Action Taken Report Against APC Reduction Gu

OPERATION PRACTICE
Sl. No. Guideline
1 Optimization of number of running CW pumps in case of reduced load condition.
2 Optimization of mill operation.
3 For drum level control, the Feed Control Station dp to be maintained as minimum as possible.
4 Re-circulation flow of BFP & CEP to be monitored.
5 Boilers should be operated in optimum excess air to reduce draft fans loading.
6 Number of running CT fans used to be reduced in winter season.
7 Ash water ratio to be reduced.
8 IGV of ID Fan to be kept in Wide Open to avoid Throttling Loss.
9 Optimization of Fuel Air Ratio and Excess Air.
10 Feed Control Station DP to be maintained for reduction of BFP loading.
11 Optimization of CT fan running hours - depending on condenser Vacuum.
12 Regular running of the OLTC & Debris filter.
MAINTENANCE PRACTICE
BOILER
Sl. No. Guideline
1 Boiler Manhole & Peephole heat loss reduced by applying heat resistant refractory liner.
2 APH Seal setting to be checked in every opportunity.
3 Regular checking of the Compressed Air line Leakage if any and to be attended accordingly.
TURBINE & AUXILIARIES
Sl. No. Guideline
1 Polymer Coating (Corro-Coating) in CW Pumps, Intake Pumps & Makeup Pumps
BFP cartridge replacement on the basis of energy consumption. Rate contract for 2 years for this job should
2 be done.

3 Energy efficient CT fan to be used.

BALANCE OF PLANT
Sl. No. Guideline
1 Slurry System Running Hours should be reduced
2 Intake Pump running hrs to be reduced
3 Idle running of Conveyor belt to be reduced. Belt Utilization factor to be monitored regularly
ELECTRICAL SYSTEM
Sl. No. Guideline

1 CVT of Higher accuracy class to be installed. From CVT JB to relay panel voltage drop to be monitored
periodically.
Higher Burden Instrument (i.e. MW, MVAR, MWH Meter) etc to be replaced by Multifunctional Digital Low
2
Burden Meter.
3 Conventional lamps to be replaced by Energy savings LED lamps along with installation of auto timer.
4 All new procurement of motors should be of Energy Efficient.
5 MVAR management should be done in proper manner.
INSTRUMENTATION
Sl. No. Guideline
1 Maximum Control loop in Auto.
 BEST PRACTICES
Sl. No. Guideline
1 Efficient Operation of Compressed Air Systems.
2 Air and Flue Gas leakage to be monitored on regular basis and corrective action to be taken in earliest
opportunity.
3 Boiler Insulation checking to be done by Thermo Vision Camera before & after OH.
4 Conducting Energy Audit by other body or agency.
5 All Central AC & Split AC machines should be switched off working hours.
6 Regular Checking of the Passing of BFP & CEP Recirculation valves and rectification if any.
7 High Energy drain point: Energy Audit in regular basis & Rectification work during opportunity.
8 Healthiness of insulation should be checked periodically.
9 Voltage reduction of all lighting Transformers by Tap changing.
10 Establishing Intermittent charging mode instead of continuous charging mode at ESP Fields.
11 Use of Screw Compressor instead of Reciprocating Compressors in central AC system.
12 Replacement of old AC machines with new Energy Efficient BEE star rating AC machines.
UPGRADATION
Sl. No. Guideline

