowers
Control Panel /Instrumentation
Neutralization pit/pH meters
8.0
Sl. No.

WQST/SWAS
To check for:

Description

Availability of Instruments (with list)


Sampling system
Cooling system
Calibration Frequency
9.0

STEAM WATER CYCLE

Sl. No.
9.1
Testings

Description

Laboratory Instruments (List)


Procedure adopted
Frequency of test
9.2

Deviations
(Core parameters : pH, Cation conductivity, DO, Sodium,
Silica)
Feed : pH, DO, kH ;
SiO2,Sodium

Boiler : pH, Cl ; Steam : kH,

Condensate : pH, DO, kH


Observations
9.3

HP/LP dosing systems


To check working/availability
HP Dosing System
LP Dosing System

10.0

CHEMICAL LABORATORIES

Sl. No.
Description
10.1
General laboratory condition
List of working equipment

Sl. No.
10.2

Calibration records

Description

Status

Remarks

Status

Remarks

Testing for Water (frequency/report)


Raw water
Clarifier
Cooling water
DM streams
Degassor
Filter water
DM Storage tanks
Neutralization pit effluents
Raw materials

10.3

Testing for Coal


Sampling procedure
Coal as fired/Coal as received/Coal at mine end
Calibration of bomb calorimeter
Calibration of other equipment
Proximate/Ultimate/HGI/Abrasion index analysis
frequency/report
Ash characterization frequency/report
Mill fineness/Combustibles frequency/report
Testing From External agency (reports)

11.0

OIL

Sl. No.
11.1
Testing

Description

To check testing frequency/report/deviations


Turbine oil
FRF
Transformer oil
`

Fuel oils
Dissolved gas analysis
Testing From External agency (reports)

12.0

PREVENTIVE MAINTENANCE SCHEDULE

Sl. No.

13.0
Sl. No.

Description
Schedule for the Preventive maintenance of Water
treatment equipment

Status

Remarks

Status

Remarks

Status

Remarks

SAFETY
To check

Description

Availability of safety showers/eye wash stations


Color coding on Chemical handling system
Safety drills records
Other safety appliances/PPE availability
14.0
Sl. No.

HOUSE KEEPING
General

Description

Acid/alkali lining
Painting of vessels, storage tanks, cylinders, pipelines

15.0

MISCELLANEOUS
Problems faced during last 3 years and solutions adopted
Major modification done during last 3 years
General Condition of civil structures and equipment in Water treatment Plant

EFFICIENCY: CHECK LIST FOR TECHNICAL AUDIT


Checking of following parameters and comparing with design values of selected Units.
PROJECT :
PARAMETER
Main steam temperature
Main steam pressure

UNIT :
DESIGN
ACTUAL VALUE
VALUE UNITUNITUNIT-

DATE :
DEVIATION

HRH steam temperature


S/H spray flow
R/H spray flow
FW temperature at Eco
inlet
Condenser back pressure
Make up water
consumption
Flue gas temperature after
APH
O2 in Flue gas before APH
Unburnt carbon in bottom
ash
Unburnt carbon in fly ash
Total Combustion air flow
Mills outlet temperature
Mills air flow
Whether site is carrying out periodic efficiency tests of following equipment/ systems of
Units. Random checking of the reports of the efficiency tests carried out by site.
EFFICIENCY TEST
RECOMMENDED
ACTUAL
SCHEDULE
SCHEDULE
Mill fineness
All the mills of one unit once in
a week.
Clean air flow test
At the time of major mill
overhaul.
Dirty air flow test
Once in 6 months
APH Seal leakage
Once in 15 days
APH gas side efficiency
Once in 15 days

EFFICIENCY TEST

RECOMMENDED
ACTUAL
SCHEDULE
SCHEDULE
Boiler efficiency test
Once in 3 months
Condenser performance test
Whenever vacuum deteriorates
from target value.
Turbine cylinder efficiency & Once in 6 months
Pressure survey
FW heaters performance test
Once in 6 months

Description
Sl. No.
3
To check whether recommendations on the basis of test
results have been
Generated and intimated to the
concerned maintenance department
4
Liquidation of all deficiencies highlighted in the
efficiency tests
5
Checking the actions taken for reducing Heat Rate
deviation as detailed in
ORT
6
Confirmation of scanning of summary log & other logs
from DAS / log sheets
and discussing the deviations in
planning meeting
7
Checking the record of SH & RH tube metal temperature
excursion
8
Checking the record of coal stock, F.O stock and also
coal stock verification frequency, oil stock verification
frequency
9
Checking the record of weighbridge calibration and
energy meter calibration
10

Checking the record of monitoring of important


parameters trend visa-vis limit value.

11

Checking the status of implementation of tripping


analysis recommendations

12

To Check Performance analysis of the Station

13

To Check implementation of the Recommendations of


Task Forces / Committees etc. as applicable

14

To check the working of POG H, POG-A etc.

Status

Remarks

Annexure 5h
GT & AUXILIARIES: CHECK LIST FOR TECHNICAL AUDIT
CONTROL ROOM CHECK LIST
Sl. No.
Description
1
Operation log book recording
Air intake differential pressure
Blade path temperature variation
Ambient temp
Minimum/Maximum turbine exhaust temp
Vibration values
Bearing oil and metal temperature
Compressor discharge pressure
Generator maximum/minimum slot temp
Gas line filter differential pressure and gas pressure at
GRS

3
4
5
6
7
8
9
10
11
12
13

Bearing oil Pressure


Pressure of each pump of flow divider
Water Injection, if applicable
NOx values (on LNG
Witness of one start up ;and shutdown already recorded
and comparison with commissioning data
Coasting down time
Start up time
Operation of Safety Devices
Checking of availability of Instructions of starting of gas
turbine in emergency / black out conditions &
Instructions for handling emergencies .
Gas Chromatograph checking and comparison of calorific
value of NTPC and GAIL.
Fire alarm panel indicator, printer and hooter healthiness
checking
Availability of D.C. light in CCR
Checking of CO2 / halon system, status manual/auto
Recording of routine testing, DC oil pump starting and
overspeed testing.
Mode of Turbine operation load control / temp. control
Availability and implementation status of fuel purging
system
Record of Fuel Testing for trace metal of APM / HSD /
Naptha carried out.
Implementation / status of dust particle monitoring at
down stream of air intake filter
Checking healthiness of Fire sensor in GT compartment
and associated areas.

Status

Remarks

OPERATION / PERFORMANCE TEST


Sl. No.
Description
1
Compressor efficiency
2
3
4

5
6
7

Status

Remarks

Real time heat rate analysis and assessment of output on


the basis of one hour test and heat rate deterioration
Changeover schedule
Routine tests of turbine equipment like AOP of
GT/DCLOP, GT black start of DG set, Fire fighting diesel
set, Gas and Naphtha leakage detection.
Air intake filters Differential Pressure analysis
Fuel check relief valve setting of liquid fuel system
Actual overspeed test after overhaul to be ensured from
record

REVIEW OF VARIOUS INSPECTIONS WITH RESPECT TO REPAIR /


REPLACEMENT TO ACHIEVE TARGET AVAILABILITY
Sl. No.
Description
1
Site preparation in respect of spares and T&P for
combustion chamber inspection, HGPI and major
overhaul
2
Action plan of various inspections
3
Work as per Quality overhaul norms & FDA involvement
in it
4
Adherence to manufacturer s guidelines and NTPC
directives
5
Air intake filter stock position and date of last replacement
6
Bypass damper position and reliability analysis
7
Equipment performance data history
8
Engineering declaration
9
Check deposits on IGV for oil / grease (fouling) during
A&B inspections.
10
Review of records of healthiness of various control valve
settings of governing system
11

Status

Remarks

Status

Remarks

OEM RECOMMENDATIONS FOR NEXT OVERHAUL


Sl. No.
Description
1
Check the report of OEM of previous overhauls and
ensure NTPC s comments have been sent to OEM
2
Check whether earlier recommendations were
incorporated in overhaul

STUDY OF MAJOR BREAKDOWNS IN GT & AUX. AND ANALYSIS AND


RESOLUTION ALONGWITH ACTION PLAN
Sl. No.
Description
1
Major equipment failure records checking,
recommendations and action taken
2
Refurbishment plan of used Hot Gas Path components
and blades / vanes and action taken for coating from OEM
3
Vanes/Buckets replacement plan
4
Hot gas path parts requirement for next overhaul
alongwith the status of stock
5
Inlet segment and inner liner status
6
Awareness of technical compliance system and ensuring
its availability at work station.
7
Status of critical components
8
Status of refurbishing as per contract

Status

Remarks

Status

Remarks

FIRE PROTECTION SYSTEM OF GT AREA


Sl. No.
Description
1
Checking of the weight of all CO2 cylinders of main and
standby headers
2
Checking of local alarm (hooter)
3
Checking of alarm window on local and CCR.
4
Checking of healthiness of nozzles on MOT and
combustion chambers

ANALYSIS OF LUBE OIL SYSTEM (GT AREA), LIQUID FUEL AND GAS WITH
ESPECT TO CV, TRACE METAL AND CONDENSATE
Sl. No.
Description
1
Fuel oil, gas and lubricants chemical analysis.
2
Lube oil consumption per month / hr. and its trend
3
Date of last centrifuging of MOT oil & date of last
changing of oil

Status

Remarks

Status

Remarks

Status

Remarks

HOUSE KEEPING IN GT AREA


Sl. No.
Description
1
House keeping around GT area & its healthiness
2
Checking of oil pits and its schedule for removal.
3
Checking of levels in condensate separator of fuel gas line
STORES VERIFICATION (GAS TURBINE PORTION)
Sl. No.
Description
1
Availability of mandatory spares
2
Spares availability for future inspection

3
4
5
6

O&M spares status


Status of preservation of spares as per OS/OEM guidelines
Frequency of Area Engineer s visits to stores
Check the Material Management System (OLYMFAS)

WALKDOWN CHECKS
Sl. No.
1
2
3
4
5
6
7
8

Description
Temperature in GT enclosures
Leakage of any gas / liquid fuel pipeline
Foundations of pipelines and equipment
Insulation
Sound level around GT area
Painting of pipes and vessels
Visible leakage of oil / fuel gas
Expansion joint healthiness

Status

Remarks

QUALITY MANAGEMENT SYSTEM: CHECK LIST FOR TECHNICAL AUDIT


Name of the Station:
Period of Audit:
Description
Sl. No.
1
Whether manual on Quality Management in Maintenance
/ Overhaul COS/ISO/00/OGN/OPS/SYST/018 Rev.0,
Maintenance Management System and short Term
Planning Vol. I and Maintenance Management Unit
Overhauls Volumes IIA & IIB are available at Site with
different depts. i.e. FQA, MTP, Maintenance Groups.
Yes/No
2
Whether the above mentioned documents are being
followed at Site during O/H and Preventive Maintenance
works. Yes/No
3
Whether detailed work plan to be taken up during O/H has
been drawn by Site and copies are available with MTP and
other maintenance groups. Yes/No
4
Whether protocols as per guidelines given in Maintenance
Management Unit Overhauls Vol. IIB & Quality
Management
in
Maintenance
/
Overhauling
COS/ISO/00/OGN/OPS/SYST/018 Rev.0 are being
maintained and signed by FQA and Maintenance
representative. Yes/No
5
Whether FQA set up at Site is adequate. Yes/No
6
Extent of involvement in O/H and other Preventive
Maintenance work. (copy of FQA organization chart
with brief details of work being done by them to be
collected).
7
8

Whether FQA group is being strengthened during O/H by


placing executives from other O&M Depts. particularly in
Boiler and Auxiliaries area. Yes/No
Check for the adequacy of Inspection and Testing
Facilities available at FQA laboratory
Radiography (source and film developing facilities (Y/N).
Ultrasonic Testing machine with trained operator (make
and capacity of machine (Y/N).
Whether trained manpower is available for handling radioactive source and ultrasonic testing machine (Y/N).
Magnetic Particle Inspection facilities (MPI) with trained
manpower (Y/N).
Dye Penetrate Test facilities (DPT) with trained
manpower (Y/N).
Universal testing machine for Mechanical Testing with

Status

Remarks

Sl. No.

trained operator (Y/N).

