Professional Documents
Culture Documents
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
3.0
4.0
Definitions
5.0
6.0
Monitoring System
Station
Regional OS
Corporate OS
7.0
8.0
9.0
10.0
11.0
Technical Audit
12.0
13.0
Recommissioning
14.0
15.0
16.0
S.No.
Description
17.0
Unit Tripping
Page No.
Page No.
18.0
Documents
19.0
20.0
Emergency instructions
21.0
22.0
Housekeeping
23.0
Safety
24.0
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
Annexure-III
Annexure-IV
Annexure-V
Annexure-VI
Annexure-VII
Annexure-VIII
Annexure-IX
Annexure-X
Annexure-XI
Annexure-XII
Annexure-XIII
Annexure-XIV
Annexure-XV
Annexure-XVI
Annexure-XVII
Annexure-XVIII
Annexure-XIX
Annexure-XX
Annexure-XXI
Annexure-XXII
Page
No.
Annexure No.
Description
Annexure-XXIII
Annexure-XXIV
Annexure-XXV
Annexure-XXVI
Annexure-XXVII
Annexure-XXVIII
Annexure-XXIX
Annexure-XXX
Annexure-XXXI
Annexure-XXXII
Annexure-XXXIII
Steam-Water Analysis
Annexure-XXXIV
Annexure-XXXV
Annexure-XXXVI
Annexure-XXXVII
Annexure-XXXVIII
Annexure-XXXIX
Annexure-XXXX
Coal Fineness
Annexure-XXXXI
Annexure-XXXXII
Annexure- XXXXIII
Chlorinators
Page
No.
Annexure No.
Description
Annexure- XXXXIV
Annexure- XXXXV
Page
No.
Annexure- XXXXVI
Annexure-XXXXVII
Annexure-XXXXVIII
Annexure-XXXXIX
Description
Page
No.
ROPR Process
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
2.0
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
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.
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
3.0
3.1
Sl.
No.
1.
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
Quality of Overhauls
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.
Units
Units
Kcal/
kwh
Kcal/
kwh
%
ml/
kwh
%
%
%
%
%
%
Rs.
Crore
3.3
Sl.
No.
1
2
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
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
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
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
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.
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 (%)
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,
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
=
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
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:
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
ED (Region)
D(O)
Head of O&M
Head of Operation
HOD-Control Room
Head of Maintenance
All Group
Heads
Corporate OS
HOD-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
4.
F or c e d
Outage Gap Major reasons for loss in Availability factor
Analysis
Unit tripping , its analysis ,implementation of the recommendations
5.
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.
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:
9.
System
Compliance
Status:
10.
Safety:
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:
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:
7.0
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)
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
a)
b)
c)
Unit Controller.
d)
Desk Engineer
Grid Failure.
b)
c)
d)
e)
f)
b)
c)
d)
e)
f)
Coal as fired, Coal mill fineness/ mill rejects, bottom/fly ash analysis.
g)
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.
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.
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.
Movement of empty and loaded trains between loading station near coal mines to unloading
station at NPTC safely.
2.
3.
4.
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.
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.
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.
F
E
E
D
B
A
C
K
FROM:
OS Control Room
Performance report of all
NTPC stations.
OS Specialist Groups
Updated status of
CORPORATE CENTRE
OS ENGG. C&M FMG
INPUTS
PREPARATION
(By Regional OS Team
consisting 3-4 members)
NTPC
ORT MEETING
Chaired by GM (Station)
(Before 10th of every month).
Regular Monitoring of
Action Plans and
highlighting of
exceptions by ORT
Coordinator.
Implementation of
Action plans at Station,
Regional and Corporate
levels. levels.
(next day).
Preparation
and
forwarding of exception
report to Regional ED
and Corporate OS
POST-ORT
(Preparation of Minutes,
Follow up of action plans
Visit of ORT Team to Site 2 to 3 days before the date of conductance of ORT.
D.
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.
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 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.
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
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
ORT COORDINATOR
FOR CENTRALIZED
ACTION POINTS
MONITORING
IN ORT
Issue Owner
Conformance
ATR Vetting by
Author
Non Conformance
OS
STA
FMG
TQM
Specific Issues
with action
plan
EN
R&D
AUD+ENV
OS
Action Completed
Review
by GM Stn (ORT)
Action plan (N-1)
Regional ORT
Coordinator
shall be
Custodian of all
Review
meetings
(N+1) Month
Action
Completed
Action Pending
(N+2) Month
ROPR Agenda
ROPR Review
Action Pending
Review month=N
Review by ED(Rgn)
Action plan of exception report
(N-1)
CENPEEP
ECM
Action Pending
Action
Completed
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
Corporate OS
All concerned
5
6
7
Regional OS
Station GMs
10
ORT coordinator-RHQ
11
Regional OS /
Corporate OS
ORT coordinator-RHQ
12
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.
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
MONITOR IMPLEMENTATION OF
THE ACTION PLAN REGULARLY
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)
l)
b)
c)
d)
e)
The Technical Audit should be able to bring out / deliver the following points
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
No. of incidences or occasions when the unit operation continued even with
known problems.
Full load generation constraints, partial loading and the reasons thereof.
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,
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.
2.
3.
4.
Matrix of all available attributes and its use in the particular site. (Refer
appendix 5)
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.
Analysis of plant performance to match with ABT policy. (DC, SG, AG and UI
optimisation).
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
Identification of weak areas which are likely to cause problem based on operators
gut feelings.
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.
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 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
Check whether safety appliances for safety of men are being used extensively.
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.
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:
P
R
E
P
A
R
A
T
I
O
N
About the issues mentioned in the Scope of audit, from CC / External agencies.
