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DADRI

NTPC LIMITED-DADRI
P.O. VIDYUTNAGAR, DISTT- G. B. NAGAR, (U.P.) 201008

Deptt:

O&M/OPN -GP

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TITLE: INTRODUCTION
CONTENTS
Sl No
1.

Doc Title

Page No.

INTRODUCTION
Contents

Integrated Policy

Issue Records

Revision History

List of abbreviations

6-7

3.
4.
5.

Terms & Definitions


Department MOU and EHS Objectives and Targets for the current year
Management Program for Department MOU and EHS Objectives and Targets
Deptt Organization Chart

8
9
10-21
22

6.

Responsibilities and Authorities

23-24

7.

Process Map

8.

Flow Chart for the process

26-29

9.

Process Models for each Process

30-43

10.

Competence Norms

44

11.

List of Infrastructure

46

12.

IMS Documents

25

List of legal / statutory requirements

47

List of documents of external origin

47

List of reference manuals

48

List of quality plans / applicable I.S.codes

49

List of reports despatched

50

List of drawings

51

List of equipment used/ calibrated

52

List of work instructions


IMS Records

53

List of formats

54

17.

List of records
Communication Matrix

55
56

18.

Initial Environment Review (IER)

57-60

19.

Group Risk Assessment (GRA)

61-63

20.

OCP

64-85

21.
22.
23.

Improvement Projects
EMP
OHS MP

15.

Prepared by: YashPal


Sr. Supdt..(OPN)

86

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
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TITLE: INTRODUCTION

IMS POLICY
(Quality, Environment, Safety and Occupational Health)
NTPC Limited -Dadri is committed to generate reliable
power cost effectively through continual improvement of
performance in the areas of quality, workplace management,
environment, occupational health and safety in a socially
responsible manner
This shall be ensured by actualizing the following strategic
objectives:
- Generating reliable power as per customer requirement
and schedule
- Optimization of Cost
Use of innovation and latest economically viable
technologies.
- Compliance of all applicable legal, contractual and
corporate requirements
- Prevention and Control of pollution, occupational
hazards, incidents, accidents & ill health.
- Developing skills and competencies of all employees
and ensuring their involvement.
- Collecting information on best practices to improve
performance.
- Enhancing satisfaction of all stakeholders
- Waste minimization, utilization of waste and
conservation of Natural Resources .
- Contributing to society.
This policy is communicated to all persons working for the
organization or on its behalf and is made available to
interested parties on demand.

General Manager

Date:15 March 2011


Place : Vidyut Nagar
Prepared by: Yash Pal
Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
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TITLE: INTRODUCTION
ISSUE RECORD
S No

COPY HOLDER

MODE

1.

DGM (O)

Hard Copy

2.

SS(O)

Soft copy in
Webdadri

3.

MR

Soft copy in
Webdadri

4.

SCE/ASCE/ MODULE ENGR/ CONTROL ROOM

Soft copy in
Webdadri

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

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TITLE: INTRODUCTION
REVISION HISTORY
S
No
1
2

Page No

AMENDMENT DESCRIPTION

Rev
No
01
02

9
9

Objectives and Targets


Objectives and Targets

79

57-59

48

DATE
01/04/2007
07/01/2009

REASON FOR
AMMENDMENT (#)
Revision of Target
Revision of Target

Control of energy consumption

01

07/01/2009

Inadequacy

Aspect register

01

04/04/09

Review of aspects

List of reference manual

01

10/01/10

IMP

50

List of reports dispatched

01

10/01/10

IMP

55

List of Records

01

10/01/10

ADT

61

Group Risk Assessment

01

10/01/10

ADT

71

Waste generated

01

10.01.10

ADT

10

86

Improvement project

01

10/01/10

ADT

11

Objectives and Targets

01

15/05/2010

Revision of Target

12

Objectives and Targets

02

06.01.11

ADT

13

57

IER

01

06.01.11

ADT

14

78

OCP

01

06.01.11

ADT

15

IMS POLICY

02

08/01/10

Revision of Policy

16

DEPTT MOU

02

01/04/11

Revision of Target

17

86

IMPROVEMENT PROJECT

02

01/04/11

New Activity

Issued by: A.N Goyal


MR

Prepared by: Yash Pal


Sr. Supdt..(OPN)

CODE

DETAILS

ADT

AUDIT OBSERVATION

CODE
E
RPO

ECH

EDIT CHANGES

IMP

Approved by: V.K.Singh


HOD(OPN)

DETAILS
REVIEW OF DEPARTMENTAL
OBJECTIVES
SYSTEM IMPROVEMENT

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
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TITLE: INTRODUCTION
LIST OF ABBREVIATIONS
Abbrvn
AHP
APC
ASCE
AUD
AUTP
Aux.
BHEL
BIS
BMD
C&I
C&M
CC
CCD
CEA
Chem.
CISF
CMO
CT
CW
DC
Dept
DG
DGM(O)
DMP
EDC
EED
EEMG
EMD
EMG
FM
FQA
GM
GT
HOD
HR
HRD
USS
WI

Description
Ash Handling Plant
Auxiliary Power Consumption
Assistant Shift Charge Engineer
Ash Utilization Department
Ash Utilization Technology Park
Auxiliary
Bharat Heavy Electrical Ltd.
Bureau of Indian Standards
Boiler Maintenance Department
Control & Instrumentation
Contracts & Materials
Corporate Center
Civil Construction Department
Central Electricity Authority
Chemistry
Central Industrial Security Force
Chief Medical Officer
Cooling Tower
Cooling Water
Declared Capability
Department
Diesel Generator
Deputy General Manager (Operation)
Disaster Management Plan
Employee Development Center
Equipment Erection Department
Energy Efficiency Monitoring Group
Electrical maintenance Department
Environment Management Group
Fuel Management
Field Quality Assurance
General Manager
Generator Transformer
Head Of Department
Heat Rate
Human Resource Department
Unit Service Swichgear
Work instruction

Abbrvn
ISO
IT
LDO
LWC
MR
MAINT
MW
NC
NCR
NRLDC
OLMMS
O&M
OPD
OPN
OS
P&S
PGCIL
PM
PTW
QSP
QMS
RCC
R&D
R&M
R&R
SCE
SG
STP
SS(O)
Supdt
TA
Th
TQM
TS
TG
UCE
UI

Description
International Standard Organization
Information Technology
Light Diesel Oil
Limited Work Certificate
Management Representative
Maintenance
Mega Watt
Non-Conformity
National Capital Region
Northern Region Load Despatch Center
Online Maintenance Management System
Operation & Maintenance
Out Door Patient
Operation
Off Sites
Planning & System
Power Grid Corporation Of India Limited
Preventive Maintenance
Permit To Work
Quality System Procedure
Quality Management System
Regional Control Center
Research & Development
Renovation & Modernization
Rehabilitation & Resettlement
Shift Charge Engineer
Steam Generator(Boiler)
Sewage Teratment Plant
Senior Superintendent (Operation)
Superintendent
Township Administration
Thermal
Total Quality Management
Technical Services
Turbo-Generator
Unit Control Engineer
Unscheduled Interchange

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Prepared by: Yash Pal

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

Sr. Supdt..(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
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TITLE: INTRODUCTION (LIST OF ABBREVIATIONS)


Abbrvn
n
ADT

Description
AUDIT OBSERVATION

Abbrvn
n
RPO

ECH

EDIT CHANGES

IMP

Description
REVIEW OF DEPARTMENTAL
OBJECTIVES
SYSTEM IMPROVEMENT

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
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TITLE: INTRODUCTION
TERMS AND DEFINITIONS
S
No

TERM

DEFINITION

1.
2.

HR= HEAT RATE


APC=AUX.POWER
CONSUMPTION
DC=DECLARED
CAPABILITY
UI=UNSCHEDULED
INTERCHANGE
DM CONSUMPTION

ENERGY REQD.(KCAL) TO GENERATE POWER (KW HOUR)


POWER CONSUMED BY PLANT EQUIPMENTS TO GENERATE
RATED OUTPUT
AVAILABLE GENERATING CAPACITY ON ANY GIVEN POINT IN
TIME OF 15 MINUTES BLOCK IN THE DAY.
GENERATION ABOVE OR BELOW SCHEDULED GENERATION
BUT WITHIN DECLARED CAPABILITY
DAILY DEMINARELISED WATER CONSUMPTION TO RUN THE
PLANT FOR COMPENSATING LOSSED WATER IN THE SYSTEM.
HEAT VALUE IN GAS/ HSD FUEL WITH MOISTURE AVAILABLE
FOR BURNING.
NET HEAT VALUE IN GAS/HSD FUEL AVAILABLE FOR BURNING
WITHOUT ANY IMPURITY
Set of interrelated or interacting activities which transforms inputs
into outputs.
Result of a process (Hardware / Software / Services / Processed
Material)
Degree to which a set of inherent characteristics fulfils requirements.
Something sought, or aimed for, related to quality.
Overall intentions and direction of an organization related to quality
as formally expressed by top management.
Organization or person that provides a product.
Set of conditions under which work is performed.

3.
4.
5.
6.

8.

GCV=GROSS
CALORIFIC VALUE
NCV= NET
CALORIFIC VALUE
Process

9.

Product

10.
11.
12.

Quality
Quality Objective
Quality Policy

13.
14.

Supplier
Work environment

7.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM

DADRI

TITLE: DEPTT. MOU


OPERATION DEPARTMENT OBJECTIVES AND TARGETS FOR THE YEAR
2010-2011
Sl.
No.
001

Parameter
GROSS GENERATION

Unit of
Measurement
MU

Target/ Bench
Mark
5400

002

ADHERENCE TO SCHEDULE

UI = 0 or +VE

003

AVAILABILITY FACTOR

93.55

004

HEAT RATE

KCAL/KWH

1975

005

AUX. POWER CONSUMPTION

2.45

006

UNIT TRIPPING DUE TO HUMAN


ERROR

NUMBER OF
OCCASION

007

STACK EMMISSION LESS THAN NORMS


(150 mg per ncum)

008

TRAINING ACHIEVEMENTS

VIOLATION
NUMBER OF
OCCASION
7 MANDAYS

009

Improvement projects

No.

100% of the
employees in
operation
department
01

010

QC presentation.

No.

01

011

To maintain occupational health of the


employees

Regular
Medical
Checkup of
Employees
(100%)

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

DADRI
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O&M/OPN -GP

11. Objective: To achieve MOU targets for Generation , Declared Capability. avail
factor
12. Target: As per MOU target.
23. Team Members: DGM(O), SCE, SR.SUPDT(O), MODULE ENGINEER,
OPERATORS
14. Action Plan:
Sl

Activity

Responsibili
ty

01 Unit wise capacity demonstration


and identifying action areas for
improvement.
02 Identifying reasons for partial
loading of units for corrective
actions
03 Availability and healthiness of all
critical equipment like HP/LP
BFPs ,HP/LP CC P/Ps, CW
PUMPS, CEPs etc apart from
boiler ,turbine and generator for
corrective action , if required, in
time.
04 Reduction of unit down time for
attending boiler tube leakage by
controlled cooling of WHRB by
Compressor washing.
05 Reduction of Forced outage due
to human Error

Target Date

Records

DGM(O)

DAILY

DAILY MTP
MEETING/ ORT

DGM ( O)

DAILY

DAILY MTP
MEETING / ORT

SCEs

DAILY

LOG BOOK /
MTP MEETING

SCEs

DURING
SHUTDOWN
DUE TO BTL

ORT REPORT

SCEs

DAILY

ORT report

Every start up
& shutdown

ORT REPORT /
Daily MTP
Meeting

DAILY

DAILY MTP
MEETING/ORT

06 Reduction of start up and


shutdown time to benchmarking
level .

DGM ( O )
/SCEs

07 Identifying areas for improving of


Heat rate, reduction in Aux.
Power consumptions and
actions for improvement .

SCEs

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
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11. Objective: To reduce Heat Rate to achieve MOU target.


22. Target: As per MOU target.
33 Team Members: DGM(O),SCE,SR.SUPDT(O), MODULE ENGINEER
0
,OPERATORS
4. Action Plan
Sl.
Activity
Responsibility Target Date
Records
No.
01
Monitoring and
SCE
DAILY
LOG BOOK/
optimization of process
ORT
parameters to achieve
target heat rate.
02
Analysis of HR deviations
SCE
REAL TIME
MTP
on real time basis and
BASIS
MEETING /
corrective actions for
ORT
improvement.
03
Merit order Operation of
DGM(O)/SCE REAL TIME
MTP
units. To run GTs in base
BASIS
MEETING /
load as far as possible.
ORT
04
Monitoring steam / water
SCE
DAILY
LOG BOOK/
leakage for corrective
MTP
actions to reduce
MEETING
consequent heat loss.
05
Need / Opportunity based
DGM(O)/SCE NEED/
LOG BOOK
condenser pass cleaning
OPPORTUNITY
to improve vacuum
Issued by: A.N Goyal
Prepared
by: coupling
Yash Pal time
06
ST
SCE
REALApproved
TIME by: V.K.Singh
MTP
MR
HOD(OPN)
Sr. Supdt..(OPN)
reduction.
BASIS
MEETING /
ORT

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TITLE: MANAGEMENT PROGRAM


MANAGEMENT PROGRAM - 3
11. Objective: To reduce Auxiliary Power Consumption to achieve MOU target.
22. Target: As per MOU target.
33. Team Members: DGM(O) , SCE, SR.SUPDT(O), MODULE ENGINEERS,
4
OPERATORS
14. Action Plan:
Sl.
No.
01
02

03

Activity

Responsibility

Current Monitoring and


optimizing all HT drives and
efficiency checking .
Identifying flue gas / Air /
Water/ Steam leakages for
corrective actions.
Shut down of auxiliaries
during GT/WHRB shut down.