Description

Status

Hardness and Impact Testing machine with trained


operator (Y/N).
Testing facilities for civil items i.e. cement, aggregate,
concrete cubes, bitunum, etc. with trained manpower
(Y/N).
Check whether FQA group is being involved in Boiler
Tube leakage and other failure analysis (Y/N).
Check whether FQA and Maintenance Personnel are sent
regularly for training in the Welding, NDT and other
specialized functional areas. (Y/N).
Check the system of ensuring testing of pressure vessels,
tools and tackles at required intervals as indicated in Tech.
Compliance documents. (Y/N).
Whether checks as per guidelines are conducted for high
rise structures, chimney, spring mounted foundations,
floating mill foundations, concrete foundations and
necessary corrective measures initiated. (Y/N)
Whether site has storage and preservation procedure for
critical spares and other important materials. How this is
being implemented. Role of FQA units implementations.
(Y/N)
Whether FQA is involved
implementation. (Y/N)

in

plant

betterment

(a)
Compliance of FQA system manual (new) in the
different areas of Plant. (Status / Remarks).
(b) Verify compliance of FQA manual procedure No.P-10
for material procurement (O&M Spare), records of few
sample items to be verified. (Y/N). (Status / Remarks)
(c) Verify compliance of FQA manual procedure No.P-11
for site contracts and role of FQA during O&M Phase of
the plant. (Status / Remarks)
(d) Verify compliance of FQA manual procedure No.P-12
for overhauling and maintenance role of FQA. (Status /
Remarks)
9

FQA involvement needed in all areas (Mech, Elect, C&I).


(Y/N)

10

FQA involvement
Equipment. (Y/N)

11

FQA lab instruments calibration being done as per


frequency. (Y/N)

12

Preparation of QA sheet before overhaul as per overhaul

in

Predictive

Maintenance

of

Remarks

Sl. No.

type. (Y/N)

Description

Status

Remarks

CHECK LIST MAINTENANCE PLANNING SYSTEM


Is station work control system functioning as per NTPC maintenance Yes/No
management guidelines?
What type of system station is following?
Equipment history is maintained. If yes, select randomly 3 nos. major
equipments and check.
Does the short term planning (STP) liaison with operation for the
planning of defect rectification and apprise them about maintenance
work and delays?
Feed back from operation department on STP involvement.
Is the STP coordinating with maintenance section and apprising them
about plant report for start of maintenance work?
Feed back from all maintenance section on STP involvement.
Does STP liaison with operation for PTW?
Feed back from Operation dept. on STP involvement.
Does STP review and improve methods of maintenance, equipment
and staff-skill and crew size?
If yes, do they revise work specifications accordingly?
Does STP organize the daily planning meeting?
If yes, Participants of the meeting.
Person chairing the meeting.

Yes/No
Yes/No

Yes/No
Yes/No
Yes/No
Yes/No
Yes/No

PREVENTIVE MAINTENANCE

1.

Are all standby equipments covered under preventive maintenance


schedule?
Do all other equipments which do not have standby are taken under
preventive maintenance during annual O/H.
Choose 2/3 equipments and check the above.
Does changeover schedule of standby equipments match with the
preventive maintenance schedule?
Pick up 2/3 equipments and check the above.
Is the frequency and duration of the PM schedules reviewed?
If yes, pick up 3 / 4 equipments and check.
Are all columns of the Work Order Card filled up properly by area
engineer after the job is completed?
If yes, pick up 2 / 3 cards and check.
Is compiled material codification directory prepared by materials
department available at site?
If yes,
Is the above directory available in 1) printed form or 2) through LAN?
Does materials department review & update the stock of material and
inform MTP?
What is the periodicity of updating?
Are work specification printed on all PM job cards?

Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
1/2
Yes/No
Yes/No

Choose 2 / 3 cards and check.


PREDICTIVE MAINTENANCE
1.
(a)
(b)
(c)
(d)
(e)
(f)
(g)
2.
3. (a)

Whether following Condition Monitoring techniques are employed i.e.


Vibration Analysis
Thermography
Wear Debris Analysis
DGA
Acoustic (including SPM, Partial Discharge)
Motor current Analysis
Noise
Which are the Condition Monitoring technique outsourced.
Type and no. of equipments covered under Condition Monitoring plan
(Check viz-a-viz OS guidelines).
3. (b) If Yes, are these techniques employed as per predecided
frequency/schedule (Check viz-a-viz OS guidelines).
4.
Whether the maintenance is acting on the advice of Condition
Monitoring (check randomly).
5.
In how many cases, Condition Monitoring has helped in optimizing
the P/M schedule?
6.
Whether the PDM coordinator is integrating the reports from various
condition monitoring specialists and generating a comprehensive
report on equipment basis, to help the management in taking
maintenance decision.
7.
Is the frequency of Condition Monitoring technique reviewed
periodically (Say yearly basis)?
8.
What is the ratio of PM / Predictive / break down WOCs.
9.
Study trend of major equipment forced outage / reliability.
10. Any constraint in implementation of Condition Monitoring
Techniques through computers including assistance from IT.
11. Any new technique or concept being applied for reliability centered
maintenance.
12. Effectiveness of condition monitoring / predictive maintenance in
optimizing maintenance cost, if not satisfactory, suggest measures.

Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Nos.
Nos.
Yes/No
Yes/No
Nos.
Yes/No

Yes/No
Ratio
Status
Status
Status
Status

BREAK DOWN MAINTENANCE


1.

2.

Do the Work Order Cards clearly indicate the following?


a) Designation & location of plant or equipment concerned and
equipment code.
b) Details of the defect being recorded (or work being
requisitioned).
c) Degree of urgency with which repairs are required (i.e. Priority
E/A/B/C).
d) Indication of condition under which work can be carried out, i.e.
load reduction, off load, etc.
Pick up two or three job cards and check.
Does the Unit Control Engineer sign the E Priority job cards?
Pick up at random 1 / 2 job cards and check.

Yes/No
Yes/No
Yes/No
Yes/No
Yes/No

LUBRICATION SCHEDULE
1.
2.

Is Master Lubrication Schedule available?


Yes/No
How are they maintaining lubricating schedule (oil top up) and
quantity?

PERMIT TO WORK SYSTEM


What are the different types of PTW being used in the station:
a)ROMP (b)SFT (c)LWC (d)P.T.W.(Elect.) (e)P.T.W.(mech.)
Are all the different columns of all types of P.T.W. properly filled up?
Pick up 2 / 3 PTWs and check.
HOT WORK SAFETY PERMIT
Does the shift charge engineer sign all the hot work safety permits?
Pick up 2 / 3 PTWs & check.
Is safety ensured during the work?
Is Site following the lock out box philosophy?
If yes,
Check the lock out box in U.C.B. and verify the P.T.W. issued with
box no. issued.
Cross Permit
How cross permits are issued and the return of all the permits
confirmed before trial run is taken.
Danger Tag
Are the danger tags put on isolated bkr., or any system?
Pick up the P.T.W. and identify the equipment and check the bkr
whether danger tag is fixed or not.

Yes/No
Yes/No
Yes/No
Yes/No

Yes/No

OVERHAULING
Availability of five-year rolling plan with current year.
Is scope of work finalized before the overhaul and made part of the
contract.
Are overhaul books distributed within 03 months of overhaul of units?
Overhaul report on CD for 2003-2004 onwards. Hard copy also
should be made as required.
Availability of spares/consumables before overhaul.
Is there any system for ensuring availability of spares/consumables?
Availability of engineering declaration before 02 months of unit
overhaul.
Are all points available in Engineering declaration as mentioned in
letter given by OS referring overhaul management book Vol.2A?
Does overhaul report contain?
All areas of work.
Spares/consumables used.
Cost of spares/consumables/contract.
Signed protocols of all area.
Areas of improvement in current overhauls from previous overhaul.
Efficiency reports before/after overhaul.
Vib. Reading before/after overhaul.
Recommissioning details (like current, vib. Etc.) of equipments.

Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No

Availability of recommissioning group/check list before unit goes out Yes/No


of bar.
Availability/ checking of lifting tools (like chain pulley, hoist, EOT Yes/No
crane, lift, etc.)

BOILER & AUX.:CHECK LIST FOR TECHNICAL AUDIT


Records
Sl. No.
Description
1
Record of tube thickness survey of all the Units
2
Safety valve floating protocol and boiler license renewal
document
3
Checking of pipe hangers
4
C1, C2 and C3 forms for boiler tube failure
5
Tube failure analysis report from R&D
6
Clean Air flow test and dirty pitot test record for mills
7
Boiler metal temperature excursion records
8
Lub oil analysis report for Fans and mills
9
Unit overhaul Report
10
Availability of LMIs with concerned Engineers and its
awareness
11
History of all equipment

Status

Remarks

Status

Remarks

Milling system
Description
Sl. No.
1
Checking availability of mills and feeders
2
Adherence of the milling system to PM schedule
3
Availability of HAG and CAG in good condition (without
passing)
4
Checking the condition of PF pipes and elbows
5
Availability of spares and consumables for mills, feeders,
HAG, CAG, PF elbow and coal pipes
6
PF fineness being maintained in the mills
7
Unburnt carbon in bottom ash and fly ash
8
PF outlet temperature
9
DP of mills
10
Mill loading and reason for running the mills on partial
loading
11
Availability of inerting system (in case of tube mills)
12
Availability of mill reject handling system and quantity of
rejects and its GCV
13
Availability of hoist for mill maintenance
14
Any major problem in milling system
Boiler

Sl. No.
Description
1
Number Tube failure in each boiler location wise and its
root cause analysis
2
Whether short term or long term action plan is in place for
reduction of tube failures
3
Adoption of OS guidelines during Unit overhaul for BTF
reduction
4
Availability of wall deslaggers and LRSBs and frequency
of its operation
5
Availability of burner tilt mechanism and SADC on auto
6
Availability of safety valves and ERVs in service
7
Condition of furnace seal trough
8
Condition of Insulation and cladding for boiler, ducting,
steam lines and valves
9
Availability of spare tubes and bends, coal compartment
assembly, spares for critical valves and safety valve
10
Availability of boiler lift
11
Boiler parameters
Furnace pressure
MS temperature (Left and right)
MS pressure
HRH temperature (Left and right)
SH and RH spray
Total Air flow
Total coal flow
PA header pressure
FW temperature at Eco inlet
O2 at Eco outlet
FG temperature at APH inlet
FG temperature at APH outlet
SA/PA temperature at APH inlet
SA/PA temperature at APH outlet
DP at SA/PA of APH
DP at gas path of APH
ID fan current
12

Status

Remarks

Status

Remarks

Any specific problem in boiler

Fans, Air Preheaters, Ducts, Dampers and Gates


Sl. No.
Description
1
Healthiness of PA, FD, ID, seal air , scanner air and pent
house pressurisation fan
Current
Vibration

Sl. No.
Description
Bearing temperatures
Availability of standby lub oil pumps
Availability of spares for all the fans
Availability of hoist for fan maintenance
Any major problem in any of the fans
2
Air preheater
Availability of fire detection system
Availability of standby lub oil pumps
Availability of ALCS
Availability of APH soot blowers
Performance of the air preheaterss
Availability of hoist for heating element replacement
Availability of spares for air preheaters
3
Ducts, dampers and gates
Any leakage in the gas/ air ducts
Condition of metallic / fabric expansion joints
Availability of gates/dampers in operating condition

Status

Remarks

Status

Remarks

ESP
Sl. No.
Description
1
Availability of no. of fields in each ESP
2
Availability of no. of rappers for emitting and collecting
system
3
Availability of opacity monitors in working condition
4
Whether RAPCON, BAPC ON and IOS system are in
service
5
No. of hopper heaters in service

ANNEXURE-XX

DAILY FLASH REPORT

NATIONAL THERMAL POWER CORPORATION LTD.


Station:
Date :
From: Shift Charge Engineer / Supdt. (O&E)
To

: ED (OS)

Copy: GM (Station)
Daily flash Report for
-----------------------------------------------------------------------------------------------------------Particulars
Unitwise
Station
I.
-----------------------------------------------------------------------------------------------------------1.

Gross Generation (MU)


(for previous day)

2.

Morning Load (MW)


(of same day)

3.

Net Generation(for previous day)

4.

DC

(for previous day)

5.

SG

(for previous day)

6.

AG

(for previous day)

7.

Coal status
a.
b.

Coal Cons. (MT)

c.
8.

Coal Recd. (MT)


By MGR / Road / Rly.
Coal Stock (MT)

Low Generation due to


a.
b.

9.

Grid restriction (MU)


Coal / Gas (MU)

Unit outages
a.

Time/Duration

b.
c.
10.

Cause
Expected Time of Syn.

Outages of Lines
a.

Time/Duration

b.

Cause

11.

Station Generation schedule by REB s

12.

Fore-Bay / Reservoir Level

Remarks
a.

If generation and load is less than 101% state brief reason.

b.

Reason for less coal receipt.

c.

Slippage / Difficulties faced for units under overhaul and likely date of
revival.

Also expected time of revival of units which are out for short

duration.
d.

Details of major happenings of any.

Station schedule.
Note: The above Flash Report must be stopped after implementation of OPPMS

ANNEXURE-XXI
REPORT FOR MAJOR HAPPENINGS

NATIONAL THERMAL POWER CORPORATION LTD.


REPORTING OF MAJOR HAPPENING / EVENTS
Station:
Date :

From : GM Site
To : ED (OS)
S.No. Happenings / Events
1.

Unit trip out at (time)

2.

Unit synchronized at (time)

3.

Reasons for outage

4.

