Technical Audit NTPC

(For Internal Circulation)
COS-ISO-00-OIN/GEN/004
Rev. No. : 0 July 2004
OPERATION INFORMATION NOTE
GUIDELINES FOR
CONDUCTING TECHNICAL
AUDIT
CORPORATE OPERATION SERVICES
National Thermal Power Corporation Ltd.
NATIONAL THERMAL POWER CORPORATION LTD.

OPERATION & MAINTENANCE FORMAL DOCUMENTATION SYSTEM
OPERATION INFORMATION NOTE : COS-ISO-00-OIN/GEN/004
Rev. No.: 0
Date : July, 2004
GUIDELINES FOR
CONDUCTING TECHNICAL
AUDIT
Approved for
Implementation by ..
ED (OS)
Date: ..
Enquiries to: Head of Corp. Operation Services
GUIDELINES FOR CONDUCTING TECHNICAL AUDIT

INDEX
S.N. Contents
Page No.
1.0
Preamble
2.0
Superseded Documents
3.0
Objectives
4.0
Deliverables
5.0
Scope
6.0
Qualities of Technical Auditor
7.0
System for Technical Audit
8.0
General Guidelines for Conducting the Technical Audit
9.0
Maintenance System
10.0 Operation System
11.0 Overhauling
12.0 Maintenance Preparedness
13.0 Spares Availability
14.0 Healthiness of Installed Equipment
15.0 Housekeeping
16.0 O&M problems and action plan
17.0 O&M Cost reduction measures
18.0 Safety aspects Plant and Equipments
19.0 MoU Targets
20.0 Benchmarking
21.0 General
22.0 Review
10
Appendix -1A Matrix for Targeted Objectives of Technical audit
11
Appendix -1B Technical Audit Plant Areas
12
Appendix -2 Schedule of Technical Audit
15
Appendix - 3A Format for reporting Audit
16
Appendix - 3B Format for Action Plan
17
Appendix - 4 Format for Executive Summary
18
Appendix - 5 Matrix of Maintenance System
20
Appendix -6a Check list of Electrical areas
21
Appendix -6b Check list of C&I areas
26

INDEX
S.N. Contents
Page No.
Appendix -6c Check list of Operation areas
34
Appendix -6d Check list of Balance of Plant Areas
42
Appendix -6e Check list of Steam Turbine
54
Appendix -6f Check list of Chemistry
59
Appendix -6g Check list of Efficiency
66
Appendix -6h Check list of Gas Turbine
73
Appendix -6i Check List of Quality Management System
78
Appendix -6j Check list of Boiler
85
Appendix -6k Check list of Waste Heat Recovery Boiler (WHRB)
88
Page - 1
COS-ISO-00-OGN/GEN/004
Rev. No.: 0
Guidelines for Conducting Technical Audit

1.0
PREAMBLE
Technical Audit of NTPC stations shall bring out problems in equipments and
deviations in systems and processes, a time bound corrective action plan
depicting responsibility and implementation of the same to achieve reduced
forced outage, optimized O&M cost, quality maintenance & overhauling,
efficiency enhancement and full system compliance leading to safe, efficient
& reliable power generation.
2.0
SUPERSEDED DOCUMENTS
Nil
3.0
OBJECTIVES
The objectives of technical Audit shall be as per the targeted objectives shown
in the matrix in annexure - 1a which include the following:
4.0
a)
Forced outage reduction
b)
Generation Optimisation & Efficiency enhancement
c)
System compliance
d)
Cost reduction / optimization
e)
Quality of routine maintenance and overhaul
f)
Safe & reliable operation & maintenance
g)
Prevention of major failures
h)
Identification & reporting of major issues / constraints
DELIVERABLES
MIS to management
Audit report
Action plan and status thereof
Achievement of Targeted Operation Matrix.
Page - 2
Rev. No.: 0
5.0
SCOPE
5.1
Technical Audits will be carried out by Operation Services and will monitor
the following:a)
All relevant statutory requirements that apply to the plant areas listed
in Appendix I 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.
O&M cost reduction measures
Safety aspects of Plant & Equipments
Commercial aspects of unit operation
Plant efficiency deviations and corrective actions taken.
Any other areas, at the discretion of the Management.
b)
c)
d)
e)
f)
g)
h)
i)
j)
k)
l)
5.2
The Technical Audit should be able to bring out / deliver the following points
Identification of instances where based on site observation and study of

O&M parameters, vigilant O&M staff had averted a major failure /
outage / tripping. Reasons, analysis and learnings thereof to be
recorded and circulated for the benefit of other stations.
Identification of specific training needs of individuals to dovetail with

the overall OS strategy to develop pools of specialized maintenance
expertise in selected area through discussions with O&M staff during
audit.
Learnings from the station which can be circulated to other stations.
5.3
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
5.4
Instances where operation & maintenance staff failed to arrive at

recommendations to prevent forced outages
No. of incidences or occasions when the unit operation continued even
with known problems.
Full load generation constraints, partial loading and the reasons thereof.
Page - 3
Rev. No.: 0
6.0
QUALITIES OF TECHNICAL AUDITOR

a.
He must be well experienced in power station operation and

maintenance procedures.
b.
He should be diplomatic, unbiased, patient, communicative, and should

propagate good practices.
c.
He should not feel / show triumph on finding discrepancies and should

not criticise people, but point out discrepancies in the system /
equipments.
d.
He should have a strong analytical and data crunching abilities.
e.
He should develop a good feel of various parametric numbers and

using them along with clinical correlation of any tangible / intangible
symptoms and identify possible root causes and corrective actions
thereof.
7.0 SYSTEM FOR TECHNICAL AUDIT

7.1
Site to be audited shall be selected, as per the Annual Plan finalized at the
beginning of each financial year, or as per the requirements of the
management.
7.2
The Frequency of Audit of each station shall be once a year or as decided by

the management.
7.3
Head of O&M of the site shall be informed with a copy to GM (site) & ED
(Region), about the audit schedule and scope, as per enclosed format in
appendix 2.
7.4
Nominations of team members from the concerned HODs shall be sought by

the Operation & Commissioning group. If required team members can also be
drawn from respective regional headquarters / other stations. In special cases
team members can be taken from other Corporate / regional functions such as
Engg. , finance etc. The audit team shall be assisted by each area
representative of site during conductance of audit.
7.5
The team leader will be nominated by the management.
7.6
Station may request Corporate OS for minor rescheduling of audit to cater for
special exigencies to ED (OS) / GM (OS), the competent authority to approve
such minor changes in schedule. Any long term deferment from the schedule
or cancellation of audit plan will have to be approved by Director (O).
7.7
In case no acknowledgment is received from site, confirmation of the schedule

shall be sought from site, at least one week in advance.
7.8
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.
Page - 4
Rev. No.: 0
7.9
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.
7.10
The findings of the audit shall be summarized in the format given in appendix
3A and presented during the closing meeting.
7.11
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.
7.12
On returning back, final report including executive summary as per format in

annexure 4 shall be made by the team leader, in association with other team
members within two weeks of reporting at the headquarters.
7.13
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.
7.14
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
as per the format given in appendix 3B 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.
7.15
The action plan available on Station LAN should be updated by the concerned
persons every month. The updated status report as per the format given in
appendix 4 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.
7.16
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.
7.17
The head of OS shall review the action plan once in 4 months or as and when
desired.
7.18
The MIS of audit to D (O) / Management should be in power point and should
include the following:
7.19
Executive Summary in line with the Targeted Operation Matrix as per the
format in appendix 4. This will be made ready by the Team Leader after
the receipt of the action plan from the site.
Major areas requiring management action and intervention along with area
of concern or neglect.
Meeting of D(O), Corp. OS and GM station along with team for discussion on
critical issues to be scheduled if required
Page - 5
Rev. No.: 0
8.0
GENERAL GUIDELINES FOR CONDUCTING THE TECHNICAL

AUDIT
8.1
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.)
8.2
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.
8.3
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.
8.4
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, we
already know the problems, tell us about the solution .... or come and solve
the problems.
8.5
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.
9.0
Maintenance System
9.1
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 replanned.
4. Wherever possible, relevant values/readings should be mentioned.
5. Verify whether equipment history is being maintained and how quickly it
can be retrieved.
9.2
9.3
Page - 6
Rev. No.: 0
9.4
Audit of Anurakshan should also include

1.
2.
3.
4.
9.5
9.6
9.7
9.8
10.0
Status of full availability

No. of bugs identified / corrected
User friendliness and seamless connectivity to other related management
system.
Matrix of all available attributes and its use in the particular site. (Refer
appendix 5)
Permit to work (PTW) system

Verify that PTW System is being followed to ensure safety of men and
machines. Random scrutiny of safety documents, like Permit to Work (PTW),
Limited Work 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.
Identification of parameters where sufficient improvement (stretched target

parameters) can be done so that excellence in O&M is achieved.
Analysis of plant performance to match with ABT policy. (DC, SG, AG

and UI optimisation).
Plant performance review with respect to stretched target operation
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.
Page - 7
Rev. No.: 0
10.1
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
Data for Renovation & Modernisation

During the Technical Audit the auditor must check the data available with
O&E / MTP and ORT minutes which would go as input for R&M. The
relevance of this data should also be checked and areas for which data is not
available should be identified. The audit should be able to deliver the
following.
Identification of the equipments which are regularly becoming a

constraint in achieving the targeted performance parameters.
Equipments / Systems whose performance is becoming a constraint in
meeting statutory / safety norms.
Identification of weak areas which are likely to cause problem based on
operators gut feelings.
Identification of items / systems which are obsolete / nearing obsolescence.
11.0
Overhauling
11.1
Review a sample report of the recent overhauling, and study it for the
following points. Record deviations and action plan thereof.
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
Deviation in planned & actual activities in bar chart

Spares and consumables consumed
Tools and tackles used.
Proper record of necessary protocols.
Records of quality checks along with involvement of FQA.
Cost of overhauling, variance analysis and pay back period.
Improvements achieved after overhauling.
Delay analysis if any.
Critical Observations / lessons learnt
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.
11.2
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.
11.3
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.
Page - 8
Rev. No.: 0
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.
12.0
Maintenance Preparedness
12.1
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.
12.2
12.3
13.0
Spares Availability
13.1
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
13.2
13.3
13.4
13.5
14.0
14.1
14.2
14.3
14.4
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.
15.0
Housekeeping
As a minimum check for the following:
Dust on the floor and the equipments, and inside the enclosures/tracks.
Spilled oil and garbage on the floor.
Spillage of fuel oil.
Water logging.
Presence of bird nests, particularly on the switchyard gantries, storage tank
breather / vents etc.
Page - 9
Rev. No.: 0
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.
16.0
O&M problems and action plan

Identification and prioritizing the O&M issues.
Action plan to resolve them as per priority
Implementation status of the action plan is also to be checked.
17.0
O&M Cost reduction measures

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
18.0
19.0
Safety aspects of Plant and Equipments
Checking of records of compliance of applicable statutory safety regulations.
Check records to ascertain that disaster management plan is being actively

practiced.
Check whether safety appliances for safety of men are being used extensively.
Checking of equipments safety system healthiness and records thereof.
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.
20.0
Benchmarking
During the audit the following should also be addressed.
Identification of parameters which can be used as Benchmarks within

NTPC.
Review of benchmarks targeted by the station in O&M areas and status of

achievement of the benchmarks.
21.0
General
21.1
Describe any other specific problem of the station; along with reasons, effect /
implication and sites action plan.
Page - 10
Rev. No.: 0
21.2
21.3
22.0
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.
Review
The Head of Corporate Operation Services will be responsible for reviewing
this document on a yearly basis or as necessary.
Page - 11
Rev. No.: 0
Appendix - 1A
Targeted objectives of the technical audit will be to achieve the following matrix through necessary corrective actions for the
deviations found.
Technical Audit Matrix
No. of
forced
outage
bet. OH
Tube Fail
Generic
Failure
Trippings
Multi unit
Trippings
Overhauling
Maximize
Red. In
scope of
OH
work of
duration
OH
Increase in
meantime
bet. OH
O&M
Cost
Efficiency
Reduction enhancement
Spares
Chemical
Staff
Tours
OH
Contract
labour
Boiler Eff
Turbine Fff
Unit Eff
Losses
Condenser Vac
Steam Pressure
Steam Temp
FG Exit temp
Others
Compliance
of all NTPC
systems
ORT
O&E
TC
Anurakshan
MMS
Others
Accidents
MOU
TargetTarget
0%
Target Actual
Fire
T&P
Safety
others
Temp Excursion
Steam
Metal
ABT Policy
Major
UI
DC SG
failures maxi
mizat
ion
AG
Page - 12
Rev. No.: 0
APPENDIX 1B
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
Feed & Condensate Heating System
2.1
2.2
2.3
2.4
2.5
Feed Water System

Boiler Feed Pump
Main Condenser / Ball Cleaning System
Air Evacuation System
Condensate System
3.0
Other Related Areas / Equipments
PLANT AREA 2 BOILER & AUXILIARIES

1.0
BOILER PLANT (GAS-SIDE)
1.1
1.2
1.3
1.4
Boiler Plant
Gas Passes
Fans and APH
Electro Static Precipitators
2.0
BOILER PLANT (WATER/STEAM SIDE)
2.1
2.2
1.2
Main Boiler (Water Circuit)

Main Boiler (Steam Circuit)
Auxiliary Steam Systems
3.0
Milling System
3.1
3.2
Mills (including mill reject system)

Feeders
4.0

Page - 13
Rev. No.: 0
PLANT AREA 3 OFFSITES
1.0
FUEL MANAGEMENT
1.1
1.2
1.3
1.5
Coal Handling Plant

Coal Conveyors and Bunkers
Coal Storage
Fuel Oil Pumping and Storage
2.0
ASH PLANT
2.1
2.2
2.3
2.4
Ash Disposal Area

Ash Handling System
Dry ash System
Chimney
3.0
STATION AIR SYSTEMS
3.1
3.2
Compressed Air System

Air Conditioning System
4.0
CW PLANT
4.1
4.2
4.3
4.4
5.0
5.1
5.2
CW Pumps and other Equipments

CW Cooling Towers
CW Dosing Equipment
Clarified water System
CHEMICAL PLANT
Water Treatment Plant
Storage of Chemicals and Gases
6.0
PLANT AREA 4 (ELECTRICAL SYSTEMS/GENERATORS)

1.0
GENERATORS
1.1
1.2
1.3
Stators and Rotors / Exciters

Stator Cooling system
Hydrogen System / Sealing Systems
2.0
ELECTRICAL SYSTEM
2.1
2.2
2.3
2.4
2.5
Switchgear
Transformers
Batteries, DC Systems & DG Sets etc.
Station Earthing Systems
Station Lightning Arrestors
Page - 14
Rev. No.: 0
2.6
2.7
2.8
2.9
2.10
H.T. Motors
Switchyards Equipments & PLCC
Relays and Protection
Cable Galleries and Fire fighting Equipments
Gas Turbine starting system
3.0
PLANT AREA 5 C&I SYSTEMS