A
U
D
I
T
F
O
L
L
O
W
U
P
ii)
To
standardize
operating
procedures,
thereby
reducing
risk
of
iv)
Better work environment / culture aimed at good efficient & safe O&M
practices.
v)
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)
ix)
x)
xi)
xii)
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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
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
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
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
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
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.
$ F WX D O + H D W 5 D WH
% 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
$ F WX D O + H D W 5 D WH
$ I WH U 2 Y H U K D X O
1 H [ W 2 Y H UK D X O
2 Y H U K D X O WR
2 Y H UK D X O
) LJ + H D W 5 D WH G H WH ULR UD WLR Q E H WZ H H Q 2 Y H UK D X O WR 2 Y H UK D X O
BILL
OF
MATL.
JOB
LIST
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.
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.
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.
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.
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
STATION TRIP
COMMITTEE (ANALYSIS)
HEAD OF STATION
REGIONAL OS
OBSERVATIONS
HEAD OF OS
MIS
OS-O & C
TRIPS
DATA BANK
CORPORATE TRIP
COMMITTEE
(ANALYSIS)
TRIP ANALYSIS
BOOK (YEARLY)
TRIP REPORTS
FILE
c)
d)
e)
Fire in Mill.
f)
g)
h)
OF
LOG
BOOK/LOG
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.
Signature with time, date at the beginning and at the end of the shift.
b)
Boiler
i)
Drum level
ii)
iii)
Main Steam & HRH steam temperatures before & after attemperation.
iv)
v)
vi)
DM make up
vii)
b.
Turbine
i)
ii)
iii)
iv)
TSE charts
v)
vi)
vii)
c.
Vibration
Generator
i)
ii)
MVAR/power factor
iii)
Frequency chart
iv)
v)
Hydrogen purity
vi)
Rotor temperature
vii)
viii)
ix)
x)
d.
Load/voltage/current
Switchyard:
i)
b)
c)
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.
Change over of Turbine lub.oil filter, where mal operation can cause unit
tripping.
Description
1.
2.
3.
Fire in Air-Preheater
4.
5.
6.
7.
8.
9.
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.
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)
e)
f)
g)
h)
Cleaning of coal from the coal handling plant & mill rejects.
i)
j)
k)
l)
m)
n)
b)
c)
d)
e)
f)
g)
Compressor room.
h)
Work-shop.
i)
j)
b)
c)
d)
Final disposal of collected waste from central waste collection centres to dumping
grounds.
CLEANING OF DRAINS:
a)
b)
All the drain lines would be cleaned at least twice a month but if required may be
earlier.
a)
b)
Equipment cleaning should be done through contract labour ,however for C&I panel
cleaning should be done through C&I department.
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)
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.
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)
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)
d)
A register will be maintained toward status of all leaky points and will be kept in SCE
room.
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.
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
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)
d)
Adequacy and coverage of permit to work system usage of safety locks are to be
ensured.
e)
f)
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)
i)
j)
k)
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.
5.
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.
b)
c)
Manufacturers works.
d)
e)
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
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
2.1
2.2
2.3
2.4
2.5
3.0
1.1
1.2
1.3
1.4
Boiler Plant
Gas Passes
Fans and APH
Electro Static Precipitators
2.0
2.1
2.2
1.2
3.0
Milling System
3.1
3.2
4.0
FUEL MANAGEMENT
1.1
1.2
1.3
1.5
2.0
ASH PLANT
2.1
2.2
2.3
2.4
3.0
3.1
3.2
4.0
CW PLANT
4.1
4.2
4.3
4.4
5.0
5.1
5.2
6.0
GENERATORS
1.1
1.2
1.3
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
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
ANNEXURE-III
AREA: EFFICIENCY
Deviations /
Non
Conformities
Number
Area Audited
Observations / Findings/deviations
(Technical / System Related)
ANNEXURE-IV
Format for Action Plan / Implementation on Findings of Technical Audit of <Station> from <
Sl. No. Deviations /
NC of Audit
(No.)
