2013 May Simhadri Commissioning Experience Book PDF

Experience in Project Commissioning....
Simhadri Stage II
Foreword
Start up and commissioning activities of a power plant directly influence
the ultimate success of the project and later its performance. Proper strategic
planning of this activity is the key to avoiding delays, cost overruns and potential
safety hazards. It is therefore necessary to develop an effective and dedicated
commissioning team, who will be posted at site early in the project. The team will
acquire extensive knowledge of the equipment and develop commissioning
procedures, checklists and hold points. They will direct, co ordinate and perform
all start up activities in a systematic and integrated manner.
I am glad to note that the Simhadri Team is bringing out a booklet on their
experiences during commissioning of Simhadri Stage-II.
I am sure this document will be useful for new projects and in reviewing
and developing a comprehensive commissioning procedure.
R.VENKATESWARAN
Regional Executive Director (South)
Simhadri Stage-II A journey towards Excellence
Simhadri Stage II
Foreword
In the present competitive and regulated market with stringent CERC
norms, it is pertinent to revisit systems, processes and disseminate experience
across the organization to sustain our position as industry leader and for taking it
to greater heights.
"Thousands of candles can be lighted with a single candle; and the life of
the candle will not be shortened. Similarly, Knowledge enhances by being shared".
In line with the above, NTPC Simhadri has come out with this booklet to share
O&M experience during various phases of Stage II project execution. This
booklet is a comprehensive outcome covering aspects of revisiting commissioning
guidelines, significance of O&M involvement during project execution from
concept to commissioning, improvements carried out and suggestions for future
projects.
I hope this effort of "Team Simhadri" will be found useful for upcoming
projects in taking pro-active measures to achieve desired objectives of timely
completion of the project with no cost over runs and ensuring quality, reliability
and sustainability towards the journey of excellence.
BALAJI IYENGAR
General Manager(I/c)
Simhadri Stage II
Foreword
NTPC has drawn a huge capacity addition plan and is poised for a
quantum jump in its Project construction activities over the next few years.
It gives me immense pleasure that Operation & Maintenance team of
Simhadri is bringing out a booklet EXPERIENCE IN PROJECT
COMMISSIONING Simhadri Stage II a unique of its kind. I congratulate
the Team for taking out this initiative to assimilate all their experiences in various
phases of Project execution.
This knowledge piece identifies and bridges the gap in all fields of our
Project execution and incorporates additional inputs to the commissioning
guidelines, role of O&M personnel in different phases in Project execution, need
for new initiatives, and effective approach in solving of problems faced.
I am sure that this booklet will serve as a guide line for both O&M and
Project personnel for taking proactive measures and will ultimately stand as an
essential input to the future Projects.
My heartfelt wishes to the future Commissioning teams for great success in all
their endeavors.
S. NARENDRA
General Manager-(O&M)
Simhadri Stage II
Foreword
NTPC Limited with its present installed capacity of 41,684 MW is
marching ahead with a challenging target of becoming 128 GW Company by year
2032.This calls for adding more than 3 times the capacity added in last 38 years in
a span of next 19 years. Achieving this, though appears herculean, is very much
possible with the dedicated team which NTPC have. Here, it is to be understood
that for realization of this goal, tandem operation of Project and O&M teams is
of prime importance.
A proactive step towards moving in this direction, Iam happy to see this
booklet titled EXPERIENCE IN PROJECT COMMISSIONING
Simhadri Stage II looking into aspects of present systems & practices,
illustrating the proactive measures,new initiatives and measures towards safety
and more importantly bringing out the importance of O&M involvement in
Project.
I am sure that this book will serve as a reference for the Project and
Commissioning teams and also serve as an input to Project Engineering for
betterments in the upcoming projects.
I wholeheartedly congratulate the team who has put the efforts to bring out this
booklet at the most appropriate time, when Simhadri is hosting the Operations
Meet.
With best wishes,
SANTOSH JAMES
General Manager (Project)

Simhadri Stage II
CONTENT
Equipment
Sl. No.
Page No
INTRODUCTION
COMMISSIONING GUIDELINES
SAFETY & PTW SYSTEM
DOCUMENTATION
13
STATUATORY & ENVIRONMENTAL READINESS
17
DEFECTS & OMMISSIONS
20
FUNCTIONING OF COMMISSIONING DEPARTMENT
24
O&M MANPOWER DEPLOYMENT STRATEGY
29
INVOLVEMENT OF O&M IN PROJECT IMPLEMENTATION
32
10
INVOLVEMENT OF SIMHADRI O&M TEAM IN STAGE-II
36
11
NEW INITIATIVES TAKEN
55
12
FACILITIES EXTENDED
57
13
CONCERNS
59
14
SUGGESTIONS
63
15
ANNEXURE
67
Simhadri Stage II
1.0
INTRODUCTION
Simhadri Stage II
1.0. INTRODUCTION
NTPC has been a front runner in project management, power generation and has
been able to achieve outstanding performance in all the related areas which has
manifested into all round excellence in power plant performance, efficiency,
reliability and availability.
Structured systems, procedures and Quality control mechanisms from conceptual
to commissioning stage are the backbone of NTPC's success. Under the current
ABT regime of operation, fast stabilization, high availability, efficient and economic
generation of new Units on sustained basis is the need of the hour. It is equally
important and essential that the Units are erected and commissioned meeting the
challenging targets with high standard of quality of erection and commissioning. But,
in the recent past major outages have taken place in new Units during the
commissioning stage or just after commissioning due to various reasons, which
have caused loss of availability, delay in Commercial Operation Declaration (COD)
of the Units, delay in conduction of PG tests, deterioration in performance and
deviation in operational parameters etc.
Since NTPC is going for huge capacity addition, the performance of newly
commissioned Units is a matter of great concern, requiring introspection and review
of our existing commissioning system. The experience gained over a period of
commissioning of 200 MW / 500 MW / 660 MW in NTPC has helped in coming out
with this unique document.
An Attempt has been made in this document to provide a base for formation of
various committees during power project construction and commissioning with role
and responsibilities of various teams from project conceptual stage to commercial
operation of the Unit by revisiting our commissioning guidelines. This document
describes clearly the type of approach needed and duties of various departments to
commission the Unit / plant successfully and most effectively.
Simhadri Stage II
2.0
COMMISSIONING
GUIDELINES
Simhadri Stage II
2.0 GUIDELINES ON COMMISSIONING OF POWER PROJECTS IN NTPC:

In the present regulated regime, availability and reliability of thermal power plant
play an important role in achieving company targets. NTPC believes that a proper
and systematic commissioning is essential in building a highly reliable and efficient
power plant for commercial operation. This document describes about how to set up
a commissioning organization ,commissioning department, its responsibility to bring
in reliable and efficient Units for commercial service and its role in simultaneously
developing other departments and facilities.
2.1 COMMISSIONING OBJECTIVE:
The objective of commissioning is to commission the plant as per commissioning
procedures of NTPC to ensure reliable operation after commissioning and to prove
that the individual equipments, which are interconnected to form the systems, are
suitable for their intended purpose.
ENSURE QUALITY COMMISSIONING:
- The aim of commissioning group should be :
a) To check that plant is supplied and erected as per design.
b) To commission the system by adhering to safety norms and the set of
commissioning procedures of the organization.
c) To commission the equipment / systems with all protection and interlocks in
minimum possible time.
d) To bring about defects and omissions in erection and rectify them before the
Unit reaches full load and trial operation.
e) To bring design deficiency (from safety / maintenance /system reliable point of
view) to the knowledge of concerned and apply necessary corrections before
trial run of the equipment / system.
f) To make the plant ready for commercial operation at the earliest possible
date.
g) To check and ensure that the plant operates reliably, safely and meets the
design parameters.
h) To establish the reason for any failure in achieving the design performance or
any other limitation.
Simhadri Stage II
I) To ensure each system performs as designed after assembly and is

connected correctly with the main system.
j) To train the operation executives for safe and efficient operation of the Unit.
k) To preserve documented history of equipment right from the date of erection
completion till the takeover of the Unit by O&M.
2.2 COMMISSIONING ORGANIZATION:
As per existing practice, full-fledged O&M personnel are not posted till the first
synchronization of the Unit and the existing business scenario of regulation
demands tight commissioning schedule followed by a reliable operating plant. Due
to non-availability of experienced O&M personnel with the agencies, it is felt that
deployment of O&M manpower (minimum of 2-3 executives from each department)
shall be made parallel to achieve the desired objective of commissioning.
In order to streamline the planning and management of commissioning activities at
NTPC's projects, commissioning organization is to be set up with the following three
bodies:
2.21 COMMISSIONING STEERING COMMITTEE:
It is to be formed as per commissioning system circular No. COS/
Commissioning/ 01/ 2010/ 1409 dated 27 / 28.10.2010(Annexure-A). In order to
resolve the issues in time, the meeting of the Steering Committee can be once in
a month through Video Conferencing in additional to existing practice as per
guidelines . (Annexure-A)
2.22 COMMISSIONING PANEL:
The constitution of the Commissioning panel shall be as under for expansion
projects. In case of green field projects, respective process commissioning
representatives shall take the responsibility of the O&M department till the
posting of remaining O&M manpower.
G HEAD OF O&M - CHAIRMAN
G HEAD OF ERECTION
G HEAD OF (COMMNG.) / (ELEC. / C&I / MECH. / BOP-MTC.) / (MTP) /
(OPN) / (CHEM) / (EEMG) / (CHP)
G HEAD OF (C&I EREC.) / (ME) / (ELEC. EREC.) / (CCD)
Simhadri Stage II
G NOMINATED MEMBER OF COS (COMMISSIONING)

