pie asset management vol i
Post on 08-Apr-2018
229 Views
Preview:
TRANSCRIPT
-
8/6/2019 Pie Asset Management Vol i
1/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
1
(
ASSET MANAGEMENT
FOR
POWER GENERATING UTILITIES
UN DER TH E PROGRAMME
PARTNERSHIP IN EXCELLENCE
-
8/6/2019 Pie Asset Management Vol i
2/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
2
(
FOREWORD
The growing shortage of electricity and the commitment of the Government of India toprovide power to all by 2012 have put all the power engineers of the country at brainstorming to find out ways and means to bridge the power needs.While exploring out various options to augment the capacity performance improvementof underperforming power utilities in the country was considered to be the quickest andcheapest.
Ministry of Power, Government of India has launched a programme under the namePartnership in Excellence on 9th August 2005, wherein all leading power utilities of thecountry were asked to associate with the underperforming power utilities and provide all
necessary support to improve the performance at optimum cost.
NTPC today, with its present installed capacity of 24, 954 MW and is poised to grow intoa 46, 000 MW plus company by 2012 has already set several bench marks in powergeneration performance. NTPC, the leading power sector utility has been allocated 15power generating stations out of the 22 identified to support the programme.
With a view to adopt a uniform approach to Asset Management it was felt essential toformulate and document an integrated system for areas of operation & maintenance.The existing document developed in line with the practices being used at NTPCaddresses the issue in a comprehensive manner covering the entire area of operation
and maintenance management.The objective and emphasis of the system document is Efficient, Economic & ReliablePower generation.
It is hoped that the document shall be adopted and used by each utility in its true spirit.It may be prudent to remodel some of the practices and procedure included in theapproach document to asset management but keeping the objective focused.
NTPC on its part shall continue to support this gigantic task of work culturaltransformation and change management and provide all assistance to willing partners.This only shall fructify the aim of Partnership in Excellence and provide power in plenty
to boost the countrys economy.
Dated: June 6, 2006 (RS SHARMA)Executive Director (PIE)
-
8/6/2019 Pie Asset Management Vol i
3/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
3
(
N T P C L im i t e dPARTNERSHIP IN EXCELLENCE
ASSET MANAGEMENT
FORPOWER GENERATING UTILITIES
UN DER TH E PROGRAMME
PARTNERSHIP IN EXCELLENCE(VOLUME-I)
PIE HEAD QUARTERPATNA-800 001
-
8/6/2019 Pie Asset Management Vol i
4/185
-
8/6/2019 Pie Asset Management Vol i
5/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
5
(
ASSET MANA GEMENT
FOR
POWER GENERATIN G UTIL ITI ES UNDER THE PROGRAMM E
PARTNERSHIP IN EXCELLENCEVolume-I
CONTENTS
S.No DESCRIPTION PAGEForeword 02
ASSET MANAGEMENT-Philosophy, Concept & Approach 091. Introduction 102. Objectives 123. Corporate Technical and O&M Services (C-TOMS) 13
4. Strategic Processes 145. Operation Management
Ownership Role
Services
Equipment Care Group
Knowledge Management
Operation Performance
Technical Efficiency & Audit Management (TEAM)
6. Maintenance Management 20
Total Work Management
Preventive Maintenance
Condition Monitoring
Long Term Planning Overhaul Management
Failure & Forced Outage Diagnostics
7. O&M Safety Management 368. Resource Management 38
Spares & consumables
Tools & Plants
Knowledge & Skill Management
CORPORATE TECHNICAL AND O&M SERVICES (C-TOMS) 421. Introduction 432. Objective 433. Role & responsibilities of C-TOMS 44
Operation Performance and Efficiency Management Maintenance & Resource Management
Fuel Management
Plant Betterment & Technology Support
Enterprise resource Planning & information Technology
NTPC- Partnership in Excellence: Role 50
-
8/6/2019 Pie Asset Management Vol i
6/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
6
(
OPERATION MANAGEMENT 521. Introduction 532. Objectives of Operation Management 553. Definitions 564. Calculation of Operation Parameters 61
5. Units in Use 716. Monitoring System 727. Reporting & Monitoring System 78
Daily Reporting & Monitoring -MIS
Daily Reporting of Plant Performance
Fortnightly Reporting and Monitoring of Generation Efficiency
Monthly & Annual reporting
8. Daily Performance Review Meeting 829. Monitoring by HOD (Operations) 8310. Shift Operations 8511. Role of UCB Engineers 8912. Role & responsibilities of SCE 90
13. Role & responsibilities of Operations General Shift 9214. House keeping 9315. Illumination & lighting within Station 9616. Monitoring by HOD (Water Chemistry) 9717. Role & responsibilities of Plant Chemist 9818. Role & responsibilities of O&EE Group 10219. Role of O&EE Engineer in Combustion Optimization 10520. Role & responsibilities of Fuel Management Group 10621. Functions of Environment & Ash Management Group 10822. Functions of O&M Civil 10923. Unit Forced Outage Analysis 110
Unit Trips
Boiler Tube Leakage
24. Preservation & Disposal of Log Books & Records 11425. ORT meetings 11826. P&I System Monitoring 12127. Emergency Instructions 12228. Safety Aspects in O&M 12429. Documentation 12630. Technical audits 127
ANNEXURE FORMATS: 132Daily Performance Flash Report 133Daily Generation Performance Report 134Plant Chemical analysis report 138Plant Generation Efficiency Performance Report 140Unit Forced Outage Reporting 142
Format A: Unit Trip Analysis
Format B: BTL Analysis
Agenda for discussion in ORT 148Equipment Availability Status Report 151Stand by Equipment in Service Report 153O&M SAFETY MANAGEMENT SYSTEM 154ANNEXURE FORMATS: Safety Documents 169Action plan for implementation of Asset Management System at PIE Stations 178
-
8/6/2019 Pie Asset Management Vol i
7/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
7
(
ASSET MANA GEMENT
FOR
POWER GENERATIN G UTIL ITI ES UNDER THE PROGRAMM E
PARTNERSHIP IN EXCELLENCE
Volume-I I
CONTENTS
S.No DESCRIPTION PAGEForeword 02
MAINTENANCE MANAGEMENT 091. Introduction 102. Historical back drop of Maintenance 12
3. Maintenance Types 164. Definitions 195. Reliability Centered Maintenance 236. RCM Objectives 297. RCM approach 32
SHORT TERM PLANNING FOR RELIABILITY 368. Total Work Management 379. Preventive Maintenance 61
10. Predictive Maintenance 6611. Maintenance Management Organization 7412. Functions of Maintenance Management Group 7813. Functions of Mechanical Maintenance 8014. Functions of Electrical Maintenance 8115. Functions of C&I Maintenance 8216. Maintenance Quality Improvement 8317. Resource Management 8418. Maintenance Performance Indicators (MPI) 86
Abbreviations 87FIGURES:
01 Factors Affecting Maintenance Dependencies 1402 Plant maintenance Optimization processes 2603 Total Work Management Concept 3904 WOC Format 4306 WOC Flow Cycle 4807 Committed Work Plan 53
08 Plant Maintenance Optimization Basis 6409 Integrated Concept of Predictive Maintenance 7210 Organization Structure of Maintenance Management 77
-
8/6/2019 Pie Asset Management Vol i
8/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
8
(
LONG TERM PLANNING & OVERHAUL MANAGEMENT 8919. Introduction 9020. Life Cycle Plan (LCP) 9321. Rolling Maintenance Plan (RMP) 9622. Station Location Annual Plan (SLAP) 101
Station Location Annual Plan Revisions 10323. Engineering Declaration 10624. Outage Category & Duration 11625. Long Term Planning & Overhaul Management Organization 12226. Long Term Planning 12227. Responsibility of LTP Management 12428. Outage Committee 12529. Functions of Outage Committee 12730. Overhaul Planning Process 13031. Outage Preparedness Index 13432. Pre-shut down Planning 13933. Pre-Over Haul Activities 16534. Overhaul Execution 16835. Outage Completion Report 179
FIGURES:11 Life Cycle plan 9512 Rolling Maintenance Plan-Preparation Flow Chart 9713 Five year rolling maintenance plan (Typical) 9814 Station Location Annual Plan (Typical) 10215 Overhaul Management Process- Support System 12916 Overhaul Planning Process of Unit Overhaul 133
ANNEXURE FORMATS:SLAP Revisions 104Engineering Declaration 112Pre-outage Performance Evaluation status Sheet 166
Daily OH Exception reporting Format 176. PLANT MAINTENANCE OPTIMIZATION 185PM Schedule & Condition Monitoring Activities
Boiler & Aux. Equipments (Typical) 202
Turbine & Aux. Equipments (Typical) 230
Balance of Plant Equipments 233
Electrical Equipments (Typical) 250
C&I Equipments (Typical) 263
Coal handling Plant Equipments 273
Standard Work Module for Overhauls
Boiler & aux.(Typical) 280
Turbine & aux. (Typical) 290
Balance of Plant Equipments 300 Electrical Equipments (Typical) 305
Coal handling Plant (Typical) 309
Maintenance Quality Check & Protocol (M-QCP) Sheets (Typical) 313Re-commissioning Check Sheets (Typical) 344
-
8/6/2019 Pie Asset Management Vol i
9/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
9
(
ASSET MANAGEMENT
FOR POWER GENERATING UTIL IT IES
UN DER PIE PROGRAMME
PHILOSOPHY , CONCEPT & APPROACH
-
8/6/2019 Pie Asset Management Vol i
10/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
10
(
1.0 INTRODUCTION:
NTPC, since its inception, in Nov. 1975 has set several bench marks of power
generation performance at national level. Today with the present installed
capacity of 24249 MW including the capacity of joint venture (19.51% of countrys
total Installed Capacity) it generated 170.88 BU to meet 27.60% of national
power supply. The sustained performance level could be achieved due to
scientific and professional approach to Operation & Maintenance Management
adopted at NTPC.
