Relevance of documentation

Documentation of O&M manuals

Signatures of equipments
Data acquisition system and analysis
Daily reporting of operation and
maintenance
Record of meetings, committee to be
constituted

Documentation of O&M manuals

The O&M manuals and the operating procedures based on them should
be made available with the shift-in-charge engineer at the plant and the
respective maintenance heads. The originals shall be located at one
place. Signature check-lists for equipment lining up, various systems
start-up and shut down and all emergency handling procedures shall be
utilized by utilities for standardizing such operational processes.
Equipment changeover guidelines along with key process diagrams for
critical equipments along with checking procedures at local for critical
and non-frequented equipment shall be available. The Key process
diagrams, Heat balance diagrams and Technical parameters handbook
indicating ideal measurement at various plant load factors Key logic
diagrams indicating interlocks, protections and associated C&I details
shall be available with Operation Personnel, which would assist in
better operational decision-making, trouble shooting and enable
enhanced operational efficiency.

Documentation of O&M manuals

In addition, Walk-down Checks shall be prepared and such

checks should be carried out in each shift by the respective
operational staff responsible for boiler, turbine, balance of
plant etc. to report any abnormalities and take corrective
actions. Checklists should be deployed to ensure that all
necessary aspects are verified during the walk-down checks.
A Central Technical Library needs to be setup preferably
under the Head of O&M at the plant. The library should have
an archive of all procedures, manuals and instructions, as
well as latest technical journals in hard and soft copy so that
the same can be accessed on-line by operations and
maintenance personnel.

Documentation of O&M manuals

Preparation of O&M Management Manual -Part I

- Operation Instruction of each and every equipment
- Maintenance Instruction of each and every equipment
- Quality Control of all maintenance procedures
- Recommissioning of each and every system after due
tests
- Security and Safety Instruction of each and every
equipment
- Environmental issues involved

Documentation of O&M manuals

Preparation of O&M Management Manual -Part I

Measures for plant abnormality
Verification and Advice
Plant Abnormality Report
Schedule Management for Inspection and Repair Work
Root Cause Analysis and Measures
Repair Work Proposal
Repair Work Management
Resources to be deployed
Improvement proposed

Documentation of O&M manuals

Preparation of O&M Management Manual -Part II

Scope of Works of O&M Contract
- Guarantee items
- Possible O&M agencies
- Schedule of O&M
- Suppliers for equipment
- Management Manual / System
- Quality, Environment and Safety Control
-Drawings
- O&M Cost

Documentation of O&M manuals

Preparation of O&M Management Manual -Part III

During Commercial Operation:
Plant Operation Management
-Operation, Security, Safety and Environment Manual /
System
- Operation and Performance Management
- Operation Record Management
-Operation, Security, Safety and Environment Plan
-Operation Staff Training
-Budget Management

Documentation of O&M manuals

Preparation of O&M Management Manual -Part IV

-Plant Maintenance Management
-Maintenance, Security, Safety, Environment Manual /
System
- Maintenance Procedure
- Consumables and Spare Parts Control
- Maintenance Record Management
-Daily / Long Term Maintenance Plan
-Maintenance Staff Training
-Diagnostic Analysis
-Budget Management

Documentation of O&M manuals

Standardization of equipment can play a powerful role in maintenance and

dependability from many angles, for which documentation shall be done. This
shall:
Allow a level of familiarity to all staff when operating and analyzing the
equipment.
Allow organizations to leverage their size during the initial buy and during
any warranty periods.
Help streamline the ongoing commissioning of equipment, ensuring
maximum efficiency throughout the lifecycle.
Allow for common spare parts to be warehoused and to be available on short
notice.
Help predict end of life strategies and simplify organization-wide solutions.
A system of standardization allows multi-site organizations the most cost
effective method of predictive maintenance (trend spotting) as they can
review like equipment for common situations.