1 Use of Refrigerant type Compressed Air Dryer instead of conventional Regenerative type silica-gel based
Dryer
2 Optimization of BFP gear stage. Seminar with M/s Voith may be organized in this regard at Corporate
office, WBPDCL.
3 Energy Efficient Vapour Absorption Machine (VAM) to be used in place of PAC for air conditioning system.
4 One stage withdrawal of CEP. May be explored after getting suggestion from M/s CESC.
LONG TERM PLANNING
Sl. No. Guideline
1 VFD drives should be installed in all LT drives. Process may be stated with CT fan after feasibility study.
2 Common header for CW pumps for new projects.
3 Wind ventilation for TG roof.
4 IFC air controller (intelligence flow controller) for compressor.
5 Commissioning of Online Energy Management System of load bearing equipments and its compatibility
with DCS.
ainst APC Reduction Guideline
ION PRACTICE
Action Taken
Followed
Generally 4 mill operation done depending upon coal quality
possible. Maintained
Monitored
O2 kept around 3.5%
Followed depending upon condenser vaccum
Maintained 6 to 8
Approximately upto 80 to 85% kept open
Followed
Maintained around 4.5 to 5
Followed depending upon condenser vaccum
Followed
ANCE PRACTICE
BOILER
Action Taken
ner. Checked by O&E and corrective action taken by BM
Followed
dingly. Followed
& AUXILIARIES
Action Taken
All CW Pumps corro-coating done during OH
ears for this job should
Cartridge repalcement done on regular interval

Used FRP blade to reduce energy consumption.

CE OF PLANT
Action Taken
Followed
Followed
egularly Followed
ICAL SYSTEM
Action Taken
o be monitored Higher accuracy class CVT installation postponed due to SAS project.
Voltage monitored at regular interval.
functional Digital Low
Followed
n of auto timer. Process start. To be done phasewise.
Followed for new procurement
Followed
UMENTATION
Action Taken
Followed
PRACTICES
Action Taken
Followed
taken in earliest
Followed
Followed
Followed
Followed
if any. Followed
ortunity. Followed
Followed
Maintained.
Fields. N/A
U#6 , Screw compressor & U#5 Reciprocating type.
es. All new procurements are Energy Efficient BEE star rating.
RADATION
Action Taken
ype silica-gel based
For U#6, Refrigerant type Compressed Air Dryer installed
rd at Corporate
N/A
conditioning system.
C. N/A
RM PLANNING
Action Taken
feasibility study.

Not feasible at present structure.

d its compatibility
On line heat rate deviation runs at STPS
 Action Taken Report Against SOC Reduction Guid
OPERATION PRACTICES
MECHANICAL
Sl. No. Guideline
1 Strategic operation of coal mills.
2 Mill outlet temperature to be maintained 80°C - 90°C, however it depends upon the plant.
3 Primary air to Fuel ratio to be maintained as per OEM curve, if available. If OEM curve is not available, this
should be prepared through experience and displayed in control room.
4 Bottom Ash Hopper Overflow monitored in some interval till burners in service
5 Oil header pressure maintained as low as practicable
6 Wind box to Furnace DP to be maintained as per OEM recommendation.
7 During firing of inferior quality coal, flame conditions to be closely monitored locally as well as in DCS. Oil
burner insertion is the last option and to be used judiciously.

8
Before boiler lit up all oil burners to be cleaned & flame scanners to be checked.
9 During short shut down (around 4-6 hours) boiler to be kept alive without or minimum oil support with HP-LP
bypass open.

10
Burner flame intensity to be monitored locally.

11 Burner cut-in & withdrawal should be based on physical flame condition checking besides flame scanner
feedback.
12 Units to be boxed up at higher drum pressure and temperature during Low System Demand shut down and
vice versa operation during Boiler Tube Leakage & other planned shutdown.

13
Coal flow and Mill availability to be ensured before synchronization of machine.
14 Burner hours to be logged
15 Wall Soot blowing to be done on regular basis, depending on the furnace stability.
16 Individual CCP temperature to be monitored daily basis to ascertain Coal Pipe chokage.
COAL HANDLING PLANT
Sl. No. Guideline
1 Good Coal & Inferior coal to be stocked separately with proper demarcation for blending. As far as possible,
good coal(relatively higher GCV & VM) to be fed in base mill bunker.

