Ims Emd 9

A Maharatna Company
SIMHADRI SUPER THERMAL POWER STATION

P.O NTPC SIMHADRI-531020,
Visakhapatnam.
Integrated Management System Manual

Complies with
ISO 9001:2015, ISO 14001:2015 and OHSAS 18001:2007
ELECTRICAL MAINTENANCE
DEPARTMENT
Document No: NTPC/SIM/IMS/EMD/01

Rev No: 00 , Issue No: 01, Effective date: 01/02/2018
Prepared by Shri.M.Nageswara Rao

DGM (EMD)
Approved by Shri. C. Malakondaiah HOD (EMD)

NTPC –Simhadri
NTPC Road, Near Pittavanipalem Village, Visakhapatnam,
Andhra Pradesh 531020
Electrical Maintenance Department-Functional Manual
ISO 9001:2015, ISO 14001:2015 and OHSAS 18001:2007 Requirements
Issue NO : Effective Date : 01/02/2018 Doc No : NTPC/EMD/01 Rev No : 00
TABLE OF CONTENTS
Contents
1. LIST OF ABBREVIATIONS .............................................................................................................. 3
2. LIST OF CONTROLLED COPY HOLDERS ........................................................................................ 5
3. AMENDMENT RECORD.................................................................................................................. 6
4. ABOUT THE DEPARTMENT OR DEPARTMENT FUNCTIONS ....................................................... 7
5. DEPARTMENT CHART.................................................................................................................... 8
6. ROLES AND RESPONSIBILITIES W.R.T QUALITY, ENVIRONMENT AND SAFETY ....................... 9
7. EHSQS POLICY ............................................................................................................................. 10
8. DEPARTMENT PROCEDURES/ PROCESSES FLOW CHARTS ....................................................... 11
9. WORK INSTRUCTIONS................................................................................................................. 24
10. DEPARTMENT LEGAL AND OTHER REQUIREMENTS ............................................................ 74
11. OBJECTIVES AND TARGETS..................................................................................................... 75
ACTION PLAN FOR ACHIEVING OBJECTIVE .................................................................................... 76
12. HIRA (HAZARD IDENTIFICATION AND RISK ASSESSMENT) ................................................. 84
OH&S OBJECTIVES ........................................................................................................................... 93
OH&S MANAGEMENT PROGRAMME (OH&S MP) ......................................................................... 95
CRITICAL TASK ANALYSIS ............................................................................................................... 97
OCP (OPERATIONAL CONTROL PROCEDURE) ............................................................................. 104
13. ENVIRONMENT ASPECTS AND IMPACTS AND LIFE CYCLE PROSPECTIVE CONCERN ........ 112
14. INTERNAL AND EXTERNAL ISSUES W.R.T QUALITY AND ENVIRONMENT ......................... 116
15. NEEDS AND EXPECTATIONS OF INTERESTED PARTIES W.R.T QUALITY AND
ENVIRONMENT ................................................................................................................................... 117
16. RISK AND OPPORTUNITIES W.R.T QUALITY AND ENVIRONMENT ..................................... 119
17. LIST OF FORMS ....................................................................................................................... 121
18. LIST OF RECORDS ................................................................................................................... 122
19. LIST OF EXTERNAL DOCUMENTS .......................................................................................... 123
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1. LIST OF ABBREVIATIONS
Abbreviation Full form
NTPC NTPC Limited

EMD Electrical Maintenance Department
BHEL Bharat Heavy Electricals Limited
APTRANSCO Andhra Pradesh Transmission Corporation
MTP Maintenance Planning
CHP Coal Handling Plant
HT High Tension
LT Low Tension
DC Direct Current
LMI Local Management Instructions
GCB Generator Circuit Breaker
EHV Extra High Voltage
PPA Power Purchase Agreement
ESP Electro Static Precipitator
TLP Test Lead Point
SCE Shift Charge Engineer
BD Break Down
PM Preventive Maintenance
WOC Work Order Card
LWC Limited Work Certificate
PTW Permit To Work
TB Terminal Block
IR Insulation Resistance
CT Current Transformer
PT Potential Transformer
ECP Electrical Control Panel
TRF Transformer
OEM Original Equipment Manufacturer
MCC Motor Control Centre
SAP Systems , Applications and Products in Data Processing
ESHQSA Environmental, Safety , Health, Quality & Social
Accountability
TG Turbo Generator
HV High Voltage
S/Y Switchyard
CVT Capacitive Voltage Transformer
SCC Short Circuit Characteristics
OCC Open Circuit Characteristics
HVR High Voltage Rectiformer
Page 3 of 125
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BAPCON BHEL Advanced Precipitator Controller

O/H Over Hauling
O&M Operation & Maintenance
DGM Deputy General Manager
QSP Quality System Procedure
HOD Head Of the department
DOC Document
UCB Unit Control Board
H2 Hydrogen
E/F Earth Fault
DG Diesel Generator
KV Kilo Volt
VAR Volt Amp Reactive
CGL Crompton Greaves Ltd.
PPM Parts per Million
BDV Break down Voltage
ID Identification
C&S Control & Switchgear
Ni-Cd Nickel- Cadmium
TP Transfer Point
MUT Meter Under Test
TTB Test Terminal Block
OTI Oil Temperature Indicator
JB Junction Box
LA Lightning Arrestor
PF Power Factor
HF High Frequency
LCM Leakage Current Monitor
LBB Local Breaker Back Up
DE Drive End
NDE Non Drive end
Mtc Maintenance
AGM Additional General Manager
DOP Delegation of Power
Eqpt. Equipment
Sr. Supdt. Senior Superintendent
SAP System Application Programme
CFC Cloro Fluro carbon
EMP Environment management programme
CEA Central Electricity Authority
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2. LIST OF CONTROLLED COPY HOLDERS
Controlled
Controlled Copy Holder Soft Copy (CD)/ Hard Copy
Copy No.
1. MR/AMR Electrical Intranet site
Hard Copy,
2. HOD-EM
Electrical Intranet site
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3. AMENDMENT RECORD
NIL
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4. ABOUT THE DEPARTMENT OR DEPARTMENT FUNCTIONS
Electrical Maintenance Department is to maintain highest levels of availability of

Electrical
Systems, Equipment through its material & human resource potential taking care of
Safety, Health and Environment. The Vision of department is to be “the best Electrical
maintenance department amongst NTPC”. In line with Simhadri vision, station objectives
and MOU, Electrical maintenance department has been set to specific objectives and
targets with a time frame of Three years; and identified the lead and lag indicators which
affect Station level key results. Various processes and sub-processes are systematically
drilled down and few critical indicators are identified by segmenting results. These are
mentioned in the below table along with graphs depicting their targets, trends and
comparison. Cause and effect of each trend is done on processes and is mentioned
against each indicator.
Departmental Road map, to achieve station objectives has been developed and is
available with the department and can be shared during Assessment Team site visit.
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5. DEPARTMENT CHART
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6. ROLES AND RESPONSIBILITIES W.R.T QUALITY, ENVIRONMENT AND

SAFETY
Sr. Job Title Responsibilities Authorities Reports to. Remarks

No.
1. HOD (EM) Overall responsibilities of As per DOP HOD (O&M)

Electrical Maintenance
functions at NTPC-Simhadri.
2. AGM(EM) -1 Responsible for maintenance -Do- HOD(EM)

of electrical equipments in
the areas indicated in the
organization chart
3. AGM(EM) -2 Responsible for maintenance -Do- HOD(EM)

organization chart
4. AGM(EM) -3 Responsible for maintenance -Do- AGM(EM) -1

organization chart
5. DGM/Area Responsible for maintenance -Do- Respective

Engineers of electrical equipments in Sectional
the areas indicated in the heads
organization chart
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7. EHSQS POLICY
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8. DEPARTMENT PROCEDURES/ PROCESSES FLOW CHARTS
Sl. Document (Procedure/Process/WI) Document ISO 9001/ ISO 14001

No Title (Procedure/Process/WI) No. Clause No.
01 Departmental System Procedure for EMD/PR/01 6.3 of 9001

EMD 4.4.6of 14001
02 Preventive Maintenance EMD/PC/01 6.3 of 9001

4.4.6of 14001
03 Break down Maintenance EMD/PC/02 6.3 of 9001
4.4.6of 14001
04 Predictive Maintenance of Electrical EMD/PC/03 6.3 of 9001
Equipments 4.4.6of 14001
1. PURPOSE
To describe the procedure for carrying out maintenance of electrical equipments

so as to generate electricity (4 X 500 MW) as per plan / target, optimize availability
of electrical equipments with full compliance of statutory provisions and safety
regulations.
2. SCOPE
The procedure covers maintenance activities of the major electrical equipments of

NTPC SIMHADRI (4X 500MW) at main plant, Switchyard, CHP and Offsite areas.
These equipments are Generator & Auxiliaries, HT/LT Switchgears, Transformers,
Switchyard equipments, DC system, HT/LT motors etc.
3. REFERENCES
6.1 Work Instructions as per the list enclosed.
6.2 LMI as per the list enclosed.
6.3 Manufacturers O&M Manuals as per list enclosed.
4. RESPONSIBILITY:
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Sl. No Description Responsibility
1. Overall responsibility HOD (EM)
2. Assisting HOD (EM) Sectional Heads
3. In Case of Absence of HOD (EM) Authorized representative of

HOD (EM)
4. Day to day Maintenance jobs Area in charge/Area Engineers
5. Planning and indenting of spares, Section in charge

initiating contract proposals &
budget preparation
5. RECORDS :
As per the list enclosed.
6. PROCEDURE:
6.1 The maintenance jobs in electrical maintenance are carried out as per “SAP”
on-line maintenance system. Maintenance Jobs are planned daily in the
planning meeting indicating the defects/condition/faults raised by
operation/MTP/ maintenance departments. As maintenance of electrical
equipments are critical activities, where- in absence of written instructions,
the quality of work is likely to get affected, the jobs are controlled through
written work instructions
Four types of maintenance jobs are carried out in Electrical maintenance

department.
i. Preventative maintenance
ii. Condition based maintenance
iii. Defect/breakdown maintenance.
iv. Overhauling
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6.1.1 Preventive maintenance
Preventive maintenance jobs are carried out as per the schedule mentioned in
“SAP” system. Depending upon the equipment, the preventive maintenance
schedules are forwarded to MTP department by the area engineers.
Accordingly preventive maintenance jobs are planned in “SAP” system. Upon
planning in the system respective area engineers are taking permits from
operation department through “SAP” system to execute the jobs. On job
completion the permits are cancelled.
6.1.2 Condition based/Predicative maintenance:
The condition of the critical & high cost equipment that effect process
capability are monitored by MTP department through “SAP” based on the
schedule given by area engineers. Accordingly predictive maintenance jobs
are planned in “SAP“ system. After planning the jobs in the SAP system,
respective area engineers are taking permits from operation department to
assess the condition of the equipment. After conducting the test / taking the
measurements permits are returned to Operation department and data is
being uploaded to the SAP for usage by different user groups like MTP,
Corporate OS etc.
6.1.3 Defect/Breakdown Maintenance:
Defects/breakdowns are reported by operation / user departments by

following means.
i. Daily planning meeting notes.
ii. Over phone/log book records.
iii. Work order cards raised in “SAP”.
iv. Defects of emergent nature are taken up immediately and others

are planned in consultation with operation / MTP department.
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6.1.4 Overhauling :
Overhauling of major / critical auxiliaries like Generator, GCB, Transformer,

EHV equipments etc, are planned & prepared by MTP in consultation with
area in charges and is carried out during Unit overhaul / shut downs. The
section in charges is responsible for adherence to the overhauling plans. In
overhauling of critical & major equipments, where assistance of
manufacturers / reputed contractors are obtained for repair / overhauling, the
same would be carried out as per agreed quality plan / procedure with the
manufacturer and accordingly no work instructions has been prepared.
6.2 Electrical Laboratory:
Protective relay testing, 400KV outgoing line energy meter calibration(Used

in billing purpose) and error checking of generator related meters &
transducers in electrical control panel activities are carried out in electrical
laboratory . As these activities are critical in nature & the quality of work is
likely to get affected, the jobs are controlled through written work
instructions / LMIs. The list of equipments, which are maintained for above
purpose in electrical laboratory are calibrated with reference to sub-standard
meters which in turn will be calibrated at national accredited laboratories. The
list of instruments which will be calibrated externally at national accredited
laboratories is enclosed as Annexure-1.
6.2.1 Relay testing:
Protective relay testing is done for electrical equipments once in a year / once
in two years in staggered manner. The testing activities are planned along
with preventive maintenance schedule of the equipments in “SAP” system &
the equipments for which shutdown cannot be availed during normal running
of Unit, are planned in Unit Overhauling or in any major outage of the unit.
Adherence to the planning schedule is monitored by MTP department. On
planning, the system respective area engineers are taking permits from
Page 14 of 125
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operation department through “SAP” system to monitor the equipment

conditions. On job completion the permits are returned to operation.
6.2.2 Energy meter Calibration:
Off-line energy meter calibration is being done for 400KV outgoing line energy
meters used in billing purpose as per PPA with Zera make 0.02 class accuracy
testing kit.
6.2.3 Error checking of meters:
Error checking of meters & transducers for generator related parameters in

Electrical Control Panel are carried out during overhauling of units as a part of
overhauling plan.
6.2.4 Internal calibration of Meters:
The meters, other than substandard meters which are required for testing &
calibration purpose, are calibrated with respect to substandard meters. The
list of instruments which will be calibrated internally is enclosed as Annexure-1.
6.2.5 External Calibration of meters.
Sub-standard meters are sent to national accredited laboratories for

calibration purpose.
6.3 Maintenance resource planning:
6.3.1 Procurement of spares and consumables:
i. Planning of spares and consumables required.
ii. Raising purchase requisitions in SAP.
iii. Technical evaluation of offers furnished by parties/vendors.
iv. Inspection & verification of received materials.
v. Issuing of materials from central stores.
6.3.2 Work Contracts:
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All maintenance jobs are carried out on Contract basis. The following activities are
carried out by area in charge to ensure timely award of contracts & their execution.
i. Preparation of work contract proposals & estimates.
ii. Technical evaluation of bids for contracts.
iii. Execution of maintenance contracts awarded, complying the

statuary and other requirements.
iv. Submission of contract closing report.
6.4 Work environment:
Cleanliness of work place, proper illumination, ventilation, house keeping are

taken care off with the help of concerned department / sections.
6.5 Safety & statutory regulations;
Maintenance jobs are carried out taking all necessary safety precautions as
per site requirement.
HOD (EM), sectional heads, area in charges and area engineers are
responsible for carrying out the work safely.
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Doc. No.: EMD/PC/01 Process Title: Preventive Maintenance Date : 01/02/2018

