ORT REPORT (FGUTPP/NTPC)

NTPC LTD
Operation Services

Ref. No: NROS/UNCHAHAR/ORT-MINUTES/206 Sub: Minutes of 206th Meeting of UNCHAHAR Operation Review Team.

Enclosed please find herewith a copy of minutes of 206th ORT Meeting held at UNCHAHAR on 1 from 03:00 pm to 06:00 pm to review the performance of the station for the month of August'09 Next Meeting of ORT will be held tentatively on 10/10/2009 at 11:00 am. This is for your information and necessary action please.

DISTRIBUTION: Concerned Station: Through LAN Corporate centre / Regional HQ: Through NTPC Intranet/e mail Projects (Through intranet/e mail):

Head of station Singrauli / Korba / Ramagundam / Rihand / Vindhyachal / Dadri(Coal) / Dadri Talcher Thermal / Talcher Kaniha / Farakka / Kahalgaon/ Badarpur /Tanda / Simhadri / Anta/ Aur Jhanor Gandhar / Kayamkulam / Faridabad FORMAT NO: OS-Q-ISO-P-010/F1-R4

UTPP/NTPC)

rvices

Date:

8/11/2009

g held at UNCHAHAR on 10/09/2009 or the month of August'09

(ORT Co-ordinator)

hal / Dadri(Coal) / Dadri(Gas) / Unchahar / nda / Simhadri / Anta/ Auraiya /Kawas /

GUIDELINES

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CONTENTS

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1.0 STATION HIGHLIGHTS & RANKING

1.0 HIGHLIGHTS 1.1 RANKING OF STATIONS (PREVIOUS MONTH): 1.2 BEST ACHIEVED PARAMETERS 1.3 TRENDING OF BEST ACHIEVED PARAMETERS 2.1 VARIATION IN MOU TARGET WITH ACTION PLAN :

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2.0 STATION PERFORMANCE 2.2 DETAILS OF PARAMETERS WITH RETRIEVAL PROGRAM 3.0 PERFORMANCE 3.1 OVERVIEW OF STATION PERFORMANCE (TREND)
3.1 OVERVIEW OF STATION PERFORMANCE DATA (MONTH WISE / CUMULATIVE): 3.2 UNIT WISE PERFORMANCE DATA (MONTH WISE / CUMULATIVE): 4.1 TRENDING OF DC GAP 4.2 ABT GAP ANALYSIS (FOR STATIONS UNDER ABT) 4.3 ACTION PLAN FOR ANY DEVIATION IN ABT GAP ANALYSIS: 4.4 DATA FOR TRENDING OF DC GAP 4.5 SCATTER DIAGRAM (AG/DC PLOT AGAINST FREQUENCY)-MONTH WISE 4.6 OPPORTUNITY MATRIX (FOR STATIONS UNDER ABT): 4.7 105% DC CAPABILITY 4.8 CONTRAINTS FOR ACHIEVING 105% DC AND ACTION PLAN 4.9 