Load reduction by more than 50% for more than 2 hrs.


(Reasons)

5.

Major damage to equipments


(Boiler, Turbine, Generator, H.T. Motor, Transformers, Switchgear, UPS, Large
Capacity Pumps etc. Brief Report)

6.

Incidence of fire, if any


(Brief Report)

7.

CHP Conveyor Belt damages


(Length etc.)

8.

Any other information.

ANNEXURE-XXII
DAILY DETAILED REPORT

NATIONAL THERMAL POWER CORPORATION LTD.


Station:
From : GM Site
To : ED (OS)

Date :

Daily Report for .


-----------------------------------------------------------------------------------------------------------Particulars
Unitwise
Station
I /II/III/IV/V/VI/VI/VII .
-----------------------------------------------------------------------------------------------------------1.

Peak / minimum load (MW)

1.

Gross Generation (MU)-Day

2.

Gross Generation (MU)-Cum

3.

Net Generation (MU)-Day

4.

Net Generation (MU)-Cum

5.

Installed DC (MU)

6.

Actual DC (MU)-Day

7.

Actual DC (MU)-Cum

8.

SG (MU)-Day

9.

SG (MU)-Cum

10.

AG (MU)-Day

11.

AG (MU)-Cum

12.

UI earned (Rs.)-Day

13.

UI earned (Rs.)-Cum

7.

PLF (%)-day

8.

PLF (%)-Cum

9.

Availability Factor (%)-Day

10.

Availability Factor (%)- Cum

12.

Generator on line (Hrs.)-Day


Availability (%)

12.

Generator on line (Hrs.)-Cum

Availability (%)
9.

Aux. Power Consumption (MU)/(%)-Day

10.

Aux. Power Consumption (MU)/(%)-Cum

10.

Oil Consumption(KL) (ml / kwh)-Day

10.

Oil Consumption(KL) (ml / kwh)-Cum

11.

Coal / Gas Cons.(MT & SMC)(Kg / kwh & SMC / kwh)-Day

12.

Coal / Gas Cons.(MT & SMC)(Kg / kwh & SMC / kwh)-Cum

13.

Make-up water consumption (MT)-Day


(% MCR)

13.

Make-up water consumption (MT)-Cum


(% MCR)

14.

Heat Rate-Day
(Kcal / kwh)

14.

Heat Rate-Cum
(Kcal / kwh)

15.

Expected generation for next


day (MU)

16.

MVAR Max. / Min.


Voltage Max. / Min.

17.

Gen. loss due to


i)
Grid (MU)
j)
Due to ABT
ii)
Coal / Gas supply (MU)
iii)
Station Problem (MU) with reason

-----------------------------------------------------------------------------------------------------------Coal Recd. (MT)


Wagon Placed
Wagon Loaded
Coal stock (MT)
Sp. Fuel Consumption
For MGR (Lit/Km.)

Net Export (MU)


Lines flow (MU)

Note: The above Detailed Report must be stopped after implementation of OPPMS

CHEMISTRY
(Site Reports)
ANNEXURE XXIII
Note: Data collection /Testing frequencies of the following Chemistry formats shall be as per
Code of practice on power plant chemistry - document no. COS-ISO-00OGN/OPS/CHEM/015 Rev. No. : 0 October 2003.

REPORT ON MAKE-UP WATER & SPECIFIC CHEMICAL CONSUMPTION


Station :
Date :
Status of Make-up Water
Make-up water in stock

Tonnes

Make-up water produced

Tonnes

Total make-up water at station

Tonnes

Make-up water consumed

Tonnes

(Signature)

RAW AND FILTERED WATER ANALYSIS


PROJECT:
S.NO.

STAGE:

DATE:

pH at 25oC
Sp. Cond. at 25oC
Turbidity
Ca-Hardness
Mg-Hardness
Total-Hardness
P-Alkalinity
M-Alkalinity
EMA
Chlorides
Sulphates
Reactive Silica
Total Silica*
Organics (KmnO4 No.)
COD*
Total Iron*
TDS
Residual Cl2
No. of samples tested

*: Once/month
REMARKS:

(Signature)

REPORTING
UNIT

-S/cm
NTU
mg/l as CaCO3

mg/l as SiO2

mg/l

mg/l as SiO2
mg/l

No.

RAW WATER

FILTERED
WATER TO
DM PLANT

RANGE

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.

PARAMETER

ANNEXURE-XXIV

RANGE

AVG.

AVG.

CLARIFIED WATER ANALYSIS


PROJECT:

STAGE:

S.NO.

PARAMETER

REPORTING
UNIT

1.

pH at 25oC

--

2.

Turbidity

NTU

3.

Organics (KMnO4 No.)

mg/l

4.

COD*

5.

Residual Cl2

6.

No. of samples tested

No.

*: Once/month
REMARKS:

(Signature)

ANNEXURE-XXV

DATE:
RANGE

AVG. VALUE

PERFORMANCE DATA PT PLANT


PROJECT:

STAGE:

ANNEXURE-XXVI

DATE:

S.NO.

PARAMETER

REPORTING
UNIT

1.

Quantity of clarified water produced

M3

2.

Quantity of ferric alum used (on 15% Al2O3 basis)

MT

3.

Quantity of lime used (on 75% Ca[OH]2 basis)

MT

4.

Quantity of chlorine used

MT

5.

Quantity of bleaching powder used (on 32% available


Cl2 basis)

MT

6.

Quantity of coagulant aid (name), if any, used

Kg

7.

Quantity of any other chemical used in PT plant (give


name and purity)

Kg

Specific chemical consumption for :


Kg/M3
8.
Alum
8.1
Lime
8.2
Chlorine
8.3
Coagulant aid
8.4
Bleaching powder
8.5
NOTES :
1.
If purity is different, it may be mentioned accordingly.
If non-ferric alum is also used, its consumption and reason for use to be mentioned.
If coagulant aid is used, mention its consumption and ensure its use as potable.
REMARKS:

(Signature)

VALUE

SOFTENED WATER ANALYSIS


PROJECT:

STAGE:

DATE:

S.NO.

PARAMETER

REPORTING
UNIT

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.

pH at 25oC
Sp. Cond. at 25oC
TDS
Inlet Turbidity
Total-Hardness
P-Alkalinity
M-Alkalinity
Sodium
Chlorides
Sulphates

-S/cm
mg/l
NTU
mg/l as CaCO3

11.

No. of samples tested

No.

REMARKS:

(Signature)

ANNEXURE-XXVII

RANGE

AVG. VALUE

ANNEXURE-XXVIII
PERFORMANCE DATA SOFTENING PLANT FOR CW SYSTEM
PROJECT:

STAGE:

DATE:

S.NO.

PARAMETER

REPORTING
UNIT

1.

Quantity of softened water produced

M3

2.

Quantity of fresh brine used for regeneration


(100%w/w)

MT

3.

Quantity of spent brine recirculated (100%w/w)

MT

4.

No. of regeneration for the month

No.

5.

Resin foulant treatment given, if any

--

6.

Quantity of coagulant aid (name), if any, used

Kg

7.

Quantity of any other chemical used

Kg

REMARKS:

(Signature)

VALUE

CIRCULATING WATER ANALYSIS


PROJECT:
S.NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.

STAGE:

PARAMETER

pH at 25oC
Sp. Cond. at 25oC
Turbidity
Ca-Hardness
Mg-Hardness
Total-Hardness
Sodium & Potassium
P-Alkalinity
M-Alkalinity
Chlorides
Sulphates
Reactive Silica
Total Silica*
Organics (KmnO4 No.)
TDS
Residual Cl2
No. of samples tested

ANNEXURE-XXIX

DATE:

REPORTING
UNIT

VALUES
RANGE

AVG.

-S/cm
NTU
mg/l as CaCO3

mg/l as SiO2

mg/l

No.

*: Once/month
Any special testing required w.r.t. chemical treatment may be included.
REMARKS:

(Signature)

ANNEXURE-XXX
CIRCULATING WATER PERFORMANCE DATA
PROJECT:
S.NO.

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.

STAGE:

PARAMETER

Langelier Index at 50oC


Ryzner Index at 50oC
Chemicals dosed
(anticorrosive, antiscalant,
dispersant, biocide, etc.)
Quantity of Cl2 dosed
Quantity of chemicals dosed
(name & purity)
Temperature, condenser I/L
Temperature, condenser O/L
Cooling water flow
Cooling water make up
Cycles of concentration (COC)
Cooling water blowdown
Type of chlorination
(continuous/shock)
No. of Cl2 shock dosings

REMARKS:

(Signature)

DATE:
REPORTING
UNIT

--mg/l
MT
Kg
o

C
C
M3/h

No.
M3/h
-o

No.

VALUES
RANGE

AVG.

DM PLANT PERFORMANCE DATA


PROJECT:

STAGE:

ANNEXURE-XXXI

DATE:

S.NO.

PARAMETER

REPORTING
UNIT

1.
2.

Quantity of DM water produced


Quantity of HCl used for regeneration
(on 30% HCl basis)
Quantity of NaOH used for regeneration
(on 100% NaOH basis)
Quantity of HCl used for neutralization
(on 30% HCl basis)
Quantity of NaOH used for neutralization
(on 100% NaOH basis)
Quantity of lime used for neutralization
(on 75% Ca[OH]2 basis)
Specific chemical consumption
HCl
NaOH
No. of regeneration of cation exchanger
(single & double)
No. of regeneration of anion exchanger
(single & double)
No. of regeneration of MB
Quantity of resin top up
(indicate vessel and brand name of the resin)
Quantity of DM water consumed as make up
Quantity of DM water consumed for
regeneration
Foulant treatment, if any
(acid/brine+caustic)

M3
MT

3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

REMARKS:

(Signature)

Kg/ M3
No.

M3

VALUE

ANNEXURE-XXXII
CONDENSATE POLISHING PLANT PERFORMANCE DATA
PROJECT:

STAGE:

DATE:

S.NO.

PARAMETER

REPORTING
UNIT

1.

Quantity of condensate polished per vessel


H-cycle (up to 0.1S/cm cond.)
NH3-cycle (up to 0.1S/cm cond.)
Service period per vessel
H-cycle
NH3-cycle
Vessel/Resin charge no.
Quantity of chemicals consumed for
regeneration
HCl (30% basis)
NaOH (100% basis)
Quantity of chemicals consumed for
neutralization
HCl (30% basis)
NaOH (100% basis)
Lime (75% basis)
No. of regeneration of resin charge
Use of CPU
Cold startup
Hot startup
Normal
Service termination criteria

M3

2.
3.
4.

5.

6.
7.

8.

VALUE

Hours
-MT

MT

No.

NOTE: 1.
After each use at unit startup, de-crud the resin batch as soon as possible.
Ensure complete transfer of the resin charge from service vessel to regeneration vessel
and vice versa.
Ensure effective resins separation during regeneration.
Check resin interface position and adjust, if required.
Ensure uniform resin mixing in the service vessel.
REMARKS:
(Signature)

STEAM-WATER ANALYSIS
PROJECT:

STAGE:

DATE:

S.No. PARAMETER

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.

ANNEXURE-XXXIII

Make up Condensate Condensate Feed Boiler Sat/


(unit
(untreated) (treated with water water Super
side)
cpu)
heated
steam
pH at 25oC

Sp. Cond. at 25oC, S/cm

Cation cond. , S/cm


Silica, reactive, mg/l

Phosphate, mg/l

Ammonia, mg/l

Residual hydrazine, mg/l

Dissolved O2, mg/l

Total Iron, mg/l

Total Copper, mg/l

Sodium, mg/l

Chloride, mg/l

Crud, mg/l

Stator water diff. Press.

15.
Expansion tank vacuum
16.
N2 capping pressure

Parameters to be tested/recorded.
NOTES:
Data to be recorded unit wise.
Limits for various parameters to be specified.
Max, min, and average values to be specified.
Number of samples outside the prescribed limit to be given.
Reasons for persistent deviation to be given.
CBD opening hours to be recorded.
REMARKS:

(Signature)

Primary
stator
water
(In/Out)

ANNEXURE-XXXIV
CHEMICAL CONSUMPTION DATA - MAIN PLANT/ETP
PROJECT:

STAGE:

DATE:

S.NO.

PARAMETER

REPORTING
UNIT

1.

Chemical consumption unitwise

MT

Hydrazine hydrate (80%)


Liquor ammonia (25%)
Trisodium phosphate
Disodium phosphate
Sodium hydroxide
2.

Effluent treatment plant

MT

Polyelectrolyte
HCl (30%)
H2SO4 (98%)
Lime (75%)
Any other chemical
3.