Rev. No.: 03 Sheet : 01 of 02
1. OBJECTIVE
To carryout preventive maintenance of electrical equipment so as to ensure and

increase the availability of the equipment.
2. BOUNDARY
Preparation of maintenance schedule to carry out maintenance.
3. REFERENCES
i. Procedure
ii. Work Instructions as per the list enclosed.
iii. SAP
4. PROCESS OWNER
Sl.No Description Responsibility
1 Overall performance HOD (EM)
2 Preventive Maintenance of Electrical Area Engrs

Equipments.
5. RECORDS
i. As per the list enclosed.
6. PROCESS MAP
6.1 PROCESS INPUTS
Sl.No Input Source Frequency Reference Review Criteria
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6.1.1 PM WOC MTP As indicated by SAP % of PM WOC

area engineer attended.
6.1.2 PM WOC MTP As indicated by SAP % Availability of the

area engineer Critical equipment
6.2 KEY ACTIVITY AND INTERFACES
Sl.No Activity Responsibility Reference

Document/format
6.2.1 Preparation of Maintenance Area engineer
Schedules
6.2.2 Implementation of PM Schedules MTP
6.2.3 Follow up of PM Schedules and WOC Sectional heads
6.2.4 Isolations and normalizations Operation PTW /LWC as per

department SAP
6.2.5 Work execution Area engineer
6.3 PROCESS OUTPUT
Sl.No Output To Reference Document / format
6.3.1 Availability of equipment Sectional heads
6.4 PROCESS MEASURES
1. % of WOC = WOC attended / WOC raised
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Doc. No.: EMD/PC/02 Process Title: Break down Maintenance Date : 01/02/2018
1. OBJECTIVE :
To carryout breakdown maintenance of electrical equipment ( 4 X 500MW) so as to

reduce the down time and make the equipment available. Break down maintenance
is being carried out as per the SAP notifications raised by operation , electrical
maintenance or any other department. Breakdown maintenance jobs are planned by
MTP as per the schedules given by the area engineers for A and C priority jobs. E
priority jobs are carried out immediately by the area engineer.
2. BOUNDARY:
Application for breakdown maintenance of electrical equipment.
3. REFERENCES
a. Past experience.
b. O&M Manuals.
4. PROCESS OWNER
1 Over all responsible HOD (EM)
2 Breakdown Maintenance of Electrical Eqpts Sectional Heads / Area

engineers
5. RECORDS
a. SAP
6. PROCESS MAP
6.1 PROCESS INPUTS
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Sl.No Input Source Review Criteria
6.1.1 Defect observed Daily inspection by maintenance BD WOC attended.

/ reported personnel or operation
6.1.2 BD WOC SAP BD WOC attended.
6.2 ACTIVITY AND INTERFACES
Sl.No Activity Responsibility Reference
Doc
6.2.1 Identifying the problem, Area engineer Past experience,

attending the problem and O&M Instruction
making the equipment Manual.
available.
6.3 PROCESS OUTPUT
Sl.No Output To Reference Doc
6.3.1 Availability of the equipment. Sectional heads
6.4 PROCESS MONITORING
Sl.No Monitoring Responsibility Stage / Reference Doc

Frequency
1 BD WOC raised , Area engineers SOS Not Applicable
attended
2 Loss of generation due Area engineers As and when Not Applicable
to non availability of the required
equipment.
3 No. of Unit trips due to Sectional As and when Not Applicable
electrical equipment required
heads
Page 20 of 125
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a. % of WOC = WOC attended / WOC raised

b. Loss of generation due to non availability of the equipment.
c. No. of unit trips due to electrical equipment.
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Doc. No.: EMD/PC/03 Process Title: Predictive Maintenance of Date : 01/02/2018

Rev. No.: 03 Electrical Equipments Sheet : 01 of 03
1. OBJECTIVE
To carryout predictive (diagnostic) maintenance of electrical equipment ( 4 X

500MW ) for finding out abnormality in the equipment so that timely action can be
taken to avoid breakdowns. These type of Maintenance jobs are planned and carried
out by area engineers.
2. BOUNDARY
Application for predictive maintenance of electrical equipment.
3. REFERENCES
a. Procedure
b. Work Instructions
c. SAP
4. PROCESS OWNER
1 Over all responsible HOD (EM)
2 Predictive Maintenance of Electrical Eqpts Sectional Heads
5. RECORDS
a. SAP
6. PROCESS MAP
6.1 PROCESS INPUTS
Sl.No Input Source Frequency Reference Review

Criteria
6.1.1 Predictive SAP As indicated NIL Break down
maintenance by area of
Page 22 of 125
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schedules engineer equipments
6.2 ACTIVITY AND INTERFACES
Sl.No Activity Responsibility Reference Doc
6.2.1 Preparation of predictive Area engineer

Maintenance Schedules
6.2.2 Implementation of predictive Area Engineer
maintenance Schedules
6.2.3 Follow up Sectional heads
6.2.4 Isolations and normalizations Operation

if applicable department
6.2.5 Work execution Area engineer
6.3 PROCESS OUTPUT
Sl.No Output To Reference Doc

6.3.1 No. of breakdowns prevented Sectional heads
due to predictive maintenance
6.4 PROCESS MONITORING
Sl.No Monitoring Responsibility Stage / Reference Doc

Frequency
1 Predictive maintenance Area engineers As per the
WOC attended schedule in
SAP

a. Cumulative no. of unit tripping due to electrical equipment
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9. WORK INSTRUCTIONS
Sl. Document (Procedure/Process/WI) Title Document ISO 9001/ ISO 14001

No. (Procedure/Process/ Clause No.
WI) No.
01 Recording of various parameter of EMD/WI/001 6.3 of 9001
generator. 4.4.6of 14001
02 Maintenance of paddle feeders. EMD/WI/005 6.3 of 9001
4.4.6of 14001
03 P.M of motors for CHP. EMD/WI/006 6.3 of 9001
4.4.6of 14001
04 Calibration of Generation related meters in EMD/WI/008 6.3 of 9001
ECP 4.4.6of 14001
05 Maintenance of 11/3.3 kV and 11/0.415 kV EMD/WI/009 6.3 of 9001

Transformer. 4.4.6of 14001
06 Transformer oil sampling for detailed EMD/WI/011 6.3 of 9001

analysis 4.4.6of 14001
07 Over Hauling of LT MCC EMD/WI/014 6.3 of 9001

4.4.6of 14001
08 Preventive Maintenance of EMD/WI/015 6.3 of 9001
4.4.6of 14001
LT Motor .
09 Monthly PM of Batteries (Ni-Cd) EMD/WI/016 6.3 of 9001

4.4.6of 14001
10 Cathodic protection checking EMD/WI/018 6.3 of 9001
4.4.6of 14001
11 Calibration of energy meters. EMD/WI/019 6.3 of 9001
4.4.6of 14001
12 400 kV CT annual / Bi Annual maintenance. EMD/WI/023 6.3 of 9001
4.4.6of 14001
13 400kV CVT annual / Bi Annual maintenance EMD/WI/024 6.3 of 9001
4.4.6of 14001
14 400kV surge /lighting arrestor annual / Bi EMD/WI/025 6.3 of 9001
Annual maintenance. 4.4.6of 14001
15 Annual / Bi Annual Bus bar protection EMD/WI/027 6.3 of 9001

healthiness checking 4.4.6of 14001
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16 Annual / Bi Annual Line protection checking EMD/WI/028 6.3 of 9001

4.4.6of 14001
19 Annual / Bi Annual 400kV bay protection EMD/WI/029 6.3 of 9001
checking 4.4.6of 14001
20 HT Motor O/H. EMD/WI/030 6.3 of 9001

4.4.6of 14001
21 HT Breaker O/H. EMD/WI/031 6.3 of 9001
4.4.6of 14001
22 HT Switchgear O/H. EMD/WI/032 6.3 of 9001
4.4.6of 14001
23 P.M. of HT Motors. EMD/WI/033 6.3 of 9001
4.4.6of 14001
24 Disposal of Batteries(Ni-Cd) EMD /WI/034 6.3 of 9001
4.4.6of 14001
25 Lead Acid battery disposal EMD/WI/036 6.3 of 9001

4.4.6of 14001
26 Handling of transformer oil EMD/WI/037 6.3 of 9001
4.4.6of 14001
27 Maintenance of Window AC- Handling of EMD/WI/020 6.3 of 9001
CFC 4.4.6of 14001
28 Construction of room for storage of EMD/EMP/001 6.3 of 9001

discarded lead acid battery 4.4.6of 14001
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Doc. No.: EMD / WI /001 WI Title : Recording of various Date : 01/02/2018

parameters of Generator
1. PURPOSE
Parameter recording of Generator and finding out any abnormalities.
2. REFERENCES
a. Supplier Manuals
3. RESPONSIBILITY
a. Area engineer
4. RESOURCES REQUIRED
Sl.No. RESOURCE DESCRIPTION

Engineer-1, Technician-1 for two
1 Manpower
hours.
2 Tools & Tackles Not Required
Personal Protection
3 Safety Helmet and safety shoe
Equipment
5. RECORDS
Sl no Description Location Format/ form no. Retention
period
1 Checklist of Sankalp EMD/FORM/001 01 Year
Generator
Parameters
Record Book
6. INSTRUCTIONS
a. Take the EMD/FORM/001 for recording the parameters.
b. Go to the Units and record generator parameters from UCB/ Local in
EMD/FORM/001 .
c. Check for any abnormality in the parameters and take necessary Corrective
action.
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Doc. No.: EMD / WI /005 WI Title: Maintenance of Paddle Feeders Date : 01/02/2018
1. PURPOSE
To carryout quarterly maintenance of Paddle feeders in CHP
2. REFERENCES
a. SUPPLIER MANUALS
3. RESPONSIBILITY
a. Area engineer
Sl no Resource Description
1 Manpower Technician –1, helper –01.
Air blower, spanner set, screw driver set,
2 Tools & tackles
hair brush, cleaning agent, Megger.
Personal protection
3 Safety helmet and safety shoe
equipment
5. RECORDS
Sl no Description Location Format/ form no. Retention
period
1 History Register CHP EMD/REC/004 Years
for Paddle Feeders
6. INSTRUCTIONS
6.1 Obtain PTW.
6.2 Check for isolation.
6.3 Externally clean the paddle feeder of all coal pieces and dust accumulation
completely clean the control panel with air blower.
6.4 Inspect the main contacts of main contactor for pump control
6.5 Replace worn out moving / fixed contacts if any or clean the contacts with petrol and
cloth. Never use emery paper for contact cleaning.
6.6 Clean other contactors with hair brush & petrol.
6.7 In case of dust accumulation over control cards clean them by blowing air.
6.8 Check tightness of all connections at contactors and terminal block.
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6.9 Check for correct setting of all overload relays.

6.10 The cover of box housing the main hydraulic motor/ pump assembly.
6.11 Check connection tightness of main motor terminal box, foundation bolts after
cleaning motor observe for any sign of overheating in motor terminal box.
6.12 Clean the slip ring assembly of PCRD & CCRD and check for proper clamping of the
cable.
6.13 Check tightness of all cable connection in CCRD / PCRD, healthiness of brass rings
and carbon brushes.
6.14 Clean the motors for CCRD/PCRD
6.15 Clean the travel motor & check connection tightness.
6.16 Measure insulation resistance of motor of hydraulic pump.
6.17 Check for any jamming in push buttons / switches
6.18 Check all indicating lamps.
6.19 Check the centre junction box and clean the junction box and check the connection
tightness
6.20 Record the observations in EMD / REC/004.
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Doc. No.: EMD / WI /006 WI Title: PM of CHP Motors Date 01/02/2018

1. PURPOSE
To carryout Preventive Maintenance of CHP area motors as per SAP Schedule.
2. REFERENCES
a. Supplier Manuals
3. RESPONSIBILITY
a. Area engineer
Sl No Resource Description
1 Manpower Technician –1, helper –01.
2 Tools & Tackles Spanner set, CRC 226, screw driver set
Personal Protection
3 Safety helmet safety Shoe.
Equipment
5. RECORDS
Sl Description Location Format/ Form Retention
No No. Period
1 History Register CHP EMD/REC/005 03 Years
for Motor
Maintenance
6. INSTRUCTIONS
6.1 Obtain PTW.
6.2 Clean the motor body and open motor T.B cover and discharge the power
termination.
6.3 Check termination tightness and clean T.B.
6.4 IF any problem like cable burning or T.B damage is noticed inform engineer in-charge
and attend the defect. damaged T.B should be replaced and re-termination of power
cable should be done if any heating in termination is observed.
6.5 Check and ensure double earthing of motor body and ensure tightness.
6.6 Ensure proper glanding of power cable and seal extra gland holes if any.
6.7 Close the T.B cover and seal if required.
6.8 Measure the IR value of the motor & also winding resistance.
6.9 Open fan cover and clean before putting back the cover.
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6.10 Clear PTW.

6.11 Record the observations in EMD/REC/005
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Doc. No.: EMD / WI /008 WI Title: Calibration of Generation Date : 01/02/2018

Rev. No.: 02 related meters in ECP Sheet : 01 of 02
1. PURPOSE
Calibration of Generation related Transducer along with indication meters in Electrical
Control Panel (ECP).
2. References :
a. Manuals and drawings of BHEL on ECP
3. RESPONSIBILTY
a. Electrical Lab in-charge
4. Resources required
Sl No Resources Description
1 Manpower 1 Engineer + 1 Technician+1 Skilled Man
1. Three phase voltage, current source.