Observation /
Deviation
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
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
OD/GEN/003
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Issue-1
22-06-94 <2>
OD/GEN/004
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Issue-1
22-06-94 <2>
5 Plant Modifications
OD/GEN/006
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Issue-1
15-03-94 <2>
OD/GEN/007
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Issue-1
11-03-94 <2>
OD/OPS/CHEM/001
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Issue-1
13-02-95 <2>
OD/OPS/ELEC/002
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Issue-1
11-03-94 <2>
OD/OPS/ELEC/003
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Issue-1
03-10-94 <2>
OD/OPS/ELEC/004
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17-11-95 <2>
OD/OPS/MECH/002
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01-09-94 <2>
OD/OPS/MECH/004
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Issue-1
22-06-94 <2>
OD/OPS/MECH/007
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11-03-94 <2>
OD/OPS/MECH/009
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21-11-96 <2>
OD/OPS/SYST/001
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Issue-1
10-12-93 <2>
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Issue-1
10-12-93 <2>
Prime Movers
17 Prevention of Air Heater Fires
OD/OPS/SYST/004
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Issue-1
10-12-93 <2>
OD/OPS/SYST/005
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Issue-1
28-09-94 <2>
OD/OPS/SYST/006
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Issue-1
22-06-94 <2>
OD/OPS/SYST/007
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Issue-1
22-06-94 <2>
OD/OPS/SYST/009
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Issue-1
11-10-94 <2>
OGN/ENG/002
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06-10-94 <2>
OGN/ENV/001
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Issue-1
22-11-96 <2>
OGN/ENV/002
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Issue-1
13-02-95 <2>
COS-ISO-00-OGN/ENV/008
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Rev. 0
02-02-99 <1>
COS-ISO-00-OGN/ENV/010
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Rev.0
02-02-99 <1>
OGN/GEN/001
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Issue-1
11-03-94 <2>
OGN/GEN/002
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Issue-1
01-09-94 <2>
COS-ISO-00-OGN/GEN/003
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Rev.0
19-04-01
OGN/OPS/C&I/003
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Issue-1
21-11-96 <2>
COS-ISO-00OGN/OPS/CHEM/001
OGN/OPS/CHEM/002
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Rev.0
31-12-99 <5>
-do-
Issue-1
11-10-94 <2>
Fire Risk
13 Turbine Generator Vibration Monitoring
<10>
Power Plant
32 Chemical Control of 500 MW KWU/BHEL Genarator Stator Primary Water
System
OD/GEN/001
09-06-99 <9>
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>
OGN/OPS/CHEM/010
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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
COS-ISO-00OGN/OPS/CHEM/011
COS-ISO-00OGN/OPS/CHEM/014
COS-ISO-00-
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Rev.0
30-10-03
OGN/OPS/CHEM/015
COS-ISO-00-
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Rev.0
19-09-04
OGN/OPS/CHEM/016
OGN/OPS/CIV/005
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Issue-1
05-04-95 <2>
OGN/OPS/CIV/006
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Issue-1
03-10-94 <2>
OGN/OPS/CIV/007
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Issue-1
22-11-96 <2>
COS-ISO-00OGN/OPS/CIV/011
COS-ISO-00OGN/OPS/CIV/012
OGN/OPS/ELEC/001
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Rev.0
04-10-99 <4>
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Rev.0
04-10-99 <4>
-do-
Issue-1
11-03-94 <2>
OGN/OPS/ELEC/004
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Issue-1
03-10-94 <2>
OGN/OPS/ELEC/005
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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>
COS-ISO-00OGN/OPS/ELEC/007
OGN/OPS/ELEC/008
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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>
OGN/OPS/ELEC/010
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Issue-1
21-11-96 <2>
OGN/OPS/ELEC/011
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Issue-1
11-03-94 <2>
OGN/OPS/ELEC/014
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Issue-1
11-03-94 <2>
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Rev.0
17-10-00 <8>
COS-ISO-00OGN/OPS/ELEC/015
OGN/OPS/ELEC/017
-do-
Issue-1
11-03-94 <2>
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
OGN/OPS/ELEC/018
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Issue-1
03-10-94 <2>
Contacts in Transformers
59 Dissolved Gas Analysis of Transformers and Reactors.
OGN/OPS/ELEC/019
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Issue-1
11-03-94 <2>
OGN/OPS/ELEC/020
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Issue-1
25-02-94 <2>
OGN/OPS/ELEC/021
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Issue-1
11-03-94 <2>
OGN/OPS/ELEC/023
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Issue-1
03-10-94 <2>
COS-ISO-00OGN/OPS/ELEC/035
COS-ISO-00OGN/OPS/MECH/001
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Rev.0
09-05-00 <9>
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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
<12>
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>
OGN/OPS/MECH/008
-do-
Issue-1
28-09-94 <2>
OGN/OPS/MECH/011
-do-
Issue-1
02-01-97 <2>
OGN/OPS/MECH/012
-do-
Issue-1
26-11-96 <2>
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>
COS-ISO-00OGN/OPS/PERF/006
COS-ISO-00-
-do-
Rev.0
15-05-02
OGN/OPS/PERF/008
OGN/OPS/SYST/001
-do-
Issue-1
16-08-94 <2>
COS-ISO-00-
-do-
Rev.0
19-04-01
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
<10>
COS-ISO-00OGN/OPS/SYST/004
OGN/OPS/SYST/005
OGN/OPS/SYST/006
OGN/OPS/SYST/007
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>
COS-ISO-00-
-do-
Rev.0
30-06-01
OGN/OPS/SYST/017
COS-ISO-00-
-do-
Rev.0
15-02-02
<11>
<14>
OGN/OPS/SYST/018
OIN/ENG/001
-do-
Issue-1
11-10-94 <2>
COS-ISO-00-OIN/GEN/001
-do-
Rev.0
02-02-99 <1>
COS-ISO-00-OIN/GEN/002
-do-
Rev.0
20-08-99 <4>
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
OIN/OPS/C&I/001
COS-ISO-00-
-do-
Rev. 0
31-03-03
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>
<20>
<22>
<31>
November, 2004 )
COS-ISO-00OIN/OPS/CHEM/003
COS-ISO-00-
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
OIN/OPS/CHEM/006
COS-ISO-00-
-do-
Rev.0
21-02-02
OIN/OPS/CHEM/007
COS-ISO-00-
-do-
Rev.0
28-07-03
OIN/OPS/CHEM/008
COS-ISO-00-
-do-
Rev.0
04-11-03
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
OIN/OPS/CHEM/012
COS-ISO-00-
-do-
Rev.0
21-09-04
OIN/OPS/CHEM/014
COS-ISO-00-
-do-
Rev.0
29-11-04
OIN/OPS/CHEM/015
OIN/OPS/ELEC/001
-do-
Issue-1
02-01-97 <2>
OIN/OPS/ELEC/002
-do-
Issue-1
21-11-96 <2>
-do-
Rev.0
29-12-99 <5>
COS-ISO-00OIN/OPS/ELEC/003
COS-ISO-00-
-do-
Rev.0
27-03-02
OIN/OPS/ELEC/005
COS-ISO-00-
-do-
Rev.0
16-04-02
OIN/OPS/ELEC/006
OIN/OPS/ELEC/007
-do-
Issue-1
03-10-94 <2>
COS-ISO-00-
-do-
Rev.0
20-03-03
OIN/OPS/ELEC/008
OIN/OPS/ELEC/009
-do-
Issue-1
03-10-94 <2>
OIN/OPS/ELEC/011
-do-
Issue-1
28-09-94 <2>
OIN/OPS/ELEC/012
-do-
Issue-1
11-03-94 <2>
<13>
<13>
<14>
<23>
<25>
<27>
<29>
<30>
<31>
<15>
<15>
OIN/OPS/ELEC/013
-do-
Issue-1
03-10-94 <2>
OIN/OPS/ELEC/014
-do-
Issue-1
11-03-94 <2>
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>
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
OIN/OPS/MECH/019
COS-ISO-00-
-do-
Rev.0
23-05-03
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>
OIN/OPS/MECH/021
COS-ISO-00OIN/OPS/SYST/003
COS-ISO-00OIN/OPS/SYST/004
COS-ISO-00OIN/OPS/SYST/005
-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
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
12-02-03
<17>
<27>
<21>
D)
<19>
<19>
Predictive Maintenance held at PMI, Noida on 26th and 27th Nov., 2002
<24>
Turbine
<26>
in a Power Plant)
<27>
Turbine
<27>
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-
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-
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.