1.0
2.0
3.0
4.0
5.0
6.0
7.0
8.0
9.0
10.0
UPS
DDCMIS
Analysers
Lab
FSSS
Local instruments
Hp / LP Bypass
ATRS / ATT
Protections
Storage of C&I Items
PLANT AREA 6 GAS TURBINE

1.0
1.1
1.2
1.3
1.4
1.5
1.6
Gas Turbines
Compressors
Air Intake Systems
Fuel Burners / Combustion System (both liquid and gas)
Fuel Firing Systems (both liquid and gas)
WHRB
PLANT AREA 7 (COMMON)

1
2
3
4
5
6
7
8
Fire Fighting System

Lifting Equipments & Lifts
Tools & Tackles
Workshop and Labs.
Environment Areas
Plant Communication System
Auxiliary Boiler
H2 Generation Plant
Page - 15
Rev. No.: 0
APPENDIX - 2
TENTATIVE SCHEDULE FOR CONDUCTANCE OF TECHNICAL AUDIT OF

FROM TO
DATE
<Date>
TIME
9.00 AM
to
9.30 AM
9.30 AM
to
5.30 PM
PROGRAMME
Meeting with Head of Project and Head of O&M along with all
section heads for introduction of the team, and briefing about scope
and methodology of conducting the Technical Audit. Coordinators
from different areas are to be identified.
Team leader will oversee the conductance of the audit and resolve
any issue causing hindrance / constraint in the audit.
Other team members will meet the respective section heads/area
engineers regarding equipment, systems & practices pertaining to
their sections as envisaged in the scope and system for Technical
audit in this document. They will also discuss the tentative action
plan for the deviations found with the section HOD.
<Date>
<Date/s
>
<Date>
9.00 AM
to
5.30 PM
9.00 AM
to
4.00 PM
4.30 PM
to
6.30PM
-Do-DoMeeting of the team with Head of Project, Head of O&M along with
all section heads, to indicate the summary of major observations /
exceptions along with tentative action plan. Critical Issues are to be
identified along with action plan identifying the responsibility and
target dates for flagging to D(O).
Page - 16
Rev. No.: 0
Appendix-3A
Format for Reporting the Findings of Technical Audit of <Station> from <date> to <date>
Deviations / Non
Conformities
Number
Equipments /
Sub-systems
Checked
Area Audited
Observations / Findings
(Technical / System Related)
Deviations and action

plan
The Non Conformities shall be given a unique no. e.g. <stn.><unit/common><year><area><no.>
Responsibility Target date
Page - 17
Rev. No.: 0
Appendix-3B
Format for Action Plan / Implementation on Findings of Technical Audit of <Station>
from <date> to <date>
Sl. No. Deviations /
NC of Audit
(No.)
Observation /
Deviation
Action Plan for Remedial Action
Responsibility
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
Target Date
Present Status
Page - 18
Rev. No.: 0
Appendix - 4
Executive Summary of Technical Audit of <Project> From <Date> To <Date>
1)
Forced Outage Review
S. No.
2)
Forced outages
since last
technical audit
Partial loading
since last
technical audit
Exceptions
recorded
Reasons of partial
Action plan to reduce partial
Loading categorized loading
as per ORT format
Responsibility
with date
Analysis of
exceptions
Action plan to improve the

quality of overhaul
Responsibility
with date
Action plan to bridge the

shortfall of the MoU targets.
Responsibility
with date
MoU Target Achievement
MoU Targets
5)
Responsibility
with date
Quality of Overhaul
Unit
No.
4)
Action plan to achieve the

target of < 1.0%
Partial Load Analysis
Unit
No.
3)
Reasons of forced
outages
Status of
Achievement of the
targets
System Review Exceptions
System
Exceptions
Action plan to correct the

exceptions
Responsibility with
date
Page - 19
Rev. No.: 0
6)
Equipments / Systems Installed but not in Service
System Installed but not

in Service
7)
Action plan to avoid such

multi unit trippings
Responsibility
with date

exceptions
Installed Capacity
Responsibility with date
Capacity
achieved
Constraints in
achieving stretched
target
Action Plan with

date
UI Optimisation
Station Target to
achieve 101% of
DC in MUs
11)
Reasons of the
trippings
Unit Capability Review (Stretched Target 105% of Installed Capacity)
Unit No.
10)
Responsibility
with date
Efficiency Exceptions
Exception details
emerging from the detail
check list
9)
Action plan to put the

equipment / system in
service
Multi Unit Trippings
Instances of Multi Unit

Trippings
8)
Constraints being
faced by the station
Shortfall in MUs
Action plan to bridge the

shortfall
Responsibility
with date
Area Wise Exceptions
Area / unit
Deviation /
exception observed

exceptions
Responsibility with date
Page - 20
Rev. No.: 0
12) Any Other Issue
Page - 21
Rev. No.: 0
Appendix - 5
MATRIX OF MAINTENANCE SYSTEM
S.No.
1
2
3
4
5
6
7
8
9
10
11
Description
Status
Reason for
Deviation
Work Control
System Operation
Job Planning
A. Preventive Maintenance
B. Break Down Maintenance
PM SCHEDULE
a. Work Specification Review.
b. Frequency Review
Work Order Card
a. Priority of work(E,A,B.C)
b. Registration
c. Filling of cards
c. History of Equipments
d. Cost Calculation
Lubrication Schedule
MIS Reports Generation
PDM
Techniques in Use
PTW SYSTEM
a.
Type of PTW
PFW,SFT,LWC,ROMP, Hot Work
PTW
b. Lock out Box System ,Use of
Danger Tag
c. Cross Permit System
d. Filling of PTW
e. Cancellation of PTW
f. Process of Operation
Equipment Change over Schedule
Overhauling
a. Preparation of Five year Rolling Plan
b. Preparation of scope of work.
c. Preparation
of
Engineering
declaration
d. Prepared ness for next two overhaul
e. Readiness for spares, consumables,
contracts
f. Schedule/Durations ,delay if any
g. Quality checks
h. Critical checks of Equipments
i. Protocol s Preparation
j. Efficiency before and after overhaul
12
13
k. Cost of overhaul & cost benefit

analysis
Preparation of Overhaul Reports
Lesson Learnt from Overhaul
Action Plan
Page - 22
Rev. No.: 0
14
Constraint faced during Overhaul
Page - 23
Rev. No.: 0
Appendix-6a
ELECTRICAL CHECK LIST FOR TECHNICAL AUDIT
STATION
PERIOD OF AUDIT
S.No.
Area/System/Sub-Sytem
1.0
1.1
COMMON ELECTRICAL AREA

LMI for electrical system
Total no. of LMI
Nos.
Total no. of LMI approved
Nos.
Non compliance e of LMI, if any
Front and rear electrical panel module
identification . (Safety point.)
Electrical spares, especially motor, HT
breaker, Generator coils, electronic cards
etc. are kept and maintained properly.
Painting of major electrical equipments.
Major electrical equipments performance
history available in computer/register.
Earth resistance of major electrical
equipments and lightening mast pit
checking and upkeep record properly.
Annual relay testing and keeping record in
a proper format with testing data and
settings.
All energy meter calibration done.
Paging system status in all areas including
off-sites.
ESP status
Statistics of failure of rectifiers,
transformer / rapping and emitting motors
failures and overall status and record
maintaining.
Calibration and testing of relays and bus
bar of LT switchgears and maintain record
properly.
Electrical lab standard meters, measuring
and test equip. testing done from
recognized institute and recorded properly.
Major electrical equipment failure history
maintained in proper format.
SWITCHYARD EQUIPMENTS
Thermo vision scanning of switchyard
equipment done monthly.
Date of attending hot spot and the value
after attending should be recorded in format.
1.2
1.3
1.4
1.5
1.6
1.7
1.8
1.9
1.10
1.11
1.12
1.13
2.0
2.1
2.2
Status
OK/Not OK
Pl. give details
OK/Not OK
Yes /No
OK/Not OK
OK/Not OK
OK/Not OK
OK/Not OK
OK/Not OK
OK/Not OK
Done/ Not done
Yes /No
Yes /No
OK/Not OK
OK/NOT OK
OK/NOT OK
OK/NOT OK
Action Plan
(For Not Ok)
Page - 24
Rev. No.: 0
S.No.
Status
2.3
De-wedding done and plant cutting and

general condition.
Surge arrestor being checked and leakage
current/counter recorded in proper format.
Bay and transformer identification
provided.
Disturbance recorders auto recloser, event
loggers and distance to fault locators etc.
working satisfactorily.
GPS commissioning done.
Approachability of fire tender to
switchyard sufficient.
Oil level in HV bushing CT/CVT.
Isolators open and close operation done
with remote.
All recording instruments are available and
healthy.
Smoke detector healthiness in switchyard
and other areas checked by safety/fire
department in regular interval and recorded
the same.
Checking protection relays of switchyard
done on regularly annual basis and
recorded the same.
GENERATOR AND AUXILIARIES
Shaft earthing brushes connected.
Earth voltage monitored and recorded.
Stator winding/core temperature in
different point noted.
Consumption of H2 cylinder.
OK/NOT OK
2.4
2.5
2.6
2.7
2.8
2.9
2.10
2.11
2.12
2.13
3.0
3.1
3.2
3.3
3.4
Fire extinguishers near generator available.

3.5
3.6
3.7
3.8
3.9
3.10
3.11
Condition of silica gel in H2 (hydrogen)

drier and readiness of drier.
RSO and ELCID test carried out during
unit overhaul and recorded the same in
proper format.
Difference between hydrogen dew point
and cold gas temperature is more than 20
Degree centigrade.
Excitation room physical condition status
of air condition and thyristor panel blowers
area running condition.
Rotor winding temperature.
Cooling water for hydrogen cooler
Yes /No
Yes /No
Yes /No
OK/NOT OK
OK/NOT OK
OK/NOT OK
OK/NOT OK
Yes /No
OK/NOT OK
OK/NOT OK
Yes /No
Yes /No
Yes /No
OK/NOT OK
Yes /No
OK/NOT OK
Yes /No
OK/NOT OK
OK/NOT OK
OK/NOT OK
OK/NOT OK
Action Plan
(For Not Ok)
Page - 25
Rev. No.: 0
S.No.
3.12
3.13
4.0
4.1
4.2
4.3
4.4
4.5
4.6
4.7
4.8
4.9
4.10
4.11
4.12
4.13
5.0
5.1
5.2
5.3
5.4
5.5
5.6
5.7
Inlet pressure / inlet temp
Outlet pressure /outlet temp in limits
Hydrogen pressure and purity.
Availability/readiness of both stator water
and seal oil pump.
DC SYSTEM & DG SET
Smoke and gas detection sensor in battery
room installed and working.
Trial run of DC auxiliaries is being taken
regularly for checking healthiness.
Physical checking of battery room.
a) Ventilation system.
b) Cleanliness .
c) Wash basin in battery room.
Physical checking of battery.
a) Level of electrolyte.
b) Vent plug cleanliness (clogging).
c) Support insulator (crack).
All cells are in service (no by pass cell)
Checked DC earth fault at DC board and
found.
Battery terminals coated with petroleum
jelly
Cell voltage and Sp gravity of all cells
checked and recorded properly.
PM/OH/testing of all DCDB have done as
per schedule.
All trickle/boost charger are in service.
Trial run of DG set daily and recorded.
Checking of auto start of DG set checked
every day.
DG set battery sp. Gravity and voltage
checking regularly.
CABLE GALLARIES
Sufficient illumination available.
Emergency DC light available and
checking done every day.
Water logging water dripping checked in
wall way and found.
All cable entries are sealed.
Cable dressing/mounting found.
Smoke detector function checked and
found.
Water sprinklers in service and simulation
carried out regularly.
Status
OK/NOT OK
OK/NOT OK
Yes /No
Yes /No
OK/NOT OK
OK/NOT OK
OK/NOT OK
OK/NOT OK
OK/NOT OK
OK/NOT OK
OK/NOT OK
OK/NOT OK
Yes /No
Yes /No
OK/NOT OK
OK/NOT OK
OK/NOT OK
OK/NOT OK
Yes /No
OK/NOT OK
OK/NOT OK
Yes /No
Action Plan
(For Not Ok)
Page - 26
Rev. No.: 0
S.No.
Status
5.8
Testing of fire protection system carried

and recorded.
MOTORS
HT motor failure list available
Major reasons of failure recorded
Action taken to minimize failures
PM record for all motor
Testing equipment and all T&P available
for any type of motor maintenance
PLCC
Whether code sent and received counter
reading being recorded regularly.
Whether signal to noise level being
recorded regularly.
Tx & RX level from panel mounted meter
monitor regularly and recorded
TRANSFORMERS
Condition of silica gel
Condition of HT bushing
a) any crack
b) oil level
c) Any leakage
Mulsifyre system in service& system kept
in auto .
Protective wall around deluge valve
available.
Direction of rotation of oil cooler fans and
oil pumps to all transformers marked.
Physical condition of transformer
a) Painting.
b) Oil leakage.
c) Marshalling box.
d) Status of cooling fans and pumps.
Transformer
a) Double earthing of transformer.
b) Shorting between two sections of tanks
with flexible for proper continuity of
tank.
Whether all protection of transformer are
in service.
BDV/PPM/tan delta/acidity and resistivity
of oil test carried out by site at their lab
regularly and record these result in proper
format.
Neutral grounding resistance (NGR) is
being checked by site during overhaul.
OK/NOT OK
6.0
6.1
6.2
6.3
6.4
6.5
7.0
7.1
7.2
7.3
8.0
8.1
8.2
8.3
8.4
8.5
8.6
8.7
8.8
8.9
8.10
Yes /No
Yes /No
OK/NOT OK
OK/NOT OK
Yes /No
Yes /No
Yes /No
OK/NOT OK
OK/NOT OK
OK/NOT OK
Yes /No
OK/NOT OK
Yes /No
OK/NOT OK
OK/NOT OK
Yes /No
OK/NOT OK
OK/NOT OK
Action Plan
(For Not Ok)
Page - 27
Rev. No.: 0
S.No.
8.11
DGA results monitoring/recording &

sending sample as per requirement.
a) Any abnormality in annual test results.
Winding and oil temp at local and at
remote working satisfactorily.
COAL HANDLING PLANT
Availability and function of pull cord of
conveyors.
Availability and function of zero speed of
conveyors.
Effectiveness of MD,MS and ILMS and
their checking by site.
Effect of mill performance due to foreign
material checked from mechanical dept.
Availability and function of stacker and
reclaimer.
Flap gate operation done from remote or
local .
8.12
9.0
9.1
9.2
9.3
9.4
9.5
9.6
Status
Yes /No
OK/NOT OK
OK/NOT OK
OK/NOT OK
OK/NOT OK
Yes /No
OK/NOT OK
OK/NOT OK
OK/NOT OK
Action Plan
(For Not Ok)
Page - 28
Rev. No.: 0
Annexure 6 b
C&I CHECK LIST FOR TECHNICAL AUDIT
STATUS OF AUTO LOOPS (UNIT WISE)