2. Multimeter
3. Testing leads.
2 Tools and tackles 4. Screw driver set.
5. Testing pins.
6. Calculator
7. 3 phase Power Meter
Personnel protective
3 Safety shoe
equipment
5. Records
Sl.No. Description Location Format Number Retention
Period
1 Transducer Calibration Electrical EMD/FORM/009 3 Years

Laboratory
6. Instructions
6.1 Ensure availability of PTW
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6.2 Find out the applicable current & voltage terminals at the terminal block for
the selected transducer from the drawing.
6.3 The current terminals shall be shorted at the terminal block towards
Current transformer side.
6.4 Disconnect the current & voltage input terminals in the transducer without
disturbing the other circuit connections.
6.5 Connect the Power meter in between the “Current & voltage injector
source” & the transducer.
6.6 Inject the required current & voltage inputs to transducer input terminal
with the help of current/voltage source.
6.7 Check the output of the transducers. If the transducer reading is not
matching with the theoretical output, replace the transducer or adjust to
get the required output.
6.8 After ensuring healthiness of the transducer, check the power meter
indication readings with the ECP indication meters reading
6.9 Adjust the ECP indication meters if required.
6.10 Record all the parameters in the format.
6.11 Normalize the connections Including Current Transformer connections.
6.12 Arrange for cancellation of PTW.
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Doc. No.: EMD / WI /009 WI Title : Maintenance of 11/3.3KV and Date : 01/02/2018
Rev. No.: 02 11/0.415 KV Transformer Sheet : 01 of 02
1. PURPOSE
Preventive Maintenance (PM) of 11/3.3KV, 11/0.415KV Transformers as per SAP schedule.
2. References
a. Manuals of BHEL/CGL/Bharat Bijlee / Voltamp
3. RESPONSIBILITY
a. Area Engineer
Sl. No Resources Description
1 Manpower 2 Technician+ 2 Skilled +1Skilled
Tools and tackles Spanner set, Screw driver, Torque wrench, Megger,
2
Multimeter
3 Spares As per requirement.
5. Records
Sl. No. Description Location Format Number Retention
Period
1 Check list for Sankalp EMD EMD/FORM/014 3 Years

transformer Office
48weekly PM
2 Check list for UAT EMD/FORM/014A 3 Years

Sankalp EMD Office
48weekly PM
6. Instructions
6.1 Ensure availability for PTW.
6.2 Identify the transformer correctly.
6.3 Ensure isolation from up stream and down stream switchgear.
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6.4 Identify the Marshalling Box A/C supply and isolate it.
6.5 Follow each and every step in line with transformer PM format EMD/FORM/014.
6.6 Box up the transformer LV/HV compartments on completion of job.
6.7 Normalise chamber Marshalling Box AC supply.
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Doc. No.: EMD / WI /011 WI Title: Transformer oil sampling Date : 01/02/2018
1. PURPOSE
Transformer oil sampling for detailed analysis as per requirement
2. References
a. Previous Experience
3. RESPONSIBILITY
a. Area Engineer
1 Manpower 1 Technician. 1 Skilled Man
Tools and tackles Steel sampling bottles, set of spanners, cotton waste,
2
sampling attachment, bucket
Personnel protective Safety Shoe and safety helmet

3
equipment
5. Records
Sl No. Description Location Format Number Retention Period
1 Record of oil Samples Sankalp EMD EMD/FORM/016 03 years

in data base. Office
6. Instructions
6.1. Ensure availability of LWC.
6.2 Open the dummy flange and clean the sampling area.
6.3 Connect the sampling arrangement to the flange and also to the sampling
bottle.
6.4 Open the sampling valve slowly and allow oil to flow freely through the
bottle.
6.5 Close the valve.
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6.6 Rinse the bottle thoroughly with the oil in the bottle.
6.7 Repeat the process two times.
6.8 The waste oil is to be collected in a bucket for proper disposal.
6.9 Collect the oil for final sampling with the non connected end of the bottle in
16 degree upward position.
6.10 Allow oil to flow freely to ensure that there is no entrapped air bubbles.
6.11 Close both the valves of the steel bottle.
6.12 Now the sampling valve can be closed.

6.13 Normalize all connections.
6.13 The date, transformer – ID and oil temperature of the transformer. are to be
pasted on the steel bottle.
6.14 Arrange for returning of LWC.
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Doc. No.: EMD / WI /014 WI Title: Over Hauling of Date : 01/02/2018

Rev. No.: 02 LT MCC Sheet : 01 of 02
1. PURPOSE
Carry out of Overhaul maintenance of LT MCC.
2. REFERENCES :
a. Switchgear maintenance manual, breaker maintenance manual, past experience.
3. RESPONSIBILITY
a. Area Engineer
Sl.No Resource Description
1 Manpower 1 Engineer + 2 Technician + 2 Skilled workmen
2 Tools & Tackles Ring Spanner set, ‘D’ Spanner set, Screw
driver(Heavy duty), Screw driver(Light duty),
Combination pliers, Ratchet spanner set, Air
Blower, Brushes of various sizes, PVC
insulation tape, Cleaners, Rust
removers/preventers, Megger, Multimeter,
Markin cloth, Jute.
3 Personal Protection Safety Helmet and safety shoe
Equipment
5. RECORDS
Sl.No Description Location Form No. Retention
Period
1 LT Switch gear checklist Sankalp EMD EMD/FORM/020 5 Y

Office
6. INSTRUCTIONS
6.1 Ensure availability of PTW.
6.2 Check all the necessary isolations and locking of Incomers and tie feeders.
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6.3 Carry out the work and record all the observations as per the format of check
sheet.
6.4 Return the PTW.
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Doc. No.: EMD / WI /015 WI Title: Preventive maintenance of LT Date : 01/02/2018

Rev. No.: 01 Motor Sheet : 01 of 02
1. PURPOSE
Preventive Maintenance of LT Motor as per SAP schedule.
2. REFERENCES :
a. Motor manufacturers recommendations and past experience.
3. RESPONSIBILITY
a. Area engineer
1 Manpower 1 Engineer + 1 Technician + 1 Skilled workmen
2 Tools & Tackles Spanner set, Screw driver, Ratchet spanner set, Air
Blower, Cleaning Brushes, Cleaning solvent/agent,
Megger, Motor checker, Markin cloth, Jute etc., as
per the requirement
3 Personal Protection Safety Shoe and safety helmet
Equipment
5. RECORDS
Period
1 LT Motor check list Sankalp EMD EMD/FORM/021 3 Years
Office
6. INSTRUCTIONS
6.1 Ensure availability of PTW.
6.2 Ensure proper isolation.
6.3 Carry out the work as per the check sheet and record the readings and observations
in check sheet.
6.4 Return the PTW for cancellation.
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Doc. No.: EMD / WI /016 WI Title: Monthly Preventive Date : 01/02/2018

Rev. No.: 02 maintenance of Batteries(Ni-Cd) Sheet : 01 of 02
1. PURPOSE
To carry out monthly preventive maintenance of batteries ( Ni-CD )
2. References
a. Manuals of HBL- NIFE batteries and AMCO batteries.
3. RESPONSIBILITY
a. Area engineer
1 Manpower 1 skilled workmen+1 unskill workmen.
2 Tools and tackles Spanners multimeter, pliers, screw driver.
3 Personnel protective equipment Gloves.
5. RECORDS
Sl.No Description Location Form No. Retention Period
1 Battery Switchyard EMD/REC/006 1 Year

Readings
6. Instructions
6.1 The work is to be carried out on monthly basis on each battery set as per the
instruction of the area engineer.
6.2 Sulphation at any cell terminals are to be removed with Insulated scrapper and
then tightness of all cell terminals to be ensured with insulated spanners.
6.3 Petroleum jelly is to be applied at cell terminals at required quantity so that a thin
layer of coating is formed over the cell terminals.
6.4 Outer surface of all the cells in the battery sets are to be cleaned with dry markin
cloth.
6.5 Reading of individual cell voltages shall be taken.
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6.6 Any abnormality observed on battery set while performing the Work shall be
informed to the area engineer.
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Doc. No.: EMD / WI /018 WITitle: Cathodic Protection Date : 01/02/2018

Rev. No.: 02 Checking Sheet : 01 of 02
1. PURPOSE
To Carryout Monthly Pipe to Soil Potential (PSP) reading for Cathodic Protection
system.
2. References
a. Supplier Manuals
3. RESPONSIBILITY
a. Area engineer
4. Resources Required
Sl No Resource Description
1 Man Power Supervisor-1,Electrician-1,Helper-1
2 Tools & Tackles Multimeter, Testing Electrode, Panel key,

Grease
3 Personnel Protection Equipment Safety Shoe
5. Records
1 Cathodic Protection Switchyard EMD/FORM/023

Checking
6. Instructions
6.1 Necessary information to be given to the Operator Present at the Location.
6.2 Record the Readings at TR Unit-1
6.3 Record the Readings at TR Unit-2
6.4 Record the Readings at all TLP Points
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6.5 Ensure the readings between ( - ) 0.85 & ( - ) 1.2 Volts

6.6 In case the recorded values are not in the range mentioned above, adjust the
Potentiometer/ Variac to adjust the impress Current at TR Units.
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Doc. No.: EMD / WI /019 WI Title: Calibration of Energy Date : 01/02/2018

Rev. No.: 02 Meters Sheet : 01 of 03
1. PURPOSE
To carry out calibration of 0.2 class commercial energy meters installed in the 400 KV
out going lines as per PPA agreement.
2. REFERENCES
a. Power Purchase Agreement
b. Energy meter Manual
c. Instruction manual for 0.02 Class ZERA testing Kit
3. RESPONSIBILITY
a. Switchyard Area Engineer
1 Manpower 1 Engineer + 1 Technician + 1 Skilled

workmen
2 Tools & Tackles Screw drivers , 1-ph 230 V ac supply ,

Off-line accuracy checking kit 0.02 Class
(Zera)
3 Personal Protection Equipment Not applicable
5. RECORDS
1 Energy meter Test Switchyard EMD/FORM-24 5 Years

Reports
2 Computed Energy Switchyard EMD/FORM-25 2 Years

Statement
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6. INSTRUCTIONS
6.1 Obtain proper PTW from Switchyard SCE
6.2 Ensure the presence of representative from APTRANSCO (interested party). Each out
going line is having two 0.2 class static energy meters. One is called as main meter
and the other as check meter. If the meter under test is main meter , then the
substitute meter will be corresponding check meter of that particular feeder.
6.3 Note down the initial readings of the substitute meter and Meter under test (MUT)
in the form EMD/FORM/025. Short the CT secondary terminals and remove the
voltage links at the energy meter TTB for MUT. Set up the testing kit and check the
functionality of the kit. Inject the voltage and current as per the EMD/FORM/024 and
record the errors obtained. If the errors obtained are within specified limits i.e ± 0.2%
then the meter can be put back in to service. Otherwise put new tested spare meter
in to service in place of failed meter.
6.4 Put back the meter and normalize the CT, PT connections.
6.5 Note down the final readings of the substitute meter and MUT in EMD/FORM/025.
6.6 Make the computed energy statement as per the EMD/FORM/025. Get the computed
energy statement and test report signed by APTRANSCO representative.
6.7 Inform the switchyard SCE about the computed energy. Cancel the PTW.
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Doc. No.: EMD / WI /023 WI Title: 400 KV CT Annual / Date : 01/02/2018

Rev. No.: 02 Bi Annual maintenance Sheet : 01 of 02
1. PURPOSE
To carry out the annual / bi annual maintenance of 400 KV Current Transformer.
2. REFERENCES
a. 400 KV CT Instruction manual.
3. RESPONSIBILITY
a. Switchyard Engineer
1 Manpower 1 Engineer + 1 Technician + 2 skilled

workmen + 2 unskilled workmen.
2 Tools & Tackles Multimeter , screw drivers , Nitrogen Filling

hose , pressure gauge.
3 Personal Protection Equipment Safety Shoe , Safety Belt and safety helmet.
5. RECORDS
1 400 KV CT History Switchyard EMD/REC/010 10 Years

Register
6. INSTRUCTIONS
6.1 Obtain PTW from Switchyard SCE.
6.2 Ensure the proper isolation and earthing of the equipment under PTW.
6.3 Open the CT secondary terminal box and ensure that no water ingress is there. If
water ingress is observed, analyze the cause and attend the same.
6.4 Check the CT secondary terminal tightness in secondary terminal box, CT JB and
in Control and Relay panels.
6.5 Clean the porcelain bushings and check for any cracks.
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6.6 Check the secondary terminal board, primary terminals and top chamber cover
for any oil leakages.
6.7 Check the oil level in the top view glass.
6.8 Check the nitrogen pressure and top up the nitrogen if required up to 5 psi.
6.9 Check the Capacitance and Tandelta values of the CT and record the same in the
CT History register. If the Tandelta value is >0.7% or Capacitance value is >1000pF
then plan for the replacement of the CT at the earliest.
6.10 Ensure the tightness of P.F terminal earthing connection after Capacitance and
tandelta measurement.
6.11 Check the tightness of primary connections.
6.12 Record any abnormalities and activities done in the history register
EMD/REC/010
6.13 Apply RTV sealant to the CT secondary terminal box for ensuring proper
sealing of the box.
6.14 Cancel the PTW
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Doc. No.: EMD / WI /024 WI Title: 400 KV CVT Annual / Bi Annual Date : 01/02/2018
Rev. No.: 02 maintenance Sheet : 01 of 02
1. PURPOSE
To carry out the annual/ Bi annual maintenance of 400 KV Capacitive Voltage
Transformer (CVT).
2. REFERENCES
a. 400 KV CVT Instruction manual.
3. RESPONSIBILITY
a. Switchyard Area engineer
Sl.No RESOURCE DESCRIPTION
1 Manpower 1 Engineer+ 1 Technician + 2 skilled

