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recommendation, so as to facilitate finalizing daily predictive maintenance activitiesduring daily planning meeting.Some of the Condition monitoring techniques are as below: Vibration AnalysisOil AnalysisTemperature Trend AnalysisCoal Mills Sieve AnalysisDGA for Generator transformersInfrared ThermographyMotor current analysisNoise level monitoringWater chemistry monitoringRLA TestsC. BREAKDOWN MAINTENANCEEquipment failure analysis Failure report by area engineer and analysis by experts/ senior functionaries. Recommendations/ remedial measures to avoid repeated failure. Planning viz.spare procurement and services required. Connect with similar previous failure and lessons from them. Add any otherlearning from present failure to those records. Adoption of Modular Maintenance approach, as it is vital for reduction in downtime.Boiler Tube Leakage Analysis at Power Stations through following steps Initial site report by BMD Engineer.Mapping of location of failure on boiler drawing with frequency of failure.BTL analysis-Root cause and material testing (if needed).Implementation of recommendations.Forwarding of BTL report with plan to reduce the same to HQ.Quality Management:Adoption of New Technologies in maintenance is the need of the hour. MaintenanceQuality Monitoring is to be taken care through FQA group at site and surveillance byteam during overhauling. Field Quality Assurance at Power Station through dedicated groups doing:MPPGCL: BEST O&M PRACTICESPage 8

NDT and destructive testing.Maintaining Radiography source with and certified person, to operate it.Involvement of FQA during overhaul as well as routine maintenance includingbreakdown of major equipments.Involvement in critical checks Turbine/Boiler/Elect./C&I.Preparation of quality plan with the help of site engineers and ensure itsimplementation.Involvement in plant betterment studies, RLA and R&M.Involvement in spare parts inspection, storage & preservation in store as wellas at site.Involvement in Quality Management regarding purchase order/contracts awardand Pre-delivery Inspection at site and works.QA Group involvement during Overhauling: where the extents of forced outagesare more, QA experts’ team to visit site for review and guidance duringoverhauling.HEALTH & SAFETYMPPGCL is committed to provide System of Safe working and Healthy workingEnvironment to all employees, while complying with all Occupational Health andSafety regulations and other requirements.Safety (PTW system): To ensure safety of human beings and equipment whilecarrying out work, Maintenance (Service function) seeks written permission fromOperation (Owner) section on a specific format before start of work. A fully fledgedsystem (being envisaged for further strengthening and implementation throughcomputer software) operates involving isolation, lockout box etc.HUMAN RESOURCESMessage of Profit & loss are sent by SMS daily to specific officers for use in decisionmaking and to other concerned to improve awareness about organization commercialperformance.Training Calendar:A ‘Training Calendar’ to be prepared every year in the month of April coveringvarious available training programs.MPPGCL: BEST O&M PRACTICESPage 9

Training Need Identification:Training Need Identification is a vital part of employee development activities. Atraining format is filled up by the concerned employee and thereafter signed by hisreporting officer and Head of Department (HOD) in annual C.R. The training needcolumn of concerned executive may be filled up by his reporting officer afterdiscussion. These can be utilized by departmental training coordinators.Technical Knowledge Up gradation Program:MPPGCL is envisaging introducing knowledge up-gradation program for itsemployees. Regarding HR our mission has to be, “To keep on developing humanresources to meet organizational needs.” Subjects of such program could be large innumber and varied in quality depending upon the field, level and workresponsibilities. Some of such programs may be the following Operation engineer to be rendered simulator training. Power plant familiarizationin new and advanced technologies. O&M personnel to be rendered training, refresher program at various trainingcenters or at the manufacturer’s work or by attending different seminars/workshop at national & international level. Inter generators conferences and knowledge sharing visits to be arranged forfrequent exchange of knowledge and experiences. Interaction with various knowledge bodies such as “Knowledge ExchangePlatform- KEP” of BEE and “Energy Enhancement Centre- EEC” and making theliterature available to all the O&M engineers. Management skill development programs for managerial level.Best Practice ReviewProcess Optimization through Best O&M Practices is a journey and not thedestination.1. Various power stations have their own best practices. There are the practices,which need to be shared between various stations so that they can benefit otherstations also. Compilation of ‘Best Practices’ could be one such step. At thestation level also there are best practices, which can be shared among variousMPPGCL: BEST O&M PRACTICESPage 10

departments. These can also be shared with colleagues from other stations,various guests and dignitaries who visit the station.2. Since the ‘Best Practices’ do keep on becoming ‘Common Practices’ as theknowledge is shared, there will be a plan for annual updating of the bestpractices so that the old and common practices are replaced with new ones andthe same shall be shared among all power engineers of MPPGCL. Suggestionsfor further improvement of these practices shall be separately invited.3. All the power stations are required to make comprehensive checklists foroperation, maintenance and overhauling of various equipments after detailedinteraction amongst the experts, user and service departments.MPPGCL: BEST O&M PRACTICESPage 11