Government of India, Ministry of Power has launched a programme on August
9th, 2005 with the objective of performance improvement of various power
generating plants located across the country under different power utilities. The
programme aptly named, Partnership in Excellence involves countrys major
power utility NTPC Ltd. as the lead player besides involving other key
performers e.g. Tata Power, APGENCO, GEB & RRVNL.
NTPC has been entrusted with 15 stations comprising of 51 generating units of
varying size ranging from 30 MW to 210 MW with a total capability of 5925.5 MW
for the turnaround in performance. The desired objective is aimed to be achieved
through two tier approach to change management which involves:
a) Management System through Expertise & Systems Engagement (EASE).
b) Equipment/System rehabilitation through quality overhauls & technical
upgrade.
-
8/6/2019 Pie Asset Management Vol i
11/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
11
(
With a view to adopt a uniform systems approach, it has been felt essential to
evolve a documented Asset Management Philosophy for all such power
generating units covered under the Partnership in Excellence (PIE) plan.
The proposed Asset Management Philosophy is based on requirements of
equipments using age old technology; control systems and considering aspects
of obsolesce yet meeting all safety requirements.
The proposed asset management philosophy shall aim to achieve the objective
of phased improvement with a focus on efficient & economic power generation
through reliability centered maintenance approach.
The document is exclusively meant for power utilities covered under the
programme Partnership in Excellence and contains general guidelines.
Suitable changes & adjustments may be required to suit vocational needs.
However it is desirable that such changes are done with due discussion and
consent of concerned executive in NTPC-PIE group for clarity & purposeful
effectiveness.
The present PIE- Asset Management Philosophy shall be used as a guideline
facilitating the defined objectives and not as mandatory & restrictive rules for
obtrusion.
-
8/6/2019 Pie Asset Management Vol i
12/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
12
(
2.0 OBJECTIVES
The PIE- Asset Management Philosophy shall focus on achieving the broad
objectives of restoration of power generating units at a sustained & high level of
performance.
The philosophy shall focus on achieving the broad objective of efficient and
reliable power generation in the area of Operation & Maintenance through
standard guidelines so as to adopt a uniform commercial approach to achieve
the following:
(i) Maximum plant availability
(ii) Maximum generation
(iii) Optimum efficiency of generation
(iv) Optimum reliability of plant/equipment
(v) Low down time of plant/equipment
(vi) Optimum maintenance cost
(vii) Optimum resource utilization
(viii) Maximum safety at works
(ix) Optimum inventory management of fuel, spares & materials
To achieve these aims PIE-Asset management Philosophy shall adopt an
integrated Operation & Maintenance Management System.
-
8/6/2019 Pie Asset Management Vol i
13/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
13
(
3.0 CORPORATE TECHNICAL AND O&M SERVICES
(C-TOMS) GROUP:
In order to ensure that the organizations objective of Economic, Efficient &
Reliable Power Generation is met successfully it is essential to create a Central
Technical and O&M Services (C-TOMS) Group at each utility head quarter.
A similar structure has earlier been recommended by GOI appointed Srinivasan
Committee on Modernization of Maintenance Practices in Large Thermal Power
Stations in March 1986.
Similar concept is being practiced by successful utilities. The concept has been
revisited in the present context of GOI-PIE programme and a suggestive
improved model is enclosed elsewhere in the document.
4.0 STRATEGIC PROCESSES:
The proposed PIE- Asset Management Philosophy aims to achieve the objectivethrough an integrated approach to O&M process and shall cover the following
systems.
a) Operation Management System.
b) Maintenance Management System.
c) Safety Management System.
d) Resource Management System.
Periodic review and re-examination of PIE-Asset management Philosophy
containing O&M systems shall be carried out at an interval of two years or as the
need be. Such review must be carried out in consultation with NTPC-PIE group.
-
8/6/2019 Pie Asset Management Vol i
14/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
14
(
5.0 OPERATION MANAGEMENT SYSTEM
The Operation Management System is structured around the power generation
programme of the plant so as to achieve maximum continuous generation at optimum
efficiency with maximum safety and minimum cost.
The main aspects of operation management system shall be as under.
5.1 OWNERSHIP ROLE:
(i) Operations shall be directly responsible for the power generation plansand hence it shall have the ownership role. It shall be accountable to all
constraints in power generation as per the schedule.
(ii) As an owner, operations shall have an effective involvement in the Total
strategic Planning Process related to generation and maintenance.
5.2 SERVICES:
(i) Operations shall requisition the services of concerned maintenance
department after physical inspection of the defective
equipment/component and reasonable diagnostics of the defect, its nature
and its location.
(ii) The term Emergency pertaining to requirement of the maintenance
services shall be limiting in its implication only in following conditions: -
a. Immediate hazard to environment including human life & plantassets
b. Immediate loss of full generationc. Potential loss of generation beyond 20% of unit size
-
8/6/2019 Pie Asset Management Vol i
15/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
15
(
All the remaining maintenance requirements shall be classified under A &
B category as defined elsewhere. Emergency Jobs (E category) shall be
addressed to by concerned maintenance group on round the clock basis
till its satisfactory completion.
(iii) Operations shall be fully authorized to unilaterally deny the permit for work
or recall the permit for work, if issued, at short notice on reasonable
grounds of emergency related to generation or safety of plant /personnel.
5.3 EQUIPMENT CARE GROUP:
(i) Operations shall prepare the Equipment Change over Schedule in
a manner such that it integrates with the Preventive Maintenance
Plans. This is to ensure uniform operational loading of the
equipments as also their availability for maintenance as per the
plan.
(ii) Operations shall manage an Equipment Care Group (ECG). This
group shall be responsible for the following functions:
To ensure equipment cleanliness and upkeep
To ensure good plant area house keeping
To ensure adequate plant area lighting including emergency
lighting
-
8/6/2019 Pie Asset Management Vol i
16/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
16
(
(iii) Responsibility of on-load testing of protection & interlocks including
testing of fire protections & fire detection devices and protection
systems for hazardous work conditions e.g. eye washer, chlorineleak detection system etc.
5.4 KNOWLEDGE MANAGEMENT:
To ensure efficient and commercial operation practices a continuous
knowledge management programme is essential. Such a programme for skill
up-gradation and development shall be coordinated by HOD (Operations). This
shall be structured with inputs from available OMIMs, P&I diagrams, flow
diagrams and technical specifications of the equipments etc. All such OMIM
shall also be available with operation and maintenance staff in hard as well as
soft copies and on local area network. These orientation & awareness
programme shall be continually updated on the basis of experience, unit forced
outage analysis and new technological developments.
5.5 OPERATION PERFORMANCE:
(i) Head of O&M as well as the station head shall monitor and review the
following performance parameters on daily/weekly basis:
Generation performance parameters
Efficiency performance parameters
-
8/6/2019 Pie Asset Management Vol i
17/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
17
(
(ii) The intent of all such reviews and deliberations in daily plan meeting with
other section heads shall be Efficient, Economic and Reliable Power
Generation of the previous day and to evolve action plan for the present
and the next day.
(iii) Reasons of variance in generation performance as well as energy
efficiency shall be deliberated in daily plan meeting. Concerned groups
shall work upon the plan of action so decided to prevent such recurrences
and to achieve better efficiency.
