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SECTION GIPL-OEM Project and Operation & Maintenance
PROCEDURE FOR FUEL AND POWER MONITORING PROCEDURE NO.: P1-GIPL-005
Purpose At all BTS locations. • Get an idea of the energy consumption pattern for budget.0 Responsibilities 2 . • Generate a database for all sites/Circles for performance analysis. • Develop Common Operating Procedures to keep track of diesel consumption. Scope • Provide Guidelines at field level to monitor consumption of diesel. • Develop procedures to monitor power consumption from respective SEBs.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-005 1. • Analyze variance in consumption of diesel with respect to Standard Operating parameters. This Fuel & Power consumption database and the derived reports have no correlation with the periodic commercial reports for energy consumption and cost. Moreover the SEB has different tariff structures and billing cycles in different states/regions. 3. State Electricity Board (SEB) is the primary source for electric power supply. This emergency generator’s prime mover engine sets use normally diesel driven. • Track the engine performance. The purpose of this procedure is to develop and establish a uniform and structured reporting system so as to: • Monitor the energy consumption at each site. booking of fuel quantity & cost. Redundancy has been provided through online battery banks and standby emergency Generator (DG) sets. This is due to differences in the basis of input data regarding the SEB billing date and frequency. etc. 2.
1 National Head Based at Corporate office–New Delhi is responsible for the technical integrity of this procedure.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-005 3. This record shall be maintained for a period of 6 months.2 Circle Manager The Circle Manager or In-charge is responsible for ensuring that all activities related to this procedure are complied with and recorded as described in this document. Accordingly number of days for that period shall be considered for report. 3. SEB/DG energy meter reading.: OEM/0001 for Field log sheet for all BTS. This data should be 1st to last date of the previous month. and run hours of DGs. 3.3 Procedure for monitoring parameters Respective cluster In-charges are responsible for recording different data like diesel consumption. • Refer Format No. The National Head or his nominated Deputy shall be authorised for any changes with this procedure. • FEOs/Technicians on duty should record the following details in the field log sheet: Date and time of current inspection Quantity of fuel in tank at previous inspection Quantity of fuel in tank during current inspection Total fuel filled in the tank (topping) Fuel consumed during the period (By computation as shown in log sheet) SEB energy meter reading 3 . Report generation will be monthly and accordingly reading to be recorded from fields.
4 .. 4. between previous inspection and current inspection). 4.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-005 DG energy meters reading (which is not present installed) hence the log sheet shall be modified accordingly at appropriate time. • The circle coordinator/Circle Manager shall ensure that the power and fuel data is entered in the portal by 10th of every month • HO has to release all circle’s compiled consolidate report to all circle and commercial after review by O&M department head. but this has been adopted keeping in view that.e. Energy consumed from SEB during the period (By computation as shown in log sheet) Energy consumed from DG during the period.2 Reporting requirements • Report period 1st day to last day of the month. wherever DG is not available as in Mumbai and Kolkata. • The FEOs/Technicians are required to update the field log sheet whenever they visits the site or at least once in a month such a way that data for the report for required specific period is available. (Based on the computation of fuel per hr of running as shown in log sheet) Cumulative run hours and from that actual number of hours DG set has run during the period (i. the availability of power supply to be ascertained by respective sites and data to be recorded.1 SEB power The availability of power supply is calculated based on the DG running hrs. The compiled report format can be changed as and when required based on information need. the difficulty of keeping track of SEB power supply availability in BTS sites. however. Though it is not so accurate. Every log sheet to be computed for arriving monthly figures as indicated in log sheet. latest by 15th of each month (for the previous month data). • The log sheet should be maintained for every site separately.