2 Tools & Tackles Multimeter , screw drivers , Nitrogen Filling

hose , pressure gauge.
3 Personal Protection Equipment Safety Shoe and safety helmet.
5. RECORDS
Period
1 400 KV CVT History Switchyard EMD/REC/011 10 Years

Register
6. INSTRUCTIONS
6.3 Open the CVT secondary terminal box and ensure that no water ingress is there. If
water ingress is observed, analyse the cause and attend the same.
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6.4 Check the CVT secondary terminal tightness in secondary terminal box , CVT JB and in
Control and Relay panels.
6.5 Clean the porcelain bushings and check for any cracks.
6.6 Check the secondary terminal box and HF link chamber for any oil leakages and attend
the same.
6.7 Check the oil level in the view glass and top up if required.
6.8 Check the nitrogen pressure and top up the nitrogen if required up to 5 psi.
6.9 Check the tightness of primary connections.
6.10 Check the Capacitance and Tandelta values of the CVT and record the same in the
CT History register. If the Tandelta value is >0.7% then plan for the replacement of
the CVT at the earliest.
6.11 Ensure the tightness of P.F terminal earthing connection after Capacitance and
tandelta measurement.
6.12 Cancel the PTW
6.13 Measure the secondary voltages after the energization of CVT and record the
values in the history register EMD/REC/011.
6.14 Record the abnormalities found, corrective actions taken and activities done
during the maintenance in the history register EMD/REC/011.
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Doc. No.: EMD / WI /025 WI Title: 400 KV Lightening Arrestor Date : 01/02/2018
Rev. No.: 02 Annual / Bi Annual Maintenance Sheet : 01 of 02
1. PURPOSE
To carry out the annual / Bi annual maintenance of 400 KV Lightening Arrestor (LA).
2. REFERENCES
a. 400 KV LA Instruction manual.
3. RESPONSIBILITY
1 Manpower 1 Technician + 1 skilled workmen + 2

unskilled workmen.
2 Tools & Tackles Multimeter , screw drivers , Leakage

Current Monitor (LCM-II) kit , 1-phase
variac.
3 Personal Protection Equipment Safety Shoe and safety helmet.
5. RECORDS
Period
1 400 KV LA History Switchyard EMD/REC/012 10 Years

Register
6. INSTRUCTIONS
6.3 Clean the LA stacks and inspect for any cracks or damages in the porcelain stacks.
6.4 Check the healthiness of the operation counter by applying 1-phase voltage to
the counter.
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6.5 Cancel the PTW

6.6 Take LA into service.
6.7 Measure the LA leakage currents (both capacitive and resistive components) On
monthly basis with the LCM-II kit and record the values in the LA history register
EMD/ REC/012.
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Doc. No.: EMD / WI /027 WI Title: Annual / Bi Annual Checking of Date : 01/02/2018
Rev. No.: 02 400 KV Bus bar Protection Healthiness. Sheet : 01 of 02
1. PURPOSE
To check the healthiness of 400 KV Bus bar protections Main 1 & Main 2 for both 400 KV
bus 1 and 2.
2. REFERENCES
a. Bus Bar Protection instruction manuals.
b. Bus Bar protection Schematic Drawings.
3. RESPONSIBILITY
a. Switchyard area engineer
1 Manpower 1Engineer + 1 Technician +1 skilled workmen.
2 Tools & Tackles Secondary injection kit , clamp on meter ,

Multimeter , screw drivers.
3 Personal Protection Equipment Safety Shoe
5. RECORDS
1 Busbar protection 400 KV EMD/REC/014 10 years

History register
Switchyard
6. INSTRUCTIONS
6.1 Obtain PTW from Operation.
6.2 Ensure the proper isolation of the corresponding 400 KV Bus.
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6.3 Inject the current in the secondary circuit of Main-1 protection and ensure the
operation of the relay. Check for the set values of alarm and trip and actual
operated values.
6.1 Inject the current in the secondary circuit of Main-2 protection and ensure the
operation of the relay. Check for the set values of alarm and trip and actual
operated values.
6.2 Inject the current in the secondary circuit of both Main-1 and Main-2 protection and
check for the operation of bus bar trip relays (96) .Ensure tripping of all the
feeders connected to that particular bus.
6.3 Check the initiation of Bus bar to LBB protection for all the feeders connected in
that bus.
6.4 Check the alarm and event logger contacts.
6.5 Check the LBB to Bus bar initiation and ensure tripping of bus bar on LBB
initiation for all the feeders connected in that bus.
6.6 Reset all the relays and ensure the changeover of all the LBB, Trip relay contacts
for all the feeders connected in that bus.
6.7 Tighten all the connections.
6.8 Record the set values and operated values of the currents and relays operated in
EMD/REC/014.
6.9 Cancel the PTW and normalize the bus.
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Doc. No.: EMD / WI /028 WI Title: Annual / Bi Annual Checking of Date: 01/02/2018
Rev. No.: 02 400 KV LINE Protection. Sheet : 01 of 02
1. PURPOSE
To check the healthiness of 400 KV line protections Main 1 & Main 2 and carrier
trippings for 400 KV Lines.
2. REFERENCES
a. Line distance protection instruction manuals.
b. Line protection Schematic Drawings .
c. Recommended Relay Settings for 400 KV Lines
3. RESPONSIBILITY
1 Manpower 1Engineer + 1 Technician +1 skilled

workmen.
2 Tools & Tackles Distance relays testing kit , Multimeter ,

screw drivers.
5. RECORDS
1 Line protection 400 KV EMD/REC/015 05 years

History register
Switchyard
6. INSTRUCTIONS
6.1 Obtain PTW from Operation .
6.2 Ensure proper isolation of the line from both ends.
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6.3 Isolate the Main-1 and Main-2 relays from yard side by opening the CT /PT
disconnecting links .
6.4 Setup the distance relay testing kit and give the CT /PT connections to the relay.
6.5 Inject the current and voltages as per the relay settings of Zone-1, 2, 3 etc and ensure
the operation of the relay for correct impedance and timings.
6.6 Ensure the carrier transmission as per the relay settings.
6.7 Check the operation of Auto re-close relay for single phase faults.
6.8 Check the operation of Over voltage relays and tee differential relays.
6.9 Check the carrier permissive and direct trippings. Check the advancement of Tx/Rx
counters for carrier send /receive and check event logger contacts also.
6.10 Check the triggering of disturbance recorder and observe the waveforms.
6.11 Remove the kit connections and normalize the CT / PT connections.
6.12 Record the observations and relays operated in EMD/REC/015
6.13 Cancel the PTW and normalize the line.
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Doc. No.: EMD / WI /029 WI Title: Annual / Bi Annual Checking of Date : 01/02/2018
Rev. No.: 02 400 KV Bay Protection. Sheet : 01 of 02
1. PURPOSE
To check the healthiness of 400 KV Switchyard bay protections Main 1 & Main 2 ,
Interlocks and alarms.
2. REFERENCES
a. Bay protection Relays instruction Manual.
b. Bay protection Schematic Drawings.
c. Recommended relay Settings for 400 KV Switchyard .
3. RESPONSIBILITY
a. Switchyard Area engineer
Sl.No. RESOURCE DESCRIPTION

workmen.
2 Tools & Tackles Secondary injection kit , Multimeter ,

screw drivers.
5. RECORDS
1 400 KV Bay 400 KV EMD/REC/016 05 years

protection History
Switchyard
register
6. INSTRUCTIONS
6.2 Measure and record the spill currents of Main-1 and Main-2 protections.
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6.3 Ensure proper isolation of the bay.

6.4 Check the bay protection Main-1 and Main-2 relays for their correct operation with
secondary injection kit . Ensure the changeover of the relay aux. contacts.
6.5 Check the operation of the Master trip relay and ensure the tripping of the breaker.
6.6 Check the correct operation of various breaker protection auxiliary relays by
initiating the contacts from 400 KV breaker. Check the corresponding alarms and
event logger contacts.
6.7 Put back the Main-1 and Main-2 relays and normalize the connections.
6.8 Record the relays operated and observations in EMD/REC/016
6.9 Cancel the PTW.
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Doc. No.: EMD / WI /030 WI Title: HT MOTOR OVERHAULING Date : 01/02/2018

1. PURPOSE
Overhauling of HT motor 11/ 3.3 KV in the main plant and off site as & when directed by
MTP.
2. REFERENCES
a. Instruction manual for HT Motors.
3. RESPONSIBILITY
a. Area engineer
1 Manpower 1Engineer + 1 Technician +2 skilled workmen + 2

unskilled workmen + 1 Fitter + 1 rigger
2 Tools & Tackles Chain block , hook chuk , D-shackles , slings , Inside &
Outside micro meter, Bearing Puller , spanner set ,
Alignment checker, Hydraulic Jack , 0- 5 KV Megger.
3 Personal Protection Safety Shoe , Safety helmet.

Equipment
5. RECORDS
1 HT Motors Switchyard EMD/REC/017 5 years

Mtc
6. INSTRUCTIONS
6.1 Obtain PTW from Operation .
6.2 Ensure the proper isolation of the corresponding HT breaker and breaker is isolated
and panel is locked .
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6.3 Open the motor T.B cover & discharge with earthing rod .
6.4 Open cable termination (power & CT cables), earthing connection and space heater
connections.
6.5 Decouple the drive after noting down the alignment reading. Disconnect all lube oil /
cooling water lines (Wherever applicable).
6.6 Dismantle and lift the rain hood wherever provided.
6.7 Lift and shift the motor with proper care to workshop or any other suitable location.
6.8 Dismantle the motor coupling, fan, DE and NDE side end covers. Take out the rotor.
6.9 Note down any abnormality in stator winding for overheating, condition of stator
wedges & slots, deposit of excess grease on stator over heating portion, mechanical
damage and crack in rotor, condition of bearings.
6.10 Clean the stator winding, rotor, bearings, end covers and all other dismantled parts
with proper cleaning agents. Clean heat exchanger tubes with nylon brush.
6.11 Check bearing condition, measure bearing clearances. Replace with new ones if
necessary.
6.12 Check the healthiness of space heaters.
6.13 Check varnishing of stator winding, rotor and apply new varnish if required.
6.14 Ensure no foreign material inside, assemble the motor with proper care and check
for rotor freeness.
6.15 Externally clean the motor surface & paint the motor with enamel painting with
existing shade.
6.16 Measure bearing insulation at 100 V/260 V, stator winding insulation at 1 KV &
stator winding resistance.
6.17 Clean motor base plate (foundation) & shift the motor back to the foundation.
6.18 Align the motor and check the alignment. Tight the foundation bolts and terminates
all the power & Control cables correctly. Connect all the lube oil & cooling water
pipes.
6.19 Check the IR of the motor along with power cable.
6.20 Take the decoupled trial run and record no load current, vibration readings in
EMD/REC/017.
6.21 Couple the motor and fix the rain hood.
6.22 Cancel the PTW.
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Doc. No.: EMD / WI /031 WI Title: HT Breaker OVERHAULING. Date : 01/02/2018

1. PURPOSE
Overhauling of HT breaker 11/ 3.3 KV in the main plant and Ash handling plant and off
sites.
2. REFERENCES
a. Instruction manual for HT Breakers.
b. Past experience
3. RESPONSIBILITY
a. Area engineer
SL.NO RESOURCE DESCRIPTION

2 Tools & Tackles 0- 5 KV Megger, Contact resistance meter ,

vacuum tester , timing kit , Multimeter,
blower , spanner set , cleaning agents and
grease.
3 Personal Protection Equipment Safety Shoe , Safety helmet.
5. RECORDS
1 HT Breaker Mtc Switchyard EMD/REC/018 3 years
6. INSTRUCTIONS
6.2 Ensure the proper isolation of the corresponding HT breaker and Breaker is kept in
test position .
6.3 Clean the breaker thoroughly.
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6.4 Check the tightness of all control cable terminations.

6.5 Inspect the healthiness of multi pin plug and replace if required .
6.6 Lubricate all moving parts.
6.7 Clean the isolating finger contacts.
6.8 Check the tightness of nut, bolts.
6.9 Inspect finger contacts for overheating, looseness and replace if necessary.
6.10 Perform close trip operation of the circuit breaker both manually and electrically in
test position .Measure close, open, Close-Open timings and adjust the timings if
required.
6.11 Measure the contact resistance and check the healthiness of vacuum with vacuum
tester.
6.12 Check the healthiness of all indicating lamps, aux.switches.
6.13 Check the electrical and mechanical interlocks.
6.14 Clean the carbon brushes of spring charging Motor.
6.15 Check the tightness of finger contacts.
6.16 Record the activities done and any abnormalities in the HT Breaker Mtc register EMD
/ REC/018.
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Doc. No.: EMD / WI /032 WI.Title: HT Switchgear overhauling. Date : 01/02/2018

1. PURPOSE
Overhauling of HT Switchgear 11/ 3.3 KV in the main plant and Ash handling plan-t and
off sites.
2. REFERENCES
a. Past experience
3. RESPONSIBILITY
a. Area Engineer

2 Tools & Tackles 0- 5 KV Megger, voltage detector ,

Discharge rod ,Torque wrench , markine
cloth Multimeter, blower , spanner set ,
cleaning agents .
3 Personal Protection Equipment Safety Shoe , Safety helmet.
5. RECORDS
1 HT Switchgear Mtc Switchyard EMD/REC/019 3 years
6. INSTRUCTIONS
6.2 Ensure the proper isolation of the HT Switchgear from corresponding incomers.
Ensure isolations from remote end also for transformer feeders.
6.3 Check that board is dead by ensuring incomer breakers are switches off and are in
racked out condition. Rack in the bus earthing truck and close it.
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6.4 Open the bus chamber. Clean the bus bar chamber thoroughly and check the
tightness of nuts /bolts with torque wrench .
6.5 Check the tightness of power cables in all the feeders. Inspect the surge suppressors
and rectify the damages if any .
6.6 Ensure proper tightness of control circuit of Bus PT Cubicle.
6.7 Check the IR value of the Bus before opening and after boxing up with 1 KV megger
and record in EMD/REC/019
6.8 Ensure that all the Tools & tackles are taken out from bus chamber and no foreign
material is inside the bus chamber.
6.9 Box up the bus chamber.
6.10 Open the bus earth truck and rack out the same.
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Doc. No.: EMD / WI /033 WI Title: Preventive maintenance of HT Date : 01/02/2018

Rev. No.: 02 Motors Sheet : 01 of 02
1. PURPOSE
Preventive maintenance of HT Motors 11/ 3.3 KV in the main plant and Ash handling
plant and off sites.
2. REFERENCES
a. Instruction manual for HT Motors
b. Past experience
3. RESPONSIBILITY
a. Area engineer
1 Manpower 1 Technician +2 skilled workmen + 2

unskilled workmen.
2 Tools & Tackles 0- 5 KV Megger, Discharge rod , markine

cloth ,Multimeter, blower , spanner set ,
cleaning agents .
3 Personal Protection Safety Shoe , Safety helmet.