Auxiliary cooling water chemical consumption

REMARKS:

(Signature)

MT

VALUE

ANNEXURE-XXXV
COAL AS RECEIVED ANALYSIS (Joint coal)
PROJECT:
S.N. DATE

REMARKS:

(Signature)

Name of the mine :


DATE:
TOTAL
PARAMETERS UNDER
MOISTURE EQUILIBRATED CONDITIONS
(%)
(40oC & 60% RH)
M (%)
ASH (%) VM (%) UHV

GRADE

COAL AS FIRED ANALYSIS


PROJECT:
S.NO. DATE

REMARKS:

(Signature)

DATE:
TOTAL
MOISTURE
(%)

ASH
(%)

VM
(%)

ANNEXURE-XXXVI

FIXED
CARBON (%)

GCV
(Kcal/kg)

ANNEXURE-XXXVII
FLY ASH AND BOTTOM ASH ANALYSIS (DRY BASIS)
PROJECT:
S.NO.

DATE

STAGE:
UNIT NO.

DATE:
COMBUSTIBLES (%)
FLY ASH

REMARKS:

(Signature)

BOTTOM ASH

ANNEXURE-XXXVIII
NATURAL GAS/NAPHTHA ANALYSIS
PROJECT:
S.NO.

STAGE:

PARAMETER

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.

N2
CO2
C1
C2
C3
I-C4
N-C4
I-C5
N-C5
C6
C7
H2O

13.
14.

Avg. Molucular Wt.


(by calculation)
Calorific Value
Net
Gross

15.

No. of samples analyzed

16.

Sample collection point

REPORTING
UNIT

REMARKS:

(Signature)

Kcal/SM3

DATE:
VALUE
LIMIT

RANGE

AVG.

No. OF
SAMPLES
OUT OF
LIMIT

ANNEXURE-XXXIX
TURBINE LUBRICATING/GOVERNING OIL ANALYSIS
PROJECT:
UNIT NO. :
S.NO.

PARAMETER

STAGE:
REPORTING
UNIT

1.

Moisture

ppm

2.

Mechanical
impurities

ppm

3.

Viscosity

4.

Neutralization No.

REMARKS:

(Signature)

Cst
mg KOH/g of oil

DATE:
VALUE
LIMIT

RANGE

AVG.

No. OF
SAMPLES
OUT OF
LIMIT

COAL FINENESS
PROJECT:

STAGE:

ANNEXURE-XXXX

DATE:

S.N DATE

UNIT MILL LOAD

COAL

COAL

COAL

NO.

ON

RETAINED

PASSING

PASSING

MILL

ON 50US

THROUGH

THROUGH

MT/hr

SIEVE (300

100US SIEVE 200US

MICRON IS

(150

SIEVE (75

SIEVE)

MICRON IS

MICRON IS

SIEVE)

SIEVE)

(Signature)

NO.

REMARKS

MILL REJECTS (DRY BASIS)


PROJECT:
S.NO.

DATE

STAGE:

ANNEXURE-XXXXI

DATE:

UNIT/

ASH

GCV

STAGE

(%)

(Gross Calorific Value)


(Kcal/kg)

(Signature)

REMARKS

ANNEXURE-XXXXII
FLUE GAS (by ORSAT or portable gas analyzer) & HYDROGEN GAS ANALYSIS
PROJECT:

STAGE:

DATE:

S.NO.

PARAMETERS

VALUE

REMARKS

1.

CARBON DIOXIDE

(%)

Online O2
analyzer to

2.

OXYGEN

(%)

be cross
checked by
ORSAT.

HYDROGEN GAS
S.NO.

PARAMETERS

VALUE

1.

H2 PURITY*

(%)

(H2 PLANT)
2.

H2 PURITY*

(%)

(GENERATOR)
3.

DEW POINT**

(GENERATOR H2)
4.

H2 PURITY*

(%)

(H2 CYLINDER)
*

by ORSAT/portable H2 purity analyzer.

**

by Dew point monitor/apparatus.

(Signature)

REMARKS

ANNEXURE-XXXXIII
CHLORINATORS
PROJECT:
Date Time

Diff.

STAGE:
Booster EjectorChlorine

DATE:
Evaporator

(Hrs.) Pressure Pump Water Header Water Gas Gas O/L Gas

Chlorinator
Gas

Free Remar

Ejector Res. ks

across Discharge Flow PressureTemp.Temp Press. Flow Press. Vacuum Cl2


Filter Pressure (M3/ (Kg/ cm2) (0C)
(Kg/ cm2)
(Kg/cm2)

H)

(mg/L)
. (Kg/ cm2 (Kg/H)(Kg/Cm2(Mm Hg)
)
(0C)

Note:
1.

Cathodic protection of evaporator shall be monitored / recorded as per O&M manual.

(Signature)

* The core parameters shall have alarms in the control rooms. The followings are the core
level parameters:

FOR AVT (O) FEED WATER TREATMENT


Cation conductivity- CPD, CP O/L or ECO I/L, RH (or MS), Down- comer (or blow
down); Specific conductivity-

Make up; pH (drum units)- Down- comer (or blow

down); Dissolved oxygen- CPD, ECO I/L;, Sodium- CPD, CP O/L or ECO I/L, RH (or
MS)
FOR AVT (R) FEED WATER TREATMENT
Cation conductivity- CPD, CP O/L or ECO I/L, RH (or MS), Down- comer (or
blow
down); Specific conductivity- Make up; pH (drum units)- Down- comer (or blow down);
Dissolved oxygen- CPD, ECO I/L; Sodium- CPD, CP O/L or ECO I/L, RH (or MS);
ORP- Deaerator I/L

ANNEXURE XXXXIV
OVERHAULING PERFORMANCE DECLARATION
A)

Boilers

1.

Unit

5.

Operation Hours
since last overhaul

2.

Station :

6.

Date of Survey

3.

Unit shutdown :
(Planned Date)

7.

Surveyed by

4.

Unit Synchronisation
(Planned Date)

a.
b.
c.

8.0 Units Operating Condition during Survey


-----------------------------------------------------------------------------------------------------------Remarks
S.No. Description
Units
Values
Design
Before After
Parameter O/H O/H
-----------------------------------------------------------------------------------------------------------8.1 Load
MW
8.2 Main steam pressure

Kg/Cm2

8.3 Main steam temperature

8.4 Steam flow

T/Hr.

8.5 Feed water flow

T/Hr.

8.6 F.W. temperature


at Eco. Inlet

8.7 Eco. Outlet FW

Temperature L&R
8.8 Flue gas + P across
Economiser L&R

mmWc

8.9 Flue gas + T across

APH (A)
8.10 Flue gas + T across
APH (B)

8.11 Flue gas + T across


Economiser L&R

8.12 O2 in flue gas at Eco.


outlet L&R

8.13 F.D. Fan (A) Load

Amps

8.14 F.D. Fan (A) vane


position

8.15 F.D. Fan (A) discharge


pressure

mmWc

8.16 F.D.Fan (B) load

Amps

8.17 F.D. Fan (B) vane


position

8.18 F.D. Fan (B) discharge


pressure

mmWc

8.19 I.D. Fan (A) load

Amps

8.20 I.D. Fan (A) vane


position

8.21 I.D. Fan (A) suction


pressure

mmWc

8.22 I.D. Fan (B) load

Amps

8.23 I.D. Fan (B) vane


position

8.24 I.D. Fan (B) suction


pressure

mmWc

8.25 Total air flow

T/Hr.

8.26 P.A. Fan (A) load

Amps

8.27 P.A. Fan (A) discharge


pressure

mmWc

8.28 P.A. Fan (B) load

Amps

8.29 P.A. Fan (B) discharge


pressure

mmWc

8.30 Mill (A) load

Amps

8.31 P.A. Flow to Mill (A)

T/Hr.

8.32 Coal flow to Mill (A)

T/Hr.

8.33 Mill (A) Bowl + P

mmWc

8.34 Mill (A) Outlet temp.

8.35 Coal fineness through


200 mesh & 50 mesh

8.36 Mill (B) load

Amps

8.37 P.A. Flow to Mill (B)

T/Hr.

8.38 Coal flow to Mill (B)

T/Hr.

8.39 Mill (B) Bowl + P

mmWc

8.40 Mill (B) outlet temp.

8.41 Coal fineness through


200 mesh & 50 mesh

8.42 Mill (C) load

Amps

8.43 P.A. flow to Mill (C)

T/Hr.

8.44 Coal flow to Mill (C)

T/Hr.

8.45 Mill (C) Bowl + P

mmWc

8.46 Mill (C) Outlet temp.

8.47 Coal fineness through


200 mesh & 50 mesh

8.48 Mill (D) load

Amps

8.49 P.A. flow to mill (D)

T/Hr.

8.50 Coal flow to mill (D)

T/Hr.

8.51 Mill (D) Bowl + P

mmWc

8.52 Mill (D) outlet temp.

8.53 Coal fineness through


200 mesh & 50 mesh

8.54 Mill (E) load

Amps

8.55 Coal flow to mill (E)

T/Hr.

8.56 P.A. flow to mill (E)

T/Hr.

8.57 Mill (E) Bowl + P

mmWc

8.58 Mill (E) outlet temp.

8.59 Coal fineness through


200 mesh & 50 mesh

8.60 Mill (F) load

Amps

8.61 P.A. flow to mill (F)

T/Hr.

8.62 Coal flow to mill (F)

T/Hr.

8.63 Mill (F) Bowl +P

mmWc

8.64 Mill (F) outlet temp.

8.65 Coal fineness through


200 mesh & 50 mesh

9.0 Vibrations & Bearing Temperatures


-----------------------------------------------------------------------------------------------------------Remarks
S.No. Equipment
Bearing
Maximum Vibration
Temperature Displacement Velocity

(Degree.C)
(Microns)
(mm/sec.)
DE
NDE
DE
NDE DE NDE
-----------------------------------------------------------------------------------------------------------9.1
ID Fan (A)
9.2

ID Fan (B)

9.3

FD Fan (A)

9.4

FD Fan (B)

9.5

PA Fan (A)

9.6

PA Fan (B)

9.7

Mill (A)

9.8

Mill (B)

9.9

Mill (C)

9.10

Mill (D)

9.11

Mill (E)

9.12

Mill (F)

9.13

CC Pumps

9.14

Seal Air Fan

9.15

Ignitor Air Fan

10.0 General Condition of Equipments


-----------------------------------------------------------------------------------------------------------S.No. Equipments
Remarks
-----------------------------------------------------------------------------------------------------------10.1 Safety Valves
10.2

Burners / Tilt mechanism/


Gun advance retract mechanism etc.

10.3

Scanners / Ignitors

10.4

Valves

10.5

PC Piping

10.6

Mills / Feeders

10.7

APH

10.8

ESP

10.9

Fans (ID / FD / PA)

10.10 Dampers / Gates


10.11 Hanger Supports
10.12 General
11.0

For Thermal Performance Analysis

11.1 Mill Combination


11.2 HRH Pressure L&R

Kg/cm2

11.3 CRH Pressure L&R

Kg/cm2

11.4 HRH Steam Temp. L&R

11.5 LTSH Outlet Steam Temp. L&R

11.6 PSH Inlet Steam Temp.


(After D SH) L&R

11.7 PSH Outlet Steam Temp. L&R

11.8 CRH D SH Inlet Steam Temp. L&R


11.9 CRH D SH Outlet Steam Temp. L&R

11.10 Boiler Drum Pressure

Kg/cm2

11.11 RH Flow

T/Hr.

st

11.12 1 Stage Steam Pressure

Kg/cm2

11.13 SH Spray Flow

T/Hr.

11.14 RH Spray Flow

T/Hr.

11.15 HPH 6A FW Inlet Temp.

11.16 HPH 6A FW Outlet Temp.

11.17 HPH 6B FW Inlet Temp.

11.18 HPH 6B FW Outlet Temp.

11.19 HPH 6A Drain Temp.

11.20 HPH 6B Drain Temp.

11.21 Condenser vacuum

mmHg

11.22 Wind Box Pressure L&R

mmWc

11.23 SAH Inlet O2 L&R

11.24 SAH Inlet CO2 L&R

11.25 SAH Outlet O2 L&R

11.26 SAH Outlet CO2 L&R

11.27 PAH Inlet O2 L&R

11.28 PAH Inlet CO2 L&R

11.29 PAH Outlet O2 L&R

11.30 PAH Outlet CO2 L&R

11.31 Eco. Outlet O2 L&R

11.32 Eco. Outlet CO2 L&R

11.33 ESP Inlet O2 L&R

11.34 ESP Outlet CO2 L&R

11.35 Ambient Temp. wet

11.36 Ambient Temp. dry

11.37 Eco. Outlet FG Temp. L&R

11.38 SAH Inlet FG Temp. L&R

11.39 PAH Inlet FG Temp. L&R

11.40 SAH Outlet FG Temp. L&R

11.41 PAH Outlet FG Temp. L&R

11.42 Air Preheater Common Duct Outlet


FG Temp. L&R

11.43 Proximate Analysis of coal


11.44 ID Fan Outlet O2 L&R

11.45 Unburnt Carbon in


a) Bottom Ash

b) Fly Ash

11.46 Burner Tilt


11.47 Secondary Air Flow L&R

T/Hr.