Sl
No
1.
Description
CMC
2.
Drum Level
3.
Furnace Pressure
4.
Air Master
5.
Oxygen correction
6.
Fuel Master
7.
Mill Outlet Temp
8.
Mill air flow
9.
PA Header Pressure
10.
Deaerator Level
11.
Hotwell Level
12.
Auxiliary steam
13.
HP Bypass
14.
LP Bypass
15.
Soot blowing Pressure
16.
Auxiliary PRDS
17.
APH cold end temp Cntrl
18.
Gland steam control
19.
Status
Remarks/Action plan
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
# Any other loop not covered in the list and specific to the unit being audited
Page - 29
Rev. No.: 0
STATUS OF UNIT PROTECTIONS (UNIT WISE)

Sl
No
1.
Drum Level Hi Hi
2.
Drum Level Lo Lo
3.
Furnace pressure Hi Hi
4.
Furnace pressure Lo Lo
5.
Air Flow< 30%
6.
Loss of Flame
7.
Loss of Fuel
8.
Reheater protection
9.
11.
Loss of critical power

supplies ( 24 v/ 48v / 110v
etc)
Inadequate waterwall
circulation
Loss of ID fans
12.
Loss of FD fans
13.
All BFP trip
14.
15.
Turbine Lub oil Pressure

Low
Condenser Vacuum
16.
Axial Shift
17.
HPT exhaust temp
18.
Stator water flow
19.
Stator water conductivity
10.
Description
Status
Remarks/Action Plan
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
In service/Out of
service
20. #
# Any other protection not included in above list but specific to the unit being audited
In case of field initiated trips the healthiness of the intiating device to be checked.
Page - 30
Rev. No.: 0
STATUS OF OTHER MAJOR SYSTEMS (UNIT WISE)

Sl
No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Description
Status
Flue gas oxygen analysers

CO analysers
APH fire detection system
Opacity monitors
SOX/NOX analysers
Rotor stoppage system
Hydrastep system
Acoustic Pyrometers
Boiler tube leak detection
system
Bunker level monitoring
system
Condenser tube cleaning
system
CW/CT PLC system
CW/CT PLC local
instruments
Coal belt weighing system
Ash handling system
PLC
a) Bottom ash PLC
b) wet ash PLC
c) Dry ash PLC
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Remarks/Action PLan
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
16. Coal handling plant PLC

Ok/not ok
17. Mill reject system
Ok/not ok
18. Alkaliser system
Ok/not ok
19. Stacker/Reclaimer PLC
Ok/not ok
20. CHP vibration system
Ok/not ok
21. Chlorine leak detector
Ok/not ok
22. Hydrogen Leak detector
Ok/not ok
23. #
# Any other Instrument not covered in the list and specific to the unit being audited
Page - 31
Rev. No.: 0
STATUS OF UPS/DC SUPPLIES (UNIT WISE)

Sl No
Description
1.
Invertors in service
2.
Chargers in service
3.
Availability of alternate
source
4.
Percentage of load shared by
both invertors
5.
Percentage of load shared by
both chargers
6.
UPS room ambient
temperature
7.
Healthiness of cooling fans
8.
UPS panel cleanliness
9.
Any alarm appearing on
system
10. Healthiness of 24V/48V DC
chargers
11. Whether earth fault present
in any DC system
12. #
Status
Ok/not ok
Ok/not ok
Ok/not ok
Remarks/Action plan
Ok/not ok
deg C
Ok/not ok
Ok/not ok
Ok/not ok
# Any other point not covered in the list and specific to the unit being audited
STATUS OF ATT/ATRS (UNIT WISE)

Sl
No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
Description
Status
ATT control valves

ATT stop valves
ATT remote trip device-1
ATT remote trip device-2
ATT Vacuum protection
ATT thrust bearing trip
ATT overspeed -1
ATT overspeed -2
Frequency of ATT done
Status of ATT local Panel
Availability of ATRS
Availability of Auto
Done/ Not done

Done/ Not done
Done/ Not done
Done/ Not done
Done/ Not done
Done/ Not done
Done/ Not done
Done/ Not done
Remarks/Action plan
Ok/not ok
Ok/not ok
Ok/not ok
Page - 32
Rev. No.: 0
Sl
No
13.
14.
15.
16.
17.
18.
19.
20.
Description
synchronizer
Load shedding relay
Turbine expansion
measurements
Turbine pedestal vibration
measurements
Turbine shaft vibration
measurements
Eccentricity measurement
Key phasor measurement
Speed Measurement
#
Status
Remarks/Action plan
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
STATUS OF CER/UCB (UNIT WISE)

Sl
No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
Description
Status
UCB temperature
CER temperature
Dust ingress
Panel bottom sealing
Large video screen
CRT/Keyboard(OWS)
Printers
Recorders
Panel cooling fans
Indicators
Annunciation System
General cleanliness
Healthiness of Power
supplies
Healthiness of indication
lamps
#
.Deg C
.Deg C
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Remarks/Action Plan
Ok/not ok
STATUS OF SWAS (UNIT WISE)

Page - 33
Rev. No.: 0
Sl
No
1.
Description
Status
Ok / Not ok
4.
Boiler water cation

Conductivity Analyser
Condensate Cation
conductivity Analyser
Main steam cation
Conductivity Analyser
Steam Sodium analyser
5.
Feedwater Ph Analyser
Ok / Not ok
6.
Boiler water Ph analyser
Ok / Not ok
7.
Ok / Not ok
11.
12.
Condensate Dissolved
Oxygen Analyser
Feedwater Dissolved
Oxygen Analyser
Pressure gauges
Leakage in sampling
panels
Availability of samples
Chiller units
13.
Primary coolers
Ok / Not ok
14.
Secondary coolers
Ok / Not ok
15.
Rotameters
Ok / Not ok
16.
Cleanliness
Ok / Not ok
17.
Corrosion in sampling
table and analyser Panels
Ok / Not ok
18.
2.
3.
8.
9.
10.
Remarks/Action plan
Ok / Not ok
Ok / Not ok
Ok / Not ok
Ok / Not ok
Ok / Not ok
Ok / Not ok
Ok / Not ok
Ok / Not ok
# Any other analyser/point not covered in the list and specific to the unit being audited
Exceptions in status of other analysers not covered above to be recorded separately
Page - 34
Rev. No.: 0
STATUS OF FIELD INSTRUMENTS (UNIT WISE)

Sl
No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
Description
Status
LIE sealing
Dust/moisture ingress in
LIE
Leakages in impulse
piping/valves/transmitters
inside LIEs
Availability of purging air
Condition of purge
rotameter
Availability of instrument
identification
Lighting inside LIE
JB sealing
JB identification
Special identification for
trip related field devices
Condition of cable glands
Cable dressing
General condition of
copper tubing
General housekeeping
Condition of local gauges
ID/FD/PA lub oil systems
Healthiness of Sealing air
for Mill/ Feeders
Availability of scanner
cooling air
Check for dryness of
instrument air
Sealing
tightness/cleanliness of
Positioners/EP
converters/Feedback
transmitter
Healthiness of solenoids
Healthiness of electrical
actuators(C&I area)
#
Ok/not ok
Ok/not ok
Remarks/Action Plan
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Ok/not ok
Any specific exceptions noticed to be recorded on a separate annexure
Page - 35
Rev. No.: 0
STATUS OF C&I LAB

Sl
No
1.
2.
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Description
Availability of
electrostatic proof test
benches
Pneumatic test bench
Dead weight testers
Standard test multimeters
Signal sources
Temperature bath
Electronic test Jigs
a)..
Status
Ok/Not ok
Ok/Not ok
Ok/Not ok
Ok/Not ok
Ok/Not ok
Ok/Not ok
Ok/Not ok
b)..
Ok/Not ok
c)
Ok/Not ok
In circuit IC tester
Calibration records
System for component
storage
Provision of tags on
instruments
Instrument handling and
storage
#
Remarks/Action Plan
Ok/Not ok
Ok/Not ok
Ok/Not ok
Ok/Not ok
Ok/Not ok
GENERAL POINTS
Sl
No
1.
2.
3.
Description
Check recommissioning
protocols
Review of card failure
analysis records of C&I
lab
Review of C&I trip
analysis and check for
implementation of
recommendations
Status
Remarks/Action Plan
Ok/Not ok
Ok/Not ok
Ok/Not ok
Page - 36
Rev. No.: 0
Appendix 6c
OPERATION CHECKLIST FOR TECHNICAL AUDIT
STATION:
DATE:
STAGE:
UNIT:
A.
INPUTS FROM ORT / MONTHLY REPORTS
(Ref: Recent ORT / Monthly Reports)

S.N.
1.
2.
3.
4.
5.
6.
7.
B.
Description
Action Plan
Status
Deviation in Operational Parameters:

Deviation in System Compliance:
Exceptions in System/Equipment healthiness:
Unit Outage / Restoration related issues:
Operational constraints:
Safety issues:
Other issues:
PENDING POINTS FROM PREVIOUS TECHNICAL AUDIT / OTHER AUDITS
(Ref: Technical Audit Reports, Peer Audit Reports, Surprise Audit reports etc.)
S.N.
Description
Action Plan
Status
1.
C.
IMPLEMENTATION STATUS OF ACTION PLANS / RECOMMENDATIONS
(Ref: Status pertaining to operation area of various reports like, Efficiency reports, Enquiry
committee reports etc.)
Page - 37
Rev. No.: 0
S.N.
Description
Action Plan
Status
1.
D.
SYSTEM COMPLIANCE / SAFETY
D1.
AVAILABILITY OF IMPORTANT DOCUMENTS (IN CONTROL ROOM)

(Ref: Concerned records)
S.N.
1.
Description
b)
c)
d)
e)
f)
3.
4.
D2.
S.N.
1.
2.
3.
4.
Remarks /
Action Plan
Emergency instructions for:a)
2.
Status
Grid failure (instructions for UCE, desk

engineers, locations and switchyard).
Total AC failure of a unit.
Total DC failure of a unit.
Fire in air heater, mill or Main Oil Tank.
Purging out of Hydrogen from Generator.
Loss of instrument air.
Technical diary, Schematics diary and

Operation management book.
Integrated start-up procedures and operating
instructions
Disaster Management Plan
ROUTINE TESTING, SCHEDULED CHANGEOVERS ETC:
Description
Status
Availability and adequacy of routine testing

schedule of emergency equipments like DC lube
oil pump, DC JOP, DC seal oil pump, DC seal
water pump, DG set, DC lighting etc.
Routine testing details of emergency
equipments: (mention exceptions method of
rectification).
Equipment changeover schedule and its
implementation.
Schedule for ATT and its implementation:
Remarks /
Action Plan
Page - 38
Rev. No.: 0
S.N.
5.
6.
D3.
S.N.
1.
2.
3.
4.
5.
6.
7.
8.
9.
Description
Status
Remarks /
Action Plan
Status
Remarks /
Action Plan
Turbine protective devicesValves testingStatus of actual over speed test of main turbine
and TD BFPs.
Record of routine checking of cable galleries.
LOGGING / MONITORING:
Description
Availability and filling up of local log sheets.
- Details of cross checking by UCE/SCE.
Availability and filling-up of UCB log sheets.
Adequacy and completeness of data in log books
(should cover deviations w.r.to. loading, Sp. Oil
consumption, Aux. Power consumption,
equipment healthiness etc.) of SCE/UCE/desk
engineer etc. check for counter signature by
superior at random.
Availability of updated chemical analysis data,
with details of water analysis, oil analysis, PF
fineness analysis, coal analysis, ash analysis etc.
Regular monitoring of systems like SADC,
burner tilt etc.
Details of monitoring of boiler tube metal
temperature and furnace temp (Refer metal temp
excursion logs / DAS records).
Start-up monitoring. Record of boiler start-up
and turbine rolling parameters for each start-up.
Availability and usage of start-up check lists.
Monitoring of Heat Rate related parameters
- Steam parameters
- Condenser vacuum
- Air heater outlet temp.
- Unburnt carbon in bottom ash and fly ash
- Mill rejects
- HP heaters availability
- Make-up water consumption
(Details of exceptions, defect raising and followup)
10.
11.
Availability and usage of operator walk down

checklists (boiler).
Preservation of records as per Operation
Page - 39
Rev. No.: 0
S.N.
Description
Status
Remarks /
Action Plan
Management system.
D4.
S.N.
IMPLEMENTATION OF ANURAKSHNAN (OLMMS):

(Ref: Physical verification at OLMMS)
Description
Status
1.
Permit To Work system
2.
Defect raising and liquidating system
3.
Availability and Response of Terminals
D5.
FIRE FIGHTING SYSTEM AND PERSONAL SAFETY:

(Ref: Records and physical verification)
S.N.
Description
1.
Availability of fire water pumps (AC, Diesel and

booster pumps) along with auto operation.
Availability of Mulsifyre and sprinkler systems
in Auto.
Schedule and checking details of Mulsifyres for
transformers and oil tanks.
Adequacy of fire water pressure at higher and far
ends.
Schedule and checking details of Fire detection
system.
Any potential fire hazard and precautions taken /
to be taken.
Adequacy and coverage of permit to work
system and isolation procedures.
Proper identification / labeling of equipments,
switchgears, valves etc.
2.
3.
4.
5.
6.
7.
8.
Remarks /
Action Plan
Status
Remarks /
Action Plan
Page - 40
Rev. No.: 0
D6.
S.N.
1.
2.
3.
4.
TECHNICAL COMPLIANCE SYSTEM:

(Ref: Records and discussions)
Description
SYSTEM HEALTHINESS
E1.
PROTECTIONS, AUTO LOOPS ETC.:

(Ref: Actual status in control rooms and records)
Description
1.
Availability of all protections & interlocks:
2.
Whether the procedure for bypassing /

restoration of protections & interlocks is
followed (as per LMI):
Whether the method and frequency of checking
Protections and Interlocks as per LMI is
followed:
Availability / usage of all auto loops:
Availability and healthiness of annunciation
system:
Yearly checking of annunciation system
(including switchyard annunciation):
Availability and Adequacy of SOE log:
Availability and Adequacy of logs like Daily log,
Pre-Post trip log, start up log etc.:
Availability and Adequacy of DDCMIS / DAS
system:
Availability and performance of recorders,
indicators, hydrasteps etc.
Availability and usage of ATRS & TSE:
Availability and usage of SADC, burner tilt,
ERVS, etc. (including Auto Operation)
Availability and frequency of operation of soot
blowers
Wall Blowers:
LRSBs:
3.
4.
5.
6.
7.
8.
9.
10.
11.
12.
13.
Remarks /
Action Plan
Status
Remarks /
Action Plan
Availability of LMIs pertaining to operation

department
Adequacy and coverage of LMIs
Implementation status of LMIs and record
keeping
Status of Technical Compliance Audit
Recommendations
E.
S.N.
Status
Page - 41
Rev. No.: 0
E2.
S.N.
EQUIPMENT HEALTHINESS:
Description
1.
Major equipment failures during the last one

year:
2.
4.
Incidences of repeated failure and

recommendations for avoiding the same:
Details of equipment failure immediately after
overhaul
Equipments not available at present:
5.
Equipments erected, but not in use:
6.
Major Equipment defects:
7.
Any abnormal operation and precautions taken

thereof:
3.
E3.
S.N.
Description
Deviation of major parameters from rated
values, if any.
1.1
Boiler & Auxiliaries
1.2
Turbine & Auxiliaries
1.3
Generator & auxiliaries:
S.N.
1.
Remarks /
Action Plan
MAJOR PARAMETERS:
(Ref: Records and actual verification of unit and equipment parameters)
1.
E4.
Status
Status
Remarks /
Action Plan
Status
Remarks /
Action Plan
APPROACH, HOUSEKEEPING ETC.:

(Ref: Physical verification and discussions
Description
2.
Adequacy of housekeeping and areas for

improvement, if any.
Status of scrap and debris removal.
3.
Approach requirement, if any.

