Happy

New
Year
2015


CTPS
WELCOME TO
39 th ORT
MEET
* * * 14 th Jan 2015 * * *

Agenda for 39

th

ORT

1. Presentation By H O team on
(A) All INDIA Performance .
(B) Mahagenco Stations Performance .
(C) O&M and other issues.
2. Presentation by SE(Operation-II ) on
Loadability constraints for Unit 5,6,7 not running the units
at rated capacity.
3. Presentation by SE (Operation I),
Unit 3 Major surprises & achievements and detail report
on unit performance after overhaul.

Agenda for 39th ORT

4. Presentation by MPD
(A) Critical spares, unit assemblies under
refurbishment/new procurement for 2014-15, and HO
related pending issues of 2013-14
(B) P/M Analysis & Schedules P/M & B/D Work order
status of December-2014.
(C) Overhaul preparedness for Unit 6 .
(D) Previous ORT discussions & implementation details.
(E) Root cause analysis of equipment failure during last
six months.
(F) Summer & Rainy season preparedness.
5. Any other issue by permission of chair.

Many Many
Congratulations to
CHP
On 28-12-14
611 Wagons unloaded
maximum in last 10
years

BEST POWER STATIONS IN THE COUNTRY

BASED ON
PLF (%) April - Dec (2014-15) / April- Nov
(2014-15)
STATION
CAPACIT
RANK
PLF (%)
Y

DAHANU

500

1/1

97.51 / 100.47

TORANGALLU (JSW)

860

2/3

96.53 / 96.51

1000

3/4

96.37 / 96.34

KAKATIYA (Andhra)

500

4/5

95.00 / 94.75

BUDGE BUDGE

750

5/2

93.34 / 96.55

TALCHER (Old)

460

6/7

91.80 / 91.17

SOUTHERN Rep.

135

7/6

91.15 / 93.57

ROSA

1200

8/9

87.79 / 88.91

TALCHER (Kaniha)

3000

9 / 12

87.63 / 86.03

240

10 / 10

87.36 / 88.34

2600

11 / 13

87.28 / 85.89

400

12 / 8

86.86 / 89.48

OP JINDAL

TITAGARH
RAMAGUNDAM
TORRANT POWER

BEST POWER STATIONS IN THE COUNTRY BASED ON

PLF (%) April- Dec (2014-15) / April- Nov (2014-15)
STATION

CAPACIT
Y

RANK

PLF (%)

KORBA

2600

14 / 15

85.63 / 85.24

UNCHAHAR

1050

15 / 16

84.98 / 84.65

SIMHADRI

2000

16 / 18

83.17 / 82.58

500

17 / 14

82.86 / 85.59

SIPAT

2980

18 / 23

82.68 / 81.36

KORBA (W) (Chhattisgarh)

1340

19 /

82.05 / 80.80

NEYVELI (Z)

250

20 / 21

81.85 / 82.26

SINGRAULI

2000

21 / 19

81.53 / 82.58

TUTICORIN

1050

22 / 22

81.36 / 81.63

KOTA ( Rajasthan)

1240

23 / 25

81.27 / 80.68

360

24 / 17

81.22 / 83.54

DSPM (Chhattisgarh)

JOJOBERA

PLANT LOAD FACTOR %

April Dec (2014-15) / April Nov (2014-15)

ALL INDIA
PRIVATE SECTOR IPP
PRIVATE SECTOR
UTL

178015 /
177052
56932 / 56333
3865 / 3865

CENTRAL SECTOR

53954 / 53591

SEBS

62263 / 63263

NTPC

37032 / 37032

MSPGCL*

7480 / 7480

65.09 /
65.07
62.74 /
62.90
68.14 /
69.54
73.39 /
73.24
59.77 /
59.62
79.42 /
79.16
56.97 /
56.29

BEST

POWER STATIONS
MAHAGENCO
DURING Dec 2014 (Nov 2014 )
STATION

CAPACI
TY
(MW)
KHAPERKH
1340
EDA
NASHIK
630

2nd / 2nd

PARAS

500

3rd / 1st

1420

4th / 5th

BHUSAWAL

RANK

PLF (%)