G NOMINATED MEMBER OF ROS
G CONTRACTOR'S REPRESENTATIVES
2.23 WORKING PARTIES:
Working parties are small groups that look after a particular area / system in micro
level on planning, reviewing and monitoring the E&C progress towards completion
as per the schedule. These are formed from members looking after a specific area /
system. Team Leader of the working party varies from system to system. The team
leaders of various Commissioning Working parties, viz., CHP, Boiler, Turbine,
Offsite, Electrical, C&I etc., should be from respective maintenance groups. Head of
Turbine maintenance or the 2nd in position should be the team leader for Turbine
and its auxiliaries. There should be one commissioning working party responsible
for operation and process commissioning and this should also be responsible for coordination among the various commissioning working parties. (Annexure-B: List of
working parties formed).
The constitution of the Working Parties shall be as under:
G MAINT. (C&I/MECH/ELECT/CHP/BOP) MEMBER-CHAIRMAN
G COMMISSIONING MEMBER-CO-ORDINATOR
G EREC. MEMBER (C&I/MECH/ELEC.)
G CONTRACTOR'S REPRESENTATIVES
2.3
ADDITIONAL COMMITTEES RECOMMENDED:
Though the present guidelines explains clearly to address the various issues that
crop up during erection from time to time, with a view to expedite the process
considering the present scenario of mobilization of required resources, it is felt to
formulate the following committees to resolve the same which may or may not be
envisaged in the scope of contract and which are required for betterment and safety
of the systems.
2.31 PLANT MODIFICATION/BETTERMENT COMMITTEE:
During commissioning, need for plant modifications may be required or the
safety of the personnel / equipment / systems (for better approach and ease of
maintenance) and for increasing the reliability of the system. Top priority shall be
given to those modifications which addresses the safety related issues.
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Simhadri Stage II
Experience demands that all modifications must be subject to standard approval

system to ensure the safety standards are preserved.
The responsibility of the committee is to evaluate the feasibility of the proposal
initiated by concerned working party group and put up to Commissioning panel /
Steering committee for necessary approval in the prescribed format as at
Annexure-C of Commissioning guide lines .While allocating budget for project, It
is essential to make adequate allowance to cover of modification which will
inevitably be required during or as a result of commissioning tests. The
constitution of the committee shall be as under
G HEAD OF O&M CHAIRMAN
G FES MEMBER
G MTP MEMBER- Convener
G MEMBER FROM MAINT. (C&I/EM/MM)
G MEMBER FROM EREC. (ELECT / C&I/MECH)
2.32 HOUSEKEEPING / SCRAP REMOVAL COMMITTEE:
In most of projects during execution stage housekeeping is given least
importance though it is stands as part of the contract packages. Sometimes it is
very difficult to reach equipment to carry out checks because of waste material /
scrap lying all around, overflowing drains etc , which ultimately results in
accidents, damage of important equipments / instruments and leads to delay in
commissioning of the equipment.
Hence, a separate housekeeping cell shall be formed and the constitution of the
cell shall be as under. The team will identify the scrap and gives notice to
concerned agencies with a target date. If agency fails to clear the same within
the stipulated period, same will be cleared at the risk and cost of the agency and
under the project cost. It is the responsibility of the team to make available safe
approach to all equipments and it will carry out special audit before start of each
milestone activity. To carry out these jobs, suitable budget provision is to be
made available with required authority and a miscellaneous contract with the
team.
Simhadri Stage II
G O&M MEMBER
G ERECTION MEMBER
G P&S MEMBER
2.33 PRESERVATION COMMITTEE:
Nevertheless equipment reaches the site; it becomes an asset of the company.
From the day the equipment reaches the site and till E&C of the same is
completed, it shall be preserved in line with the OEM guidelines / the best O&M
practices. Presently not much of a focus is given on preservation of equipment
by the agency though it is specifically mentioned in the Scope of Work (SOW).
Also many cases are seen wherein due to improper preservation, equipment
damages occurred and agencies poor response in corrective actions has
delayed the project schedule. It is felt that adequate storage space and required
closed sheds are not available in time for proper preservation of equipment.
Even some times it has consumed many days in identifying and retrieving the
material. In this background it is very much essential to constitute a preservation
committee during the E&C stage itself.
The constitution of the committee shall be as under
G MEMBER FROM C&M
G MEMBER FROM O&M
G MEMBER FROM CONCERNED AGENCY
G MEMBER FROM COMMISSIONING
G MEMBER FROM ERECTION (ELECT/C&I/MECH)
The committee shall do periodical inspection at site / storage yard. Any major
observations shall be brought to the commissioning panel once in a month so as
to address them in time. Also segregation is to be made w.r.t. item wise
categorization visa vis type of storage required and the preservation checks to
be followed based on the nature of the equipment. Timely provision of adequate
resources in terms of space, manpower and budget provision shall be made.
Simhadri Stage II
3.0 SAFETY &

PTW SYSTEM
Simhadri Stage II
3.0 SAFETY:
Safety rules shall be a part of commissioning documents and activities. Safety
related training is a must for all the members of the commissioning team. The
responsibility of commissioning team includes:
3.1 : Safety Awareness:
G Arranging Safety training classes to entire commissioning team.
G Arranging pep talks
G Communicating alert / warning / caution messages through e-mails to all
concerned including agencies before start of and completion of energization.
G Conducting safety review before start of commissioning activity
G Bringing the safety related issues observed during walk down checks to the
concerned and getting them rectified.
G Educated all about commissioning of Electrical modules and equipments by
displaying 'COMMISSIONED' tags.
G Providing Danger tags / Equipment commissioned tags in bilingual form
including local language.
G Labeling/identification of equipments/modules/breakers shall be ensured
since beginning
3.2 : Equipment/Personal Safety :
G Providing safe environment at work place.
G Ensuring availability of necessary statutory licenses of the specific system
before energizing the electrical / mechanical system. List of such
requirement is enclosed as annexure. However the list is only indicative and
not an exhaustive one.
G Ensuring proper isolation of the system both mechanically and electrically
after completion of the commissioning activity, in case of idle period
G Safe barricading of area undergoing energisation.
G Identifying and acquiring Safe tools with respect to working in Hazardous
areas and Electrical systems.
G Complete and Clear labeling of commissioned equipment.
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Simhadri Stage II
G Ensuring Deployment of right extinguishers in addition to the fire fighting

system in advance and fire tender during charging
G Ensuring Deployment of additional fire extinguishers/fire tender along with
fire fighting personnel round the clock during critical commissioning activities
like BLU, Chemical cleaning, Steam blowing and Unit Synchronization.
G Strict compliance to SRCC, P&I Checks, P&I bypass register, PTW system
G A safety audit shall be conducted before start of important mile stone
activities like Boiler Hydro test, BLU, Chemical cleaning, Steam blowing and
Unit Synchronization. The audit team shall constitute with members from
CC-OS, ROS and site representatives.
G Labeling/identification of equipments/modules/breakers shall be ensured
since beginning
G Eye wash stations, safety showers, safety belts, breathing apparatus, ear
plugs,first aid centre, first aid boxes should be made ready
G PTW system should be implemented religiously. Lock out boxes and locks
are to be procured in advance.
G Commissioning team has to help MTP in allocation of code to various
systems and equipments. If require a team has to be deputed to running plant
for identifying systems required for PTW system.
3.3 PTW SYSTEM DURING PROJECT STAGE:
The commissioning period is the most difficult and accidents prone phase in the life
of the plant because during project execution handover of equipment/systems, precommissioning, commissioning and construction works proceed in parallel to
complete project schedule in time. To avoid untoward incidents which may delay or
affect the project schedule, it requires meticulous commissioning planning and a
comprehensive safety PTW system through SAP. Project Department will be
required to carry out pending works on already commissioned works and interface
works between running equipment and erection equipment. In order to ensure safe
working, separate guidelines/procedures shall be formed. The following may help in
forming the procedure specific to site requirement.
G Erection / construction department will identify Senior Authorized Persons
through an Office Order who will be authorized to request for PTW through
the format as per Annexure-D to their counterparts in O&M Maintenance.
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Simhadri Stage II
G Based on the above request, the concerned Maintenance department shall

apply for PTW as per existing procedure followed in SAP. In
notification/order, the concerned Maintenance department has to mention
the work details and erection personnel details under SUBJECT LONG
TEXT column.
G Operation shall issue PTW to the applicant of the concerned Maintenance
department. The Original Hard Copy shall be signed by Maintenance
representative and the Erection / Construction representative. After joint
signature, the Original shall be taken by Erection / Construction
representative along with the lockout box key. Maintenance shall keep a
photocopy of the PTW after joint signatures.
G After receiving the PTW, the Erection / Construction representative shall
check and get confirmed regarding the adequacy of isolation done by
operation / commissioning, since prime responsibility of work execution and
safety related aspects lies with erection / construction department.
G In case of extension beyond duration indicated, the Senior Authorized
Person shall request extension in the hard copy and send it to the counterpart
in O&M Maintenance who will get it extended by Operation through entry in
PTW Register with SCE and returns the hard copy to Erection / Construction
representative.
G After completion of job, Erection representative shall sign the hard copy of
PTW and return to concerned maintenance department.
G Maintenance representative shall cancel PTW as per existing practice in
SAP.
G Operation department will enter PTW details in PTW register kept in SCE
room exclusively for Stage - II works. O&M Commissioning group will
coordinate all works.
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Simhadri Stage II
4.0
DOCUMENTATION
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Simhadri Stage II
4.0 DOCUMENTATION:
To ensure safe and successful execution of commissioning activity it is must to be
defined, documented, conducted and recorded. Any commissioning activity
whether it is small equipment or a big system, it requires documentation and
certification depending on the requirement.
G NTPC is using latest technology in making all related documents from
agency available to site vide e-desk. Project / commissioning team should
have the access to the same for preparation of documents for safe and
quality commissioning.
G Based on experience COS is issuing guidelines in the form of technical
circulars on various equipment / systems. Hence, it is the responsibility of
COS to make these circulars available to the site in the beginning itself.
G Commissioning team should take initiative in collecting the entire statutory
and legislative requirement for including the same in commissioning testing
schedules for compliance.
4.1 DOCUMENTS TO BE COLLECTED:
The following documents shall be referred in commissioning and preparing various
documents applicable to the particular Unit.
G Commissioning guidelines
G Contract documents
G COS approved commissioning procedures pertaining to site on critical
systems
G Operation management System
G COS technical documents / circulars
G Related approved drawings
G Commissioning checklists obtained from Agency
G O&M manuals, GA drawings, Equipment datasheets
G Control philosophy, control schemes/Control Logics
G QA documents
G Factory test reports
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Simhadri Stage II
G CEA guidelines
G Trial operation guidelines from COS
4.2 DOCUMENTS TO BE PREPARED:
The following documents shall be prepared.
G Process Networks
G Standard checklist for various equipments of Unit.
G Plant item completion list consisting of Electrical/Mechanical/C&I list
G Erection completion protocol, SRCC, Charging Clearance Certificate, RIOC
G P&I Checklists
G Testing and Commissioning schedules for various equipments of Unit
G Equipment log sheet
G Emergency Instructions
G Local work Instructions
G Communication register
G Protection Interlock bypass Register
G Equipment preservation procedures
G Commissioning reports for various systems
G Unit /Equipment outage reports
G Equipments/system defects/deficiency
G Engineering issues
G Trial run operation reports
4.3 DOCUMENTATION CENTRE:
In order to maintain the total documents / records at single place and for ease of
access to the concerned, a centrally located Document Control Centre (DCC) is to
be set up. DCC has to be opened well in advance (along with formation of
commissioning team) and an executive of the rank of DGM to be made
documentation in-charge and shall be assisted by 2 or 3 data operators.
Infrastructure facilities like a heavy duty photo copier, Fax machine, scanner and
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Simhadri Stage II
LAN connected PCs with heavy duty printers are to be essentially and exclusively
provided for DCC including storage compactor cabins.
All the commissioning documents viz., standard checklist, testing schedules,
commissioning procedures, protocols duly filled and signed by the concerned
parties are to be filed equipment wise and system wise. Procedures related to COD
of the Unit are to be also handled by I/c. of DCC. It has to maintain list of defects /
shortcomings / deficiencies observed by commissioning team and same has to be
circulated to all and has to monitor, review, update and follow up with concerned
department for their liquidation.
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Simhadri Stage II
5.0 STATUATORY
&
ENVIRONMENTAL
READINESS
17
Simhadri Stage II
5.0 STATUATORY AND ENVIRONMENTAL READINESS:

In view of stringent environmental and statutory norms prevailing, Commissioning
team has to take lead in identifying, follow up and ensuring the following well before
energizing or start of system depending upon the type of activity and Commissioning
group has to follow up and ensure availability of valid licenses before start of relevant
activity.
G Thorough study of Plant drain system to ensure Separation of storm water
drains and plant effluents
G Installation of required flow meters, energy meters at designated / required
locations for monitoring /metering/ /accounting purposes
G Ensuring Availability of AAQMS data right from the date of first
synchronization
G Installation of Stack emission monitoring instruments and ESP IOS System
well before first synchronization
G It is experienced that a lot many delays have occurred in obtaining the same
due to various reasons which has resulted in delay in the commissioning
activities. Though obtaining license is in the scope of agency in few cases, in
order to avoid delay, since beginning a responsible person need to be
identified right from the commissioning stage.
G Identifying the systems / equipments that require licenses / permissions.
G Collecting the statutory bodies from whom permission is to be taken
G Obtaining the relevant procedural aspects with respect to documents
required, application forms, fee payment etc
G Liaison officers shall be identified for each license / permission in line with
practice of existing stations
G Renewal of licenses thereafter till the requirement is complete. It shall be the
responsibility of erection department till COD of unit.
G The tentative lists of equipments which may require clearance from statutory
authorities (Director of Boiler, CEA etc.,) are as below. The mandatory and
statutory requirements may vary from state to state.
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Simhadri Stage II
G Boiler license
G Aux Boiler
G Storage of chlorine
G Storage of Fuel Oil (HFO/LDO/Diesel)
G Storage of Compressed gas cylinders like H2, N2, CO2, O2,
G H2 plant generation & Storage
G Statutory testing of tools
G License for all elevators
G Charging clearance for Electrical equipment
G Consent for Operation
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Simhadri Stage II
6.0 DEFECTS
&
OMMISSIONS
20
Simhadri Stage II
6.0 DEFECTS & OMISSIONS:

Commissioning team has to prepare list of deficiencies/shortcomings and other
defects which may come to surface during the process of commissioning of various
equipments/systems/sub-systems of a unit. All such defects that surface during precommissioning checks and initial runs of equipment/ system shall be listed by the
commissioning group in the format specified for the purpose refers Annexure-E.
Possibility may be explored to integrate this data with SAP for uploading all such
defects & omissions pending before start of COD for ease of monitoring, review,
liquidation and record.
OBJECTIVES:
G To keep a systematic record of all plant defects right from a precommissioning stage to final contract clearance certificate.
G To keep the records of all deviations and omissions from approved drawing.
G To assist owner in the assessment of plant/engineering health at important
stages of plant like SRCC, ITOC, FICCC.
G To force contractor to complete all his contractual obligations before the
contract is declared to be over.
The defect liquidation Progress Review Meetings shall be held on weekly basis
under the chairman ship of station commissioning in-charge and once in a month at
the level of GM (Proj.) and Head of O&M. This review shall be done since first
equipment/system commissioning. Basis of weekly review meeting shall be the
Defect Liquidation schedule furnished by Contractor in consultation with erection
department as per the format given at Annexure-F.
The defects that are noticed during various stages of commissioning phase can be
classified primarily in to the following four (4) categories:
6.1 Defects Classification
6.11 Pending jobs/Erection Defects- CATEGORY-I:
These are the erection jobs yet to be completed due to either time constraints or
material constraints, as also the jobs that may not have been done in proper manner
(e.g. loose or hanging cables, pipes routed at site, improper cable termination etc.,).
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6.12
Simhadri Stage II
Additional Features-CATEGORY-II:
Though listed as defects by the commissioning group , these are additional

features which are desirable by O&M group but are not specially included in the
scope of contractor as per specs/drawings/data sheets. These may also be such
feature which may be needed as per Good engineering practices. These include
provision of additional staircase, platforms, inter connections, relocation of valves or
other equipments for ease of access, operation and maintenance.
6.13
Engg./Operational system related Deficiency-CATEGORY-III:
These are the deficiencies noted during partial set up runs or complete system runs
during the commissioning /Trial operations of unit and relate to the basic
Engineering / Design aspects of system/equipment and may need
change/modification in the existing plant /system for meeting the contractual
requirement.
6.14 Warranty Defects-CATEGORY-IV:
These are the defects which come to the surface during continuous running of plant
and equipment after the trial operation has been successfully completed and the
equipment is under warranty period.
6.15 PROCEDURE FOR NUMBERING THE DEFECTS
a. The list of defects for any system/ sub-system/ equipment shall be prepared
under four categories viz. Mechanical, Electrical, C&I and others/general
b. Each category of defect has been allotted a specific number series as below:
Mechanical Defect
001-199
Electrical Defects
200-299
C&I Defects
300-999
Others/General
1000 on wards
c. Each defect shall be allotted a specific defect number for its easy identification,
reference, and retrieval.
d. The defect number shall comprise of following components:
i.
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Main system in its abbreviated form
Simhadri Stage II
ii. Sub-system in its abbreviated form

iii. Category of defect viz. Mechanical, Electrical, C&I etc., denoted by single letter
i.e. M,E, C&I and Gen.
iv. The serial no. as per the specific number series category as referred above for
various categories of defects.
e. ILLUSTRATION:
To illustrate, a Mechanical defect noted in the ID Fan-A, a sub-system of SG &
Auxiliaries shall be numbered as below:
SG & Aux/ID fan-A/M/001 (Annexure :G) (Main system)/(subsystem)/(category)/(serial no. under Mechanical)
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Simhadri Stage II
7.0 FUNCTIONING
OF
COMMISSIONING
DEPARTMENT
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Simhadri Stage II
7.0 FUNCTIONING OF COMMISSIONING DEPARMENT:

Successful project execution demands the highest professionalism from all
members of the project team including commissioning
and contractors.
Commissioning is as much a management task and a technical task.
Commissioning phase is a crucial and final quality check of design, erection phases.
Any previous mistakes or omissions which have been overlooked will be uncovered
during commissioning. To ensure quality commission, the O&M core team
consisting of 2 to 3 people from each department should be posted in parallel with
erection people.
7.1 CRITERIA FOR SELECTION OF MANPOWER:
The commissioning team should be mix of experienced personnel from all
departments and fresh personnel from all disciplines. The head of commissioning
shall be in the level of AGM rank and should have sufficient experience (at least 20
yrs) and knowledge about O&M activities. The experienced personnel shall be in the
level of E4 to E7 and should have sufficient knowledge about operation and
maintenance activities. The fresh personnel shall be from different disciplines. The
purpose of above mix of team is to obtain the following advantages.
a) The engineers have thorough knowledge of operation of plant unit hence
commissioning becomes easy.
b) The engineers have maintenance knowledge of the systems hence the process
problems and deficiencies, which are likely to come due to new design, will be
addressed.
c) It helps maintenance team in identifying spares required for reliable running of
the plant and also helps in developing scope of contract.
d) The ownership feeling for the executives will always be prevalent and will work
as a great motivator.
e) In the process, smooth knowledge transformation will take place from
experienced personnel to fresh personnel.
f) It helps in smooth transformation from construction to operation to maintenance
stage.
7.2 ROLE OF COMMISSIONING DEPARTMENT:
The head of commissioning department plays pivotal role in timely available of
different O&M personnel for running the commissioned plant smoothly by formation
25
Simhadri Stage II
of various departments in O&M till the posting of AGM(O&M) and has to identify and
ensure the phased requirement of personnel/resources for various departments.
NET WORKS:
Net works for the critical activity BOILER LIGHT UP and
SYNCHRONISATION are to be drawn. This network charts shall be
prepared made along with the erection personnel, hence the realistic
assessment of the activities will be there. These charts help the management
for finding the bottlenecks and thus they can divert resources on these
activities. Daily progress reports are to be generated. This also helps the
corporate management in having an update of the progress and the position
of the plant. This helps the corporate-monitoring group to effectively monitor
the delays and take action.
26
Commissioning team has to identify consumables (chemicals, lube oils, coal,

HFO/LDO etc.,) ,required for commissioning the plant and running it
thereafter , well in advance so that same can be procured in time.
Commissioning team has to ensure commissioning spares and help other

departments in procuring spares in advance
Classes, trainings shall be arranged for fresh commissioning and operation

engineers on commissioning aspects by equipment suppliers.
Requirements for system completion, Engineering issues, deficiencies in the

system are to be discussed on regular basis in PRT and Daily planning
meetings. Commissioning team has to conduct daily commissioning
planning meeting
Erection has to be informed the sequence of the system required to be

commissioned. Works are to be prioritized so that all resources will be put in
right direction for early system completion .Issues related to the system /
equipments to be commissioned shall be discussed in details and
requirements shall be identified well in advance and any shortcomings in the
supply of materials or drawings shall be brought in the notice of supplier
through project group, for his readiness of supplying in time.
To develop process network and implement it. To take a lead in scheduling of

process networks, activity schedules for proper review and monitoring.
7.21
Simhadri Stage II
EMERGENCY INSTRUCTIONS:
Commissioning department along with operation department has to ensure the

availability of emergency instruction, before Light up of Boiler, for various
equipments and failures. The following is the tentative list which requires emergency
instructions.
1. Grid failure (instructions for UCE, desk engineers, locations and switchyard).
2. Total AC failure of a unit.
3. Total DC failure of a unit.
4. Fire in air heater, mill or Main Oil Tank.
5. Purging out of Hydrogen from Generator.
6. Loss of instrument air.
7.22
LOGGING:
Commissioning department along with operation department has to prepare

different operation logs, Start up logs Boiler light up procedure, Synchronization
procedure, Unit Schematic drawings, Unit Technical data book etc., as listed in CC
Operation management manual.
7.23
TRIP ANALYSIS:
For trouble free operation of the Unit, Trip analysis is to be carried out for every
outage since beginning to avoid repeated failures and to take correct actions so that
unit reliability improves during commercial service.
7.3 COMMISSIONING STEPS:
All Equipments/systems shall be commissioned as per commissioning guidelines,
approved COS procedures and approved testing schedules and standard
checklists. The tentative steps involved in commissioning of equipment is as below
1. Obtain Erection completion protocol
2. Before energizing/running, Clearance shall be taken from erection (Mechanical,
Electrical, Civil & C&I) and FQA.
3. SRCC shall be issued
4. SCL and Plant item completion list shall be filled.
27
Simhadri Stage II
5. Equipment / System P& I checks shall be carried out