2 Cleaning at CHP should be under close vigilance. Drains at Stockyard & other areas to be kept cleaned. Penalty
Clause to be incorporated in Cleaning Contract.
3 Compaction of coal to be done to avoid spontaneous combustion.
4 Wherever feasible, first in first out principle of coal from stock yard to be adopted.
5 Chute cleaning to be done by poking only, water jetting should be avoided as far as practicable.
6 Low VM / GCV coal to be avoided for 100 % direct feeding.
7 Strategic Feeding of imported coal to be done. Tracking of coal rake through FOIS to be monitored & informed
up to the ground level.
8 Penalty clause to be incorporated in Stone Picking Contract
MAINTENANCE PRACTICES
MECHANICAL
i. Mill
1 Mill OH to be done as per schedule based on Running Hours as well as performance indicators.
2 For minimisation of Duration of mill overhauling, incentive to be incorporated in service order.
3 All preparatory work to be done before mill overhauling
4 During monsoon lower elevation mill OH to be avoided as far as practicable.
5 All Coal pipe orifices / venturi to be replaced during boiler OH.
ii. Boiler
1 All Coal nozzles to be replaced during boiler OH irrespective of condition
2 Burner tips to be cleaned & checked in every start-up of units.
Tip size (diameter) of all oil burners to be uniform and as minimum as possible. Need to be monitored at
3 regular intervals.
Feeder OH to be done in schedule time. During schedule checking of feeder if any abnormality is found,
4 proper planning is to be done for replacement in next opportunity to avoid unwanted outage.
5 Coal Impellers to be replaced at 3 months interval (BTPS 1 & 2 and KTPS 1 – 4).
6 Scanner fan hose to be replaced during Boiler OH.
Proper planning for replacement of CCP including bend, to be done. This job to be done during unit
7 overhauling / mill overhauling. Mill shutdown to be avoided for this type of job.

iii. Coal Handling Plant

a) Stockyard (Crushed / Uncrushed) covering to be done during monsoon as far as practicable (except
1 Sagardighi TPP).
b) Regular checking and rectification of chute liners done and detail to be included in Pre- monsoon plan
2 along with timeline.

3 c) Chute Lock / Chute Overflow switch to be installed at jamming prone chutes.

4 d) Crusher Screen plate PM to be checked through Maintenance Planning. Health of Crusher screen plate to be done
e) Bunker gratings to be checked weekly through PM & jointly between CHP –Operation, CHP – Mechanical
5 Maintenance & MTP.

6 f) Check and ensure healthiness of Metal Detector and ILMS in service

iv. Instrumentation
1 a) PA Flow Calibration to be done regularly
2 b) Oil gun engagement procedure may be changed to pair mode from elevation mode.
c) Flame scanners checking & cleaning through PM should be in practice. Also flame scanners to be
3 monitored closely & replaced if abnormality found.
4 d) Mill DP & WB to furnace DP purging to be done periodically through PM.
5 e) Feeder calibration to be done at 03 months interval.
F. Short Term Planning
Crusher Hammer to be replaced timely. (if possible total set to be changed)
G. Long Term Planning
1 i. Bunker Level indicator to be installed wherever not available.
ii. SS liner fittings on coal bunkers (conical portion) to reduce arch formation, particularly at Bandel TPS.
2
iii. SS drop pipe & SS chute (feeder to mill) to be introduced for reduction of chokage during monsoon
season particularly at Bandel TPS.
3
 iv. During Monsoon, coal in the yard must be covered with Silpholine
4
5 v. CCTV installation at Bunker Floor
6 vi. Covered Shed for crushed coal in coal yard (except SgTPP)
7 vii. Bandel Stack yard gradation to be done. Proper engineering to be explored
8 viii. Vibration monitoring for crusher to be installed & if required balancing to be done timely
9 ix. Furnace temperature measurement to be explored.
H. Special Recommendation
1 i. Bandel Unit – 5 flame scanners to be put into service at the earliest.
2 ii. Mass flow meter in fuel oil line to be installed wherever not available
3 iii. Attempt is made to avoid delay in start up.
a)Vacuum pulling to be done by taking common TAS from other unit. For STPS &
KTPS Units 5 & 6 and BTPS this should be introduced on opportunity.

b)At the start of turbine rolling 1 mill to be put into service keeping close
st

observation of MS Temperature.

c) Availability of milling system ensured to reduce stabilization oil during start up.