4.
5.
6.
7.
8.
9.
Analysis of tripping.
10.
Root Cause
11.
12.
13.
14.
15.
Recommendations/Action Plan.
S.N. Recommendation
Action Plan
Resposibility
Schedule/Targe
t date
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.
5.
6.
7.
8.
9.
Analysis of tripping.
10.
Root Cause
11.
12.
13.
14.
15.
Recommendations/Action Plan.
S.N. Recommendation
Action Plan
16.
Schedule/Targe
t date
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 CAUSE
CODE
S.N
TRIPPING CAUSE
COD
E
1.
2.
01
02
05
03
0301
0302
0303
0304
0305
0306
0307
0308
0309
0201
0202
0203
0204
0205
0206
0207
0208
0209
0210
0211
0212
0213
0214
0215
C&I System
4.
0101
0102
0103
0104
0105
0106
0107
0108
0109
0110
0111
0112
0113
0114
0115
0116
0117
0118
0119
0120
0121
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
6.
Human Error
Operators Mistake
Maintenance Staffs Mistake
Contract Labours Mistake
Unidentified People Mistake
7.
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
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
CODE
01
0107
0119
0120
0121
0131
0132
0133
0134
0135
0136
0137
0138
0139
0140
0141
0142
0143
0144
0145
0146
0147
0148
0149
0150
02
0201
0202
0203
0204
0205
0206
0207
0208
0209
0211
0212
0213
0215
0216
0218
03
0301
0302
0303
0304
0305
0306
0307
0308
0309
0310
0311
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
5.
0601
0602
0603
0604
0605
08
0810
0811
0812
0813
10
1004
1005
CODE
6. C&I System
05
0501
0502
0503
0504
0505
0506
0507
0508
0509
0511
0512
0513
0514
0515
07
0701
0703
0703
0704
0705
0706
0707
0708
0709
0710
0711
0712
0713
0714
0715
0716
0717
09
0901
0902
0903
11
1101
1102
CODE
1103
1104
1105
1106
1107
1108
1109
1110
1111
1112
1113
13
1201
1202
1203
1204
1205
1301
1302
ANNEXURE-X
MODEL EMERGENCY INSTRUCTIONS FOR TOTAL POWER FAILURE
A.
1.
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.
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.
2.
In case DC seal oil pump does not start on auto, then following action will be taken.
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.
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.
2 Nos. of Helpers
2.
3.
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.
Case 2 :
1.
2.
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.
Confirm no fuel input to the Furnace by closing oil and ignitor valves (Burner Floor
Operator).
3.
4.
5.
6.
7.
8.
9.
10.
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.
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.
6.
7.
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.
12.
13.
If L.T. supply is restored, the electrically operated valves which ever is required
should be operated from Control Room.
2.
3.
Send Jr. Controller to yard for visual inspection of Breakers, Transformers etc.
4.
5.
6.
If 132 KV system is healthy and the fault in 400 KV external to station, establish
power supply through 132 KV System.
7.
8.
9.
10.
11.
12.
13.
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.
5.
6.
7.
8.
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.
6.
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.
10.
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.
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.
Responsibility : Unit Controller, Boiler Desk Engineer, Boiler Controller & Mill Area
Operator
Fire in the mills can be classified into two categories
a)
Caution: Never use water or any other liquid, as it may crack the grinding elements.
b)
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)
e)
f)
Trip the boiler and draft plant and close all the associated dampers, leaving the air
heater running
b)
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
Keep the air heater running and open the inspection doors when safe to examine the
airheater
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).
Copious amount of water only and not other extinguishers like CO2, Halon etc. is
effective during air preheater fire.
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.
Before loading new baskets into the air heater, they should be steam cleaned to
remove the preservative oil.
should be avoided.
Care should be taken to prevent the accumulation of ash on the heating elements
while duct cleaning etc.
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 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.
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..
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.
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.
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
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.
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)
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
(Nos)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
(MUs)
Unit-I
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
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)
Unit
KL
KL
KL
KL
KL
KL
KL
KL
KL
KL
KL
Unit-I
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
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.
R2
(Revision)
R3
R4
MOU
TARGET
Pro rata
ACT
UAL
TILL
Date
VARI
ATION
GENERATION-MU
PLANNED OUTAGE-%
FORCED OUTAGE-%
HEAT RATE-KCAL/KWH
SP. OIL-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
ml/kwh
MT
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.
