OR-Sep R2

OPERATION REVIEW - 02
STPP 2x600MW
r 2015
11/06/2020 September-2017 1
OR#1
INDEX
S.No. Particulars
1 Highlights
2 Station Performance
3 Station Performance Analysis
4 Chemistry
5 Coal handling Plant
6 Statutory /Regulatory Updates
10 OR#1 2
Highlights and Lowlights
 Highlights
11/06/2020 3
OR#1
Highlights and Lowlights
 Highlights
11/06/2020 4
OR#1
2. STATION PERFORMANCE
DC-SG-AG
110.00
100.11
98.55
98.36
98.00
98.00
98.00
95.32
94.01
93.69
100.00
88.90
87.81
87.08
90.00
80.00
70.00
DC
SG
60.00 AG
50.00
40.00
30.00
20.00
Aug Sept Target for Oct FY 2017-18
11/06/2020 OR#1 5
Plant Load Factor
105
99.26
98.43
97.61
100
95.38
95.00
95.00
93.84
95
95
92.30
91.23
Unit-I
87.53
90
Unit-II
Station
83.83
85
80
75
11/06/2020 OR#1 6
Availability Factor
105
99.54
99.08
100
100
97.17
98
98
98
95.49
93.8
95
92.5
89.04
Unit-I
90
Unit-II
85.58
Station
85
80
75
11/06/2020 OR#1 7
Auxiliary Power Consumption(%)
8.00
7.50
7.00
6.28
6.3
6.3
6.50
5.96
6.0
5.9
5.75
5.8
5.8
5.69
6.00
5.8
5.8
Unit-I
5.50
Unit-II
Station
5.00
4.50
4.00
3.50
3.00
11/06/2020 OR#1 8
Specific Oil Consumption (ml/kwh)
0.45
0.39
0.4
0.38
0.4
0.35
0.3
0.25
0.24
0.24
0.24
0.24
0.24
0.25
Unit-I
Unit-II
0.18
0.2 Station
0.15
0.09
0.1
0.05
0.01
0
11/06/2020 OR#1 9
DM Cycle Make-up (%)
1.2
0.95
1
1
1
1
0.85
0.76
0.74
0.8
0.72
0.71
0.69
0.68
0.66
Unit-I
0.6
Unit-II
Station
0.4
0.2
0
11/06/2020 OR#1 10
STATION
PERFORMANCE INDICES UNIT – 1 UNIT – 2
(2X600MW)
Generation (MU)
Actual for the Month 398.72 412.04 810.76
443.08 448.54 878.81
Previous Best
Aug’ 17 May’ 17 Aug’17
YTD 2208.98 2404.19 4613.17
STATION
2X600MW
PLF (%)
100 100.11 98.43
Previous Best
Apr’ 17 Feb’ 17 Aug’ 17
YTD 83.83 91.23 87.53
Deemed PLF For the Month 93.48 96.66 95.07
100.53 100.2 99.91
Previous Best(Deemed)
Aug’ 16 Feb’ 17 Aug’17
Deemed PLF-YTD 88.47
11/06/2020 OR#1 11
AUX POWER CONSUMPTION (%)
STATION
(2X600MW)
APC (%)
5.69 5.59 5.82

Previous Best
Aug’ 17 May’ 17 Aug’ 17
YTD 6.22 6.25 6.24
11/06/2020 OR#1 12
STATION
(2X600MW)
SCC (gms/kwh)
SCC 594 599 597
Design @ 4529 GCV 486 486 486
YTD 571 568 569
Coal Consumption (MT)*
Monthly (MT) 236846 246856 483701
Yearly (MT) 1261846 1365334 2627180
* Subject to Physical verification
11/06/2020 OR#1 13
SPECIFIC OIL CONSUMPTION
STATION
(2X600MW)
SOC (ml/kwh)
0.01 0.18 0.09

Previous Best
Aug’ 17 Aug’ 17 Aug’ 17
YTD 0.40 0.38 0.39
Oil Consumption (KL)
Monthly 94.41 101.20 195.61
YTD 879.07 922.37 1801.44
11/06/2020 OR#1 14
DM WATER
STATION
(2X600MW)
DM MAKE UP (%)
0.60 0.76 0.72

Previous Best
Mar’ 17 Aug’ 17 Aug’ 17
YTD (After COD) 0.74 0.95 0.85
11/06/2020 OR#1 15
3. STATION PERFORMANCE ANALYSIS
OUTAGE STATISTICS – (NO. OF SHUTDOWN)
Station
Performance Indices Unit-1 Unit-2 (2X600 MW)
During Month
a) Planned 0 0
Tripping 0 02
03
b) Forced BTL 1 0
Withdrawl
During Financial Year

a) Planned 0 0
b) Forced YTD 10 17 27
11/06/2020 OR#1 16
TRIPPING & WITHDRAWL DETAILS FOR THE MONTH
Tripping Synchronization
Outage
Gen Loss
Unit duration Reason of Tripping
Date Time Date Time (MU)
(hr:min)
1 08.09.17 01:51 10.09.17 22:22 44:31 26.71 BTL
2 12.09.17 13:33 13.09.17 07:11 17:38 10.58 Cold Gas Temp High
Furnace Pressure
2 24.09.17 16:24 24.09.17 19:08 02:44 1.64
Very Low
Total Outage 64:53 38.93
11/06/2020 17
OR#1
Action Plan for Availability
Unit Observation Action Plan Target