DGM(O)/SCE
SCE

Target Date
DAILY
Daily &
Opportunity

DGM(O)/SCE

During shut
down

Records
LOG BOOK
/ ECE
Report
LOG
BOOK/MTP
MEETING
Log book

04

Reducing Idle running of


equipment

SCE

-do-

LOG BOOK

05

Optimize circulating water


pump / Aux Raw cooling water
pump /CT Fans operation in
winter by stopping of pump
Identifying reasons for partial
loading of units for corrective
actions

SCE

DURING
WINTER

LOG BOOK

DGM(O)/SCE

Daily

Daily MTP
Meeting /
ORT

SCE

Dailly

06

07

Reduction in Lighting loads

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL

DADRI

TITLE: MANAGEMENT PROGRAM


MANAGEMENT PROGRAM - 4
11. Objective: Reduction of Unit tripping due to Human error .
22. Target: Zero
33. Team Members: DGM(O) , SCE, SR.SUPDT(O), MODULE ENGINEERS,
OPERATORS
14. Action Plan:
Sl.
No.

Activity

01

Critical operational
procedures are standardized
and standard
checklist/Formats to be
online / followed.
Discussion/ Training on
emergency handling of
Operational staff.

DGM(O)/SCE

In
Practice

DGM(O)/CCR

DGM(O)/SCE

As per
Schedule

Communication
Meeting /
Department site

Awareness development and


discussion on near miss
incidents on regular basis.
Need based In house and
Simulator training.

DGM(O)/SCE

As per
Schedule

Communication
meeting

DGM(O)/SCE

Need
Based

02

03
05

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Responsibility Target
Date

Issued by: A.N Goyal


MR

Records

In Net

Approved by: V.K.Singh


HOD(OPN)

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1. Objective: To maintain Stack Emission within Norms


2. Target: Number of violation Nil
3. Team Members: DGM(O) , SCE, SR.SUPDT(O), MODULE ENGINEERS,
OPERATORS
4. Action Plan:
Sl.
No.
01

Activity

02

Monitoring of Field
parameters reading and
corrective actions for
improvement.
GTs to be run on premix
mode .

03

Monitoring of NOX once in


a month of all GTs .

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Responsibility Target
Records
Date
DGM(O)/SCE MONTHLY LOG Book /
MTP Meeting
/ ORT
DGM(O)/SCE

Daily

Log Book

DGM(O)/SCE

Daily

LOG Book /
MTP Meeting
/ ORT

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


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11. Objective: Dm Water Consumption


22. Target: As per MOU target.
33. Team Members: DGM(O) , SCE, SR.SUPDT(O), MODULE
ENGINEERS,
OPERATORS
44. Action Plan:
Sl. No. Activity
1
Monitoring and checking of all
open points for leakage of
steam.
2
Monitoring and checking of all
open points for leakage of
water.
3
Optimising start up time /
Boiler coupling time to reduce
water consumption.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Responsibility
SCE

Target Date
Daily.

SCE

Daily.

SCE

During start
up.

Approved by: V.K.Singh


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TITLE: MANAGEMENT PROGRAM


MANAGEMENT PROGRAM - 7

51. Objective: UI (Adherence to Schedule )


62. Target: 0 or +VE
73. Team Members: DGM(O) , SCE, SR.SUPDT(O), MODULE ENGINEERS,
OPERATORS
84. Action Plan:
Sl.
No.
1

Activity

Responsibility

Target Date

Maximizing efforts to extract


+ui on real time basis.

DGM(O)/SCE

Daily. MTP meeting


review. ORT

Issued by: A.N Goyal


MR

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
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TITLE: MANAGEMENT PROGRAM


MANAGEMENT PROGRAM - 8

91. Objective: Training Achievements(Trg. order Compliance)


102. Target: 85% of all staff.
113. Team Members: DGM(O) , SCE, SR.SUPDT(O), MODULE ENGINEERS,
OPERATORS
124. Action Plan:
Sl.
No.
1

Activity

Responsibility

Target Date

To impart training to all staff on


Power Station Management. 7
days per year.

DGM(O)/SS(O)

Every Year

Issued by: A.N Goyal


MR

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
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TITLE: MANAGEMENT PROGRAM


MANAGEMENT PROGRAM - 9

131. Objective: To maintain Occupational health of the employees


142. Target: Regular Medical Checkup Of Employees.

153. Team Members: DGM(O) , SCE, SR.SUPDT(O), MODULE ENGINEERS,


OPERATORS
164. Present status / Performance criteria: Medical check-up is carried out in an
irregular basis.
175. Action Plan:
Sl.
No.
1
2

3
4
5

Activity

Responsibility

Identification of employees working in


hazardous area
Handing over list of identified employees
to CMO in 03 categories
( below 40 years, above 40 years, above
45 years)
Medical checkup in phased manner as
per schedule.
Reffering to specialist for specialised
treatment if any alinment is detected
Job rotation of employees or any other
action for minimisation of affect

Safety in charge

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

HOD(HR)

CMO/ HOD (CNI)


CMO
CMO/ HOD (CNI)/
HOD(HR)

Approved by: V.K.Singh


HOD(OPN)

Target
Date
Every
Year
Every
Year

Every
Year
Every
Year

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TITLE: MANAGEMENT PROGRAM


MANAGEMENT PROGRAM - 10

181. Objective: Customer Satisfaction Rating


192. Target: AV 3, ON 0-4 SCALE.
203. Team Members: DGM(O) , SCE, SR.SUPDT(O), MODULE ENGINEERS,
OPERATORS
214. Action Plan:
Sl.
No.
1
2

Activity

Responsibility Target Date

Internal customer Audit on


biannual basis.
Implementation of audit
enquiry points on regular
basis.

DGM(O)

Twice Every year.

DGM(O)

Twice Every year.

Issued by: A.N Goyal


MR

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
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TITLE: MANAGEMENT PROGRAM


MANAGEMENT PROGRAM - 11

221. Objective: Performance Improvement Initiatives


232. Target: four areas:: forced outage, parameter improvement, generation
improvement .
243. Team Members: DGM(O) , SCE, SR.SUPDT(O), MODULE ENGINEERS,
OPERATORS
254. Action Plan:
Sl. No.
Activity
1
To achieve Zero forced
outage
2
To better operating
parameters than past year.
3
Improvement in Availability
and PLF.

Responsibility
DGM(O)

Target Date
Year end

DGM(O)/DGM(M) Every year


DGM(O)/DGM(M) Every year

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 21/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

TITLE: MANAGEMENT PROGRAM


MANAGEMENT PROGRAM - 12

261. Objective: Employee Involvement Quality Initiatives: 5S, QC, PC &


Suggestion Scheme.
272. Target:
283. Team Members: DGM(O) , SCE, SR.SUPDT(O), MODULE ENGINEERS,
OPERATORS
294. Action Plan:
Sl.
No.
1
2
3
4

Activity
To involve staff on improvement activities
and suggesting ways of reducing wasteful
expenditure.
Regular internal 5S audit and
implementation .
Participation in QC and PC activities.
Participation in suggestion scheme
through out the year.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Responsibility Target
Date
DGM(O)
Regular
DGM(O)

Regular

All Staff

Regular

All Staff

Regular

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 22/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

TITLE: DEPTT. ORG. CHART

ORGANISATION CHART
DGM (OPN) I/C
SS (OPN)
SCE
MOD-I ENGR

Prepared by: Yash Pal


Sr. Supdt..(OPN)

MOD-II ENGR

Issued by: A.N Goyal


MR

OFFSITE ENGR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 23/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

TITLE: RESPONSIBILITY & AUTHORITIES


RESPONSIBILITIES AND AUTHORITIES
The main power plant is operated round the clock, throughout the year. To ensure
uninterrupted operation, the operation staff is divided in to four groups. Each day is
divided in to three shifts viz. Morning shift, Evening shift & Night shift.
Shift Charge Engineer (SCE):
In each shift main plant operation is headed by SCE, who is responsible for all
activities of process control system during his shift. SCE takes instructions from
HOD(Opn) and takes decision to meet the requirements of process control system.
He is given generation schedule from NRLDC / NCRHQ through switchyard or
directly to the SCE and instructs all the MODULE ENGINEERS about the schedule
and Unit load to be maintained, depending upon the Unit constraints and grid
requirements. In the morning shift SCE reports all the major problems and pending
problems in the Daily planning meeting. SCE acts as a nodal point in case of any
emergency. SCE is assisted by MODULE Engineers who co-ordinates the
operational activities of the whole plant with special attention to Common utilities like
Switch Yard , Fuel Oil Pump House , Compressor House, CW Pump house & Raw
Water Pump House.
SCE maintains a record of activities during the shift & availability of equipment and
their defects.
MODULE Engineer: The MODULE ENGINEER is the in-charge of the concerned
unit and is responsible for all the processes & activities of that Unit. MODULE
ENGINEER takes Instruction from the SCE about unit load, startups & shutdown of
the unit. MODULE ENGINEER monitors health of all equipment and plants and
raises equipment defects, issues PTW, cancels PTW and checks the availability of
stand by equipment. To assist the Unit operation, supervisors & local operators are
posted in each unit and they work according to the instructions given by the control
engineer.
OFFSITE Engineer : OFFSITE ENGINEER is responsible for carrying out safe &
efficient operation of switchyard AND OTHER OFF SITE AREAS.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 24/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

TITLE: RESPONSIBILITY & AUTHORITIES


RESPONSIBILITY / AUTHORITY CHART
S
No
1.

2.

KEY
RESPONSIBILITY
PERSONNEL
DGM (O)
RESPONSIBLE
FOR
IMS IMPLEMENTATION
IN
OPERATION
DEPARTMENT
SS(O)
OPERATION
COORDINATION FOR
IMS ACTIVITIES

3.

SCE

4.

MODULE
ENGR.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

IN CHARGE OF TOTAL
OPERATIONAL
ACTIVITIES
IN
SHIFT
IN CHARGE OF TOTAL
OPERATIONAL
ACTIVITIES
IN
ONE MODULE.

Issued by: A.N Goyal


MR

AUTHORITY
ACTIVITIES COMMENSURATE
WITH RESPONSIBILITIES IN
CONSULTATION
AND
APPROVAL OF HOD/DOP.
ACTIVITIES COMMENSURATE
WITH RESPONSIBILITIES IN
CONSULTATION
AND
APPROVAL OF HOD/DOP
ACTIVITIES COMMENSURATE
WITH RESPONSIBILITIES IN
CONSULTATION
AND
APPROVAL OF HOD/DOP
ACTIVITIES COMMENSURATE
WITH RESPONSIBILITIES IN
CONSULTATION
AND
APPROVAL OF HOD/DOP

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 25/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

TITLE: PROCESS MAP


PROCESS MAP

Availability/Sup
ply of DM Water

NRLDC
Revised
Schedule

DC
Revised
DC

Gas from GAIL

CCR

Supply of Soft
Water

Feedback
from NRLDC

Gas Allocation
from NCR of
Availability
M/Cs
Availability of
HSD
TO Northern Grid

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

Gen.,
Schedule

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 26/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

TITLE: FLOW CHART FOR THE PROCESS

OBJECT
UI =0 or +VE

START

RECEIVE UI SHEET
FROM O&E

Net UI
0/+VE

YES

NO

Analyse the Daily UI


Report
Reason Established

NO
Record
reason

Reason
Controllable

YES

Take Corrective/Preventive
Actions

Maintain Records of UI
CA / PA Deviation

STOP

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 27/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

TITLE: FLOW CHART FOR THE PROCESS


FLOW CHART OF THE PROCESS LEADING TO OBJECTIVES' REALIZATION

START
Record DM Water
Consumption from
Balance log at 24:00 hrs

DM
CONS.
Mod.#1

OBJECT
DM WATER
CONSUMPTION
100% OF MOU
TARGET

DM
CONS.
Mod.#2

Corrective
Action

TOTAL
DM
CONS.
NO
DEVIATION
FROM DAILY
AVG. OF
YEARLY
TARGET
JUSTIFIED?

YES

LOG

STOP

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

Deptt:

O&M/OPN -GP

Page : 28/86

Doc Ref:ND-IM-OPG

Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

TITLE: FLOW CHART FOR THE PROCESS


FLOW CHART OF THE PROCESS LEADING TO OBJECTIVES' REALIZATION

OBJECT
Heat rate (CC)

-HEAT RATE
HR

+ Heat rate (OC)

START

(CC)

100% OF MOU

HR

(OC)
NHR Nominal Heat Rate

IS
HR (CC)
NHR

NO

HR (OC)
HR(OC)

Yes

Analysis causes of Higher HR

Remedial Measures to be
taken to reduce HR

Yes

IS
HR (CC)

NO
NHR

HR (OC)
HR(OC)

STOP

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Heat rate is now <_ NHR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 29/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

TITLE: FLOW CHART FOR AUXILIARY POWER CONSUMPTION


FLOW CHART OF THE PROCESS LEADING TO OBJECTIVES' REALIZATION

Actual value of APC (%)

START

Target Value (TV)


No
Check APC >
Set value

Yes
Analysis the cause of higher
APC

Remedial measures to be
taken to reduce APC

Yes

Check APC >


Target APC

No
STOP

APC is now < target APC


Prepared by: Yash Pal
Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

OBJECT
AUXILIARY
POWER
CONSUMPTI
ON
100% OF
MOU

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 30/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

TITLE: PROCESS MODEL


PROCESS MODEL
Whole process divided into Five steps:
1A. RECEIPT OF NATURAL GAS/ RLNG/HSD AT DGPS TERMINAL.
2B. Process of burning of fuel to generate power in gas turbines.
3C. Process of steam generation in WHRB by GT exhaust gas.
4D. Supply of steam to turbine and generation of electricity in generator .
5E. the process of supply of generated electricity to the grid .
PROCESS: A. RECEIPT OF NATURAL GAS/ RLNG/HSD AT DGPS
TERMINAL
1.0 PURPOSE: The purpose of this document is to describe the process of
receipt of fuel in DGPS terminal.
2.0 SCOPE: To plan ,monitor and take necessary corrective action for receiving
fuels for firing in gas turbines.
3.0 DEFINITIONS: Nil
4.0 PRPCESS OWNER : DGM (O)
PROCESS FLOW:
Sl.No. Activity
Responsibility Ref. Doc.
Clean Natural gas/ RLNG is supplied by M/S GAIL through
pipeline at a pressure of 20(+/-5) bar. Rombach filters are
provided for further cleaning of the gas and subjected to
next stage of filtration at Filtan filters before being fired at
the gas turbine combustion chambers. The fuel gas is
supplied to 16 burners of each gas turbine ( each having 2
combustion chambers). The following parameters are
measured continuously : pressure of gas : 20( +-/-) 5 bar
:. Temperature of gas 15+ ^0 centigrade.
: gas CV is measured by Chemistry and by M/S GAIL
Apart from the above mentioned process parameters
monitoring following also is monitored :
:- HSD receipt:: HSD is supplied by PSU OIL companies.
IOCL, BPCL, HPCL. DIESEL is stored in 1 mother tank and
2 day tanks.
During receipt density and viscosity of the product is
measured by chemistry . other metallic and non metallic
contaminants are measured by chemistry from time to time.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

DGM(O)
Sr. Mgr
(Chemistry)

Approved by: V.K.Singh


HOD(OPN)

Siemens
documents.
Technical
specification.
MTP meeting
ORT meeting.