%
%
%
%
%
DC
installed
(A)
MONTH
DC
(bar)
%of
A
SG
%
of
DC
bar
AG %
of DC bar
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
Reasons
Action Plan
Fuel
quality
Fuel
supply
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
S.N
Unit
Outage
No.
S.N
Unit
Outage
No.
Outage From
Date/
Time
Outage
Duration
(Hrs.)
Outage Category
Root Cause
Responsibility
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
Root cause of
failure
(As per central
committee)
Supplementary Jobs
Attended
Outage
Hours
Postponed
Location
Action Plan
Description
Unit-1
Month
Total (Equipment)
1.1
1.2
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
Regulation
Total
7.2 ACTION PLAN FOR REDUCING PARTIAL LOADING FOR THE MONTH
Sl.No
Unit
Corrective Action
8.0 EFFICIENCY
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
Unit
System/
Parameter
Loss
(Kcal/Kwh)
Action plan
PARAMETER
Unit-1
Unit-2
Unit-3
Unit-4
S.N
Heading
Unit-5
Unit-6
Unit-7
Unit No
Type
of Overhaul
SCHEDULE
II
III
Unit
1
2
3
4
5
6
7
Unit
1
2
3
Duration &
Type of O/H
Near
miss
Root cause
Station
B) FIRE INCIDENTS:
Unit /
Off site
No. of
fire
incidents
Root Cause
Station
Description
Unit/area
Status/Reason
Target
date
Audit/Date
Work in progress
Responsibility
Work in progress
Responsibility
ROPR No./Date
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
Area
Boiler &
Aux.
S.No.
1
2
Turbine &
Aux.
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
S.N
GT DETAILS *
PROJECT
UNIT
2
14.0 MISCELLANEOUS
14.1 STATION HIGHLIGHTS
Description
Date of approval
Cumulative amount
spent till date
No. of schemes
completed in FY
Cumulative no. of
schemes completed
10
Status
S.No
System
Description
S.No
Unit
Parameter
Description
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
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, %
Up to Jan 07
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
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)
(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
THE INCIDENT
WHAT WENT
WRONG
CORRECTIVE
ACTION
ROOT CAUSE
OUTAGE RECOMMEND
CODE
ATIONS
OUTAGE RECOMMEND
CODE
ATIONS
OUTAGE RECOMMEND
CODE
ATIONS
10
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
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
MAJOR
CONSTRAINTS
ACTION PLAN
DADRI
(COAL)
BADARPUR
14
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
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
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
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
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
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
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
S
N
Issues
Status
Target
1
2
3
4
23
Issues
Status
Target
1
2
3
4
24
SAFETY
ISSUES
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
Description
Date of approval
3
4
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
27
ANNUAL
TARGET
PRORATA
TARGET
ACTUAL UP TO
JAN07
LMT
Till Jan07
SHORTFALL /
EXCESS
LMT
DADRI
(COAL)
BADARPUR
ENVIRONMENTAL ISSUES
(AS ON 31.01.07)
STATION
DESCRIPTION
STATUS
REMARKS
DADRI
(COAL0
29
ENVIRONMENTAL ISSUES
(AS ON 31.01.07)
STATION
DESCRIPTION
STATUS
REMARKS
BADARPUR
30
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
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
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)
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
Recovery
Un Accountable
Post OH losses
Cooling Towers
Post OH loss
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
CT Revamping
HP rotor
Diaphragms
F) IP Turbine Loss
1
IP rotor
Diaphragms
Tip Seals
G) Unaccountable Loss
1
HE Drain Valve
U-1
U-2
U-3
U-4
U-5
U-6
2
3
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
FEB
MAR
EXPECTED
MOU
Slide 3
Till Jan'
07
FEB
MAR
EXPECTED
MOU
Slide 4
FORCED
OUTAGE
Slide 5
Reference
Outage
Hours
CAUSE
Location *
Recomme
ndations
2
3
4
5
6
7
8
Slide 6
Slide 7
Reference
Outage
Hours
CAUSE
Recomme
ndations
Location *
2
3
4
5
6
7
8
Slide 8
Slide 9
Slide 10
MONTH
1.1.
Duratio
n
when
AG<SG,
%
1.2.
Durati
on
when
AG>S
G, %
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
11
Slide 12
12
Slide 13
MONTH
1.1.
Duratio
n
when
AG<SG,
%
1.2.
Durati
on
when
AG>S
G, %
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
Recd
FSA
Coal
Stock
April
May
June
July
Aug
Sep
Oct
Nov
Dec
Jan'
07
TOTAL
14
Slide 15
Coal
Recd
FSA
Coal
Stock
April
May
June
July
Aug
Sep
Oct
Nov
Dec
Jan'
07
TOTAL
15
Slide 16
OPI
NO
Critical
Spares
(Max-300
Overall
score%
1
2
3
4
Slide 17
TOTAL CRITICALSPARES
PI
Raised
PE
Sent
PO
Placed
Matl
recd
PI
Raised
PE
Sent
PO
Placed
Matl
recd
1
2
3
4
17
Slide 18
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
Slide 19
TOTAL CRITICALSPARES
PI
Raised
PE
Sent
PO
Placed
Matl
recd
PI
Raised
PE
Sent
PO
Placed
Matl
recd
1
2
3
4
19
Slide 20
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
Slide 21
TOTAL CRITICALSPARES
PI
Raised
PE
Sent
PO
Placed
Matl
recd
PI
Raised
PE
Sent
PO
Placed
Matl
recd
1
2
3
4
21
Slide 22
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
Slide 23
TOTAL CRITICALSPARES
PI
Raised
PE
Sent
PO
Placed
Matl
recd
PI
Raised
PE
Sent
PO
Placed
Matl
recd
1
2
3
4
5
23
Slide 24
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
24
Slide 25
TOTAL CRITICALSPARES
PI
Raised
PE
Sent
PO
Placed
Matl
recd
PI
Raised
PE
Sent
PO
Placed
Matl
recd
1
2
3
4
5
25
Slide 26
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
Slide 27
TOTAL CRITICALSPARES
PI
Raised
PE
Sent
PO
Placed
Matl
recd
PI
Raised
PE
Sent
PO
Placed
Matl
recd
1
2
3
4
5
27
Slide 28
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
%
Slide 29
29
Slide 30
30
Slide 31
Project Objective
Enabling
process
selected
Project
sponsor
Process
Owner
Team
members
Present status
31
Slide 32
Project Objective
Enabling
process
selected
Project
sponsor
Process
Owner
Team
members
Present status
32
ANNEXURE-XIX
2.0
SN
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.