Page - 42
Rev. No.: 0
F.
FORCED OUTAGE REDUCTION

S.N.
Description
1.
Number of trips on account of Operation Human

Error and Recommendations to avoid the same.
Implementation of Trip Committee
recommendations pertaining to Operation.
Training needs, if any.
Ability of Operation staff to predict forced
outages based on operational data and actions
taken thereof.
Restoration of units after trip / outage:
2.
3.
4.
5.
Status
Remarks /
Action Plan
Status
Remarks /
Action Plan
Adherence to start up proceduresAdherence to start up duration6.

7.
8.
9.
10.
G.
S.N.
1.
Adherence unit/equipment shut down / lay up

procedures.
Constitution of recommissioning teams with
office order, clearly indicating responsibility.
Availability and usage of recommissioning
checklists and other protocols.
Details of protections and interlocks checking
during overhauls and availability of protocols.
Adequacy of defects identification prior to
overhauls and their liquidation.
COST CONSCIOUSNESS
(Ref: Verification of parameters and discussion)
Description
2.
Sensitivity of Operation staff to Commercial

issues like schedule, UI etc.
Efforts to maintain heat rate related parameters.
3.
Efforts in minimising downtime.
Page - 43
Rev. No.: 0
H.
MISCELLANEOUS
(To be compiled by discussion with selected O&M staff)
H1.
Any other specific technical problem / constraints being faced by station (w.r.t full load,
reliability, efficiency), its reasons & actions taken thereof:
Formulate recommendations and Action plan for the identified problems.
H2.
Incidents or occasions where due to vigilant Operation staff, a major failure / outage /
tripping was averted, reasons, analysis and learning thereof for the benefit of other stations.
-
DATE:
SIGNATURE:
Page - 44
Rev. No.: 0
Appendix 6d
BALANCE OF PLANT CHECK LIST FOR TECHNICAL AUDIT
AVAILABILITY OF EQUIPMENTS (A.H.S.)
S.NO. DESCRIPTION
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
Scraper Conveyor A
Conveyor-B
Standby Scrapper Conveyor
Clinker Grinder 1A/1B/2A/2B
Healthiness of Nozzles
Hydro Ejectors
Gate Operating Mechanism
BA.SP. Series A/B/C/D/E
Booster Pumps A/B/C/D/E
Sump Level Switchs
Disposal Ash Pipe Line 1/2/3/4/5
A.P.N./Econ. Hopper Flushing arra
ngement
P/H Drainage Pump A/B/C/D
PIT Isolating Gate Availability
ESP Flushing Boxes
Dry Ash Silo 1/2/3/4
Vacuum Pumps
U-1 A/B/C/D
U-2
Trans. Air Comp.
1A/1B/1C
2A/2B/2C
Ins.Air Comp.
1A/1B/1C
2A/2B/2C
Buffer Hopper Areation Blower
1A/1B/1C
2A/2B/2C
Silo Areation Blower
U-1/2/3/4
U-2
Air Drying Plant
1A/1B/1C
Fly Ash Extraciton Line Isolation
Valves Population
Fly Ash Extraction Line
Seggrating Valves Population
AVAILABILITY
STATUS
Avl/N.Avl.
REMARKS/ ACTION
PLAN
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Page - 45
Rev. No.: 0
S.NO. DESCRIPTION
22
23
24
25
Fly Ash Storage Silo

1/2/3/4
BAHP
1A/1B/1C/1D
2A/2B/2C/2D
FALP
1A/1B/1C/1D
2A/2B/2C/2D
PLCC Bottom Ash System
1/2/3/4
Fly Ash System
1/2/3/4
Dry Ash Eva.Sys.
1/2/3/4
AVAILABILITY
STATUS
Avl/N.Avl.
REMARKS/ ACTION
PLAN
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Compressors
1
2
3
1
2
3
4
5
6
7
1
2
Instrument Air Comp.

1/2/3/4
A.D.P. Blowers
1/2/3/4
Plant Air Compressors
1/2/3/4
C.W. System
C.W. Pumps
1/2/3/4/5
Lub Water Pumps
1/2/3/4/5
T.W.S.
1/2/3/4/5
Seal Water Pumps
1/2/3/4
Intake Channel Gate Operating
Mechanism
CT Pumps
1/2/3/4/5
Cooling Tower Fans
U#1 A1/A2/A3/A4
B1/B2/B3/B4
C1/C2/C3/C4
U#2 A1/A2/A3/A4
B1/B2/B3/B4
C1/C2/C3/C4
Misc. Pumps & Dm Plants
Raw Water Pumps
1/2/3/4
Service Water Pumps
1/2/3/4
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Page - 46
Rev. No.: 0
S.NO. DESCRIPTION
3
4
5
6
7
8
9
10
11
12
13
14
15
16
1
2
3
4
5
6
7
8
1
2
Clarified Water Pumps

1/2/3/4
Clarifoculator
1/2/3
Gravity Filter
Chlorinator
1/2/3
Acid Unloading Pump
1/2/3
Alkali Unloading Pump
1/2/3
Acid Metering Pump
1/2/3
Alkali Metering Pump
1/2/3
Filter Water Pump
1/2/3
Sludge Disposal Pump
1/2/3
Drinking Water Pump
1/2/3
Degassed Water Pump
De Gassed Blowrs
1/2/3/4
Booster Water Pump (Chlorinator)
1/2/3/4
Air Conditioning Unit
Chiller Water Pump
1/2/3/4
Condenser Water Pump
1/2/3/4
Air Washing Pump
Tg Bld 1/2/3
Esp Room 1/2/3
Lab Area 1/2/3
C.T. Fans
1/2/3/4
Vam. System
Compressors 1/2/3
Chiller Wate Pump
1/2/3
Condensate Water Pump
1/2/3
Air Handling Units 1/2/3/4
F.O.P. System
HSD Unloading Pump
1/2/3/4
HSD Pump
1/2/3/4
AVAILABILITY
STATUS
Avl/N.Avl.
REMARKS/ ACTION
PLAN
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Page - 47
Rev. No.: 0
S.NO. DESCRIPTION
3
4
5
6
7
8
9
HFO Unloaidng Pump

1/2/3/4
HFO Pump
1/2/3/4
Heaters
1/2/3/4
HSD Tanks
1/2/3
HFO Tanks
1/2/3
HFO Tank Heaters 1/2/3
Level Switches In Tanks
HSD
1/2/3/4
HFO
1/2/3/4
D.G. SET
DG set
1/2/3/4
AVAILABILITY
STATUS
Avl/N.Avl.
REMARKS/ ACTION
PLAN
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
Avl/N.Avl.
FIRE PROTECTION SYSTEM

S.NO. DESCRIPTION
STATUS
Avl/ Not.Avl.
2
3
4
5
6
7
8
9
10
11
12
13
14
Availability Of All Electric Hydrant

Pumps.
Availability Of All Diesel Engine
Driven Hydrant Pumps
Availability Of All Electric
Spray/Sprinkler Pumps
Driven Sprinkler Pumps
Availability Of All Electric Make Up
Pumps
Driven Make Up Pumps
Availability Of All Jocky Pumps
Availability Of All Hydro Pneumatic
Tank System
Availability Of All Hydrant Water
Loops
Availability Of All Spray/Sprinkler
Water Loops
Availability Of All Isolating Valves In
Hydrant System
Availability Of All Isolating Valves In
Spray Lines
Auto Start Of All Electric Hydrant And
Spray Pumps On Pressure Interlock Is
In Service
Auto Start Of Diesel Engine Driven
Hydrant And Spray Pumps On Pressure
Interlock Is In Service
REMARKS/
ACTION PLAN
Avl/ Not.Avl.
Avl/ Not.Avl.
Avl/ Not.Avl.
Avl/ Not.Avl.
Avl/ Not.Avl.
Avl/ Not.Avl.
Avl/ Not.Avl.
Avl/ Not.Avl.
Avl/ Not.Avl.
Avl/ Not.Avl.
Avl/ Not.Avl.
Yes/No
Yes/No
Page - 48
Rev. No.: 0
S.NO. DESCRIPTION
STATUS
15
Yes/No
16
17
18
Whether Leakage Takes Place In

Hydrant/Spray Pipelines
No. Of Hydrant Valves In
Service/Installed
Hydrant Pressure At Highest Point (To
Be Recorded)
Hydrant Pressure At Farthest Point (To
Be Recorded)
REMARKS/
ACTION PLAN
___ Nos/
___ No.
___ Kg./Cm2
___ Kg/Cm2
Transformers
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
Whether All Transformers Are Covered

By Emulsifier Spray System
Whether Emulsifier System Of
Transformers Is In Auto
Deluge Vlave Stations Proected By
Brick Wall Enclosure
Availability Of Soak Oil Pit
Quarterly Checking Of Deluge Vlave
System Is Done (Protocols To Be Seen)
Yes/No
Yes/No
Yes/No
Avl./N.A.
Yes/No
Cable Galleries
Whether All Cable Galleries Are
Covered By Smoke Detection And
Lhsc System
Whether All Cable Galleries Are
Covered By Water Spray System
System Kept In Auto
Whether Cable Galleries Are Inspected
Jointly Daily (Protocols To Be Seen)
Whether Cable Galleries Are Properly
Lighted And Free From Dust, Debries,
Stagnant Water Etc.
Whether Entry Points To Cable
Galleries From
Tg/Boiler/Switchgear/Cr/Cer Are
Properly Sealed
Whether Inter-Unit Fire Walls Provided
Whether Fire Rating Doors Provided In
Cable Galleries
Whether All Isolating Valves Are
Outside Cable Galleries
Whether Proper Drainage/Pumping
Arrangements Are In Place To Drain
Out Water In Case Spray System Is
Energised
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
MOT/DOT/COT, OIL TUNNEL

1
Whether All Areas Are Covered By
Yes/No
Page - 49
Rev. No.: 0
S.NO. DESCRIPTION
2
3
4
5
6
7
Fire Detection And Water Spray

System
Whether Routine Checking Of Fire
Detection Cum Water Spray System Is
Done (Protocols To Be Seen)
Whether Mots Are Proviced With
Brick Wall Enclosure
Whether Pipe Entry Points To Mot
Enclosures Etc. Are Properly Sealed
Whether Fire Rating Doors Are
Provide
Whether Mot Is Properly Sealed
Whether System In Auto
STATUS
REMARKS/
ACTION PLAN
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Seal Oil System

1
2
3
Whether Seal Oil System Provided

Yes/No
With Fire Detection Cum Water Spray
System
Whether Regular Checking Of The
Yes/No
System Is Done (Protocols To Be Seen)
System In Auto
Yes/No
Boiler Burner Front

1
2
Whether Regular Checking Of The Fire Yes/No

Detection Cum Water Spray System Is
Done (Protocols To Be Seen)
System Kept In Auto
Control Room, CER

1
2
3
4
5
Fire Detection System Is In Service

Halon/Inert Gas Flooding System
Provided
Halon/Inert Gas Flood System Kept In
Auto
Regular Checking Of System Done
(Protocols To Be Seen)
Whether Fire Dampers, Hvac
Interlocks Checked Regularly
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Switchgear / Battery Room/Excitation Room

1
2
3
Whether Smoke Detection/Heat

Detection System Kept In Service
Whether Regular Checking Of The
System Done (Protocols To Be Seen)
Cable Trenches Free Of Waste Paper,
Debries Etc.
Yes/No
Yes/No
Yes/No
Fuel Oil Tanks & Foph

Page - 50
Rev. No.: 0
S.NO. DESCRIPTION
STATUS
1
2
Yes/No
Yes/No
3
4
5
6
7
8
9
Foam System Provided In All Tanks

Foam System Of All Tanks Kept In
Auto
Spray System Provided In All Tanks
Spray System Kept In Auto
Fire Detection System In Foph
Provided
Fire Detection System In Foph Kept In
Auto
Water Spray System Provided In Foph
Water Spray System Of Foph Kept In
Auto
Regular Checking Of All System Done
REMARKS/
ACTION PLAN
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Conveyor Galleries & Chp

1
2
3
4
5
6
7
8
9
10
Whether All Conveyros, Transfer

Points, Crusher Houses Provided By
Fire Detection (Lhsc) And Water Spray
System/Sprinkler System
Whether Above Systems Kept In
Service And In Auto
Whether Irds Provided Are In Service
Whether Regular Checking Of System
Done
Whether Cable Trays Are Run Outside
Conveyor Galleries, Tps & Chps
Whetehr Cable Trays Are Vertical
Whether Hydrant Water Proided In All
Conveyor Galleries, Underground
Tunnels, Transfer Points, Crusher
Houses (Each Floor)
Whether All Areas Of Chp Are Free Of
Coal Dust, Debrie Etc.
Whether Fire Escape Stair Cases
Provided For All Transfer Points,
Crusher Houses, Trestles Of Long
Conveyors, Control Rooms
Status Of Implimentation Of Lmi
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
COAL HANDLING PLANT

A
1
2
Operation
Check system of issue of work orders
to maintenance section identifying
defects which require rectification
Whether all equipments are daily
In Place/Not In
Place
Yes/ No
Page - 51
Rev. No.: 0
S.NO. DESCRIPTION
2
3
4
7
8
B
1
2
3
4
5
6
7
8
9
checked by shift operation engineers

Whether walk-down check-lists are
followed and filled in by operation
staff
Whether change-over schedule is
dispayed and followed
Whether the following are in place
(a) PTW Register indicating the
equipment for which the PTW is issued
and cancelled in the shift.
b)
Equipment availability sheet.
c)
Log-book indicating the
operating hours, forced outages and
critical points requiring attention.
Availability of communication system
(PA system, telephones, wireless)
between the control room and different
equipment locations, mobile
equipments
Protection by-pass registered being
maintained
Availability of emergency supply in
control room , switchgear rooms,
tunnels etc. and its regular testing
CONVEYORS AND CONVEYOR
GALLERIES
Availability Of All Conveyors
Whether any oil leakage at gear
boxes/fluid couplings and the oil levels
are correct
Chutes are free from jamming and
choking and coal sliding surfaces are
smooth
Flap Gates can be operated from
remote
inspection doors are kept closed and
are dust proof
Sufficient lighting in all conveyor
galleries, tunnels, crusher house, TPs,
Bunker floor etc.
Availability Of All Protection Systems
Of Conveyors (Pull Cord, Belt Sway,
Zero Speed, Other Switches)
Availability Of Guards Over Couplings
Availability Of Belt Scrappers
STATUS
REMARKS/
ACTION PLAN
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Avl/ Not Avl
Yes/ No
Avl/ Not Avl
Avl./ Not Avl.