Equipment
5. RECORDS
Period
1 HT Motors PM Record Switchyard EMD/REC/020 03 years
6. INSTRUCTIONS
6.2 Ensure the proper isolation of the HT motor from corresponding breaker incomer.
6.3 Open the motor T.B cover and discharge with discharge rod.
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6.4 Check the tightness of power and control cables.

6.5 Check the oil level of motor bearings is applicable and top up if required.
6.6 Check the tightness of earthing connections and ensure double earthing of TB and
motor body.
6.7 Check the power cable end terminations for any overheating.
6.8 Check the healthiness of space heaters.
6.9 Close the TB cover.
6.11 Record the history in EMD/REC/020.
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Doc. No.: EMD / WI /034 WI Title: Disposal of Ni-Cd Batteries Date : 01/02/2018
1. PURPOSE
Identifying the defective Ni-Cd batteries, replacing with new ones and safe disposal of
the defective ones.
2. REFERENCES
a. Battery manufacturer Instruction Manual.
3. RESPONSIBILITY
a. Area engineer
1 Manpower 1 Technician +1skilled workmen
2 Tools & Tackles Multimeter , cell tester , hydrometer
3 Personal Protection Equipment Safety Shoe , asbestos hand gloves
5. RECORDS
Period
1 Battery History Switchyard EMD/REC/021 05 years

Register
6. INSTRUCTIONS
6.1 Measure the individual cell voltages. Ensure that the voltage is not less than the
minimum voltages specified by the manufacturer as indicated in the Instruction
manual.
6.2 If voltage of any cell is found to be less than the specified minimum value, then
identify the cell and record in the EMD / REC / 021. Take corrective action if any as
suggested by OEM. If the cell voltage does not improve then plan for Replacement
of the defective cells.
6.3 Obtain the PTW and ensure proper isolation of the battery bank.
6.4 Replace the defective cell with new one and boost charge it up to the voltage
specified Instruction manual.
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6.5 Cancel the PTW and ensure the normalization of the battery bank.
6.6 Hand over the defective cell to NTPC Stores for further handing over to
6.7 Original equipment manufacturer / supplier for the safe disposal / re cycling of the
cell.
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Doc. No.: EMD / WI /036 Date : 01/02/2018

Rev. No.: 01 WI Title: Lead Acid Battery Disposal Sheet : 01 of 02
1. PURPOSE
To control work environmental pollution in handling and disposal of discarded lead acid
batteries.
2. References
a. Past Experience
3. RESPONSIBILITY
a. Area Engineer
Sl.No Resources Description
1 Manpower 1 Technician+ 1 Skilled
2 Tools and tackles Multimeter, Hand gloves
5. Records
Sl. No. Description Location Format Number Retention Period
Battery disposal Sankalp EMD

1 1802/43 5 Years
Balance Office
6. Instructions
6.1 Limited quantity of Lead acid batteries are available for starting of Diesel generators
in main plant DG room & Fire water pump houses.
6.2 Check the lead acid batteries as per the respective scheduled Preventive
Maintenance to identify the defective batteries.
6.3 Check for defective batteries during attending breakdown work orders on batteries.
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6.4 Ensure availability of pre-designated earmarked area for temporary storage of the
discarded batteries.
6.5 Shift the discarded batteries to the earmarked area.
6.6 Return the discarded batteries to store through Material Return Note.
6.7 Care should be taken to avoid any spillage during the storage handling and
transportation to stores.
6.8 Keep a record of discarded batteries and update the records as and when job is
done.
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Doc. No.: EMD / WI /037 Date : 01/02/2018

Rev. No.: 01 WI Title : Handling of Transformer Oil Sheet : 01 of 02
1. PURPOSE
To control work environmental pollution in handling and disposal of Transformer Oil.
2. References
a. Past Experience
3. RESPONSIBILITY
a. Area Engineer
Sl .No Resources Description
1 Manpower 1 Technician+ 1 Skilled
2 Tools and tackles Oil collecting/ Storage Containers
5. Records
Sl. No. Description Location Format Number Retention Period
Transformer oil
1 Sankalp EMD Office 1802/44 5 Years
disposal Balance
6. Instructions
6.1 Ensure observation of transformers for oil leakages and physical healthiness as per
respective scheduled checklist.
6.2 Identify the transformers from where oil leakages are observed and take necessary
steps to avoid ground contamination by placing a suitable waste oil container, and
then transferred into waste oil drums.
6.3 Depending upon severity of oil leakages problem will be attended during
opportunity/shutdown of the equipment.
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6.4 Ensure availability of designated area for keeping Waste Oil to be disposed.
6.5 Measure should be taken to handle used transformer oil with care to avoid any land
contamination due to spillage.
6.6 Proper care should be taken whenever transformer oil is drained from tank for
sampling, maintenance.
6.7 Note that waste transformer oil shall be properly handled and returned to stores
through MRN.
6.8 Keep a record of oil disposal and update the records as and when job is done
6.9 During the storage handling and transportation to stores care should be taken to
avoid any spillage.
6.10 Return the waste transformer oil drums to store through MRN & keep the record.
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Doc. No.: EMD / WI /038 WI Title: Maintenance of Window AC- Date : 01/02/2018
Rev. No.: 01 Handling of CFC Sheet : 01 of 02
1. PURPOSE
To Control and minimize CFC leakages into the atmosphere during operation and
Maintenance of Window, Split, Package Air Conditioners. and Water coolers
2. REFERENCES
a. Past Experience
3. RESPONSIBILITY
a. Area Engineer
1 Manpower 1 Technician +2 skilled workmen.
2 Tools & Tackles Spanner Set, Screw Driver
5. RECORDS
Period
1 Gas leak & filling Record Sankalp- EMD/REC/028 05 years

EMD
6. INSTRUCTIONS
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6.1 Window air conditioners , Split , Package Air Conditioners and Water coolers of are
located at various plant locations, Communication building, Documentation
building, Sea water and Sweet water pump houses.
6.2 Note that any release of Freon / CFC into the atmosphere has significant
environmental impact. Until eco-friendly technology replaces the existing one,
utmost importance to be given for control and minimize of CFC releases.
6.3 Ensure quarterly observation checklist for healthy running of Window, Split, Package
Air Conditioners. and Water coolers The item which is prone to regular complaints is
to be inspected for complete healthiness of components including gas tightness
check.
6.4 Whenever any air conditioner or water cooler is taken for any type of Maintenance
work for compressor/fan or other problems, gas leak check is to be conducted
without fail and “Gas leak & filling Record” is to be maintained.
6.5 All the Air Conditioners and Water coolers should be inspected once in three months
for observation of healthy functioning / maintaining normal grill temperature.
6.6 Whenever compressor failure occurs for any Air Conditioner or Water cooler the gas
leak test with N2 should be carried out at the time of replacement of compressor.
Further, the manufacturer’s recommendations are to be followed for maintenance
works.
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10. DEPARTMENT LEGAL AND OTHER REQUIREMENTS
Sl.
Statute Requirement Authority Frequency Responsibility
No.
01 Indian Storage of gas Cylinders Chief 10 Years Hydrogen Plant

Explosive Controller of
Valid up to In-charge
Act 1884(4 Explosives
30.09.2015
of 1884)
02 IE Act 1956 List of Authorized AGM(O&M) Yearly AGM(O&M)

Persons to operate and
maintain Electrical
Installations
03 CEA Inspection of CEA Two Year HOD(EM)

installations by CEA
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11. OBJECTIVES AND TARGETS
Target for Review

Sl.
Departmental objective Measure frequency &
no 2018-19 responsibility
1 Compliance to PM, Break % of SAP WOC 95 % in every Quarterly by

down and PDM job attended month.
HOD (EM)
schedules.
2 No loss of generation due Cumulative % of loss 0% Quarterly by

to breakdown of electrical of generation due to
HOD (EM)
equipment electrical equipment.
3 Zero tripping due electrical Cumulative no. of 0 Quarterly by

equipment. unit tripping due
HOD (EM)
electrical equipment.
4 Continual Improvement in No. of suggestions Minimum 30 Quarterly by

the process and systems. given.
HOD (EM)
5 Provide training to the Cumulative Training 300 Quarterly by

employees Man days
HOD (EM)
6 Providing training to No. of trainings/ 20 Quarterly by

internal customers to interaction meetings
HOD (EM)
enhance their knowledge with operation dept.
7 Reduction in Non-moving Reduction of NMI 5% of no. of Quarterly by

Items items items. 2% of
HOD (EM)
value.
8 Preventive, BD & OH maint. Compliance to 24X7 100% in every Quarterly by

Process safety points month
HOD (EM)
9 Preventive, BD & OH maint. Timely payment of 100% by 7th of Quarterly by

Process wages to contract every month
HOD (EM)
workmen
10 Preventive, BD & OH maint. Availability of ESP 100% Quarterly by

Process fields from EMD side availability
HOD (EM)
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PROCESS MEASURES REVIEW MATRIX
Effective Date: 01.04.2013

Review Status for Status for
Sl. Process Target for Source of
Process Title & Number Process Measures Frequency & Remarks
No. Owner 2016-2017 data Apr-17 May-17
Responsibility
Compliance to PM, Break down and % of SAP WOC 95 % in every ORT Data / Quarterly by 59.6% 52.12%
1 HOD
PDM job schedules. attended month. SAP HOD (EM) (649/1089) (910/1746)
Cumulative % of loss of 0% for

No loss of generation due to Quarterly by
2 HOD generation due to Financial Year ORT Data 0.01% 0.01%
breakdown of electrical equipment HOD (EM)
electrical equipment. 2016-17
Cumulative no. of unit
Zero tripping due electrical 0 for Financial Quarterly by
3 HOD tripping due electrical ORT Data 0 0
equipment. Year 16-17 HOD (EM)
equipment.
Minimum 30 TQM Site &
Continual Improvement in the No. of suggestions Quarterly by
4 HOD for Financial Record: 7 0
process and systems. given. HOD (EM)
Year 16-17 1801 / 11
300 for
Cumulative Training Quarterly by
5 Provide training to the employees HOD Financial Year 1801/ 214 51
Man days HOD (EM)
2016-17
Providing training to internal No. of interaction 20 for
Quarterly by
6 customers to enhance their HOD meetings with Financial Year 1801/ 3 0
HOD (EM)
knowledge operation dept. 16-17
5% of no. of 460.62 316.31
Quarterly by
7 Reduction in Non-moving Items HOD Reduction of NMI items items. 1801/ Lakhs 1720 Lakhs 1631
HOD (EM)
2% of value. No's No's
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Compliance to 24X7 100% in every Quarterly by

8 Preventive, BD & OH maint. Process HOD 85.00% 92.17%
safety points month HOD (EM)
Timely payment of
100% by 7th of Quarterly by
9 Preventive, BD & OH maint. Process HOD wages to contract 100.00% 100.00%
every month HOD (EM)
workmen
Availability of ESP 100% Quarterly by
10 Preventive, BD & OH maint. Process HOD HOD (EM) 100.00% 96.88%
fields from EMD side availability
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ACTION PLAN FOR ACHIEVING OBJECTIVE
ACTION PLAN FOR ACHIEVING OBJECTIVE-1 :
95% compliance to PM, Break down and PDM job schedules.

SN Activity Target date Responsibility Remarks
Taking PTW and executing the Continuous Area In charge

1 jobs as per the schedule Process
Completion of PTW WOC by Continuous Area In charge

2 filling relevant details as per Process
schedule
Co-ordination with MTP and Continuous Area In charge

3
Operation for issue of PTW Process
Review of Status Continuous HOD(EM)

4 Process
No loss of generation due to breakdown of electrical equipment

Following PDM & PM activity Continuous

1 Area In charge
schedule of equipments Process
Reviewing previous
As and when
2 occurrence of critical Area In charge
occurred
equipment trippings
As and when
3 Analyzing the root causes, HOD (EM)
occurred
4 Taking corrective / preventive As and when Area In charge
Page 78 of 125
NTPC –Simhadri
actions occurred
HOD (EM)
5 Review of Status Quarterly
Zero tripping due electrical equipment.

Reviewing tripping of NTPC As and when Sectional In charge

1 Simhadri and other plants & occurred
analyzing the root causes.
Taking corrective / preventive As and when Sectional In charge /

2 actions to avoid such tripping occurred HOD (EM)
at NTPC Simhadri.
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Continual Improvement in the process and systems.

Record the suggestions in on Continuous Individual employees

line suggestion scheme or Process of EM
1
make the proposal for
improvement.
Take the approval for Continuous Individual employees
2
modifications if required. Process of EM
Implement the approved Continuous Individual employees
3
modifications Process of EM
Review of Status Quarterly HOD(EM)
4
Provide training to the employees on various systems and equipment

Obtaining details of the training Continuous Dept Training

1 programmes from EDC & Process coordinator
outside.
Nominate the employees for the Continuous Dept Training

2 programmes and get the Process coordinator
approval of HOD(EM)
Send the approval to EDC for Continuous Dept Training

3
processing. Process coordinator
After approval of the Continuous Dept Training

nomination by competent Process coordinator
4
authority, intimate the individual
concerned.
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NTPC –Simhadri
Providing training to internal customers to enhance their knowledge

Obtaining details of the training Continuous HOD(EM)

needs of the operating Process
1
personnel from SCE or
HOD(OPN) .
Make the schedule for imparting Continuous HOD(EM)

2 the training. Process
Depute the concerned person Continuous HOD(EM)

3
for imparting the training. Process
Discuss with the operating Continuous Concerned engineer.