3.3KV 2CA Sec-A Mill G
breaker shutter lifting
2 3.3 KV Bus Got Dead mechanism bolt was Attended
found in open condition.
2CA I/C-1 upstream control cable

connected to UAT-2B incomer
Cross connection of
(HT) and incomer-2 Breaker
control cable to be During SD
upstream control cable
corrected .
connected to UAT-2A incomer
2
breaker(HT)
Relay setting of HT side
relay to be done.
HT side relay setting During SD
Approval awaited from
BHEL
Availability of Clinker
2 AHP-Clinker grinder availability In process
Grinder to be ensure.
11/06/2020 18
OR#1
Generation Loss % For The Month Sep,2017
Grid restriction;
Electrical;
Operation;
BTL; 26.71; 3% 10.66;
1.64;
10.58; 1% 1%
0%
Generation
BTL
Operation
Electrical
Grid restriction
Generation; 810.76; 94%
11/06/2020 19
OR#1
Availability Loss % For The Month Sep,2017
Electrical;17.6;
BTL; 44.5;Operation;
6% 2.75;2%
0%
Availability
BTL
Operation
Electrical
Availability; 687.56; 91%
11/06/2020 20
OR#1
Area wise % of Availability loss during Financial Year 2017-18
AREA WISE OUTAGE SUMMARY
AREA NOS HOURS MU %
BTL 10 857.9 514.71 11.16
Electrical 6 65 38.8 0.84
C&I 4 9.8 5.7 0.12
Operation 6 28 16.7 0.36
AHP 1 1.7 1 0.02
Total 27 963.1 576.91 12.51
AREA WISE OUTAGE SUMMARY

Unit-I Unit-II
AREA NOS HOURS MU % NOS HOURS MU %
BTL 6 620.5 372.31 17 4 237.4 142.4 8.1
Electrical 1 5 2.8 0.2 5 60 36 1.0
C&I 2 7 4.0 0.2 2 2.8 1.7 0.1
Operation 1 1 0.5 0.03 5 27 16.2 0.7
AHP 1 1.7 1.0 0.1
Total 10 633.5 379.61 17.43 17 329.6 197.3 10.0
11/06/2020 21
OR#1
Area wise % of Availability loss during Financial Year 2017-18
C&I;
AHP;9.8;
Operation
Electrical; 65; 7% 1.7;1%
; 28; 0%
3%
BTL
Electrical
Operation
C&I
AHP
BTL; 857.9; 89%
11/06/2020 22
OR#1
GENERATION VARIANCE
Generation Loss (MU) Details
U#1 U#2 Station

Rated Generation 432 432 864
Actual Generation 398.72 412.04 810.76
Generation Loss 33.28 19.96 53.24
CATEGORY TYPE CAUSE U#1 U#2 Station
Planned 0 0 0
Outage
Forced 26.71 12.22 38.93
Partial Grid Grid Restriction 5.13 5.53 10.66

Loading Equipment Problem.
1.52 3.265 4.785
11/06/2020
OR#1 23
UNBURNT CARBON IN ASH
Unit-1 Unit-2
ITEM LIMIT
Max Min Avg Max Min Avg
Bottom Ash 2.45 2.16 2.35 2.46 2.18 2.34

< 2.5%
Fly Ash 0.43 0.20 0.35 0.45 0.23 0.35
< 1%
11/06/2020 OR#1 24
U#1 APH PERFORMANCE FOR THE MONTH OF SEP
ONLINE OFFLINE
SI.No. Parameter Unit Design
APH-A APH-B APH-A APH-B
1 FG I/L temperature °C 335 376 385 349 363
2 FG O/L temperature °C 138 145 135 145 135
3 APH FG I/L O2 % 3.53 3.95 3.42 3.9 3.26
4 APH FG O/L O2 % 5.03 5.72 5.65 5.18 5.4
5 APH Leakage % 9 12 15 8 14
6 Corrected FG O/L temp °C 150 161 152 156 152
U#2 APH PERFORMANCE FOR THE MONTH OF SEP

ONLINE OFFLINE
S.No. Parameter Unit Design
APH-A APH-B APH-A APH-B
1 FG I/L temperature °C 335 357 382 342 367
2 FG O/L temperature °C 138 121 126 120 128
3 APH FG I/L O2 % 3.53 3.98 3.88 3.65 3.25
4 APH FG O/L O2 % 5.03 6.27 4.64 5.05 4.45
5 APH Leakage % 9 16 5 9 7
6 Corrected FG O/L temp °C 150 137 132 130 136
11/06/2020 OR#1 25
HEAT RATE & DEVIATIONS - U#1
Actual Heat rate
deviation
PARAMETER Rated Expected (avg (Kcal/kwh Reasons
values) )
Unit Load (MW) 600 600.0 592 3.2
Main Steam Pressure (Ksc) 168.97 168.97 169.9 -0.9 Within limit
Main Steam temp(0C) 537 537.0 535.8 0.6

RH Steam Temp(0C) 565 565.0 559.6 2.7
Part load operation, High
RH Spray(TPH) 0 0.0 7.2 1.3 Excess Oxygen in view of
Clinkering tendancy
Due to Condensor tube fouling.
Low effectivness of Cooling
Cond Vacuum (Kg/cm2) 0.1047 0.1047 0.1562 47.3 tower, CW quality not as per
standarad
DM cycle make up (%) 2 0 0.626 10.8* Within limit
Feed Water Temp 278 278.0 281.6 -3.0
BOILER
Excess air (O2) 3.53 3.5 3.7 1.5
Exit Flue Gas Temp 138 138.0 137.7 0
Unburned Carbon 3.62 3.6 2.7 -2.6
Coal Moisture 7.29 7.3 10.54 6.48
Total ( Heat Rate Deviation) - - 97.38
* Calculated based on loss method of Turbine.