Yes/ No
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Avl./ Not Av.
Avl./ Not Av.
Avl./ Not Av.
Page - 52
Rev. No.: 0
S.NO. DESCRIPTION
STATUS
10
Yes/ No
11
12
13
14
15
16
17
18
19
20
21
22
23
24
25
26
27
28
29
30
31
Whether All Pulleys Of Conveyors Are

Properly Lagged
Whether Walkways Are Free From
Coal/ Debries Etc. And All Chequered
Plates/ Concrete Slabs Are In Place
Availability of sump pumps in track
hopper, under ground tunnels, control
rooms etc
Availability of all transformers,
incomers, MMCs, switchgear boards
Availability of Electro
Magnetic/Thrust Brakes on conveyor
drives
Adequate lighting in conveyor tunnels,
Crusher house, TPs
Availability of O&M manuals in
control room
Whether coal is stacked in layers of 11.5 m and compacted
Whether the philosophy of First in
First out is being followed in coal
stockyard and suitable record
maintained about the dates of stacking
and reclaiming in different segments of
each stock pile
Whether drains on sides of coal
stockyards are clean and away from
stock pile
Availability Of All Paddle Feeders
Any oil leakage from hydraulic circuit,
gear boxes and correct oil levels
Proper reeling and unreeling operation
AVAILABILITY OF ALL CRUSHERS
no leakage at gear box and fluid
couplings and the oil levels are correct.
Check vibration records to ensure
that these are within permissible
limits
Check availability of crusher vibration
probes
Availability Of All Vf/Vgf
Availability Of All Trippers
Availability Of All Belt Feeders
Availability Of All Stacker/Reclaimers
Availability Of All Suspended
Magnetic/Ilms
REMARKS/
ACTION PLAN
Yes/ No
Avl./ Not Av.
Avl./ Not Av.
Avl./ Not Av.
Avl./ Not Av.
Avl./ Not Av.
Yes/ No
Yes/ No
Yes/ No
Avl./ Not Avl.
Yes/ No
Yes/ No
Avl. /Not Avl.
Yes/ No
Yes/ No
Avl. /Not Avl.
Avl./ Not Avl.
Avl./ Not Avl.
Avl./ Not Avl.
Avl./ Not Avl.
Avl./Not Avl.
Page - 53
Rev. No.: 0
S.NO. DESCRIPTION
STATUS
32
33
34
Availability Of All Metal Detectors

Availability Of All Belt Weighers
Availability Of All Coal Sampling
Units
Availability Of All Wagon Tipplers
Availability Of All Dozers
Availability Of All De Systems
Availability Of All Ds Systems
Availability Of All Ds Pumps
Availability Of All Ventilation System
Availability Of All Crusher Vibration
Monitoirng System
Whether All Conveyors Are Of Fr
Grade
Whether Stone Picking Being Done
Whether proper & safe stone-picking
platforms are provided
Whether trestle bases in the vicinity of
stones are encased by concrete
Whether stones are regularly disposed
Average Life Of Coal Crusher
Hammers
Utilisation Factor Of
(1) Bunker Coneyors
(2) Track Hopper Conveyors
Genration Loss Due To Chp During
Previous Year
Whether Critical Spares Are Available
(Conveyor Belts, Crusher Hammers,
Idlers, Pulleys Etc.)
Availability of hooters
Availability Of All Protection Systems
(Pull Cord, Belt Sway, Zero Speed,
Other Switches)
Avl./Not Avl.
Avl./Not Avl.
Avl./Not Avl.
Availability Of Elevators
Availability Of Flap Gates/Rpgs
Availability Of Sump Pumps
Availability Of Hoists
Implementation Of Lmi
Conveyor Galleries, Underground
Conveyor Tunnels Are Free From Coal
Dust, Debries, Belt Pieces Etc.
Floors Of Transfer Points, Crusher
House, Bunker Floor Are Free From
Avl./ Not Av.

Avl./ Not Av.
Avl./ Not Av.
Avl./ Not Av.
Avl./ Not Av.
Yes/ No
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
54
55
56
57
58
REMARKS/
ACTION PLAN
Avl./Not Avl.
Avl./ Not Avl.
Avl./ Not Avl.
Avl./ Not Avl.
Avl./ Not Avl.
Avl./ Not Avl.
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Yes/ No
___MT
____HR
______MT/Hr.
______MT/Hr
___MU
Yes/ No
Avl./ Not Av.
Avl./ Not Av.
Yes/ No
Page - 54
Rev. No.: 0
S.NO. DESCRIPTION
59
60
61
62
63
64
65
66
67
68
69
70
71
72
73
74
75
76
Coal Dust, Debries Etc.

Any Stagnant Water In Underground
Tunnels, Floors Of Tps, Crusher
House, Bunker Floor Etc.
Whether Bunker Sealing Belt Is In Use
Whether Any Fires Exist In Stockyard
Whether Stacked Coal Is Compacted
Regularly By Dozer
Whether Stacked Coal In Stockyard Is
Sprayed With Water Regularly
Whether Skirt Rubbers, Discharge
Pulley Hoods Etc. Are In Place And
Successful In Arresting Dust/Spillage
Of Coal
Whether Drains In Chp And Stockyard
Are Clean
Whether Coal Slurry Settling Pits Are
In Service
Whether Grizzly Over Track Hopper Is
In Use
STATUS
REMARKS/
ACTION PLAN
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Availability of thruster operated hydraulic

rail clamps of Stacker Reclaimer
Availability of Manual rail clamps of
Stacker Reclaimer
Availability of all the thruster operated
Long Travel drive brakes of Stacker
Reclaimer
Availability of all thruster operate slew
drive brakes of Stacker Reclaimer
Whether Stacker Reclaimer is parked with
(a) boom in line with yard conveyor
(b) boom lowered at 4 below
horizontal, and
(c) boom locked by locking
device
Yes/ No
Whether Stacker Reclaimer is parked with

anchored during shut down and when gales
are imminent
Whether written operating work
instructions of Stacker Reclaimer are made
available to operation staff and pasted in
the beginning of its Log Book
Whether all start up/shut down check lists
of Stacker Reclaimer are made available to
operation staff and pasted in the beginning
of its Log Book
Whether all limit switches related to safe
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Page - 55
Rev. No.: 0
S.NO. DESCRIPTION
77
operation of stacker reclaimer are available

Whether height and width of coal pile is
STATUS
REMARKS/
ACTION PLAN
Yes/ No
not exceeded beyond designed values,

specially its distance from rails.
78
79
80
81
82
83
84
Availability of buffers and end stoppers of

stacker reclaimer
Availability of Manual rail clamps of
Tripper
Availability of all the thruster operated
Long Travel drive brakes of Tripper
Trippers
Availability of all the Long Travel drive
brakes of Paddle Feeders
Availability of all anti collision devices
- infra red type
- electro-mechanical
Paddle Feeders
Avl./ Not Av.

Yes/ No
Yes/ No
Yes/ No
Yes/ No
Yes/ No
Yes/ No
COOLING TOWER
1
2
Availability Of All Ct Fans

Condition Of All Spray Nozzles
3
4
Condition Of Fills, Splash Bars, Drift

Eliminators
Condition Of Water Distribution
Condition Of Rcc Structure
Position Of Algae Growth In Tower
Condition Of Cell Doors And Their

Sealing
Whether Overflow From Cold Water
Basin Is There
Avl./Not Av.
In Order/ Not In
Order
In Order/ Not In
Order
In Order/ Not In
Order
In Order/ Not In
Order
In Order/ Not In
Order
In Order/ Not In
Order
Yes/ No
Page - 56
Rev. No.: 0
Annexure-6e
STEAM TURBINE CHECK LIST FOR TECHNICAL AUDIT
Part-A
*Normally status should be positive , if otherwise, Explain its reason
there it self
Sl.
No.
Sub Area
Check point
Status*/
Readings
Main
turbine
Turbine full Load Capability
Yes/No
Is the machine on EHC (if provided)

Status of the Operating parameters e.g. Flow
Pr., Temp, Vibration etc.
No restriction in Control/Stop valve opening
Transient speed rise during full load throw off
Yes/No
Coasting down time

Check frequency of Overspeed testing
Check Frequency of Oil Injection testing
Rise in HP exhaust temperature during hot
trip outs
Yes/No
Normal /
Abnormal
Normal /
Abnormal
HP/LP Bypass system is available on auto and Yes/No

fast opening mode is av.
Opening of gland steam leak off valve is
normal (Bypass and control valve)
Check that no major /high energy drain is
passing
Rated vacuum attainability (Load restriction)
Yes/No
Check that ATRS is being used regularly

during rolling
Check that ATT is being performed and
frequency of testing (Safety devices and
valves)
Check start up procedure (Randomly, to see
that steam quality is maintained and no
parameter excursion is taking place from
startup time till rated load)
Yes/No
Check that no major oil/water/steam leakage

is taking place.
Yes/No
Lub Oil and Status of the Operating parameters e.g. Flow

Control
Fluid
system
OK/
N. OK
Yes/No
Yes/No
Reason
for
Deviation
Action
Plan
Page - 57
Rev. No.: 0
Sl.
No.
Sub Area
Check point
Status*/
Readings
Check that AOPs are available
Yes/no
Check that DCEOP is available and being

tested regularly and its pressure being
recorded.
Yes/No
Check that Centrifuge is av. And being run

regularly
Yes/No
Check that Oil vapor extraction fans are av.

And running
Yes/No
Check that oil samples are being tested

regulalrly for oil properties , externally also
Yes/No
and
frequency
Yes/No
Check that MOT room is clean and well

illuminated
Check that frequency of choking of duplex
filter is normal
Yes/No
Check That Mot Room ventilation is working
Yes/No
Check Lub oil and FRF oil consumption
Normal/A
bnormal
Yes/No
Check that central oil purification system is

available and oil top up is done through it
Check that Standby FRF pump is av.
Regenerative Check Availability of Heaters
System
Check performance of Heaters
Yes/No
Yes/No
Check that HP heater bypass protection on

level high-2 is in service
Check standby Vacuum pump/Ejector is av.
Yes/No
Is there is any major leakage
Y/N
Yes/No
Feed Pumps Status of the Operating parameters e.g. Flow

Check that recirculation valve is not passing
excessively
Availability of standby BFP (auto standby
mode)
Yes/No
Check source of steam to TDBFP (If

applicable)
Condensate Standby Availability (Auto start selection)
Yes/No
Reason
for
Deviation
Action
Plan
Page - 58
Rev. No.: 0
Sl.
No.
Sub Area
Check point
Status*/
Readings
No. of pumps operating vis--vis load

Condenser, Check that condenser performance is normal,
Evacuation if not identify causes of poor performance
System and
CW
Check Condenser on load tube cleaning
system availability, records of operating hours
& balls consumption
Yes/No
No. of tubes plugged in condenser

Check the frequency of operation of
Condenser priming system
Common
General
Check that vacuum is being maintained with

one ejector/Vacuum pump and standby
Vacuum/Ejector is av.
Yes/No
Standby CW pump availability
Yes/No
Overhaul preparedness w.r.t spares,Contracts

etc.
Check Overhauling Protocols are av., critical
checks witnessed by FQA
Yes/No
Yes/No
Performance of Plate Heat Exchangers

Check that applicable LMIs are av. with
TMD and same being followed
Yes/No
Check Housekeeping in Turbine and Aux.

area
OK/N.OK
Any other Check

observation
from ORT
Stores
Check for store-preservation guidelines
Preservation availability and formation of stores
preservation cell. Check codification of stores
material as per NTPC policy
Sample check for stacking and allocation of
spares bin as per NTPC store system
Check for adequacy of covered space for
keeping the spares
Check for adequacy of handling equipments,
lifting tool and tackles
Check adequacy of fire fighting system and
availability in gas cylinder store, spare stores
Reason
for
Deviation
Action
Plan
Page - 59
Rev. No.: 0
Sl.
No.
Sub Area
Check point
Status*/
Readings
and oil & chemical stores

Checks for availability of first aid box and
water shower
Check availability of hot and cold room for
storing relevant material
Check formation of inventory control cell and
steps taken by station in controlling inventory
level
Check preservation of turbine, generator,
rotors, journals and their rotation once in six
months
Reason
for
Deviation
Action
Plan
Page - 60
Rev. No.: 0
Part- B Qualitative aspects

S.No.
Aspects
1.
Effectiveness of
recent Overhaul
2.
Maintenance
cost
Optimization
3.
Reliability
4.
Efficiency
Safety
Station Best
Practice (if any)
Any other
applicable
7.
Observation
Deviation
Action
Plan
Pre and Post O/H

efficiency gains
Any problem with in
6 months of overhaul
Repetitive jobs
Evaluate Over/under
maintenance from
Breakdowns/Failures
trend
Root cause of the major
failures and subsequent
corrective action evaluation
Trending of cylinder
efficiency
Other measures to maintain
equipment efficiency
Turbine Hall EOT crane
testing
Fire protection
system/,measures
Part-C
S.N.
Description
Details
Incidents or occasions where due to
vigilant Operation staff, a major failure /
outage / tripping was averted, reasons,
analysis and learning thereof for the benefit
of other stations.
Design Modifications done by site in the
system /Equipment (To be listed and
observed)
Page - 61
Rev. No.: 0
Annexure-6f
CHEMISTRY CHECK LIST FOR TECHNICAL AUDIT
STATION :
PERIOD OF AUDIT:
S.NO. AREA/SYSTEM/SUB-SYSTEM
1.
PT PLANT (for DM plant)
1.1
Chemical House
Alum tanks
Alum tanks agitators
Alum tanks level indicators
Alum dosing pumps/gravity dosing
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
Lime slaking tanks

Lime dosing tanks
Lime tanks agitators
Lime tanks level indicators
Lime dosing pumps/gravity dosing
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
Chemicals storage area

Chemicals lifting arrangements
House keeping
1.2
OK/ Not OK
OK/ Not OK
OK/ Not OK
Clariflocculators
1.3
STATUS
Aeration tower cleanliness