(iv) Station Head and Head of O&M shall review and monitor monthly
performance of generation & energy efficiency, forced outages and other
related parameters in full details with root cause analysis and action
plan/action taken.
(v) Such a review shall be done along with Operation Review Team (ORT)
in a meeting to be carried out by Central O&M Services (COMS) of the
Utility in association with NTPC-PIE HQ services.
5.6 TECHNICAL EFFICIENCY AUDIT MANAGEMENT:
(i) An annual technical audit shall be carried out by a cross functional
team drawn from O & M personnel working at different stations alongwith Corporate Technical and O&M Services (C-TOMS) Group of the
Utility in association with NTPC-PIE HQ services.
-
8/6/2019 Pie Asset Management Vol i
18/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
18
(
(ii) The objective & intent of all such technical audit shall be as
follows:
To review the operational regime of the unit and variance
To assess the performance efficiency of the unit
To identify areas of generic problem or constraint areas likely to
affect the performance of unit/station.
To suggest remedial action plans addressing these areas
To identify areas of betterment & evolve suitable action plans
Safety aspects of O&M areas and to suggest corrective actions if
any
Compliance to statutory requirements of the environments,
electricity act and Indian boiler regulations etc. Analysis of non
compliance and remedial action plan.
Protections & Interlocks (P&I) not kept in service during the past
months and analysis of the same
System approach in O&M Practices and deviations if any, with
reasons for such deviations and recommendations if such
deviations in practices call for a permanent/temporary changes in
the system.
(iii) Major aspects which shall be under audit review for coal based
stations shall be as under:
Main steam pressure/temperature variance
HRH/CRH pressure/temperature variance
Back pressure across condenser (vacuum).
CW temperature variance
Head transfer in FW System (across HPH)
-
8/6/2019 Pie Asset Management Vol i
19/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
19
(
Water chemistry controls
Boiler metal temperature variance
Mill condition for out put & fineness
Carbon in bottom/fly ash
SADC operation & control
Oxygen in flue gas
Heat transfer across air pre-heaters
Flue gas exit temperature
Fuel Quality and its effect
Heat Rate including specific fuel consumption
Aux. Power Consumption
Emission & effluent disposal wrt environmental norms (e.g.
Sox, NOx, SPM etc)
Operation practices (Machine startup/ loading/ shutdown
parameters & processes)
Protections by passed or not in service and restoration plan
Unit trips analysis with action plan.
Major equipment outages & non-availability status and action
plan.
Equipment failures leading to partial/ total generation loss and
action plans.
Generation Performance wrt declared capability and grid
conditions
Status of emergency support system e.g. DC system & fire
protection system etc
Safety aspects, Emergency handled and lessons learnt
Fuel stock and action plan
Spares & material criticality analysis and action plan
Areas of high consumption pattern of materials and theiranalysis
-
8/6/2019 Pie Asset Management Vol i
20/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
20
(
All variance shall be analyzed wrt PG test values/ best
achieved values with action plan to reduce/eliminate negative variance.
(iv) Corporate Technical and O&M Services (C-TOMS) Group of the Utility
shall be responsible for coordination and implementation of all action
plans arising out of such technical audits and shall issue a quarterly
ATR.
6.0 MAINTENANCE MANAGEMENT SYSTEM
Maintenance Management System is structured around the equipment and plant
maintenance needs to ensure maximum availability and reliability at minimum
cost and shall be based on the concept of Total Work Management (TWM)
The major aspects of the maintenance management system shall be as follows:
6.1 TOTAL WORK MANAGEMENT:
(i) Maintenance Management system shall be based on the concept of total
work management. The maintenance strategy shall ensure distribution of
maintenance workload uniformly through the year. All maintenance jobs
shall be initiated through a work order card, monitored till completion and
documented into history system.
-
8/6/2019 Pie Asset Management Vol i
21/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
21
(
(ii) Maintenance functions shall be fully responsible for providing services so as
to facilitate operations meet the power generation plans. Maintenance shall
keep adequate resources of men, spares, material and T&P to ensure the
above function but in a most cost effective manner.
(iii) Engineering functions of maintenance e.g. equipment fault diagnostics,
identification of resource requirement, resource management, work
execution and work quality shall be the responsibility of maintenance
executives.
(iv) Planning functions of maintenance e.g. job planning and coordination for
scheduling of work, timely availability of identified resources to maintenance
and MIS as per the requirement of different levels of management use shall
be the responsibility of maintenance planning engineer.
(v) A concept of opportunity-based maintenance shall be evolved and applied
on such equipment having no redundancy. The preventive maintenance on
equipments having no redundancy shall be taken up during minor, medium
or major overhauls.
6.2 PREVENTIVE MAINTENANCE:
(i) PM Schedule: Station shall prepare a schedule of preventive
maintenance which in its early stages shall incorporate equipment
checks based on manufacturers recommendations and station
experience under the following categories:
-
8/6/2019 Pie Asset Management Vol i
22/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
22
(
(a) Weekly, fortnightly or monthly in service/walk down checks,
in addition to daily operations checks. Such checks shall not
call for stoppage of the equipments
(b) Monthly, Quarterly, Half yearly & yearly checks which may
call for equipment outage/isolations
(c) Lubrication schedule calling for complete replacement based
on manufacturer recommendations
(d) Overhaul & servicing checks at periodic intervals as
recommended by the manufacturer.
(ii) Reviews of Preventive Maintenance Schedule:
The preventive maintenance schedule so developed shall be updated once
a year based on experience on equipment behavior gained by the area
O&M engineer, periodic interaction with the equipment manufacturer as well
as the experience gained by other power utilities having similar equipments
with matching duty conditions shall also be taken into account while carrying
out the Plant Maintenance Optimization (PMO) activity for updating the
preventive maintenance schedules as well as overhaul planning.
The intent of all such annual review of PM Schedule shall be to evolve the
optimum maintenance needs specific to equipment in a particular duty
condition at a specific location.
-
8/6/2019 Pie Asset Management Vol i
23/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
23
(
The equipment specific approach rather than a general approach shall avoid
excessive or too little maintenance. All reviews of PM Schedules shall be
aimed at Condition Based Maintenance (CBM)
(iii) Equipment Changeover Schedule:
In order to ensure that preventive maintenance and condition monitoring
schedules are effective i.e. all such equipments are available in desired
state of health; an Equipment Changeover Schedule (ECS) shall be
prepared by operations in consultation with maintenance and maintenance
planning. ECS schedule shall be coordinated for implementation by
maintenance planning.
Thus maintenance planning shall ensure that equipments having
redundancy do not call for any abrupt stoppage/start of the equipment for
the purpose of implementation of preventive maintenance and condition
monitoring schedules.
(iv) Execution of PM Schedules:
Maintenance planning has to further ensure that preventive maintenance
and condition monitoring schedules of all disciplines (Mechanical, Electrical
and C&I) are integrated into single equipment isolation to the extent
possible. Maintenance planning shall therefore ensure that different
departments execute their maintenance work plan during a single isolation
and separate isolations/shutdowns are not requested.
-
8/6/2019 Pie Asset Management Vol i
24/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
24
(
6.3 CONDITION MONITORING:
(i) Condition Monitoring Schedule:
As a first step towards condition based maintenance it is essential
that Condition monitoring of all critical equipments is initiated in the first phase
and later extended to all other non-critical equipments. A condition-monitoring
schedule shall be developed for all critical equipments and executed upon by a
condition-monitoring group at each station under maintenance planning.
The condition-monitoring group shall equip itself with necessary expertise so
as to undertake behavioral trend analysis of critical equipments.
This group shall gradually develop its expertise to work as a predictive
maintenance and diagnostics group. The group shall attempt to predict likely
failure pattern in qualitative and quantitative terms. It is likely that initially these
forecasts may not be very accurate. But it is envisaged that over a reasonabletime frame expertise shall be developed to with a larger degree of confidence
affecting saving in maintenance cost.
(ii) Condition Monitoring Techniques:
Various available techniques and latest technology shall be used for condition-
based maintenance so as to impart a good degree of reliability and low
maintenance.
-
8/6/2019 Pie Asset Management Vol i
25/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
25
(
Different conditions monitoring techniques shall be used in an integrated
manner to compile conditioning monitoring database for evaluation of the
equipment condition and behavioral trend.
The initial integration of condition monitoring shall include the following:
Vibration Spectrum: Vibration and behaviour trends of all critical
rotary equipments through on/off line vibration measuring
instruments.