4
personnel and impart training Process
Interaction meeting with Continuous Concerned engineer.

5
operation general shift people Process
Reduction of Non Moving Items

Identify the list of NMI Continuous Sectional Heads(EM)

1
Analyse the reasons Continuous Sectional Heads(EM)

2 & HOD(EM)
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NTPC –Simhadri
Take necessary corrective and As and when Sectional Heads(EM)

3 preventive actions to reduce the required & HOD(EM)
NMI
Control the indents ( PRs) to As and when HOD(EM)

4
reduce the inventory required
5 Monitor the implementation Continuous HOD(EM)
ACTION PLAN FOR ACHIEVING OBJECTIVE- 8 :
Compliance to 24 X 7 CFST points

Monitor the 24X 7 CFST points of Continuous Sectional Heads(EM)

1 the CFST register maintained in & HOD(EM)
the o/o HOD (O&M)
Identify the points pertaining to Continuous Sectional Heads(EM)

2 the relevant section
Take necessary corrective and Continuous Sectional Heads(EM)

3 preventive actions to close the
points
4 Monitor the status Continuous HOD(EM)
ACTION PLAN FOR ACHIEVING OBJECTIVE-9:
Timely Payment of monthly wages to workmen by 7th of every month

Ensure that payments are being Monthly by Concerned E-I-C.

1 done to the workmen deployed 7th
by 7th of every month.
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NTPC –Simhadri
If any deviation is there , take Continuous Concerned E-I-C.

2 necessary corrective and
preventive action
If still problem is persisting and Continuous Concerned E-I-C/

3 payments were not done report Sectional head
to HOD (EM) , HOD(O&M)
Monitoring the status and Monthly HOD(EM)

4 sending the MIS report to HOP
and HOD(O&M)
ACTION PLAN FOR ACHIEVING OBJECTIVE-10:
100% Availability of ESP Fields from EMD side.

Monitor the status of ESP field’s Daily Area Engineer

1 availability.
If any field is not available due to Continuous Area Engineer

2 electrical problem , analyze the
cause
Take necessary corrective and Continuous Area Engineer

3 preventive action to make the
field available
4 Monitoring the status Continuous Area Engineer
Page 83 of 125
NTPC –Simhadri
12. HIRA (HAZARD IDENTIFICATION AND RISK ASSESSMENT)
Type of Harm Risk Assessment (before) Risk Assessment (after)

R/ Type of Injury/ Damage
Sl.No Work Activity Probabili Risk OCP Probabil Risk
NR Hazard Ill Loss to Severity Severity
ty Code ity Code
Health Property
1 2 3 4 5 6 7 8 9 10 11 12 13
Electric shock √ √ III B 9 OCP 01 III D 14
1. HT/LT Motor,
ILMS,SM – Flash Over &
Maint. √ √ II D 10 OCP 01 III D 14
Burns
2. HT/LT swgr, Dust √ IV B 16 IV C 18
EM-01 R
Panel Maint.
Lack of
3. Testing of training, Not
HT/LT swgr, OCP01,
following √ √ II B 5 III D 14
Equip & Cables. OCP02
instructions,
Improper tools
Flash Over &
√ √ II D 10 OCP01 III D 14
Transformer Burns
EM-02 NR
Maint.
Falling From
√ I D 8 OCP02 III D 14
heights
Page 84 of 125
NTPC –Simhadri
Lack of
training, Not
OCP01,
OCP02
instructions,
Improper tools
Fire and OCP01 ,
√ √ I D 8 II D 10
explosions OCP02
Electric shock √ III B 9 OCP01 III D 14
Falling From
Transformer Oil √ I D 8 OCP02 III D 14
EM-03 NR heights
Filtration
Lack of
training, Not
OCP01,
OCP02
instructions,
Improper tools
OCP 01,
Electric shock √ III B 9 III D 14
OCP 03
EM-04 R Lighting Maint. Flash Over &

√ √ II D 10 OCP 01 III D 14
Burns
Falling From
heights
Page 85 of 125
NTPC –Simhadri
Lack of
training, Not
OCP01,
OCP02
instructions,
Improper tools
Flash Over &
√ √ II D 10 OCP 01 III D 14
Burns
Maintenance Falling From
and Testing of √ I D 8 OCP02 III D 14
EM- 05 NR heights
switch yard. Lack of
Equipment training, Not
OCP01,
following √ II B 5 III D 14
OCP02
instructions,
Improper tools
Flash Over &
√ √ II D 10 OCP 01 III D 14
Burns
Hot line washing Falling From

EM- √ I D 8 OCP02 III D 14
NR of switch yard heights
06 Lack of
Equipment
training, Not
OCP01,
OCP02
instructions,
Improper tools
EM- 07 R Lift and Hoist Electric shock √ III B 9 OCP 01 III D 14
Page 86 of 125
NTPC –Simhadri
maintenance Falling From

heights
Lack of
training, Not
OCP01,
OCP02
instructions,
Improper tools
Flash Over &
√ √ II D 10 OCP 01 III D 14
Burns
Cable laying, Falling From

EM- √ I D 8 OCP02 III D 14
NR jointing and heights
08 Lack of
termination
training, Not
OCP01,
OCP02
instructions,
Improper tools
1.Injury due to
manual
handling of
Motor
EM- loads
NR replacement/ √ √ II D 10 OCP02 III D 14
09 2. fall of
overhauling
objects
3. Falling of
People
Page 87 of 125
NTPC –Simhadri
Lack of
training, Not
OCP01,
OCP02
instructions,
Improper tools
Fire and
√ √ I E 12 OCP 01 III E 17
explosions
1.Injury due to
manual
handling of
loads
Generator √ √ II D 10 OCP02 III D 14
EM- 10 NR 2. fall of
overhauling objects
3. Falling of
People
Lack of
training, Not
OCP01,
OCP02
instructions,
Improper tools
Flash Over &
√ √ II D 10 OCP 01 III D 14
Maintenance of Burns
EM-11 R
33 KV Lines
Falling From
heights
Page 88 of 125
NTPC –Simhadri
Lack of
training, Not
OCP01,
OCP02
instructions,
Improper tools
Tall Ladder / OCP 01 ,
Flash Over &
Tall objects / Tall √ √ II D 10 OCP02, III D 14
Burns
Vehicles shifting OCP 03
EM-12 NR at Railway Lack of
Crossing below training, Not
25 KV Traction OCP01,
OCP02
Line instructions,
Improper tools
Control Measures taken for Hazard types:
Sl. No. Type of Hazard Control Measure in Place

1. Permit to Work as per NTPC Safety Rules Handbook.
1 Electric shock 2. Clear Identification of equipment./Electrical Panels( On both sides wherever applicable) by
painting.
3. Confirmation of isolation ( for up and down streams wherever applicable by) PTW Holder
4. Provision of Earthing .
5. Proper training and work instructions.
2 Flash Over & Burns
6. Use of personal protective equipments.
7. Provision of Insulated mats for 0.4KV/11KV/33KV SWGR Panels.
3 Dust usage of Dust Mask is ensured.
Page 89 of 125
NTPC –Simhadri
Lack of training, Not following Hands on training is imparted to the workers by the area engineer in-charge.
4
instructions, Improper tools Continuous close supervision by the engineer in- charge during the execution of the job.
1.Use of personal protective equipments.

5 Falling From heights
2.Cleanliness of Transformer surfaces from traces of oil is ensured

6 Fire and explosions 2. Continuous close supervision by the area in- charge during the execution of the job.
3. Imparting proper training and sharing of knowledge about the work practices.

2. Clear Identification of equipment./Electrical Panels ( On both sides wherever
1. Injury due to manual applicable) by painting.
handling of loads 3. Confirmation of isolation ( for up and down streams wherever applicable by PTW
7
2. fall of objects Holder )
3. Falling of People 4. Provision of Earthing .(Local also )
5. Proper training and work instructions.
6. Use of personal protective equipments
RISK ASSESSMENT TABLE
Severity Category People Costs
Catastrophic I Death due to serious injuries or illnesses Plant outage > one week and/or losses > Rupees 100 crores
Page 90 of 125
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Disabling injury or severe occupational Facility outage upto one week and/or losses > Rupees 20
Critical II
illness crores but < Rupees 100 crores
Medical Aid Injury or minor occupational Facility outage upto 2 days and/or losses > Rupees 1 crore but
Marginal III
illness < Rupees 20 crores
Negligible IV Minor injury or illness (First Aid case) Facility outage upto 1 day and/or losses < Rupees 1 crore
Probability Level Frequency or Likelihood
Frequent A Likely to occur frequently or at least once per year or more frequently
Probable B Likely to occur several times in life of the system or at least once in 3 year period
Occasional C Likely to occur sometime in life of the system or once in 6 years period
Remote D Unlikely, but possible to occur in the life of the system or once in 15 years period
Improbable E Highly unlikely, but possible to occur in the lifecycle of the system or once in more than 15 years period.
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NTPC –Simhadri
RISK CODES:
PROBABILITY SEVERITY
I II III IV
CATASTROPHIC CRITICAL MARGINAL NEGLIGIBLE
FREQUENT A 1 3 7 13
PROBABLE B 2 5 9 16
OCCASSIONAL C 4 6 11 18
REMOTE D 8 10 14 19
IMPROBABLE E 12 15 17 20
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NTPC –Simhadri
OH&S OBJECTIVES
Objective no. : EM/OBJECTIVE -01
Reference No (From the Risk EM01, EM02, EM05, EM07, EM09, EM10 & EM11
Assessment worksheet).
Department(s)/Section(s) Electrical Maintenance
Work Activity (ies) Flashover/Electric Shock
Overall Risk Code 14 to 14
(As shown on the Risk Assessment Worksheet)
Legal Requirements, if any
 Indian electricity Rules 1956,
 S 36-A ( Chapter IV) of The Factories Act,
1948
 Corporate guidelines
Define external interested parties Contractors
Define controls Work instructions / PTW /control measures
Description of Objective Imparting OHSAS awareness-cum-Refresher
training to Newcomers to the Dept.
Objective No. : EM/OBJECTIVE -02
Reference No. (From the Risk EM01 to EM13

Assessment Worksheet)
Department(s)/Section(s) Electrical maintenance
Work Activity (ies) Risk of Electric Shock/ flashover while
carrying out electrical maintenance jobs etc
Overall Risk Code 10 to 16
Legal Requirements, if any
 Indian Electricity Rules 1956
 S 36-A ( Chapter IV) of The Factories Act,
1948
 Corporate guidelines
Define external interested parties Contractors
Define controls Work instructions / PTW /control measures
Description of objective Capturing of all incidents from the Dept.
Page 93 of 125
NTPC –Simhadri
Objective No. : EM/OBJECTIVE -03
Reference No. (From the Risk All

Assessment Worksheet)
Department(s)/Section(s) Electrical maintenance
Work Activity (ies) Implementation of PPEs during work
Overall Risk Code 15
Legal Requirements, if any Nil
Define external interested parties Nil
Define controls Training and Awareness
Description of objective Human tendency is to avoid use of PPEs. By giving
training and awareness during pep talks their
behaviour will be changed.
Page 94 of 125
NTPC –Simhadri
OH&S MANAGEMENT PROGRAMME (OH&S MP)
OH&S EM: MP : 01
Target: Imparting OHSAS awareness-cum-Refresher training to Newcomers to the Dept.
Sl Time of Performance Resources

Activities Responsibility Implementation Status
No completion Indicators Required
As and when
Informing TQM Dept. about joining of
1 HOD (EM) New comer Being followed
newcomer to Dept
joins
Imparting training as per the TQM
2 HOD (EM) As necessary Being followed
Schedule
OH&S EM: MP : 02
Target: Capturing of all incidents from the Dept.