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
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
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
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.
Description
Status/Reason
Remark
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.
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
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.
Description
DATE:
Description
1.
2.
3.
4.
5.
6.
SYSTEM HEALTHINESS:
Status
Remarks
S.N.
Description
1.
Status
Remarks
Status
Remarks
3.
4.
5.
Availability/usage of auto loops;- Reasons for nonavailability /no usage and action plan for improvement.
6.
7.
8.
9.
10.
11.
12.
13.
Description
S.N.
Description
Status
1.
Remarks
Status
Remarks
(Schedule, result
3.
4.
5.
MONITORING:
S.N.
Description
1.
2.
3.
4.
S.N.
Description
Status
Remarks
Status
Remarks
6.
7.
8.
9.
10.
11.
ANALYSIS:
S.N.
Description
S.N.
Description
Status
1.
Remarks
Status
Remarks
Status
Remarks
value.
2.
3.
4.
5.
6.
7.
POG/other
committee
recommendations
and
their
implementation.
OVERHAUL AND RECOMMISSIONING:
S.N.
Description
1.
2.
3.
4.
SAFETY:
S.N.
Description
1.
3.
4.
5.
6.
7.
IMPLEMENTATION OF OLMMS:
S.N.
Description
1.
PTW system.
2.
Status
Remarks
ENVIRONMENT:
S.N.
Description
1.
2.
Status
Remarks
Status
Remarks
system.
3.
4.
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.
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
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
DATA
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
7
8
10
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
13
B
Sl. No.
Description
1
Main oil pump suction Pr/discharge Pr.
2
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
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
Availability of stand by of
FRF pump
Auxiliary oil pump
10
11
12
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
Source of steam to
TDBFP
Deaerator
Sl. No.
Description
1
Availability of standby BFP (Remote manual/auto)
2
10
Sl. No.
Description
1
Availability of standby
2
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
Status
G
GENERAL
Sl. No.
Description
1
Any additional observation on equipments/systems
2
Lighting
Cleaning
Ventilation
Structure healthiness
10
11
12
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
Sl. No.
Description
6
Checks for availability of first aid box and water shower
7
Status
Remarks
10
11
12
13
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
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
2.5
Status
Remarks
Sl. No.
Inspection of Tanks
Description
Status
Remarks
Status
Remarks
Status
Remarks
Status
Remarks
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
COC
Description
Chemical in use
LI/RI
5.0
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
Sl. No.
9.1
Testings
Description
Deviations
(Core parameters : pH, Cation conductivity, DO, Sodium,
Silica)
Feed : pH, DO, kH ;
SiO2,Sodium
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
10.3
11.0
OIL
Sl. No.
11.1
Testing
Description
Fuel oils
Dissolved gas analysis
Testing From External agency (reports)
12.0
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
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
UNIT :
DESIGN
ACTUAL VALUE
VALUE UNITUNITUNIT-
DATE :
DEVIATION
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
11
12
13
14
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
Status
Remarks
5
6
7
Status
Remarks
Status
Remarks
Status
Remarks
Status
Remarks
Status
Remarks
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
3
4
5
6
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
Status
Remarks
Sl. No.
Description
Status
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
10
FQA involvement
Equipment. (Y/N)
11
12
in
Predictive
Maintenance
of
Remarks
Sl. No.
type. (Y/N)
Description
Status
Remarks
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
PREVENTIVE MAINTENANCE
1.
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
1/2
Yes/No
Yes/No
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
2.
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
LUBRICATION SCHEDULE
1.
2.
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
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
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
: ED (OS)
Copy: GM (Station)
Daily flash Report for
-----------------------------------------------------------------------------------------------------------Particulars
Unitwise
Station
I.
-----------------------------------------------------------------------------------------------------------1.
2.
3.
4.
DC
5.
SG
6.
AG
7.
Coal status
a.
b.
c.
8.
9.
Unit outages
a.
Time/Duration
b.
c.
10.
Cause
Expected Time of Syn.
Outages of Lines
a.
Time/Duration
b.
Cause
11.
12.
Remarks
a.
b.
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.
Station schedule.
Note: The above Flash Report must be stopped after implementation of OPPMS
ANNEXURE-XXI
REPORT FOR MAJOR HAPPENINGS
From : GM Site
To : ED (OS)
S.No. Happenings / Events
1.
2.
3.
4.
5.
6.
7.
8.
ANNEXURE-XXII
DAILY DETAILED REPORT
Date :
1.
2.
3.
4.
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.
10.
12.
12.
Availability (%)
9.
10.
10.
