KSK Mahanadi Power Company Limited

3600 MW TPP, Chhattisgarh, India

Opportunity for improvement(OFI)

 Agility

1. Faster bill processing.

2. lamp indicated pull cord switches to be introduced at

conveyors, so that which leads minimum time to
detect pull cord resetting. Which leads to start-up of
coal conveyor system immediate basis.
 Cost Optimization

1. Optimization of expenses
2. To control wastage of potable water
3. Treatment of leakage and seepage to minimize the use of
dewatering pump to save electricity.
4. Minimising Boiler losses, heat loss and maintaining operation
parameters to enhance GHR
5. Reduction in maintenance cost.
6. Set up Solar Power generation within plant boundaries to lower
auxiliary power consumption
7. Utilisation of mill reject to gain some financial benefits
8. Reduce Specific oil consumption and raw water consumption
below 2 l/kwh
 Effectiveness

1. Trip Analysis Committee, RCA committee, DCN/LCN review

committee should be formed and ensure it's implementation
and functioning.
2. Fault detection and diagnosis methods in power generation
plants.
3. Relay Coordination Between Pooling station and Power Plant.
4. Certification courses to be encouraged for employee.
5. Integrated HR Portal and Re-Establishment of Learning &
Development Team with Knowledge Portal
6. Proper Delegation of Authorities & Responsibilities
7. Annual organizational goals are to be defined. Accordingly, HR
policy such as Performance evaluation through reworking on
KRAs and KPIs We should have software systems in place for
better control. should be implemented
 Cont.

8. Soft skill training to be continued on different soft skill topic

this will help in changing the approach and through process of
the people.
9. Regular Assessment of Performance & Rewards and
Recognizance
10. Employee Development Programs for High Potential Performers
11. Defining Job Positions of all department
12. Improve the customer value proposition by improving the
service to users.
13. Implementation of SAP like software for O&M, Material
management & planning modules
14. Regular audit of store to need check preservation of long stored
material.
 Housekeeping

1. Bunker floor spillage control

2. Coal dust management

3. Total plant housekeeping and scrap management.

 Indigenization

1. Identification of equivalent standard materials for Chinese GB

standards material to IS/ASTM standard material for Spare
indigenization
 Reliability

1. Bottom ash feed gate Power Cylinder modification.

2. Increased component life cycle.
3. Under ground fire water line to be taken above ground.
4. Focus on Mill area dust emission control.
5. To reduce coal mill MTTF
6. Reduce frequent failure in MDV area
7. Phase#1&2 Compressor house direction of exhaust fan toward
the inside building and it is effected to Suction filter of
compressor IAC & SAC. Dusts are accumulating on filter.
Orientation of exhaust fan to be change.
8. AHP-SILO PURGING ELECTRONIC CONTROLLERS TO BE
MODIFIED TO MICROPLC BASED
9. Unit#2 ,3 &4 mill rejection JB’s to be prepare canopy so to
avoid dust accumulation on JB’s and malfunctioning of signals
and also shift SOV from location to separate JB’s so sov defects
will be reduce and damages also reduced. 8
 Cont.

10.Unit#2 & 3 ESP hopper RTD’s (40 no’s)to be shift from micro PLC to
main PLC so RTD’s values reliability will be increase, easy for trouble
shooting and electronic cards spare cost will be reduce.
11.Unit#2 & 3 mill MDV SOV’s to be shift from classifier floor to HAG floor
so SOV damages and malfunctioning will be reduce and spare
consumption will be reduced.
12.Chp-wagon tippler clamp and release,sov cables jb mounted on tippler
wall,jbs tbs getting shortened due to rainy season, which leads to
interruption in delay of wagons tippling, affects demurrage charges
modification planned to put jbs independent of wall. which avoids
shortening of cables tbs.
13.Belt cutting to be avoided.
14.Improvement on equipment efficiency and reliability (sudden
equipment failure).
15.To improve the workmanship to increase the durability of work
16.HP Bypass and LP Bypass valve passing in U#3 & U#4 - It is
frequently observed in HP bypass and LP bypass valves passing after
OH of both valves. Need to be weld seat area by high hardened 9

electrodes.
 Safety

1. Road & drain repairing & new roads across entire plant
2. Ash/ Coal vehicles Parking area at main gate to be concrete/hard
base
3. Safety Protocols, Defects Identification & Redressed.
4. Road safety
 ?

1. One more HRSCC (High Rate Solid Contact Clarifiers) for PT Plant for
any emergency maintenance in HRSCC and all 03 units are smooth
operation, Present only 02 No’s HRSCC are available.
2. One more ETP Clarifier for WTP Plant for any emergency maintenance
in ETP and all 03 units are smooth operation, Present only 02 No’s ETP
are available.
3. Shed for incoming & out going vehicles near ash silo.
4. Testing of coal sample
5. Increase number of leaves
6. Employee Engagement activities must start.
7. Review & modification of existing HR policies.
8. Plant runs due to coordination of all departments, all departments are
equally important just like our body parts. Each department equally
contributes in successful running of the plant. No department and its
people are burden but all are qualified professionals and assets to the
organization. We should treat them accordingly.
9. Proper planning
 Availability

1. Foreign materials avoiding.

12
Thank You
13