11.48 Side wall Radian RH Outlet


Steam Temp. L&R

11.49 Front Wall Radian RH Outlet


Steam Temp. L&R

11.50 SH Spray Water Pressure

kg/cm2

11.51 SH Spray Water Temp.

11.52 RH Spray Water Pressure

Kg/cm2

11.53 RH Spray Water Temp.

11.54 PA Header Pressure L&R

mmWc

11.55 PAH Outlet Air Pressure L&R

mmWc

11.56 SAH Outlet Air Pressure L&R

mmWc

11.57 PAH Inlet Air Pressure L&R

mmWc

11.58 SAH Inlet Air Pressure L&R

mmWc

11.59 FG Pressure SAH Outlet L&R

mmWc

11.60 FG Pressure SAH Outlet L&R

mmWc

11.61 ID Fan Inlet Gas Pressure L&R

mmWc

11.62 ID Fan Outlet Gas Pressure L&R

mmWc

11.63 Chimney Inlet Gas Pressure L&R

mmWc

B)

Turbines

1.

Unit

5.

Operation Hours
since last overhaul

2.

Station :

6.

Date of Survey

3.

Unit shutdown :
(Planned Date)

7.

Surveyed by

4.

Unit Synchronisation
(Planned Date)

a.
b.
c.

8.
Units Operating Condition during Survey
-----------------------------------------------------------------------------------------------------------S.No. Description
Units
Values
Remarks
Design
Before After
Parameter O/H O/H
-----------------------------------------------------------------------------------------------------------8.1
Load
MW
8.2

Turbine speed

rpm

8.3

Steam pressure at
ESV (LHS/RHS)

Kg/cm2

8.4

Steam Temperature at
ESV (LHS/RHS)

8.5

Steam pressure at
IP inlet

Kg/cm2

8.6

Steam temperature
at IP inlet

8.7

Turbine exhaust steam


pressure (HP)

Kg/cm2

8.8

Turbine exhaust steam


temperature (HP)

8.9

Condenser back press.

mmHg

8.10

Turbine axial shift

mm

8.11

Overall expansion
(HP/IP)

mm

8.12

Eccentricity at
Barring Gear

mm

8.13

Differential expansion
(HP / IP / LP)

mm

8.14

Final feed water


temperature

8.15

Feed water temperature


after LP Heaters

8.16

Condenser CW
temperature (Inlet/Outlet)

8.17

LP exhaust hood
temperature

8.18

HPC difference (Bottom/


Top) Temperature

8.19

(Bottom / Top) IPC


difference temperature

8.20

Bearings drain oil


temperature rise across
bearings

8.21

Bearing babbit
(metal) temperature

8.22

Lube oil pressure

Kg/cm2

8.23

Control oil pressure

Kg/cm2

8.24

Seal Oil pressure

Kg/cm2

8.25

Hydrogen cylinder
consumption per day (if
taken during overhauling).

Nos.

8.26

BFP (A) load

Amps.

8.27

BFP (A) discharge


pressure

Kg/cm2

8.28

BFP (B) load

Amps

8.29

BFP (B) discharge


pressure

Kg/cm2

8.30

BFP (C) load

Amps

8.31

BFP (C) discharge


pressure

Kg/cm2

8.32

CEP (A) load

Amps

8.33

CEP (A) discharge


pressure

Kg/cm2

8.34

CEP (B) load

Amps

8.35

CEP (B) discharge


pressure

Kg/cm2

9.

Vibrations & Bearing Temperatures

-----------------------------------------------------------------------------------------------------------S.No. Equipment
Bearing
Maximum Vibration
Remarks
Temperature Displacement Velocity
(Degree.C)
(Microns)
(mm/sec.)
DE
NDE
DE
NDE DE NDE
-----------------------------------------------------------------------------------------------------------9.1
BFP (A)
9.2

BFP (B)

9.3

BFP (C)

9.4

CEP (A)

9.5

CEP (B)

10.

General condition of Equipments

-----------------------------------------------------------------------------------------------------------S.No. Equipments
Remarks
-----------------------------------------------------------------------------------------------------------10.1 Main turbine
10.2

Generator

10.3

Condenser

10.4

Seal Oil System

10.5

Stator Water Cooling System

10.6

LP Heaters

10.7

HP Heaters

10.8

Deaerator

10.9

General

11.

Vibration record

-----------------------------------------------------------------------------------------------------------Brg. No. Displacement


Velocity
Shaft Vib.
BBT
Microns
mm / sec.
Microns
C
H
V
A
H
V
A
H
V
-----------------------------------------------------------------------------------------------------------1.
2.
3.
4.
5.
6.
------------------------------------------------------------------------------------------------------------

C)

Generator

1.

Unit

5.

Operation Hours
since last overhaul

2.

Station :

6.

Date of Survey

3.

Unit shutdown :

7.

Surveyed by

4.

a.

Unit Synchronisation
(Planned Date)

b.
c.

8.
Units Operating Condition during Survey
-----------------------------------------------------------------------------------------------------------Remarks
S.No. Description
Units
Values
Design
Before After
Parameter O/H O/H
-----------------------------------------------------------------------------------------------------------8.1
Generator Parameters
a)
b)
c)
d)
e)
f)
g)
h)

Load
Power Factor
Current
Voltage
Frequency
Field current
Calculated value
field voltage
H2 pressure at ambient
temperature

8.2

Winding Temperature
Recorder Points

a)

Stator Core
01
02
03
04
05
06
07
08
09
10
11
12

MW
MVA
Amps
KV
Hz
Amps
V
Kg/cm2
C

b)

Stator winding
01
02
03
04
05
06
07
08
09
10
11
12

c)

Rotor
01
02
03
04
05
06
07
08
09
10
11
12

8.3

Insulation Resistance

a)
b)

IR Value of Rotor
PI Value of Rotor
(In case unit is under shut-down)

8.4

Generator Transformer Parameters

a)
b)
c)
d)
e)
f)

Load
Voltage
Tap Position
Winding Temp. (Local)
Winding Temp. (Remote)
Oil Temp. (Local)

8.5

Stator Water System

a)
b)

Pump in service
Vacuum in Expansion
Tank
Stator Water Flow
Inlet / Outlet Temp.
Inlet / Outlet Pressure
Stator Water Differential
pressure

c)
d)
e)
f)

Mohms

MW
KV
C
C
C
Nos.
mmHg
m3/Hr.
C
Kg/cm2

g)
h)
i)
j)
k)

Conductivity
PH value
Dissolved Oxygen
Undissolved / Dissolved
copper
Undissolved / Dissolved
Iron

8.6

Oil Pressure Turbine


end seals
Oil Pressure Exciter
Exciter end seals

ppm
ppm
ppm

Seal Oil System

a)

m mho

b)

Kg/cm2
Kg/cm2

8.7

H2/CO2 status

a)

c)
d)

Cold Gas Temperature


(Nominal)
Dew Point / Relative
Humidity
Purity
Pressure

8.8

Healthiness of Pedestal Insulation

a)
b)

Voltage Pedestal to Earth


Voltage Shaft to Earth
(with oil film)
Voltage Shaft to Earth
(without oil film)

b)

c)
8.9

AVR Status

a)
b)

Auto / Manual
Excitation limits & PSS
status (in service/ out of
service)

C
C
%
Kg/cm2
V
V
V

ANNEXURE-XXXXIV
CRITICAL PARAMETERS DEVIATION RECORD
Date:
Station/Unit
Period
Sl Parameters
Rated
Deviated
Dur Cu
No.
Value
Value
atio m
From
To
(Max)
n
Dur
(Hr.
(Hr.
Min)
Min) (Hrs atio
)
n
BOILER

1
2

SH
Outlet
Temperature
RH Outlet Temp

SH Metal Temperature

RH
Metal
Temperature
LTSH
Metal
Temperature
Boiler Stop Valve
Steam Pressure
Boiler Water PH

Boiler Steam Silica

5
6

TURBINE

11

Turbine First Stage


Pressure
Turbine
Metal
Temperature
Turbine Brg Vibration

12
13
14

Turbine Axial Shift


HPT Diff. Expansion
IPT Diff. Expansion

10

GENERATOR

15

Gen. Voltage(R/Y/B)

16

Gen. Current (R/Y/B)

17

MVAR

18

Hydrogen Hot & Cold


Gas Temperature
Rotor Temperature

19
20

Stator
Winding
temperature
Slot No./Temp.

Rema
rks

GENERATOR TRANSFORMER
21

GT
Winding
temperature

Period

ANNEXURE XXXXV

500 MW BOILERS
COLD START-UP CHECK LIST (POST OVERHAUL)
UNIT:
S.N.

DATE:
DESCRIPTION

RESP.

01.

Men & material removed from furnace


& second pass & manholes /peepholes
closed.

PP

02.

All ducts cleared and manholes closed.

PP

03.

All works on pressure parts completed


and boxed up.

PP

04.

All safety valve gags and hydro-plugs


removed.

PP

05.

All available oil guns are flushed


checked for any leakage, cleaned
and clamped.

PP

06.

All wall blowers and LRSBS are


retracted fully.

PP

07.

All air pre-heater soot blowers


checked & cleared for operation.

PP

08.

Men and material cleared from ducts,


dampers, fans and airpreheaters.

RM

09.

All air pre-heaters fire water is


charged upto the last valve.

RM

10.

All air pre-heater oil carry over probes


are fixed in position and cleared
for operation.

RM

11.

Clearance given from mills, feeders


& fuel piping side.

RM

12.

Men and material removed from bottom


ash hopper, economiser hopper, air

AHM

STATUS

REMARKS

pre-heater hopper and boxed up.


S.N.

DESCRIPTION

RESP.

13.

Minimum two passes in ESP boxed up


and cleared for operation.

AHM

14.

Clearance given from critical piping,


HP / LP bypass & main turbine side.

TM

15.

All instruments related to APHs and


boiler combustion are working.

C&I

16.

For all APHs, fire detection system


is kept in service.

C&I

17.

All protections & interlocks of boiler


(FSSS) are checked & kept in service.

C&I

18.

All alarms set as per the design, tested


and kept in service.

C&I

19.

APH soot blowers are cleared for


operation.

C&I

20.

Bottom ash hopper and seal trough


Filled.

Opn.

21.

Boiler is filled upto the normal level.

Opn.

22.

Burner front & air pre-heaters


Fire water ensured.

Opn.

23.

Burner front, air pre-heaters and


Other boiler areas are accessible.

Opn.

24.

All boiler protections are checked


and kept in service

Opn.

25.

Availability of APH fire detection


System, oil carry over probes, air
Pre-heater dampers & air pre-heater
Soot blowers ensured.

Opn.

26.

Service air availability ensured for


Air pre-heater and igniters.

Opn.

27.

Main turbine is on barring gear.

Opn.

STATUS

REMARKS

S.N.

DESCRIPTION

RESP.

28.

Clearance obtained from Pressure


Parts Rotary Machines, ash handling
Maint. & C&I maint. for light-up and
all major PTWs are cancelled.
Major deviations from standard
Check list noted and submitted for
Approval by competent authority.

REMARKS

Opn.

29.

STATUS

Opn.

CLEARANCES
S.N.

DEPARTMENT

01.

Rotating Machines (RM)

03.

Turbine Maintenance (TM)

04.

C&I Maintenance (C&I)

05.

Ash Handling Maint. (AHM)

06.

REMARKS

Pressure Parts (PP)

02.

SIGNATURE

Operation / Recommissioning

DEVIATIONS:

Shift Charge Engineer /


Supdt. (Opn.)
DGM / AGM (O&M) :

Sr. Supdt. (Opn.)

DGM (Opn.)

ANNEXURE XXXXVI

MODEL START-UP CHECKLIST OF


500 MW BOILER & AUXILIARIES (COLD-START)
1.0

INITIAL CONDITION:
1.1
1.2

Boiler is filled upto the normal level.

1.3

All boiler auxiliaries are cleared for operation.

1.4

2.0

Boiler is depressurised condition.

CC pumps cavities are filled.

LINE-UP:

The following systems/ equipments should be lined up and made ready for operation:
2.1

Aux. Steam system.

2.2

Fuel oil-handling system.

2.3

Instrument air system.

2.4

Plant air system.

2.5

Equipment cooling water system.

2.6

All three CC pumps: Cavity filling completed and discharge valves are kept
open.

2.7

Both secondary and primary air heaters with associated dampers.

2.8

Both ID fans should be ready and lined up.

2.9

Both FD fans should be ready and lined up.

2.10

AC and DC scanner air fans.

2.11

SCAPH for primary and secondary air heaters.

2.12

Both PA fans should be ready and lined up.

2.13

Mills: Those required for full load operation should be made ready and which
are not available should be isolated.

2.14

Coal feeders.

2.15

Both seal air fans.

2.16

Electrostatic precipitator.

2.17

Pent house pressurising fan.