Documentation of O&M manuals

Documentation shall be also done for emergency procedures:
What are power house emergencies
Fire in the power house
Earth quake
Flooding of power house
Riots outside power house
Riots inside power house
Terrorist Attack
Chemical leakage/pollution
Accident in power house
Assistance to be provided to outside agencies
Assistance required from outside agencies

Documentation of O&M manuals

Documentation for handling various issues shall be prepared
for verification of respective authorities.
Disaster management
CERC
Environmental issues
Vehicle act
Fire safety
Factory Act
Hazardous Material handling
Releases from power house

Signatures of equipments

The signature of new equipment is baseline for its performance/

characteristics. The performance of the equipment also
depreciates over the time. It may happen that after lapse of time
the performance of equipment may drop down below the
minimum required performance level. It is therefore imperative
to refer to the test certificate/ model test reports provided by the
manufacturer. This demonstrates what was specified and what
was provided. After installation the field tests carried out are
good reference for future performance. These data must be made
available online for reference of O&M staff. These data are very
helpful in diagnostic activity.

Signatures of equipments

Electric Signature Analysis (ESA) is a diagnostic and

analysis technique that is being used to analyze motors,
generators, alternators, transformers, and other electric
equipment. This technology has the ability to test operating
electrical equipment and identify a variety of mechanical
and electrical problems. ESA traces can be used to analyze
the driven load, the power supply, and perform inrush
testing on motors. As a preventative maintenance tool, ESA
can be used to perform a one-time test or periodic testing to
track and trend equipment performance. ESA is remote,
non-intrusive, and is invisible to the equipment being
monitored. ESA is used to evaluate rotors, stators, and rotorstator air gap conditions in electric motors.

Signatures of equipments

Current and voltage data are acquired directly from the Motor
Control Centre (MCC), while the equipment is in operation. The
collected data is then used to determine phase imbalance, motor
load, power factor, power harmonics, and the impact of the
driven equipment on the motor. Rotor bar as well as stator health
and rotor-stator eccentricity (air gap) characteristics are also
assessed. In addition, degraded bearings can also be observed
from the traces. ESA is particularly helpful in accessing
mechanical conditions when it is not possible or convenient to
make vibration measurements. ESA becomes even more useful,
however, for trending motor indications; because, in some cases,
a motors base-line signature may not be known.

Signatures of equipments

Software and Data Analysis Advantages including key

determinations are made automatically, such as:
Line Frequency, Running Speed and Pole Pass Frequency
Software Automatically looks for patterns related to Stator
Slot and
Rotor Bar fault frequencies
Automatic detection of Static or Dynamic Eccentricity faults
Evaluation of Incoming Power including Harmonics
Calculates Efficiency for AC Induction & DC Motors
Power Analysis includes Sag/Swell and Transient Detection
plus
Energy Consumption Data Logging

Signatures of equipments

When a new transformer is commissioned, establishing the Time Zero

conditions is essential to start building the transformers analysis history.
This shall include the key tests to run every time a new unit is put in
place. The recommended tests in this package are as follows:
Dissolved Gas Analysis
Key gases detected: H2 (Hydrogen), O2 (Oxygen), N2 (Nitrogen),
CH4 (Methane), CO (Carbon Monoxide), CO 2 (Carbon Dioxide),
C2H4 (Ethylene), C2H6 (Ethane), C2H2(Acetylene). DGA as per ASTM
D3612-A.
Water Content
Water reduces the insulation capacity of the oil, excessive moisture
accelerates the decomposition of the paper insulation. Moisture in Oil
content
test
as
per
ASTM
D1533.

Signatures of equipments

Furan Content
Furanic compounds are produced as the paper insulation
deteriorates; measuring the concentration of those compounds
gives an indication on the condition of the paper insulation.
Furan content as per ASTM D5837.
ASTM Package
Physical, Electrical and Chemical tests including: visual
examination, dielectric breakdown, acidity, interfacial tension,
density and color. All as per their specific ASTM test methods.
Oxidation Inhibitor
Oxidation occurs and inhibitor is consumed, controlling the
inhibitor content extends the life of the oil by preventing sludge
formation. Oxidation Inhibitor test as per ASTM D4768.