1st / 3rd

79.54 /
75.41
78.29 /
76.06
77.68 /
77.15
60.18 /
50.77

BEST UNITS IN MSPGCL BASED

ON
PLF (%)
Dec
- 2014
(%)
(NovCOAL
-2014)
STATION
UNIT
CAPACI
RANK
PLF
/
LD
TY

WATER
SHORT LOSS
%

LOSS
%

KHAPERKHE
DA

UNIT
4

210

1/3

89.48 /
81.26

3.09

5.02

KHAPERKHE
DA

UNIT
3

210

2/1

88.75 /
81.80

3.61

4.35

NASHIK

UNIT
3

210

3/2

87.77 /
81.62

0.35

4.96

PARALI

UNIT
6

250

4/6

86.88 /
77.88

10.52

2.33

NASHIK

UNIT
5

210

5 / 14

85.53 /
71.71

0.48

4.23

CHANDRAP
UR

UNIT
4

210

6/4

83.58 /
81.04

1.59

8.80

PARAS

UNIT
3

250

7/5

81.20 /
77.94

7.63

2.54

KORADI

UNIT

210

8 / 13

78.77 /

5.46

0.63

ON
PLF (%) Dec - 2014 (Nov
COAL /
LD
STATION
UNIT CAPACIT RANK
PLF (%)
WATER
LOSS
Y
-2014)
SHORTAGE
KHAPERKH
EDA

UNIT
5

500

15 /
15

74.54 /
71.54

2.44

5.97

PARAS

UNIT
4

250

16 / 8

74.17 /
76.37

4.81

1.53

CHANDRAP
UR

UNIT
6

500

17 /
17

72.40 /
69.32

5.16

3.98

PARALI

UNIT
5

210

18 /
16

70.59 /
70.82

14.41

0.91

KORADI

UNIT
6

210

19 /
21

65.13 /
62.28

5.14

0.40

CHANDRAP
UR

UNIT
2

210

20 /
19

64.50 /
64.06

2.45

0.02

CHANDRAP
UR

UNIT
7

500

21 /
20

63.86 /
63.41

8.45

3.35

NASHIK

UNIT
4

210

22 /
10

61.56 /
74.84

0.68

2.80

BEST UNITS IN MSPGCL BASED ON

Loadability (%)
Dec

2014
(Nov

2014)
UNIT
CAPACIT RANK
LF (%)
SOC ml/kwh
Y
KHAPERKHEDA 4

210

1/3

89.48 / 81.26

0.093 / 0.01

KHAPERKHEDA 3

210

2/1

88.75 / 81.80

0.000 / 0.00

NASHIK - 3

210

3/2

87.77 / 81.62

0.124 / 0.22

PARALI - 6

250

4/9

86.88 / 78.67

0.291 / 0.43

NASHIK - 5

210

5/6

85.53 / 80.14

0.157 / 1.30

PARALI - 7

250

6/8

84.23 / 79.14

0.532 / 0.51

NASHIK - 4

210

7/7

83.91 / 79.55

1.726 / 0.86

CHANDRAPUR 4

210

8/4

83.58 / 81.04

0.031 / 0.30

KHAPERKHEDA
-5

500

9/5

83.51 / 80.55

1.200 / 0.62

PARAS - 3

250

10 / 10

81.20 / 77.94

0.131 / 0.18

BHUSAWAL - 4

500

11 / 18

80.47 / 69.85

0.199 / 0.56

BEST UNITS IN MSPGCL BASED ON

Loadability (%)
Dec
- 2014
(NovLF-2014)
UNIT
CAPACIT
RANK
(%)
SOC ml/kwh
Y
CHANDRAPUR
5

500

15 / 14

76.58 / 71.98

0.320 / 0.04

KHAPERKHEDA 2

210

16 / 13

75.09 / 72.61

0.196 / 0.70

BHUSAWAL - 5

500

17 / 17

74.98 / 69.90

0.007 / 1.24

KORADI 6

210

18 / 21

74.91 / 68.23

1.746 / 2.02

CHANDRAPUR
7

500

19 / 22

73.57 / 66.91

0.267 / 1.14

CHANDRAPUR 6

500

20 / 19

72.40 / 69.32

0.150 / 0.18

BHUSAWAL - 3

210

21 / 23

71.28 / 66.85

2.167 / 0.69

PARALI - 5

210

22 / 16

70.59 / 70.82

0.000 / 0.17

CHANDRAPUR 2

210

23 / 20

65.32 / 68.35

0.784 / 0.92

CHANDRAPUR 3

210

24 / 24

64.83 / 65.47

25.96 / 0.64

Highlights of Dec 2014

PARAMETERS

MAHA
GENC
O NO
OF
UNITS

POWER STATION AND UNITS

Units having PLF

> 80%

CSTPS-4, KPKD-3 & 4,NTPS-3 &5,

PARAS -3 & PTPS-6

Units having PLF

between 70 & 80
%

11

CSTPS 5 & 6, BTPS-4 &5,KPKD1,2&5,KTPS-7,PARAS-4 & PTPS-5 &

7

Units having LF
>80 %

11

CSTPS-4,BTPS-4,KPKD3,4&5,NTPS-3,4 &5, PARAS-3

PTPS-6&7

Units having LF
between 70 & 80
%

11

CSTPS -5,6 &7,BTPS -3 &5,KPKD-1

& 2, KTPS-6 &7, PARAS -4 PTPS-5

Units having 100

% Availability

13

CSTPS -4 &6, BTPS-5,KPKD 1 to 4,

KTPS-7, NTPS -3 & 5, PARAS -3 &

BEST UNITS IN MSPGCL BASED

ON
PLF (%)UNIT
April
to Dec
STATION
CAPACITY
RANK - 2014
PLF (%)
CHANDRAPUR

UNIT 4

210

76.999

NASHIK

UNIT 5

210

76.884

KHAPERKHEDA

UNIT 4

210

75.132

NASHIK

UNIT 4

210

75.033

PARAS

UNIT 4

250

74.706

NASHIK

UNIT 3

210

70.361

BEST UNITS IN MSPGCL BASED

ON
Availability (%) April to Dec STATION
UNIT
CAPACITY
RANK
Av (%)
2014
CHANDRAPUR
UNIT 6
500
1
95.31
CHANDRAPUR