Lube Oil Spectrum/Analysis: Routine test of lube oil for moisture
impurities and acidity, wear debris analysis etc. shall be carried out
to determine oil condition and need for centrifuging or supplement
with additives for full life usage.
Bearing Condition Monitoring & Analysis: Monitoring of
conditions such as Lubrication, Temperature, Noise, SPM etc shall
be used to predict condition of anti-friction bearings.
Acoustics & Noise Surveys: To defect any abnormality in the
equipment as also the hazard to health of personnel working.
Infra Red Thermography: Infrared thermo-vision techniques shallbe used to detect hot spots on critical equipments e.g. SWY
transmission lines, Transformers, Steam valve leaks, bearing
condition etc.
Motor Current Analysis: Motor current analysis shall be carried
out on critical electrical motors and data used to evaluate their
performance and general condition.
Transformer Condition Analysis: Dissolved gas analysis on
transformer oil along with IRT techniques shall be used at a pre-
defined periodicity to carry out transformer condition analysis and
predict the behavior pattern so as to take timely action and avoid
costly breakdowns.
-
8/6/2019 Pie Asset Management Vol i
26/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
26
(
TAN-DELTA: Test shall be carried out on critical electrical
equipments and data used to evaluated their long-term
performance
Pressure Parts Survey: Boiler pressure parts shall be monitored
for erosion and rate of wear during overhauls. The inspection shall
be carried out by area maintenance engineer along with a
representative of quality team.
Wear Rate Survey: Mill components especially the grinding
elements shall be regularly monitored for wear rate for every 1000
MT of coal ground. This data shall be used to make life extension
action plan for grinding components of the coal mills, in addition to
component replacement plans.
Turbine Parameters: Number of starts, grid frequency, MS
pressure and temperature, First stage pressure, Condenser
vacuum/Back pressure etc.
Boiler Parameters: Boiler metal temperature variance. Trips &
thermal stress, Water Chemistry, FW heat transfer across HPH etc.
Boiler Combustion: Oxygen, flue gas exit temperature, SADCcontrols, carbon in ash, soot blowing frequency, slagging & flame
condition etc.
Unit Forced Outage Analysis: All unit tripping due to P&I shall be
analyzed for root cause and corrective action plan evolved for
implementation on techno-economic basis.
Milling System Performance: Mill/ coal fineness, Coal quality, PA
flow & Mill outlet temperature etc.
-
8/6/2019 Pie Asset Management Vol i
27/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
27
(
6.4 LONG TERM PLANNING: (LTP)
(i)Life Cycle Plan (LCP) & Life Extension Plan (LEP):
It is desirable that each utility develops a Life Cycle Plan (LCP) for the
entire life cycle of 25-30 years for each of its units which are new or have
operated for a lesser period incorporating major replacement plans.
The Initial life cycle plan shall be developed by Corporate Technical and
O&M Services (C-TOMS) Group based on the utility experience in
consultation with OEM & experience of the leading power generating
utilities as well as NTPC-PIE head quarter.
Since most of the PIE operating units are very old and already have run for
above 25-30 years, it is essential to study the unit life condition based on
their past part load operation to ensure that all repair and maintenance
plans for Life Extension Plan (LEP) are adequately identified based on cost
benefit evaluations (CBE). Station shall prepare a life extension plan (LEP)
for each of its unit based on unit behavior; RLA studies technological
developments and anticipated needs of renovation and modernization.
All such life extension plans shall be on the basis of cost benefit analysis
and shall be evaluated by the Corporate Technical and O&M Services (C-
TOMS) Group of the Utility in association with NTPC-PIE HQ services.
-
8/6/2019 Pie Asset Management Vol i
28/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
28
(
These plans shall cover replacement of high value components and /or
equipments likely to become redundant due to service conditions or
anticipatory technological improvements.
Such plans shall also indicate likely trend of replacement of the
equipment/parts which are likely to fail before the life expectancy of the
entire unit such as super heaters, re-heaters, high pressure valves, safety
valves, gear reducers, ash disposal lines, slurry pumps, chemical piping,
resins, conveyor belts and drives, coal crushers, turbine rotor blades,
turbine bolts, boiler feed pump rotor, H.P. heater coil, H.T. motor,
transformer, switch gears, cables etc. Input for such plans shall be the
experience of the industry with similar equipments/ suppliers and the
technological advancements taking place world wide.
The objective is to make a long term engineering assessment of the
equipment/component and plan the budget as well as resources to take up
such jobs.
(ii) Station Rolling Maintenance Plan:
Each station shall prepare a rolling plan for each unit overhaul. The station
rolling maintenance plan (RMP) shall be made for a minimum period of
five years.
Rolling Maintenance Plans shall have a consolidation of five year and
shall be a derivative of the life cycle plan (LCP) & life extension plan (LEP)
of the station. The plan shall have projections of five years.
-
8/6/2019 Pie Asset Management Vol i
29/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
29
(
The first two years shall have a fairly accurate assessment of major jobs
to be taken up along with work duration and budget requirement whereas
subsequent three years shall be indicative. These plans shall be reviewed
/updated every year to project the assessment for the next five years in a
rolling manner.
This plan shall be updated every year and used to anticipate requirement
of resources e.g. spares and material, skill and expertise, finances &
budget projections. These plans shall be updated every year in April in a
rolling manner. These plans shall be examined by the Corporate Technical
and O&M Services (C-TOMS) Group of the Utility in association with
NTPC-PIE HQ services.
(iii) Station Location Annual Plan:
Each station shall prepare station location annual plan for each unit
derived out of its rolling plan. This plan shall be used for final planning as
well as organizing the resources e.g. spares and material, skill and
expertise, finance & budget provisions and execution of the plan.
-
8/6/2019 Pie Asset Management Vol i
30/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
30
(
6.5 OVERHAUL MANAGEMENT: (OHM)
(i) Planned & Forced Outages:
Only unit outages budgeted under the station annual plan and approved
by the station management as well as the grid management/statutory
authority shall be termed as Planned Outage. All other outages shall fall
under the category of forced outages.
(ii) Overhaul Category:
The category of overhaul for thermal units based on frequency and
duration of planned unit outage shall be as follows:
Minor Overhaul: Any budgeted outage not exceeding seven
days.
Medium Overhaul: Any budgeted outage of seven days or
more but of not more than twenty five days duration.
Major Overhaul: Any budgeted outage exceeding twenty
five days duration.
(iii) Overhaul Duration:
For the purpose of calculating the planned outage duration, period from
bar to bar (de-synchronization to re-synchronization) shall be considered.
Extension of planned outage on account of surprise defects and
unforeseen or force-majures shall be accounted under unscheduled
extension of planned outage.
-
8/6/2019 Pie Asset Management Vol i
31/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
31
(
For thermal generating units following duration shall be considered:
S.No. Unit Size (MW) Work category Overhaul
Duration
(days)
01 Below 100 MW size Boiler statutory Inspection 15 days
02 100 MW & above but
less than 200 MW size
-do- 20 days
03 200 MW & above -do- 25 days
04 Below 100 MW size Turbine overhaul
(all cylinders)
30 days
05 100 MW & above but
less than 200 MW size
Turbine (one or more
cylinders at a time)
35 days
06 200 MW & above Turbine (one or more
cylinders at a time)
45 days
These are initial time frames which shall be improved upon as the
experience of PIE stations grow and all efforts shall be made to match
national levels of performance benchmarked by NTPC.
-
8/6/2019 Pie Asset Management Vol i
32/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
32
(
(iv) Engineering Declaration:
An engineering declaration of each unit planned for an outage shall be
prepared by the station maintenance planning defining the objective of
outage, work plan, present performance of the unit and anticipated
quantitative improvements in performance, availability and reliability.
Engineering declaration shall also justify expenditure in terms of projected
gains. The document shall be submitted in January each year to
Corporate Technical and O&M Services (C-TOMS) Group of the Utility
which shall be examined by them in association with NTPC-PIE HQ
services.
(v) Maintenance Quality Check & Protocol Sheets:
Station maintenance planning group shall coordinate to develop
maintenance Quality Check & Protocol Sheets (MQCP) in association with
station area maintenance engineers. These QCP shall have the category
of checks also defined. These MQCPs shall be used during all major PM
jobs including Equipment or Unit Overhauls. The primary responsibility of
work and it quality shall rest with the area maintenance executive.
-
8/6/2019 Pie Asset Management Vol i
33/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
33
(
6.6 FAILURE & FORCED OUTAGE DIAGNOSTICS:
(i) Unit Forced Outage: All unit forced outages shall be categorized under
following three categories.