11/06/2020 OR#1 26
HEAT RATE & DEVIATIONS - U#2
Actual Heat rate
PARAMETER Rated Expected (avg deviation Reasons
(Kcal/kw
values) h)
Unit Load (MW) 600 600.0 593 2.8
Main Steam Pressure (Ksc) 168.97 168.97 169 0.9
Main Steam temp(0C) 537 537.0 535.7 0.7
RH Steam Temp(0C) 565 565.0 567.1 -1 Load variation.
Part load operation, High Excess
RH Spray 0 0.0 24 4.1 Oxygen in view of Clinkering
tendancy
Due to Condensor tube fouling.
Low effectivness of Cooling
Cond Vacuum (ata) 0.1047 0.1047 0.159 49.9
tower, CW quality not as per
standarad
DM cycle make up (%) 2 0 0.67 12.7 Within limit
Feed Water Temp 278 278.0 279 -1
BOILER
Excess air (O2) 3.53 3.5 4.0 3.48
Exit Flue Gas Temp 138 138.0 134.2 -4.56
Unburned Carbon 3.62 3.6 2.7 -2.6
Coal Moisture 7.29 7.3 10.46 6.32
Total - 101.74
* Calculated based on loss method of Turbine.
11/06/2020 OR#1 27
GENERATOR OPERATING PARAMETER
PARAMETERS Description Limit Max/Min U-1 U-2
Min 97% 97%
Purity(online) ≥98 %
Max 98% 98%
-25°C Min -9.7 -9.9
Dew Point
-5°C Max -9.7 -9.9
Hydrogen Parameters
Hot Gas temp ≤ 68°C Max 82°C 75°C
Cold Gas Temp ≤ 48°C Max 56°C 52°C

Stator Water Winding Outlet < 73 °C Max 72°C 68°C
Parameters Temp
Max 53.4°C 48°C
Winding inlet Temp 40 °C to 50 °C
Min 50°C 46°C
Conductivity 0.5-2.0 μs/cm Max 1.01 1.2
11/06/2020
OR#1 28
PARAMETERS Description Limit Max/Min U-1 U-2

Conductivity 0.5-1.5 μs/cm Max 1.01 1.2
Stator Water
Parameters Min 8.4 8.76
pH 8.5 to 9.0
Max 8.5 8.76
>2 ppb Min

<20 <20
DO
<20 ppb Max
<20 <20
Min 78°C 54°C

Core Temp <120 °C
Max 102°C 82°C
Stator Core & Slot
temperatures Min 68°C 68°C
Slot Temp <120 °C
Max 72°C 72°C
11/06/2020
OR#1 29
PARAMETERS Description Limit U-1 U-2
H2 Consumption Filling / Purging 2 per day/unit 45 89*

( No of Cylinder)
H2 dryers in service A or B or Both A+B A+B
Both are Both are

H2 dryers Availability A/B available available
CO2 consumed NIL NIL
CO2 Cylinders in stock 30 per unit 30 13**
*Leakage identified from Dew point sensor and attended,

**17 CO2 cylinders are pending from STPP.
11/06/2020
OR#1 30
CT PERFORMANCE FOR THE MONTH
Unit-1 Unit-1 Unit-2 Unit-2

PARAMETERS DESIGN
1-A 1-B 2-A 2-B
RANGE 10.5 9.02 12.19 10.92 9.46
APPROACH 4.3 11.69 7.69 10.38 9.74
EFFECTIVENESS 70.9 43.56 61.31 51.28 49.27
COC FOR THE MONTH
PARAMETERS DESIGN
Average 4.78
COC Max 5.0 5.35
Min 4.12
11/06/2020 OR#1 31
ESP PERFORMANCE & STATUS
Unit-1 Unit-2
Average Fields in service 70/72 67/72
EERM – 72/72 EERM – 72/72

Availability of Rapping CERM – 71/72 CERM – 71/72
Motors
GDRM-8/8 GDRM-8/8
Availability of Ash level 72 72

indicators
11/06/2020 OR#1 32
SOOT BLOWERS AVAILABILITY
Unit-1 Unit-2
Frequency Non Availability Non Availability
6 Nos defective out of 88 Nos

Water Wall Soot 6Nos defective out of 88
Twice in a day
blowers Nos
8 Nos defective out of 42 8 Nos defective out of 42 Nos

LRSB Twice in a week
Nos
APH Soot Available Available

Once in a Shift
blowers
11/06/2020 OR#1 33
Auto Loops Status
Description Reason for not
UNIT-1 Reason for not in UNIT-2 in Auto
Auto
FD Fan Controller Auto Auto
PA Fan controller Manual Hdr. Pr. fluctuation Manual Hdr. Pr. fluctuation
Furnace Pressure Controller Auto Auto
O2 Controller Auto Auto
No clearance from
Feeder Controller Auto Manual
BHEL
Mill Cold PA controller Auto Manual Fine Tuning Required
Mill hot PA controller Auto Manual Fine Tuning Required

Auto loops status
Reason for
Reason for not
Description UNIT-1 not in Auto UNIT-2 in Auto
Hot well level Controller Auto Auto
D/A Level Controller Auto Auto
Drum level Controller Auto Auto
D/A Pegging steam control Auto Auto
SH Spray Controller (L/R) Auto Auto
Auto Tuning
RH Spray Controller (L/R) Auto Manual
Required
Coordinated Master control Auto Manual No clearance from

BHEL
Turbine drains controller Auto Auto
Auto Tuning
Mill outlet temp. controller Auto Manual Required
Operation Operation
Burner tilt controller Manual Manual
requirement requirement
11/06/2020 35
Auto loops status
Reason
Reason for
Description UNIT-1 for not in UNIT-2
Auto not in Auto
HFO/LDO pr. controller Auto Auto
Atomizing steam pr. controller Auto Auto
SADC Controller Auto Auto
Boiler Master Auto Manual No clearance

from BHEL
GSC Min. R/C controller Auto Auto
BFP recirculation controller Auto Auto
MOV spare not