I. Best Practices
i. Mill fineness checking by Iso-kinetic sampling to be done regularly by O & E Department. At the same day
1 BA/FA sampling to be done and different boiler parameters to be monitored.
2 ii. Clean Air Test to be done regularly by O & E, particularly after mill overhauling
3 iii. Dirty Air Test to be done regularly by O & E, particularly after mill overhauling.
4 iv. SADC & Burner Tilting checking should be done with local position on regular basis.
v. Trip committee recommendations to be followed strictly and to be discussed in DPM & also in spare
5 meeting.
6 vi. Each & every oil consumption to be discussed in DPM and to be minuted.
7 vii. Start-up log to be maintained (As per Annex – I).
8 viii. Bench mark for oil consumption of different start-up to be mentioned in LMI book.
9 ix. LMI for Oil Gun insertion may be introduced. As reference LMI for same of KTPS is attached.
10 x. Bunker arch checking to be done before each mill overhauling and unit overhauling.
xi. Instant GCV to be measured like SgTPP (1.5 Hours) for all plants. Physical checking of BA (color) & to be
11 informed to SCE, if possible to be brought to control room.
12 xii. Cleaning of oil burners of all elevations on weekly basis at both units & logged in SCE log
13 xiii. Status of Grinding Elements to be discussed in ORT meeting.
14 xiv. All ILMS which are not in service to be noted in exception report.
15 xv. Thermography of Boiler insulation to be monitored at 6 – month interval.
 ainst SOC Reduction Guideline
TION PRACTICES
ECHANICAL
Action Taken
Followed
the plant. Followed depending upon coal quantity.
e is not available, this Handle on basis of experience.

Followed
maintained around 5.5 to 6.0 Kg/cm2
Followed as per requirement.
as well as in DCS. Oil
Followed

Followed
m oil support with HP-LP
Followed

Followed
ides flame scanner
Followed
emand shut down and
Followed

Followed
Followed
Followed
e. Followed
ANDLING PLANT
Action Taken
ding. As far as possible,
Followed
be kept cleaned. Penalty
Followed
Followed
Followed
racticable. Followed
Followed , but depending upon the condition.
be monitored & informed
Followed
Followed
NANCE PRACTICES
ECHANICAL
ndicators. Followed
ce order. Followed
Followed
Followed
Followed

Followed
Followed
d to be monitored at
Followed
normality is found,
outage.
Followed
N/A
Followed
ne during unit

Followed

racticable (except
Followed
n Pre- monsoon plan

Followed
Installed in some chutes
Crusher screen plate to beOverall
done jointly
Crusherthrough
PM to MTP.
be done.
ation, CHP – Mechanical
Followed , Join vist done on requirement basis.
Followed

Followed
de. Elevation mode during Synchronized condition.
scanners to be Generally opportunity maintenance done,

Followed
done when belt cut or load cell replacement.

not to be done at present stock position.

Installed.
ularly at Bandel TPS. NA

ge during monsoon NA
 Tarpoline present
installed.
Future plan
NA
one timely installed in Crusher.
Will be explored

NA
Installed

r unit. For STPS & TAS interconnection commissioning & put in service during U#6 OH
tunity.

eping close
Followed
oil during start up.
Followed

rtment. At the same day

Followed
To be followed
To be followed
sis. Followed
DPM & also in spare
Followed
Discussed in DPM
Followed
ook.
is attached.
ng. Arch breaking done during bunker Run-out.
ng of BA (color) & to be Followed

n SCE log Followed

Monthly Grinding data send to OS cell on regular basis.
Followed
Thermography done.