UNIT 4

210

94.05

KHAPERKHEDA

UNIT 5

500

93.97

KORADI

UNIT 7

210

93.76

KHAPERKHEDA

UNIT 4

210

93.75

BHUSAWAL

UNIT 5

500

93.50

KHAPERKHEDA

UNIT 2

210

93.14

PARAS

UNIT 4

250

92.73

NASHIK

UNIT 5

210

91.69

CHANDRAPUR

UNIT 5

500

10

91.38

NASHIK

UNIT 4

210

11

90.12

BEST UNITS IN MSPGCL BASED

ON
Loadability (%) April to Dec 2014
STATION
UNIT
CAPACITY
RANK
LF (%)
NASHIK

UNIT 5

210

83.84

NASHIK

UNIT 4

210

83.25

NASHIK

UNIT 3

210

82.99

CHANDRAPUR

UNIT 4

210

81.80

PARAS

UNIT 4

250

80.56

KHAPERKHEDA

UNIT 4

210

80.13

PARALI

UNIT 6

250

79.41

KHAPERKHEDA

UNIT 3

210

79.07

PARALI

UNIT 7

250

78.08

CHANDRAPUR

UNIT 5

500

10

75.09

PARAS

UNIT 3

250

11

74.62

MAHAGENCO
THERMAL
POWER
STATIONS
MONTHLY
PERFORMANCE
Dec - 2014
V/S
Dec - 2013

Mu Dec -2014

GEN
MU

BTPS

CSTP
S

KHDT
PS

KTPS

NTPS

PRST
PS

PTPS MAHAG
ENCO

DEC
14

356.8
90

1025.7
85

793.01
0

224.83
2

366.95
2

288.9
82

410.9
00

3467.35
5

DEC 13

351.0
90

958.82
4

619.60
0

221.24
0

372.12

294.7
78

483.8
30

3301.48
6

Monthly Performance PLF % Dec 2014

PLF %

BTP
S

CSTP
S

KHDT
PS

KTPS

NTPS

PRST
PS

PTPS

MAHA
GENC
O

DEC
14

52.1
4

58.92

79.54

48.74

78.29

77.68

48.88

62.30

DEC 13

51.2
9

55.07

62.15

47.96

79.39

79.24

57.55

59.32

Monthly Performance Availability

Factor %
Dec - 2014

AVF %

BTPS

CST
PS

KHDT
PS

KTPS

NTPS

PRST
PS

PTPS

MAHA
GENC
O

DEC
14

66.31

76.6
1

95.99

63.32

91.12

96.68

60.33

77.82

DEC 13

81.36

73.6
0

87.29

70.11

94.44

94.05

79.89

80.79

Monthly Performance Load ability

Factor %
Dec - 2014

LF %

BTPS

CSTP
S

KHDT
PS

KTPS

NTPS

PRST
PS

PTPS

MAHA
GENC
O

DEC 14

78.6
3

76.91

82.86

76.97

85.92

83.35

81.02

80.07

DEC -

63.0

74.82

71.20

68.41

84.06

84.25

72.04

73.43

Monthly Performance Specific Oil

Consumption
ml / Kwh Dec - 2014

SOC
ml/Kw
h

BTPS

CSTP
S

KHDT
PS

KTPS

NTPS

PRST
PS

PTPS

MAHA
GENC
O

DEC
14

0.56

0.61

0.53

0.86

0.56

0.25

0.29

0.53

DEC -

1.87

0.95

4.35

3.96

0.61

0.48

0.72

1.77

Monthly Performance Aux. Power Consumption % Dec - 2014

APC %

BTPS

CSTP
S

KHDT
PS

KTPS

NTPS

PRST
PS

PTPS

MAHA
GENC
O

DEC
14

7.69

8.41

7.99

12.21

10.96

10.74

10.92

9.25

DEC -

10.7

8.65

9.31

13.32

10.82

10.27

10.89

10.03

Monthly Performance Aux. Power

Consumption % Dec 2013 v/s Dec - 2014

Station

BTPS

CSTPS KPKD

KTPS

NTPS PRSTP
S

PTPS

Dec Normati 8.19

-13
ve
Actual 10.74

8.84

8.34

10.81

13.35

8.50

11.58

8.65

9.31

13.32

10.82

10.27

10.89

Deviatio - 2.55
n
Dec Normati 8.17
-14
ve
Actual
7.69

0.19

- 0.97

- 2.51

2.53

- 1.77

0.69

8.75

8.33

10.51

13.48

8.50

11.68

8.41

7.99

12.21

10.96

10.74

10.92

0.34

0.34

- 1.70

2.52

- 2.24

0.76

Deviatio
n

0.48

Monthly Performance Heat Rate

Kcal / Kwh Dec - 2014

HR
Kcal/K
wh

BTP
S

CSTP
S

KHDT
PS

KTPS

NTPS

PRST
PS

PTPS

MAHA
GENC
O

DEC
14

2458

2647

2524

2777

2688

2454

2544

2584

DEC -

2619

2687

2566

2841

2687

2426

2745

2653

Monthly Performance Heat Rate Kcal /

Kwh
Dec - 2013
v/s Dec - 2014

Station

BTPS

KTPS

NTPS PRSTP
S

PTPS

Dec Normati
-13
ve

2580

2686

2538

2835

2736

2450

2669

Actual

2619

2687

2566

2841

2687

2426

2745

Deviatio
n

- 39

-1

- 28

-6

49

24

- 76

2570

2680

2539

2814

2719

2450

2668

Actual

2458

2647

2524

2777

2688

2454

2544

Deviatio
n

112

33

15

37

31

-4

124

Dec Normati
-14
ve

CSTPS KPKD

Monthly Performance Forced

Outage %
Dec - 2014

FORCED
OUTAGE
%

BTP
S

CST
PS

KHDT
PS

KTPS

NTPS

PRST
PS

PTPS

MAHA
GENC
O

DEC 14

10.8
7

3.13

4.01

4.42

8.88

0.00

2.50

4.53

DEC - 13

18.6

4.34

12.71

18.51

5.56

5.95

1.94

8.62

Monthly Performance Planned

Outage %
Dec - 2014

PLANNE
D
OUTAGE
%

BTP
S

CST
PS

KHDT
PS

KTPS

NTPS

PRST
PS

PTPS

MAHA
GENC
O

DEC 14

22.8
3

11.0
7

0.00

0.00

0.00

0.00

0.00

6.27

Parameter-wise Ranking ( Dec 2014)

Rank

PLF%

KPKD
(79.5
4)

NTPS
(78.29
)

PRTP
S
(77.6
8)

CSTPS
(58.92
)

BTPS
(52.14
)

PTPS
(48.88
)

KTPS
(48.74
)