Boiler tube leakages
Unit tripping due to protections & interlocks
Grid disturbances
(ii) Equipment Failure Analysis: All major equipment failure shall be
investigated and analyzed in detail and action plan evolved to prevent
such recurrence. Initially following equipment/system may be covered for
failure analysis.
Steam Generator
Main turbine
Turbo generator Air pre-heater
ID/FD/PA fans
Milling system
Boiler feed Pump
Condensate Extraction Pump.
C.W. Pumps
Compressors BFP drive turbine
Transformers (GT/ST/UT/IBT)
HT Motors
-
8/6/2019 Pie Asset Management Vol i
34/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
34
(
The above list is suggestive and not mandatory and may have additions
and deletions on the basis of requirement at each station.All such failures analysis shall be carried out by a diagnostic committee
formed out of the available experts at station level with members drawn
from different disciplines e.g. operation, boiler maintenance, turbine
maintenance, electrical maintenance, C&I maintenance, chemistry and
maintenance planning as well as operation performance and energy
efficiency group. All analysis shall contain the details of previous such
recurrence over the past three years and remedial actions taken, if any.
(iii) Boiler Tube Leakage Analysis: Boiler Tube Leakage (BTL) shall be
investigated and analyzed in detail and action plan evolved to prevent
such recurrence. Boiler Tube Leakage (BTL) shall be investigated and
analyzed by the station and remedial action plans shall be integrated with
unit overhauls for major replacement of pressure part components to
prevent boiler tube leakages. Wherever required this group shall take the
help of NTPC R&D / IIT or other test labs for the purpose.
(iv) Unit Trip Analysis: All unit trips shall be investigated and analyzed in
detail and action plan evolved to prevent its recurrence. Such action plan
shall be integrated with unit overhauls or opportunity based maintenance
plans so as to achieve the target of zero tripping.
(vi) Failure and forced outage report shall be submitted by the committee
within a week of restoration of the equipment/unit to station management
for onward submission to Corporate Technical and O&M Services (C-
TOMS) Group of the Utility for review and evaluation in association with
NTPC-PIE HQ services.
-
8/6/2019 Pie Asset Management Vol i
35/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
35
(
Based on all such failure analysis each station shall organize every six-month
awareness and knowledge sharing workshops, wherein action plan
implementation shall also be discussed & deliberated.
(v) Plant betterment plans: Plant betterment plans shall be evolved
out from unit outage analysis and other major equipment failure
studies. Plant betterment plan shall also focus on technical
obsolescence. The aim of such plant betterment plans shall be to
achieve enhanced reliability and use of new and cost effective
technology.
(vi) RLA studies & Life Extension Plans (LEP): Residential life
assessment studies need to be initiated in a planned manner and
necessary data bank created from base material or the time of first
unit/equipment overhaul.
A few of such aspects of RLA studies that need to be incorporated are as
follows:
Creep measurement of high temperature/pressure lines e.g.
MS, HRH, and CRH etc.
Creep measurement of high temperature/pressure pressure
parts headers.
Creep measurement of high temperature fasteners e.g.
turbines, ESV/IV & CV/GV fasteners and spindles etc.
Copper Pickup Test of pressure parts shall be carried out
during each major overhaul, especially where Copper or its
alloy is use in steam circuit.
-
8/6/2019 Pie Asset Management Vol i
36/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
36
(
In situ Oxide thickness (IOT) measurement on steam coils.
Weld joint inspection on critical areas e.g. MS, HRH, CRH
steam lines, boiler drum, turbine chest, super heater bi-
metallic joints etc. shall be carried out using NDT
techniques.
Microstructure replica shall be taken at select places e.g.
turbine casings, steam chest gas turbine combustion
chamber, steam generator headers etc.
Natural frequency measurement of turbine blades
RLA study database shall be used to define maintenance needs and life
extension plans leading into useful renovation & modernization.
7.0 O & M SAFETY MANAGEMENT SYSTEM
(i) All power generating plants and machinery are subjected to fluid flow
at high velocity with high pressure and temperature, flow of high
current and voltage, handling of bulk chemicals and gases as well as
exposure to radiation hazards. O&M Safety Management System
shall have a focus on handling of such situations arising out of all
such conditions of plant & machinery in a manner that ensures a
continual safe work environment to men, machine and surrounding
environment and its habitat.
-
8/6/2019 Pie Asset Management Vol i
37/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
37
(
(ii) The system of permit for work shall be therefore well defined,
authenticated and approved to meet the above requirements of
safety of machine, environment & personnel. Different safety
documents to be put in use shall be under following categories:
LWC- Limited work certificate: shall be applicable in situations
where the equipments is in service or in standby mode and such
standby equipment can start any time without prior intimation.
Observance of predefined precautions is an essential condition.
PTW-Permit to work: shall be applicable in situations where
equipment is fully isolated and certified by operations. Observance
of predefined precautions is necessary.
PTW with HWP (Hot Work Permit): shall be applicable in
situations where working maintenance personnel are allowed to
carry out welding and other such jobs, which have a potential fire
hazard. Observance of predefined precautions is necessary as also
preparedness to prevent any fire or untoward incident.
ROMP-Restoration of Motive Power: shall be applicable insituations where working maintenance personnel are allowed of
restoration of motive power by authorized person for trial run &/ or
adjustments during the maintenance work. Observance of
predefined precautions is necessary.
SFT- Sanction for Test: shall be applicable in situations where
working maintenance personnel shall be with authorization to
perform specified test after observing necessary precautions on a
live or isolated system.
-
8/6/2019 Pie Asset Management Vol i
38/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
38
(
8.0 RESOURCE MANAGEMENT SYSTEM
Success of O & M systems shall depend upon the timely availability of
resources, their efficient use & effective management.
In order to address these aspects it is essential that a Corporate technical
and O&M Services (C-TOMS) Group is created at each utility corporate
office. This group shall be focal point for achieving the generation
objectives of the organization. The details of such a group and its role and
responsibilities are defined elsewhere in the document. Also it is essential
that the support services e.g. purchase contracts, finance & human
resource groups are also sensitized to the organizations generation plan
and its associated requirements.
The various practices and procedures need to be formulated with this sole
objective. The aspect of resource management shall also comprise the
following:
(a) Spares & Consumable Material Management
(b) Knowledge & Skill Management
-
8/6/2019 Pie Asset Management Vol i
39/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
39
(
8.1 SPARES & CONSUMABLE:
(i) Spares management shall call for identification of spares,
equipment wise & developing the full specification. The category of
spares common to more number of equipments can be thereafter
evolved while retaining link with the individual equipments.
(ii) Equipment spares with propriety cases need to be procured under
a pre-agreed rate contract to have minimum inventory yet ensuring
timely availability of spares. Such purchase shall be governed
under pre-defined and pre-approved purchase process.
(iii) For spares & materials which are available with alternate/ more
vendors, procurement need to be rationalized under a pre-tendered
rate contract to have minimum inventory yet ensuring timely
availability of spares.
(iv) Management of common use and fast moving Consumables &
other materials shall call for identification of estimated annual
consumption at the station. Item in this category can be put on rate
contract for quick response deliveries. Continued procurement from
such vendors shall depend upon performance evaluation by each
such station in their respective area.
-
8/6/2019 Pie Asset Management Vol i
40/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
40
(
8.2 TOOLS & PLANTS:
(i) Tools & plants form an integral part of the O&M processes. It is
therefore essential to have T&P of good quality and in good
condition. Wrongful use of T&P must be discouraged as it may lead
to poor quality of work as well as may create unsafe work
conditions.
(ii) It is always desirable to have the latest tools, tackles & plant
services as this helps eliminate long and prolonged outages. It
should be considered as an investment in better methods, practices& procedures. Otherwise also a good methodology shall be to work
out cost economics of the investment in T&P.
8.3 KNOWLEDGE AND SKILL MANAGEMENT:
(i) To encourage knowledge based approach amongst power
professionals of PIE stations area specific workshops and technical
journals on feed back sharing can be evolved.
(ii) To keep abreast of latest technology as well as to keep Operation &
Maintenance personnel afresh, training & refresher programs need
to be organized. These training programmes could be structured in-
house or with the support of external expert faculty or throughnational level institutes involved in training in power &
management. A continuous interaction also need to be maintained
among all levels of employees for dissemination of knowledge,
identification of training needs etc.
-
8/6/2019 Pie Asset Management Vol i
41/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
41
(
(iii) For overhauling jobs enlistment of vendors/agencies can be done
based on periodic evaluation & past work performance in terms of
quality, time duration & reliability.