Turbine lube oil temp. controller Auto Manual available
Seal steam pr controller Auto Auto
TDBFP lube oil temp. controller Auto Auto
11/06/2020 36
Auto loops status
Reason
for Reason for
Description UNIT-1 UNIT-2
not in not in Auto
Auto
Primary water temp controller Auto Auto
Over Head(ECW) tank level controller Auto Auto

MOV spares
Gen Cold Gas Temp controller Auto Manual not available
HP BY pass Auto Auto
HP BY pass Temp Controller Auto Auto
LP By pass Auto Auto
LP By pass Temp Controller Auto Auto

MOV spares
HPCF Temp control Man not available Auto
11/06/2020 37
CRITICAL PROTECTION CHECKS
UNITS PROTECTIONS DATE OF LAST TESTING
Boiler- MFT 25/07/2017
Turbine- TP 25/07/2017
UNIT-1 Turbine- Over Speed (Oil injection test) 20.02.2017
Turbine ATT
Generator 13.03.2016
Boiler- MFT 30/07/2017
Turbine- TP 30/07/2017
UNIT-2
Turbine- Over Speed (Oil injection test) 28/01/2017
Turbine ATT
Generator 28.05.2016
11/06/2020 OR#1 38
3.STATION PERFORMANCE ANALYSIS
SWITCHYARD EQUIPMENT AVAILABILITY:
S.No. Description SWYD (bays)
1 Primary Equipments All 14 bays are in service.
2 Protection Panels All are in healthy condition
3 OPGW Panels Panel is working properly

4 SCADA System Both server & DR system is working properly
11/06/2020 OR#1 39
STATION PERFORMANCE ANALYSIS
BATTERY BANK STATUS
Sp. Electrolyt
Equipment Nos Volts(DC) Gravity e Level Remarks
• Total cells 340 cells available in each Section A & B.

U#1 Battery Two 220 1220 Normal • In section –B battery number 206,240,262, 234,287,340
banks and also section-A battery number 6,213,&329 found
leakage .
• Total cells 340 cells available in each Section A & B

• At battery section-A , battery number 256 cell is not
available & in battery 201,207,234,320 are found
U#2 Battery Two 220 1220 Normal leakage and in section –B ,battery number
banks 254,255,256,257 not available and are found leakage .
Normal • in leakage condition at Unit-2 .

Unit#01 &02 All are in healthy condition except one number 79 & 6 is
Ups battery One 340V 1220
Normal •
CHP Battery Battery Charger –A&B both are in service condition and
Two 220 1220
Bank healthy condition.
11/06/2020 OR#1
STATION PERFORMANCE ANALYSIS
BATTERY BANK STATUS
Volts Sp. Electrolyt
Equipment Nos (DC) Gravity e Level Remarks
Normal •
AHP Battery Battery Charger –A&B both are in service
Two 220
Bank 1220 condition and healthy condition
48
SWYD Banks One Dry cell N/A • All Battery are in healthy condition.
Normal • battery bank B are in by pass condition

5 number in battery bank A & 2 numbers in
Two 220 1220
SWYD Banks
Normal •
48 V Battery charger-2 has not
Two 48 1220
commissioned
Normal • healthy condition

All 4 numbers of battery in each set are in
DG Set Three 24 1230
Diesel Fire
Hydrant One 24 1230 Normal • Battery Charger is in service condition
Pump
Diesel Fire
Spray Pump One 24 1220 N/A • Yet To be commissioned
11/06/2020 OR#1
PLC AVALABILITY
LOCATION STATUS REMARK

Make-up water ,PT Plant, Chlorination and
DMP in service Service water are under commissioning.
DMP
CSSP -- Erection Pending
Under Service Local PLC, Stacker/ Reclaimer, Track Hopper

CHP and concern belt ways under commissioning
Local PLC, Ash Water Recovery System,

AHP Under Service HCSD, SILO & Ash water Pump House are
under commissioning
H2 Plant Erection under progress Erection under progress
Comp House Commissioning under progress
CW Chlorination and SACW are

IDCT under Comissioning Commissioning under progress
Fire Water Pump House under Booster Pump System and Foam Pump
Fire Fighting service House are under commissioning
CW Chlorination and SACW are
CW Chlorination under Comissioning
Air conditioning Erection Pending
System(BOP)
11/06/2020 OR#1 42
UPS AVALABILITY
LOCATION CAPACITY BATTERY REMARK
STATION DCS UNIT#1 2X150 KVA From Main DC bank Working normal
STATION DCS UNIT#2 2X150 KVA From Main DC bank Working normal
2 X 10KVA SMF Battery Commissioned, Battery

CHP bank not connected.
Commissioned but not in
AHP 2 X 10KVA SMF Battery service (used only for
Ethernet Switch)
DM Plant 2 X 10 KVA SMF Battery service (used only for
Ethernet Switch)
Compressors (BTG) 2 X 10 KVA SMF Battery service (used only for
Ethernet Switch)
2 X 10 KVA SMF Battery Commissioned but not in