6. Charging /Energizing the Equipment / System as per approved procedures.
7. Defects, omission and Deficiency list shall be prepared.
8. RIOC shall be issued.
9. Protocols shall be prepared after commissioning of each equipment / system.
The protocol should contain commissioning details, commissioning logs,
operation logs and systems omissions if any, defects if any observed and
schedule for attending same.
7.4 CERTIFICATES:
During erection and commissioning various certificates shall be issued to start
further activities (Annexure :H)
7.5 BUSINESS EXCELLENCE ACTIVITIES:
The following BE activities shall be carried out.
1. O&C personnel shall be sent to other commissioned plant within NTPC or other
projects to familiarize with system and to discuss various problems to be come
during commissioning / operation and methodology adopted in overcoming
same.
2. Separate COMMISSIONING WEB SITE shall be opened and all relevant
documents are to be posted for transference and knowledge dissemination.
3. Educate erection department and agency about requirement for system
completion and priority systems through animation.
4. All O&M manuals shall be scanned and put on commissioning website for future
reference and soft copies may be prepared and to be given to various
departments.
5. All commissioning documents shall be scanned and put on commissioning Web
site
6. Before Commissioning of any equipment/system, it is to be discussed
thoroughly among team members for smooth commissioning.
28
Simhadri Stage II
8.0 O&M
MANPOWER
DEPLOYMENT
STRATEGY
29
Simhadri Stage II
8.0 O&M MANPOWER DEPLOYMENT STRATEGY:

The project implementation process is complex which requires simultaneously
attention to a wide variety of human, budgetary and technical variables. Out of these
three, addressing human variable is very challenging.
At Present, in our organization massive expansion is taking place. The design,
construction, erection, testing, and commissioning of power projects is very much
influenced by the competence levels of the managers, professionals, technicians of
both employer and contractor involved in erection and commissioning. In this
present power sector regulated market timely execution of project with quality
without incurring any extra cost overruns are essential for power plant and it can only
be achieved through excellence in human performance during project and O&M
stage.
As per existing contract conditions, NTPC will provide operating personnel for
operating of the equipment under the supervision of the contactors / manufacturers
supervision. And contractually it is the responsibility of the agency till trial operation
completion to rectify and attend to the teething problems arising during
commissioning and initial run. But it was observed at times in many cases
mobilization is not up to the mark due to which delays are occurring and equipments
are getting damaged and ultimately it is hampering project schedule and it is more
felt in case of BOP packages. Hence timely availability of requisite Commissioning
Manpower, O&M manpower from the beginning along with erection is very much
essential.
In this back ground to achieve desirable object of project, the following approach in
deployment of O&M in green field project may be followed:
G Posting of manpower should include mix of O&M and erection background
during erection and commissioning
G In the present scenario where in construction and commissioning works are
going on simultaneously in many project across NTPC, it is very difficult to meet
entire requirement of commissioning, operation and maintenance manpower
from pool of experienced people. It should be blend up of new and experienced
people.
G Deployment of fresh Executive manpower to be done 36 months prior to
schedule date of synchronization of first Unit (to give them sufficient time for
training at existing units and thereafter at OEM works (especially it is very much
30
Simhadri Stage II
required in case of new technologies). Initially identified maintenance EETs

shall be attached to erection to capture knowledge required for maintenance
and as commissioning progress they shall be absorbed into O&M gradually as
per requirement. In case of maintenance EETs Erect and maintain philosophy
and in case of commissioning EETs commission and operate philosophy shall
be followed to motivate and bring belongingness since beginning.
G Setting up of O&M department to commence approx 30 months prior to schedule
date of synchronization of the first Unit. At least 2-3 executives from each
department shall be made available to achieve the desired objective of the
O&M.
G Complete O&M executive manpower for first unit to be in position at least 18
months prior to schedule date of synchronization of First unit. Manpower for the
subsequent units to be in position 12 months prior to schedule date of
synchronization of respective units to take care of parallel commissioning,
operation and maintenance activities.
G Deployment of non executive manpower to be done progressively and the
required non executive manpower (after completion of their induction & training)
for first unit should be in position at least 6 months ahead of schedule date of
synchronization of the first unit. If require non executive manpower may be hired
in the beginning itself to assist core commissioning group.
G As units trial operation completes, commissioning man power may absorbed
into various departments as per requirement.
G At present in some of our projects, during overhaul experienced ex BHEL are
being engaged to supervise critical works such as Boiler pressure parts, FANs,
TDBFP etc., to get quality work and to address experienced manpower shortage
problem. Same method may be followed for critical works in erection and
commissioning.
31
Simhadri Stage II
9.0 INVOLVEMENT
OF O&M IN
PROJECT
IMPLEMENTATION
32
Simhadri Stage II
9.0 INVOLVEMENT OF O&M IN PROJECT IMPLIMENTATION:

O&M intervention at various stages of project in any thermal power plant plays a vital
role in erection and commissioning of the project. It reduces the gap between first
synchronization and COD. And also, operational and financial commitments are met
after the plant has gone into commercial operations thereby resulting in efficient,
reliable and sustainable units.
NTPC is having vast experience in project execution and is getting improved from
one project to other project by incorporating suggestions from Erection, agencies
and its O&M staff. In spite of this during design, engineering & erection stage, O&M
requirements are not fully met because of many constraints and it takes lot of time in
getting approval for modifications in O&M stage. In General, Erection team is busy
with tight schedule, in mobilization of resources and less / no time to concentrate on
modifications/ Improvements required by O&M. More over scope of work may not
allow them to carry out modification through existing agencies.
In some cases O&M intervention is required at the time of erection stage, based on
the learning from other projects and existing units and to implement COS latest
guidelines so that maintenance problem in the future can be minimized and
availability of unit increased for commercial operation. It is very important to capture
behavior of the equipment since its initial run because it will be the reference for
maintenance to carry out rectification of defect in future.
Based on the past experience in commissioning, it is felt that involvement of O&M
expertise is essentially required to take up the different roles in the following phases
of project for getting quality, timeliness and cost effective project.
9.1 PROJECT CONCEPUTAL STAGE:
During project conceptual stage of green field project, it is not possible to identify
O&M manpower. Hence COS and ROS of that particular project has to play O&M
role and has to ensure the following. In case of expansion project, existing O&M
personnel should involve.
G Incorporation of learnings & best practices.
G Due importance is to be given to location condition (Saline / dusty / ash slurry
etc.) of the equipment during equipment selection & engineering.
G Due care has to be taken for additional systems/facilities required for easy O&M.
G Special task force shall visit the nearby projects & shall come out with a feed
back and same should be reflected in detailed engineering.
33
Simhadri Stage II
9.2 PROJECT ENGINEERING STAGE:

During project engineering stage, series of interaction meetings shall require to
ensure the following.
G Proper layout of plant & equipments.
G Proper approach to all equipments.
G Locking facility (for valves and supply feeders).
G Proper routing of power/control cables.
G Redundancy of protection system.
G Location of local control panel / equipment.
G Proper distribution of power supply for reliability.
9.3 PRE COMMISSIONING AND PLANNING STAGE:
G Identification of O&M man power.
G Formation of commissioning team and various departments.
G Planning for T&PS /Spares/Services/lab equipments.
G Identification and procurement of consumables and process requirements.
G Review of P&I and exposure to new system/technology.
G Exposure to new technologies through involvement in factory tests, arranging
training sessions by OEM, visits to OEM workshops, visits to contemporary
projects.
G Preparation of commissioning documents.
G Identification of space for preservation of equipments& maintenance bay.
9.4 CONSTRUCTION & COMMISSIONING STAGE:
G Identification and rectification of safety gaps.
G Implementation of Operation Management System.
G Involvement of O&M and OS in all critical checks.
G Carrying out Modifications for safe and smooth operation.
G Implementation of learnings and COS guidelines.
34
Simhadri Stage II
G Ensuring availability minimum / miscellaneous contracts for Rectification of

problems for keeping project progress.
G Deployment of O&M experts during important activities round the clock.
9.5 COMMISSIONING & OPERATION:
G Identified requirements well in advance.
G Dissemination of knowledge thru regular presentations.
G Online PTW through SAP.
G Deployment of experienced operation personnel for quick stabilization and
guidance.
G Modifications in logics and mimics for safety of equipments and operational
ease.
G Implementation of all operation practices (Schedule changeovers, ensuring DC
equipment).
G P&I checks to be carried out in each start up.
G Introduction of maintenance practices.
G Ensuring Renewal of all statutory and environmental licenses/permission
35
Simhadri Stage II
10.0
INVOLVEMENT
OF
SIMHADRI O&M
TEAM
IN STAGE-II
36
Simhadri Stage II
10.0 INVOLVEMENT OF SIMHADR O&M TEAM IN STAGE-II UNITS:

The following factors influenced team Simhadri to take different approach in getting
Stage-II units.
G High performance of STAGE-I units after COD
G BUILT in your way by becoming part of erection team
environment
for trouble free
G Company guidelines
G High expectation from Stakeholders after COD
G ABT Environment
G Strict Project Schedule and MOU targets
G Paucity of skilled and limited manpower with agencies for repair during
Commissioning especially in case of BOP Packages
The following Successful O&M program was implemented during various stages of
Project execution in Stage-II.
10.1
PROACTIVE MEASURES:
G Based on learnings from Stage-I units ,Series of presentations and interaction

meetings with CC planning, Engineering and COS for implementing Stage-I
learnings in Stage-II
G Feedback regarding special conditions of Simhadri (such as corrosive
environment because of its location in coastal area) is given to cc during engineering
stage and also necessary corrections were suggested during erection stage
G In this competitive world and customer driven market, If an organization has to
survive and sustain and has to complete project in time without incurring extra cost
and reliable operation thereafter, it has to adopt a system where in agencies/supplier
is a part of system in every phase of the project whether it is planning, engineering,
erection, commissioning etc., When agency is a part of the system, it is easy to
resolve issues by adopting WIN- WIN situation.
G NTPC has commissioned many units ahead of schedule because it believes in
this philosophy. By keeping this in mind the management at Simhadri (though it was
expansion project) has formed a commissioning team, with members from various
functions before the synchronization of the unit to ensure quality commissioning.
37
Simhadri Stage II
Experienced (both operation and maintenance) persons were deployed in and

formed various teams as per CC guidelines and given additional responsibility to
other departments in involve actively in Stage-II.
G Equipment Supply source Discrepancies : During document review it was
observed that he following feeders were not envisaged and same were conveyed to
Engg. and resolved in time.
y
Mill lub oil heaters modules were not identified. Identified from spare modules
of BMCC.
TG DMCW-C feeder was not envisaged. Indentified from USS Sec-2 spare
module.
CW LWP modules were not identified for CW P/P-2, 3, 4, 5. Supply was given
from spare modules.
The power supply modules for MRHS Compressors, Condensate transfer

pumps for Emergency makeup water system (CST System) and associated
valves are re-designated from Service Building Switchgear / DM Plant MCC
to Station Service Switchgear / CPU MCC after necessary approval.
Early Introduction of PM schedules : Thermo vision scanning is done for all

drives and power transformers during initial load run, periodical monitoring is
done and incorporated the practice in PM Schedules. This has helped in early
detection and rectification which resulted in increased availability.
In VFD transformers of Stage-II we received Dyn1 for CH-2 which is not