Suitable procedure for evaluation of work performance of such
enlisted vendors based on pre-defined/pre-determined parameters
needs to be evolved to encourage quality work.
-
8/6/2019 Pie Asset Management Vol i
42/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
42
(
CORPORATE TECHNICAL AND O&M SERVICES
(C-TOMS)
-
8/6/2019 Pie Asset Management Vol i
43/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
43
(
1.0 INTRODUCTION:
In order to ensure that the organizations objective of Economic, Efficient &
Reliable Power Generation is met successfully it is essential to create a central
O&M Services group at each utility head quarter.
This has earlier been recommended by GOI appointed Srinivasan Committee on
Modernization of Maintenance Practices in Large Thermal Power Stations in
March 1986.
The concept is being practiced by successful utilities. This has been revisited in
the present context of GOI-PIE programme and a suggestive improved model is
presented in this document.
2.0 OBJECTIVE:
The objective of the creation of a Central O&M Services Group at all PIE Utilities
is to ensure that the organizations objective of Economic, Efficient & Reliable
Power Generation is met successfully.
Most the power generating units of these stations are over 25-30 years old and
hence need a well structured technical support to ensure that power generation
plans of the organization are met without interruptions, while ensuring that O&M
needs are met in a cost effective manner and without any delay .
-
8/6/2019 Pie Asset Management Vol i
44/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
44
(
The proposed group shall have roles and responsibilities as defined in
subsequent para though not limiting. The group shall be headed by a chief
executive reporting directly to Director (Generation/ Operation/Thermal) as the
case may be who in turn reports direct to CEO of the power utility.
3.0 ROLE & RESPONSBILITIES OF THE C-TOMS:
A centralized Corporate Technical and O&M Services (C-TOMS) group shall be
structured so as to perform following broad spectrum of key functions. This shall
cover though not limiting to the following to ensure that the organizational
objective of Efficient, Economic & Reliable Power Generation is continually met
1. Coordinate all O&M requirements of the different stations of the
organization starting from the conceptual design stage to erection,
commissioning to efficient, economic & reliable power generation.
2. Development of O&M Management Systems
3. Installation & implementation of all such systems.
4. Periodic review of the systems effectiveness and suitable improvements
& amendments
5. To ensure technical expertise and skill engagement as well as engineering
support for plant betterment, improvements and modernization plans overthe life cycle of the units/plant.
-
8/6/2019 Pie Asset Management Vol i
45/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
45
(
The central Corporate Technical O&M Services (C-TOMS) group shall cover the
following areas
1. Operations Performance & Efficiency Management System
2. Maintenance & Resource Management System
3. Fuel Management System
4. Plant Betterment & Technology Support System
5. Information Technology & Enterprise Resource Planning
The role & responsibilities of each group, though not limiting, is summarized
below
OPERATIONS PERFORMANCE & EFFICIENCY MANAGEMENT SYSTEM
The group shall be responsible for the following:
1. Development of standard operations performance & efficiency monitoring
systems
2. Creation of adequate awareness at different level about the same and
ensure implementation of these systems at each stations with suitable
location changes with due approval
3. To evolve safe operating procedures and check list/ sheets of
commissioning, re-commissioning, operation, start up and shut down of
the plant at all levels.
-
8/6/2019 Pie Asset Management Vol i
46/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
46
(
4. To ensure that all equipment/plants are thoroughly checked and made to
operate at guaranteed performance levels in a safe and effective manner.
5. Preparation of safety manuals incorporating the safe operation & isolation
procedures to ensure safety of plant, personnel and environment during all
times of O&M activities.
6. Monitoring the variance in efficient operation & identify reasons. To
introduce the world wide best practices which facilitate energy efficient
operation
7. To set norms of water chemistry performance and to ensure that water
chemistry is maintained to desired quality at all its operating plants.
8. To provide assistance and to ensure adequate and effective
implementation of operation performance & energy efficiency
management system incorporating activities of water chemistry
management.
MAINTENANCE & RESOURCE MANAGEMENT SYSTEM
The group shall be responsible for the following:
1. Development of standard maintenance & resource management system
with focus on short term as well as long term maintenance needs and
resource requirements.
2. Creation of adequate awareness at different level about the same and
ensure implementation of these systems at each stations with suitable
location changes with due approval
3. Monitoring the maintenance performance indices. To introduce the world
wide best practices which facilitate safe & quality maintenance practices to
impart reliability to equipment service condition.
-
8/6/2019 Pie Asset Management Vol i
47/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
47
(
4. To implement systems for optimization of maintenance needs
incorporating a judicious mix of preventive, corrective and predictive
maintenance as well as condition based overhauls.
5. To provide assistance and to ensure adequate and effective
implementation of maintenance management system incorporating
activities of short & long term, overhaul management and condition
monitoring.
FUEL MANAGEMENT SYSTEM
The group shall be responsible for the following:
1. To ensure effective coal coordination between the organization, coal
companies and transporter so that adequate quantity of coal is always
available at the stations to meet the generation plans.
2. To devise & implement proper test procedures of coal sampling and
quality measurement to ensure low cost of fuel input.
3. To coordinate with different central and state agencies such as railways
etc to ensure cheaper mode of coal haulage & transport
4. To coordinate with railways & stations to ensure adequate loading/
unloading to avoid demurrage etc.
-
8/6/2019 Pie Asset Management Vol i
48/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
48
(
PLANT BETTERMENT & TECHNOLOGY SUPPORT SYSTEM
The group shall be responsible for the following:
1. Analysis of all type of equipment failures & forced outages including trips,
BTL etc especially of repetitive nature and propose engineering solutions
for its prevention.
2. To provide adequate engineering support to all such plant betterment
plans.
3. Technical Audit of the units/power generation plant. Set standards of test
procedures for testing of coal, water, equipment and system performance
etc
4. Undertake plant betterment proposals wrt environmental & ecological
needs, statutory needs as also the optimum generation & reliability
requirements with due cost benefit evaluations.
5. Creation of adequate awareness at different level about all such needs,
organize budget & finance and ensure implementation of these plans in a
cost efficient manner.
6. To create expert & specialist groups in the areas of Mechanical- Boiler,
Turbine, Balance of Plant etc, Electrical- Generator, Transformer, Switch
yard etc, Control & instrumentation, Operation- Water chemistry, Energy
Efficiency etc.
-
8/6/2019 Pie Asset Management Vol i
49/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
49
(
ENTERPRISE RESOURCE PLANNING (ERP) & INFORMATION
TECHNOLOGY (IT)
The group shall be responsible for the following:
1. Advance planning of O&M requirements of the station, resource gap
analysis & management wrt manpower, skill, training needs, centralized
spare pools & inventory management, organization structure &
restructuring from time to time to face the new business challenges before
the organization.
2. Define & revisit the role & responsibilities of the organization structure to
meet the present as well as the future anticipated needs based on
business expansion plans.
3. Training & redeployment of O&M personnel for proper & effective
utilization.
4. Computerization & net working of all O&M Systems with ERP and usage
of Information Technology to ensure quick management information
system (MIS)
5. Use of MIS for management decision support system (M-DSS) to reduce
dependence on human judgment, better planning & coordination and
optimum resource utilization
6. Commercial Management of the organization through efficient cost control
& financial discipline.
-
8/6/2019 Pie Asset Management Vol i
50/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
50
(
NTPC
PARTNERSHIP IN EXCELLENCE
HEAD QUARTER GROUP
-
8/6/2019 Pie Asset Management Vol i
51/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
51
(
ROLE OF NTPC: PIE-HQ GROUP
1. To assist the station in formulating guidelines for operation & maintenance
2. To carry out selective analysis of unit outages and other operational
related problems.
3. To compile data & feed back from each station related to the following:
Major operational events
Major equipment outage & their analysis
Plant Betterment Plans & Modification of schemes
Equipment/unit performance & corrective plans, if any.
Uniform code of practices wrt O&M of units & equipments
4. To organize workshops and awareness programme on various tropics
connected to operation & maintenance.
5. Review & evaluate the performance of protection & interlocks and other
auto loops and suggest improvements, if any.
6. To assist SRM-NTPC, PIE group & station heads to conduct monthly
operation review team meetings.
7. To review & monitor the efficiency parameters of each unit of the stations.
-
8/6/2019 Pie Asset Management Vol i
52/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
52
(
OPERATION PARAMETER PERFORMANCE
MANAGEMENT SYSTEM
FOR
NTPC - PIE STATIONS
-
8/6/2019 Pie Asset Management Vol i
53/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
53
(
1.0 INTRODUCTION:
Operation Management System has been developed to standardize all systems
related to Operation Performance and to achieve uniform implementation of
practices through-out all PIE stations. Sincere efforts and implementation of the
systems shall pay rich dividends in the form of high generation, plant load factor,
availability as well as high loading factor on sustained basis.