Signatures of equipments
It is recommended the FRA test be performed in the factory at the time
of original transformer testing to provide a baseline reading of the
windings in an as-new condition. Frequency Response Analysis is a
low-voltage, off line measurement of the impedance of the transformer
winding as a function of frequency. The test is performed by applying a
variable frequency ac voltage to each individual winding of the
transformer and measuring the current that flows out of the winding. The
plot of the current divided by voltage vs. frequency is known as the
Swept Frequency Response Analysis (SFRA) of the winding. For
installed transformers, a test in the field can be used to provide the
baseline value. FRA should be performed periodically during the service
life of the transformer or after a specific incident producing significant
through fault currents in the transformer. Comparison of such an FRA
test to the original baseline value is very useful in diagnosing the
condition of the windings.

Data acquisition system and analysis

A database based on power plants performance can be used as a

benchmark for power plants availability analysis. The comparison
should be used for initial evaluation of the power plant performance.
the availability index is concerned. Considering that the failure rate
of power plant is decreasing one can expect that the frequency of
failures can continue to decrease until the equipment reaches the
random failure stage. Based on the reduction of the failure frequency,
caused by maintenance policies or even operational procedure
improvement, an availability increase can be expected. For complex
electromechanical systems, the availability can be different for
identical equipment located in the same site. This difference can be
associated with the operational profile of the equipment

Data acquisition system and analysis

The company shall make efforts for data acquisition:
Make operators aware of the importance of data and its
role in determining the performance of individual
equipment and unit
Streamline the collection of data and ensure operators are
reporting such information on a consistent basis;
Ensure that all departments are using consistent data, for
example operation and maintenance bodies; and
Ensure this data accurately models the reliability of
operation
The data shall be stored properly for reference of others.

Data acquisition system and analysis

The data shall not be dumped but shall be ready for use. For analysis of
Forced outages caused by a station specific problem, it can be grouped as
under:
Any failure of mechanical, fuel handling, controls or electrical equipment
within the Power House;
A failure of fuel transport system (hydrological storage) dedicated to that
power station with a resulting fuel shortage that results in a reduction in
output;
Inadvertent or operator error;
Limitations caused by fuel quality that cannot be avoided even if there was
a strong commercial desire to do so;
Outages caused initially by a network disturbance where the generator
could be reasonably expected to remain in service as specified by Grid
code
Limitations caused by environmental or safety restrictions that cannot be
legally exceeded even for a short period;

Daily reporting of operation and

maintenance
Daily Operational Review of Plant Performance Structured Daily
Plant Meetings chaired by the head of plant O&M should be held
each morning to analyze the previous days performance and plan
the generation target as well as the maintenance activities for the
current day. Relevant inputs from the specialized cells/committees
mentioned above are also discussed in these meetings. Apart from
the daily meetings, a monthly operational review meeting chaired
by the head of the plant should be held to follow-up on O&M
aspects as well as other plant issues. Daily plant report shall
include maintenance schedule in separate format in addition to
plant parameters. Shift in charge shall be consulted on regular
basis for maximising output.

Record of meetings, committee to be

constituted
Operations and Efficiency (O&E) committee at the Plant shall be
constituted. The O&E committee measures and analyses energy
efficiency performance of the plant on a regular basis and is
responsible for strict monitoring of the unit heat rate and its
deviations. It ensures the operation of the plant and auxiliaries at
optimum efficiency by identifying and rectifying gaps in efficiency
compared to the design parameters. This is achieved by ensuring the
operation of the unit at rated parameters and minimizing the
consumption of coal, secondary oil, auxiliary power and make-up
water. Another aspect specifically monitored by the O&E cell is
achievement of optimum water chemistry parameters. The tests shall
be routinely carried out by the O&E cell in association with O&M
divisions