IDCT
service
2 X 10 KVA SMF Battery Commissioned but not in

Fire Fighting
service
H2 Plant 2 X 10 KVA SMF Battery Not erected
11/06/2020 OR#1 43
Concern
Description
Condenser CW tube fouling, affecting heat rate of the turbine.
Poor effectiveness of Cooling tower & Frequent failure of CT fans. (Structure stability) .
High slagging tendency resulting into clinker formation.
Non availability of critical spares particularly in AHP.
ESP hopper Ash Evacuation demonstration by EPC.
Mill Rejection system yet to be proven.
LRSB Pressure setting
Inlet & outlet Isolation valves are passing on DMCW-PHE coolers, ACW A,B & C
Boiler different elevation, the furnace cladding skin temperature are on higher side due to lack of insulation.
When ever the safety valve floats the entire insulation get dislodged from the pipes
Cable Trench water ingress.
44
11/06/2020 OR#1
Concern
Description
Electric Lab, Mechanical Workshop not available.
Auto Coal sampler.(3A/3B)-Pending
Emergency Light to be commissioned in Track Hopper and Tunnels, Switch Gear Room, stair case
Data concentrator is not properly through , many relays are not communicating properly.
Recommended relay setting to be implemented for BOP area to avoid spurious tripping of transformer &
board.
Auto bus change over is not successful in 3.3 KV and LT board.
Ventilation in track hopper and tunnel.
Conveyor system water spray system.
45
11/06/2020 OR#1
CHEMISTRY
DEVIATION IN WATER CHEMISTRY
A) RAW- CLARIFIED water Parameters
Raw Water Limit DM Clarifier Outlet

Parameters UOM
Min Max Average Min Max Average
pH at 25 degree 8.30 8.65 8.42 7.0-8.2 7.00 7.82 7.45
Specific 750 843 814 763 862 831

us/cm
Conductivity
Turbidity NTU 3.03 5.05 4.14 <2.0 2.86 4.94 3.59
Total Hardness as 188 210 204 188 210 204

mg/L
CaCO3
Chloride as CaCo3 mg/L 100 114 108 67 102 116 110
Total Dissolved 487 548 529 495 560 539

mg/L
Solids
Silica as SiO2 mg/L 17 21 19 20 20 20
Alkalinity as 122 150 134 120 112 138 121

mg/L
CaCo3
Free Residual 0.2-0.5 0.2 1.0 0.5
mg/L
Chlorine
5 January 2015 OR#47 46
CHEMISTRY
COOLING WATER PARAMETERS
CW Clarifier Outlet CW Forebay

Parameters UOM Limit
Min Max Average Limit Min Max Average
pH at 25 degree 8.0 7.45 8.14 7.68 7.5 – 8.0 7.72 7.98 7.90
Specific 350 2500
us/cm 771 859 830 3140 3670 3394
Conductivity
Turbidity NTU < 5.0 2.65 5.30 3.19 < 10 10.2 19.3 15
Total Hardness as 186 900
mg/L 190 210 204 846 1020 916
CaCO3
Chloride as Clˉ mg/L 75 102 120 113 < 600 472 568 513
Total Dissolved 231 1650
mg/L 501 834 549 2041 2385 2206
Solids
Alkalinity as 120
mg/L 112 136 123 100 ± 20 32 58 47
CaCo3
Cycle Of
5.0 4.10 5.01 4.49
Concentration
Free Residual
mg/L 0.6 1.0 0.9 0.2- 0.5 0.1 0.2 0.2
Chlorine
Langelier Index 0.5 +0.18 +0.69 +0.54
Silica as CaCo3
5 January 2015 Mg/L 16.58 17 21
OR#47 18 < 100 68 90 7847
CHEMISTRY
B) DM WATER
Parameters UOM Range Min Max Remarks
pH at 25 degree 6.8 - 7.3 6.56 6.80

Silica as SiO2 ug/L 10 <10 <10
Conductivity us/cm 0.5 0.10 0.15
DM Water (m³)
DM Water Production Consumption Internal Closing Stock

Opening Stock consumption
2709 39357 36591 2460 3015
5 January 2015 OR#47 48

CHEMISTRY
WATER CHEMISTRY PARAMETERS
Unit-1 Unit-2
System Parameter Limits
Max Min Avg Max Min Avg
CC (us/cm) < 0.2 0.20 0.11 0.15 0.18 0.09 0.11
Condensate 9.31 8.88 9.12 9.30 8.95 9.11

pH 8.8 - 9.3
Water
DO (ppb) <30 ppb Off line instrument not available
CC (us/cm) < 0.3 0.35 0.20 0.21 0.29 0.11 0.16
Feed Water pH 8.8 - 9.3 9.37 8.91 9.16 9.29 8.99 9.14
Off line instrument not available
DO (ppb) < 7 ppb
S.Conductivity 15 5.41 8.87 19.78 4.66 8.46
< 50
(us/cm)
Boiler Water pH 9.0 - 9.5 9.44 9.06 9.25 9.41 9.04 9.23
SILICA (ppb) < 100 58 40 44 800 41 91.46
pH 8.8 - 9.3 9.34 8.95 9.18 9.30 9.01 9.17

Main Steam
SILICA (ppb) <20 ppb 12 10 10 48 10 12.60
CC(us/cm) < 0.2 0.18 0.09 0.12 0.15 0.10 0.13
CPU (O/L) pH 6.68 6.06 6.32 6.44 6.09 6.21
Silica(ppb) < 15 10 6.0 8.23 10 10 10
5 January 2015 OR#4.7 49

CHEMISTRY
WATER CHEMISTRY PARAMETERS (ONLINE-Average)
System Parameter Limits Unit-1 Unit-2
CC (µs/cm) < 0.2 0.15 0.11

Condensate
Water S.Conductivity(µs/cm) <6 5.84 5.65
DO (ppb) <30 ppb NW NW
CC (µs/cm) < 0.3 0.21 0.16
pH 8.8 - 9.3 9.02 8.82
Feed Water
DO (ppb) < 7 ppb NW NW
S.Conductivity(µs/cm) <6 5.95 5.64
S.Conductivity(µs/cm) < 50 10.12 12.16
Boiler Water pH 9.0 - 9.5 9.46 9.35
SILICA (ppb) < 250 NW NW
CC (µs/cm) < 0.2 0.15 0.14