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 31/86

Doc Ref:ND-IM-OPG

Correction and preventive action for


Rombach/ Filtan filter/HSD FILTERS. :
.
1 When DP across Rombach filter reaches
40 % filter change over is initiated. Chocked
filter cartridges are cleaned and put back
into the system for future use.
2
3 Filtan filters are cleaned from time to
time .
. HSD filters are cleaned in every shift so as
to keep them as clean as possible from solid
contaminants.
PROCESS OUTPUT
Output
To
CLEAN GAS
GT
CLEAN HSD

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

DGM(MM)
DGM(o)
SCE

SCE LOG
B
O
O
K
MTP meeting
fineness
report

Ref. Doc.
SIEMENS
MANUAL,TECHNICAL
SPECIFICATION
LMI. IS 1460 FOR HSD.

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

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Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Monitoring Brief

Acceptance Criteria

Responsibility

Review
Frequency

Ref. Doc.

GAS FLOW

40-45 SM^3/HR. AT
FULL LOAD

MODULE
ENGR..

continuous

AIR INTAKE
FILTER
DP

< 15 m BAR. ALARM


AT >30 mbar. To
replace filters

MODULE
ENGR

continuous

Compressor outlet
pressure(cpd)

> 9 bar.

MODULE
ENGR

continuous

Load : 130 MW IN
EACH GT ON
TEMP.
CONTROL.

> 130 MW ON TEMP.


CONTROL AT
3000RPM, 27^ CENT.

MODULE
ENGR

continuous

GT EXHAUST
TEMPERATURES
AND OUTLET
TEMP.

< FLOATING
ALARM/TRIP VALUE.

MODULE
ENGR

continuous

Electricity
generation

As per generation
schedule

DGM(O/MM)

Daily/
monthly

SIEMENS MANUAL,
TECH. SPEC, DFR,
OPPMS, Report in
MTP meeting.
Daily O&E report/ORT
report
SIEMENS MANUAL,
TECH. SPEC, DFR,
OPPMS, Report in
MTP meeting.
Daily O&E report/ORT
report
SIEMENS MANUAL,
TECH. SPEC, DFR,
OPPMS, Report in
MTP meeting.
Daily O&E report/ORT
report
SIEMENS MANUAL,
TECH. SPEC, DFR,
OPPMS, Report in
MTP meeting.
Daily O&E report/ORT
report
SIEMENS MANUAL,
TECH. SPEC, DFR,
OPPMS, Report in
MTP meeting.
Daily O&E report/ORT
report
SIEMENS MANUAL,
TECH. SPEC,

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 33/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

1.0 PURPOSE: The purpose of this document is to describe the process of


combustion of GAS IN COMBUSTION CHAMBERS FOR GENERATION OF
POWER.
2.0 SCOPE: To plan, monitor and take corrective action for power generation in
GT by combustion of gas/ hsd fuel
3.0 DEFINITIONS: Nil
4.0 PRPCESS OWNER : DGM (O)
5.0 PROCESS INPUTS:
Inputs
Source
Ref Doc.
GAS
M/S GAIL
SIEMENS MANUAL,
TECH. SPEC,
HSD Oil
FOPH
SIEMENS MANUAL,
TECH. SPEC,
DM water
Water treatment plant
SIEMENS MANUAL,
TECH. SPEC,
Air
AIR INTAKE FILTERS
SIEMENS MANUAL,
TECH. SPEC,
PROCESS FLOW:
Sl.No. Activity
POWER GENERATION : IN GAS TURBINE::
THE CLEAN FUEL IS FIRED IN COMBUSTION
CHAMBERS OF EACH GT AND EXHAUST GAS AT
HIGH TEMP. IS RELEASED. AIR IS TAKEN INTO
THE COMPRESSOR OF THE GT THROUGH AIR
INTAKE FILTERS. GAS IS SUPPLIED TO
COMBUSTION CHAMBERS THROUGH BURNERS
FOR FIRING AND 1050 ^ CENT. IS ACHIEVED. THIS
IS REFLECTED THROUGH COT . THE HOT GAS
MIXTURE IS PASSED THRIUGH TURBINE TO
PRODUCE ELECTRICAL POWER AND HIGH HEAT
EXHAUST GAS IS RELEASED.
1

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Responsibility Ref. Doc.


SCE
SIEMENS
MODULE ENGR.
MANUAL,
TECH.
SPEC,
LMI

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 34/86

Doc Ref:ND-IM-OPG

Sl.No. Activity

Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Responsibility

Monitoring of cpd, ambient temp. , hot


air/ cold air bearing temp.,
vibration, cot, outlet /
exhaust temp.
Under this system, following parameters
are monitored / maintained by the
module engineer
1a. Air intake DP with < 30m bar
2b. Compressor discharge pressure.
3c. Hot air/ Cold air 80/55
4d. Bearing Temp. generator TE/EE,
Turbine
5 /Compressor
6e. Bearing vibration generator TE/EE,
Turbine
7 /Compressor
8f. Calculate outlet temp.
9g. Outlet temp. 1 to 8, exhaust temp. 1
to 6 within limit values.

DADRI

SCE
MODULE ENGR.

Ref. Doc.
SIEMENS
MANUAL, TECH.
SPEC,
LMI

Correction and preventive action


In this system Air intake DPs >30 m bar
filter are being replace by informing
Mech. Maint. If compressor discharge
pressure decreases O&E is intimated
and if require compressor washing is
done. Hot air/ Cold air exceeds alarm
values than PGB recooler fan / spray is
being checked. If any abnormalty is
found it it reported to concerned
department. Any abnormalty in bearing
temp. is checked for probable reason like
lub oil temp. rise etc. than remedial
action is taken accordingly. Any increase

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 35/86

Doc Ref:ND-IM-OPG

Monitoring
Brief

Total Gas flow

HSD flow

Compressor
discharge
pressure
Air intake DP
Bearing Temp.
Bearing
vibration
Aux power
consumption
Heat Rate

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Acceptance Responsibility Review


Ref. Doc.
Criteria
Frequency
SIEMENS
MANUAL, TECH.
SPEC,
As per Gas
-do-doLMI
turbine load
Daily Mtp
10 3
meeting
report
45sm /hr
Daily O&E
As per Gas
-do-doreport/ORT
turbine load
report
10 to
3
45sm /hr
Up to 10.3
-do-dobar
<30 m bar
< 100 C
< 7 mm/
sec.
2.4 %

-do-doDGM(O)
-do--

-do-doDaily/
monthly
-do-

1970 kcal /
-do-dokwhr
6.0 RECORDS- Boiler desk log book, UCE Log Book, Daily MTP Report, ORT
Report,

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 36/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

1.0 PURPOSE: Process of steam generation in WHRB by GT exhaust gas


2.0 SCOPE: To plan monitor and take necessary corrective action in the process
of steam generation in WHRB by GT exhaust gas
3.0 DEFINITIONS: Nil
4.0 PRPCESS OWNER : DGM (O)
5.0 PROCESS INPUTS:
6.0
Inputs
Source
Hot Gas to WHRB Gas Turbine exhaust
DM water to Boiler Dm water p/p house
PROCESS FLOW:
Sl. Activity
No.
WHRB SYSTEM
The exhaust gas from gas turbine at 560 deg(at gas
turbine base load) passed to WHRB. WHRB is dual
pressure boiler in which steam is generated in two parts
that is HP and LP steams. HP superheated steam
generated in HP circuit which consists of HP drum eco
1/ 2 , evaporator and super heater, feed water is passed
from eco through FRS into HP drum and in HP
evopourator saturated steam is generated by for
circulation, HP super heater generate super heater
steam. LP superheated steam generated in LP circuit
which consists of LP drum eco, evaporator and super
heater, feed water is passed from eco through FRS into
LP drum and in LP evaporator saturated steam is
generated by for circulation, LP super heater generate
super heater steam.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Respon
sibility

Ref. Doc.

SCE
MODULE
ENGR.

LMI/OD/OPS/S
YST/006

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 37/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

2.0 SCOPE: To plan monitor and take necessary corrective action in the process of Supply of
steam to turbine and generation of electricity in generator.
3.0 DEFINITIONS: Nil
4.0 PRPCESS OWNER : DGM (O)
5.0 PROCESS INPUTS:
Inputs
Source
Ref Doc.
HP STEAM
LP STEAM
DM WATER
CW WATER

WHRB HP CKT.
WHRB LP CKT.
Dm water p/p house
Dm water p/p house

BHEL MANUAL
SIEMENS MANUAL
CHEMISTRY
CHEMISTRY

Sl.No Activity
The Condensate, Feed Water & Boiler Water system
The condensate from the Hotwell is extracted by CEP & is pumped, via,
Gland steam cooler ,CONDENSATE PRE-Heaters (where it gets heated
up) to the De-aerator for removing dissolved oxygen . The condensate now
becomes Feed water & gets stored in the Feed Water Storage Tank just
below Deaerator. The HP/LP BFPs take Suction from this Feed Storage
tank & pumps this feedwater through economizerAND feed control station
(FRS) to the Boiler Drum, where it becomes Boiler Water. This boiler water
goes to the boiler water tubes where it absorbs heat, transforms in to steam
& return back to the Boiler drum through HP /LP CIRCULATING PUMPS.
Monitoring of the Condensate & feed water system
Under this system, following inspection & testing are conducted by the
module engr. on regular basis for smooth running of the unit .
1a. Boiler drum level.
2b. Feed water and main steam flow etc .
1c. Hotwell level.
2d. Condenser back pressure.
3e. CEP discharge header pressure
4f. Deaerator level/Pressure.
5g. Cycle make up water flow.
6h. BFPs flow.
Corrective and Preventive actions for .The Condensate & feed water
system
Being part of a closed cycle, the deviations in the level of all three storage
vessels Hotwell, Deaerator and Boiler drum are constantly watched and
corrected in order to maintain them at normal level with the help of
respective control system.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Resp.

Ref. Doc.

SCE
MODULE
ENGR.

BHEL
manual
LMI

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 38/86

Doc Ref:ND-IM-OPG

Sl.No. Activity
The abnormal variation of any of the above storage
vessel level will lead to the failure of the pump, which is
taking suction from it. This calls for maintaining correct
level in these vessels to prevent the failures.
The Boiler drum level control is of utmost importance as
low drum level may cause the starvation of boiler tube
and its failure & high drum level may cause priming and
water carry over to the turbine. To prevent this the Boiler
drum level is maintained with in limits by FRS control
valves. DP is maintained across the FRS control valve to
ensure required feed water flow to Boiler drum by varying
BFP speed with the scoop control mechanism.
The Boiler feed pump draws water from the Deaerator,
whose pressure is maintained by supplying steam to it, in
order to provide positive NPSH to BFP. Deaerator level is
maintained by supplying condensate water through CEP,
which draws water from Hotwell. The Hotwell receives
the condensate from the condensation of steam in
condenser. The Hotwell level is controlled by adjusting
the condensate flow to Deaerator through a control valve.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Responsibility Ref. Doc.


SCE
BHEL
MODULE ENGR. manual
LMI

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 39/86

Doc Ref:ND-IM-OPG

Sl.No.

Activity
Condenser back pressure is maintained by creating
vacuum in condenser by drawing out the non
condensable gases as well as by condensing the LPT
exhaust steam with the proper cooling water flow.
Deviations in the condenser back pressure are corrected
by giving proper CW flow in condenser to effectively
condense the LPT exhaust steam & preventing air
ingress to the condenser.
Deviation in condenser back pressure from its design
value causes cycle inefficiency and large deviations in it
may lead to LP blade overheating & its failure. To
prevent this the condenser back pressure is maintained
with in limits
TG lube oil & Governing System
The TG lube oil system lubricates the bearings of the
Main TG & also carries away the heat produced in the
TG bearings. The lube oil systems basically consist of
Main oil tank which stores the governing/lube oil. It
consists MOP (mounted on Main TG shaft), AC LOP, DC
LOP & lube oil coolers. The Governing system controls
the output & speed of the Turbo Generator (TG) through
stop valves and control valves at the steam entrance of
HP & LP Turbine.

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Responsibility
SCE
MODULE
ENGR.

Monitoring of TG lube oil & Governing System


Under this system, following inspection & testing are
conducted by the MODULE ENGR. on regular basis for
smooth running of the unit .
1a. MOT level
2b. TG lube oil temperature.
3c. TG bearing temperature/vibration.
4d. Availability of AC LOP, DC LOP
Main oil tank is reservoir of lubrication
oil for TG bearing and Seal oil system of generator. Lube
oil is provided by the shaft mounted MOP which is in
running along with main turbine, however, if the lube oil
pressure falls due to any reason, Standby lube oil
pumps are taken in service to prevent the TG bearing
from failure. These standby lube oil pumps (AC LOP and
DC LOP) are checked regularly, to ensure their
availability. Most of these parameters are available on
DAS system for regular monitoring.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

Ref. Doc.