matching our requirement. Both at 11kv and 2.3kv we have swapped the cable
of R&Y phases for bring the vector group to Dyn-11.
Coal Feeders control circuit 110 V AC supply taken from the supply of Boiler
ACDB. Feeders used to trip during minor grid disturbances also. To avoid such
tripping supply was given from UPS since beginning.
G System technical audits were carried out by both regional and COS team before
synchronization and COD to find deficiencies in the system and it has helped a
lot.
10.2 PLANNING:
G To avoid untoward incidents and outages during interface works with existing
facilities a well defined PTW SYSTEM was placed in position.
38
Simhadri Stage II
G The following measures taken:

y
Commissioning web site opened
Prepared all SCL and NETWORKS required for critical activities and made
available on webpage
Power point presentation (animation) made for easy understanding of

commissioning process
Identified Consumables and Chemical required for different process

commissioning to make them available in time
Deployed O&M personnel at workstations of BHEL (since Max. DNA was

new system for Simhadri), ABB and Emerson to acquaint with systems in well
advance.
Reviewed P&I drawings and brought system deficiencies to the notice of

concerned
G Identified various process requirements (detergent flushing, EDTA etc.) early

and informed erection accordingly for timely completion of process.
G Proper provision was made available in existing contracts to deploy staff as per
requirement.
G In the absence of regular operators, UPL operators were deployed both in CHP
and main plant
G Since commercial regime for Stage-I and II is different, proper exposure to
operation was given well in advance to handle properly after COD
G COMMISSIONED tags / stickers got printed well in advance.
G Walkie-talkies, Log sheets and infrastructure for commissioning team were
made available.
G To acquaint with new systems a series of presentations arranged during general
shift for Operation people through commissioning department.
G By seeing delay in getting DM equipments it was planned to get interconnection
of stage-II DM tanks with Stage-I DM water system and same was got done
which has resulted in meeting DM water requirement in stage-II activities.
39
10.3
Simhadri Stage II
MEASURES FOR KEEPING PROJECT PROGRESS ON SCHEDULE:
G Completion of Boiler Drum lifting is a major mile stone in boiler. During drum
lifting, Lifting mechanism (STRAND JACK SYSTEM) has given problem after
reaching drum at certain height and agency was unable to solve problem. C&I
and Electrical maintenance immediately intervened and solved problem
G To carry out Air leak test of ducts ,FD Fan-3A was initially run with site PLC facility
as by that time the Main control room was not ready
G Unit-3 BLU was completed with contingent cooling water arrangement.
Availability of SG ECW pump was must to carry out subsequent Boiler activities
such as EDTA, Steam Blowing etc., High vibrations were observed during initial
running of SG ECW Pump.TMD has analyzed the problem along with condition
monitoring and found problem with coupling and same was replaced with new
type coupling which resulted reduction in vibrations. TMD helped a lot in
reducing vibration levels in TGECW and ARCW pumps.
G In project phase, Completion of TG lub oil flushing is an important milestone
activity because TG alignment and subsequent activities of generator depend
on it. In U-3 TG lub oil flushing was held up due to high vibrations in KBL make
AOPs. Agency failed to address the problem and time gap was less for achieving
capacity addition target. At the advice of Maintenance existing KSB make spare
pump was installed and lub oil flushing activity was completed.
G During Steam blowing of Unit-3 lot problems were faced with EOTV (12/1500
class) and it has taken more time and same was brought to the notice of higher
authority. In Unit-4 EOTV of 15/1500 class was used and achieved steam
blowing completion in 18 days it was record.
G Steam blowing was carried out for MS and CRH lines together.
G In Unit-4 for Pre-Boiler system, steam flushing was carried out instead of
Detergent flushing.
G A special expert team was constituted to commission and address the valves
problem.
Daily commissioning meeting conducted at TG hall to discuss the issues at micro

level for smooth commissioning of systems.
G Inputs required for systems/equipments commissioning at micro level were

prepared well before and circulated to concerned, resulted in timely erection
completion.
40
Simhadri Stage II
G Wherever power supply could not be extended from Main Plants designated
MCC, temporary power supply from stage-1 nearby MCC was extended to meet
the power supply requirement.
G Cautious & well documented approach towards use of common
resource/facilities done.
G Extensive help was extended in carrying out electrical testing during erection &
commissioning of units.
G 2nd EOT crane support was provided with immediate procurement of trailing
cable for speedy erection work.
G Timely help extended in providing necessary spares / T&P / services to augment
efforts of erection agencies to meet erection mile stones.
G In absence of Station transformer power supply, complete commissioning
activities carried out with Stage-1 Standby transformer.
G Electrical and Mechanical work shop facilities were extended as per requirement
round the clock.
G Temporary synchronising skid is prepared in absence of permanent
synchronising relay with circuitry & unit was synchronised successfully with
temporary synch circuit.
G In absence of cable trays, Stage-I Cable trays are utilised for cable laying &
charging of offsite transformers
G Deployed O&M manpower round the clock during important commissioning
activities such as Boiler EDTA, Steam blowing, synchronization and during
stabilization period.
G The Main turbine lube oil throttles are supplied as solid. The throttles were
machined at NTPC workshop as per the drawing of BHEL, Haridwar.
G Repeated failure of FD-3A surge arrestors during starting due to resonance
could be resolved by altering power cable length. It has helped in commissioning
of subsequent activities.
10.4 MEASURES FOR INCREASING AVAILABILITY & RELIABILITY:
G IMPLEMENTATION OF OPN. MANAGEMENT PRACTICES:
During Project implementation improper operation, start up and shutdown of
equipment /system will directly influence the ultimate success of an entire
41
Simhadri Stage II
project. Proper operation planning is the key to avoiding delays, improving

process sustainability, cost overruns due to equipment failures and potential
safety hazards. Since supply of operation staff is in the scope of NTPC, O&M
thought it was apt to deploy operation manpower along with commissioning
team. The following measures adopted to introduce NTPC OPERATION
MANAGEMENT SYSTEM for increasing system reliability.
G P&I checks were put in service and checked during every light up and
synchronization religiously.
G Deficiencies observed in the system got rectified at the earliest.
G All Log books/sheets ,start up/shutdown logs, change over schedules etc.,
implemented as per existing practice in running units
G Modifications carried out in MIMICS for easy Operation and emergency handling
G Experienced operation staff were deployed round the clock during important
activities such as BLU, EDTA, Steam Blowing, safety valves floating, H2/CO2
filling, Synchronization, Full load etc., to avoid untoward incidents which may
cause delay for project completion.
G Communication resister and P&I bypass resister opened since beginning.
G Proper modifications were carried out in Logics as per existing practices and CC
guide lines.
G BCW pumps cavity purging carried out during boiler draining and filling to
prevent entry of debris into motor cavity thereby increased BCW pumps
availability.
G Material mix up study was carried out both boiler and turbine side and improper
material got replaced before trial operation thereby avoided forced outage.
G TMD played a major role in increasing TDBFPS availability by attending all
oil/water leakages ,attending governing controls problems, misalignment &
mechanical seal leakages problems.
G In absence of DDCMIS logics for changeovers, logics were built inside the relay
with additional inputs to the relay to meet the interlock & protection requirement.
G All the defects noticed during initial running and trial operation of the unit were
immediately attended in Unit # 3 resulting in high availability of TG
G O&M feedback from experiences of Stage-I and commissioning experiences
42
Simhadri Stage II
from stations such as Dadri, Korba are utilized during Simhadri Stage-II
electrical system erection and commissioning
G Some of the OS recommendations which were not complied in design stage
were highlighted and efforts were put by O&M for carrying out appropriate mid
course corrections during the erection commissioning stage.
G Non availability of CW pump leads to reduction in capacity of the unit and some
times it may lead total shutdown of the unit. During initial operation vibration
problems in Motor and cracks in suction bell of CW pumps were observed. O&M
carried out Welding repair of cracks in the suction bell of CWP # 5 and vibration
problem was highlighted and tried best to contain for pump availability.
G With help of Condition monitoring group vibration problems in SGECW, TGECW
and ARCW pumps. Condition monitoring group played a major role in equipment
availability by taking vibration measure regularly particularly in Main TG and CW
pumps and by deploying man power as per requirement.
G Implementing all O&M chemistry practices.
G ELECTRICAL:
y
In Stage-I integration with Stage-II package, Bay control units are supplied
with 2 bays in one numerical relay. If relay fails, especially on GT side bays,
the two bays connected to the relay are at stake, may lead to unit/bus
tripping. To resolve the same, Each BCU is provided separately for all the
400KV breakers.
There are no parallel paths provided in the 400 KV circuit anywhere as per
the scheme. Parallel paths are provided in 400 KV circuitry with wedge
connectors in all transformer bays and, bus side which are critical to avoid
hotspots/online maintenance.
UST-A and B temperatures were reaching to trip limits (140deg c) when

loaded fully 6 nos of exhaust fans each 60W provided beneath core in USTA/B and SST-A/B by through OEM -VOLTAMP, fan cut in/ cut out set at 90
DEG C.
Seal air fan motors were tripping on overload during starting. Heavy duty
overload relay was provided.
CW motors Thrust Brg. oil coolers are made of MS material, causing frequent
leakages due to sea water. Coolers are changed with SS material
Original supplied Melcon make generator hydrogen gas driers internal

43
Simhadri Stage II
components found rusted. Replaced with Jindal make Spare driers available
with O&M.
y
Clinker grinders are controlled from bottom Ash MCC, not having
forward/reverse operation facility at local. Separate control panel erected
and commissioned, now feeders in bottom Ash MCC are used as SFUS.
CGL supplied GT Common Marshalling Box for power and control cable
terminations are too much congested. Stand by source termination could not
be possible with the existing clearance and segregation was done.
Main TG AOP-1 and 2 feeders are from same transformer i.e. UST-A. AOP-1
from TMCC SEC-1 and AOP-2 from UES Sec-1. AOP-2 feeder shifted from
UES Sec-1to UES Sec-2.
Generator seal oil p/p-1 and 2 supply feeders are from same transformer i.e.
UST-A. SOP-1 from TMCC Sec-1 and SOP-2 from UES Sec-1. SOP-1
feeder shifted from TMCC Sec-1 to TMCC Sec-2.
GT cooler main and stand by supplies are fed from SSS Sec-1 and 2
respectively. Cooler main supply shifted from SSS to USS.
Control supplies of IAC/PAC-1 and IAC/PAC-2 are fed from station ACDB-3
and station ACDB-4 respectively. IAC/ PAC-1 shifted to UES-3 and
IAC/PAC-2 shifted to UES-4.
VAM -1 & 2 main supplies are fed from section-1 of AC MCC. VAM-2 supply
shifted to sec-2.
In CW MCC, Supply for LWP-1 of all CW P/PS from sec-1 and LWP-2 of all
CW P/PS from sec-2 of CW MCC were distributed.
In DC systems of 220V DCDB for over voltage protection relay setting was at
242V which was operating continuously even at normal float voltage. By
adding resistor in series with the coil for making the relay to operate at 264V
i.e. 10% of 240v.
G Control Scheme Modifications:

y
Auto reclose logic is incomplete. Auto reclose scheme with proper logic has
been implemented both in relay logic and wiring modification by using extra
fast tripping relays to tie breaker separately.
In main-2 distance protection relay of make Siemens, the gates used in the
logic are not fast operating gates which impaired the auto re-closer scheme.
The same is over come by using fast operating gates in the logic.
44
Simhadri Stage II
In bus bar protection scheme, there is no trip circuit supervision provided for
the bus bar trip relays (96). The same has been implemented by additional
wiring wired as binary input.
For all LT switchgears dc supply auto change over scheme was not
envisaged. Auto change over scheme was implemented.
LT breaker latching relay contactors problem, resulted in supply

disturbances during changeovers. Breaker status to DDCMIS taken from
breaker aux contacts directly.
HT/LT Switchgear numerical relays DC supply isolation scheme not

envisaged. In HT swgr DC supply to numerical relay directly taken from TB
and for LT swgr separated with a MCB.
Station C&I UPs main and stand by supplies are from same transformer i.e.
UST-4A. Main supply from USS sec-1 and stand by supply from UES sec-1.
Stand by supply shifted to UES sec-2.
Long distance trf feeders tripping spuriously on wdg/buchholtz/oil

protections. Resistance elements were added in binary inputs.
Long distance Xr feeders tripping spuriously on wdg / buchholtz / oil

protections. Resistance elements were added in binary inputs.
220v DCDB breaker status and ht boards DC annunciation not envisaged in