SILICA (ppb) <20 ppb NA NA
Main Steam
Sodium (ppb) < 10 ppb NW NW

5 January 2015 OR#47 50
CHEMISTRY
CHEMICAL STOCK AS ON
26/08/17
Consumption Present Stock Inventory

Chemical Remarks
(MT) (MT) Duration (Days)
Hydrochloric acid (HCL ) 101.833 7.03 2.0
Caustic Lye (NaOH) 36.055 7.795 6.5
Tri Sodium Phosphate (TSP) 0.009 1.0 333
Hydrazine hydrate(N2H4H2O) 0.338 1.30 65
Liquor ammonia(NH3H2O) 0.575 6.00 55
Potassium hydroxide(KOH) NIL NIL NIL
Alum 35.247 5.50 5.5
Lime 3.875 8.00 88
NaOH Flakes NIL NIL NIL
Sulphuric Acid 0.17 0.064 8
5 January 2015 OR#47 51

5. CHP
 Bullet Points
S.No Description UOM Best parameters July,17 Aug,17 Remarks
1 Opening Stock MT 3,55,136 3,47,347 ↑
Total Coal received MT 4,17,516 4,95,914 ↑

2 Total Coal
Conveyed MT 4,24,404 5,29,253 ↑
from(BCN-3A & 3B)
3 Closing Stock MT 3,47,447 3,55,639 ↑
4 Belt Utilization % 34.65 39 *** ↑
5 SPC (Bunkering) KWH/Ton 2.6 2.51
*** Low Utilization factor due to :-

1. Con-1A , VSF-1 Not available since 15-06-2017 due to drum problem(MBE).
2. Con-5A/5B and Con-7A/7B Over load problem.
3. Paddle Feeder feeding Restricted.
11/06/2020 OR#1 52
5. CHP
 CONVEYOR BELT REPLACEMENT (For 2017)
Qty. Replaced Actual Thickness Original

Sl. No. Belt No. Reason Replaced On when belt replaced Thickness
(m) (mm) (mm)
1. NOV-16 NIL
2. DEC-16 NIL
3. JAN-17 NIL
4. ILMS-1 BELT CUT 19-02-17 7 11 14
5. MAR-17 NIL
6. CON-3A BELT JOINT WEEK 05-04-2017 19M 15 16
7. MAY-17 NIL
8. JUNE-17 NIL
9. JULY-17 NIL
11/06/2020 OR#1 53
5. CHP
 CONVEYOR PROTECTIONS BYPASSED: NIL
Equipment Total Installed Available Not Available Remarks

CHP CHP CHP
Pull chord Switch 5A-2
326/328 326 2
(Not in service due
to PCS installed but
cable N/A )
Belt Sway switch 9B-4 (Not installed)
209/216 209 7
BF4-1,2A-1,1A-1
(lever N/A)
ZSS Con-1A,Cr-A/B ,Cr-
5/20 5 15
C/D are Available &
Remaining are Not
In Service
11/06/2020 OR#1 54
5. CHP
CONVEYOR PROTECTION
 CONVEYOR PROTECTIONS BYPASSED: NIL
Protections Local PLC Remarks
PULL CORD OK OK Con-9B not in service through PLC

BELT SWAY OK OK BF-3,Con-8A,9B BSS Cable N/A
ZSS OK OK
METAL DETECTOR OK OK
SUSPENDED MAGNETS OK OK
IN LINE MAGNETIC ILMS-3 N/A pressure Pulley damage
OK OK
SEPARATORS
EQUIPMENT AVALABILITY
Equipment Availability N/A Since Status
Paddle feeder A - A
Crusher A, Screen A A - A
Crusher B, Screen B A - A
Crusher C, Screen C A - A
Crusher D, Screen D A VSF-1 N/A 15-06-17 A
Stacker/Reclaimer 1 A - Initial Trial Taken
Stacker/Reclaimer 2 A - Under Erection
A - 10,11,12,13,14B
All Conveyors Under Erection
D-80NEW(10-08-17)
D-155 (20-05-2017)
Bull dozers A D-120(24-08-17)
D-120NEW(14-8-17)
11/06/2020 OR#1 55
5. CHP
INVENTORY
BELT STOCK :-
Type of Capacity
Location Installed Longest Current
Belt Type (TPH) Quantity belt in the No. of WIDTH Idle Stock at
(m) Group Ply (mm) Stock Store (m)
I NN1600/4 1400 1&3 4376 1380 4 1400 - nil
II NN800/4 1400 RBF-1&2 60 30 4 1800 - nil
III NN630/4 770 BF-1TO4 78 19.5 4 1600 - nil
IV NN800/4 1400 14 1733 870 4 1400 - nil
NN630/4 1400 2,4,5,6,7,8,9, 7368.28 798.5 4 - nil

V 10,11,12,13 1400
11/06/2020 OR#1 56
5. CHP
IDLER STOCK:-
Type of For Belt Diameter Installed Current

Idler Name Width (mm) Location Quantity Stock at
Idler (mm) Store
10° Transition 1400 152.4 Con-1 to 14 64 Nil
1 Idler
20° Transition 152.4 Con-1 to 14 64 NIL
2 Idler 1400
3 S.A Carrying idler 1400 152.4 Con-1 to 14 448 150
4 Impact 35° 1400 190 Con-2 to 14 372 90
5 Carrying 35° 1400 152.4 Con-1 to 14 5392 Nil
S.S Carrying 35° 152.4 Con-1 & 3 20 Nil
6 idler 1400
7 F.S.A Return idler 1400 152.4 Con-2 to 13 246 Nil
Self cleaning 152.4 Con-1 to 14 28 Nil
8 R . Idler (Flat) 1400
9 Flat Return Idler 1400 152.4 Con-1 to 14 1207 75
V-Type Return 152.4 1A/B,14A/B 764 80
10 Idler 1400
11 Deflector Roller 1400 219 Con-1 to 14 28 Nil
10° Transition 152.4 BF-1 to 4 8 Nil
12 Idler 1600
20° Impact 152.4 BF-1 to 4 8 Nil
13 Transition Idler 1600
14 S.A Carrying idler 1600 152.4 BF-1 to 4 4 Nil
15 Impact 35° 1600 190 BF-1 to 4 42 Nil
16 F.S.A Return idler 1600 152.4 BF-1 to 4 4 Nil
Self cleaning 152.4 BF-1 to 4 4 Nil
5. CHP
IDLER STOCK:-
Type of For Belt Diameter Installed Current