BHEL
manual
LMI

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 40/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Generator System:
The mechanical energy is converted to the electrical
energy
( Product ) in the generator and is supplied to
the switchyard via GT at 400 KV.. Rotor and other
elements of the generator are cooled by the hydrogen
gas, which circulates in the generator by the shaftmounted fans and is in turn cooled by the cooling water
in the gas coolers. To have effective cooling, hydrogen
gas is filled at high pressure. This hydrogen gas is sealed
by generator seal oil system at both the ends. Sealing at
both ends of generator is done by providing the seal oil at
higher pressure than generator hydrogen pressure. In
order to prevent escapement of hydrogen as well as the
formation of explosive mixture of hydrogen & air, Seal oil
to hydrogen differential pressure is maintained with the
available control system. The availability of DC SOP are
checked regularly. The deviation in seal oil temp is
corrected by
regulating cooling water flow to seal oil coolers.
The generator voltage is maintained by AVR, it is kept
under constant watch & corrective actions are initiated in
case of its deviation or generator instability by changing
excitation. Stand by exciter is readily available to meet
the main exciter problem of any unit.

Output
Electricity

Prepared by: Yash Pal


Sr. Supdt..(OPN)

To
Switchyard

Issued by: A.N Goyal


MR

Ref. Doc.
MAN/002/ST-1/GEN-001
MAN/002/ST-2/GEN-001

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 41/86

Doc Ref:ND-IM-OPG

Monitoring
Brief
Steam temps

Acceptance
Criteria
530-540 C

Condenser
Back
Pressure
MOT level

40-100 mmHg

EOP
availability

Daily trial to
check
healthiness
40-47 C

TG lub oil
temp
TG brg temp
and vibration
MW and
MVAR
Generator
H2 gas
pressure
Seal oil DP

> -20 mm

As per load
As per grid
condition
2.7-3.0
Kg/cm2

Responsibility
MODULE
ENGR.
MODULE
ENGR.

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Review
Frequency
continuous
-do-

MODULE
ENGR.
MODULE
ENGR.

Daily

MODULE
ENGR.
MODULE
ENGR.
MODULE
ENGR.
MODULE
ENGR.

continuous

Ref. Doc.
SIEMENS,
BHEL,
TECH.
SPEC.

daily

CONTINUOUS
-do-do-

1.2- 1.5
MODULE
-doKg/Cm2
ENGR.
Electricity
As per
MODULE
Daily/ monthly
generation
Schedule
ENGR.
PROCESS E: The process of supply of generated electricity to the grid .
1.0 PURPOSE: The purpose of this document is to describe the process of
supply of generated electricity to the grid
2.0 SCOPE: To plan monitor and take necessary corrective action for supplying
generated electricity to the grid.
3.0 DEFINITIONS: Nil
4.0 PRPCESS OWNER : DGM (O)
5.0 PROCESS INPUTS
Prepared by: Yash Pal
Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 42/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Inputs
Source
Ref Doc.
Electricity after voltage step up From Generator MAN/002/ST-1/GEN-001
MAN/002/ST-2/GEN-001
Sl.No. Activity
Responsibility Ref.
Doc.
Corrective and preventive Actions for Switchyard
SCE
LMI
Engineer
Electric power generation in all units is maintained by
SCE/ MODULE ENGINEER as per generation schedule,
this as the final output flows to the 400 kV Switchyard.
From switchyard this power instantaneously goes to the
grid through 400 KV and 220 KV lines.
The switch yard Incharge keeps a close watch on the out
put of all units & the line loading of all the 400 KV and
220 KV lines. He also remains in touch with grid
controllers about the availability & loading of other
important transmission lines. In case of significant
deviations in unit / line loading or any trip out in DGPS
switch yard or other important generating station &
transmission lines of Eastern grid, he takes corrective &
preventive action by informing the SCE/MOD. ENGR. &
coordinates with grid controller.
The grid frequency and the bus voltage at DGPS end are
also kept under close watch & in case of deviations in
them, appropriate corrective actions are initiated by the
switchyard Incharge by consulting SCE and grid
controlling authorities.
All 400 KV & 220 KV equipments such as breakers,
isolators, transformers, reactors, CTs & CVTs, are
checked regularly for healthy functioning in order to
prevent them from failure.
SF6 pressure is watched and its deviations are corrected
by getting defects attended by maintenance department
in order to ensure healthiness of circuit breakers. For SF 6
gas filled breakers, their gas pressure is watched &
corrective actions are initiated in case of deviation (such
as getting gas filled by maintenance department).

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

MODULE ENGR.

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


PROCESS MONITORING(FOR EFFECTIVENESS AND EFFICIENCY)
Monitoring Brief Acceptance
Responsibility
Review
Criteria
Frequency
220 KV bus
210-230 KV
Switchyard
Continuous
voltage
Engr/UCEs
MVAR
As per grid
-do-docondition
Electricity
DGM(O/MM)
Daily/ monthly
As per
generation
Sched
ule
6.0 RECORDS :Switcyard log book, SCE logbook, ORT Report
7.0 REFERENCE(include ref. Docs like Work Inst etc)
1. Switchyard
2. Blackout Instructions

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

DADRI
Ref.
Doc.

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 44/86

Doc Ref:ND-IM-OPG

SL.
NO.

DESIGNATION

01

DGM (O) I/C

02

SCE

03

MODULE
ENGINEER
DGM(O)

04
05

OFFSITE
ENGR.

06

OPERATORS

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

SKILLS REQUIRED
(FOR CRITICAL
ACTIVITIES)
Monitoring of MOU
targets, managing
manpower
Monitoring of shift
activities, managing
people
-DO-

TRAINING REQUIRED

Monitoring ,
management of
people
Operation OF GT/
ST.

Advance Trg on
simulator,Tech. Trgs,
Management Trgs
Simulator trg

Local equipment
operation

-DO-

Management Trgs
Advance Trg on
simulator,Tech. Trgs,
Management Trgs
-DO-

REMARKS

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 45/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

TITLE: LIST OF INFRASTRUCTURE


LIST OF INFRASTRUCTURE
Details

S.
No.
01 CCR FOR OPERATION OF gt /st UNITS
02 220 KV SWITCHYARD
03 OFFSITE AREAS LIKE CW PUMP HOUSE,
COMPRESSOR HOUSE ,DG SETS,
04
06
07

OFFSITE AREAS LIKE CW PUMP


HOUSE,,COMPRESSOR HOUSE , NEW DG
SETS,
WORKSPACE ,BUILDING FOR PLANT AND
OFFICES
SUBMERSIBLE PUMPS

Quantity/Capacity
01 NOS
O1 NO
01 EACH

01 EACH

18 NOS

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 46/86

Doc Ref:ND-IM-OPG

S No

APPLICABLE LEGISLATION

1. The Water (Prevention And Control Of


Pollution ) Act, 1974, Rules1975
2. The Air (Prevention And Control Of
Pollution ) Act, 1981 Rules1982 / 1983
3. The Factories Act (As amended till 1987)
1948 / 1952
4. The Indian Boilers Act, 1923
5. The Noise Pollution (Regulation &
Control) Rules, 2000

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

RESPONSIBILITY
DGM(O), DGM (CHE )

RECORDS A/V
WITH
EMG/CHEMISTRY

DGM(O), DGM (CHE )

EMG/CHEMISTRY

DGM (O)

SAFETY

DGM(O),DGM(MM),
DGM(EEMG)
DGM (O),DGM(MTP)

MTP
MTP

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 47/86

Doc Ref:ND-IM-OPG
REFERENCE MANUAL

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

S
No
01

Technical Diary

IDENTIFICATION
CODE
QM-OPG-01

02

Siemens Gas Turbine Manual

QM-OPG-02

03

ST MANUAL

QM-OPG-03

04
05

GT fault alarm with description


ST fault alarm with description

QM-OPG-04
QM-OPG-05

A/V WITH
SOFT COPY IN CCR
PC / WEB DADRI
LIBRARY/CONTROL
ROOM / SOFT COPY
IN WEB DADRI
LIBRARY/CONTROL
ROOM / SOFT COPY
IN WEB DADRI
CONTROL ROOM
CONTROL ROOM

LIST OF DOCUMENTS OF EXTERNAL ORIGIN


S
No
01

TITLE OF DOCUMENT
NRLDC GENERATION SCHEDULE

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

IDENTIFICATION
CODE
NRLDC-01

A/V WITH
CONTROL ROOM

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 48/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

LIST OF QUALITY PLANS / APPLICABLE I.S. CODE


S
No
01

EQUIPMENT / COMPONENT

Prepared by: Yash Pal


Sr. Supdt..(OPN)

QUALITY PLAN No.

A/V WITH

Nil

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 49/86

Doc Ref:ND-IM-OPG

S
No
01
02
03
04

TITLE OF REPORT
Format- A (DC)
Details of Generation & Line Flow Data
Generation Data (SAP)
ORT Data

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

DESPATCHED TO
RCC
NRLDC
OS
EEMG

FREQUENCY
Daily
Daily
Daily
Monthly

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 50/86

Doc Ref:ND-IM-OPG

S
No
01
02
03
04
05
06

TITLE OF THE DRAWING

Prepared by: Yash Pal


Sr. Supdt..(OPN)

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

DRAWING CODE /
NO.

A/V WITH

NIL

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 51/86

Doc Ref:ND-IM-OPG

S
No
01
02
03
04
05
06

EQUIPMENTS (CRITICAL /
REQUIRING CALIBRATION)
Nil

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

EQUIPMENT CODE

CALIBRATION
RECORD A/V WITH

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 52/86

Doc Ref:ND-IM-OPG

S No
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15
16

Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

TITLE OF THE WORK INSTRUCTION(s)


PREPARATION AND NORMALISATION OF PTW.
ST START UP PROCEDURE.
ST SHUTDOWN PROCEDURE.
SHUTDOWN PROCEDURE FOR ONE WHRB.
HYDROGEN FILLING PROCEDURE IN ST GENERATOR.
HYDROGEN PURGING OF ST GENERATOR.
STATION BLACK OUT PROCEDURE.
GT START UP PROCEDURE WITH BLACK START DG SET.
HSD RACK UNLOADING PROCEDURE.
OPERATION DURING ST TRIPPING.
PROCEDURE FOR TAKING SECOND WHRB IN SERVICE
CRITICAL PARAMETERS
BLACK START DG SET START UP PROCEDURE
CT SYSTEM OPERATION
GAS TURBINE COMPRESSOR WASHING PROCEDURE
EHC-HC GOVERNOR CHANGEOVER PROCEDURE

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

DADRI

W.I. No.
OPG-WI-1
OPG-WI-2
OPG-WI-3
OPG-WI-4
OPG-WI-5
OPG-WI-6
OPG-WI-7
OPG-WI-8
OPG-WI-9
OPG-WI-10
OPG-WI-11
OPG-WI-12
OPG-WI-13
OPG-WI-14
OPG-WI-15
OPG-WI-16

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 53/86

Doc Ref:ND-IM-OPG

S No
01
02
03
04
05

FORMAT DESCRIPTION
Department Distribution Register
Record matrix
Non conformity register
Format A For DC TO RCC
Revised DC Format

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

FORMAT No.
F-IM-02
F-IM-06
F-IM-33
F-08(GPS-P-01)
F-08(GPS-P-02)

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 54/86

Doc Ref:ND-IM-OPG

Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

S
No
01
02
03
04
05
06
07
08
09
10
11
12
13
14
15

RECORD DESCRIPTION

RECORD No.

SCE LOG BOOK


MODULE-1 ENGINEER LOG BOOK
MODULE-2 ENGINEER LOG BOOK
MOD 1 OPERATOR LOG BOOK
MOD 2 OPERATOR LOG BOOK
FOPH OPERATOR LOG BOOK
S-YARD / SW-GR OPERATOR LOG BOOK
OFFSITE OPERATOR LOG BOOK
STEAM TURBINE OPERATOR LOG BOOK
CLEARANCE REGISTER
ABT SCHEDULE REGISTER
DAILY CHEMISTRY REPORT
OIL TEST RESULT
PTW REGISTER
WEEKLY EQUIPMENT CHANGEOVER

16

SCHEDULE
EMERGENCY

17
18
19
20

SCHEDULE
PROPOSED ABT D.C. FOR NEXT DAY
MESSAGE BOOK
DFR REGISTER
GAIL/ENERGY METER REGISTER

Prepared by: Yash Pal


Sr. Supdt..(OPN)

EQUIPMENT

DADRI

CHECKING

Issued by: A.N Goyal


MR

LS-GP-01-00
LE-GP-02-01
LE-GP-02-02
LO-GP-03-01
LO-GP-03-02
LO-GP-04-00
LO-GP-06-00
LO-GP-07-00
LO-GP-08-00
F-01(GPS-P-01)
F-02(GPS-P-01)
F-03(GPS-P-01)
F-04(GPS-P-01)
F-05(GPS-P-01)
F-06(GPS-P-01)

RETENTION
PERIOD
TWO YEARS
TWO YEARS
TWO YEARS
TWO YEARS
TWO YEARS
TWO YEARS
TWO YEARS
TWO YEARS
TWO YEARS
FIVE YEARS
ONE YEARS
TWO YEARS
TWO YEARS
ONE YEARS
TWO YEARS

RETENTION
AT
EEMG
EEMG
EEMG
EEMG
EEMG
EEMG
EEMG
EEMG
EEMG
EEMG
EEMG
EEMG
EEMG
EEMG
EEMG

F-07(GPS-P-01)

TWO YEARS

EEMG

F-08(GPS-P-01)
F-11(GPS-P-01)
F-12(GPS-P-01)
F-13(GPS-P-01)

ONE YEARS
FIVE YEARS
ONE YEARS
FIVE YEARS

EEMG
EEMG
EEMG
EEMG

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 55/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

SL
NO

COMMUNI
CATION
DETAIL

MODE

RESP
ONSIBI
LITY

FREQUENC
Y

1.