Over the last decade, the Government of India (GOI) has introduced several
changes under Power Sector Reforms. The beginning of the process of
liberalization & decontrol, advent of availability base tariff (ABT) system, free
governor mode operation (FGMO) regime and the Indian Electricity Act 2003 has
opened new and challenging opportunities. The business scenario of power
sector has begun to change with the introduction of availability based tariff (ABT)
and new initiatives in the grid management. The changed scenario also shifts
focus to merit order generation by power utilities.
Operation Management System manual has a focus on efficient, economic and
reliable power generation.
The following aspects are covered in the Operations System Management
manual.
1. Objective of operation management
2. Reporting, logging & monitoring system at station
3. Reporting & monitoring system at PIE head quarter
4. Operation performance & efficiency - review system
5. Operation review team (ORT) system
-
8/6/2019 Pie Asset Management Vol i
54/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
54
(
6. Technical audit system
7. Role of operations staff
8. Role of operation efficiency staff in monitoring of plant performance.
9. Role of chemist & desirable water chemistry parameters
10. House keeping at station
11. Guidelines for allowing by pass of P&I, auto loops etc and their
restoration
12. Guidelines for availability of technical documents e.g. OMIM, P&I
diagrams and latest technical documents.
13. Guidelines for enhancement of technical skill through periodic
training, orientation and awareness programme.
14. Guidelines for preservation & disposal of charts, log sheets,
DAS printout, Log book.
-
8/6/2019 Pie Asset Management Vol i
55/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
55
(
2.0 OBJECTIVES OF OPERATION MANAGEMENT
The Objectives of Operation Management are described as under:
1. To ensure safe and accident free operation wrt surrounding environment
and in compliance with the statutory provisions
2. To operate the stations at maximum capability
3. To ensure minimum partial loading of units
4. To ensure the compliance of all operational systems, as envisaged
5. To operate the plant and accessories at optimum efficiencies within
defined operational regime
6. To ensure efficient and reliable operation of units with sustained
performance.
7. To operate the plant at minimum oil consumption, auxiliary consumption
and make up water consumption
8. To ensure optimum water chemistry parameters
9. To operate the units at maximum availability
10. To ensure continuous development & up-gradation of operational skill of
the operating personnel
-
8/6/2019 Pie Asset Management Vol i
56/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
56
(
3.0 DEFINITIONS:
ITEM DEFINITION
Installed Capacity The maximum capability of the generating unit/ station to
deliver ex-bus MWh or maximum continuous rating
De-rated Capacity The duly certified and approved by competent authority (CEA)
the maximum capability of the generating unit/ station to
deliver ex-bus MWh or maximum continuous rating,
Availability Factor on
bar
Availability Factor on bar of a unit is the percentage ratio of
operating hours and the total hours for a given period of time.
Reserve Shut down Duration of shutdown of unit because of no power demand
situation and unit with drawl imposed by the grid.
Auxiliary Power
Consumption (APC)
The ratio as a percentage of energy generated (in KWh) at
generator terminals minus energy delivered (in KWh) at the
generating station switchyard to gross energy in KWh
generated at the Generator terminals.
Actual Generation ex
bus (AG)
Actual generation of station available for dispatch or actual
sent out energy (Ex-bus) .
Black Start Procedure The procedure necessary to recover the unit from a total
blackout condition i.e. total power failure in the grid.
-
8/6/2019 Pie Asset Management Vol i
57/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
57
(
CEA Central Electricity Authority.
CERC Central Electricity Regulatory Commission.
Declared Capacity(DC)
The capability of the generating unit/ station to deliver ex-busMWh declared by the generating station.
Demand The demand of active power MW and reactive power MVAR
of electricity unless otherwise stated.
Dispatch Schedule Net MW (ex-bus) and MWH output of a generating station,
schedule to be exported to the grid from time to time.
Drawl Schedule Net MW (ex-bus) that a state is scheduled to receive from the
Inter State Generating Station (ISGS) including bilateral
exchanges from time to time.
Downtime Time duration for which an equipment or unit is out of service,
as a result of equipment/unit failure.
Disaster Management
Plan
Action plan to provide the maximum practicable protection for
equipments, personnel and the environment in the event of a
major man made disaster or natural crisis e.g. earthquakes,
floods, fire, etc.
Dry Flue gas loss The heat loss from the boiler in the dry component of gases to
the stack.
Expert System A software based system, which makes or evaluates
decisions based on rules established within the software.
Emergency
Instructions
Standing instructions to be carried out by operation engineer/
operator during emergencies like grid failure, hydrogen
leakage, fire etc.
Free Governor Modeof Operation (FGMO)
Operation of unit with turbine governor modulation in actionwith respect to grid frequency.
-
8/6/2019 Pie Asset Management Vol i
58/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
58
(
Gross Generation Total electrical output from the generator terminal.
Governor Droop The percentage drop in system frequency which would cause
the generating unit under free governor action to change itsoutput from zero to full load.
Gross Calorific Value
(GCV)
The heat produced in kcal by complete combustion of one kg
of solid fuel or liquid fuel or one standard meter of gaseous
fuel, as the case may be.
Gross Heat Rate
(GHR)
The heat energy in kcal input required to generate one KWh
of electrical energy at generator terminal
Heat Balance
Diagram
A diagram expressing temperature, pressure, enthalpy and
flow values throughout the cycle for a given set of conditions.
Loading Factor (LF) It is the percentage ratio of plant load factor and availability
factor on bar.
Maximum Continuous
Rating (MCR)
The maximum continuous output at the rated generator
terminals, guaranteed by the manufacturers at rated
parameters.
Make up water
consumption
It is the percentage ratio of DM water consumption and MCR
capacity of boiler.
Multiple Unit Tripping Outage of more than one unit simultaneously due to any fault
Net Generation Total electric output at switchyard. It is the difference betweenelectrical generator output and the auxiliary output.
Net Heat Rate(NHR) The heat energy in Kcal,input to a generating unit to deliverone KWh at the switchyard.
Operation &
Maintenance Cost(O&M Cost)
In relation to a period means the expenditure incurred in
operation & maintenance of the generating station includingmanpower, spares, consumables, insurance & overheads.
Operation Co-ordination Committee(OCC)
A committee of REB with members from all the constituentswhich decides the operational aspects of the Regional Grid
-
8/6/2019 Pie Asset Management Vol i
59/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
59
(
Operating Hours The length of time that an item of equipment is actuallyoperating.
Outage recurrence Outage of same unit over the period for same nature of fault.
Overall PlantEfficiency
It is the ratio of electrical energy sent out to the heat suppliedto steam in boiler.
Plant Load Factor(PLF)-actual
In relation to a given period, is expressed as the percentageof total actual KWh generated at generator terminals toinstalled capacity, expressed in KW multiplied by number ofhours in that period.
Plant Load Factor(PLF)-deemed
In relation to a given period, is expressed as the percentageof total deemed (actual plus restriction imposed by the grid)KWh generated at generator terminals to installed capacity,expressed in KW multiplied by number of hours in that period.
Partial Loading It is the percentage by which unit runs at reduced load.
Protective Device Devices and assets intended to eliminate or reduce theconsequences of equipment failure.
Permit To Work(PTW)
The prime document used by the maintenance unction tomanage maintenance tasks.
PerformanceParameters
Those variables in a power cycle which can be measured orcalculated and which are indicative of the level of performanceof a component, system, equipment or unit.
Regional Electricity
Board (REB)
A board constituted by resolution of Central Government for a
specified region for facilitating the integrated operation of thpower system in that region.
Regional LoadDispatch Centre(RLDC)
The center so designed for a specified region where theoperation of the power system in that region and theintegration of the power system with other regions and areasare coordinated.
Re-commissioningChecklist
List of checks, which are adhered for every equipment duringthe trial run and re-commission for safe and trouble freeoperation of the equipment.
Sent Out Capability(SOC)
Sent out capability of a generating station means thecapability to deliver ex-bus MHh based on which availability
shall be worked out.Schedule Generation(SG)
Ex bus scheduling in MW as given by RLDC to the generatingstation.
Specific OilConsumption
It is the consumption of oil (ml) per KWh generation.
Specific CoalConsumption
It is the consumption of coal (Kg) per KWh generation.