Idler Name Width (mm) Location Quantity Stock at
Idler (mm) Store
18 Deflector Roller 1600 219 BF-1 to 4 4 Nil
10° Transition 152.4 RBF-1&2 4 Nil
19 Idler 1800
20° Transition 152.4 RBF-1&2 2 Nil
20 Idler 1800
20° Impact 152.4 RBF-1&2 2 Nil
21 Transition Idler 1800
22 S.A Carrying idler 1800 152.4 RBF-1&2 2 Nil
23 Impact 35° 1800 190 RBF-1&2 22 Nil
24 Carrying 35° 1800 152.4 RBF-1&2 6 Nil
25 F.S.A Return idler 1800 152.4 RBF-1&2 2 Nil
Self cleaning 152.4 RBF-1&2 2 Nil
27 Flat Return Idler 1800 152.4 RBF-1&2 2 5
28 Deflector Roller 1800 219 RBF-1&2 2 Nil
6. STATUTORY / REGULATORY
UPDATES
Sl. No. PARTICULARS STAT. AUTHORITY FREQUENCY VALIDITY/ STATUS

1 Fire tender fitness RTO Yearly December 13, 2017
The Oriental
2 Fire tender Insurance Yearly August 28, 2017
Insurance
April 06, 2017 (sent for
3 Portable gas detector Factories Act 1948 Half yearly
calibration)
Due in Sept 2017 (in final
4 Employee health checkup Factories Act 1948 Yearly
stage)
5 Lifting Tools & Tackles Factories Act 1948 Yearly May 2018 & Jan 2018
TS Boiler Inspection
6 Boiler #1 Licence Form VI Yearly once March 02, 2018
Dept.
7 Boiler #2 Licence Form VI Yearly once August, 2018
Dept.
8 Pressure Vessels examination Factories Act 1948 Half-yearly Awaited from SCCL
9 Ambient Air Monitoring Third Party Monthly Yet to be Installed by SCCL
Submission of Environmental
10 SPCB - TS Yearly September 2017
statement
11 Environmental Audit SPCB - TS Yearly April 2017
Conducted in March
12 External Safety Audit Factories Act 1948 Yearly
2017
11/06/2020 OR#1 59
Thank You
11/06/2020 OR#1 60
APC Deviation
APC DEVIATION FOR MONTH

UNIT# UNIT#2 STATION
S.NO. PARAMETERS MOU 1 Reason Unit#1 Reason Unit#2
443.08 435.73 878.81
1 GROSS GENERATION MU
5.75 5.75 5.75
2 TARGET APC %
25.20 25.91 51.12
3 APC MU
5.69 5.95 5.82
4 %
0.101 0.715 0.82

5 MU MDBFP was in operation during TDBFPA
MDBFP CONSUMPTION Bearing failure a & main control valve
fluctuation rectification work,
0.02 0.16 0.09
6 %
0.00 0.12 0.12 During Unit shut down auxiliary
7 SHUTDOWN APC MU consumption
0.00 0.03 0.01
8 %
25.10 25.08 50.19
9 MU
NET APC
5.67 5.76 5.71
10 %
11/06/2020 OR#1 61
STATION PERFORMANCE
Oil Consumption Detail
FD fan 1 A blade pitch; 5.86; 7%
Unit Tripping & start

FD fan 1 A blade pitch
Unit Tripping & start; 77.12; 93%
11/06/2020 OR#1 62
Reason wise BTL Financial Year 2017-18
Reason Wise Boiler Tube Leakage In FY-2017-18
Shop Joint Failure Field Joint Failure Flue Gas erosion Blocking/Fish mouth
U#1 0 1 2 2(Right angle Found in

Platen Super Heater)
U#2 1 3
11/06/2020 65
OR#1
UPDATES
Sl. No. PARTICULARS STAT. AUTHORITY FREQUENCY VALIDITY/ STATUS
1 Schedule maintenance of All Fire BIS - 2190 Monthly As per PM plan

extinguishers
 DCP,FOAM,WATER -  DCP,FOAM,WATER - July

Once in three years 2018
2 Fire extinguishers Hydro test PESO/ Dy. CCOE, Hyd.  CO2 - Once in five  CO2 - July 2020
years
3 Fire tender fitness RTO Yearly December 13, 2017

4 Fire tender Road Tax RTO Yearly March 31, 2018
The Oriental
5 Fire tender Insurance Yearly August 28, 2017
Insurance
6 Ambulance Insurance National Insurance Yearly July 28, 2018
7 Portable gas detector Factories Act 1948 Half yearly April 06, 2017 (sent for
calibration)
Smoke / Heat detectors / Alarms BIS- 2189, 3034,

8 Half yearly Yet to be commissioned
Testing NFPA 72 / Internal
9 Employee health checkup Factories Act 1948 Yearly Due in Sept 2017 (in final
stage)
Conducting of Mock drill in plant
10
11/06/2020
Factories Act 1948
OR#1
Six months Conducted on 31.08.17
66
area
UPDATES
STAT.
Sl. No. PARTICULARS AUTHORITY FREQUENCY VALIDITY/ STATUS
11 Register of accidents Factories Act 1948 Incident based Register is in place
12 Storage of Petroleum Class - C PESO/ Dy. CCOE, Hyd. Once in Ten years December 31, 2024
Decibel meter yet to be