Integrated
Policy

Display in
Dept

Dept
Head

Once in 3
Months

2.

MoU

Dept
Head

3.

Progress
on MoU

Display in
UCB /Deptt
Meeting
Deptt Meeting
/ LAN

4.

Corrective
&
Preventive
Actions
External /
Internal
Customer
Complaints
Statutory &
Regulatory
Requireme
nts
All Tech. /
General
Communic

Daily MTP
meeting/
ORT/ Deptt
Meeting
Daily MTP
meeting/ Dept
meeting

Dept
Head

All time/
Once a
Month
Once a
Month/All
Time
Daily/
Monthly

Dept
Head

Daily/
Monthly

All
Empl
oyees

Displays in
LAN

-do-

All time

All
Empl
oyees

All
Emplo
yees

LAN / Display
in UCB/
Communicati

Dept
Head

All Time/ As
and when
reqd.

All
Empl
oyees

5.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Dept
Head

Issued by: A.N Goyal


MR

COMMUNICATION TO
Within
MR /
Othe
Cust
Deptt
TQM
r
omer
Cell
Dept
t
All

Empl
oyees
All

Empl
oyees
All

Empl
oyees
All

Empl
oyees

Approved by: V.K.Singh


HOD(OPN)

Deptt:

O&M/OPN -GP

Page : 56/86

Doc Ref:ND-IM-OPG

Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: IER
(A)QUANTITY

(B)
OCCURRENCE

(C)IMPACT

(D)LEGAL REQ

(E)DETECTION

(F)CONTROL

SCORE G = ABCDEF

Negligible
1
Low

Rare
1
Once in week
2

No visual effect

No
1
Yes
10

Immediate
1
With in 1 hour
2

Control effective &


reliable 1
Secondary control
2

2
Moderate
3
High
4
Excessive
5

With in 24
hours
3
Several times
a day
4
Continuous
5

Nuisance /
discomfort
2
Depletion of
natural
resources
3
Global concern
4

With in 8 hrs

Human interference
needed
3

3
With in 24 hrs
4

Control exists, not


checked
4
Control not reliable
5
Absence of control
6

Human health
After 1 day
effect 5
5
Fatal
6
If score is > 30 or impact is >4 or D=10 aspect is significant

ND-ROA-OPG
S No

ACTIVITY

D/I

HSD Unloading from


Rake

HSD Unloading
Pump Operation

HSD Storage Tank


Area
HSD Tank Fire

Movement of
Tankers & Rakes

4
5

I
6

Air Filter Cleaning


System

Prepared by: Yash Pal

ENV ASPECT

N/ A/
E

ENV
IMP

QT
Y
A

OCCR
B

IMP
C

LEG
D

DET
E

CON
F

SCOR
E
G

ACTION/
REMARK
S

OCP-26

Leakage
from Hose
Pipe
Leakage
from
Unloading
P/p
Leakage

W/S

36

W/S

W/S

10

160

Fire /
Explosion
Vehicular
Emissions
Leakage of
Lube Oil
Dust
Emission

10

240

12

W/S

A/W

Issued by: A.N Goyal

Approved by: V.K.Singh

OCP-26,
DMP
OCP24,DMP

Sr. Supdt..(OPN)

MR

HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 57/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: IER
S
No

7
8
9
10

ACTIVITY

HSD Firing in Gas


Turbines
Operation of Fuel
Transfer Pump
Operation of Fuel
Injection Pump
Blow Down of CW
System

D
/I

Chlorination Plant
Operation

Leakage

Leakage
Waterblow
down
Water
Drainage
Leakage of
Chlorine
Leakage of
Chlorine
Dust
Emission

DNR

A/W

12
13

D
D

D
D

Noise
Energy
Consumptio
n
Gas
Leakage
Energy
Consumptio
n
Explosion

D
D

CO2
emission
Leakage

N
A

A
A

NOISE

WATER USE
WATER
LOSS

DNR

DNR

W.POL

D
D

Leakage
SPILLS

A
A

DNR
W

NOISE
Energy
Consumptio
n

DNR

14
15

16

17

Compressed Air
Plant Operation
Air Conditioning
System

Operation of Gas
Turbine on Fuel Gas
(Bursting
of
Pipeline)

QUENCHING OF
CBD

D
D

18
19
20
21
22

STEAM LEAKS
EFFLUENT
DICHARGE
Fire Fighting Line
Leakage
OIL SYSTEM
CW Pump
Operation (GAS &
Thermal)

ENV
IMP

Gas
EMISSION

D
Air Filter Changing
Compressed Air
Plant Operation(Gas
& Thermal)

N/ A/
E

D
11

ENV ASPECT

A
A

DNR
O3
DEPL

A
E

DNR
A

QTY
A

OCCR
B

IMP
C

LEG
D

DET
E

CON
F

SCORE
G

ACTION/
REMARKS

72

OCP-47

36

OCP-26

24

54

OCP-39

54

OCP-4

10

400

12

10

600

60

OCP-43

10

360

OCP-38

60

OCP-43

10

480

OCP-47

120

OCP/OPNGP/01

10

600

36

OCP-4

10

320

OCP-21

27

12

40

OCP-15

90

OCP-43

OCP-44
DMP

OCP-15

OCP-15

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 58/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: IER
S
No
23
24

25
26
27

ACTIVITY
Seal Oil System
Hydrogen in
Generator
Hydrogen in Rack
Carbon Dioxide Gas
Main Oil Tank

D
/I
D

ENV
ASPECT
Oil Leakage

N/ A/
E
A

ENV
IMP
W

D
d
D
D
D
D
D

A
E
A
E
A
A
A

A
A/W
A
A
A
W/S
A

N
N

DNR
A

DNR

DNR

Leakage
Fire
Leakage
Fire
Leakage
Oil Leakage
Fire
energy
consum
NOISE
Feed water
leakage
Condensate
water
leakege
Sludge
Disposal

W.Gen.

Leakage

A/W

D
D
D

Leakage
Acid leakage
Fumes

A
A
N

A/W
A/W
A

D
D
D
D

Leakage
SPILLS
NOISE
Oil leakage
Smoke
LEAK OF
DISEL

A
A
N
A
N

W
W
A
W/S
A

A
A
E

DNR
W
A

A
N

W
DNR

DNR

28
Boiler Feed Pumps

D
D
D

29
30
31
32
33
34

Condensate
Extraction Pumps
Central Oil
Purification system
Hydrazine Dozing
System
Phosphate Dozing
System
Battery Room
Storage & Issue of
Lube Oil

35
DG Set Operation

36
Cooling Tower
( GAS )

D
D
D

37

CT FAN
OPERATION

FIRE
Oil leakage
from Gear
Boxes.
plume drift
Water
leakage
(Splashing)
ENERGY
CONS

Prepared by: Yash Pal


Sr. Supdt..(OPN)

DNR

Issued by: A.N Goyal


MR

QTY
A
2

OCCR
B
1

IMP
C
2

LEG
D
1

DET
E
3

CON
F
3

SCORE
G
36

12

5
2
3
2
2
4

1
1
1
1
2
1

6
1
6
2
2
2

10
1
1
1
1
1

1
2
1
2
2
1

2
3
2
3
2
1

600
12
36
24
32
8

90

60

OCP-15

36

OCP-4

36

OCP-4

36

18

2
1

1
5

1
1

1
1

3
5

3
1

18
25

24

1
3
2
3

2
3
1
2

2
2
2
2

1
10
1
1

1
1
1
1

3
2
2
2

12
360
8
24

1
3

1
1

4
4

1
1

1
1

2
3

8
36

18

15

18

30

Approved by: V.K.Singh


HOD(OPN)

ACTION/
REMARKS
OCP-3

DMP
DMP
OCP-3
DMP

OCP- 41

OCP-15

DMP

OCP-43

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

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Page : 59/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: IER
38

39

TRANSPORTATION
OF NATURAL GAS
BY 1.4 KM GAS
PIPE LINE FROM
GAIL TERMINAL TO
GAS PLANT
GAIL TERMINAL

I
I
I

LEAKAGE

FIRE
LEAKAGE
FIRE

Prepared by: Yash Pal


Sr. Supdt..(OPN)

A
A
A

DNR

AIR
DNR
AIR

Issued by: A.N Goyal


MR

30

OCP-49

4
1
5

1
1
1

5
3
6

10
1
10

2
3
1

2
3
3

800
27
900

DMP

Approved by: V.K.Singh


HOD(OPN)

DMP

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

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Page : 60/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: Group Risk Assessment (GRA)


ND-ROH-OPG

Activity

Hazard

D-Direct,

N-Normal

I -Indirect

ANAbnormal

RRoutine

Likeli
hood
L
HUL
(1)
UL
(2)

EEmergency

NR-NonRoutine

Likely
(3)
Very
Likely
(4)

Scale
S
1-Spot

Level of
Consequen
ce
C
1-Slightly
Harmful

Detecta
bility
D
1Instanta
neous
2-High

Risk
Classification
(TotalS+L*C+
D)
3
Trivial

Over
Riding
Factor

4-8
Moderate

DCDomino
concern
CEChronic
effect

2-Within
Dept

2-harmful

3-Within
Factory

3-Very
Harmful

3-Low

9-15
Substantial

Outside
Factory4

4-extremely
harmful

Nil-4

16-24
Intolerable

LC-Legal
concern

*If total score is >12 or overriding factor LC/DC/CE the risk is significant

Risk

Total

Risk

Detec

Adequacy of
Measure

Sever

Condition

Level

Hazard

Scale
Likeli

Activity

Risk Assessment

Over riding

F-IM-19
Risk Identification

Risk
Control
Measure

Inspect
ion of
GT
area

Exposu
re to
noise (~
80 dB)

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Use of ear
plug

---

Issued by: A.N Goyal


MR

unli
kel
y

hearin
g
disco
mfort

Approved by: V.K.Singh


HOD(OPN)

Si
g

(LC/ DC/ CE)factor

Classification

[SC+SE+D]

tibility [D]

[SE = L x C]ity

of Cons- equence [C]

[SC]
hood [L]

Consequence

Likelihood

Gaps, if any

Existing

Ha
zar
d

N/AN/E

R/NR

D/I

Activi
ty

LC

Existing
measures
to continue,
OCP-15

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL

WHRB
/ BFP
house
inspecti
on &
monitor
ing
Combiti
on
chamb
er
inspecti
on

Consequence

Likelihood

Ha
zar
d

a) Fire
due to
oil
spillage

AN

Fire
protection
equipments
placed

--

unli
kel
y

may
cause
dama
ge to
man &
mach

1
1

Si
g

b)
Slippag
e

AN

No
leakages,
Proper
housekeepi
ng

--

unli
kel
y

1
0

S
ub

Exposu
re to
physica
l heat /
High
pressur
e
Exposu
re to
heat

AN

Proper
insulation,
sealing of
equipment

---

unli
kel
y

may
lead
to
physic
al
injury
may
cause
burnin
g

M
od
er
at
e

AN

Fire
sensors,
immediate
actions to
attend
leakages

--

unli
kel
y

may
cause
fire

1
1

Si
g

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

(LC/ DC/ CE)Over riding factor

HSD
handlin
g in
FOPH
area

Risk

Gaps, if any

D/I

R/NR

Activi
ty

Adequacy of
Measure

Risk Classification

Condition

Existing

Hazard

N/AN/E

Activity

Risk Assessment

Scale [SC]
Likelihood [L]

Risk Identification

Total [SC+SE+D]

Doc Ref:ND-IM-OPG

Detectibility [D]

Page : 61/86

Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

[SE = L x C]Severity

O&M/OPN -GP

[C]Level of Cons- equence

Deptt:

DADRI

Risk
Control
Measure

LC

Fire
control
equipment
s, proper
maintenan
ce.OHSM
S OCP24,26
Proper
maintenan
ce & good
housekeeping

LC

Proper
sealing,
gland
packing,
insulation
have been
provided
Fire
sensors,
proper
railing
etc.OHMS
OCP6,

INTEGRATED MANAGEMENT SYSTEM


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Deptt:

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Page : 62/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

R/NR

N/AN/E

Existing

Gaps, if any

[C]Level of Cons- equence

[SE = L x C]Severity

(LC/ DC/ CE)Over riding factor

Risk
Control
Measure

D/I

Title: Group Risk Assessment (GRA)

Switch
gear/
EHV
switch
yard

Exposure to
flash
over,
Electric
shock

AN

Insulation
, proper
Earthing,
precautio
ns

---

unl
ike
ly

Damag
e to
man &
materia
l

1 S
1 i
g

LC

Steam
turbine
MOT
area
inspecti
on

Oil
spillage &
fire

AN

Proper
maintena
nce and
house
keeping

---

Hi
ghl
y
unl
ike
ly

Accide
nt,
damag
e to
equipm
ent

8 S
i
g

DC

Hydrog
en
filling
station

Explosion
due to
leakage
of
hydrogen

AN

Leakage
detection
& pursing
FF
Equipme
nt
available,
LMI
available

---

Hi
ghl
y
unl
ike
ly

Explosi
on

9 S
i
g

DC

Ensuring
additional
earthing &
proper
isolation
OHSMS
OCP5,12
Good
house
keeping,
maintenan
ce, Fire
protection
system
installed
existing
measure
to
continued
OCP-16

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Haz
ard

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

Total [SC+SE+D]
Risk Classification

Risk

Detectibility [D]

Activity

Adequacy of
Measure

Likelihood [L]

Condition

Consequence

Hazard

Likelihood

Activity

Risk Assessment

Scale [SC]

Risk Identification

INTEGRATED MANAGEMENT SYSTEM


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Deptt:

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Page : 63/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-3, CARRY OVER OF OIL (SEAL AND LUBE) TO DISCHARGE


1. PURPOSE : To establish a system for controlling the Water contamination resulting
from oil carry over to drains from the leaks in oil system(Seal oil, Lube Oil)
2. SCOPE : All equipment Lub. Oil system, T/G seal oil system of Coal & Gas stations,
All other related areas of NTPC Dadri
3. DEFINITION : UCE : Unit Control Engineer
4. RESPONSIBILITY
:
HoD(Opn_Th),
HoD(Opn_Gas),
Hod
(Mntc_Th),
Hod(Mntc_Gas), HoD(MTP_Th), HoD(MTP_Gas)
5. PROCEDURE: As described below
DESCRIPTION

RESPONSIBILITY

REF. DOC.