Clariflocculator cleanliness
Flow meter
Flash mixer
Bridge
Flocculating agitator
De-sludging facility
Leakage/painting
Cleanliness of surrounding area
Clariflocculator performance
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
PT Chlorination plant
Chlorinator
Lifting arrangement for cylinders
OK/ Not OK
OK/ Not OK
ACTION PLAN
(for Not OK)
Page - 62
Rev. No.: 0
1.4
Weighing arrangement for cylinders

Safety kit
Cl2 leak absorption system
Leak detectors/Alarms
Exhaust fans
Display of safety instructions
House keeping
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
Filtration plant (gravity/pressure)
Backwash frequency
Backwash water requirement
Level indicator
Blower
Filter water pump
Instruments (LOH/ROF)
Media availability for top up
Performance of filtration plant
House keeping
2.
PT PLANT (for CW system)
2.1
Chemical House
Alum tanks
Alum tanks agitators
Alum tanks level indicators
Alum dosing pumps/gravity dosing
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
Lime slaking tanks

Lime dosing tanks
Lime tanks agitators
Lime tanks level indicators
Lime dosing pumps/gravity dosing
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
Chemicals storage area

Chemicals lifting arrangements
House keeping
2.2
STATUS
OK/ Not OK
OK/ Not OK
OK/ Not OK
Clariflocculators
ACTION PLAN
(for Not OK)
Page - 63
Rev. No.: 0
2.3
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
CW Chlorination plant
2.4
Aeration tower cleanliness

Clariflocculator cleanliness
Flow meter
Flash mixer
Bridge
Flocculating agitator
De-sludging facility
Leakage/painting
Cleanliness of surrounding area
Clariflocculator performance
STATUS
Chlorinator
Evaporator
Lifting arrangement for cylinders
Weighing arrangement for cylinders
Safety kit
Cl2 leak absorption system
Leak detectors/Alarms
Control panel
Exhaust fans
Display of safety instructions
House keeping
Filtration plant (gravity/pressure)
Backwash frequency
Backwash water requirement
Level indicator
Blower
Filter water pump
Instruments (LOH/ROF)
Media availability for top up
Performance of filtration plant
House keeping
3.
DM PLANT
3.1
DM Streams
ACTION PLAN
(for Not OK)
Page - 64
Rev. No.: 0
Internal inspection (once/2-years):
1. ACF
2. WAC
3. SAC
4. DG
5. WBA
6. SBA
7. MB
ACF/Resins testing (once/year)
Spare ACF/Resins availability
Spare resin storage conditions
Stream output/Quality
Instrumentation in DM stream
Press./DP gauges in DM stream
Flow meters in DM stream
Degasser performance
3.2
Done/ Not done

Done/ Not done
Done/ Not done
Done/ Not done
Done/ Not done
Done/ Not done
Done/ Not done
Done/ Not done

OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
DM plant Control room
3.3
STATUS
Integrators
Analyzers
Alarms
Mimic
Regeneration mode
(Auto, semi-auto, manual)
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
Used/ Not used
Regeneration system
Acid storage tanks condition

Alkali storage tanks condition
Level indicators, acid storage tanks
Level indicators, alkali storage tanks
Fume absorbers, acid storage tanks
CO2 absorber, alkali storage tanks
Alkali filter
ACTION PLAN
(for Not OK)
Page - 65
Rev. No.: 0
3.4
Alkali heating system

Acid/Alkali unloading system
Acid/Alkali dosing pumps
Acid/Alkali ejector system
Condition of pipes/vessels
Flushing arrangements
Showers/Eye-washers
Exhaust fans
Equipment/structure condition
STATUS
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
Done/ Not done

OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
Neutralization pit
3.5
Pit condition
pH meter
Effluent disposal pumps
Recirculation/mixing system
DM Water storage tanks
Internal inspection (once/2-years)

Level indicators
CO2 breathers
Over flow seal
Conductivity meter, makeup line
4.
SOFTENING PLANT
4.1
Softener Streams
Internal inspection of exchanger
vessels (once/2-years):
Done/ Not done
Resins testing (once/year)
Done/ Not done
Spare Resins availability
OK/ Not OK
Spare resin storage conditions
OK/ Not OK
Stream output/Quality
OK/ Not OK
Instrumentation in softener stream
OK/ Not OK
ACTION PLAN
(for Not OK)
Page - 66
Rev. No.: 0
4.2
STATUS
Press./DP gauges in softener stream
OK/ Not OK
Flow meters
OK/ Not OK
Softening plant Control room
4.3
Integrators
Analyzers
Alarms
Mimic
Regeneration mode
(Auto, semi-auto, manual)
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
Salt solution preparation area

Condition of salt lagoon
Mixing arrangements
OK/ Not OK
OK/ Not OK
OK/ Not OK
ACTION PLAN
(for Not OK)
Page - 67
Rev. No.: 0
5.
5.1
CONDENSATE POLISHING PLANT

CPU operation
Online instruments
STATUS
OK/ Not OK
OK/ Not OK
Regeneration system
Acid/alkali storage vessels

Alkali filter/heater
Regeneration vessels
Pumps
Air blowers
Control panel
Neutralization/pH meter
6.
STEAM-WATER CYCLE
MONITORING
6.1
Core level instruments
Cation conductivity, Condensate

Cation conductivity, Feed water
Cation conductivity, Main steam
Cation conductivity, Boiler water
Sp. Conductivity, Makeup
pH, Boiler water
Dissolved O2, Condensate
Dissolved O2, Feed water
Sodium, Condensate
Sodium, Steam
ORP, Deaerator inlet (for mixed
metallurgy units)
Alarms provided in control room for
core parameters
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
Yes/ No
ACTION PLAN
(for Not OK)
Page - 68
Rev. No.: 0
Other online instruments provided
a
b
c
d
e
.
.
.
Inter comparison with lab testing
Sample temperature
7.
8.
STATUS
.
.
.
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
OK/ Not OK
CHEMICAL DOSING SYSTEM

LP dosing
HP dosing
OK/ Not OK
OK/ Not OK
CHEMICAL LABORATORY
9.
10.
Water testing facility
OK/ Not OK
Oil testing facility
OK/ Not OK
Coal sampling/testing facility
OK/ Not OK
Flue gas testing facility
OK/ Not OK
Generator H2 testing facility
OK/ Not OK
Instruments calibration records
OK/ Not OK
Testings (as per code of practice)
OK/ Not OK
LMI STATUS
LAST AUDIT POINTS STATUS
STATION:
PERIOD OF AUDIT:
ACTION PLAN
(for Not OK)
Page - 69
Rev. No.: 0
Annexure-6g
EFFICIENCY CHECK LIST FOR TECHNICAL AUDIT
1.0
Deviation in parameters affecting heat rate
Deviation in Turbine Heat Rate

Readings of parameters taken when Unit is running at full load
Date :
Unit
:
Parameter
Design
value
Actual
value
Deviation in
Parameter
Deviation in Turbine
heat rate from design
(Kcal/KWH)
Main steam temp. (oC)

Main steam pressure (Kg/cm2A)
Hot reheat temp. (oC)
F.W. temp. before economizer (oC)
Superheater spray flow (T/H)
Reheater spray flow (T/H)
HP turbine cylinder efficiency (%)
*
IP turbine cylinder efficiency (%)
*
Condenser back pressure (mm of
Hg)
Make-up water consumption
(T/H)
Reheater pressure drop (Kg/cm2)
* These are derived / calculated parameters
Note : 1. Instantaneous readings to be taken at full load and unit parameters in stabilized
condition
2. 3-4 readings with a gap of 5 minutes may be taken and averaged out.
Deviation in Boiler Efficiency
Loss component
Design
Actual
Difference
Page - 70
Rev. No.: 0
Dry flue gas loss (%)
Wet flue gas loss (%)
Unburnt carbon loss (%)
Page - 71
Rev. No.: 0
2.0
COMPONENT LEVEL ANALYSIS OF HEAT RATE DETERIORATION

Losses accounting to controllable/ uncontrollable factors
Boiler
Boiler
Design Actual
(1)
Dry flue gas loss (%)
(2)
(3)
Actual
corrected for
design coal
quality and
design
ambient
temperature
(4)
Deviation Controllable Uncontrolla

(Actual loss (Actual
ble loss
-design)
corrected
(Actual
-design)
corrected
actual )
(5)
(4-2)
(6)
(4-3)
(7)
Wet flue gas loss (%)

Unburnt carbon loss
(%)
Turbine :
Parameter
(1)
Condenser
back
pressure
Design
Actual Controllable Uncontrollab Controllable

corrected deviation in le deviation loss in T.H.R
for design parameter in parameter
CW inlet
(4-2)
(4-3)
temp.
(mmHg) (mmHg) (mmHg)
(mmHg)
(mmHg)
(Kcal/KWh)
(2)
actual
(3)
(4)
(5)
(6)
(7)
Uncontrol
lable loss
in T.H.R
(Kcal/KW
h)
(8)
Page - 72
Rev. No.: 0
3.0
A.
Reason for deviation & improvement plan

Reason for low Turbine Heat Rate and Improvement plan
Date :
Unit :
Parameter
Reason
Yes/No
Main
steam
temp. S/H spray more than required
lower than design (oC)
Low heat transfer in S/H zone
Other
Main steam pressure Less coal firing
lower than design
Poor coal quality
Other
Hot reheat temp. lower More than required R/H spray
than design
flow
Lower mills in service
Poor coal quality
Burner tilts negative
Other
F.W. temp.
before Heater out of service
economizer lower than
design
Air entrapped in heater
Heater level not optimum
Drip cooler zone problem
Heater tubes fouled
Many tubes plugged
Heater
bypass
valve
open/passing
Other
Superheater spray flow Passing of spray valve
higher than design
Problem in spray control circuit
More heat absorption in S/H
Other
Reheater spray flow
Passing of spray valve
Problem in spray control circuit
More heat absorption in R/H
Other
Action plan
for
improvement
Page - 73
Rev. No.: 0
Parameter
Reason
Yes/No
HP turbine cylinder Increased steam path area

efficiency lower than
design
Reduced steam path area
Mechanical damage
Increased tip seal leakage
Increased gland seal leakage
Other
IP turbine cylinder Increased steam path area
efficiency
Reduced steam path area
Mechanical damage
Increased tip seal leakage
Increased gland seal leakage
Other
Condenser
back Low C.W inlet temperature
pressure
less
than
design
Air ingress in condenser
Fouled condenser tubes
Low CW flow
High steam load
Other
Make-up
water Leakages
consumption more than
design
High CBD opening
Unwanted opening of drain
valves to atmosphere
More flow to APRDS
Other
Reheater pressure drop
more than design
Action plan
for
improvement
Page - 74
Rev. No.: 0
B. Reason for low Boiler efficiency & improvement plan
Date :
Unit :
Higher than design
dry F.G loss
High O2 in F.G at
APH exit
High F.G temperature

at APH exit
Higher than design

Unburnt Carbon loss
High Unburnt in ash
Higher than design

wet F.G loss
Reason
Yes/No
High APH seal leakage

High air in leakages in Boiler
High air flow through fans
Other
Low efficiency of APHs
Soot deposit in Boiler
Low heat absorption in Boiler
elements
High ambient air temperature
Low air flow through APH
Other
Improper combustion due to
Disturbed F/A ratio
Mill fineness not proper
Low flame temperature
Low secondary air
temperature
Low mill outlet temperature
Low mill air flow
High air velocity
Eroded coal nozzle tips
High ash content in coal
Uncontrollable
Other
Higher
coal
Higher
coal
Higher
temp.
Higher
air
Other
than design Moisture in Uncontrollable

than design Hydrogen in Uncontrollable
than design ambient air Uncontrollable
than design moisture in Uncontrollable
Action Plan
Page - 75
Rev. No.: 0
4.0
Efficiency testing schedule vs. Actual
Whether site is carrying out periodic efficiency tests of following equipment/ systems of
Units. Random checking of the reports of the efficiency tests carried out by site.
1. Routine Test
EFFICIENCY TEST
RECOMMENDED
ACTUAL DONE - UNITS Y/N
SCHEDULE
1
2
3
4
5
Mill fineness
All the mills of one unit
once in a week.
Clean air flow test
At the time of major mill
overhaul.
Dirty air flow test
Once in 6 months
APH Seal leakage
Once in 15 days
APH gas side efficiency
Once in 15 days
Boiler efficiency test
Once in 3 months
Condenser performance Whenever
vacuum
test
deteriorates from target
value.
Turbine
cylinder Once in 6 months
efficiency & Pressure
survey
FW heaters performance Once in 6 months
test
1. Pre & Post O/H tests
EFFICIENCY TEST
ACTUAL DONE - UNITS Y/N

1
2
3
4
APH Seal leakage

APH gas side efficiency
Boiler efficiency test
Condenser performance test
Turbine cylinder efficiency & Pressure
survey
FW heaters performance test
Cooling Tower Performance
Turbine Heat rate & H.R deviations due
to parameter
Page - 76
Rev. No.: 0
To check whether recommendations on the basis of test results have been

generated and intimated to the concerned maintenance department.
Liquidation of all deficiencies highlighted in the efficiency tests.
Checking the actions taken for reducing Heat Rate deviation as detailed in
ORT.
Discussing the H.R deviations in planning meeting.
To Check implementation of the Recommendations of Task Forces / Committees etc.