Informing Dept and Contract Staff
Every Monday
1 about giving information of ‘incidents’ HOD(EM) Being followed
in Pep Talk
as and when it occurs
Page 95 of 125
NTPC –Simhadri
Capturing of all incidents with complete As and when it

2 HOD(EM) Being followed
analysis and remedial action occurs
OH&S EM: MP : 03
Target: Implementation of PPEs during work

List out all the PPEs to be used by
1 workforce while carrying out different Area InCharge Monthly Being followed
maintenance activities.
Find out the persons not using PPEs in
2 Area InCharge Monthly Being followed
Work Place
Find out the root cause for reasons for Respective
3 Daily Being followed
not using PPEs Section Incharges
4 Take Corrective Actions HOD Monthly Being followed
Page 96 of 125
NTPC –Simhadri
CRITICAL TASK ANALYSIS
DEPT : O & M - EM SECTION : ELECTRICAL MAINTENANCE
Area : TOTAL PLANT AREA RISK ASSESSMENT WORKSHEET Ref. No. EM- 07
RISK CODE : 11
Work Activity : Lift & Hoist Maintenance
Activity and Tasks performed :
Sl
Tasks Performed P S F T =P x Sx F
No
1. Permit to work as per NTPC Safety Rules hand book 1 1 2 2
2 Clear Identification of equipment./Electrical Panels( On both 1 1 2 2

sides wherever applicable) by painting.
3 Use of personal protective equipments. 1 4 2 8
4 Use of Insulated Tools is ensured. 1 4 2 8
CRITICAL TASK : Tasks 3 & 4 are critical
LEGEND :
P Probability of failure to comply with laid down controls/procedures
S Severity
F Frequency of operation of the task
T Total = P x S x F
Sl Task Observation/
Critical Task Responsibility
No Review Frequency
1 Use of personal protective equipments Section In-

Once in a year
2 Use of Insulated Tools is ensured. charge
Page 97 of 125
NTPC –Simhadri

RISK CODE : 11
Work Activity : Cable laying, jointing and termination
Sl T=
Tasks Performed P S F
No PxSxF
2 Clear Identification of equipment./Electrical Panels( On both sides 1 4 1

4
wherever applicable) by painting.
3 Confirmation of isolation ( for up and down streams wherever 1 4 1

4
applicable by PTW Holder )
5 Use of Insulated Tools is ensured. 1 4 1 4
CRITICAL TASK : Nil
LEGEND :
S Severity
T Total = P x S x F
No Review Frequency
Page 98 of 125
NTPC –Simhadri

RISK CODE : 12
Work Activity : Generator Overhauling
Sl T=
No PxSxF
2 Confirmation of isolation ( for up and down streams 1 4 1

4
wherever applicable by PTW Holder )
3 Provision of Earthing 1 4 1 4
4 Purging out H2 gas from Generator casing as per Generator 1 4 1 4

O&M Manual
CRITICAL TASK : Nil
LEGEND :
S Severity
T Total = P x S x F
No Review Frequency
Page 99 of 125
NTPC –Simhadri

RISK CODE : 10
Work Activity : Maintenance of 33 KV Lines
Activity and Tasks performed by :
Sl T=
No PxSxF
2 Clear Identification of equipment./Electrical Panels( On both 1 4 2 8

sides wherever applicable) by painting.
3 Confirmation of isolation ( for up and down streams wherever 1 4 2 8

applicable by PTW Holder )
4 Provision of Earthing. 1 4 2 8
CRITICAL TASK : All above tasks are critical
LEGEND :
S Severity
T Total = P x S x F
No Review Frequency
1 Permit to work as per NTPC Safety Rules hand book
2 Clear Identification of equipment./Electrical Panels( On

both sides wherever applicable) by painting.
Section In-
3 Confirmation of isolation ( for up and down streams Once in a year
charge
wherever applicable by PTW Holder )
4 Provision of Earthing
5 Use of personal protective equipments
Page 100 of 125

NTPC –Simhadri

RISK CODE : 12
Work Activity : Hot-line washing of Switchyard Equipment
Activity and Tasks performed by:
Sl T=
No PxSxF
1 To ensure that the conductivity of the DM water that will be used for 1 4 2 8
hot line washing, to be less than 1 micro mho
2 To ensure that the warning system for the leakage current > 1 milli 1 4 2 8
amp is working properly
LEGEND :
S Severity
T Total = P x S x F
No Review Frequency
1 To ensure that the conductivity of the DM water that

will be used for hot line washing, to be less than 1 micro
mho Section In-
Every occasion
charge
2 To ensure that the warning system for the leakage
current > 1 milli amp is working properly
Page 101 of 125

NTPC –Simhadri

RISK CODE : 12
Work Activity : Tall Ladder / Tall objects / Tall Vehicles shifting at Railway Crossing below 25 KV
Traction Line
Activity and Tasks performed by:
Sl T=
No PxSxF
1 Shifting the Tall Ladder/ objective / Vehicle in the presence of 1 4 2 8

NTPC Executive / Supervisor
2 Availability of Track Barricade at Railway Crossings on both sides 1 4 4 16

indicating the the max height of the crossing item
3 Provision of "DANGER -HIGH VOLTAGE (25,000 VOLTS)" Board on 1 4 4 16

Track Barricades on both sides of the Track
4 Provision of Caution Board: " NOT TO CROSS THE RAILWAY TRACK 1 4 4 16

WITH TALL OBJECTS/VEHICLES/ETC" on both sides of the track
5 Crossing the tall ladder / tall object in horizontal position. 1 4 2 8
LEGEND :
S Severity
T Total = P x S x F
No Review Frequency
1 Shifting the Tall Ladder/ objective / Vehicle in the

presence of NTPC Executive / Supervisor Section In-
Once in six months
2 Availability of Track Barricade at Railway Crossings on both charge
sides indicating the the max height of the crossing item
Page 102 of 125

NTPC –Simhadri
3 Provision of "DANGER -HIGH VOLTAGE (25,000 VOLTS)"

Board on Track Barricades on both sides of the Track
4 Provision of Caution Board: " NOT TO CROSS THE

RAILWAY TRACK WITH TALL OBJECTS/VEHICLES/ETC" on
both sides of the track
5 Crossing the tall ladder / tall object in horizontal position.
Page 103 of 125

NTPC –Simhadri
OCP (OPERATIONAL CONTROL PROCEDURE)
OCP-01: SAFE PRACTICES WHILE CARRYING OUT MAINTENANCE

TO REDUCE THE RISK OF FLASHOVER
1. Purpose: To reduce the risk of flashover and/or burns while carrying out
Maintenance activities on electrical equipment.
2. Scope: Electrical Maintenance Activities on

(a) HT/LT motors, ILMS and SM; HT/LT Switchgear, Electrical Panels and cables
(b) Transformers including oil filtration
(c) Lighting Equipment
(d) Switchyard Equipment including hotline washing
2. Responsibility: H.O.S. (O&M/EM)
3. Performance Criteria: No flashover and/or burns while carrying out maintenance

of Electrical Equipment.
4. Cross Reference:
(a) NTPC Safety Rules Hand-book (E&M)
(b) Risk Assessment Work-sheets (EM)
8. Activities:
Sl.
Activity Responsibility
No
Area Maint.
1. To ensure proper PTW system is followed
Engineer
To ensure that proper isolation of power supply for the

2. Operation Engineer
concerned equipment has been done.
To conform isolation of the equipment(for up and down Area Maint.

3. streams wherever applicable) by PTW Holder Engineer
To ensure proper earthing of the equipment before start of Area Maint.

4. the work, wherever necessary Engineer
5. To ensure that work is carried out as per NTPC Safety Rules Area Maint.
Page 104 of 125

NTPC –Simhadri
Engineer
Area Maint.
6. To ensure that proper work instructions are followed. Engineer
Area Maint.
7. To ensure that proper tools and testing equipment are used
Engineer
To ensure that proper personal protective equipment are Area Maint.

8. used Engineer
6. Verification, Corrective & Preventive Actions:

Section In-charge shall conduct site visits and check for deviations from laid down
procedures.
7. Records:
Records of PTW & details of work carried out on on-line SAP system.
Records of Site visit /inspection.
Page 105 of 125

NTPC –Simhadri
OCP-02: SAFE PRACTICES TO REDUCE THE RISK OF FALLING

FROM HEIGHTS DURING MAINTENANCE
1. Purpose: To reduce the risk of falling from heights while carrying out
Maintenance activities on electrical equipment.
2. Scope: Electrical Maintenance Activities on

o Lighting Equipment
o Transformers including oil filtration
o Switchyard Equipment including hotline washing
o Lifts and Hoists
4. Performance Criteria: No instances of falling from height while carrying out

maintenance of Electrical Equipment.
5. Cross Reference:
o NTPC Safety Rules Hand-book (E&M)
o Risk Assessment Work-sheets (EM)
6. Activities:
Sl.
Activity Responsibility
No.
1 To ensure proper PTW system is followed Area Maint. Engineer
To ensure that proper isolation of power supply for the

2 Operation Engineer
concerned equipment has been done.
To conform isolation of the equipment(for up and down

3 Area Maint. Engineer
streams wherever applicable) by PTW Holder
To ensure proper earthing of the equipment before start

of the work, wherever necessary
To ensure that work is carried out as per NTPC Safety

Rules
6 To ensure that proper work instructions are followed. Area Maint. Engineer
To ensure that proper tools and testing equipment are

used
Page 106 of 125

NTPC –Simhadri
To ensure that proper personal protective equipment (

8 safety belt, lifeline, rubber hand gloves, electrical safety Area Maint. Engineer
shoes, helmet) are used
To ensure that insulated tools are used wherever

necessary
To ensure proper scaffolding including access

arrangement is provided wherever necessary

procedures.
7. Records:
o Records of PTW & details of work carried out on on-line SAP system.
o Records of Site visit /inspection.
Page 107 of 125

NTPC –Simhadri
OCP-03: SAFE PRACTICES TO REDUCE THE RISK OF FLASHOVER /

SEVERE INJURY WHILE CROSSING TALL LADDER /
OBJECTS AT RAILWAY CROSSING BELOW 25KV TRACTION
LINE
1. Purpose: To reduce the risk of flashover / severe injury while crossing tall ladder /
objects at railway crossing below 25 KV traction line.
2. Scope: Various Electrical Maintenance Activities in different areas of the plant
4. Performance Criteria: No instances of flashover / severe injury while crossing tall

ladder / objectives at railway crossing below 25 KV traction line .
5. Cross Reference:
(a) NTPC Safety Rules Hand-book (E&M)
(b) Risk Assessment Work-sheets (EM)
6. Activities:
Sl.
No Activity Responsibility
.
To ensure that the ladder / tall objective is shifted in the Area Maint.
1. presence of NTPC Executive / Supervisor Engineer
To ensure that the tall ladder / objective is shifted in Area Maint.

2. horizontal position. Engineer
To ensure that “DANGER /25 KV TRACTION” board is Area Maint.

3. displayed at the crossing on both sides. Engineer
To ensure that a caution board “TALL OBJECTS SHOULD NOT Area Maint.
4. BE CROSSED”–is provided at all crossings on both sides Engineer
Area Maint.
5. To ensure that work is carried out as per NTPC Safety Rules
Engineer
Page 108 of 125

NTPC –Simhadri
To ensure that proper personal protective equipment are Area Maint.

6. used Engineer

procedures.
8. Records:
Records of PTW & details of work carried out on on-line SAP system.
Records of Site visit /inspection.
Page 109 of 125

NTPC –Simhadri
OCP-04: FOR SAFE PRACTICES WHILE ALKALI HANDLING
1. PURPOSE: To reduce the risk of injury during loading, hazard due to leakage while
filling when the H2 Plant is in operation.
2. SCOPE: Can minimize the chances of injury while loading & leakage of Hydrogen
3. RESPONSIBILITIES: Engineer-in-Charge
4. PERFORMANCE CRITERIA: Reduction in injuries while hydrogen plant is in

operation & while loading and unloading cylinders.
5. CROSS REFERENCE:
1. NTPC safety rules Handbook
2. LMI
3. Risk assessment worksheets
6. ACTIVITY:
S.No Activity Responsibility
1 Ensure the availability of H2 leak detector in Operator

manifold room.
2 Ensure the Availability of PPE such as Safety Operator

shoe.(electrical)
3 Ensure the availability / usage of non sparking Operator

tools as earmarked for h2plant
4 Ensure all the filled cylinders are fitted with cap. Operator
5 Ensure the proper positioning & healthiness of Operator

trolley.
6 Ensure Sufficient space is available & marked for Operator

filled cylinders
7 Ensure the filled cylinders are chained Operator
8 Ensure the healthiness of portable leak detector. Operator
Page 110 of 125

NTPC –Simhadri
9 Ensure the availability of fire fighting protection Operator

System.
10 Ensure that the empty cylinders are placed in the Operator

area identified.
7. VERIFICATION, CORRECTIVE & PREVENTIVE ACTIONS:

Engineer-in-charge shall conduct site visits and check for deviations from laid down
procedures.
Safety officer shall conduct fortnightly inspections.
8. RECORDS:
Records of PTW on online SAP.
Report of fortnightly inspections by safety officer with safety department.
Page 111 of 125

NTPC –Simhadri
13. ENVIRONMENT ASPECTS AND IMPACTS AND LIFE CYCLE PROSPECTIVE CONCERN
Reference: ISO 14001
Sl. N/ Rating
D/I F+ Significance
No Activity Aspect A/ Impact Applicable LOR Remark
D L R F EI P T EI (YES/NO)
. E
Ground
Transformer Oil spillage, Contaminati HWM Sec Work instruction
01 oil filtration & A D on, 5 1 1 1 1 9 2 5,6,7,9,10,20 Yes is prepared.
Waste oil
use generation Water (4) (EMD/WI/037)
Pollution
Ground
400 kV Contaminati
Breaker Failure of on, HWM Sec
02 Hydraulic seals and oil A D 0 1 1 1 1 4 2 5,6,7,9,10,20(4 No
Health
operating leakages )
Hazard
machine
400 kV
Breaker SF6
03 Gas leakage A D Air Pollution 0 1 1 1 1 4 2 No
gas for arc
quenching
Page 112 of 125

NTPC –Simhadri
Ground E’ waste
Lighting
04 Fused lamps N D Contaminati 0 1 3 1 1 11 4 management No
maintenance
on rule
Cleaning Air Pollution,

Usage of
electrical N D Health 0 3 3 1 1 8 4 No
05 solvents
equipment Hazard
Generation of
Maintenance Cotton Ground
HWM Sec
06 of electrical waste, waste N D Contaminati 0 1 3 1 1 6 4 No
6,7,10,20(4)
equipment oil, soldering on
waste
Yes Work instruction

Maintenance Leakage of
07 N D Air Pollution 5 1 1 1 3 11 2 ODS is prepared.
of Window A/C CFC
(EMD/WI/038)
Disposal of Ground E’ waste Work instruction

Ni-Cd batteries
08 damaged A D Contaminati 5 1 1 1 1 9 2 management Yes EMD/WI/034 is
usage
cells on rule prepared
Generation of
Ground
Actuator Cotton HWM Sec
09 E D Contaminati 0 1 1 1 1 4 2 No
maintenance waste, waste 6,7,10,20(4)
on
oil
Page 113 of 125

NTPC –Simhadri
Ground
Generation of Contaminati
Switchgear on,
10 scrap, like E D 0 1 1 1 1 4 2 No
maintenance
fuses Health
hazard
Water
Acid spillage , Pollution, Batteries
Maintenance Yes Work instruction
Generation of
11 of Lead Acid A D Ground 5 1 1 1 1 9 2 Mgmt rules (EMD/WI/036) is
Used
batteries Contaminati 2001, sec 10.1 prepared.
batteries
on
12 DG Set 1. Noise A D Noise 0 1 3 1 1 11 4 HWM Sec NO

Running Pollution 5,6,7,9,10,20(4
)
2. Exhaust N D Air Pollution 0 1 2 1 1 6 3
3. Leakage of A D Water 0 1 1 1 1 5 2
Oil Pollution
N : Normal, A : Abnormal (startup/shutdown/process disturbance), E : Emergency