Availabili
ty %

PARA
S
(96.6
8)

KPKD NTPS
(95.99
)
(91.1
2)

CSTPS
(76.61
)

BTPS
(66.31
)

KTPS
(63.32
)

PTPS
(60.33
)

Loading
Factor %

NTPS
(85.9
2)

KPKD
(82.86
)

PTPS
(81.0
2)

PRTPS
(80.35
)

BTPS
(78.63
)

KTPS
(76.97
)

CSTPS
(76.91
)

PARA PTPS
S
(0.30)
(0.25)

KPKD

NTPS
(0.56)

BTPS
(0.56)

CSTPS
(0.61)

KTPS
(0.86)

(0.53)

APC %
Deviatio
n

NTPS
(2.52)

PTPS
(0.76)

BTPS
(0.48)

KPKD
(0.34)

CSTPS KTPS
(0.34)
(1.70)

PRTPS
(2.24)

Heat

PTPS

BTPS

KTPS

CSTPS

NTPS

PRTPS

SOC
ml/Kwh

KPKD

CUMULATIVE
PERFORMANCE
MAHAGENCO
THERMAL
POWER
STATIONS
April to Dec (2014
15)
V/S
April to Dec (2013
14)

Cumulative Performance Gen MU

April Dec (14-15 V/S 13 -14)

GEN
MU

BTPS

CSTPS

KHTPS

KTPS

NTPS

PRST
PS

PTPS

MAHAG
ENCO

2014 2686.0
60
2015

9247.8
28

5911.7
60

1735.3 3080.7
25
71

2271.8
22

3191.7
60

28125.32
6

2013 2969.1
10

7949.2
86

5028.0
00

1785.4 3115.0
81
93

2491.6
24

2045.2
40

25383.83
4

Cumulative Performance PLF %

April Dec (14-15 V/S 13 -14)

PLF
%

BTPS

CSTPS

KHTP
S

KTPS

NTPS

PRSTP
S

PTPS

MAHA
GENC
O

20142015

44.24

59.88

66.84

42.41

74.09

68.84

42.80

56.97

20132014

48.90

51.47

56.85

43.63

74.92

75.50

27.42

51.42

Cumulative Performance Availability Factor %

April Dec (14-15 V/S 13 -14)

AVF
%

BTPS

CSTPS

KHTP
S

KTPS

NTPS

PRSTP
S

PTPS

MAHA
GENC
O

20142015

65.91

83.69

89.92

61.58

88.86

88.56

55.17

77.24

20132014

81.14

76.78

84.26

68.50

89.74

96.61

38.80

74.65

Cumulative Performance Loading Factor %

April Dec (14-15 V/S 13 -14)

LF %

BTPS

CSTPS

KHTP
S

KTPS

NTPS

PRSTP
S

PTPS

MAHA
GENC
O

20142015

67.12

71.55

74.33

68.87

83.38

77.73

77.58

73.76

20132014

60.27

67.04

67.47

63.70

83.49

78.15

70.67

68.88

Cumulative Performance Specific Oil Consumption

ml / Kwh April Dec (14-15 V/S 13 -14)

SOC
ml /
Kwh

BTP
S

CSTP
S

KHTP
S

KTPS

NTPS

PRSTP
S

PTPS

MAHA
GENC
O

20142015

1.7

1.52

1.33

3.22

1.16

1.23

0.95

1.47

20132014

7.43

3.62

8.25

9.85

1.02

1.37

2.54

4.79

Cumulative Performance Aux. Power Consumption

% April Dec (14-15 V/S 13 -14)

APC %

BTPS

CST
PS

KHTP
S

KTPS

NTPS

PRST
PS

PTPS

MAHA
GENC
O

20142015

10.05

9.21

9.39

13.22

11.36

11.38

11.22

10.21

20132014

11.51

10.34

10.56

14.46

11.16

11.83

11.79

11.08

Monthly Performance Aux. Power

Consumption % April Dec (13-14 V/S 14
-15)

Station

BTPS

2013 Normati
ve
2014 Actual

8.19

CSTPS KPKD

8.84

8.34

KTPS

NTPS PRSTP
S

10.81 13.35

8.50

PTPS

11.58

11.5 10.3 10.5 14.4 11.1 11.8 11.7

1
4
6
6
6
3
9
Deviatio -3.32 - 1.50 - 2.22 - 3.65 2.19 - 3.33 - 0.21

n
2014 Normati
-2015
ve
Actual

8.17

8.75

8.33

10.51 13.48

8.50

11.68

10.0 9.21 9.39 13.2 11.3 11.3 11.2

5
2
6
8
2
Deviatio - 1.88 - 0.46 - 1.06 - 2.71 2.12 - 2.88 0.46
n

Cumulative Performance Heat Rate Kcal / Kwh

April Dec (14-15 V/S 13 -14)

HR
Kcal/k
wh

BTP
S

CSTPS

KHTP
S

KTPS

NTPS

PRSTP
S

PTPS

MAHA
GENC
O

20142015

256
3

2671

2547

2815

2691

2462

2552

2615

2013-

280

2711

2611

2877

2705

2464

2596

2680

Monthly Performance Heat Rate Kcal / Kwh

April Dec (13-14 V/S 14 -15)

Station

BTPS

CSTPS KPKD

KTPS

NTPS PRSTP
S

PTPS

2686

2538

2835

2736

2450

2669

2711

2611

2877

2705

2464

2596

- 25

- 73

- 42

31

- 14

73

2014- Normati 2570

2015
ve

2680

2539

2814

2719

2450

2668

Actual

2563

2671

2547

2815

2691

2462

2552

Deviatio
n

-8

-1

28

- 12

116

2013 Normati 2580

ve
2014
Actual 2805
Deviatio
n

-225

Cumulative Performance Forced Outage %

April Dec (14-15 V/S 13 -14)