as applicable, on efficiency related issues.
To check the working of POG H
Page - 77
Rev. No.: 0
Annexure 6h
GT & AUXILIARIES CHECK LIST FOR TECHNICAL AUDIT
I)
CONTROL ROOM CHECK LIST
Sl. No.
Description
1
Operation log book recording (Based on present and
past date)
3
4
5
6
7
8
9
10
11
12
Status
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
Bearing oil Pressure
Pressure of each pump of flow divider
Water Injection, if applicable
NOx values (on liquid and gas)
Witness of one start up ;and shutdown already recorded
and comparison with commissioning data
Coasting down time
Start up time
Operation of Safety Devices
Checking of availability of Instructions of starting of gas
turbine in emergency / black out conditions &
Instructions for handling emergencies.
Gas Chromatograph checking and comparison of calorific
value of NTPC and GAIL.
Fire alarm panel indicator, printer and hooter healthiness
checking
Availability of DC light in CCR
Checking of CO2 / halon system, status manual/auto
Recording of routine testing, DC oil pump starting and
overspeed testing.
Mode of Turbine operation load control / temp. control
Availability and implementation status of fuel purging
system
Record of Fuel Testing for trace metal of HSD / Naptha
carried out.
Implementation / status of dust particle monitoring at
Remarks
Page - 78
Rev. No.: 0
Sl. No.
13
14
II)
Description
down stream of air intake filter
Checking healthiness of Fire sensor in GT compartment
and associated areas.
Frequency of online/offline compressor wash and its
optimization.
Status
Remarks
Status
Remarks
OPERATION / PERFORMANCE TEST
Sl. No.
Description
1
Compressor efficiency
2
3.
4
5
6
7
8
III)
Real time heat rate analysis and assessment of output on

the basis of one hour test and heat rate deterioration
Comparison with heat rate and output in open and output
combined cycle being observed in the past
Changeover schedule
Routine tests of turbine equipment like AOP of
GT/DCLOP, GT black start of DG set, Fire fighting diesel
set, Gas and Naphtha leakage detection.
Air intake filters Differential Pressure analysis and
optimization of filter with past data
Fuel check relief valve setting of liquid fuel system
Actual overspeed test after overhaul to be ensured from
record
REVIEW OF VARIOUS INSPECTIONS WITH RESPECT TO REPAIR /
REPLACEMENT TO ACHIEVE TARGET AVAILABILITY
Sl. No.
Description
1
Site preparation in respect of spares and T&P for
combustion chamber inspection, HGPI and major
overhaul
2
Action plan of various inspections
3
Work as per Quality overhaul norms & FQA involvement
in it
4
Adherence to manufacturers guidelines and NTPC
directives
5
Air intake filter stock position and date of last replacement
6
Bypass damper position and reliability analysis
7
Equipment performance data history and dearation
analysis
8
Engineering declaration document issue before overhaul
9
Check deposits on IGV for oil / grease (fouling) and
compressor washing during A&B inspections.
10
Review of records of healthiness of various control valve
settings of governing system
11
Assessment report of inspections for hot gas bath
Status
Remarks
Page - 79
Rev. No.: 0
Sl. No.
Description
Status
Remarks
Status
Remarks
components.
IV)
OEM RECOMMENDATIONS FOR NEXT OVERHAUL
Sl. No.
Description
1
Check the report of OEM of previous overhauls and
ensure NTPCs comments have been sent to OEM and
obtained recommendations.
2
Check whether earlier recommendations were
incorporated in overhaul
V)
DEVIATIONS OBSERVED DURING ORTs
S.N
DESCRIPTION
VI)
STUDY OF MAJOR BREAKDOWNS IN GT & AUX. AND ANALYSIS AND

RESOLUTION ALONGWITH ACTION PLAN
ANALYSIS REWNAL
SOLUTION
Sl. No.
Description
1
Major equipment failure records checking and capturing
from ORT, root cause analysis, recommendations and
action taken
2
Refurbishment plan of used Hot Gas Path components
and blades / vanes and action taken for recoating/repairs
and their availability emergency revival.
3
Vanes/Buckets replacement plan
4
Hot gas path parts requirement for next overhaul
alongwith the status of stock
5
Awareness of technical compliance system and ensuring
its availability at work station.
6
Status of refurbishing as per contract
VII)
Status
Remarks
Status
Remarks
FIRE PROTECTION SYSTEM OF GT AREA
Sl. No.
Description
1
Checking of the weight of all CO2 cylinders of main and
standby headers
2
Checking of local alarm (hooter)
3
Checking of alarm window on local and CCR.
4
Checking of healthiness of nozzles on MOT and
combustion chambers
Page - 80
Rev. No.: 0
VIII) ANALYSIS OF LUBE OIL SYSTEM (GT AREA), LIQUID FUEL AND GAS
WITH ESPECT TO GCV, TRACE METAL AND CONDENSATE
Sl. No.
Description
1
Fuel oil, gas and lubricants chemical analysis and
comparision with design.
2
Lube oil consumption per month / hr. and its trend
3
Date of last centrifuging of MOT oil & date of last
changing of oil
4.
Settlement time being observed in liquid fuel, tanks before
firing.
IX)
Sl. No.
1
2
3
4
5
6
XI)
Sl. No.
1
2
3
4
5
6
7
8
9.
10.
Remarks
Status
Remarks
HOUSE KEEPING IN GT AREA
Sl. No.
Description
1
House keeping around GT area & its healthiness
2
Checking of oil pits and its schedule for removal.
3
Checking of levels in condensate separator of fuel gas line
X)
Status
SPARES INVENTORY AND STORES VERIFICATION (GAS TURBINE

PORTION)
Description
Availability of mandatory spares
Spares availability for future inspection
O&M spares status
Status of preservation of spares as per OS/OEM guidelines
Frequency of Area Engineers visits to stores
Check the Material Management System (OLYMFAS)
Status
Remarks
Status
Remarks
WALKDOWN CHECKS
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
Air intake filter conditions
Expansion joint healthiness
Illumination
Availability of operators record keeping and preparedness
to handle emergency.
Page - 81
Rev. No.: 0
XII)
S.N
1.
2.
3.
4.
REPAIR AND MAINTENANCE COST OF GAS TURBINES (LAST 2 YEAR

COMPARISON)
DESCRIPTION
Cost of routine mtc.
Cost of overhaul spares
Cost of service agencies for O/H overhaul
Expatriate cost of supervision
STATUS
REMARKS
XIII) EXTENT OF EXPERTISE AVAILABILITY:

S.N
DESCRIPTION
STATUS
1.
2.
Expertise availability in inspection/overhaul

Expertise availability in operation
REMARKSTraining
needs
XIV) IMPROVEMENT CARRIEDOUT IN GAS TURBINES AND ITS

APPLICABILITY FOR OTHER STATIONS
S.N SUB AREA PROBLEM

ANALYSIS
DESCRIPTION
1.
XV)
Air intake Filter Cloggy

system
SOLUTION
IMPLEMENTED
ADAPTABILITY
TO
OTHER
STATIONS
Fine dust Use of socks in Yes
and carbon first row
deposits
on
top Change of filter
of 1st row
layer
FORCED OUTAGES OF GTS FOR LAST ONE YEAR
Page - 82
Rev. No.: 0
Annexure 5i
Check List of Quality Management System for Technical Audit
Area to be audited : Quality Management System Implementation at the Plants
different areas.
S.No.
01
02
03
04
05
06
Description
Remarks
Whether manual on Quality Management in Maintenance
Yes/No
(OGN:018:2002 and Vol. I, IIA, IIB are available at Site with different
deptts. I.e. FQA, MTP, Maintenance Groups.
Whether the above mentioned documents are being followed at Site
Yes/No
during O/H and Preventive Maintenance works.
Whether detailed work plan to be taken up during O/H has been drawn
Yes/No
by Site and copies are available with MTP and other maintenance
groups.
Whether protocols as per guidelines given in Vol. IIB, Quality
Yes/No
Management in maintenance/overhauling (OGN:018:2002) are being
maintained and signed by FQA and Maintenance representative.
Whether FQA set up at Site is adequate.
Yes/No
Extent of involvement in O/H and other Preventive Maintenance work. Adequate /
Not Adequate
(Copy of FQA organization chart with brief details of work being done by them to be
collected).
S.No.
07
08
Description
Whether FQA group is being strengthened during O/H by placing
executives from other O&M Deptts. particularly in Boiler and Auxiliaries
area.
Check for the adequacy of following Inspection and Testing Facilities
available at FQA laboratory:
i)
Radiography (source and film developing facilities
ii)
Ultrasonic Testing machine with trained operator (make and
capacity of machine
iii)
Whether trained manpower is available for handling radioactive source and ultrasonic testing machine
iv)
Magnetic Particle Inspection facilities (MPI) with trained
Manpower
v)
Dye Penetrate Test facilities (DPT) with trained manpower
vi)
Universal testing machine for Mechanical Testing with
trained operator
vii)
Hardness and Impact Testing machine
with trained operator
viii) Testing facilities for civil items i.e. cement, aggregate, concrete
cubes, bitunum, etc. with trained manpower
Remarks
Yes/No
(Y/N)
(Y/N)
(Y/N)
Y/N)
(Y/N)
(Y/N)
(Y/N)
(Y/N)
(Y/N)
Page - 83
Rev. No.: 0
S.No.
Description
Check whether FQA group is being involved in Boiler
Tube leakage and other failure analysis
x)
Check whether FQA and Maintenance Personnel are sent
regularly for training in the Welding, NDT and other
specialized functional areas
xi) Check the system of ensuring for testing of pressure
vessels, tools and tackles at required intervals as indicated
in tech. compliance documents. Copy of the list covering
all the items to be tested as per statutory norms with latest
status of testing to be enclosed. Random verification to
be done and exception to be recorded.
xii) Whether checks as per guidelines are conducted for high
rise structures, chimney, spring mounted foundation,
floating mills foundation, concrete foundations, and
necessary corrective measure initiated.
(In case of any discrepancy time bound action plan for
corrective measures to be made available)
xiii) Whether site has storage and preservation procedure for
critical spares and other important materials. How this is
being implemented. Role of third party for surveillance of
implementation status is there or not
xiv) Whether FQA is involved in plant betterment implementation
xv)
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.
( c) Verify compliance of FQA manual procedure No.P-11
for site contracts and role of FQA during O&M Phase of the
plant.
(d) Verify compliance of FQA manual procedure No.P-12 for
overhauling and maintenance role of FQA.
FQA involvement needed in all areas (Mech, Elect, C&I).
FQA involvement in Predictive Maintenance of Equipment
FQA lab instruments calibration being done as per required frequency.
Preparation of QA sheet before overhaul as per overhaul type
( Filling of the details in the formats to be verified)
ix)
09
10
11
12
Remarks
(Y/N)
(Y/N)
(Y/N)
(Y/N)
(Y/N)
(Y/N)
(Y/N)
Status/
Remark
(Y/N)
Status/
Remark
Status/
Remark
Status/
Remark
(Y/N)
Y/N)
Y/N)
Y/N)
Page - 84
Rev. No.: 0
MAINTENANCE PLANNING SYSTEM

S.No.
1.
2.
3.
4.
5.
6.
7.
(i) Description
Is station work control system functioning as per NTPC
maintenance management guidelines?
What type of system station is following?
Equipment history is maintained. If yes, select randomly 3
nos. major equipments and check.
Does the short term planning (STP) liaison with operation
for the planning of defect rectification and apprise them
about maintenance work and delays?
Feed back from operation department on STP involvement.
Is the STP coordinating with maintenance section and
apprise them about plant report for start of maintenance
work?
Feed back from all maintenance section on STP involvement.
Does STP liaison with operation for PTW?
Feed back from Operation dept. On STP involvement.
Does STP review and improve methods of maintenance,
equipment and staff-skill and crew size?
Remarks
Yes/No
If yes, do they revise work specifications accordingly?

Does STP organize the daily planning meeting?
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
If yes, Participants of the meeting.

Person chairing the meeting.
PREVENTIVE MAINTENANCE
S.No.
1.
2.
3.
4.
(ii) Description
Remarks
Do all standby equipments covered under preventive Yes/No
maintenance schedule?
Do all other equipments which do not have standby are Yes/No
taken under preventive maintenance during annual O/H.
Choose 2/3 equipments and check the above.
Do changeover schedule of standby equipments is matching Yes/No
with the preventive maintenance schedule?
Pick up 2/3 equipments and check the above.
Do the frequency and duration of the PM schedules is Yes/No
reviewed?
If yes, pick up equipments and check.
Do all columns of the WORK ORDER CARD are filled up Yes/No
Page - 85
Rev. No.: 0
S.No.
(ii) Description
properly by area engineer after the job is completed?
Remarks
If yes, pick up 2/3 card and check.

5.
Does compiled material codification directory prepared by Yes/No

materials department is available at site?
If yes,
Does the above directory available in 1) printed form or 2)
through LAN?
Do materials department review & update the stock of Yes/No
material and inform MTP?
What is the periodicity of updating?
6.
Do work specification are printed in all PM job cards?
Yes/No
Choose 2/3 cards and check.
PREDICTIVE MAINTENANCE
S.No.
1.
(a)
(b)
( c)
(d)
(e)
(f)
(g)
2.
3. (a)
(b)
4.
5.
6.
7.
8.
Description
Whether following Condition Monitoring techniques are employed
i.e.
Vibration Analysis
Thermography
Wear Debris Analysis
DGA
Acoustic (including SPM, Partial Discharge)
Motor current Analysis
Noise
Which are the Condition Monitoring technique outsourced.
Type and no. of equipments covered under Condition Monitoring
plan (Check viz-a-viz OS guidelines).
If Yes, are these techniques employed as per predecided
frequency/schedule (Check viz-a-viz OS guidelines).
Whether the maintenance is acting on the advice of Condition
Monitoring (check randomly).
How many cases, Condition Monitoring helped in optimizing the
P/M schedule?
Whether the PDM coordinator is integrating the reports from various
condition monitoring specialists and generating a comprehensive
report on equipment basis, to help the management in taking
maintenance decision.
Does the frequency of Condition Monitoring technique is reviewed
periodically (If yes, what is the periodicity)?
What is the ratio of PM/Predictive/break down WOCs.
Remarks
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
Page - 86
Rev. No.: 0
S.No.
9.
10.
11.
12.
Description
Study trend of major equipment forced outage/ reliability.
Any constraint in implementation of Condition Monitoring
Techniques through computers including assistance from IT.
Any new technique or concept being applied for reliability centered
maintenance.
Effectiveness of condition monitoring/predictive maintenance in
optimizing maintenance cost, if not satisfactory, suggest measures.
Remarks
Status
Status
Status
Status
BREAK DOWN MAINTENANCE

S.No.
1.
(iii) Description
Do the work order cards clearly indicate the following?
a) Designation & location of plant or equipment concerned
and equipment code.
b) Details of the defect being recorded (or work being
requisitioned).
c) Degree of urgency with which repairs are required (i.e.
Priority E/A/B/C).
d) Indication of condition under which work can be carried
out, i.e. load reduction, off load, etc.
Remarks
Yes/No
Yes/No
Yes/No
Yes/No
Pick up two or three job cards and check.