L : LEGAL / REGULATORY REQUIREMENT :
0= There is no legal requirement, 5= There is a legal requirement
Page 114 of 125

NTPC –Simhadri
R : RISK – POTENTIAL RISK TO EMPLOYEES AND/OR NEIGHBOUR POPULATION

1=Low risk (No. effect on health/limbs) 3=Intermediate risk (Health hazard) 5=High risk (Fatal to human life)
F : ENVIRONMENTAL IMPACT FREQUENCY
1 : Low (once in an year or more) 3 : Intermediate (once in a month or more) 5 : High (once in a day or more)
EI :ENVIRONMENTAL IMPACT (IMPACT ACCORDING TO THE IMPROTANCE
1 : Low (No loss to human/property/environment) 3 : Intermediate (Temporary effect on human life/property/environment)
5 : High (Fatal to human life/Damage to property/environment)
P : PUBLIC PERCEPTION (IMPORTANCE OF THE ENVIRONMENTAL IMPACT IN TERMS OF PUBLIC PERCEPTION
1 : Low perception (No public concern) 3 : Intermediate perception (concern to employees)
5 : High perception (concern to neighbour population)
CRITERIA FOR DETERMINING SIGNIFICANCE OF THE ASPECT :
Aspect where the sum of the value is > or = 15

Aspect where F+EI > 6. 3. Aspect where P or L = 5
Page 115 of 125

NTPC –Simhadri
14. INTERNAL AND EXTERNAL ISSUES W.R.T QUALITY AND ENVIRONMENT
S.No Issue QMS/EMS Impact Mitigation Internal/External Responsibility Remarks

1. Not complying EMS Business impact Monitoring the Internal/External HOD
the Legal and compliance as per
statutory the desired
obligations schedules
2. 33KV OH Lines EMS Public grievance New towers have Internal/External HOD
Low height in been planned in
the village road crossings
with increased
corridors
height
3. Dust QMS/EMS Business impact due to Availability of Internal/External HOD
suppression regular monitoring by Electrical
system in ash Pollution Control Boards Equipment
dyke and public grievance /systems related
to Water
Sprinkling System
Page 116 of 125

NTPC –Simhadri
15. NEEDS AND EXPECTATIONS OF INTERESTED PARTIES W.R.T QUALITY AND ENVIRONMENT
Type of
Sl Interested Needs and
interested party Responsibility EMS/QMS Risk Level , Action to Mitigate the Risk
NO Parties Expectation
Internal/External
Compliance to IEGC High Risk – Violation of Rules and Codes

Grid Codes and will attract penalties and may jeopardize
Reports as per
SRLDC/SRPC the Stability of grid.
1 External HOD formats provided by QMS
parties Action: Strict compliance is ensured by
adopting adherence to schedules, reports
and safe operating procedures.
External HOD QMS

CEA Compliance to High Risk – Violation of Rules may attract
Electricity Act cancellation of Electrical License and may
2 Guidelines and lead to stoppage of Electrical Apparatus
procedures and
Action: Strict Compliance is ensured with
Statutory payments
timely audits by agency.
Power Utilities External HOD Maintaining Cordial QMS Low Risk: May not extend help during
3
in the Vicinity Relations and
Page 117 of 125

NTPC –Simhadri
viz. exchange of Views requirement

APTRANSCO, and sharing of expert
Action: Relations being maintained.
PGCIL, HNPC services and tools if
required
Internal HOD QMS

Employees Providing Reliable and Medium Risk- May reduce service
Quality Utility Power satisfaction level of customers
4 at Township and Plant
Action: Prompt response and feed back
premises
system is in place
External HOD QMS

Contracting Ensuring Timely Medium Risk-Contract workers may
Agencies payment to agitate for non compliance and lead to
Agencies/Contract productivity loss.
5 workmen and
Action: Ensured timely payments through
creating conducive
Online billing and Information system ,
work environment
various facilities are being extended.
Page 118 of 125

NTPC –Simhadri
16. RISK AND OPPORTUNITIES W.R.T QUALITY AND ENVIRONMENT
Effect on Quality Risk Mitigation

Action Opportunities
Key Expected Objectives/ measures
Uncertainty Risk Plan for &
Activity Result Performance Indicators (Existing /
Controls Action Plan
(Low/Medium/High) New Controls)
PM/BD Shutdown Wrong Electrocutio High SWP,JSA and OCP

of Motive Isolation n checklists
Power
Safe AMC with OEM
Working People may periodical load
Lifts/Hoists Stoppage High OCP
and Struck inside testing and joint
availability inspection
Due to Low Replacement
Regular checking
Illumination of
Area Proper Low of Illumination
may pose High OCP Conventional
Illumination Illumination Illumination levels and
hazard fittings with
regular PM jobs
LED
Maintenanc Compliance Low Outage of Strict Review of PM
High OCP
e of to PM reliability Equipment Compliance to Indices
Page 119 of 125

NTPC –Simhadri
equipment schedules PM schedules
Page 120 of 125

NTPC –Simhadri
17. LIST OF FORMS
Sl. Revision No. &

Format/Form title Format/Form No.
No. Effective date
01 Recording of various parameters of EMD/FORM/001 01/02/2018

Generator
02 Transducers Calibration EMD/FORM/009 01/02/2018
03 Check list for transformer 48weekly PM EMD/FORM/014 01/02/2018
04 Check list for UAT 48weekly PM EMD/FORM/014A 01/02/2018
05 TRANSFORMER OIL SAMPLING FOR EMD/FORM/016 01/02/2018

DETAILED ANALYSIS
06 Lye replacement EMD/FORM/018 01/02/2018
07 Over Hauling of LT MCC EMD/FORM/020 01/02/2018
08 Preventive Maintenance of LT Motor EMD/FORM/021 01/02/2018
09 Cathodic Protection Checking EMD/FORM/023 01/02/2018
10 Calibration of Energy Meters EMD/FORM/024 01/02/2018
11 Computed Energy EMD/FORM/025 01/02/2018
12 Joint Monthly Report (JMR) for energy sent outEMD/FORM/028 01/02/2018
13 Thermo vision Scanning Report EMD/FORM/029 01/02/2018
14 Hydrogen leakage check list(daily) EMD/FORM/030 01/02/2018
15 Hydrogen compressor maintenance check EMD/FORM/031 01/02/2018
list
Page 121 of 125

NTPC –Simhadri
18. LIST OF RECORDS
Sl. Location of
Drawing No. Description of drawing
No. Storage
01 35620060357 Generator Relay Panel Electrical Lab
02 36590050612 Electrical Control Panel -2 Electrical Lab
03 36590050610 Electrical Control Panel -1 Electrical Lab
04 35620060299 Line Protection Control Schematic Switchyard
05 400 KV Bus bar protection Schematic Switchyard
06 Stage-2 Lines protection and control Switchyard

Schematic
07 Stage-2 GRP Schemes Electrical Lab
08 Stage-2 HT switchgear Drawings HT group
Page 122 of 125

NTPC –Simhadri
19. LIST OF EXTERNAL DOCUMENTS

(OEM/OES Manuals)
Sl. Location of
Equipment OEM/OES Document Description
No. Storage
01 Transformer BHEL 200MVA, 420/21KV, 1Phase, 50Hz Electrical

OFAF cooled Generator laboratory
Transformer. Volume-I
02 Transformer BHEL 50MVA, 420/11.5KV, 3Phase, 50Hz Electrical

ONAN/ONAF cooled Standby laboratory
Transformer, Volume-I
03 Transformer BHEL 50MVA, 420/11.5KV, 3Phase, 50Hz Electrical

ONAN/ONAF cooled Unit Auxiliary laboratory
Transformer, Volume-I
04 Transformer BHEL Instruction manual for Power Electrical

Transformers 16MVA,34.5/11KV, laboratory
Volume-I

Transformers 16MVA,34.5/11KV, laboratory
Volume-II

Transformers 16MVA, 11/3.5KV, laboratory
Volume-I

Transformers 16MVA, 11/3.5KV, laboratory
Volume-II

Transformers 7.5MVA,33/11.5KV, laboratory
Volume-I

Transformers 7.5MVA,33/11.5KV, laboratory
Volume-II
Page 123 of 125

NTPC –Simhadri

Transformers 7.5MVA, 11/3.5KV, laboratory
Volume-I

Transformers 7.5MVA, 11/3.5KV, laboratory
Volume-I

transformers & reactors laboratory
13 Transformer BHEL Instruction Manual for Cast resin Electrical

Dry Type LT indoor Auxiliary laboratory
transformer
14 Transformer CGL Operation, Erection, Electrical

Maintenance(Servicing) Manual for laboratory
CGL Make Transformer
15 Transformer CGL O&M manual for oil filled LT CGL Electrical

make service Transformers laboratory
16 Transformer Bharat Installation, Commissioning and Electrical

Bijlee Maintenance manual for Bharat laboratory
Limited Bijlee limited
17 Relay Alstom Alstom relay manual Electrical

laboratory
18 Relay ABB Manual for ABB make PPX-111 Low Electrical

forward power relay laboratory
19 Relay ABB Manual for ABB make RAGUA relay Electrical

laboratory
20 Relay Siemens Numerical M/C protection Relay Electrical

manual- 7UM515- Siemens laboratory
21 GRP Panel SEMS SEMS Energy meter Manual Electrical

laboratory
22 Disturbance Hathaway Hathaway Disturbance recorder Electrical

Recorder Manual laboratory
Page 124 of 125

NTPC –Simhadri
23 LT Swgr C&S Ltd C&S make Operation & LT Swgr.

maintenance manual for power Almira
control centre & Motor Control
Centre
24 LT Swgr C&S Ltd C&S Instruction manual for Air LT Swgr.

circuit breaker Almira
25 Energy meter ZERA ZERA manual for Energy meter Switchyard

calibration kit
26 ESP BHEL Rectiformer Manual Switchyard
27 Current BHEL CT manual Switchyard

Transformer
28 Capacitive BHEL CVT manual Switchyard

Voltage
Transformer
29 Lightning arrestor WS LA Manual Switchyard
30 Busbar protection Alstom Alstom relay manual for Busbar Switchyard

protection
31 HT Swgr BHEL Instruction Manual for HT Switchyard

Switchgear
32 HT Motor BHEL HT Motor Manual Switchyard
33 Compressor Fluitron Hydrogen Plant compressor Manual Hydrogen

Plant
34 REL 670 ABB O&M manual Switchyard
35 REB 670 ABB O&M manual Switchyard
36 CGL 400KV CGL O&M manual Switchyard

BREAKER
37 400KV CT CGL O&M manual Switchyard
38 VFD BHEL O&M manual VFD ROOM
--*--*--
Page 125 of 125

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A Maharatna Company

SIMHADRI SUPER THERMAL POWER STATION

Integrated Management System Manual

Document No: NTPC/SIM/IMS/EMD/01

Prepared by Shri.M.Nageswara Rao

Approved by Shri. C. Malakondaiah HOD (EMD)

Abbreviation Full form

NTPC NTPC Limited

BAPCON BHEL Advanced Precipitator Controller

2. LIST OF CONTROLLED COPY HOLDERS

1. MR/AMR Electrical Intranet site

4. ABOUT THE DEPARTMENT OR DEPARTMENT FUNCTIONS

Electrical Maintenance Department is to maintain highest levels of availability of

6. ROLES AND RESPONSIBILITIES W.R.T QUALITY, ENVIRONMENT AND

Sr. Job Title Responsibilities Authorities Reports to. Remarks

1. HOD (EM) Overall responsibilities of As per DOP HOD (O&M)

2. AGM(EM) -1 Responsible for maintenance -Do- HOD(EM)

3. AGM(EM) -2 Responsible for maintenance -Do- HOD(EM)

4. AGM(EM) -3 Responsible for maintenance -Do- AGM(EM) -1

5. DGM/Area Responsible for maintenance -Do- Respective

8. DEPARTMENT PROCEDURES/ PROCESSES FLOW CHARTS

Sl. Document (Procedure/Process/WI) Document ISO 9001/ ISO 14001

01 Departmental System Procedure for EMD/PR/01 6.3 of 9001

02 Preventive Maintenance EMD/PC/01 6.3 of 9001

To describe the procedure for carrying out maintenance of electrical equipments

The procedure covers maintenance activities of the major electrical equipments of

6.1 Work Instructions as per the list enclosed.

6.2 LMI as per the list enclosed.

6.3 Manufacturers O&M Manuals as per list enclosed.

Sl. No Description Responsibility

1. Overall responsibility HOD (EM)

2. Assisting HOD (EM) Sectional Heads

3. In Case of Absence of HOD (EM) Authorized representative of

5. Planning and indenting of spares, Section in charge

As per the list enclosed.

Four types of maintenance jobs are carried out in Electrical maintenance

ii. Condition based maintenance

iii. Defect/breakdown maintenance.

6.1.1 Preventive maintenance

6.1.2 Condition based/Predicative maintenance:

6.1.3 Defect/Breakdown Maintenance:

Defects/breakdowns are reported by operation / user departments by

i. Daily planning meeting notes.

ii. Over phone/log book records.

iii. Work order cards raised in “SAP”.

iv. Defects of emergent nature are taken up immediately and others

Overhauling of major / critical auxiliaries like Generator, GCB, Transformer,

6.2 Electrical Laboratory:

Protective relay testing, 400KV outgoing line energy meter calibration(Used

6.2.1 Relay testing:

operation department through “SAP” system to monitor the equipment

6.2.2 Energy meter Calibration:

6.2.3 Error checking of meters:

Error checking of meters & transducers for generator related parameters in

6.2.4 Internal calibration of Meters:

6.2.5 External Calibration of meters.

Sub-standard meters are sent to national accredited laboratories for

6.3 Maintenance resource planning:

6.3.1 Procurement of spares and consumables:

i. Planning of spares and consumables required.

ii. Raising purchase requisitions in SAP.

iii. Technical evaluation of offers furnished by parties/vendors.