FO %

BTP
S

CSTPS

KHTP
S

KTPS

NTPS

PRST
PS

PTPS

MAHA
GENC
O

20142015

15.1
9

6.66

4.20

7.68

6.88

5.59

1.40

6.51

20132014

15.5
8

4.95

7.41

18.28

4.71

3.36

4.02

7.54

Cumulative Performance Planned Outage %

April Dec (14-15 V/S 13 -14)

PO %

BTP
S

CSTPS

KHTP
S

KTPS

NTPS

PRSTP
S

PTPS

MAHA
GENC
O

20142015

15.7
4

5.29

4.44

0.43

4.26

5.33

0.00

14.46

Parameter-wise Ranking- Apr to Dec

(2014-15)
Rank

PLF%

NTPS

PARAS

Availabili
ty %

(74.0
9)

(68.84
)

KPKD CSTPS
(66.84
)
(59.88
)

BTPS
(44.24
)

PTPS
(42.80
)

KTPS
(42.41
)

KPKD

NTPS
PARAS CSTPS
(88.86
)
(88.56 (83.69
)
)

BTPS
(65.91
)

KTPS
(61.58
)

PTPS
(55.17
)

PARAS PTPS
KPKD CSTPS
(77.58 (74.33
(77.73
)
)
(71.55
)
)

KTPS
(68.87
)

BTPS
(67.12
)

KPKD NTPS
PARA
(1.101 (1.164
S
)
)
(1.225
)

BTPS
(1.299
)

CSTPS
(1.518
)

KTPS
(3.218
)

PTPS
(0.46)

BTPS
(-

KTPS
(-

PRTPS
(-

(89.9
2)
Loading
Factor %

NTPS
(83.3
8)

SOC
ml/Kwh

PTPS
(0.85
2)

APC %

NTPS

CSTPS KPKD
((-

TRIPPINGS Dec - 2014 v/s Dec 2013

BTP CSTP KHTP KTP NT PRST PTP MAHA
TRIPPINGS
BTL
PR PART LKGS
COAL CYCLE
PROBLEM
ID/FD/PA FAN
FLAME
FAILURE /
FUENACE
DRAFT
DRUM LEVEL
GOVERNING
PROBLEM
TURBINE VIB /
ECCEN

PS

PS

GENCO

4
(3)

5 (7)

1
(15)

4
(10)

2
(3)

1 (2)

1
(2)

18
(42)

2
1 (3)
(1)
0 (0) 0 (0)
0 (0) 0 (0)

0 (1)

1
0
0 (1)
(1)
(2)
0 (0) 0 (0) 0 (0) 0 (0)
0 (0) 0 (1) 0 (0) 0 (0)

1
(0)
0 (0)
0 (0)

5 (9)

0 (1) 0 (0)
0 (1) 0 (0)

0 (0) 0 (1) 2 (0) 0 (0)

0 (6) 0 (1) 0 (0) 0 (1)

0 (0)
0 (0)

2 (2)
0 (9)

0 (0) 0 (0)
0 (0) 1 (0)

0 (1) 0 (0) 0 (0) 0 (0)

0 (0) 0 (0) 0 (0) 0 (0)

0 (0)
0 (0)

0 (1)
1 (0)

0 (0) 0 (0)

0 (0) 0 (0) 0 (0) 0 (0)

0 (0)

0 (0)

0 (0)
0 (1)

TRIPPINGS Dec - 2014 v/s Dec 2013

BTP CSTP KHTP KTP NTP PRST PTP MAHAG
S

BFP PROBLEM

0 (0)

0 (0)

0 (0)

VACUUM LOW

0 (0)

0 (0)

CONDENSER
TUBE LKG

1 (0)

HYDROGEN
LEAKAGE

PS

ENCO

0 (0) 0 (0)

0 (0)

0 (0)

0 (0)

0 (0)

0 (0) 0 (0)

0 (0)

0 (0)

0 (0)

0 (0)

0 (0)

0 (0) 0 (0)

0 (0)

0 (0)

1 (0)

0 (0)

0 (0)

0 (0)

0 (0) 0 (0)

0 (0)

0 (0)

0 (0)

ELECTRICAL
PROBLEMS

0 (0)

1 (1)

0 (2)

1 (4) 0 (1)

0 (0)

0 (0)

2 (8)

TIC PROBLEMS

0 (0)

1 (1)

0 (0)

1 (2) 0 (0)

0 (0)

0 (0)

2 (3)

CHP PROBLEM

0 (0)

0 (0)

0 (0)

0 (0) 0 (0)

0 (0)

0 (0)

0 (0)

START UP /
WITHDRAWL

0 (0)

0 (0)

0 (0)

0 (0) 0 (0)

0 (0)

0 (0)

0 (0)

ANY OTHER
PROBLEM

1 (0) *1 (2)

1 (5)

1 (0) 0 (0) *1 (0) 0 (2)

5 (9)

* U#5
GTR B
Jumper
Switch
Yard

* Switch
Yard
problem

TRIPPINGS April - Dec (14-15)V/S (13-14

BTPS

CSTP
S

KHDT
PS

KTPS

NTPS

PRST
PS

PTPS

MAHAGENC
O

TRIPPINGS

60
(86)

72
(69)

40
(90)

38
(68)

30
(35)

24
(18)

24
(25)

288 (391)

BTL

22
(5)

26
(27)

13
(13)

9
(15)

13
(8)

6 (6)

3 (0)

92 (74)

PR PART
LEAKAGE

0 (0)

5 (2)

0 (0)

0 (0)

1 (0)

0 (2)

0 (0)

6 (4)