ANNEXURESOME IMPORTANT PRACTICES TO BE ADOPTED1. Measures To Minimize Boiler Tube FailureGeneral Measures:Following general measures to be adopted in thermal power station to minimize theboiler tube failures: Visual inspection of heating surface to be carried out to identify type of failureviz. eroded tube, deformation, swelling, bulging of tube etc. Shielding of tubes / bends in identified highly erosion prone areas to be done toreduce erosion due to gas velocity in second pass. Tube thickness survey and thickness mapping in all identified areas to becarried out. 100% welding inspection to be carried out to ensure quality weld joints.Involvement of experience IBR welders to be ensured for pressure partswelding works. Emphasis to be given to prevent flue gas / ash erosion. Erosion prone areas areto be extensively inspected and protected by providing shield / baffles,refractory etc.Preventive techniques to minimize tube failures:Following innovative measures may be adopted in thermal power stations tominimize the boiler tube failures: Extensive Inspection of Pressure Parts as below During annual overhaul, inspection of LTSH/ Economiser banks on left andright sides to be carried out after removing skin casing and cutting fins atplaces based on experience. Economiser coils to be lifted on both sides for inspection and to assesshealthiness of tubes.MPPGCL: BEST O&M PRACTICESPage 12

Annual inspection of Platen super heaters and Re-heater bank bends to bedone by arranging sky climber and platforms. Inspection of Roof tubes: Final super heater tubes and Super heaterterminal tubes to be carried out by arranging multi tier platforms. Shielding the Tubes at Critical Zones To avoid ash erosion failures, shrouding / sacrificial shields to be provided forwater wall screen/ extended water wall, Super heater screen tubes, extendedsteam cooled wall, LRSB’s opening bends, LTSH terminal tubes/ ECO hangertubes, LTSH straight tube, ECO coil straight tubes and rear side straight tubes.LTSH supply tube 90 deg. bends/ offset bends etc. Cassette baffles to be provided for bends of LTSH and ECO coil assembly toreduce erosion.Importance of Boiler Tube Stoppers The alignment of all coil assemblies and tubes in the horizontal pass andsecond pass to be thoroughly checked. Stoppers (locking arrangement) to prevent movement of steam-cooled spacersto be provided for Platen and Re-heater coil assemblies. Tubes that come out of connectors / distorted attachment can cause failure andhence to be corrected during boiler overhaul. Vibration arrestors/ clamps get deformed and make dent on tubes. They are tobe repaired as and when noticed.Quality Welding: Welding electrodes to be procured as per the recommendation of manufacturerand preserved as per standards. 100% Radiography of weld joints to be carried outMaintenance of Flue Gas Path: Through inspection of refractory to be made to avoid flue gas diversion andimpingement on bends and headers.MPPGCL: BEST O&M PRACTICESPage 13

Refractory linings to be provided in areas of high ash erosion where shieldingof tubes is difficult.Expert Analysis of Tube Failure: Failure analysis to be carried out through manufacture’s experts andmetallurgical laboratories to identify root cause of tube failure as and whenrequired.Post Operational Chemical Cleaning: With continued operation over a period of time the magnetite layer grows inthickness due to slow corrosion of boiler steel tubes. Also carryovers fromcondensers and pre-boiler systems deposited on the inner surface of boilertubes where the heat transfer is high. This growth of oxides and carryovers result in loss of heat transfer andaccelerated corrosion of boiler tubes. This makes the boiler less efficient andmore prone to localized heating. At times it may lead to tube failure. Therefore,importance to be given for chemical cleaning of boilers.2. Check Lists for various O&M activitiesCheck lists are to be prepared to check completion of all pre-decided activities.These are required to be done to ensure that all pre-requisite step in the maintenanceor operation/ start up of the Auxiliaries. Some of such activities are given here under.It is required that all field engineers should actively participate in the preparation ofall major and micro level activities. Some of such check lists are given here under asexample to aid the process of preparation of these check lists at site level.2.1 WORKS CARRIED OUT: CHECK LIST2.1.1 EQUIPMENT: XRP-1003 MILLS DETAILSS.No.0102Work DescriptionMillADoneVenturi outlet Repl.By New outlet/repairVenturi collar Repl. Doneby New collar Repl.MPPGCL: BEST O&M DoneMillGDoneMillHOkDoneDoneDoneDoneDoneDoneOkPage 14