DDCMIS. DCDB breaker status and all HT boards DC failure alarm provided
in DDCMIS.
11kv station tie to unit board auto change over healthy annunciations scheme
not envisaged. Change over healthy status provided in DDCMIS.
DC segregation for relays to be done.
DC Supply segregation in HT Swgr Panels.
Binary pick up voltages of ABB make RET relays in HT switchgear is 63-68V

resulting in false tripping of transformers on Buchholz/ PRV/WTI/OTI. M/s
ABB is supposed to add additional binary input resistances to resolve the
issue.
Direct breaker service position contact is required to be extended to DDCMIS

for LT breakers logic building purpose as presently the same is extended
through contact multiplication relay whose contacts get changed with DC
supply resulting in unit outage.
45
Simhadri Stage II
LT incomer tripping on upstream breaker tripping not provided. Circuit is

modified by incorporating line PT under voltage and Bus PT under voltage
contacts in the logic for tripping Incomer breaker.
In ESP LT breakers even in test condition also on feed back going to UCB
which is causing tripping of tie breakers. Breakers internal cabling done to
give close feedback to UCB only during service position.
In 220V DCDB voltage feedback of section taken before incomer breaker

which is giving false indication that section is dead whenever charger is
under permit. DCDB voltage feedback is taken after incomer breaker in
stage-2 DCDB which solved the problem.
G In the scheme, for furnace draft control, IGV and VFD control was envisaged.
The control has been changed to VFD control for smooth operation
G In Boiler drum level protection scheme Very High OR Very low signal generation
either of left or right levels has been taken into consideration. To avoid spurious
tripping, both the left & right signals have been put in.
G PA fan Lub oil pressure transmitter tapping was envisaged before pressure
regulating valve. This will give the control oil pressure. To get lub oil pressure
tapping has been shifted to after regulating valve.
G Time delay has been incorporated to avoid spurious tripping of Fans on bearing
temperature high.
G In APHs Air motor on feedback was taken from pressure transmitter signal.
Sometimes this caused delay in sensing the on feedback of Air motor because of
transmitter response and MFT also acted because of this. Pressure switch was
erected and same also hooked up for APH on feed back with Air motor in service.
G PW pumps logic modified to avoid spurious trips during pump changeovers as
per corporate guide lines.
G Seal oil pumps logic modified to take care of spurious trips during pump
changeovers.
G HT MOTORS winding temp protections removed as per communication
received from COS.
G CEP recirculation valve opening restricted so as to avoid jamming of the control
valve in full open condition.
G Logic for hp bypass modified to take care of ease of switching from auto to
manual and vice versa.
46
Simhadri Stage II
G BFP speed restricted to 5600 rpm to avoid operation in the over speed region
due to sudden FW demand.
G Shifted exhaust steam pressure transmitters of TDBFPs to 17 mtr from 8.5 mtr to
avoid spurious tripping of the BFPs due to condensation in the impulse pipes.
G Provided wiring for speed interlock for generator H2 drier compressors.
G Time delay introduced in the vibration protection circuit to avoid tripping of the
CW pump during start up as per approved modification from COS.
G Digital outputs were dropping whenever there is a disturbance in processor
causing process disturbance in Max DNA system. Digital output cards jumper
setting was changed to HOLD mode to avoid the same.
G APHs rotor stoppage alarm was coming intermittently so timing optimsed.
G PA Fan trip due to discharge gate not open was from single contact. To avoid
spurious tripping of PA fan, Logic was modified to 2 Out Of 3 by using 2 close limit
switch contacts and one open LS contact.
G In Air flow control logic, In case of one of the two running FD fan trips the
remaining FD fan blade pitch control was going to manual and same was leading
to tripping of Boiler on Air flow low. Time delay was introduced for operator
intervention.
G In Drum level control logic, FW master used to trip to DP mode from FW mode on
sensing FD-16 close status. This has caused disturbance in drum level control
and even lead to unit trip. To avoid this, FD-16 not open status .included with
close status for ensuring the reliability.
G Field devices like HFOTV SOV supply connected without fuse protection. Any
fault in the field will cause Unit panel MCB trip and lead to boiler trip due to loss of
24 V DC(T). To avoid it fused TBs provided. This modification was carried out by
learning through ORT report of other station.
G During Boiler Cold start up, CAG of Mill used to close on protection of Mill ON
and outlet temperature low. Sometimes because of it Mill was forced to trip due
overload because of coal accumulation. To avoid it this protection was removed.
G Initially it was observed that Whenever CW pump trips, ARCW pump used to trip
on suction pressure low. Same was avoided by introducing time delay with
optimum pressure.
G HP stop valve was tripping suddenly after some time when unit was with load.
The stop valve was again opened from the local and was tripping after some time
47
Simhadri Stage II
delay. The coupling between valve and servomotor was inspected during shut
down of unit. The coupling gap was not as per the drawing. 5mm instead of 7mm
required the coupling gap was corrected by correcting the shims.
G TDBFP BOOSTER PUMP suction valve is not having equalizing / filling valve.
Pump is charged through opening suction valve makes improper venting,
jamming or time consuming. To avoid it equalizing valve was provided.
G In TDBFP seal steam tapping is provided in downstream of aux steam block
valve. when this valve is closed, seal steam gets isolated causing barring gear to
be stopped (in vacuum pulled condition) Seal steam tapping is provided now
from upstream of aux steam block valve, making the BFP in barring gear which
helps governing characteristic setting could be done without barring gear
stoppage. This saves lot of time.
G In TDBFP when CRH or AUX steam is taken into service, ACV flange joint is
used to leak due to condensation of steam in upstream of ACV to block valve due to
non availability of drain. To avoid it drain is provided.
G In Bottom Ash HP water system, vent is provided to reduce hammering and
failure of HDPE lines.
G Recirculation line was introduced in BAHP and FAHP system to avoid pressure
surges in system resulting in line failures/leakages.
G The Following modification carried out in CLINKER GRINDERS:
y
Conversion of CG seal water lines from MS to SS thus avoiding corrosion

problems.
Replacement of CG seal water hoses from lengthy Rubber hoses (as

erected) to SS braided hoses of shorter length.
By providing deflectors CG bearing damage due to ingress of seal water was

addressed
G Ash slurry disposal system pumps foundation strengthening of ASP B and ASP
C SERIES (MOTOR-FC-GB-PUMP) was done to address vibration problem.
G In Bottom Ash hopper, additional overflow line was given to eliminate probability
of touching sea water with boiler tubes.
G Continuous Ash Evacuation ensured in ECO hoppers by The Following:
y Use of oversize mixing/flushing chambers, modification in water supply and
drain lines to seal chamber & mixing chamber w.r.t. size & layout
48
Simhadri Stage II
y Provision of additional nozzles in flushing apparatus, for better turbulence

and ash evacuation.
y Provision of filters (in-situ developed) in FAHP supply lines to flushing &
sealing chambers, to avoid frequent nozzle chokages.
10.5 MEASURES TAKEN FOR SAFETY DURING COMMISSIONING:
G To ensure failsafe of Boiler, Air lock relay of HFOTV and LDOTV was removed.
G The Following measures were taken for SAFETY
y
PTW system strictly followed. Online PTW system was made available well
in advance from stage-2 since first PTW. To avoid untoward incidents during
interface works with existing facilities a well defined PTW SYSTEM was
adopted.
Isolation of non running equipments during pre commissioning period.
COMMISSIONED tags / stickers displayed in LOCAL LANGUAGE.
Cautioning all concerned through email after ENERGIZATION of

equipments.
Motor/system P&I checks done before each activity.
Deployment of firefighting personnel round the clock during important

commissioning activities
Naming the equipment/ commissioned stickering since beginning
Meggering of HT MOTORS IF remained idle for more than 30 days.
G Cautious & well documented approach towards use of common

resource/facilities done
G During important commissioning activities, Fire tender was deployed round the
clock. Fire fighting personals were deployed at 17 mtr TG hall to tackle any
eventuality.
G Prime importance was given for Fire tender approach.
G To complete pending defects and erect pending system a special cross
functional task force team was constituted to give permission for hot permit.
G TMD has erected Platforms & approaches for valves /equipments required for
commissioning as scope was not clear.
G The envisaged welding receptacles in Stage-2 are without ELCB protection.
49
Simhadri Stage II
Also the quantity envisaged is very less as compared to the requirement by O&M
personnel. In view of the safety consideration and based on the guidelines of
COS, the available welding receptacles with ELCB protection in stock with O&M
is issued to project group and erection & commissioning of the same is done at
120 locations.
G In ALI for low level RED led has been configured for no ash and GREEN for
sensing ash which created problems which calibration and ALI checking. Wiring
modifications done inside the controller of ALI for RED led for high level and
GREEN for no ash.
G In switchyard, there are no pavements/roads in between bays for easy
movement of heavy vehicles during maintenance. The same is over come by
providing roads in between bays.
G Articulating boom lift is used for safe working and to save time.
G A proper precaution like isolation of LBB DC during the stability / current injection
testing is done to avoid tripping of other breakers / units.
G Feeder control TFS contactor does not get de-energized when feeder gets
tripped. This caused auto start of feeder when feeder was kept in remote. Wiring
was modified to de-energize the TFS contactor.
G VFD auto logic - in the scheme VFD used to trip to manual whenever MFT
occurs. This caused huge negative pressure in furnace. Logic was modified to
put the VFD in auto mode even after MFT.
G Identification and tagging of Electronic Earthling is not done properly. The same
was done during subsequent opportunity.
G Trip Popup Alarm is provided to important drives for the immediate attention of
the operator.
G Power supply monitoring is not provided for network panels .Since the total
control system is network dependent same was provided.
G Mills used to trip during LOPs auto changeover due to disturbance in flow and
Pressure. To avoid Mill trip, Time delay introduced with the permission of OEM.
G Approach was made for Mill scrapper chamber area.
10.6 MEASURES TAKEN FOR QUALITY DURING COMMISSIONING:
G All maintenance teams were involved in alignment of all capital equipments.TG
maintenance involved from initial TG deck floating to final alignment and
50
Simhadri Stage II
catenary correction.
G Under suggestion & supervision of TMD, Air ingress in condenser of U # 3 was
rectified by helium detection method
G During TG lube oil flushing fine cloth was provided in return line basket strainers
to avoid damage to the strainer, the cloth was changed in regular intervals
resulted in better oil flushing.
G Control fluid was not changed by BHEL after completion of oil flushing. Mobile
filtration unit (M/s Hydac make) was used in control fluid system. The
mechanical Impurities (MI) & particle count in Control fluid was brought back
from NAS-10/11 to NAS-5/6 level
G It is very important to capture behavior of the equipment since its initial run
because it will be the reference for maintenance to carry out rectification of
defect in future. By seeing availability of necessary equipments and man power
with agencies it was decided to extend the help from existing condition
monitoring group. The following was done through MTP.
y
With the help of Commissioning department required PTW modules were