COAL
CYCLE
PROBLEM

0 (0)

0 (0)

0 (1)

0 (1)

0 (0)

0 (0)

0 (0)

0 (2)

ID/FD/PA
FAN

6
(13)

4 (1)

3 (1)

12
(17)

8 (1)

1 (0)

1 (0)

35 (33)

FLAME
FAILURE /
FUENACE
DRAFT

7
(35)

1 (8)

11
(42)

9 (9)

0 (2)

5 (7)

6 (2)

39 (105)

DRUM
LEVEL

2 (5)

1 (2)

1 (4)

0 (0)

0 (0)

1 (0)

2 (3)

7 (14)

GOVERNIN
G PROBLEM

1 (1)

3 (0)

1 (1)

0 (0)

0 (0)

0 (0)

3 (1)

8 (3)

TRIPPINGS April - Dec (14-15)V/S (13-14)

BTP
S

CSTP KHDT
S
PS

KTPS NTP
S

PRSTP
S

PTPS

MAHAGEN
CO

BFP
PROBLEMS

0 (0)

0 (0)

0 (0)

0 (1)

0 (0)

0 (0)

0 (0)

0 (1)

VACUUM
LOW

3 (1)

2 (0)

0 (1)

0 (0)

1 (0)

0 (1)

0 (1)

6 (4)

CONDENSE
R T/L

1 (1)

0 (0)

0 (0)

0 (1)

0 (0)

0 (0)

0 (1)

1 (3)

HYDROGEN
LEAKAGE

0 (0)

0 (0)

0 (0)

0 (0)

0 (0)

0 (0)

0 (0)

0 (0)

ELECTRICA
L
PROBLEMS

9 (6)

11
(6)

6 (5)

1 (5)

2 (4)

2 (0)

6 (4)

37 (30)

TIC
PROBLEMS

4 (1)

5 (3)

2 (5)

2 (5)

4 (1)

1 (0)

1 (0)

19 (15)

CHP
PROBLEM

0 (1)

0 (1)

0 (1)

1 (5)

0 (0)

2 (1)

0 (3)

3 (12)

START UP /
WITHDRAW
AL

0 (0)

0 (0)

0 (0)

0 (0)

0 (0)

0 (0)

0 (0)

0 (0)

ANY OTHER

12

3 (16)

3 (9)

6 (1)

2 (10)

31 (85)

Analysis of financial impact of performance

parameters
Approved parameters are considered as per Tariff order for
FY 14-15.
Data for

Nov 2014 is as per MORM report and is

provisional
Deemed AVF / PLF considered as provided by Works
section

Comparison of Approved Parameters

% Availability
Station
Khaperkheda
Bhusawal
Nasik
Parli
Koradi
Chandrapur
Paras-3
Paras-4
Parli-6
Parli-7
KPKD-5
BSL-4

% Aux. Consumption

FY 12-13 FY 13-14 FY 14-15 FY 15-16 FY 12-13 FY 13-14 FY 14-15 FY 15-16

80.00%
80.00%
78.58%
80.00%
73.94%
80.00%

85.00%
80.00%
80.00%
80.00%
72.00%
80.00%

85.00%
80.00%
80.00%
80.00%
72.00%
80.00%

85.00%
80.00%
80.00%
80.00%
72.00%
80.00%

9.77%
10.80%
11.80%
11.32%
10.81%
8.91%

9.74%
10.79%
13.35%
14.02%
10.81%
8.84%

80.00%

85.00%

85.00%

85.00%

9.00%

8.5%

8.5%

8.5%

80.00%

85.00%

85.00%

85.00%

9.00%

8.5%

8.5%

8.5%

80.00%
80.00%

85.00%
85.00%

85.00%
85.00%

85.00%
85.00%

7.50%
7.50%

6.00%
6.00%

6.00%
6.00%

6.00%
6.00%

85.00%

85.00%

85.00%

6.00%

6.00%

6.00%

55.00%

55.00%

55.00%

3.00%

3.00%

3.00%

BSL-5
Gas Thermal 55.00%

2.40%

9.71% 9.70%
10.75% 9.94%
13.48% 13.41%
14.21% 14.57%
10.51% 9.91%
8.75% 8.71%

50

Comparison of Approved Parameters

SHR (only Coal component
for Coal Thermal) kcal/kWh

SHR kcal/kWh
Station

FY 12-13 FY 13-14 FY 14-15 FY 15-16 FY 12-13 FY 13-14 FY 14-15 FY 15-16

Khaperkheda

2613

2606

2607

2607

2594

2588

2589

2589

Bhusawal

2788

2764

2743

2739

2772

2746

2725

2721

Nasik

2757

2736

2719

2715

2728

2709

2692

2688

Parli

2868

2842

2841

2850

2849

2824

2823

2832

Koradi

2826

2835

2814

2761

2799

2810

2788

2735

Chandrapur

2698

2686

2680

2684

2680

2668

2662

2666

2500

2450

2450

2450

2481

2441

2441

2441

2500

2450

2450

2450

2481

2441

2441

2441

2450

2425

2425

2425

2431

2416

2416

2416

2450

2425

2425

2425

2432

2416

2416

2416

2425

2425

2425

2416

2416

2416

2017

2021

2025

Paras-3
Paras-4
Parli-6
Parli-7
KPKD-5
BSL-4
BSL-5
Gas Thermal

1980

51

Comparison of Approved Parameters

Sp. Oil Consumption ml/kWh
Station

% Transit Loss

FY 12-13 FY 13-14 FY 14-15 FY 15-16 FY 12-13 FY 13-14 FY 14-15 FY 15-16

Khaperkheda

0.80%

0.80%

0.80%

0.80%

Bhusawal

0.80%

0.80%

0.80%

0.80%

Nasik

0.80%

0.80%

0.80%

0.80%

Parli

0.80%

0.80%

0.80%

0.80%

Koradi

2.81

2.81

2.81

2.81

0.80%

0.80%

0.80%

0.80%

Chandrapur

0.80%

0.80%

0.80%

0.80%

0.80%

0.80%

0.80%

0.80%

0.80%

0.80%

0.80%

0.80%

KPKD-5

0.80%

0.80%

0.80%

0.80%

BSL-4

0.80%

0.80%

0.80%

0.80%

0.80%

0.80%

0.80%

0.80%

Paras-3
Paras-4
Parli-6
Parli-7

BSL-5

52

New visit points

AHP ,Stage I : All instrument air compressor not in service

since long ,
newly installed compressor also not in
service.