0304050607080910111213141516171819202122Venturi collar heightmaintained at:MPO base plateReconditioning:Venturi vanesreplaced by ceramiclined vanes:MPO Replacementby (a) New MPO(b) Recond. MPOMill discharge Valvedoor servicingMill dis. valve discplate repl.MDV repl. by(a) New(b) ReconditionedCoal pipe orificesrepl. (new set)Victaulic gasketsrepl.Spring assembly,servicingSpring assly brasesleeve repl. (nos.)Spring compressionset at:Vertical shaft upperradial brg clearance(D)Vertical shaft oilseals replacement:Seal air housingadjustment & sealair gap:Dust guardadjustment &clearanceInsulation coverplate resetting/adjustmentPA Duct Insulationcover plateScrapper box bodyliner repair orreplacementScrapper box bottomliner �DoneDoneDoneDoneDoneDoneOkOkDone04 NoDone04NoDone04NoDoneDoneDone04NoDoneOk--04 e-04NoDoneOkOkOkOkOkOkOkOkOk04 o07NoDoneDoneDoneDoneDoneDoneDoneDone01 kOkMPPGCL: BEST O&M PRACTICESPage 15

er box dustguard repairLower skirtassembly repla. bynew setPA duct guide vanesreplacementScrapper assly.rectificationPyrite hopper topspout replacementPyrite hopper topassly. replacementPyrite hopper bottomspool pipe repairPyrite hopper bottomgate valve servicingand plate repla. bynew plateGrinding rolls andbullring segmentsreplacementMill internal patchrepair workMill Lub oil pumpservicing/repl.Mill Lub oil pumpcoup[ling servicingMil Lub oil filterscleaningMill coal inlet pipelength replacementMill classifier conemanhole door repla.Mill scrapper boxdoor framerectificationMill worm shaftseals topping upMill gear box oillevel topping upMill motor to gearbox shaft alignmentMill coupling oilchangingRoller to bowl gapadjustmentSpring seat oneDoneDoneDoneDoneDoneDoneDoneDoneDoneDoneMPPGCL: BEST O&M PRACTICESPage 16

454647484950Classifier vaneposition seat(position no)Mill seal air valvesservicingCold air DamperservicingCold air gateservicingHot air gateservicingHot air eDoneDoneDoneDoneDoneDone4FDone4GDone4GDone2.1.2 EQUIPMENT: GRAVIMETRIC FEEDERS:S.NWork Description01Internals removal,general servicing andfixing backFeeder beltreplacement.Take up pulleyreplacementTake up pulley brgreplacedHead pulleyreplacementHead pulley begreplacementHead pulley studsreplacementHead pulley bushesreplacementHead pulley couplinghalf replacementInlet span roller repl.Inlet span roller brgreplacementWeight span rollerreplacementBrg 6204 replacement0203040506070809101112131415Side skirt platereplacementShear pin/bolt repl.4ADone4BDone4CDoneFEEDER NO4D4EDone DoneReplacedOkOkOkOkOkOkOkOkOkOkOkOk02 NoRepla OkOkced01 No 01 No OkOkOkOkOkOkOkOkOkOkOkOk01 No 01 No Ok01 No OkOkOk14 No14 No 14 No 14 No 14 No 14 No 06 No Ok14 No14 No 14 No 14 No 14 No 14 No 06 No Ok01 NoOk04 No08 No02 No 04 No 01 No 07 No 03 No 07 No 04 No04 No 08 No 02 No 14 No 06 No 14 No 08 No01 No01 N0 02 No 03 N0 01 No 02 No 01 No Ok02 No02Nos.02Nos.01NoOk01NoMPPGCL: BEST O&M PRACTICESOkOk01 No Ok04Nos.02Nos.01NoOkOkOkOkOk01 No 01 No 02 No OkOkOkOkOkOk01No01No01No01No01NoPage 17