5.1 Inspect the oil lines thoroughly during the shift and
ensure the tank oil levels are normal

OPERATOR

5.2 In case of any leaks noticed, inform the unit control


engineer and record in the log book. Keep a watch on
the leak till it is attended

OPERATOR

LO-MP-O8-XX
LO-GP-08

5.3 In case of leaks, inform the maintenance engineer for


attending the same

UCE

Job card/Work
order card

5.4 Attend to the leaks and record corrective action taken

Mntc Engineer

Job card/Work
order card

5.5 Wherever sub drains are provided, ensure that the oil
leak is not entering the sub drains. Wherever sub
drains are not provided ensure oil from settling pit
does not enter the main drain. In case it is entering
the main drain from the sub drain/settling pit, isolate
the sub drain/settling pit temporarily from the main
drain to avoid carry over

OPERATOR

5.6 Arrange to pump out the oil from the sub drain/settling
pit and ensure that no oil is getting carried over to the
drain.

TECHNICIAN

5.7 Wipe out the oil spills/ leaks with cotton waste and put

TECHNICIAN

the soiled waste into the bin provided for it.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 64/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-4, Control Of Water Leaks From Feed / Steam And Fire
Water Systems
1.
2.
3.

PURPOSE: To establish a system for controlling the Depletion of Natural


Resources resulting form the leakage from feed water / steam / fire water
system and to ensure least impact of the same.
SCOPE :
Feed / condensate lines of Boiler / Turbine in Thermal & Gas
Stations / Fire Fighting System of NTPC Dadri.
DEFINITION : UCE : Unit Control Engineer

4. RESPONSIBILITY:
HoD(Opn_Th), HoD (Mntc_Th) HoD(Opn_Gas), HoD
(Mntc_Gas) HoD(FM), HoD(AHP) & all concerned HODs.
5. PROCEDURE: as described below
DESCRIPTION

RESPONSIBILITY

5.1 Check once in a shift for leakage in feed / Concerned area


condensate line. If any leaks are observed, inform Operator
UCE and record in log book the zone & type leak
5.2 Verify the leak and decide its cause of action i.e.
whether the leak can be arrested on line or to plan
for a shut down. In case the leak can be arrested
on line, inform maintenance & get it attended.

UCE

5.3 If it can not be attended on line and needs an


isolation, plan it accordingly
Maintenance
Engineer
5.4 If the leak is to be attended by isolating the line,
which is possible only during a shut down, record
the same and inform the concerned area operator
to keep a watch on it. Inform Maintenance to put a
tag for identification for attending it.

UCE

5.5 If possible, put a shield to control its dispersion


range

Maintenance
Engineer

5.6 Get the leak attended as per priority basis


5.7 Record the corrective action taken

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

REF. DOC.
LO-MP-O7-XX
LO-MP-08-XX
LC-OS-05
LO-GP-03-XX
Job card/Work
order card

Job card/Work
order card
Job card/Work

Maintenance Engineer
Maintenance Engineer
Approved by: V.K.Singh
HOD(OPN)

order card

Job card/Work
order card

INTEGRATED MANAGEMENT SYSTEM


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Deptt:

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Page : 65/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OHSMS OCP-5 Prevention and Control of Electrocution of


personnel
1. Purpose
2. Scope
3. Responsibility
4. Performance
criteria
5. Cross
references
6. Activities:
1.
2.
3.
4.
5.

: To eliminate/control Electrocution of personnel


: All human beings during operation & maintenance of Electrical
installation in Plant.
: Engineer in-charge
: Incident /Accident register/ record
: Indian Electricity Rules, 1956
IS 18001 clause 4.4.3 operational control

Activity
To ensure display of safety instruction and shock Treatment Chart
(CPR)
To ensure deputation of trained personnel, in First Aid and shock
treatment.
Availability of safety appliances and first aid box.
To ensure display of telephone nos. of hospital.

Switch off affected installation from live circuit


Remove the affected persons from incident place
Provide shock treatment as per chart
If required, provide artificial respiration by recuperate
Call ambulance to shift the affected persons to Hospital
Inform duty officer, executive -in-charge.

Responsibility
Technician
-do-doSupervisor/
Technician on
duty.
-do-

8.0 CHECKING, CORRECTIVE AND PREVENTIVE ACTION :


Engineer I/c shall ensure effective implementation of above procedure. In case of any
deviation he shall undertake necessary connective preventive action.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 66/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OHSMS OCP -6 CONTROL LOSSES DUE TO FIRE/


EXPLOSION
1.0

Purpose

2.0

Scope

3.0

Responsibility

04.

Performance Criteria: Incident/ Accident register/ record.

5.0

Cross Reference

: IS 18001 clause 4.4.3 operational control

6.0

Activities

S.
No.
1.
2.
3.
4.

6.1
1.

2.
7.0

: To eliminate/control losses due to Fire/Explosion.


: Electrical equipment/ installation and over head lines of Plant.
: Engineer in-charge.

Activity

Responsibility

To ensure display of telephone nos. of Executive in- Executive In-charge.


charge, other Sr. executives of department, fire station,
CISF control room, Night duty officer and Ambulance.
Availability of Fire extinguishers for electrical/ oil fire.
CISF Fire/ Executive
In-charge.
To ensure deputation of trained personnel, in Fire Executive In-charge.
fighting and First Aid, for operation & maintenance of
Electrical installations.
To check and ensure proper functioning of protection Technician on duty
controls.
Response Plan
:
Disconnect the affected area from live line.
Use appropriate Fire Extinguisher
Contact CISF fire control room for calling fire
tender.
Inform duty officer, Executive in-charge.
Place Do Not Switch ON notice board on affected
installation.

Technician on duty

Technician on duty

Checking, Corrective and Preventive Action:

Concerned HOD shall ensure effective implementation of above procedure.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 67/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OHSMS OCP-12 LOCKOUT, TAGOUT DURING ELECTRICAL


MAINTENANCE
1.0

Purpose

: Safe working for Electrical maintenance, lockout, tagout.

2.0

Scope

: Electrical equipment/ installation and over head


lines.

3.0

Responsibility

: HOD (Operation ) & HOD (Elect.)

4. 0

Performance Criteria : Incident/ Accident register/ record.

5.0

Cross Reference

6.0
Activities
S.No.
1.
2.
3.
4.
5.
6.
7.

: Indian Electricity Rules, 1956


: Indian Electricity Act, 1910.
: IS 18001 clause 4.4.3 operational control
Activity

Responsibility

PTW (Authorization for maintenance work)


Provision of safety devices like insulated hand gloves, electrical shoes,
safety belt, ladder, earth connection devices, helmets and line tester.
Taking electrical shutdown of equipment/ installation and over
headlines for maintenance.
De-energising & isolation of installation/ equipment from live line
ensuring lockout and tagout.
Discharging and Earth connection of installation, after ensuring visual
isolation of installation from both ends of live line, as per Indian
Electricity Rule 36.
Repair/ maintenance of equipment as per instructions of supplier/
manufacturer and job card.
Return of shutdown after repair, removal of earth connection, testing
for insulation resistance before re-energizing.

Engineer in-charge
-do-

7.0
Checking, Corrective and Preventive Action:
HOD (Elect.Maint.) shall ensured effective implementation of above programme. In case
of any deviation he shall take appropriate Corrective & Preventive action. He shall
conduct monthly meeting for ensuring effective progress.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

-do-do-do-do-do-

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 68/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-15, CONTROL OF NOISE


1. OBJECTIVE :
To establish a system for minimising the effect of the noise at
different locations to ensure a least impact.
2. SCOPE : TG hall & Boilers of Unit 1,2,3,4 , AHP Compressors of Units 1,2,3,4,
Vacuum Pumps, DG Set, Mill Areas, Compressors Of Thermal And Gas Stations,
Pump Houses, Crusher House, Conveyors, Work Shops.
3. DEFINITION : AHP : Ash Handling Plant DG : Diesel Generator
PPE : Personal Protective Equipment
4. RESPONSIBILITY
:
HoD(Opn_Th),
HoD(Mntc_Th,
HOD(Opn_Gas)
&
HOD(Mntc_Gas) HOD(FM), HoD(AHP), HoD(Safety)
5.PROCEDURE : As described below
DESCRIPTION
RESPONSIBILITY REF. DOC.
5.1

Ensure the availability of PPE like ear muffs


and insist to use the same

SCE

5.2

Ensure the display of awareness Boards to


insist on usage of PPE at work locations that
are noise prone zones

SCE,
SrMgr(Safety)

5.3

Check the condition of doors of all the


enclosures, gaskets, sealings under normal
conditions ensure the doors to be closed.
Under abnormal conditions of noise, check the
equipment for leaks of steam, vacuum
conditions etc.

Operator

5.4

Inform maintenance for attending abnormalities

UCE

5.5

Inform MTP
recording

UCE

for

Noise

level

monitoring/

UCE
5.6

Records of abnormalities and actions taken in


log book
Sr.Mgr( Safety)

5.7

Ensure the periodic checking of PPE for their


effectiveness/healthiness
Concerned HOD

5.8

If a PPE is found defective, replace the same.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

Job
card/work
order card
Job
card/work
order card
LE-GP-02-XX
LE-CHP-01
LE-AHP-01-00
LE-AHP-05-00

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 69/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-16, CONTROL OF FIRE FROM H2 AND OTHER GAS


SYSTEM
2. PURPOSE :
To establish a system for the control of fire from flammable gas
Cylinders Storage location
3. SCOPE : H2 cylinders rack at all Units, H2 gas filled system at all Units,
Store Open Yard, Acetylene gas, storage areas, LPG at Canteen ,all other storages
in Coal and Gas Stations
4. DEFINITION : LPG : Liquified petroleum Gas
H2 : Hydrogen
CMC : Canteen Management Committee
5. RESPONSIBILITY : HoD(Opn_Th), HoD(Opn_Gas), HoD(C&M), Head(CMC) are
responsible for the operation of this procedure.
DESCRIPTION
RESPONSIBILITY
REF. DOC.
5.1 Check for leakages of valves, union joint and
headers once in a shift to ensure that there is no
leakage in the filling rack and H2 filled gas
system.
5.2 In case of any leakage, isolate if possible and
inform the Unit controller/incharge concerned
5.3 Identify the point of the leakage .
5.4 Instruct operator to keep a vigil & stop the filling
process(in case it is on).
5.5 Inform maintenance to attending the leak
5.6 Ensure the availability & use of sparkless tools to
attend the leak
5.7 Ensure the display of safety boards in the
respective locations
5.8 Ensure the availability and healthiness of Fire
fighting system and record the same at least once
in a day
5.9 Check the point after the leak is attended to
ensure that there is no leak
5.10Keep records of leak, actions taken

Operator

LO-MP-08-XX
LO-GP-08-00
LC-STORE-02

Operator
UCE
UCE
UCE
Job card/WOC
I/C (Mtce -TG),Coal and
Gas
DGM(O-Coal& Gas)
Sr.Mgr(Safety)
Operator
Operator

LO-MP-08-XX
LO-GP-08-00
LC-STORE-02

Concerned Area Mntc


5.11At the storage areas check for leaks once daily Engineer
Job card/WOC
and keep records.
Supervisor(Stores)
5.12Report abnormalities to Stores In charge
5.13Expedite immediate action to arrest leakage
Supervisor(Stores)
5.14Incase of fire, use suitable fire extinguisher and Incharge(Stores)
inform Emergency Control room and concerned Operator
HOD
Supervisor(Store)
5.15Ensure employees do not carry inflammable
materials and display No Smoking zone boards
Concerned HOD
Sr,MGR(Safety)

Prepared by: Yash Pal

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

Sr. Supdt..(OPN)

INTEGRATED MANAGEMENT SYSTEM


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DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-19, WASTE DISPOSAL FROM WORK LOCATIONS


1. PURPOSE : To establish a system for safe disposal of solid waste to identified
locations.
Applicable to all kinds of wastes such as hazardous / non-hazardous, ferrous /
non-ferrous including asbestos, that is generated from work place during various
operations such as maintenance, house-keeping, storage, handling activities.
2. SCOPE : All the working locations (of temporary and / or permanent nature)
3. DEFINITION : During the power generation operation/maintenance operations
different kinds of wastes are generated as described in point No 1.
At NTPC - Dadri, all such wastes are categorized into three categories viz 1.
Ferrous, 2. NonFerrous, 3. Hazardous such as chemical sludge from lagoon, oil
sludge from centrifuge.
4. RESPONSIBILITY : The responsibility of implementing this procedure lies with
the concerned HODs.
5. DESCRIPTION:
DESCRIPTION
5.1 Ensuring the availability of containers of sufficient
capacity at various permanent locations (Separate
containers for scrap & waste materials)
5.2 Ensuring the availability of similar containers, if
required, at/near temporary working sites.
5.3 Display of hoardings about the nature and kind of
solid wastes as described in point 3
5.4 Display of hoardings/instruction for the safe
handling/disposal of the solid wastes as described in
point 3
5.5 Ensuring the usage of PPE for the
handling/disposal of waste into the identified
containers and from the containers/bins
to the
disposal sites, depending upon the type of waste on
regular basis
5.6 Ensure the Deployment of sufficient number of
tractor trolleys/for unloading of waste from containers
and transport it to stores Scrap Yard/any other
specified destination depending upon the nature of
the waste.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

RESPONSIBILITY
ALL HODs
ALL HODs
ALL HODs
ALL HODs
HOD (Safety)

ALL HODs

Approved by: V.K.Singh


HOD(OPN)

REF. DOC.