uploaded in SAP well in advance and it has helped in implementing on line
PTW system.
Condition monitoring group was involved since first trial of first equipment
All DC drives, TDBFP and Main turbine speeds were crosschecked.
G Bus duct pressurization unit of make M/s MVS is of sub standard and sub items
of poor quality is being used in the panel. Issue was referred to CC-QA, PE and
COS and got it resolved . Now the system is available in both the Units.
G Wrong supply of PW N2 relief valves. Issue was taken up with BHEL for
replacement and was agreed upon. In the meantime, the same were replaced
with O&M Spares.
G All mills main motor re-termination is done due to under sized lugs and reterminated with long barrel lugs.
G CGL supplied GT Common Marshalling Box for power and control cable
terminations are too much congested. Stand by source termination could not be
possible with the existing clearance. Segregation done.
G ABT System Issues: Supplied ABT meters are not able to meet the present ABT
requirement (Polling time is more than 7 sec. and time synchronization of energy
meters supplied is not possible). Separate package is awarded by the site to
51
Simhadri Stage II
meet the requirements and for integration with Stage-I ABT system thus making
the ABT system more reliable and accurate.
G VFD channels were tripping on ground faults and other channel faults. Treated
earth pits provided for individual VFD transformers
G Control transformers of ESP electronic controllers of rating 415v/24-18v failing
during start up due to manufacturing defect. Replaced with transformers with
different make.
G FD FAN -3A blade pitch actuator was erected in such a way that calibration
mechanism was facing downwards. This caused problem during calibration.The
orientation was changed to ease the calibration process
G ID/FD/PA Fans discharge pr. transmitter tapping was envisaged after discharge
gate. This will not give the correct reading. The tapping point has been shifted to
before discharge gate so that individual discharge pressure can be measured.
G Network connectors (RJ45) used were of very low quality due to which frequent
network errors were diagnosed, later changed to standard make D-link / Digi-link
G Present control systems are completely network dependent. The dressing,
tagging and configuration backup is utmost important for trouble free
maintenance of the system. This was not followed in Simhadri during erection of
the system. The same was done during subsequent opportunity
G Ladders are provided in Boiler wind box to have approach to SADC for checking
and repair from inside.
10.7 Observations :
It was observed from our experience in Stage-II project that with the involvement of
O&M from the conceptual stage of project helped in achieving the following:
G
Project was completed successfully and achieved most of MOU targets
Deficiencies in the system was brought to the knowledge of Engg. in time.
Most of O&M issues were tried to address during erection stage itself.
Smooth transition from Erection stage to Commercial Operation stage taken

place
Availability and sustainability of the units increased because of implementation

of O&M practices since beginning.
New O&M executives became familiar and got expertise with new systems
before commercial operation of the unit.
52
Simhadri Stage II
10.7 Glimpses of Modification / Best Practices:
Unit Overview
Unit Important Parameters

in One page
Direct Starting of Emergency

Drives From UCB
Maintenance of Bus Duct Using

Articulating Boom lift Vehicle
Servers Installed
in Cabinets
Re-wiring of Network Panel
53
Simhadri Stage II
10.8 MEASURES TAKEN THROUGH CONTROLLING SYSTEM CHEMICAL

REGIME:
During project execution deficiency in cleaning, preservation methods and in
Chemistry related issues including cycle chemistry, water treatment, CW treatment
and stator water system etc reduce the efficiency and performance of plant
components and leads to outage of capital equipment and outage of system which in
turn leads delay in subsequent commissioning activities. Non optimum chemistry
conditions can take more time for stabilization and shorten the useful service life of
plant components. Therefore, proper management of cycle chemistry is a key factor
in the success of any project completion in time and getting reliable and efficient
units. By observing deficiencies with agencies in the form lab facilities, availability
skilled lab assistants and right quantity and quality chemical consumables, the
following measures adopted to meet the project schedule and desired process
parameter quickly and safely.
G
Since beginning Chemistry people are involved in all activities including oil
tank inspection.
At Simhadri sea water is used for condenser cooling. In view of severe

corrosive atmosphere of sea water it is very important to maintain quality of
sea water. By seeing delay in getting CW chlorination system, special
initiative taken to maintain CW water quality by introducing Sodium hypo
chlorite dosing in CW bay.
CPU was put in service
Existing Lab facilities availed
Deployed man power round the clock
System availability and reliability increased by implementing all O&M

chemistry practices
54
Simhadri Stage II
11.0
NEW INITIATIVES
TAKEN
55
Simhadri Stage II
11.0 NEW INITIATIVES DURING STAGE-II COMMISSIONING:

G
First time in the history of NTPC, while erection is in progress, PTW system for
STAGE-II was implemented through SAP since beginning.
Unique defect registration number generation in auto for various commissioned

systems.
Caution stickers and danger tags are made in local language also and pasted
on all charged electrical equipments.
As the envisaged DG set is not ready, temporary DG set hired and fed to
emergency MCC during initial synchronization
Dry air generator was used during opening the inspection covers of the power
transformers which has reduced risk of moisture and the filtration time was
saved by using dry air.
First time steam flushing procedure was adopted for unit-4 condensate and
feed water circuits, resulted in reduced activity cycle time and resources
mobilization as well, as compared to conventional detergent flushing and saved
time
Canteen facilities were extended to all including agencies work force at 17m TG
floor round the clock to motivate and reduce time.
NTPC management has deployed an expert group headed by head of O&M

and team members from each maintenance department to address the
problem immediately and it has given good results in meeting targets.
System technical audits were carried out by both regional and COS team before
synchronization and COD to find deficiencies in the system and it has helped a
lot.
Grouping of Alarms and programming of facia alarms, development and

integration of Trip pop up alarm in Emerson system done for easy operation.
Development of Applications for easy updation of Control sheets, graphics and

macros in Ovation workstations drops without "downloading of drop".
56
Simhadri Stage II
12.0 FACILITIES
EXTENDED
57
Simhadri Stage II
12.0FACILITIES EXTENDED FROM EXISTING UNITS:

Because of various constraints PTP/DM Plant, LDO/HFO systems and Fire Fighting
system have not come. Extension of the following facilities helped in getting the units
in time
G
DM WATER
LDO in Unit-3
FIREWATER
CABLE TRESTLES FOR BOP AND IN U-3
COAL THROUGH STAGE-I INTERCONNECTION FOR U-3
Work shop and Labs
58
Simhadri Stage II
13.0 CONCERNS
59
Simhadri Stage II
13.0COMMISSIONING CONCERNS :
G
Poor preservation & handling of Equipment. (Ex. Positioners failure of

pneumatic control valves, Temperature indicators / Terminal boxes damages,
missing of lifting hooks, Base plate damages in Motors, Actuator E-pack
modules rusting, LT Motor Bearing failures, Transformer radiator damages,
Studs damaged near connection to the radiator banks resulting in oil leakages,
LT Motor TB Covers / Fan cowl damages/missing of components, HT Motor
Temperature indicator damages, Damage of Actuator motor and control units
due to water entry).
Lack of skilled manpower with agencies.
Non-availability of Commissioning Spares / Delay in identifying and receipt of

Mandatory Spares.
Poor Deployment of Commissioning Manpower by Agencies.
Lack of Expertise and Poor response from Agencies: This is predominant in

BOP Packages.
Inadequate tools & Testing equipment with agencies.
Delay in Civil Works/ Cable laying/Temporary routing of cables/Cable failures.
Coastal environment is not taken care of.
Non-availability of Standby source for Lighting MLDB at Off-site locations. It is

felt that it shall be from adjacent BOP MCC.
Delay in Civil Works
The drains designed and constructed in the switchyard are below the level of
gravel filled which causes the gravel to fall into the drains.
No drains were provided for the trenches used for air line/ control cables of the
circuit breakers.
In LBB protection logic, if initiation comes before the relay senses current LBB
will not operate and disables LBB function. This design deficiency was
intimated to Engg. and COS. Matter referred to ABB Sweden for necessary
modification.
Servers systems supplied with Emerson system are rack mounted, but rack is
not supplied along with the system. The Server rack for the servers is
purchased and proper installation is done.
60
Simhadri Stage II
Panels are commissioned before the civil work completion including floor work
in the control room. Due to this the card failure rate of the systems is more and
the dust ingress and deposition on the control cards is more and life of the
electronics cards is affected.
The system PCs and servers had failed many times due to the dust ingress
during commissioning of the system.
The restoration of the system in prescribed time during server crash (in server
dependent systems like Emerson) is to be demonstrated in site by the vendor.
This is required to build up the confidence in maintenance of the system. In
Simhadri this could not be demonstrated by the vendor.
13.1EQUPT/SYS FAILURES IN STAGE-II
61
Simhadri Stage II
13.2 RESOURCE CONSTRAINTS:

G
Inadequate competent Commissioning manpower and expert from agencies
Delay in mobilization OEM representative persons during initial