2.18

Soot blowing system for air heaters.

2.19

Furnace temp. probes.

2.20

Water / steam sampling system.

The equipments readiness can be ensured by complying with the Recommissioning


checklists.

3.0

CHARGING OF SYSTEMS:
3.1

3.2

Start instrument air compressors and charge instrument air to boiler, turbine,
auxiliaries and off-sites.

3.3

Start plant air compressors and charge plant air igniter cooling, air heater, air
motors and other cooling/cleaning requirement.

3.4

Start equipment cooling water pumps and charge the coolers for all
equipments.

3.5

4.0

Charge aux. Steam to the boiler (from running unit or aux. Boiler). Ensure
proper draining of the lines before charging. Aux. Steam for oil heating, oil
lines tracing, atomising steam, air heater, soot blowers and steam coil air
heaters should be made available.

Charge HF up to the burner front and keep it on long recirculation.

PRESTART CHECKS:

Fill the Boiler cold start-up checklist and get the deviations approved by the competent
authority.

5.0

START-UP:

The sequences of starting of the equipments are given below. For details refer to the
standard operating procedure of the individual equipment.
5.1
Start two CC pumps one by one and keep them in service. Check for the
differential pressure and ensure that it is normal. Drum level has to be
maintained high (about + 300 mm) before starting the pump and it should be
maintained Normal afterwards.

5.2

Start the secondary air heaters one by one and keep the associated dampers
open.

5.3

Start the primary air heaters one by one. Though it is not required as a purge
permissive, it is better to keep them in service from the safety angle. Keep the
gas outlet dampers closed, till air flow is established.

5.4

Start the first ID fan. Ensure that its suction & discharge dampers open to full.
Also check for the closure of the suction / discharge damper / inlet vane of the
other fan.

5.5

Gradually raise the scoop and then vane of the running fan and maintain a
furnace draft of about 10mmwc.

5.6

Start the corresponding FD fan (if it is not available the other FD fan can be
started). Ensure that the discharge damper of the running fan opens full and
the blade pitch and discharge damper of the non-running fan closes full.

5.7

Gradually raise the load on the FD fan. Parallely control the scoop and vane
of the running ID fan to maintain the furnace draft. (Ensure that the secondary
air dampers are open and modulating). Raise the total air flow to more than
30% (630 tph), which is the purge requirement.

5.8

Put the wind box pressure control (aux. air dampers) in auto and maintain the
desired wind box to furnace differential pressure.

5.9

Start the second ID fan. Ensure fuel opening of its suction and discharge
damper.

5.10

Slowly raise the scoop and vane of the second ID fan and reduce those of the
first ID fan to equalise the heading on both fans, always maintaining the
furnace draft within limits.

5.11

Start the second FD fan. Ensure that its discharge damper opens fully.

5.12

Gradually raise the blade pitch of the second FD fan and reduce that of the
first FD fan to equalise the loading on both fans maintaining the minimum air
flow and normal furnace draft.

NOTE: If so desired, the second set of ID / FD fans can be started at a later stage (after
synchronisation and auxiliary supply changeover) to reduce the auxiliary power consumption
and loading on station transformer. But keeping both the fans in service is preferable from
the operation flexibility point of view. It avoids tripping of the boiler on protection in the
event of outage of one fan and reduces the furnace disturbance at a later stage while starting
the second set of fans.
5.13

Put the furnace draft control in auto. However, the performance of the auto
loop should be kept under observation during low load operation.

5.14

Start the AC scanner fan and keep it in service. Keep the other fan as auto
standby. Ensure that the scanner air pressure is normal.

5.15

Charge the SCAPH of both FD fans. Regulate the steam flow to maintain the
air heater cold end temp.

5.16

Close the HFO Trip Valve and Recirculation Valve (which were opened
earlier for charging and warming up the oil lines Refer Sec. 3.5). Open the
Short Recirculation Valve.

5.17

After completing the above activities, ensure that the following Purge
Permissives are satisfied and the PURGE READY Light is ON :
a)
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)

5.18

All HFO nozzle valves are closed.


All mills are OFF.
No boiler trip.
All feeders are OFF.
All scanners sense No Flame .
All auxiliary air dampers are modulating.
Both PA fans are OFF.
All hot air gates are closed.
Air flow > 30% and <50%.
HFO Trip valve is closed.
Wind box to furnace difference pressure is normal.

Ensure that the cold start-up checklist is completed in all respects and the
deviations are noted.

BOILER LIGHT-UP:
5.19

Start the furnace purge cycle by depressing the PUSH TO PURGE button.
PURGING light comes ON and purging continues for 5 minutes (if the
purge time is disturbed, it should be corrected).

5.20

If the purging is interrupted due to any reason (loss of one or more of the
purge permissive), purging should be restarted.

5.21

On completion of purge PURGE COMPLETE light becomes ON . MFT


gets reset.

5.22

Open the HO Recirculation Valve and HO Trip Valve; close the Short
Recirculation Valve.

5.23

Bring the HFO header pressure and temperature to normal value. Ensure that
atomising steam pressure is normal.

5.24

Ensure that Burner tilt is horizontal.

5.25

Select the oil burners to be fired. During cold start-up normally lower (AB)
elevation oil burners are selected.

5.26

Give start command to the selected burner. It is preferable to start one burner
at a time, by monitoring its performance at local. (Individual burner selection
can be done by keeping its selector switch in Remote at local).

5.27

Check and ensure that the burner is firing properly. In case of poor flame or a
leak, take out the burner immediately. Identify the cause and attend it.

5.28

After proving the first burner successfully select the next burner (preferably on
the other side in the same elevation) and give start command. Ensure proper
flame. Similarly all the four burners in the elevation (maximum) can be kept
in service. Regulate the oil pressure.

5.29

Keep the furnace draft at normal values while cutting in oil burners.

5.30

Ensure that the auxiliary air dampers of the burners in service are open.

5.31

Check the chimney exit. If excessive black smoke is observed, adjust air flow.

5.32

Start Air preheater soot blowers. Check for any oil carry over with the help of
oil carry over probe. Inspect the air heater through the inspection doors
provided on the air side.

5.33

Maintain drum level within normal limits (+ 100mm). Keep economiser


recirculation valve open when there is no feeding to the drum.

5.34

Monitor the boiler pressure increase and ensure that it is within allowable
limits (It should not exceed a corresponding increase in saturation temp. of
100C/hr.).

5.35

At a drum pressure of 2kg/cm2 close all SH vents and drains. Leave the startup vents open.

5.36

Insert furnace temp. probe occasionally and ensure that the gas temp. is less
than 540C.

5.37

Monitor the rate of increase of SH outlet temp. and ensure that it is within
limits (less than 5C/min.).

5.38

Monitor the drum, SH and RH metal temp. and ensure that they are within
limits. (Drum metal temp. raise should be within 2C/min.).

5.39

Start the dosing pumps and do chemical dosing as per Chemist s advice. Open
CBD as per the Chemist s advice.

MAIN STEAM LINE CHARGING:


5.40

Do condenser vacuum pulling after making the associated system ready.

5.41

Ensure that MS, CRH and HRH line drains are open (turbine side) and system
is ready for operation; turbine is on turning gear and stop/control valves are
closed.

5.42

Ensure the readiness of HP/LP Bypass System.

5.43

When drum pressure reaches about 4 kg/cm2, start charging main steam line
by gradually opening the bypass (warm up) valves of Boiler Stop Valves on
both sides. {Ensure that the main valves are not in Auto. In auto the valves
gets open command when the bypass valves are full open).

5.44

Open the Boiler Stop Valve Monitor the pressure rise of MS line bypass
valves to full. Open HP Bypass warm-up valves to warm-up the CRH lines.
Observe for any abnormality (like hammering etc.) in the system.

5.45

Open HP bypass valves partially and ensure that the pr. control valves, spray
valves and the protection system is working properly.

5.46

Open HP bypass valves partially and ensure that the pr. control valves, spray
valves and the protection system is working properly.

5.47

Monitor the pressure rise in the boiler. When the pressure exceeds 5kg/cm2,
open Boiler Stop Valves and regulate HP Bypass Valves to control the
pressure close start-up vents. Close HP Bypass worm-up valves.

5.48

Open LP Bypass Valves and keep it partially open at lower pressures. When
the pressure improves control the LP Bypass Valve opening so as to maintain
a pr. of about 12 kg/cm2 in the HRH.

5.49

When boiler pressure reaches 7kg/cm2, start the third CC pump and keep it in
service.

(NOTE: Pumps should not be started during intervals of rapid boiler water temp. change).
TURBINE ROLLING & SYNCHRONISING:
5.50

Raise the boiler parameters (by controlling the firing rate) as per the
requirements of Turbine by following the allowable ramp rate.

5.51

At a main steam pressure of 15kg/cm2 and HRH pressure of 8-12 kg/cm2


reset the turbine (Refer Turbine start-up procedure).

5.52

At 50 kg/cm2 MS pressure, 12kg/cm2 HRH pressure and 350C MS/HRH


temp. roll the turbine and synchronise the machine.

5.53

After taking block load, close HP/LP Bypass and keep it in auto with proper
pressure set point.

5.54

Close CRH, HRH and MS drains. Ensure closing of MAL drains in auto.

5.55

Before the feed water flow to the boiler reaches the capacity of the low load
line, one of the high capacity lines should be placed in service.

5.56

Economiser recirculation valves should be closed after establishing a constant


feed water flow.

COAL FIRING:
5.57
5.58

Ensure that both ID / FD fans are in service and are equally loaded. Furnace
draft control is put in auto.
Start the first PA fan. Ensure that its discharge damper opens in auto and the
discharge damper of the other fan closes in auto.

5.59

Start the second PA fan. Ensure opening of its discharge damper. Load both
the fans gradually and raise the PA header pressure to normal value. (PA fans
should not be run without air flow for long duration).

5.60

Ensure that one of the seal air fans starts in auto. If not, keep it in service,
keep the other fan as standby.

5.61

Open the gas dampers of the primary air heaters. Improve the primary air
temperature.

5.62

Start the first mill (preferably bottom elevation) and keep it in service.
Increase the loading gradually.

5.63

Keep the other mills in service as per the load requirement.

5.64

Gradually raise the steam parameters and unit load as per the start-up curves
by observing TSE margins.

(STATION)

UNIT:
S.N.
01

BOILER START UP LOG

ACTIVITY DESCRIPTION

02

Initial Unit condition:


Cold / Hot
Drum Metal temp C-L / R:

03

Number of guns proved:

05

APH soot blowing started at, hrs-L


/R:

06

Second elevation guns taken in


service at, hrs:
Boiler drum / SH vents closed at,
hrs:
Drum pr. ksc:
SH / RH header drains closed at,
hrs:
Drum pr. ksc:
MS line charged at,
hrs:
Drum pr. ksc:
HP bypass charging
Time, hrs:
MS pr, ksc:
LP bypass charging
Time, hrs:
HRH pr, ksc:
Coal firing started at, hrs:

07**
08**
09**
10
11
12
13
14
15
16
17

DATE:

PARAMETER
Recommended*
Actual

Boiler Light up time, hrs:

04

ANNEXURE XXXXVII

Sequence / time of starting


subsequent mills:
Unit synchronising time:
Oil support removed at, hrs:
Load, MW:
(Total oil cons.):
Full load reached at, hrs:
Constraints faced, if any during light
up and loading
* Recommended as per integrated start up procedures.
** Applicable during cold start ups

REMARKS

(STATION)

Sl.
No.

UNIT:

1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
30.
31.
32.
33.
34.
35.
36.
37.
38.
39.
40.
41.
42.

Parameter

BOILER START UP LOG: MAJOR PARAMETERS


DATE:

LDO Pr.
Atm. Air Pr
HFO Pr.
HFO temp
Atm. Stm. Pressure
Scanner air Pr
Total Air Flow
Furnace Draft
Flue Gas O2
Drum Pr.
ID fan-A/B Vane position
ID fan -A Speed / Scoop position
ID fan-B Speed / Scoop position
FD Fan A/B Blade pitch position
SAPH-A air outlet temp
SAPH-A gas inlet temp
SAPH-A gas outlet temp
SAPH-B air outlet temp
SAPH-B gas inlet temp
SAPH-B gas outlet temp
PAPH-A air outlet temp
PAPH-A gas inlet temp
PAPH-A gas outlet temp
PAPH-B air outlet temp
PAPH-B gas inlet temp
PAPH-B gas outlet temp
SH temp before/after attem..LHS
SH temp before/after attem.RHS
MS temp. at Blr O/L LHS/RHS
RH temp before/after attem..LHS
RH temp before/after attem..RHS
HRH Temp. LHS/RHS (blr side)
SH attem. Flow LHS /RHS
CBD opening
Silica (drum)
Drum level
FW temp. at economizer inlet
Feed water flow/MS flow
PA header pressure
Seal air header pressure
Total coal flow
Max. SH / RH metal temp.