-
8/6/2019 Pie Asset Management Vol i
60/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
60
(
Technical Co-ordination Committee(TCC)
The committee set up by REB to coordinate the technical andcommercial aspects of the operation of the Regional grid.
Throttle Governing All first stage nozzles are in common annulus and aresubjected to the same amount of throttling.
UnscheduledInterchange (UI)
Variation in actual generation and the schedule generation
Unit Tripping Outage of a unit due to actuation of any protection or theoutage of unit during emergency condition.
Un burnt carbon loss This loss is due to amount of carbon, which remains as aresidue in the ash from boiler.
Variable PressureOperation
An operating method in which the load is changed by varyingthrottle pressure in lieu of changing valve position .
Valves Wide Open The turbine control valve setting which corresponds to allturbine control valves fully open.
Wet Flue gas loss This is the heat loss from the boiler in the flue gas due towater vaqpour present as moisture & hydrogen in coal.
-
8/6/2019 Pie Asset Management Vol i
61/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
61
(
4.0 CALCULATION OF OPERATIONAL PARAMETERS
1.0 PLANT LOAD FACTOR (PLF):
a) Plant Load Factor for the Unit (%):
Gross Generation (MU) of a Unit (Reference period)PLF (Unit) = ------------------------------------------------------------------------------ x 100
Rated Gen. Capacity (MW/1000) of Unit x No. of Hrs (Ref. Period)
b) Plant Load Factor for the Stage I (%):
Sum of Gross Generation (MU) of Stage-I units (Ref. period)PLF (Stg-I) = ------------------------------------------------------------------------------ x 100
Rated Gen. Capacity (MW/1000) of Stg-I x No. of Hrs (Ref. Period)
c) Plant Load Factor for the Stage-II (%):
Sum of Gross Generation (MU) of Stage-II units (Ref. period)PLF (Stg-II) = ----------------------------------------------------------------------------- x 100
Rated Gen. Capacity (MW/1000) of Stg-IIx No. of Hrs (Ref. Period)
d) Plant Load Factor for the Station (%):
Sum of Gross Generation (MU) of all Units over a reference periodPLF (Station) =----------------------------------------------------------------------------- x 100
Rated Gen. Capacity (MW/1000) of all Units x No. of Hrs (Ref. period)
2.0 AVAILABILITY FACTOR ON BAR:
a) Availability Factor on bar for the Unit (%)
Operating Hours of the unit over the reference periodA.V.F (On bar) = -------------------------------------------------------------------- x 100
Total hours (Reference period)
-
8/6/2019 Pie Asset Management Vol i
62/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
62
(
b) Availability Factor on bar for Stage-I Units, (AVFs1) (%)
Sum of the Availability Factor of Stage-I UnitsA.V.F (On bar) = -------------------------------------------------------------
Number of units of the Stage-I (N1)
c) Availability Factor on bar for Stage-II Units, (AVFs2) (%)
Sum of the Availability Factor of Stage-II UnitsA.V.F (On bar) = -------------------------------------------------------------
Number of units of the Stage-II (N2)
d) Availability Factor on bar for Station, (AVFs) (%)
AVFs1 x N1 x C1 + AVFs2 x N2 x C2A.V.F (On bar) = ------------------------------------------------
N1 x C1 + N2 x C2
Where,
AVFs1, AVFs2 =Availability Factor On bar,(%) of Stage- I & Stage-II respectively
N1, N2 = Number of Units of Stage - I & Stage-II respectively
C1, C2 = Capacity (MW) of units of Stage -I & Stage-II respectively
3.0 MACHINE AVAILABILITY:
a) Machine Availability Factor for the Unit (%)
Sum of Operating Hours & outage hours due to fuel andgrid restriction of unit (Reference period)
A.V.F (M/C) = ---------------------------------------------------------------------------- x 100Total hours (Reference period)
-
8/6/2019 Pie Asset Management Vol i
63/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
63
(
b) Machine Availability Factor for Stage-I Units (%)
This can be calculated sane way as shown in 2b)
c) Machine Availability Factor for Stage-II Units (%)
This can be calculated sane way as shown in 2c)
d) Machine Availability Factor for Station (%)
This can be calculated sane way as shown in 2d)
4.0 AVAILABILITY BASED ON DC:
In relation to a thermal generating station Availability for any period means the
average of the daily average declared capacities (DCs) for all the days during that
period expressed as a percentage of installed capacity of the generating station
minus normative auxiliary consumption. Availability shall be computed in
accordance with the following formula:
NAvailability = 10000 DCi /{ N x IC x (100-AUXn)} %
i=1
Where,
I.C = Installed Capacity of the station in MW
DCi = Average declared capacity for the ithday of the period in MW.
N = Number of days during the period
AUXn = Normative Auxiliary power consumption as a percentage of gross
generation
-
8/6/2019 Pie Asset Management Vol i
64/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
64
(
5.0 LOADING FACTOR,(%):
Loading Factor (%) of Unit or Stage-I/II or Station:
Plant load Factor of Unit or Stage-I/II or Station (%)Loading Factor = -------------------------------------------------------------------- x 100
Availability Factor on bar of Unit or Stage-I/II or Station (%)
6.0 PARTIAL LOADING:
Partial Loading of Unit or Stage-I/II or Station:
Partial Loading (%) = (100 - Loading Factor in %)
7.0 EQUIPMENT PARTIAL LOADING (%)
Equipment Partial Loading (%) of Unit, Stage-I/II or Station:
Loss of Generation of Unit, Stage-I/II or Station in MU (Ref. period)=----------------------------------------------------------------------------------------- x 100Total rated Generation (MU) of Unit, Stage or Station
(Ref. Period excluding outage Hours)
8.0 GROSS HEAT RATE:
Gross Heat rate (Kcal/KWh) of the Unit, Stage-I/II, and Station is expressed asfollows:
Average GCV for the ref. Period (Kcal/Kg) x Total Coal Cons. (Kg) (Ref.period)= -----------------------------------------------------------------------------------------------------
Total Generation (KWh) (Ref. period)
Gross Heat rate (Kcal/KWh) of the Unit can also be expressed as follows:
Gross Turbine Heat Rate (Kcal/Kwh)= ------------------------------------------------ x 100
Boiler Efficiency (%)
-
8/6/2019 Pie Asset Management Vol i
65/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
65
(
Where,Heat input to Turbine (Kcal)
Gross Turbine Heat Rate = -----------------------------------------
Generation at Generator terminal
Heat input to Turbine = [ Main Steam flow (Kg) x (Enthalpy at HP Turbine inlet Enthalpy of FW at ECO inlet) + CRH Steam flow (Kg) x (Enthalpy at IP Turbine inlet- Enthalpy at HP Turbine exhaust) + Super heater spray flow (Kg) x (Enthalpy atHP Turbine inlet Enthalpy of S/H spray) + Reheat spray flow (Kg) x (Enthalpy at IPTurbine inlet Enthalpy of R/H spray)]
Where, unit of enthalpy of steam and water is Kcal/Kg
Net Heat rate (Kcal/KWh) of the Unit, Stage-I/II, and Station is expressed as follows
Gross Heat Rate (Kcal/KWh)=----------------------------------------- x 100
(100- APC in %)
The monthly / yearly average Gross Heat Rate shall be calculated by weightedaverage as per the following formula
GHRix KWh
i= ----------------------- KWhi
Where,GHRi = Gross Heat Rate (Kcal/KWh) of the i
th dayKWhi = Generation (KWh) of the i
th day
9.0 SPECIFIC OIL CONSUMPTION (ml/KWh):
Specific Oil Consumption (ml/KWh) of Unit, Stage-I/II, and Station is expressed asfollows:
Oil Consumption (KL) (Ref. period)= ---------------------------------------------------------------------------------------------------
Total gross generation (MU) of the Unit, Stage-I/II, Station (Ref. period)
-
8/6/2019 Pie Asset Management Vol i
66/185
Asset Management: PIE
Anil Kumar AGM (Mech)-PIE: e-mail: akntpc@gmail.com
66
(
10.0 SPECIFIC COAL CONSUMPTION (Kg/KWh):
Specific Coal Consumption (Kg/KWh) of Unit, Stage-I/II, and Station is expressed asfollows:
Coal Consumption (MT) (Ref. period)= ---------------------------------------------------------------------------------------------------
Total gross gen. (MU) of the Unit, Stage-I/II, Station (Ref. period) x1000
11.0 AUXILIARY POWER CONSUMPTION (%):
Aux. Power Consumption (%) of Unit, Stage-I/II, and Station is expressed as follows:
top related