2.
Does the Unit Control Engineer sign the E Priority job Yes/No
cards?
Pick up at random job cards and check.
LUBRICATION SCHEDULE
S.No.
1.
2.
(iv) Description
Does Master Lubrication Schedule available?
How they are maintaining lubricating schedule (oil top up)
and quantity?
Remarks
Yes/No
Page - 87
Rev. No.: 0
PERMIT TO WORK SYSTEM

S.No.
1.
2.
3.
4.
5.
(v) Description
What are the different types of PTW being used in the
station:
a)ROMP (b)SANCTION FOR TEST (c)LWC
(d)P.T.W.(ELECT.) (e)P.T.W.(Mech.)
Do all the different columns of all types of P.T.W. are
properly filled up?
Pick up 2/3 and check.
HOT WORK SAFETY PERMIT
Does the shift charge engineer sign all the hot work safety
permits?
Pick up 2/3 & check.
Does safety ensured during the work?
Is Site following the lock out box philosophy?
If yes,
Check the lock out box in U.C.B. and verify the P.T.W.
issued with box no. issued.
6.
Cross Permit
How cross permits are issued and confirmed the return of all
the permits before trial run is taken.
7.
Danger Tag
Is the danger tag is put on isolated Bkr., or any system?
Remarks
Yes/No
Yes/No
Yes/No
Yes/No
Yes/No
Pick up the P.T.W. and identify the equipment and find out
the BKR and check that danger tag is fixed or not.
OVERHAULING
S.No.
1.
(vi) Description
Availability of five-year rolling plan with current year.
2.
Is scope of work finalized before the overhaul and made part of Yes/No
the contract.
3.
Are overhaul books distributed within 03 months of overhaul of Yes/No

units? Overhaul report on CD for 2003-2004 onwards. Hard
copy also should be made as required.
Availability of spares/consumables before overhaul.
Yes/No
4.
5.
Is there any system

spares/consumables?
for
ensuring
availability
Remarks
Yes/No
of Yes/No
Page - 88
Rev. No.: 0
S.No.
6.
7.
8.
9.
10.
11.
12.
13.
14.
15.
16.
17.
18.
19.
20.
21.
22.
23.
24.
25.
26.
27.
28.
29.
(vi) Description
Remarks
Availability of engineering declaration before 02 months of unit
Yes/No
overhaul.
Are all points available in Engineering declaration as mentioned
Yes/No
in letter given by OS referring overhaul management book
Vol.2A?
Does overhaul report contain the details given below?
Yes/No
All areas of work.
Yes/No
Spares/consumables used.
Yes/No
Cost of spares/consumables/contract.
Yes/No
Signed protocols of all area.
Yes/No
Areas of improvement in current overhauls from previous
Yes/No
overhaul.
Efficiency reports before/after overhaul.
Yes/No
Vib. Reading before/after overhaul.
Yes/No
Recommissioning details (like current, vib. Etc.) of equipments.
Yes/No
Availability of recommissioning group/check list before unit goes
Yes/No
out of bar.
Availability/ checking of lifting tools (like chain pulley, hoist,
Yes/No
EOT crane, lift, etc.)
Cost benefit analysis of the present overhaul
Yes/No
Whether O/H has been started as per scheduled plan
Yes/No
If deferred , the reason for it and whether the approval of
Yes/No
competent authority has been taken
Fresh program / planning to undertake the O/H of the works
Yes/No
deferred earlier
Whether O/H has been completed as per schedule
Yes/No
If completed beyond scheduled time, the reason for it and
Yes/No
whether the approval of competent authority has been taken
If completed before schedule time, it may be mentioned whether
Yes/No
all the jobs completed or some portion have been left out, if left
out, then the reason for it and whether the approval of competent
authority has been taken
In case some jobs have been left out then, whether any fresh
Yes/No
schedule has been made for these jobs
What system is followed for ensuring zero accident in the plant
Yes/No
during routine maintenance and also during the Overhaul ? If the
system exists, review the same
No. of accidents in the plant during last one year and corrective Mention
measures initiated for avoiding recurrence
brief status
Status of compliance to statutory norms by the plant in %
Date :
Name & Signature of the auditor
Page - 89
Rev. No.: 0
Annexure 6j
Check List of Boiler for Technical Audit
S.No. AREA/ SYSTEM/ SUB-SYSTEM
1
RECORDS
Records of tube thickness survey of all units
Safety valve floating protocol & boiler renewal
document
Checking of cold & hot readings of pipe supports &
hangers protocol
C1, C2 & C3 forms of each BTF
BTF analysis reports from R&D and its
implementation
Clean air test & dirty pitot test
Boiler metal temperature excursion
Lub oil analysis reports for fans & mills
Unit overhaul report
Air heater & mills performance report
Availability of LMI with concerned Engineers & its
awareness
History of all equipments
All failed tube samples being sent to OS (CC) for

analysis
BOILER TUBE FAILURE
No. of BTF in each unit
Adequacy of tube thickness survey
Replacement of tubes whose thickness is less than
recommended
Involvement of FQA during thickness survey
Analysis by site BTF committee
Implementation of OS guidelines / action plan during
OH for BTF reduction
Mapping of Boiler tube failures
DPT & random radiography of DMW joints during OH
Tube capping during BTF repair
STATUS
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Yes/ no
Yes /no
Yes/no
Yes/ no
Done/ not
done
Yes /no
Done/ not
done
Done / not
done
Yes /no
ACTION
PLAN
Page - 90
Rev. No.: 0
100% radiography of repair joints

Monitoring of temperature excursion
Radiography of existing joints in phased manner incase
of weld failures
BOILER
Availability of wall deslaggers & LRSB & frequency
of operation
Availability of burner tilt mechanism & SADC on auto
Availability of safety valves & ERV in service
Passing of valves (drains, vents & spray)
Air in leakage in pass I & II, penthouse
Availability of boiler lift
Condition of insulation & cladding for boiler, ducting,
steam lines, valves
Availability of spare tubes & bends, coal burners
BOILER PARAMETERS
MS temperature (L&R)
MS pressure
HRH temperature (L&R)
SH & RH spray
Total air flow
Total coal flow
PA header pressure
FW temperature at Eco inlet
O2 at Eco outlet (L&R)
Furnace pressure
FG temperature at APH I/L
FG temperature at APH O/L
SA/PA temperature at APH I/L
SA/PA temperature at APH O/L
DP at SA/PA of APH
DP at gas path of APH
MILLING SYSTEM
Availability of all mills & feeder
Adherence of milling system to PM schedule
Availability of HAG & CAG in good condition
Recommended PF fineness
Whether unburnt carbon in bottom & fly ash is less
than recommended
Availability of mill inerting system in case of tube mills
Availability of mill reject handling system
Partial loading of mills
Checking the condition of PF pipes and elbows
PF outlet temperature
STATUS
Yes/ no
Yes/no
Yes/ no
Av./ not av
Av./ not av.
Av./ not av.
Yes/no
Yes /no
Av./ not av.
Available/ not
av.
Yes/no
Yes/ no
Yes/no
Yes/no
Yes/no
Yes/no
Yes/no
----deg.C
ACTION
PLAN
Page - 91
Rev. No.: 0
Mill DP
Availability of hoist for mill maint.
Availability of critical spares
Checking of correct PA flow to the mill by hot K
calibration
FANS, AIR HEATER DUCTS DAMPERS
FANS
Availability of standby lub oil pumps
Availability of hoist for fan maintenance
AIR HEATER
Availability of fire detection system
Availability of ALCS
Availability of APH soot blowers
DUCTS, DAMPERS & GATES

Any leakage in air/gas ducts
Any leakage from metallic / fabric expansion joints
Availability of gates/dampers in operating condition
ESP
Availability of all fields in ESP
Availability of no. of rappers for Emitting & collecting
system
Availability of opacity monitors in working condition
7
8
9
10
11
12
STATUS
Yes/ no
Yes/no
Yes /no
Available/ not
av.
Available/ not
av.
Available/ not
av.
Available/ not
av.
Available/ not
av.
Available/ not
av.
Yes /no
Yes/ no
Yes / no
Available/ not
av.
Available/ not
av.
Available/ Not
Av.
Emission level for last two years

Generation loss due boiler & auxiliaries
Efficiency loss due to boiler & auxiliaries
Repetitive failure of equipments
Forced outage between overhauls
Maintenance practice
Safety
ACTION
PLAN
Page - 92
Rev. No.: 0
Annexure 6k
Check List of Waste Heat Recovery Boiler for Technical Audit
1
RECORDS
Records of tube thickness survey of all units (Those
location where thickness measurement is possible, like
bends etc)
Safety valve floating protocol & boiler renewal
document
Checking of cold & hot readings of pipe supports &
hangers protocol
C1, C2 & C3 forms of each BTF
BTF analysis reports from R&D and its
implementation
Boiler metal temperature excursion
Lub oil analysis reports for HP & LP CC pump
Unit overhaul report - Job carried out and next O/H
preparedness
Availability of LMI with concerned Engineers & its
awareness
History of all equipments
Any Modification done
Maintenance Practices
Tools & Tackles
All failed tube samples being sent to OS (CC) for
analysis
WHRB TUBE FAILURE
No. of BTF in each unit
Adequacy of tube thickness survey depending upon
approach
Replacement of tubes whose thickness is less than
recommended
Involvement of FQA during thickness survey
Cleaning of tube for better heat transfer
Analysis by site BTF committee
Implementation of OS guidelines / action plan during
OH for BTF reduction
Mapping of Boiler tube failures
STATUS
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Available/not
av.
Yes/ no
Yes /no
Yes/no
Yes/ no
Yes/ no
Done/ not
done
Yes /no
Done/ not
ACTION
PLAN
Page - 93
Rev. No.: 0
DPT & random radiography of Stub joints during O/H
Tube Cleaning & capping during BTF repair

100% radiography of repair joints
Radiography of existing joints in phased manner incase
of weld failures
Forced Outage due to WHRB
Partial Loading due to WHRB
Re-commissioning Defects
WHRB
Availability of safety valves & ERV in service
Passing of valves (drains, vents & spray)
Passing/Leakages of Expansion Joints
Air in leakage of WHRB
Condition of insulation & cladding for boiler, ducting,
steam lines, valves and Thermal Insulation Audit
Condition of structure and staircase
Thermal expansion - Marking points Availability and
records of expansion
Availability of spare tubes, bends, Valves, Expansion
Joints etc
WHRB PARAMETERS
Load
MS Flow
HP MS temperature (L&R)
HP MS pressure
LP MS temperature (L&R)
LP MS pressure
Spray
FW temperature at HP Eco inlet
FW temperature at LP Eco inlet
Gas Temperature Inlet
Gas Temperature Outlet
CPH Temperature Inlet/Outlet
CC Pumps, DUCTS DAMPERS
CC Pumps
Cleaning/ replacement of filters, oil etc
Availability of hoist for Pump maintenance
DUCTS, DAMPERS & GATES
Any leakage in air/gas ducts
Any leakage from metallic / fabric expansion joints
STATUS
done
Done / not
done
Yes /no
Yes/ no
Yes/ no
Av./ not av.

Yes/no
Yes/no
Yes /no
Available/ not
av.
Available/ not
av.
Yes /no
Yes/ no
ACTION
PLAN
Page - 94
Rev. No.: 0
Availability of gates/dampers in operating condition
STATUS
Yes / no
ACTION
PLAN
Document for Distribution to:

CONTROLLED
Power Stations
1. General Manager
Rihand
2. General Manager
Vindhyachal
3. General Manager
Kahalgaon
4. General Manager
Farakka
5. General Manager
Dadri (Coal & Gas)
6. General Manager
Unchahar
7. General Manager
Korba
8. General Manager
Ramagundam
9. General Manager
Badarpur
10. General Manager
Talcher Kaniha
11. General Manager
Anta
12. General Manager
Kawas
13. General Manager
Simhadri
14. General Manager
Singrauli
15. General Manager
Auraiya
16. General Manager
Talcher Thermal
17. General Manager
Jhanor Gandhar
18. General Manager
Tanda
19. General Manager
Kayamkulam
20. General Manager
Faridabad
UNCONTROLLED
II Regional Head Quarters
21. Executive Director (NR), Lucknow
22. Executive Director (SR), Hyderabad
23. Executive Director (WR), Mumbai
24. Executive Director (ER), Patna
25. Executive Director (NCR), New Delhi
III Corporate Head Quarter

26. Chairman & Managing Director, SCOPE, New Delhi
27. Director (Technical), SCOPE, New Delhi
28. Director (Operations) , SCOPE, New Delhi
29. Director (Commercial), SCOPE, New Delhi
30. Director (Projects) , SCOPE, New Delhi
31. Executive Director, PMI, Noida
32. Executive Director (OS), EOC, Noida
33. Executive Director (Engg.), EOC, Noida
34. General Manager (R&D), Noida
35. All Group Heads in Operation Services, CC
IV
Head of O&M
36. Singrauli
37. Korba
40. Ramagundam
41. Farakka
40. Vindhyachal
41. Rihand
42. Kahalgaon
43. Dadri(Coal)
44. Unchahar
46. Talcher Kaniha
47.Talcher Thermal
47. Badarpur
48. Simhadri
49. Auraiya
50. Anta
51. Kawas
54. Kayamkulam
55. Faridabad
52. Jhanor Gandhar 53. Dadri (Gas)

56. Tanda

Technical Audit NTPC

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OPERATION INFORMATION NOTE

CORPORATE OPERATION SERVICES

National Thermal Power Corporation Ltd.

NATIONAL THERMAL POWER CORPORATION LTD.

Date : July, 2004

GUIDELINES FOR CONDUCTING TECHNICAL AUDIT

Qualities of Technical Auditor

System for Technical Audit

General Guidelines for Conducting the Technical Audit

10.0 Operation System

12.0 Maintenance Preparedness

13.0 Spares Availability

14.0 Healthiness of Installed Equipment

16.0 O&M problems and action plan

17.0 O&M Cost reduction measures

18.0 Safety aspects Plant and Equipments

19.0 MoU Targets

Appendix -1A Matrix for Targeted Objectives of Technical audit

Appendix -1B Technical Audit Plant Areas

Appendix -2 Schedule of Technical Audit

Appendix - 3A Format for reporting Audit

Appendix - 3B Format for Action Plan

Appendix - 4 Format for Executive Summary

Appendix - 5 Matrix of Maintenance System

Appendix -6a Check list of Electrical areas

Appendix -6b Check list of C&I areas

GUIDELINES FOR CONDUCTING TECHNICAL AUDIT

Appendix -6c Check list of Operation areas

Appendix -6d Check list of Balance of Plant Areas

Appendix -6e Check list of Steam Turbine

Appendix -6f Check list of Chemistry

Appendix -6g Check list of Efficiency

Appendix -6h Check list of Gas Turbine

Appendix -6i Check List of Quality Management System

Appendix -6j Check list of Boiler

Appendix -6k Check list of Waste Heat Recovery Boiler (WHRB)

GUIDELINES FOR CONDUCTING TECHNICAL AUDIT

Forced outage reduction

Generation Optimisation & Efficiency enhancement

Cost reduction / optimization

Quality of routine maintenance and overhaul

Safe & reliable operation & maintenance

Prevention of major failures

Identification & reporting of major issues / constraints

Action plan and status thereof

Achievement of Targeted Operation Matrix.

National Thermal Power Corporation Ltd.

Identification of instances where based on site observation and study of

Identification of specific training needs of individuals to dovetail with

The Technical Audit team should be able to do identification of repeated trips

Instances where operation & maintenance staff failed to arrive at

QUALITIES OF TECHNICAL AUDITOR

He must be well experienced in power station operation and

He should be diplomatic, unbiased, patient, communicative, and should

He should not feel / show triumph on finding discrepancies and should

He should have a strong analytical and data crunching abilities.

He should develop a good feel of various parametric numbers and

7.0 SYSTEM FOR TECHNICAL AUDIT

The Frequency of Audit of each station shall be once a year or as decided by

Nominations of team members from the concerned HODs shall be sought by

The team leader will be nominated by the management.