CHP B : Scrap material along Bunker belts to be

removed.

New visit points

WTP ,Stage I : Clarifloculator 4 no Gear box not

available, out of 24 since 4 months.
WTP , Stage I: Most of the Exhaust fans are
inoperative.
Stage I : Instrument air pressure after drier is
not sufficient

OLD visit points

AHP Unit 3,4 : New & used material are mixed up and
lying around pumps. Segregation will be done after Unit 3
overhaul.
AHP Stage I : Air compressor in AHP not in service since
long , but new compressor procured available at site and
not commissioned
Unit 7 : Spare Coal mill motor not available.

OLD visit points

Unit 6,7 : Cooling tower Hot water Basin not covered by

concrete slippers resulting in large amount of Algae
formation.
WTP B
Salt lagoon 6 & 7 not in service.
SDP Area : 3 pumps not available out of 6 pumps.

OLD visit points

CHP A tunnel area cleaning is good, but lighting and belt

lining out needs improvement.
Stacker Re-claimer yard in CHP-B retaining wall progress
extremely slow WIP
CHP C crusher motor 1 and 2 burnt. Crusher motor taken in
service and other expected by January end.

CHP A & B
Multi core control cable is not in stock may lead to
emergency situation Red indent sent to HO ,some
material received.
Average wagon unloading to be increased particularly in
CHP A. Corrective action taken for improved unloading.
Vibrating feeder replaced 2 nos. for fast evacuation -4
feeders replaced, remaining 2 will be replaced in FY-201516. Order under process expected upto Dec-14.

CHP A & B

CT Failure in Transformer no 1 in CHP B, & standby

source non availability may lead to critical situation.

General cleanliness to be improved in CHP A & B

particularly in tunnel area Work in progress.

Equipment not available >15 days

Unit no 4 : CW Pump no 5 ,Heavy vibration since 9-9-14

Impeller ,wear ring, neck ring damaged proposal for
reconditioning in process.
Unit No.5:
HP ash water pump no.1 motor (15-07-13) Motor DE side
vibration high Target date (20-06-14)(10-9-14)(10-10-14)
Motor trial unsuccessful .

Equipment not available >15 days

Non DM Raw water 7B: Work in progress
Target Date : 20.08.14 , PO Placed , material awaited.
Non DM Raw water 7A : Work in progress
Target Date : 20.08.14 , PO Placed , material awaited.
Rectifier transformer 4A1 Winding problem-N/A(01-1012), (10-10-13)(15-4-14)(15-06-14) Rectiformer sent
to Repair on 01-07-2014 ,Work completed load trial
pending.
Unit 6 Ash raw water pump 7A,6C Not available since

26-2-2013. 7A- PO placed material awaited,6CBudgetory offer

called.

Equipment not available >15 days

WTP2
Waste hold recovery Pump P8 NA RP 38
is in process for
spares.

Equipment not available >15 days

UNIT 6

UAT-6C- (out since 19-7-2013), PO Placed.

UAT-6A- Was taken in service on 18-8-14 and again failed
on 7-9-14 on differential protection. Budgetary offer called
for Repairy.

Equipment not available >15 days

CHP -LOCO 653 N/A- Engine failed in Trial, Budgetary
offer received from Cummins, PR initiated.
CHP- LOCO 654 -N/A- Due to transmission assembly ,
Transmission assembly despatched from BANGLORE ,
proposal for new engine initiated.
Loco 401-cummins Engine prob ,Material awaited.
Dozer No 4 engine seized: Engine O/H pending for OEM
spares, PO placed to MDS. Material received ,work will start
soon Target date (31-12-14).
Dozer No.6 engine head prob. Spares awaited.
11 kv CT s for restoration of source. M/s swati enterprises
is developing CT as OEM M/s Jyoti has refused the same.

MAJOR O&M LOSS BREAKUP U#2

PARAMETERS

% LOSS

APH

9.34

ID /FD/PA

6.76

Poor coal receipt

4.43

Duct lkg/modification

2.24

Electrical Problem

1.52

Coal mill

0.96

UNIT 2

Load restriction due to ID 2B scoop restriction of 50% due

to vibration in fan.
HPT thrust pad no 8 is showing 105 deg c , and 9 temp is
varying between 40 to 130 deg,
-C O/H.
ESP emissions are high. Field voltage and charging current
are very low -C O/H.
AH Air leakage 18.8 /17.02%
RH Coil replacement is due : R/H coil red indent returned as
no provision of CAPEX during FY 2015-16

UNIT 2
Fineness of coal mill + 5o mesh : 2B and 2F both is 2.5%
as per November -14 report.
H2 Consumption 166 cylinders in November- 14.
Frequent BTL near Burner Bend. CPRI findings to be
discussed.
IPT Top /Bottom temperatures are 470/429 deg c.
Steam temperature difference between SH outlet and
Turbine inlet is around 30 deg c.
Turbine speed and eccentricity not showing on chart & DCS.