10.
11.
12.
13.
13.
14.
Heat Rate-Day
(Kcal / kwh)
14.
Heat Rate-Cum
(Kcal / kwh)
15.
16.
17.
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.
Tonnes
Tonnes
Tonnes
Tonnes
(Signature)
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.
STAGE:
S.NO.
PARAMETER
REPORTING
UNIT
1.
pH at 25oC
--
2.
Turbidity
NTU
3.
mg/l
4.
COD*
5.
Residual Cl2
6.
No.
*: Once/month
REMARKS:
(Signature)
ANNEXURE-XXV
DATE:
RANGE
AVG. VALUE
STAGE:
ANNEXURE-XXVI
DATE:
S.NO.
PARAMETER
REPORTING
UNIT
1.
M3
2.
MT
3.
MT
4.
MT
5.
MT
6.
Kg
7.
Kg
(Signature)
VALUE
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.
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.
M3
2.
MT
3.
MT
4.
No.
5.
--
6.
Kg
7.
Kg
REMARKS:
(Signature)
VALUE
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
REMARKS:
(Signature)
DATE:
REPORTING
UNIT
--mg/l
MT
Kg
o
C
C
M3/h
No.
M3/h
-o
No.
VALUES
RANGE
AVG.
STAGE:
ANNEXURE-XXXI
DATE:
S.NO.
PARAMETER
REPORTING
UNIT
1.
2.
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.
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
Phosphate, mg/l
Ammonia, mg/l
Sodium, mg/l
Chloride, mg/l
Crud, mg/l
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.
MT
MT
Polyelectrolyte
HCl (30%)
H2SO4 (98%)
Lime (75%)
Any other chemical
3.
REMARKS:
(Signature)
MT
VALUE
ANNEXURE-XXXV
COAL AS RECEIVED ANALYSIS (Joint coal)
PROJECT:
S.N. DATE
REMARKS:
(Signature)
GRADE
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.
15.
16.
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
COAL
COAL
COAL
NO.
ON
RETAINED
PASSING
PASSING
MILL
ON 50US
THROUGH
THROUGH
MT/hr
SIEVE (300
MICRON IS
(150
SIEVE (75
SIEVE)
MICRON IS
MICRON IS
SIEVE)
SIEVE)
(Signature)
NO.
REMARKS
DATE
STAGE:
ANNEXURE-XXXXI
DATE:
UNIT/
ASH
GCV
STAGE
(%)
(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)
*
**
(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
H)
(mg/L)
. (Kg/ cm2 (Kg/H)(Kg/Cm2(Mm Hg)
)
(0C)
Note:
1.
(Signature)
* The core parameters shall have alarms in the control rooms. The followings are the core
level parameters:
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.
Kg/Cm2
T/Hr.
T/Hr.
Temperature L&R
8.8 Flue gas + P across
Economiser L&R
mmWc
APH (A)
8.10 Flue gas + T across
APH (B)
Amps
mmWc
Amps
mmWc
Amps
mmWc
Amps
mmWc
T/Hr.
Amps
mmWc
Amps
mmWc
Amps
T/Hr.
T/Hr.
mmWc
Amps
T/Hr.
T/Hr.
mmWc
Amps
T/Hr.
T/Hr.
mmWc
Amps
T/Hr.
T/Hr.
mmWc
Amps
T/Hr.
T/Hr.
mmWc
Amps
T/Hr.
T/Hr.
mmWc
(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
9.15
10.3
Scanners / Ignitors
10.4
Valves
10.5
PC Piping
10.6
Mills / Feeders
10.7
APH
10.8
ESP
10.9
Kg/cm2
Kg/cm2
Kg/cm2
11.11 RH Flow
T/Hr.
st
Kg/cm2
T/Hr.
T/Hr.
mmHg
mmWc
b) Fly Ash
T/Hr.
kg/cm2
Kg/cm2
mmWc
mmWc
mmWc
mmWc
mmWc
mmWc
mmWc
mmWc
mmWc
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
Kg/cm2
8.8
8.9
mmHg
8.10
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
8.15
8.16
Condenser CW
temperature (Inlet/Outlet)
8.17
LP exhaust hood
temperature
8.18
8.19
8.20
8.21
Bearing babbit
(metal) temperature
8.22
Kg/cm2
8.23
Kg/cm2
8.24
Kg/cm2
8.25
Hydrogen cylinder
consumption per day (if
taken during overhauling).
Nos.
8.26
Amps.
8.27
Kg/cm2
8.28
Amps
8.29
Kg/cm2
8.30
Amps
8.31
Kg/cm2
8.32
Amps
8.33
Kg/cm2
8.34
Amps
8.35
Kg/cm2
9.
-----------------------------------------------------------------------------------------------------------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.
-----------------------------------------------------------------------------------------------------------S.No. Equipments
Remarks
-----------------------------------------------------------------------------------------------------------10.1 Main turbine
10.2
Generator
10.3
Condenser
10.4
10.5
10.6
LP Heaters
10.7
HP Heaters
10.8
Deaerator
10.9
General
11.
Vibration record
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
a)
b)
c)
d)
e)
f)
Load
Voltage
Tap Position
Winding Temp. (Local)
Winding Temp. (Remote)
Oil Temp. (Local)
8.5
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
ppm
ppm
ppm
a)
m mho
b)
Kg/cm2
Kg/cm2
8.7
H2/CO2 status
a)
c)
d)
8.8
a)
b)
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
5
6
TURBINE
11
12
13
14
10
GENERATOR
15
Gen. Voltage(R/Y/B)
16
17
MVAR
18
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.
PP
02.
PP
03.
PP
04.