ABT COMPLIANCE (GENERAL): 4.10 No. of time blocks when the unit generated at 105% DC 5.1 TREND OF AVAILBILITY LOSS (STATION) FOR LAST 5 YEARS (%): 5.2 OVERVIEW OF AVAILBILITY LOSS BREAK UP(STATION)-UNIT WISE-FIN YEAR -CUMULATIVE (%): 5.3 OVERVIEW OF FORCED OUTAGE-% -UNIT WISE-FIN. YEAR- CUMULATIVE 5.4 SUMMARY OF AVAILBILITY LOSS BREAK UP(STATION)-MONTH WISE: 5.5 UNIT WISE AVAILBILITY LOSS BREAK UP: 5.6 DETAILS OF AVAILBILITY LOSS BREAK UP DUE TO EQUIPMENT(UNIT WISE & MONTH WISE): 6.1 TREND OF NUMER OF OUTAGES (STATION) FOR LAST 5 YEARS (No.): 6.2 ACTION PLAN TO ACHIEVE 'ZERO FORCED OUTAGE". 6.3 STATUS OF MATERIAL PROCUREMENT AS PER ACTION PLAN 6.4 DETAILS OF UNIT OUTAGES 6.5 EXCEPTIONS OF THE ACTION PLAN OF LAST FINANCIAL YEAR: 6.6 RESTORATION OF UNITS 6.7 START UP PARAMETERS 6.8 DETAILS OF MULTIPLE UNIT TRIPPING: 6.9 DETAILS OF MAJOR FAILURES: 6.10 FAILURE OF TRANSFORMERS: 7.1 TREND OF PARTIAL LOADING (%) FOR THE LAST 5 FIN. YEARS (STATION) 7.2 OVERVIEW OF PARTIAL LOADING--CUMULATIVE-CURRENT FIN. YEAR (%) 7.3 ACTION PLAN FOR REDUCING PARTIAL LOADING 7.4 SUMMARY OF PARTIAL LOADING (STATION) MONTHWISE,%: 7.5 SUMMARY OF EQUIPMENT PARTIAL LOADING UNITWISE-MONTHWISE (%)7.6 SUMMARY OF EXTERNAL PARTIAL LOADING UNITWISE-MONTHWISE (%)7.7 DETAILS OF PARTIAL LOADING DUE TO EQUIPMENT: 8.1 SPECIFIC OIL CONSUMPTION-UNIT-WISE-MONTH WISE (ml/Kwh): 8.2 MAJOR REASONS FOR OIL CONSUMPTION DURING THE MONTH: 8.3 AUXILIARY POWER CONSUMPTION-UNIT-WISE-MONTH WISE (%): 8.4 MAJOR CONTRIBUTORS FOR AUX. POWER CONSUMPTION: 8.5 STEPS TAKEN FOR ENERGY CONSERVATION: 8.6 STATUS OF ENERGY AUDIT 9.1 COAL RECEIPT / STOCK STATUS: 9.2 TREND OF GCV (KCAL/KG) 9.3 FUEL STOCK DETAILS 9.4 DM WATER CONSUMPTION / STOCK DETAILS 10.1 TREND OF BOILER TUBE LEAKAGE FOR THE LAST 5 FIN. YEARS 10.2 TUBE LEAKAGE WITHIN 3 MONTHS OF OVERHAUL-CURRENT FINANCIAL YEAR 10.3 OVERVIEW OF BOILER TUBE LEAKAGE-CUMULATIVE (CURRENT FY)-% 10.4 DETAILS OF BOILER TUBE LEAKAGES DURING THE FINANCIAL YEAR: 10.5 EXCEPTIONS OF THE ACTION PLAN OF LAST FINANCIAL YEAR: 10.6 DETAILS OF BOILER TUBE LEAKAGES-LOCATION WISE:

4.0 ABT ANALYSIS

5.0 AVAILABILITY LOSS

6.0 OUTAGE ANALYSIS

7.0 PARTIAL LOADING

8.0 OIL & APC

9.0 FUEL-WATER-

10.0 TUBE LKG

10.0 TUBE LKG

10.7 DETAILS OF BOILER TUBE LEAKAGES-CAUSE WISE: 10.8 METAL TEMPERATURE EXCURSION 10.9 ACTION PLAN FOR REDUCING METAL TEMP. EXCURSION: 10.10 AVERAGE MILL ROLL LIFE (In Hrs.) 11.1 TREND OF RATIO OF GROSS SALE OF ENERGY/FUEL COST 11.2 OVERVIEW OF EFFICIENCY GAP ANALYSIS -UNIT WISE 11.3 DETAILS OF TEST PARAMETERS : 11.4 EQUIPMENT TEST RESULTS 11.5 BOILER EFFICIENCY LOSS BASED ON TESTS (%) 11.6. TURBINE HEAT RATE DEVIATION BASED ON TEST -KCAL/KWH 11.7. UNIT HEAT RATE DEVIATIONS BASED ON TESTS (kcal/kWh): 11.8 HEAT RATE IMPROVEMENT ACTION PLAN & STATUS OF PROCUREMENT 11.9 HIGH ENERGY DRAIN VALVE PASSING 11.10. PRE & POST OVERHAUL PERFORMANCE 11.11 PG TEST STATUS 11.12 PG TEST STATUS FOR PENDING PACKAGES 12.1 SUMMARY OF ADVERSE PARAMETERS & ACTION PLAN 12.2 DETAILS OF CRITICAL PARAMETERS : 12.3 COMBUSTION RELATED PARAMETERS: 12.3.1 UNBURNT CARBON 12.3.2 MILL FINENESS 12.3.3 OXYGEN 12.3.4 BOILER FLUE GAS PRESSURE DROP (Month) 12.4 SOOT BLOWERS AVAILABILITY/OPERATION DETAILS : 12.5 GENERATOR HYDROGEN COOLING SYSTEM: 12.6 GENERATOR STATOR WATER SYSTEM: 12.7 ASH WATER RATIO (SAMPLE TAKEN AT PIPE DISCHARGE) 13.1 DEVIATION IN WATER CYCLE CHEMISTRY 13.2 ACTION PLAN FOR ANY DEVIATION IN STEAM-WATER CYCLE CHEMISTRY: 13.3 MOT / FRF OIL ANALYSIS 13.4 ACTION PLAN FOR ANY ABNORMALITY IN THE MOT / FRF OIL ANALYSIS: 13.5 CPU AVAILABILITY 13.6 ACTION PLAN FOR ANY DEVIATION IN WTP/ DM PLANT: 13.7 SWAS (STEAM WATER ANALYSIS SYSTEM): 13.8 CBD OPENING HOURS 13.9 CHEMICAL CONSUMPTION 13.10 NO. OF REGENERATION 13.11 DEW POINT OF INSTRUMENT AIR 13.12 CIRCULATING WATER PARAMETERS 13.13 STATUS OF CW CLORINATION/PT CLORINATION PLANT 14.1.1 OPI-PART-A 14.1.2 OPI-PART-B 14.2.1 KEY SPARES & CONTRACTS REQUIRED FOR OH 14.2.2 KEY SPARES & CONTRACTS REQUIRED FOR OH 14.3 ORT SUMMARY SHEET 14.4 MONTHLY EXCEPTION REPORT 14.5 DEVIATION IN PLANNED OUTAGE SCHEDULE & DURATION DURING THE YEAR (ACTUAL VS PLANNED): 14.6 OERVIEW OF OVERHAULING QUALITY 14.7 PLANNED OUTAGES-QUALITY OF OVERHAULS 14.8 OVERHAULING COST : 14.9 MAJOR (CAPITAL) SPARES CONSUMED (Recently completed Overhauls):: 14.10 PLANNED MAINTENANCE ROLLING PLAN FOR 8 YEARS: 14.11 DETAILS OF SCOPE OF WORK FOR FORTHCOMING OVERHAULS: 14.12 RUNNING HOURS OF THE UNIT SINCE LAST OVERHAUL & SNCE INCEPTION 15.1 ANURAKSHNAN SYSTEM: 15.2 EQUIPMENTS NOT AVAILABLE FOR MORE THAN 15 DAYS: 15.3 EQUIPMENTS WHERE REPEATED FAILURES OCCURRED (CURRENT FY): 15.4 MAJOR EQUIPMENTS HAVING HIGH VIBRATIONS: 15.5 WOC QUANTITATIVE ANALYSIS: 15.6 STATUS OF MOU PARAMETERS 15.7 REPAIR & MAINTENANCE COST 15.8 FINANCIAL RATIOS (MOU) 16.1 SAFETY: MAJOR DEVIATIONS (FOR THE FIN. YEAR): 16.2 STATUS OF SAFETY AUDIT ACTION PLAN: 16.3 DETAILS OF FIRE PROTECTION SYSTEM: 16.4 OBSERVATIONS ON THE CHECKING / INSPECTION OF SAFETY SYSTEMS: 16.5 TESTING OF TOOLS & TACKLES (FINANCIAL YEAR): 16.6 MANDATORY LICENSES: 16.7 STRUCTURE CHECKING:

11. EFFICIENCY

12.0 OPERATIONAL PARAMETERS

13.0 CHEMISTRY

14.0 PLANNED MAINTENANCE

15.0 MAINTENANCE MANAGEMENT SYSTEM & FINANCIAL PARAMETERS

16.0 SAFETY GAP ANALYSIS

16.0 SAFETY GAP ANALYSIS

16.8 MACHINE FOUNDATIONS: 16.9 CHIMNEY INSPECTION: 16.10 PAINTING OF STRUCTURES: 17.1 STATUS OF TECHNICAL AUDIT ACTION PLAN: 17.2 STATUS OF PEER AUDIT ACTION PLAN: 17.3 STATUS OF ROPR ACTION PLAN 17.4 STATUS OF ACTION PLAN OF OTHER COMMITTEES / REVIEWS 17.5 STATUS OF AUDITS CONDUCTED BY ORT COORDINATOR: 17.6 IMPLEMENTATION OF RECOMMENDATIONS OF KNOWLEDGE TEAM 17.7 STATUS OF TECHNICAL COMPLIANCE AUDIT ACTION PLAN: 17.8 TECHNICAL COMPLIANCE: 17.9 DEPARTMENT-WISE LMI STATUS 17.10 STATUS OF PENDING LMIS 17.11 LIST OF TC DOCUMENTS NOT APPLICABLE TO STATION 18.1 STATUS OF PROTECTION & AUTO LOOPS: 18.2 STATUS OF PROTECTIONS CHECKING & AVAILABILITY: 18.3 DETAILS OF AUTO LOOPS NOT IN SERVICE: 18.4 CONVEYOR PROTECTIONS AVAILABILITY: 18.5 DETAILS OF TESTING OF TURBINE: 18.6 TURBINE GOVERNING SYSTEM: 18.7 DETAILS OF ELECTRICAL TESTING (During the month): 18.8 STATION BATTERY SYSTEM 18.9 ACTION PLAN FOR ANY ABNORMALITY IN THE BATTERY SYSTEM: 18.10 TRANSFORMERS DGA TEST STATUS 19.1 ENVIRONMENT MANAGEMENT 19.2.1 MOU TARGET 19.2.2 ASH PRODUCTION DETAILS (IN MT) 19.2.3 ASH UTILISATION-MONTH-WISE 19.2.4 DETAILS OF ASH UTILISATION (IN MT) 19.2.5 MARKETING EFFORTS CARRIED OUT FOR ASH UTILISATION 19.3.1 ASH-DYKE-MAJOR SAFETY RELATED OBSERVATIONS WITH ACTION PLAN 19.3.2 STATUS OF ASH DYKE WITH REGARD TO THEIR CAPACITY 19.3.3 ENVIRONMENTAL PARAMETERS 19.3.4 Ash Dyke Disposal Program for next 5 years: 19.3.5 Five Year rolling plan for ash dyke raising 19.3.6. Status of Ash Dyke raising ( for next 2 Financial years ) 19.3.7 Status of other action plan based on Audits / Visits by PE etc. 19.3.8 Majors taken for Fugitive Dust Supression 19.3.9 Free board level measured by ORT Coordinator 20.1 ACTION PLAN FOR ANY DEVIATION IN CHP HEALTHINESS 20.2 CONVEYER UTILISATION FACTOR (%) 20.3 CONVEYOR BELT REPLACEMENT DETAILS 20.4 CHP EQUIPMENT AVAILABILITY (%) 20.5 CONVEYOR STARTS/STOPS (%) 20.6 CONVEYOR PROTECTIONS: 20.7 PULLEYS LAGGING IN THE MONTH: 20.8 CONVEYOR BELT INVENTORY-FOR THE MONTH (IN MTRS) 20.9 FIRE FIGHTING SYSTEM STATUS: 20.10 FIRE PROTECTION SYSTEM STATUS: 20.11 EQUIPMENT NOT AVAILABLE FOR MORE THAN 15 DAYS: 20.12 TRACK HOPPER EMPTY HOURS DUE TO NO COAL 21.1 OPERATION PARTICULARS: 21.2 SPEED RESTRICTIONS/ CAUTION ORDER FOR SPEED 30 KMPH OR LESS 21.4 AVAILABILITY OF ROLLING STOCK (INCLUDING POH) AND Sp. FUEL OIL CONSUMPTION: 21.5 IMPORTANT TRACK MAINT. ACTIVITIES 21.6 INSPECTION OF MGR SYSTEM (ATLEAST 50% INSPECTION DURING NIGHT (BET.23-00 TO 4-00 HRS)) 21.7 AVAILABILITY OF S & T 21.8 CONSTRAINTS IF ANY 21.9 CHECK POINTS FOR INSPECTION OF MGR SYSTEM BY HEAD OF STATION, O&M AND SAFETY 21.10 COAL LINKAGE/FSA & RECEIPT (QUARTER WISE): 21.11 CLEANING/ HEALTHINESS OF BOP EQUIPMENTS: 22.1 O & M ISSUES

17.0 SYSTEM COMPLIANCE

18.0 SYSTEM HEALTHINESS

19.0 ENVIRONMENT & ASH DYKE

20.0 CHP

21.0 MGR

21.3 ACCIDENT DERAILMENTS: (ANY OCCURRENCE WHICH AFFECTS SAFETY OF MGR SYSTEM,DELAY TRAINS,BREACH OF SAFET

22 .0 O&M ISSUES

22.2 CRITICAL ISSUES (OTHER THAN O&M ISSUES) 22.3 ISSUES TO BE TAKEN UP WITH CORPORATE CENTRE DEPARTMENTS 23.1 IDENTIFICATION OF R&M NEEDS:

23.0 R&M ISSUES

23.0 R&M ISSUES

A. EQUIPMENTS WHICH ARE CONSTRAINTS IN ACHIEVING THE TARGETED PERFORMANCE PARAMETERS B. EQUIPMENTS / SYSTEMS WHOSE PERFORMANCE IS BECOMING A CONSTRAINT IN MEETING STATUTORY / C. WEAK AREAS / SYSTEMS WHICH ARE LIKELY TO CAUSE PROBLEM BASED ON OPERATORS GUT FEELINGS: D. ITEMS / SYSTEMS WHICH ARE OBSOLETE / NEARING OBSOLESCENCE: 23.2 STATUS OF R&M WORKS OF STATION 23.3 DEPARTMENT WISE REPAIR & MAINTENANCE EXPENDITURE AND PROJECTED EXPENDITURE 24.1 TQM STATUS 24.2 INVENTORY STATUS 24 .3 SOFTWARE 24.4 NEW POINTS DISCUSSED DURING ORT MEETING 24.5 ANY ABNORMAL INCIDENT DURING THE MONTH 24.6 FEEDBACK TO SITE 25.1 START UP PARAMETERS 25.2 SHUT DOWN PARAMETERS

24.0 MISCELLANEOUS 25.0 MAIN TURBINE Annexure: LIST OF PARTICIPANTS

PUT SHEET (EEMG-EFF)

INPUT SHEET PERF)

MONTH WISE / CUMULATIVE):

QUENCY)-MONTH WISE

ST 5 YEARS (%): ATION)-UNIT WISE-FIN YEAR -CUMULATIVE (%): IN. YEAR- CUMULATIVE ATION)-MONTH WISE:

TO EQUIPMENT(UNIT WISE & MONTH WISE):

LAST 5 YEARS (No.):

5 FIN. YEARS (STATION) CURRENT FIN. YEAR (%)

ITWISE-MONTHWISE (%)TWISE-MONTHWISE (%)-

WISE (ml/Kwh): NG THE MONTH: MONTH WISE (%):

ST 5 FIN. YEARS UL-CURRENT FINANCIAL YEAR ATIVE (CURRENT FY)-% THE FINANCIAL YEAR:

ATUS OF PROCUREMENT

ATER CYCLE CHEMISTRY:

MOT / FRF OIL ANALYSIS:

DURATION DURING THE YEAR (ACTUAL VS PLANNED):

ly completed Overhauls)::

MING OVERHAULS: VERHAUL & SNCE INCEPTION

CURRED (CURRENT FY):

ON OF SAFETY SYSTEMS:

KNOWLEDGE TEAM

BATTERY SYSTEM:

ATIONS WITH ACTION PLAN

PEED 30 KMPH OR LESS

WHICH AFFECTS SAFETY OF MGR SYSTEM,DELAY TRAINS,BREACH OF SAFETY RULES OR LOSS TO NTPC IS ACCIDENT

POH) AND Sp. FUEL OIL CONSUMPTION:

SPECTION DURING NIGHT (BET.23-00 TO 4-00 HRS))

EM BY HEAD OF STATION, O&M AND SAFETY

NTRE DEPARTMENTS

EVING THE TARGETED PERFORMANCE PARAMETERS IS BECOMING A CONSTRAINT IN MEETING STATUTORY / CAUSE PROBLEM BASED ON OPERATORS GUT FEELINGS: NG OBSOLESCENCE:

XPENDITURE AND PROJECTED EXPENDITURE

ANNEXURE: LIST OF PARTICIPANTS

A. STATION
S.No.
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

Name / Shri
Y.V. Rao Vipan Kumar Amit Mukherjee Ram Kuber S.K. Srivastava A.K. Shrivastava D. Paul R.K. saxena K. Das RB Pandey T Ravindran GC Aggarwal Prasanna Kumar A.K. Sharma M.Z.A. Siddhiqui S.K. Chaturvedi B.S. Rao P. Srivastava Manish Aggarwal R.S. Juneja V.K. Karan P.M. Tripathi S. M. Chaubey N.K. Singh Mustak Ali Vikram Paul Nathi Ram S. Chakraborty

Designation
GM (U) AGM (O&M) AGM (Opn) AGM (Maint.) AGM (FM) DGM (Chem) DGM (EEMG) DGM (MTP) DGM (CHP) DGM (F&A) DGM (TMD) DGM (MTP) DGM (BMD) DGM (EMD) DGM (EMD) DGM (TS) DGM (Opn.) DGM (AMG) DGM (C&I) Sr. Supdt. (EEMG) Sr. Supdt. (MTP) Sr. Supdt. (AMG) Sr. Supdt. (AUC) Supdt. (EEMG) Dy.Supdt. ( EEMG) Finance Officer Engr. (EEMG) Engr. (EEMG)

B. REGIONAL HQ
S.No. 1 2 3 Name Sushil Sriwastava Pyush Kumar L.M. Shah Designation DGM (NR-OS) DGM (NR-OS) Sr. Engineer (NR-OS)

C. CORPORATE CENTRE
S.No. 1 Name Md. Riyaz Ahmad Designation DGM (OS-CC)

CONTENTS