INTEGRATED MANAGEMENT SYSTEM


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DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-21, DISCHARGE OF EFFLUENT


1. PURPOSE: To establish a system for controlling the quality of effluents of Main
Plant, CHP & AHP for ensuring least impact on the environment.

2. SCOPE: Effluent discharge points of Main Plant, CHP, AHP, Ash Mound and BHEL
pump house.
3. DEFINITION :

4.
5.
S.N
o.
5.1

5.2
5.3

5.4

5.5
5.6

5.7
5.8

TSS :Total Suspended solids


O&G : Oil & Grease
BOD: Biological oxygen demand COD: Chemical oxygen demand
CHP: Coal handling plant
TDS: Total dissolved solids
AHP: Ash handling plant
RESPONSIBILITY : HoD(Opn_Th), HoD(Opn_Gas), HoD(FM), HoD(AHP),
HoD(EED)
PROCEDURE: As described below
RESPONREF. DOC.
ACTIVITY
SIBILITY
List the instrumentation required for monitoring the I/c Chemistry F-01 (OCP-21)
various effluent parameters and include the same by
informing the Head (MTP) for covering under the
calibration schedule.
Ensure that the calibration of the same is traceable to I/c Chemistry
the national standards.
Establish a Schedule for monitoring of the effluents Mgr
LO-DM-08
from various discharge points for the required physical Chemistry
and chemical parameters.
Various parameters like TSS, TDS, Temperature, pH Lab Asstt
are to be measured as per format F-DM-08 (E). Keep
records of measurements.
Monitor and record the parameters specified and Lab Asstt
LO-DM-O8
verify the compliance of the same to the limits
specified. In case of any deviations, inform the same
to the I/c Chemistry.
Review the deviations and Inform the concerned HOD I/c Chemistry F-DM-08(E)
for affecting
required corrective and preventive
actions
Check the reasons for the deviations and take the Concerned
necessary corrective action. Inform I/c Chemistry to HOD
re-monitor the same so as to ensure the compliance to
the limits.
Ensure the regulatory compliance for all the I/c Chemistry
parameters as applicable before letting the discharge
to the final drain.
Record the corrective & preventive actions.
Concerned
HOD

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


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DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OHSMS OCP-24 CONTROL OF FIRE WHILE HANDLING OF DIESEL, PETROL


1. PURPOSE : To establish a system for the control of fire while handling
diesel/petrol/HFO in the stores and ensure the least impact of the same
2. SCOPE : Stores, Diesel, Petrol, MTO Storage areas of all NTPC Dadri handling
locations
3. RESPONSIBILITY: HOD(C&M), HOD(FM), HOD(Maint.Gas),HOD(Opn_Gas),
HOD(Safety)
4. PERFORMANCE CRITERIA : Accident / Incident records
5. CROSS REFERENCE:
The petroleum Act1934 including amendment of 1997
IS 18001 clause 4.4.3 operational control
6. ACTIVITIES:
S.NO
1.
2.

3.

4.
5.
6.
7.
8.

DESCRIPTION
Display No smoking Zone boards wherever necessary.
Ensure that the personnel working in the area does not use
flammable materials like lighters, cigarretes Bidis etc.
Ensure the availability of ventilation system/exhaust to dispel
emissions if any and fire fighting system of the storage area.
If its not so, ensure its working condition by getting it
attended immediately.
Ensure the availability of correct sized equipment like funnel,
cans etc in good condition, for facilitating the issue in
required quantities at the issue locations. If it is not so,
ensure to make the same available.
Ensure the issue and transfer of the Diesel/Petrol so that
there are no spills on the ground and record the issue in the
issue register.
Ensure PCC flooring at the storage areas with adequate
containment and drainage facilities.
In case of any spills, leaks, ensure to contain and recover the
same. Ensure that the cotton waste/ Jute used for cleaning
the spills/floor is put the identified dust bin.
Record the leaks/spills and actions taken in the log book.
Weekly once ensure the healthiness of fire fighting
equipment and if it is not so, inform concerned I/c for
affecting the corrective actions and record the availability.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

RESPONSIBILITY
Incharges
of
all
individual sections as
per point No.4
Incharges
of
all
individual sections as
per point No.4
Store Keeper

Store Keeper
Incharges
of
all
individual sections as
per point No.4
Store Keeper
Store Keeper / operator
of
the
concerned
location
-Do-

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


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DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-25 ACCIDENT DUE TO HYDROGEN GAS CYLINDERS


1. PURPOSE :
To establish a system for the control of fire from flammable gas
Cylinders Storage location
2. SCOPE : H2 cylinders rack at all Units, H2 gas filled system at all Units,
3. DEFINITION : LPG : Liquified petroleum Gas
H2 : Hydrogen
4. RESPONSIBILITY : HoD(Opn_Gas), is responsible for the operation of this
procedure.
5. PROCEDURE :
DESCRIPTION
RESPONSIBILITY
REF. DOC.
5.1 Check for leakages of valves, union joint and
headers once in a shift to ensure that there is no
leakage in the filling rack and H2 filled gas
system.
5.2 In case of any leakage, isolate if possible and
inform the Unit controller/incharge concerned
5.3 Identify the point of the leakage .
5.4 Instruct operator to keep a vigil & stop the filling
process(in case it is on).
5.5 Inform maintenance to attending the leak
5.6 Ensure the availability & use of sparkless tools to
attend the leak
5.7 Ensure the display of safety boards in the
respective locations
5.8 Ensure the availability and healthiness of Fire
fighting system and record the same at least once
in a day
5.9 Check the point after the leak is attended to
ensure that there is no leak
5.10Keep records of leak, actions taken

Operator

LO-GP-08-00

Operator
SCE
SCE
I/C (Mtce) Gas

Job card/WOC

DGM(O),Sr.Mgr(Safety)
Operator

LO-GP-08-00

Operator

Concerned Area Mntc Job card/WOC


Engineer
5.11Incase of fire, use suitable fire extinguisher and Operator
inform Emergency Control room and concerned
HOD
5.12Ensure employees do not carry inflammable DGM(O)
materials and display No Smoking zone boards
Sr,MGR(Safety)

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

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Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-26, CONTROL OF OIL SPILLS


1.
2.
3.
4.
5.

PURPOSE : To avoid the spillage of the oil, HFO, LDO during the oil unloading
activity and carry over to the drain.
SCOPE :
Fuel oil unloading area.
DEFINITION : HFO : Heavy furnace oil LDO : Light diesel oil,HSD: High Speed
Diesel
RESPONSIBILITY : HoD(FM), HoD(Opn_Th), HoD(Opn_Gas)
PROCEDURE: As described below
DESCRIPTION
RESPONSIBILITY
REF. DOC.
5.1 Ensure that all the drains leading to the separation
pit are clear and ensure the out let gate of the
separation pit is in closed condition.
5.2 Check for the healthiness of the unloading hoses
and ensure all the bolts and nuts are secured
properly.
5.3 Ensure the header valves are in the closed
condition and open the unloading port valves.
5.4 Start the unloading and inspect the hose and
header for any leakage. In case of any leakage,
stop unloading, inform the same to the engineer
incharge to get it attended.
5.5 Ensure the complete evacuation of the oil from
the rake.
5.6 Disconnect the hoses and ensure the placement
of the same in the hose stand.
5.7 In case of any spills on the ground,ensure the
cleaning of the same with cotton waste and put
the soiled waste into the dust bin provided for it.
5.8 Check the drains leading to the separation pit and
ensure that there is no oil carry over.
5.9 In case of any carry over, ensure the separating
pit is effectively containing the oil carry over.
5.10If, it is not so, inform the area incharge to take the
corrective action.
5.11If necessary do the reclamation of the oil from the
separating pit.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Operator
Technician
Technician
Technician

Area Engineer
Technician

F-FM-01

Technician
Operator
Technician
LO-FO-01
Technician
Technician

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


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Deptt:

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DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-33, To Minimize Possibility Of Fire At Different


Locations And Mitigate Its Impact
1. PURPOSE: To minimize the possibility of fire at different locations and mitigate the
impact of the same.

2. SCOPE: Applicable to all areas of Fuel storage and handling, material storage and
handling.

3. DEFINITION:
4. RESPONSIBILITY: Concerned HODs
5. PROCEDURE: As described below
ACTIVITY
5.1 Ensure the availability of the adequate fire fighting
system as indicated in the locations by filling the
check list of the fire fighting system

5.2 review the fire fighting check lists and ensure


the refilling,inspection by the CISF personnel
as pert he schedule indicated on the tags
attached to the fire fighting system
5.3 in the coal handling area ,ensure the regular
inspection of coal conveyors for any
abnormality in conveyor idlers
5.4 ensure adequate house keeping in conveyor
galleries and the transfer points
5.5 ensure the person carrying any Hot work
under maintenance at the above mentioned
areas is possessing Hot work permit for
carrying the same

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

RESPONSIBILITY
Area incharge

Area incharge

Area incharge

Area incharge
Area incharge

Approved by: V.K.Singh


HOD(OPN)

REF DOC
Checklist for fire
fighting

INTEGRATED MANAGEMENT SYSTEM


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DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-38, Reduction In Consumption Of Mafron In Dadri


1. PURPOSE: To establish a system for reduction in consumption of the refrigerant gas
2.
3.
4.
5.

cylinders in NTPC Dadri-Gas.


SCOPE: Concerned Maintenance dept and Operation dept.
DEFINITION: Nil
RESPONSIBILITY: HoD(Mntc_Gas), HoD(Opn_Gas), HoD(MTP_Gas)
DESCRIPTION:
S.
No.
5.1
5.2
5.3
5.4
5.5

ACTIVITY
Ensure complete isolation of refrigerant gas system
when issuing PTW on A/C system.
Condition of the running A/C equipments to be monitored
(Vibration).
During weekly PM of A/C system, check for leaks using
soap solutions, record and attend the problems if any.
Record filling of gas when required during PM or B/D
maintenance work.
Record annual consumption of refrigerant gas cylinders.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

RESPONSIBILITY
HoD
(Opn_Gas)
HoD
(MTP_Gas)
HoD
(Mntc_Gas)
HoD
(Mntc_Gas)
HoD
(MTP_Gas)

Approved by: V.K.Singh


HOD(OPN)

REF.
DOC.

Maint. log
book
Maint. log
book

INTEGRATED MANAGEMENT SYSTEM


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DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-39, To Minimize Scaling Tendency Of Circulatng Water


During Borewell Feeding.
1.
2.
3.
4.

5.

PURPOSE: To minimize the scaling tendency of circulating water in condenser


during bore-well feeding.
SCOPE: All the condensers of Thermal-Coal and Gas project.
DEFINITION: ppm Parts Per Million
RESPONSIBILITY: HoD(Opn_Th), HoD(Opn_Gas).
DESCRIPTION:
S.
No.
5.1
5.2

5.3
5.4

5.5

ACTIVITY
During borewell feeding, ensure premature exhaustion
of Softening plant vessels. Hardness in fore bay not to
exceed 25 ppm.
In case of any technical constraint, e.g.
(a) Lack of sufficient borewell water
(b) Reduced availability of Softening plant due to
overloading of resin etc
Which in turn may affect generation, I/c Chemistry in
consultation with DGM (Opn_Coal) shall take the
appropriate action. Record of the above to be
maintained.
Simulation study to be carried out in one of the
Thermal-Coal units using a trial heat exchanger for
preparing baseline data for further analysis.
Carry out inspection of each condenser during annual
overhauling of each unit and record its scaling status
before and after mechanical cleaning.
Carry out its inspection for next three years and study
the impact of chemical cleaning. Loss in condenser
vacuum due to scaling to be evaluated for the above
period.
Based on the conclusions drawn from the activities
mentioned in 5.3 and 5.4, determine the optimum
period for carrying out acid cleaning.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

RESPONSIBILITY
Mgr (Chem)

REF.
DOC.
LO-DM-07

I/c (Chem)

LO-DM-12

I/c (Chem),
HoD (Opn_Th),
I/c (TMD)
I/c (Chem),
HoD (Opn_Th),

LO-DM-12

I/c (TMD),
HoD(O&E_Th)

I/c (Chem),
HoD (Opn_Th),
I/c (TMD)

Approved by: V.K.Singh


HOD(OPN)

LO-DM-12

INTEGRATED MANAGEMENT SYSTEM


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DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-41, To Establish A System For Dozing Ammonia In


WHRB System
1. PURPOSE: To establish a system for dozing ammonia in WHRB system.
2. SCOPE: All the four waste heat recovery boilers of the Gas project.
3. DEFINITION(s): WHRB: Waste Heat Recovery Boiler
ppm : Parts Per Million
ppb : Parts Per Billion
SCE : Shift Charge Engineer
LP
: Low Pressure
4. RESPONSIBILITY: Sr Supdt (Chem), Sr Supdt (Opn_Gas)
5. DESCRIPTION:
S.
ACTIVITY
No.
5.1 Analyze the ammonia levels once per shift
5.2

Maintain the parameter in Feed, Steam and Condensate


cycles as:
pH
: 8.8-9.2
Ammonia : < 1.0 ppm

5.3

LP dozing should be continuous and normally 500 ml of


ammonia to be added in the LP dozing tank in the morning
shift daily.
In case of any deviation, dilute the dozing tank or add
additional ammonia in lot of 500 ml only. Any extra addition
should be carried after checking the effect of previous
addition.
In case pH of the system is 8.9, add 500 ml of ammonia
in the LP dozing tank.
Send the analysis report as per format F-03 GPS-P-01
along with recommendation in every shift to SCE and Sr
Supdt (Opn_Gas). Keep record of the same.
Carryout LP dozing as per the recommendations of
Chemistry.
Keep the ammonia cans inside an enclosure and in case
of leakage or spillage, neutralize with sodium hypo-chlorite
inside the enclosure itself. Test for residual ammonia
before disposing off the same and inform Mgr (Chem).
Keep record of any spillage / leakage. Use rubber gloves
while handling ammonia.