1617181920212223242526272829Feeder gear boxservicingBrg Timken 552/360 areplacementGear box output shaftreplacementIntermediate gear boxshaft repla.Brg 6206 replacementIntermediate gear boxbearing 6307 replFeeder clean outconveyorFeeder gate & bunkergate servicingFeeder gaterectification and siderack replacement.Feeder gate side rackrequirementFeeder outlet chutepreventive shieldingwith SS plateFeeder gate studbearing CF 6526replacementFeeder front and reardoors servicingFeeder gate shaftbearing 6207 repla.DoneDoneDoneDoneOk01 Set OkOk01SetOk01 No OkOk01 No OkOkOk01No01NoDoneDoneDoneDoneDone01 Set OkOkOk01 No OkOkOkOk01 No OkOkOkDoneOkOkOkOkOkOkOk62NoOkOkDoneDoneDone08 neDoneDoneDoneDoneDone02 NoOkOkOkOkOkOkOkDone2.1.3 EQUIPMENT: FD & PA FANS:S.No.0102030405060708DESCRIPTIONFD FANAFD FANBPA FANAPA FANBFan cleaning and inspectionSilencer cleaningSCAPH cleaningServicing Lube of unitServicing of Main bearinghousingServicing of Servo motorServicing of RotorsAlignment of motor of fanMPPGCL: BEST O&M PRACTICESPage 18

2.1.4 EQUIPMENT: ID rnal cleaningNDT or critical weld joints of shaftBoth bearings servicingShaft levelingAlignment of voith to fanAlignment of motor to voithLub oil coolers servicingServicing of water linesInlet vane operationSpare & Consumables UsedSS 150 oilST 10 oilM16X65 bolts with nut8 mm packing ropeID FAN AID FAN B80 Lt100 Lt.30 Nos.5 Kg80Lt100 Lt.30 Nos.5 Kg2.1.5 EQUIPMENT: AIR 181920DESCRIPTIONSAPHASAPHBPAPHAPAPHBCleaning and inspectionSupport bearing inspectionGuide bearing inspection and rotorlevelingSector plate levelingChecking and connection of T-barAxial seal plates checking &correctionBypass seal angle correctionBroded bypass scals replacementSeals setting including replacementKaowool packing replacementPatch up workTabs weldingLube oil unit servicingDrive unit servicingWater washing line vales servicingGeneral servicing of ALCSRemoval of Jamming in push rodBaskets replacementBasket reversalDuct & Bracing repairMPPGCL: BEST O&M PRACTICESPage 19

OPERATION: CHECKLIST FOR UNIT STARTUPSChecklists earlier developed for STPS units No. 6 and 7 are produced here under as samples.Similarly, checklists for all operations are to be developed and followed in all units, forimplementation of best practices.UNIT START UP CHECK LIST (WARM STATE STARTUP)SAMPLE – Unit No. 6/7 210 MW, STPS SARNI.BOILER LIGHT UPDATES. No.Activity1.01All permits should be cancelled.1.02Check water level in CS tank. It should be normal i.e. above 4.5 M.1.2(a)Ensure bunker level Normal.1.03Check air vents, M.S., CRH, HRH line drains are open and BoilerTimeActionstop valve is closed.1.04Check S/H drains and start up valves are open.1.051.06Start filing pump & take water in boiler through low point drains upto 4 ports.Check supply to FSSS panel is ON1.07Check C.W. Pumps are running normal.1.08Check Two BABP pumps are running normal.1.09Check cooling water for ID, FD, PA and mills and check furnacesealing.Check Two BCW pumps & TABP pumps are running.1.101.111.121.13Run instrument and plant air compressor, check air pressure 5.5 to6.0 Kg./cm2.Run: LOP’s of ID check auto start of LOP’s.1.15Run LOP of FD & PA check other pumps comes on auto when therunning LOP trips.Run LOP of PA fan and check other pump comes on auto whenrunning pump trips.Run LOP of air heaters, furnace sealing, ESP, A/H hopper sealing.1.16Run ID & FD air fans, igniter air fans and scanner air fan.1.17Light oil guns are ready in AB elevation.1.18Check following boiler protection and see that boiler trips by.a) Tripping of both IDb) Tripping of both FDc) Furnace Pressure highd) Loss of

Mapping of location of failure on boiler drawing with frequency of failure. BTL analysis-Root cause and material testing (if needed). Implementation of recommendations. Forwarding of BTL report with plan to reduce the same to HQ. Quality Management : Adoption of New Technologies in maintenance is the need of the hour. Maintenance