Unit

Ksc
Ksc
Ksc
o
C
Ksc
mmwc
TPH
mmwc
%
KSC
%
rpm/%
rpm/%
%
0
C
0
C
0
C
0
C
0
C
0
C
0
C
0
C
0
C
0
C
0
C
0
C
0
C
0
C
0
C
0
C
0
C
0
C
TPH
%
ppm
MM
0
C
TPH
mmwc
mmwc
TPH
0
C

Time

ANNEXURE XXXXVII

MODEL START-UP CHECKLIST OF


500 MW TURBO-GENERATORS
UNIT:

DATE:

S.
DESCRIPTION
RESPONSINO.
BILITY
01. All major works on TG completed, PTWs TM/Opn.
cancelled. Check list for putting TG on
turning gear is filled.
02.

TG put on turning gear.

Opn.

03.

MS, HRH strainer drains, header drains, CRH Opn.


drains including manual valves are kept open.

04.

All drains manual valves are open. Valves Opn.


are open or working in auto.

05.

Gland steam drain valves are working in auto.

06.

Both CW passes are charged and CW flow is Opn.


>50,000 tph.

07.

Condenser vacuum pulled & vacuum switches Opn./C&I


are reset;
Vacuum:

08.

Boiler is in service with sufficient steam flow: Opn.


BLI, tph:

09.

HP/LP bypass are completely available & TM/C&I/


charged.
Opn.

10.

All TSI, indicators & recorders are available C&I


& switched ON .

11.

DAS is switched ON ; X-T curves & temp. C&I


margin values are available.

12.

Turbine protections and interlocks checked C&I/Opn.


and kept in service.

13.

SLC AOPs, JOPs & CF Pumps are switched Opn.


ON .

14.

Turbine oil temp. control and CF temp. Opn.


control are in auto.

15.

ATRS and EHC availability ensured.

Opn.

C&I/Opn.

STATUS

REMARKS

16.

ATT programme is available.

C&I

17.

Main and middle breaker are open and Opn.


isolators are closed.

18.

All trip relays are reset.

19.

GTs, UATs and bus ducts cleared; all allied EM/Opn.


supplies made '
ON and mulsifiers kept in
auto.

20.

GTs, OLTC checked and cleared.

21.

Exciter panel and allied supplies readiness EM/Opn.


checked and kept ' .
ON

22.

Generator casing H2 filling completed and Opn.


pressure is >3.7 ksc, H2 purity-%:

23.

H2 coolers charged and temp. control put in Opn.


auto.

24.

PW system is in service; Flow adjusted and EM/Opn.


temp. control put in auto. PW N2 capping
pressure is normal.

25.

Exciter coolers charged.

Opn.

26.

Availability of AVR ensured.

EM

27.

Seal oil system is completely available, oil Opn.


pumps interlocks checked.

28.

Seal oil system is in service; standby pumps Opn.


supply is made ON .

29.

Seal oil coolers are charged and oil temp. is Opn.


normal.

30.

Turbine governing characteristics taken and TM


cleared.

31.

DG set is available and diesel tank level is Opn.


normal.

32.

Turbine parameters on TG are noted and no Opn.


abnormality is observed.

33.

Turbine start-up parameters (as given in Opn.


integrated start-up procedure) achieved.

34.

Major deviations (if any) from the above Opn.


checklist noted and brought to the notice of
competent authority.

35.

Clearance for Turbine rolling:


Turbine Maintenance
:

Opn.

EM

Signature

Electrical Maintenance
C&I Maintenance
Operation

:
:
:

36.

Ensure that turbine is not accelerating on Opn.


opening of stop valve.

37.

Turbine rolled to 360 rpm. Parameters noted Opn.


and found OK. Ensure Turning gear valve
closed.

38.

Turbine rolled to 3000 rpm after soaking Opn.


(whenever required). Parameters noted &
found OK. Ensure stopping of J0P, AOP etc.

39.

Speed cross checked at 3000 rpm with off line Condition


instrument and found satisfactory.
Monitoring/
Opn.

40.

ATT carried out for protective devices and Opn.


found OK.

41.

All Electrical tests completed, and bypassing EM


done, if any, normalised.

42.

Sufficient margins are available as per TSE.

43.

Information given to grid / switchyard Opn.


Engineer
and
clearance
taken
for
synchronising.

44.

Clearance for Generator synchronising:


Electrical Maintenance
:
Operation
:

45.

Unit synchronised and block load taken. TG Signature


cleared for operation.
Operation
:
Counter Signature
:

Opn.

Signature

ANNEXURE XXXXVIII
MODEL RECOMMISSIONING CHECKLIST OF MAIN TURBINE (500 MW)
EQUIPMENT : MAIN TURBINE
S.NO.

DESCRIPTION OF ACTIVITY

1.0.0

DETAILS OF JOBS TAKEN UP WITH PTW NOS:

2.0.0

SHUT DOWN ACTIVITIES:

2.1.0

Turbine stopped at:

2.2.0

Maximum metal temperature at the time of stopping turbine

2.3.0

Turning Gear stopped at: DATE/TIME

2.4.0

Maximum metal temperature at the time of turning gear


stopping.

2.5.0

AOP stopped at:

2.6.0

Maximum metal temperature at the time of stopping oil pump

3.0.0

MOT drained and level switches checked.

4.0.0

MOT cleared and inspected.

5.0.0

MOT mulsifier operation checked and found dry

6.0.0

MOT filling completed and level switches checked while filling


MOT level (should be more than + 400 mm).

7.0.0

Thrust bearing filters cleaned.

8.0.0

MOT cooler works completed.

9.0.0

All TG bearings cleared for C&I jobs (T.M.)

10.0.0

C&I connections given and TSI calibration completed (C&I).

11.0.0

TSI alarm checked and cleared.

DATE/TIME

DATE/TIME

STATUS

S.NO.

DESCRIPTION OF ACTIVITY

12.0.0

All bearings boxed up area cleaned and clearance and


clearance given for oil flushing.

13.0.0

OIL FLUSHING

13.1.0

Turbine front pedestal works completed and boxed up.

13.2.0

All turbine generator and excitor bearing oil line throttles


removed and line filters provided.

13.3.0

MOT centrifuge is available and kept in service.

13.4.0

Pressure gauges are available before and after thrust bearing


filter.

13.5.0

Thrust bearing Oil filter DP high alarm checked and found


healthy.

13.6.0

Lube oil temperature and pressure gauges at local and in


UCB are available and made ON.

13.7.0

Lube oil system is properly lined up for pump trial up to the


bearings. Lube oil cooler and thrust bearing filter vents
opened and drains closed.

13.8.0

OIL PUMPS LOAD TRIAL CHECKS:


i)

Motor is undamaged, fitted and satisfactorily mounted


with foundation bolts tight.

ii)

Motor is properly coupled with pump.

iii)

All bolted joints and cover plates on the stator frame are
provided with Gasket and properly lightened.

iv)

Motor bearings are lubricated properly.

v)

Power cables and earthing connections are complete,


secure and tight.

vi)

Terminal box is clean, dry and properly tightened.

vii)

Space heater connections are complete, secure and


tight.

viii)

MCC (DCDB, USS or EMCC) charged & module


cleared.

STATUS

S.NO.

DESCRIPTION OF ACTIVITY
xi)

STATUS

Winding megger values are measured and recorded.


R /Y /B:
AOP-1:
AOP-2:
DCOP:

x)

Winding resistances are measured and recorded.


AOP-1:
AOP-2:
DCOP:

xi)

Space heater megger value is measured and recorded:


AOP-1:
AOP-2:

13.9.0
13.10.0
13.11.0

xii)

Space heater resistance value is measured and


recorded:
AOP-1:
AOP-2:

MOT and its surrounding area are properly cleared and


illuminated.
All field defects inside MOT room attended.

13.12.0

13.13.0

Clearance for starting oil flushing / pumps trial.


SIGNATURES:
TM:
EM:
C&I:
OPN:
Power and control supply extended for the pumps (ensure
that SLC AOPS is not ON and fire protection / oil level lowlow is not acting, before switching on the supply).
DCOP started and line filling started:
DATE/TIME :
CURRENT, A:
NOTE: During oil pumps trial, first bump test is to be done to
confirm DOR.

S.NO.

DESCRIPTION OF ACTIVITY

13.14.0

Vents closed after filling the lines

STATUS

13.15.0

13.16.0
13.17.0

13.18.0

DCOP on-load vibrations


----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------Abnormality noticed, if any during trial.
AOP-1 started and DCOP stopped:
DATE/TIME:
CURRENT, A:
LUBE OIL PR.:
UCB, LUBE OIL PR.:
AOP-1 on load vibrations

13.20.0

-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

13.21.0

Abnormality noticed if any during AOPs trial:

13.19.0

Lube oil temperature Deg.C


13.22.0

AOP-2 started and AOP-1 stopped


DATE/TIME:
CURRENT,A:
LUBE OIL PR. (UCB):
AOP-2 on load vibrations

13.23.0

----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------Abnormality noticed if any during AOPs trial

S.NO.

DESCRIPTION OF ACTIVITY

13.24.0

Continue oil flushing for 2 hours or till thrust bearing filter gets
chocked (which ever is minimum).

13.25.0

Oil pumps stopped and all filters cleaned (Bucket strainers,


thrust brg., filter and line filters)
DATE/TIME:

13.26.0

Continue oil flushing with increased intervals of pump


running.

13.27.0

Lube oil flushing log sheet

13.28.0

S.
No.
Date
Starting time
Stopping time
Lines included
Filters chocking

13.29.0
13.30.0
13.31.0

13.32.0
14.0.0
14.1.0
14.2.0
14.3.0

STATUS

MOT VEF kept in service.


Line filters are found to be clean.
Thrust bearing filter chocking frequency has reduced (less
than once in 8 Hrs.).
Oil flushing completed successfully.
TM:
OPN:
Pumps stopped and supply made OFF.
OIL SYSTEM ADJUSTMENTS
All line filters removed and throttle fixed.
Throttle lifts adjusted and readings taken (protocol made)
throttle screws are removed and locknuts tightened.
DCOP started and lines fitted.

S.NO.

DESCRIPTION OF ACTIVITY

14.4.0

AOP kept in service pilot oil pressure (should be more than


4.8 ksc)

14.5.0

Oil flow chocked at all bearing oil return lines flow measured
and recorded.

14.6.0
15.0.0
15.1.0
15.2.0
15.3.0
15.4.0
15.5.0
15.6.0
15.7.0
15.8.0
15.9.0

15.10.0

SLC AOPS commissioned.


JACKING OIL PUMPS RECOMMISSIONING
Motor is undamaged, fitted and satisfactorily mounted with
foundation bolts tight.
Motor is properly coupled with pumps.
All bolted joints and cover plates on the stator frame are
provided with Gasket and properly tightened.
Motor bearings are lubricated properly.
Power cables and earthing connections are complete, secure
and tight.
Terminal box is clean, dry and properly tightened.
Space heater connections are complete, secure and tight.
MCC (DCDB TMCC or EMCC) charged and module cleared.
Winding megger valves are measured and recorded:
JOP-1:
JOP-2:
DCJOP:
Winding resistances are measured and recorded:

15.11.0

JOP-1:
JOP-2:
DCJOP:
Space Heater megger values, measured and recorded:
JOP-1:
JOP-2:

STATUS

S.NO.

DESCRIPTION OF ACTIVITY

15.12.0

Space Heater resistances are measured and recorded:


JOP-1:
JOP-2:

15.13.0

MOT level is normal.

15.14.0

Jacking oil pressure gauges at local and UCB are available.

15.15.0

JOP LOAD TRIAL CLEARANCES:


SIGNATURES:

15.16.0
15.17.0

15.18.0
15.19.0

TM:
EM:
C&I:
OPN:

Power and control supply extended.


DCJOP started for lines filling
Starting
Time / Date:
Current, A:
Heater Pressure:
DCJOP

15.20.0

JOP-1 / JOP-2 started along with stopping of DCJOP

15.21.0

Starting

15.22.0
16.0.0
16.1.0
16.2.0
16.3.0

Time / Date:
Current, A:
Pressure (UCB):
Vibrations:

Jacking oil pressure noted and recorded at all bearings:


Light at each bearings recorded
SLC JOPs commissioned
COMMISSIONING OF VEFS
VEF-1 Load Trial : Date:
VEF-2 Load Trial : Date:
VEF-1/2 kept in service and all vapour lines are made
through

STATUS

S.NO.

DESCRIPTION OF ACTIVITY

17.0.0

Turbine insulation works completed.

18.0.0

Turbine and its surroundings cleaned:


Men and material removed.

19.0.0

Checklist for putting turbine on turning gear completed.

20.0.0

Clearance obtained for putting turbine on turning gear.

21.0.0

Turbine put on turning gear:


Date / Time :
Speed RPM :
Lube oil pressure :

22.0.0

Parameter on turning gear noted and found OK.