MAJOR O&M LOSS BREAKUP U#3

PARAMETERS

% LOSS

Poor Coal receipt

---

Air Heater

----

Vacuum

-----

Governing

1.28

Coal mill

---

UNIT 3

UNIT-3

RWP 1- Pump is not available since 6-1-14. RP -19 in

process.

MAJOR O&M LOSS BREAKUP U#4

PARAMETERS

% LOSS

Low system demand

8.80

Turbine Control valve

2.13

Poor Coal receipt

1.59

Coal mill

0.23

UNIT 4
HP CV no 1 : Stem broken since 2-9-14. Presently valve is
kept open, will be attended in opportunity shutdown.
Air Heater leakage - 41.73/36.35 %
CW PUMP No 5 : N/A due to vibration, Impeller repairing
work order to be placed.
Availability of soot blowers poor, 36 available out of 56.
Now availability is increased upto 45.

MAJOR O&M LOSS BREAKUP U#5

PARAMETERS

% LOSS

Poor Coal receipt

8.21

Low System Demand

4.10

Air Heater

1.91

Vacuum

0.98

Electrical Problem

0.29

UNIT 5

Primary

APH

air

outlet

temperature

is

running

low( 289/264 deg against design of 332 deg c) --Shut

down job.
Secondary APH flue gas outlet temperature are 153/196
against design of 136 deg.

MAJOR O&M LOSS BREAKUP U#6

PARAMETERS
Poor coal receipt

% LOSS
5.15

Vacuum

4.04

Low system Demand

3.98

Air Heater

3.00

Duct lkg

1.98

UNIT 6
High energy drain valve Passing, Before ESV-3 (202 DEG),
MAL -14 (149 DEG ) -S/D JOB
Turbine

Bearing

no

4-

Velocity

component

is

9.--

Overhaul job. Bearing not available ,work order placed for

repairing/rebabbiting.
Primary

APH

air

outlet

temperature

is

running

low( 272/287 deg against design of 332 deg c) Due to use

of high moisture import coal , temp. maintaining lower side.
Secondary APH flue gas outlet temp. is 170/179 against
design of 136 deg.
Condenser cleaning factor is 35 % against design of 89.29.
Condenser Efficiency is 48.3 % against design of 77.86.

UNIT 6
Estimated CW Flow is 32659 T/hr against that of Unit 5
(56317) and Unit 7 (45193)
Condenser vacuum very poor- 8180 mmHg @ 390 MW.
Condenser Cleanliness factor is 35% against design of
89%. COH JOB.
Both TDBFP steam consumption is high.COH JOB

UNIT 6
Primary APH : Dry flue gas losses are

166.58

kcal/kwh
Primary Air heater leakages are 27.4/26.2 %
Secondary Air heater leakages are 41.9/42.6 %
TG

Bearing

no.

side(90micron).

1
AOH,

vibration

on

Minimum

higher
10

days

shutdown needed.
Around 400 MW load , 2 TD BFPs and 1 MD BFP

is to be operated.

MAJOR O&M LOSS BREAKUP U#7

PARAMETERS
% LOSS
Poor coal receipt

8.45

Low System Demand

3.35

Coal Mills

3.07

Electrical Problem

0.08

TIC Problem

0.12

 UNIT 7

Mill gear boxes abnormal sound in Mill-AB, EF,GH & JK.

Pinions to be replaced. Mill GH gear box replaced with
repaired one - One set of pinion available , other
procurement in process. Spare MSR G. Box in DPR. 7JK
will be replaced in month of Nov-2014.
Long restoration time of EF MILL.

UNIT - 7

Flue gas temperature after Secondary Air preheater is

high( 170/160 deg c).
PAH Air leakage is 33.9/35.1 % and SAH is 39.3 /
29.8%.
TD BFP 7B : Running on hydraulic mode.

UNIT - 7

ID Fan 7A : IGV Motor not in service.

FD Fan 7B : IGV Link broken , DE side 2no ,NDE side 1no.
FRF Acidity is on higher side.--- Action plan is prepared
and send to HO for information & appraisal.
On line condenser ball collection is poor.
R/H spray (RHS) flow not increasing above 9 cubic
meter/hr (NRV replaced).

WTP I and II
SITE VISIT ISSUES

WTP 1

Spent
brine injection system is not in service leading to
extra requirement of salt. Spent brine process building is
about to collapse "FOR ST-I T-1382-Repair of spent brine
tank & pump house for ST-II T-1306 -Proposal for new
construction -order to be placed" CIVIL Pending .

Consultancy work provision to be made in GR76,construction work order will be finalized

thereafter.

WTP2
Regeneration system of DM Plant is not Healthy -Temporary
arrangements are made for permanent arrangement work
is being carried out by project. PO for AMT is placed.
Pipeline replacement work is to be carried out by project.
Tender not yet finalized.
Chlorination system is kept in service in general shift only.
Chlorine dioxide treatment is in service from 25/06/2014
along with chlorination at CW system.
DM Storage tank Inlet & Outlet valve passing
shall be taken up during Unit# 6 COH.

PRESENTATION BY
SE (Operation)-II

Operational constraints for Unit

5,6,7 not running the units at rated
capacity

PRESENTATION BY SE
(Operation-I)

Unit -3 Major surprises & achievements

and detail report on unit performance
after O/H

PRESENTATION BY MPD

1. CRITICAL SPARES,UNIT ASSEMBLIES UNDER

REFURBISHMENT.
2. PM ANALYSIS & SCHEDULES B/D WORK ORDER
STATUS FOR December- 14.
3. OVERHAUL PREPAREDNESS of unit 6.
4. Previous ORT discussions and & implementation
details.
5. Root cause analysis of equipment failure during
last six months.
6.Summer & Rainy season preparedness.