Record of meetings, committee to be constituted

The operation and efficiency cell committee shall carry out

the tests at regular interval and/ or after major overhaul. The
record must be maintained and shall be available to
maintenance department for further action
(i) Boiler Efficiency,
(ii) Air Pre-Heater X- Ratio,
(iii) Condenser Efficiency,
(iv) Turbine Cylinder Efficiency,
(v) Dirty Pitot Tube Test for Mills,
(vi) Cooling Towers Efficiency
(vii) Efficiency Tests for Heaters and De-aerators.

Record of meetings, committee to be constituted

A Trip Committee shall be constituted which is entrusted with

the task of root cause analysis of trips and suggesting corrective
actions to prevent recurrence of trips. The suggested corrective
actions are typically formulated as an action plan with clearly
ear-marked responsibility centre and schedule. Compliance with
such recommendations is monitored at plant as well as corporate
levels and an institutional framework for achieving this is also
put in place. Recommendations of the trip committee also feed
into the maintenance plan. The record of trip committee will be
made available online for reference of all departments may be at
plant level or corporate level. Chairman of the committee will be
personally responsible for all details/ implementation.

Record of meetings, committee to be

constituted
It is recommended to constitute a Forced Outage Committees to
analyze other causes of forced outage in detail. These causes may be of
repetitive nature. The committee could be of higher level or corporate
level and could be supported by experts from outside. In some cases,
specialized committees are also in place for example analyzing boiler
tube leakages one of the most frequent reasons for forced outages.
There could be Testing committee to deal with problems of grid
connectivity. Generally these committee will provide input to the Trip
committee, but looking to the severity of the outages these committee
may function independently as well. The record of trip committee will
be made available online for reference of all departments may be of
plant level or corporate level. Chairman of the committee will be
personally responsible for all details/ implementation.

Record of meetings, committee to be constituted

Energy Audit Committee may be constituted at the Plant level. The

Energy Audit Committee is mandated with preparing the Energy Audit
Plan for the plant, conducting in-house energy audits and coordinating
third party external audits at the plant. The Energy Conservation Act,
2001 mandates periodic energy audits for all energy intensive industries
(including power plants). It has been observed that Energy Audits lead
to significant inexpensive performance improvements by enabling
capture of low hanging fruits (energy losses). An efficiency audit
should be carried out based on which the Energy Efficiency indicators
should be defined for major energy consumption/loss centres. However
it is also essential to set up mechanisms and institutional processes for
ensuring that the recommendations of the Energy Audit Committee are
evaluated through a cost-benefit assessment and implemented in a time
bound manner. The record of its finding shall be on line.

Record of meetings, committee to be constituted

A Pool of Technical Experts is developed across the organization,

deriving expertise in different areas (such as turbine, boilers, C&I
etc) from different locations. From this pool, Knowledge Teams
are derived, which bring knowledge and experience in different
areas from different power plants and provide in-house
consultancy to technical problems at any location. This team will
be responsible for R&D works of the company with or without
support. The selection of expert within the organisation will be
done sensibly to avoid heart burning. The record of experts
findings will be made available online for reference of all
departments may be of plant level or corporate level. Chairman of
the committee will be personally responsible for all details/
implementation.

Record of meetings, committee to be constituted

Maintenance Related Operational History Comprehensive

database of performance trends and failure history is often not
available even for critical assets such as mills, pumps and
balance of plant. Also, where available data is recorded in hard
copy maintenance registers and is not generally used for
failure history analysis or for monitoring Mean Time Between
Failures (MTBF). Failure Modes and Effect Analysis is
usually absent as an institutional practice. A cell shall be
created at plant level to ensure such records are maintained.
This cell shall report to the plant head and at corporate level
this shall be monitored. Weekly a compliance report shall be
submitted to Director technical