23.0.0

SLC turning gear put in AUTO.

24.0.0

Vacuum in pulling completed : Vacuum mmhg:

25.0.0

Turbine polling parameters achieved and recorded.

26.0.0

Turbine rolling checklist completed.

27.0.0

Clearance obtained for rolling the turbine from all agencies.

28.0.0

Turbine rolled upto 360 RPM Date / Time

29.0.0

Sealing at 360 RPM completed and readings taken.

30.0.0

Turbine rolled to 3000 RPM Date / Time

31.0.0

Sealing at 3000 RPM completed and readings taken

32.0.0

TG vibrations at 3000 RPM


-------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------

STATUS

S.NO.

DESCRIPTION OF ACTIVITY

33.0.0

Turbine speed cross checked with Off-line instrument and


found OK.

34.0.0
35.0.0
36.0.0
37.0.0
38.0.0
39.0.0

Turbine Testing (ATT) carried out at 3000 RPM.


Clearance given for EM for electrical tests:
Date / Time :
Electrical test completed and system normalized
Date / Time :
Electrical checks as per Turbine rolling and synchronizing
check list completed.
Clearances obtained for synchronizing the mechanism.
Generator synchronizing
Date / Time :

40.0.0

Mode (Auto/Manual) :
Full local reached
Date / Time :

STATUS

41.0.0 MAIN TURBINE PARAMETERS


SL.
PARAMETERS
NO.
01. DATE / TIME
02.

SHAFT VIBRATIONS:

03.

BEARING VIBRATIONS:

04.

BEARING TEMP. BEARINGS-1

05.

BEARING TEMP. BEARINGS-2


(THRUST)

06.

BEARING TEMP. BEARINGS


1,2 (RADIAL)

07.

TURBINE BEARINGS 3,4 TEMP

EQUIPMENT : MAIN TURBINE


SL.
NO.

PARAMETERS

TURBINE SPEED RPM


360
3000 500 MW REMARKS

--------------------------------------------------------------1-------------------------------------------------------------2-------------------------------------------------------------3-------------------------------------------------------------4-------------------------------------------------------------5-------------------------------------------------------------6-------------------------------------------------------------7-------------------------------------------------------------1-------------------------------------------------------------2-------------------------------------------------------------3-------------------------------------------------------------4-------------------------------------------------------------5-------------------------------------------------------------6-------------------------------------------------------------7-------------------------------------------------------------1-------------------------------------------------------------2-------------------------------------------------------------3-------------------------------------------------------------4-------------------------------------------------------------1-------------------------------------------------------------2-------------------------------------------------------------3-------------------------------------------------------------4-------------------------------------------------------------1-------------------------------------------------------------2-------------------------------------------------------------3-------------------------------------------------------------4-------------------------------------------------------------1-------------------------------------------------------------2-------------------------------------------------------------3-------------------------------------------------------------4--------------------------------------------------------------

TURBINE SPEED RPM


360
3000 500 MW REMARKS

08.

GENERATOR BEARING 5,6


TEMP.

09.

EXCITOR BEARING 7 TEMP.:

10.

AXIAL SHIFT:

11.

HP RELATIVE EXP.:

12.

IP RELATIVE EXP.:

13.

LP RELATIVE EXP.:

14.

OVERALL EXP: AT HP FRONT

15.

ABSOLUTE EXP: IP FRONT

1-------------------------------------------------------------2-------------------------------------------------------------3-------------------------------------------------------------4-------------------------------------------------------------1-------------------------------------------------------------2----------------------------------------------------------------------------------------------------------------------------

-----------------------------------------------------------------------------------------------------------------------------

---------------------------------------------------------------

--------------------------------------------------------------

--------------------------------------------------------------

SIGNATURE :
RECOMMISSIONING:
DATE / TIME :
42.0.0 ALL TURBINE SIDE ALARMS CHECKED AND FOUND OK.
SIGNATURE OF DAS ENGINEER

(STATION)
ANNEXURE XXXXIX

UNIT:
S.N.
01
02
03
04
05

06
07

TURBINE START UP LOG


ACTIVITY DESCRIPTION

Initial Unit condition:


Cold / Warm / Hot
Turbine speed on TG, rpm
Mode of Rolling

PARAMETER
Recommended*
Actual

EHC,ATRS
through SGC
Turbine

Turbine reset at, (time, hrs)


At the time of opening stop valve:
Throttle pressure, ksc
HRH pressure, ksc
MCV body 50% temp. C
HP casing mid wall temp. C
MS temp. C
As per X-1:
As per X-2:
HRH temp. C
Cond. Vacuum, mmhg
HP control fluid temp C
Oil temp after cooler C
Turbine rolled to 360 rpm, at
(time, hrs)
At the time of opening control
valves:
Throttle pressure, ksc
HRH pressure, ksc

HP casing mid wall temp. C


As per X-4:
MS temp. C
As per X-5:
Simulated mid wall temp of IP shaft
C
HRH temp. C
08
09
10

11

Soaking done at 360 rpm, min.


Turbine rolled to 3000 rpm, at
(time, hrs)
Before Rolling to 3000 rpm:
HP casing mid wall temp. C
MS temp. C
Soaking done at 3000 rpm, min.

DATE:

As per X-6:

REMARKS

12
13

Unit synchronized and block load


taken, at hrs:
Before synchronizing:
Simulated mid wall temp of IP shaft As per X-7:
C
HRH temp. C

14

With turbine on load:


TSE margins:

* Recommended as per integrated start up procedures or the curves(X1 to X7).

ANNEXURE XXXXX
OPERATION PHILISOPHY OF COAL HANDLING PLANT
A)

Operation Philosophy
1.

Running Hours of Plant


While designing the coal handling plant, concept of two shift operation and one shift for
maintenance is envisaged. However, during plant operation, it is seen that plant is not
available for maintenance for full shift due to round the clock movement of coal rakes.
It was felt that at least 6 hours in general shift should be given for maintenance of coal
handling plant, and bunker feeding should be completed in 16-18 hours.
With this practice, availability and reliability of the plant will improve.

2.

Coal Stock Yard Management


It is seen that when crushed coal is reclaimed after long period of storage, the coal in the
bottom is found to have burnt due to spontaneous ignition.
To overcome this problem, the stacker reclaimer along with yard conveyors (reclaiming
system) should be run for at least 2 hours every day to ensure availability of the system
as well as to minimize possibilities of spontaneous ignition.
The crushed coal being stocked, should be compacted, to avoid spontaneous ignition.
Also while reclaiming the coal, from a particular area of the stock, it should be ensured
that coal is completely removed from that particular area before reclaiming coal from
other areas of the stock.

3.

Operation of Paddle Feeders and Trippers


Paddle feeders have provision for operating them from local or remote, but it is seen that
remote operation of paddle feeder, with stones and foreign materials present in the coal,
is not possible. Such operation may result in damage to the feeder. It is, therefore,
suggested that paddle feeders should be operated from local station only.

4.

Checking of Protections
Zero speed switches, pull cords, belt sway switches, PA system, magnetic separator and
metal detectors should be checked by the operator every day and a record of the same
should be maintained. Non functioning devices should be attended immediately to
ensure safety of the conveyor system.

5.

Stone Picking from Conveyors


In almost all the stations stones and shales come along with raw coal affecting the life of
crusher hammers, mills and paddle feeders besides causing interruption in running of the
plant. Hand picking of stone from running conveyors is to be done to reduce damage to

the equipments and to increase the life of crusher hammers and grinding elements of
mills.
In those stations where hand picking of stones has not yet been started, the same may be
started if sizeable quantity of stones is being received by the station.
6.

The running hours of the belts, Crushers, Stacker Reclaimer, Paddle Feeders, Traveling
Trippers, to be recorded to help in future planning and maintenance.

7.

Site to ensure continuous availability of Coal Samplers for which a person is to be


identified, who will be responsible to ensure its availability so that NTPC may pursue the
Mine Authorities for accepting results of our Coal Sampler in case their Coal Sampler is
not available.

8.

House keeping
Proper house keeping is essential for safe and reliable operation of coal handling plant.
However, deployment of contract labour should be done judiciously so that house
keeping can be done with minimum possible man power.

9.

Computerisation
Coal handling plant should be provided a separate computer terminal to monitor their
maintenance schedules, equipments, history, spare parts availability etc.

MERRY GO ROUND (M.G.R.)


A)

General Philosophy
1.

Safe to run certificate for rake shall be issued by the Wagon Maintenance staff / Train
Examiner & shall be signed as token of acknowledgement by the Loco Driver.

2.

A log register shall be maintained in each loco besides drivers journal, where loco
parameters shall be entered by the driver. Journal shall be handed over to Operation
Engineer by Driver in each shift.

3.

Each rake brake power shall be checked at least once in 24 hours or whenever the rake is
disturbed for any reason (Minimum 80% brake efficiency is required for safe working).

4.

Control charts shall be drawn by Shift In-charge / Shift Controller for each day showing
the rake movement. This chart must be put up to HOD each day.

5.

Drivers recruited shall be sufficiently literate & shall be able to fill up the log book and
other relevant documents.

6.

Medical standards for local drivers shall be in accordance with Railway Medical
Standards and shall be strictly adhered to. The periodical medical examinations shall be
carried out at an internal of six months for retired local drivers, for which the respective
P&A Department shall take necessary action.

7.

8.

For any lapse in duty by an employee concerned in MGR, a note of the same shall be
taken. Also P&A to explore the possibility of introduction of Indian Railway conduct &
disciplinary rules for implementation in MGR system.

9.

B)

Training, updating and familiarization of new loco driver and other operation staff, shall
be carried out at least for one week at training centres of respective projects where the
crew shall be familiarized with route, road learning, learning of safety rules, operating
instructions, discipline in MGR etc.

Inspection for implementation of safety / operation rules shall be carried out by the MGR
In-charge, HOD, DGM once in ten days, once in a month and once in three months
respectively or more frequently where it is needed. It shall be ensured that the rules are
strictly adhered and such inspections are logged and recorded by the concerned
inspecting officials. The GMs shall also carry out formal inspection once in a year as in
the Railway, where formal inspection is carried out by GM (Railways).

Communication
1.

2.

Necessary check lists and formats for proper maintenance and availability of
communication system shall be prepared by the concerned project, and proper records be
maintained. The same shall be counter checked and signed by MGR In-charge daily.

3.

C)

To have a proper transportation of coal and to achieve it effectively and efficiently,


100% reliable and effective communication is to be maintained, as communication being
the primary requirement.

Any repair of VHF equipments to be carried out through C&I Departments of the
projects.

Signaling
1.

The history of signaling gears and failure registers shall be maintained in accordance
with Railway Signaling systems. The details of failure shall be discussed once in six
months.

2.

Wherever the erection of signaling installations are in progress. The O&M personnel
shall also be associated to ensure proper quality in commissioning of system. The
personnel engaged for maintenance of S&T system shall be properly trained to upkeep
the systems along with the necessary literature, manuals and training.

3.

No S&T system shall be bypassed unless approved by the HOD MGR in writing in case
of emergency only. Before giving the clearance, safety operation to be ensured.

4.

The guidelines and action to be followed in case of total interruption of S&T system
shall be prepared by the projects and the same shall be adhered strictly, as it can be
different from project to project.

5.

All the personnel engaged in maintenance of S&T systems shall be trained in the nearest
zonal training school of Railways and in IISET/Secunderabad and this shall be arranged

through training departments and in case of difficulty in arranging training, OS/CC may
render necessary help.
D)

Loco Wagon
1.

All the preventive maintenance schedules of locos and wagons as followed in Indian
Railways shall be strictly adhered, copy of the same was sent to projects in 1982.

2.

The records of maintenance of locos and wagons shall be properly maintained and these
records shall be checked and countersigned by the concerned Maintenance Engineer, and
will be put up to HOD for deviations. Regular auditing of the same shall be carried out
by Maintenance Planning Department of concerned project.

3.

Further to the earlier decision of catering to the six monthly schedule departmentally, it
was brought out that the projects are facing difficulties in getting slot in Railways. It
was proposed that the matter be taken up at Railway Board level, in order to enter into a
rate contract with Railway for maintenance. All the projects are requested to send the
rolling plan of maintenance for 5 years period to OS/CC so that the matter can be taken
up at the appropriate level in Railway Board.

4.

The following record shall be maintained at all projects.


a)
b)
c)
d)
e)
f)

Kilometers run/ loco/ month


Wagons hauled/ loco/ month
Fuel consumed/ loco/ month
Lube oil consumed/ loco/ month
The above records shall be used for deriving the specific fuel consumption, lub
oil/ fuel oil ratio, loco utilization, and wagon utilization, to be monitored by the
Project Efficiency Cell.
Exception report of any maintenance schedule of wagons and locos must be
generated by Maintenance Planning and put up to DGM & GM of the project on
monthly basis.

FLOW CHART FOR DESIGN CHANGE REQUEST

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