PP
05.
PP
06.
PP
07.
PP
08.
RM
09.
RM
10.
RM
11.
RM
12.
AHM
STATUS
REMARKS
DESCRIPTION
RESP.
13.
AHM
14.
TM
15.
C&I
16.
C&I
17.
C&I
18.
C&I
19.
C&I
20.
Opn.
21.
Opn.
22.
Opn.
23.
Opn.
24.
Opn.
25.
Opn.
26.
Opn.
27.
Opn.
STATUS
REMARKS
S.N.
DESCRIPTION
RESP.
28.
REMARKS
Opn.
29.
STATUS
Opn.
CLEARANCES
S.N.
DEPARTMENT
01.
03.
04.
05.
06.
REMARKS
02.
SIGNATURE
Operation / Recommissioning
DEVIATIONS:
DGM (Opn.)
ANNEXURE XXXXVI
INITIAL CONDITION:
1.1
1.2
1.3
1.4
2.0
LINE-UP:
The following systems/ equipments should be lined up and made ready for operation:
2.1
2.2
2.3
2.4
2.5
2.6
All three CC pumps: Cavity filling completed and discharge valves are kept
open.
2.7
2.8
2.9
2.10
2.11
2.12
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
2.16
Electrostatic precipitator.
2.17
2.18
2.19
2.20
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.
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
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
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
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
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.
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
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
5.52
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
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
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
ACTIVITY DESCRIPTION
02
03
05
06
07**
08**
09**
10
11
12
13
14
15
16
17
DATE:
PARAMETER
Recommended*
Actual
04
ANNEXURE XXXXVII
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
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
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.
Opn.
03.
04.
05.
06.
07.
08.
09.
10.
11.
12.
13.
14.
15.
Opn.
C&I/Opn.
STATUS
REMARKS
16.
C&I
17.
18.
19.
20.
21.
22.
23.
24.
25.
Opn.
26.
EM
27.
28.
29.
30.
31.
32.
33.
34.
35.
Opn.
EM
Signature
Electrical Maintenance
C&I Maintenance
Operation
:
:
:
36.
37.
38.
39.
40.
41.
42.
43.
44.
45.
Opn.
Signature
ANNEXURE XXXXVIII
MODEL RECOMMISSIONING CHECKLIST OF MAIN TURBINE (500 MW)
EQUIPMENT : MAIN TURBINE
S.NO.
DESCRIPTION OF ACTIVITY
1.0.0
2.0.0
2.1.0
2.2.0
2.3.0
2.4.0
2.5.0
2.6.0
3.0.0
4.0.0
5.0.0
6.0.0
7.0.0
8.0.0
9.0.0
10.0.0
11.0.0
DATE/TIME
DATE/TIME
STATUS
S.NO.
DESCRIPTION OF ACTIVITY
12.0.0
13.0.0
OIL FLUSHING
13.1.0
13.2.0
13.3.0
13.4.0
13.5.0
13.6.0
13.7.0
13.8.0
ii)
iii)
All bolted joints and cover plates on the stator frame are
provided with Gasket and properly lightened.
iv)
v)
vi)
vii)
viii)
STATUS
S.NO.
DESCRIPTION OF ACTIVITY
xi)
STATUS
x)
xi)
13.9.0
13.10.0
13.11.0
xii)
13.12.0
13.13.0
S.NO.
DESCRIPTION OF ACTIVITY
13.14.0
STATUS
13.15.0
13.16.0
13.17.0
13.18.0
13.20.0
-----------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------------
13.21.0
13.19.0
13.23.0
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
13.26.0
13.27.0
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
S.NO.
DESCRIPTION OF ACTIVITY
14.4.0
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
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
15.13.0
15.14.0
15.15.0
15.16.0
15.17.0
15.18.0
15.19.0
TM:
EM:
C&I:
OPN:
15.20.0
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:
STATUS
S.NO.
DESCRIPTION OF ACTIVITY
17.0.0
18.0.0
19.0.0
20.0.0
21.0.0
22.0.0
23.0.0
24.0.0
25.0.0
26.0.0
27.0.0
28.0.0
29.0.0
30.0.0
31.0.0
32.0.0
STATUS
S.NO.
DESCRIPTION OF ACTIVITY
33.0.0
34.0.0
35.0.0
36.0.0
37.0.0
38.0.0
39.0.0
40.0.0
Mode (Auto/Manual) :
Full local reached
Date / Time :
STATUS
SHAFT VIBRATIONS:
03.
BEARING VIBRATIONS:
04.
05.
06.
07.
PARAMETERS
--------------------------------------------------------------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--------------------------------------------------------------
08.
09.
10.
AXIAL SHIFT:
11.
HP RELATIVE EXP.:
12.
IP RELATIVE EXP.:
13.
LP RELATIVE EXP.:
14.
15.
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
PARAMETER
Recommended*
Actual
EHC,ATRS
through SGC
Turbine
11
DATE:
As per X-6:
REMARKS
12
13
14
ANNEXURE XXXXX
OPERATION PHILISOPHY OF COAL HANDLING PLANT
A)
Operation Philosophy
1.
2.
3.
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.
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.
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.
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)
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.
ANNEXURE XXXXX
' HWDL O / RJ L F
6 K HHW I URP
6 WDWL RQ
6 WRS
6 WRS
5 HJ L RQ DO 26
6 WRS
' HWDL O H
(Q J L Q HHU
1 HFHV V DU\ , Q
Z L WK L Q P
' D\ V
' D\ V
&RUS RUDWH 26
1 R
< HV
' D\ V
1 R
(Q J L Q HHUL Q J
' D\ V
6 WRS