13 Noise Level Monitoring Factories Act 1948 Monthly
procured by SCCL
14 Safety Committee Meeting Factories Act 1948 Monthly Done on 04.08.17
Register containing particulars of

15 monitoring of working Factories Act 1948 Quarterly Ongoing
environment
16 Lifting Tools & Tackles Factories Act 1948 Yearly May 2018 & Jan 2018
17 Factories Drawing/ Plan Approval Director of Factories One Time Approved in February 2017
18 Factory License Director of Factories One Time Issued in March 2017

19 Boiler #1 Licence Form VI Yearly once March 02, 2018
Dept.
2011/06/2020
Boiler #2 Licence Form VI TS Boiler Inspection Yearly once August, 2018 67
OR#1
Dept.
UPDATES
STAT.
Sl. No. PARTICULARS AUTHORITY FREQUENCY VALIDITY/ STATUS
21 Pressure Vessels examination Factories Act 1948 Half-yearly Awaited from SCCL
Periodic Testing of Chlorine Tonner

22 (38 nos) PESO Two Years August 23, 2018
License of Hydrogen gas cylinders

23 storage room CCOE Yearly Awaited from SCCL
Factories Dept. / Third

24 Stability Certificate for Buildings Party Once in Five years Awaited from SCCL
Factories Act 1948/

25 Industrial all risk policy schedule Yearly In place
Insurance
26 Drinking water analysis BIS - 3025 & CPCB Yearly Awaited from SCCL
27 Ambient Air Monitoring Third Party Monthly Yet to be Installed by SCCL
28 Water Sample Analysis – CMB BIS - 3025 & CPCB Monthly Under construction
Water Sample Analysis – CW Blow
29 BIS - 3025 & CPCB Weekly Ongoing
Down
Sludge Sample Analysis- Storage
30 SPCB Under construction
sludge
11/06/2020 OR#1 68
UPDATES
Sl. No. PARTICULARS STAT. FREQUENCY VALIDITY/ STATUS

AUTHORITY
31 Compliance Report of water SPCB, TS Quarterly To be provided by SCCL
32 Compliance Report of Air SPCB, TS Quarterly To be provided by SCCL
Compliance CCA Report for the

33 storage, handling and transport of SPCB, TS Once in Five years Valid up to April 2022
Hazardous waste / chemicals
Submission of Environmental
34 statement SPCB - TS Yearly September 2017
35 Environmental Audit SPCB - TS Yearly April 2017
36 Consent for Operation (Air and SPCB - TS Once in Five years April 2022
Water Act) & HWA
Conducted in March
37 External Safety Audit Factories Act 1948 Yearly
2017
11/06/2020 OR#1 69

OR-Sep R2

Uploaded by

Copyright:

Available Formats

OR-Sep R2

Uploaded by

Document Information

Original Title

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

OR-Sep R2

Uploaded by

Copyright:

Available Formats

OPERATION REVIEW - 02

3 Station Performance Analysis

5 Coal handling Plant

6 Statutory /Regulatory Updates

Actual for the Month 5.96 5.84 5.90

5.69 5.59 5.82

YTD 6.22 6.25 6.24

SCC 594 599 597

Design @ 4529 GCV 486 486 486

YTD 571 568 569

Coal Consumption (MT)*

Monthly (MT) 236846 246856 483701

Yearly (MT) 1261846 1365334 2627180

* Subject to Physical verification

0.01 0.18 0.09

YTD 0.40 0.38 0.39

Oil Consumption (KL)

Monthly 94.41 101.20 195.61

YTD 879.07 922.37 1801.44

Actual for the Month 0.66 0.71 0.68

0.60 0.76 0.72

YTD (After COD) 0.74 0.95 0.85

During Financial Year

TRIPPING & WITHDRAWL DETAILS FOR THE MONTH

Action Plan for Availability

Unit Observation Action Plan Target

2CA I/C-1 upstream control cable

Generation; 810.76; 94%

Availability Loss % For The Month Sep,2017

Availability; 687.56; 91%

AREA WISE OUTAGE SUMMARY

BTL; 857.9; 89%

Generation Loss (MU) Details

U#1 U#2 Station

Actual Generation 398.72 412.04 810.76

Generation Loss 33.28 19.96 53.24

CATEGORY TYPE CAUSE U#1 U#2 Station

Partial Grid Grid Restriction 5.13 5.53 10.66

Bottom Ash 2.45 2.16 2.35 2.46 2.18 2.34

U#2 APH PERFORMANCE FOR THE MONTH OF SEP

* Calculated based on loss method of Turbine.

Hot Gas temp ≤ 68°C Max 82°C 75°C

Cold Gas Temp ≤ 48°C Max 56°C 52°C

PARAMETERS Description Limit Max/Min U-1 U-2

>2 ppb Min

Min 78°C 54°C

PARAMETERS Description Limit U-1 U-2

H2 Consumption Filling / Purging 2 per day/unit 45 89*

H2 dryers in service A or B or Both A+B A+B

Both are Both are

CO2 consumed NIL NIL

CO2 Cylinders in stock 30 per unit 30 13**

*Leakage identified from Dew point sensor and attended,

Unit-1 Unit-1 Unit-2 Unit-2

RANGE 10.5 9.02 12.19 10.92 9.46

APPROACH 4.3 11.69 7.69 10.38 9.74

EFFECTIVENESS 70.9 43.56 61.31 51.28 49.27

COC FOR THE MONTH

COC Max 5.0 5.35