PROCESS MANUAL

SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-005

PROCEDURE FOR FUEL AND POWER MONITORING PROCEDURE NO.: P1-GIPL-005

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-005

1. Purpose
At all BTS locations, State Electricity Board (SEB) is the primary source for electric power supply. Redundancy has been provided through online battery banks and standby emergency Generator (DG) sets. This emergency generators prime mover engine sets use normally diesel driven. The purpose of this procedure is to develop and establish a uniform and structured reporting system so as to: Monitor the energy consumption at each site, Track the engine performance, Get an idea of the energy consumption pattern for budget, Generate a database for all sites/Circles for performance analysis. This Fuel & Power consumption database and the derived reports have no correlation with the periodic commercial reports for energy consumption and cost. This is due to differences in the basis of input data regarding the SEB billing date and frequency, booking of fuel quantity & cost, etc. Moreover the SEB has different tariff structures and billing cycles in different states/regions.

2. Scope
Provide Guidelines at field level to monitor consumption of diesel. Analyze variance in consumption of diesel with respect to Standard Operating parameters. Develop Common Operating Procedures to keep track of diesel consumption. Develop procedures to monitor power consumption from respective SEBs.

3.0 Responsibilities
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PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-005

3.1 National Head

Based at Corporate officeNew Delhi is responsible for the technical integrity of this procedure. The National Head or his nominated Deputy shall be authorised for any changes with this procedure.

3.2 Circle Manager

The Circle Manager or In-charge is responsible for ensuring that all activities related to this procedure are complied with and recorded as described in this document.

3.3 Procedure for monitoring parameters

Respective cluster In-charges are responsible for recording different data like diesel consumption, SEB/DG energy meter reading, and run hours of DGs. This data should be 1st to last date of the previous month. Accordingly number of days for that period shall be considered for report. Report generation will be monthly and accordingly reading to be recorded from fields. Refer Format No.: OEM/0001 for Field log sheet for all BTS. This record shall be maintained for a period of 6 months. FEOs/Technicians on duty should record the following details in the field log sheet: Date and time of current inspection Quantity of fuel in tank at previous inspection Quantity of fuel in tank during current inspection Total fuel filled in the tank (topping) Fuel consumed during the period (By computation as shown in log sheet) SEB energy meter reading

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-005

DG energy meters reading (which is not present installed) hence the log sheet shall be modified accordingly at appropriate time. Energy consumed from SEB during the period (By computation as shown in log sheet) Energy consumed from DG during the period. (Based on the computation of fuel per hr of running as shown in log sheet) Cumulative run hours and from that actual number of hours DG set has run during the period (i.e., between previous inspection and current inspection). The log sheet should be maintained for every site separately. Every log sheet to be computed for arriving monthly figures as indicated in log sheet. The FEOs/Technicians are required to update the field log sheet whenever they visits the site or at least once in a month such a way that data for the report for required specific period is available.

4.1 SEB power

The availability of power supply is calculated based on the DG running hrs. Though it is not so accurate, but this has been adopted keeping in view that, the difficulty of keeping track of SEB power supply availability in BTS sites, however, wherever DG is not available as in Mumbai and Kolkata, the availability of power supply to be ascertained by respective sites and data to be recorded.

4.2 Reporting requirements

Report period 1st day to last day of the month. The circle coordinator/Circle Manager shall ensure that the power and fuel data is entered in the portal by 10th of every month HO has to release all circles compiled consolidate report to all circle and commercial after review by O&M department head, latest by 15th of each month (for the previous month data). The compiled report format can be changed as and when required based on information need.
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PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-005

All variances which are not as per norm are to be supported by proper justification/reasons in the remarks column against each site by respective maintenance points.

4.3 Fuel consumption measurement and calculation:

All type of DG, particularly where sight level gauge is not available and the fuel stock measurement in the DG fuel tank must be done only by dipstick. The fuel stock checking is required for calculating fuel consumption as and when required. No other indirect practice to be adopted for calculating fuel consumption calculation. Dipstick shall be preferably of 5mm X 25mm GI strip of suitable length as per tank height. The least count for the measurement scale should not be less than 5mm for better accuracy. The dipstick material, colours etc. is not mandatory, but it is to be ensured that fuel consumption is measured accurately, consumption calculation error should not be more than 5% of actual volume due to error in reading. It has been observed that, if the dipstick is paint with dark colour like red, brown, green etc. it gives better visibility of fuel marking while taking dip. In case of DG sets without any provision for inserting dipstick in the tank, arrangement to be made by preparing a hole of suitable size at the top of the fuel tank.

For monthly fuel consumption calculation:

(Previous month fuel stock) (current month fuel stock) + Fuel quantity added (as per diesel purchased slip/data) during this period. Monthly once fuel dipstick reading (for monthly report) shall be taken more precisely, by taking three dipstick reading at the same time and averaging them for arriving correct dip and then multiplied by factor (as per calibration) for arriving actual fuel stock. While measuring, insert the dipstick vertically in the tank as far as possible. This reading shall be referred for next months fuel consumption calculation. Any intermediate fuel stock calculation can be done by simply one dip to just keep track of fuel stock. For both the readings the same dipstick shall be used. It is better to keep separate dipstick for every site. After
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PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-005

taking monthly reading of fuel consumption in the field, corresponding DG run hour and power generation reading needs to be checked. Fuel consumption in terms of liters per hour and specific fuel consumption should be realistic; else, it is to be rechecked for fuel consumption and power generation readings.

4.4 Engine speed

It is very important to maintain engine speed within limit of 1470 rpm to 1500 rpm to avoid unnecessary extra fuel consumption due to higher speed. With this speed range, the alternator coupled with engine will be able to produce power in the frequency range of 49 to 50 HZ. Sometime, engine speed may vary to higher side due setting disturbance in the governor of the engine. While taking monthly reading or during any routine maintenance check, it is very important to check system frequency (HZ) while DG is on load. Frequency less than 49 HZ is not a good indication.

4.5 Fuel filling in DG fuel tank:

1) Fuel filling frequency for different DG sets is to be reduced as minimum as possible. Filling can be done on the basis of fuel level low alarm (Which should be modified already, not to trip the m/c). Even after low-level alarm, on an average DG can run at least for 10 hrs, which is sufficient time for refilling. Depending on the sites SEB power availability condition, FEO/technician can have general idea about fuel filling requirement, in case low-level alarm does not appear for long unexpected period due to faulty alarm management. Sometimes it may be a general practice for filling the fuel during routine maintenance visit, though DG tank having sufficient fuel. Such fuel filling needs to be avoided if the available quantity is sufficient till next routine visit. Fuel filling container should be clean and moisture free. Periodically container shall be cleaned or replaced to avoid any residual sludge.

PROCESS MANUAL
SECTION GIPL-OEM Project and Operation & Maintenance

PROCEDURE P1-GIPL-005

4.6 Tracking the Specific Fuel Consumption (SFC) of different DGs in all the facilities
Every Cluster Location should have a system to track the SFC-actual and vis--vis SFC-norm of all DG sets for the successive months in sequence. At a glance, performance of particular DG set can be visualized by this data. It is necessary to analyze if the SFC is more than norm by 5.3% i.e. [(SFC actual) > 1.053* (SFC norm)]. The possible causes to be mentioned in the remark column for increase in specific fuel consumption and they needs to be rectified during next month report by eliminating actual cause. Responsible person of that region In-charge should maintain the record of this analysis.

5.0 Records and Frequency Format No. Description

OEM/0001

Frequency

Field log sheet BTS( Diesel & Power Monitoring As and when data sheet) required