5.4
5.5
5.6
5.7

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

RESPONSIREF. DOC.
BILITY
Lab
Asstt
(SWAS-GP)
Lab
Asstt
(SWAS-GP)

Lab
Asstt
(SWAS-GP)

Lab
Asstt
(SWAS-GP)
Lab
Asstt F-03GPS(SWAS-GP)
P-01
SCE (Gas)
Lab
Asstt
(SWAS-GP)

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


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Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-42, To Establish A System For Phosphate Dozing In


WHRB System
1. PURPOSE: To establish a system for phosphate dozing in WHRB system (both HP
and LP).

2. SCOPE: All the four waste heat recovery boilers of the Gas project.
3. DEFINITION(s): WHRB: Waste Heat Recovery Boiler
ppm : Parts Per Million
ppb : Parts Per Billion
SCE : Shift Charge Engineer
LP
: Low Pressure
HP
: High Pressure
TSP : Tri Sodium Phosphate
Ms/cm : Micro Siemens per cm
4. RESPONSIBILITY: Sr Supdt (Chem), Sr Supdt (Opn_Gas)
5. DESCRIPTION:
S.
ACTIVITY
No.
5.1 Analyze the phosphate levels in all the running LP and HP
boilers once per shift
5.2 Maintain the parameter in boiler drum as :
pH
: 9.5-10.5
Phosphate : 2000-6000 ppb
Conductivity: 50 ms/cm
5.3 Recommend dozing of phosphate if pH of boiler drum
reaches 9.6 or phosphate level 2.5 ppm. Normally
recommend dozing for max 30 minutes.
5.4 For preparing a full tank of TSP solution, normally add 810 kg of TSP.
5.5 In case of any deviation, consult Manager (Chem) for
further action. Recommendation for further dozing should
be after checking the effect of previous dozing.
5.6 Send the analysis report as per format F-03 GPS-P-01
along with recommendation in every shift to SCE and Sr
Supdt (Opn_Gas). Keep record of the same.
5.7 Carryout phosphate dozing as per the recommendations
of Chemistry.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

RESPONSIREF. DOC.
BILITY
Lab
Asstt
(SWAS-GP)
Lab
Asstt
(SWAS-GP)

Lab
Asstt
(SWAS-GP)
Lab
Asstt
(SWAS-GP)
Lab
Asstt
(SWAS-GP)
Lab
Asstt
(SWAS-GP)
SCE (Gas)

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

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Page : 80/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-43, Monitoring Of Auxiliary Power Consumption


1. PURPOSE: To establish a system for operational control to monitor the auxiliary
power consumption in CW system/BFP/Compressor/Airconditioning system and
fans
2. SCOPE: Applicable to the area of operation of Dadri (Gas) power station.
3. DEFINITION(s):
EEMG
: Energy efficiency management group
Opn
: Operation
SCE
: Shift Charge Engineer
CW
: Circulating Water
4. RESPONSIBILITY: HoD(O&E_GP), HoD(Opn_GP)
5. DESCRIPTION:
S.
ACTIVITY
RESPONSINo.
BILITY
5.1 Monitor CW flow, CW inlet temp, CW outlet temp and HoD(EEMG_G
Condenser vacuum on regular basis.
P)
5.2 If CW inlet temp is 20C and inlet/outlet differential temp SCE
is < 10.8C, stop one CW temp.
5.3 Keep on monitoring CW inlet temperature and inlet/outlet SCE
differential temp in one CW pump stopped condition.
5.4 (a) If differential temperature rises above 10.8C (design SCE
value), start CW pump again.
(b) With one CW pump in stopped condition, if CW inlet
temp is 20C and inlet/outlet differential temp is <
10.8C, stop one more CW temp.
5.5 Continue to monitor Condenser performance for any DGM(OPNdeterioration as per 5.1 and recommend corrective action GP)
in case of deterioration in performance.
5.6 Reporting
Higher
power
consumption
in DGM(OPN/BFP/Compressor/ Air-conditioning system and Raw water GP)
pumps in maintenance planning meeting
5.7 Ensuring that corrective and preventive actions are carried DGM(OPNout on
GP)
5.8 Carrying out periodic energy audit once in two year
HOD(EEMGGP)
5.9

Ensuring that corrective and preventive actions are carried


out on energy audit findings

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

DGM(OPNGP)

Approved by: V.K.Singh


HOD(OPN)

CT

REF. DOC.

report available
with EEMG

Energy
audit
report available
with EEMG

Deptt:

O&M/OPN -GP

Page : 81/86

Doc Ref:ND-IM-OPG

Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-44, Monitoring Of Safety Related Aspect Wrt


Chlorine
1. PURPOSE: To establish a system for monitoring the healthiness of safety related
aspect w.r.t. Chlorine.

2. SCOPE: Chlorination Plant

- Thermal (PTS AND CW)


- Gas (CW)
3. DEFINITION(s):
PTS: Pretreatment Softening
CW: Circulating water
4. RESPONSIBILITY: Sr Mgr (Chem), HoD(Opn_Th), HoD(Opn_Gas)
5. DESCRIPTION:
S.
RESPONSIACTIVITY
No.
BILITY
5.1 All filled Chlorine cylinders should be on rollers & all cylinders Optr.
inside the building should have a visible tag of Empty / Full / (Chlorination
Service.
Plant)
5.2 Keep a record of Chlorine tonners status at each location and Optr.
note the cylinder number which are full.
(Chlorination
Plant)
5.3 Keep at least one Breathing Apparatus set at each location Manager
and one at D. M. Plant Control Room also in proper condition.
(Chem.)
5.4 Check the following fortnightly:
Sr Chemist
(a)
Eyewash
(b)
Shower at CW Chlorination (Thermal) & DM Plant
(c)
Strength of neutralization pit. It should have specific gravity
>= 1.2
(d)
Pressure of B. A. Set cylinder > 50 kg/cm2
In case of any deviation, inform Manager (Chem.). Keep
record of above.
5.5 Carry out the following on monthly basis:
Sr Chemist
(a) Mock drill using BA Set and Emergency Kit.
(b) Emergency kit item checking.
(c) Availability of Chlorine leak detectors and alarm system
(d) Availability of hoist and exhaust fans of chlorination room
Keep Record.
5.6 In Gas Plant, check the automatic Chlorine absorption system Sr Chemist
for auto start and caustic strength on monthly basis. Caustic
solution should have specific gravity of 1.1 0.02.
Keep record.
5.7 Ensure availability of duplicate keys of Emergency kit and Manager
chlorination room at D M Plant Control room for Thermal & at (Chem.)
SWAS Lab for Gas Plant.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

REF. DOC.

LO-DM-12
LO-DM-13
LO-DM-14
LO-DM-12
LO-DM-13
LO-DM-14

LO-DM-12
LO-DM-13
LO-DM-14

LO-DM-14

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 82/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-47,Methodology Of NOx Monitoring On Weight/Volume


Basis
1.
2.
3.
4.
5.
S.
No.
5.1
5.2

5.3
5.6
5.7

PURPOSE: To establish a system for NOx monitoring on weight/volume basis.


SCOPE: Applicable to all the four gas turbines of NTPC Dadri-Gas.
DEFINITION(s):
RESPONSIBILITY: HoD(Opn_Gas)
DESCRIPTION:
ACTIVITY
RESPONSIREF. DOC.
BILITY
Measure the offline NOx values of al the gas turbines I/c (Chem)
LO-DM-08
once every fortnight.
Obtain the GT operating hours on fortnightly basis I/c (O&E_Gas)
F-13-GPS-Pfrom O&E dept.
01 [GAIL /
Energymeter
register
Compute the total NOx release from gas plant based HoD (Opn_Gas)
on the data as per 5.1 and 5.2.
I/c (O&E_Gas)
Plot the trend of NOx release from Gas plant.
HoD (Opn_Gas)
Analyze and discuss the NOx generation and trend of HoD (Opn_Gas)
NOx in MTP/ORT meeting every month.

OCP/ OPN-GP/01

Control of CO2 emission

1. PURPOSE: To establish a procedure for control of CO2 emission in Gas station.


2. SCOPE: Applicable to all the four gas turbines of NTPC Dadri-Gas.
3. DEFINITION(s): EOH Equivalent operating hours calculated based on running
hours of GT and GT tripping.
4. RESPONSIBILITY: HOD (Opn Gas), HOD (MM GP)
5. DESCRIPTION:
S.
ACTIVITY
RESPONSINo.
BILITY
5.1 Obtain the GT operating hours on fortnightly basis from O&E dept.
I/c (O&E Gas)
5.2
5.3
5.4
5.5

Ensure that compressor washing done during forced outage


whenever there is opportunity.
Ensure that compressor washing done during planned outage at
2000 EOH. 4000 EOH, 8000 EOH, 16000 EOH.
Ensure that burner inspection is done during planned outage at
2000 EOH. 4000 EOH, 8000 EOH, 16000 EOH and corrective
action is taken.
Ensure that refurbishment is done during outage at 25000 EOH.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

HOD(OpnGas),
HOD (MM GP)
HOD(OpnGas),
HOD (MM GP)
HOD(OpnGas),
HOD (MM GP)
HOD(OpnGas),
HOD (MM GP)

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 83/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-49, Checking Of Natural Gas Pipeline In Gas Plant


1. PURPOSE: To establish a system for checking the healthiness of Natural Gas
pipeline system in Gas plant.
2. SCOPE: 1.4-km long gas pipeline from GAIL Dadri terminal to Dadri Gas Power
Plant.
3. DEFINITION(s):
4. RESPONSIBILITY: HoD(Opn_Gas), HoD(Mntc_Gas)
5. DESCRIPTION:
S.
RESPONSIREF.
ACTIVITY
No.
BILITY
DOC.
5.1 Surveillance checks of Gas pipeline across the line HOD (Mntc_Gas)
Maint
once in a month.
Record
5.2 Checking of pedestals of Gas pipeline, Drains and HOD (Mntc_Gas)
Maint
Vents along the length once in a month.
HOD (Opn)
Record
5.3 Thickness measurement of bends of Gas pipeline once HOD (Mntc_Gas)
Maint
in a year.
Sr Mgr (FQA)
Record
5.4 Painting of Gas pipe line once in two years.
HOD (Mntc_Gas)

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 84/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-53, Monitoring Of Natural Gas Quality And Quantity At


Gas Plant
1. PURPOSE: To establish a system of monitoring Natural Gas quality and quantity at
Dadri Gas Power Station.

2. SCOPE: Dadri Gas Power Station and GAIL terminal.


3. DEFINITION :

GAIL: Gas Authority India Limited


NCV: Net Calorific Value

4. RESPONSIBILITY : HoD (Opn_Gas), HOD (EEMG_Gas)


5. PROCEDURE : As described belowS
No
5.1
5.2

5.3
5.4

ACTIVITY

RESPONREF. DOC.
SIBILITY
GAIL- Gas flow meter readings will be jointly checked by HOD
O&E Gas and GAIL representatives daily.
(EEMG_Gas)
Calibration of GAIL Gas chromatograph computer HOD
printouts will be checked by O&E_Gas representative (O&E_Gas)
daily. The printouts will be under the custody of GAIL.
Computation of average NCV of Natural Gas supplied to
Dadri_Gas will be carried out by O&E section of Gas plant
based on Gas chromatograph readings of GAIL.
Checking and signing of daily Joint Ticket of Gas NCV and HOD
2 KF 8.2
Gas quantity supplied to Dadri_Gas shall be done.
(O&E_Gas)
Monitoring of Gas pressure and temperature at CCR as HOD
per WI-12.
(Opn_Gas)

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 85/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: OCP-OPN-GP/01, Control of CO2 Emission


1. Purpose: To establish a procedure for control of CO2 emission in gas
station.
2. Scope: Applicable to all the four gas turbines of NTPC Dadri- Gas.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

3. Definition: EOH- Equivalent operating hour calculated based on running


hour of GT and GT tripping
4. Responsibility: HOD ( Opn- gas), HOD ( MM- GP)
5. Description:
S
No
5.1
5.2

ACTIVITY
Obtain the GT operating hours on fortnightly basis from
EEMG deptt
Ensure that compressor washing is done during forced
outage whenever there is opportunity.

RESPONSIBILITY
HOD
(EEMG_Gas)
HOD(Opn_Gas)
HOD(MM_Gas)

REF. DOC.

5.3

Ensure that compressor washing is done during planned


outages at 2000EOH, 4000EOH and 8000EOH.

HOD(Opn_Gas)
HOD(MM_Gas)

5.4

Ensure that burner inspection is done during outages at


2000EOH, 4000EOH and 8000EOH and corrective action
is taken.
Ensure that refurbishment is done during outage at 25000
EOH inspection.

HOD(Opn_Gas)
HOD(MM_Gas)

5.5

HOD(Opn_Gas)
HOD(MM_Gas)

INTEGRATED MANAGEMENT SYSTEM


DEPARTMENT MANUAL
Deptt:

O&M/OPN -GP

Page : 86/86

Doc Ref:ND-IM-OPG

DADRI
Revision : 00
ISSUE No. 03
Issue Date: 29 Nov11

Title: Improvement projects


S
Improvement project
RESPONNo
SIBILITY
1
Optimising Compressor efficiency of gas turbine DGM(O)
through regular off line & on line compressor
washing.

Prepared by: Yash Pal


Sr. Supdt..(OPN)

Issued by: A.N Goyal


MR

Approved by: V.K.Singh


HOD(OPN)

REF. DOC.
OEM tech
Manual

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