particularly where sight level gauge is not available and the fuel stock measurement in the DG fuel tank must be done only by dipstick. While measuring. is not mandatory. It is better to keep separate dipstick for every site.3 Fuel consumption measurement and calculation: All type of DG. consumption calculation error should not be more than ± 5% of actual volume due to error in reading. but it is to be ensured that fuel consumption is measured accurately. After 5 . For both the readings the same dipstick shall be used. The dipstick material. This reading shall be referred for next month’s fuel consumption calculation. by taking three dipstick reading at the same time and averaging them for arriving correct dip and then multiplied by factor (as per calibration) for arriving actual fuel stock. it gives better visibility of fuel marking while taking dip. green etc. 4. colours etc. if the dipstick is paint with dark colour like red.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-005 • All variances which are not as per norm are to be supported by proper justification/reasons in the remarks column against each site by respective maintenance points. Monthly once fuel dipstick reading (for monthly report) shall be taken more precisely. In case of DG sets without any provision for inserting dipstick in the tank. No other indirect practice to be adopted for calculating fuel consumption calculation. The fuel stock checking is required for calculating fuel consumption as and when required. The least count for the measurement scale should not be less than 5mm for better accuracy. insert the dipstick vertically in the tank as far as possible. brown. Dipstick shall be preferably of 5mm X 25mm GI strip of suitable length as per tank height. It has been observed that. For monthly fuel consumption calculation: (Previous month fuel stock) – (current month fuel stock) + Fuel quantity added (as per diesel purchased slip/data) during this period. arrangement to be made by preparing a hole of suitable size at the top of the fuel tank. Any intermediate fuel stock calculation can be done by simply one dip to just keep track of fuel stock.
PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-005 taking monthly reading of fuel consumption in the field. Frequency less than 49 HZ is not a good indication. Fuel consumption in terms of liters per hour and specific fuel consumption should be realistic. 4. Fuel filling container should be clean and moisture free. Periodically container shall be cleaned or replaced to avoid any residual sludge. the alternator coupled with engine will be able to produce power in the frequency range of 49 to 50 HZ. on an average DG can run at least for 10 hrs. Even after low-level alarm. Sometime. With this speed range. it is to be rechecked for fuel consumption and power generation readings. 6 . else. in case low-level alarm does not appear for long unexpected period due to faulty alarm management. Sometimes it may be a general practice for filling the fuel during routine maintenance visit. Filling can be done on the basis of fuel level low alarm (Which should be modified already. Such fuel filling needs to be avoided if the available quantity is sufficient till next routine visit. Depending on the site’s SEB power availability condition. engine speed may vary to higher side due setting disturbance in the governor of the engine. which is sufficient time for refilling. 4. it is very important to check system frequency (HZ) while DG is on load. FEO/technician can have general idea about fuel filling requirement. not to trip the m/c). though DG tank having sufficient fuel.4 Engine speed It is very important to maintain engine speed within limit of 1470 rpm to 1500 rpm to avoid unnecessary extra fuel consumption due to higher speed. While taking monthly reading or during any routine maintenance check. corresponding DG run hour and power generation reading needs to be checked.5 Fuel filling in DG fuel tank: 1) Fuel filling frequency for different DG sets is to be reduced as minimum as possible.
Responsible person of that region In-charge should maintain the record of this analysis. performance of particular DG set can be visualized by this data. Description OEM/0001 Frequency Field log sheet BTS( Diesel & Power Monitoring As and when data sheet) required 7 . The possible causes to be mentioned in the remark column for increase in specific fuel consumption and they needs to be rectified during next month report by eliminating actual cause.0 Records and Frequency Format No.PROCESS MANUAL SECTION GIPL-OEM Project and Operation & Maintenance PROCEDURE P1-GIPL-005 4. It is necessary to analyze if the SFC is more than norm by 5.e.053* (SFC norm)]. [(SFC actual) > 1. 5.6 Tracking the Specific Fuel Consumption (SFC) of different DGs in all the facilities Every Cluster Location should have a system to track the SFC-actual and vis-à-vis SFC-norm of all DG sets for the successive months in sequence.3% i. At a glance.