Commissioning and later stage attending defects
Delay in mobilization of mandatory and non supply Commissioning spares.
Poor T&P mobilization from agencies.
Non availability of O&M manuals before Commissioning
62
Simhadri Stage II
14.0 SUGGESTIONS
63
Simhadri Stage II
14.0SUGGESTIONS:
G
As per new definition, A thermal unit may be considered as commissioned when

the construction and commissioning of all plants and equipments required for
operation of the unit at rated capacity are complete and unit achieved full rated
load on the designated fuel and time gap between first synchronization to COD
is six months otherwise it requires permission from CERC. Hence more focus
should be on early readiness of BOP packages and equipment wise system
completion for sustainable operation.
After Safety valve floating and before start of trial operation of the Unit in the
available opportunity the following activities should be taken up and it shall be
covered in the scope of work.
Ensure healthiness of CEPs, BFPs, MS and HRH strainers
Lapping of important valves (High energy ,Boiler drain valves etc.)
Wherever multi agencies are involved in carrying out various works in the
building (like works of Air conditioning system, Fire fighting works, catwalk
structure, ventilation system in CER/CCR /ESP VFD/Ash handling control room
buildings etc.) at ceiling level and roof level, top priority shall be given with
respect to releasing drawings, mobilization of resources, erection completion
etc, well before start of pre-commissioning works. Once equipments start
operating from these buildings, it is very difficult to complete these works. It may
be identified as milestone activity.
In case of Ash handling Ash water system, separate headers are to be travelled
for each unit with a isolating valve to carry out maintenance activities in each
unit without affecting other units de-ashing operation.
Isolating valves shall be included in the scope to have inter unit isolating valves
in common systems like DM make up ,ECW make up system, Fuel oil system
etc., to facilitate further erection works in other units.
Suitable flow regulation type valves having isolating valves on both sides and
motorized type bypass valve (globe type) with isolating valves shall be used in
makeup system of SG/TG ECW tanks. At present in simhadri Butter fly type
valves without any isolating valves are given and these valves developing
passing problems frequently.
Many cable failures (both power and control cables) are experienced right from
64
Simhadri Stage II
commissioning period resulting in equipment non-availability. Critical

equipment failures such as FD Fan, PA Fan, ID Fan, CW Pump, Power
transformers, Valve actuators like blade pitch actuators occurred. Delay in civil
works led to non-availability of designated trestles for cable routing forced to go
for alternate routes in a cumbersome manner resulting in improper
identification of route and required dressing and tagging. Moreover it is nearly
impossible to again normalize the cables as envisaged.
Utilization of un-armoured cables for such critical equipment shall be

reviewed by taking into consideration the ground reality prevailing during
erection.
Cable laying methodology shall be revisited to incorporate latest

techniques/T&Ps and shall be included in the scope of work.
Cable trestles should be given utmost priority and cable laying work should
start only after availability of clear fronts.
Interfacing of MCC/Cables/Drive/C&I panel to be done with unique

code(ex.KKS coding)
Across NTPC different Knowledge teams are in position. These groups are to
make frequent visits to ongoing projects to disseminate knowledge and
practices and stationed prior to important milestone address the gaps found.
To get consent to operate in time, Engineering and contractual provision shall

be made in such a way that ETP, Ambient Air Quality Monitoring system are
functional before the COD of Unit.
A milestone audit is to be conducted by a team comprising members from COS /

Engg. / C&M/ PPM and ROS to find gaps with respect to readiness and
completion by taking safety also into consideration.
Quick erect scaffolding (QES) to be supplied along with Hydro test materials.
QES shall be erected to carry out checks on burners and pressure parts from
inside to save time and to rectify defect in least time.
It is better to have erection sequence/methods in the form animation for better

understanding and finding gaps.
To increase belongingness and motivation erect, operate and maintain

philosophy may be adopted especially in case of new Ets.
65
Simhadri Stage II
Approach Roads & Internal roads and drains: To be laid by NTPC including
maintaining and should be awarded along with the main contract to avoid delay
in shifting material.
In brown field expansion projects Engg. may utilise the existing trestle
network to the extent possible for laying pipe & cable as otherwise it involves
excavation in the operating zone.
Incentive scheme for early front handing over/milestone achievement may be

introduced.
A special contract is to be in position to tackle situations arrived because of

natural calamities during construction.
66
De-watering services: NTPC needs to facilitate during rainy season in

some of the interface areas. It was done in Simhadri. Trailer mounted
dewatering pumps with diesel engine may be procured for easy shifting.
Simhadri Stage II
15.0 ANNEXURES
67
COMMISSIONING STEERING COMMITTEE
68
Simhadri Stage II
Annexure : A
WORKING PARTIES FORMED (18)
Simhadri Stage II
Annexure : B
G EOT Crame.
G New Admin Bldg RF & SWGR.
G HT SWGR, Battery Bank, DG set.
G LT SWGR.
G Sea Water Pump House.
G Boiler.
G Turbine
G Turbine auxiliaries
G Fire detection & protection system
G AC & Ventilation system
G CW, make up system & NDCT
G PTP, DM Plant & CPU
G Coal Handling Plant
G Power transformers ^ SWYD
G Generator
G Generator & Auxiliaries
G Ash Handling System
69
Simhadri Stage II
MODIFICATION PROPOSAL
Annexure : C
NATIONAL THERMAL POWER CORPORATION

................................STPP....................................................................................
Ref:.......................................................................................................................
Dated:...................................................................................................................
Rectification /requirement suggested by commissioning group
Area/package of inspection:
Date of inspection:
List of participants
Erection:
1.
2.
Commissioning:
1.
2.
I.
Observations/additional works to be done with justification enclosed:
1.
2.
3.
4.
II
III.
70
Whether the present work can proceed or to be stopped till the additional
works identified are completed:
1.
Can proceed/to be stopped?
2.
3.
4.
Whether the above work are in the present contractors scope or not:
1.
Yes/no
2.
Yes/no
3.
Yes/no
4.
Yes/no
IV.
Simhadri Stage II
If yes, the program for completion of these works:

1.
2.
3.
4.
V.
If these works are not in the scope of the contractor indicate the estimates
for carrying out those works (please enclosed the working
sheets/drawings etc.)
1.
2.
3.
4.
VI
Period for completion of above works

1.
2.
3.
4.
Erection engineer
VII.
Finance for concurrence
VIII
Competent authority for approval
Engineer in-Charg
(Commissioning)
(As per delegation of power)

Commissioning copy
Erection copy
P&S copy
Finance copy
71
Simhadri Stage II
Annexure : D
PTW REQUEST FORM
REQUEST FOR PTW/LWC/HOTWORK PERMIT

FOR PROJECT WORKS
REF.NO.SMPP/DATE:
A. PROJECT SECTION: ME/EE/C&I/CIVIL
B . 1. SYSTEM ON WHICH PTW/LWC REQUIRED:
2. TYPE OF ISOLATION REQUIRED
C. LOCATION:
D. PURPOSE:
E. AGENCY DOING THE WORK:
F. TIME OF START OF WORK(ESTIMATED):
G. TIME OF FINISH OF WORK(ESTIMATED):
H. REQUIREMENT BY
NAME :
DEGN :
E.NO :
TO
TM/BM/C&I/ELECT.MAINT/CIVIL(O&M)/FM/OFF-SITES
THROUGH: SHIFT CHARGE ENGINEER
72
Simhadri Stage II
Annexure : E
DEFECT REGISTRATION
NTPC LTD.,
-------------------------------- THERMAL POWER PROJECT
Unit No.:
Date :
Name of Main System/ Sub-system/ Equipment :
LIST OF DEFECTS AND OMISSIONS
(Pre-commissioning Inspections/Initial Test Runs)
SNO
Description of
Defect/
Pending job
Schedule of
Liquidation
(to be filled in
by Contacting
agency)
Status of
Liquidation
As on
Remarks
Checked
And
tested
As on
(Erection Engineer) (Commissioning Engineer)

Contractors Erection/ Commissioning Representative
73
Simhadri Stage II
Annexure : F
DEFECT LIQUIDATION PROGRESS
WEEKLY PROGRESS REPORT

SUMMARY OF STATUS OF LIQUIDATION OF DEFECTS AS ON
Name of system.................................................................................
Name of Contractor...........................................................................
Date of Initial start/ Run Test.............................................................
Status of
defect
Nature
of
defect
Total
No of
defects
No of
Defects
Liquidated
No of
Defects
Pending
Date of
Liquidation
Sch
Ant
Mechanical
Electrical
C& I
others
74
Defects
Pending
more
Than
two(2)
weeks
Unique Defect Registration Program
Simhadri Stage II
Annexure : G
Please
select
Equipment
by Drop
down menu
Please
select
Main Sys
by Drop
down menu
Please
select
Sub Sys
by Drop
down menu
Please
Enter
Defect
description
and select
the Defect
either M/E/C
for Mech /
Elec / C&I
respectively (OR)
O&M Flexibility,
Engg Issue
The Unique
Registration
number
will be
automatically
generate
75
Simhadri Stage II
Annexure : H
Commissioning Certificates
NATIONAL THERMAL POWER CORPORATION
...........................SUPER THERMAL POWER PROJECT

To................. Certificate no...........
(contractor)
SAFETY RULES CLEARANCE CERTIFICATE
I hereby give notice that the equipment scheduled below is being made alive/put into service
or by reason of its proximity or relation to other apparatus must be regarded as being
ALIVE/IN SERVICE, and as from __________________hrs. on _________ will come under
control of NTPC so far as safety rules are concerned. No further work may be done on or
near the equipment after this time and date unless the person in charge of such work is in
possession of a permit to work card or sanction for testing card issued by a senior authorised
person in employ of NTPC will you please sign the master certificate retain the copy
addressed to you.
1. Description and location of plant.
For NTPC Erection department
Signature-----------------------------------Designation--------------------------- Date--------------------2. Acceptance :
I agree with the issue of a safety rules clearance certificate for this plant that it will become
subject to the NTPC - Safety Rules from the date and time specified above.
For NTPC O&M department
Signature ----------------------------Designation------------------------------Date-------------------------.
3. Acknowledgement
I/we acknowledge receipt of the above notice and confirm `that all persons in my/our charge
have been duly warned of the above. My/our men and material have also been removed
from the area/equipment of testing.
Signed for
Firm or Deptt.
Time
Date
Distribution
Note :1. Once this certificate is issued, no work can be done on the piece of equipment under
consideration with out
a proper PTW from NTPC.
2. Fire fighting system envisaged for the equipment under consideration should be available before raising this
certificate.
76
Simhadri Stage II
Annexure : H
NATIONAL THERMAL POWER CORPORATION LTD.
SUPER THERMAL POWER PROJECT.

Certificate no.To Erection department
RECORD OF INITIAL OPERATION CERTIFICATE
Contract------------------------- Contract ref--------------------------Contractor-------------------------1.
Description and Location of Plant.
2.
Initial Operation
The above plant satisfactorily completed its initial operation tests on -------------------------- in
the presence of the following witnesses. The defects and omissions noticed during this trial
run that are to be liquidated by the contractor is also attached.
For Erection Deptt.
(Signed)------------------------
For O&M Deptt.
(Signed)------------------------
For Contractor
(Signed)------------------------.
Defects or omissions found in initial operation

Defects or omissions Contract ref.
Defects or omissions
Contract ref.
Note:
a) To be issued only after the issue of safety clearance certificate.
b) All the maintenance as well as the equipment lubrication of the plant under
consideration will be the responsibility of the contract even after issue of this certificate.
Defects and omissions noticed during the test run should be liquidated by contractor..
c) This certificate should be issued after obtaining all operation and maintenance volumes
Erection/FQA log sheets pertaining to the equipment under consideration.
77
Simhadri Stage II
Annexure : H
.......................................SUPER THERMAL POWER PROJECT.

To
O&M department
INTERNAL TAKING OVER CERTIFICATE
Contract------------------------Contract Ref.-----------------------------Contractor----------------------In accordance with the conditions of contract, the contractor is entitled to a taking over
certificate for the following plants. However, issue of ITOC does not absolve the contractor of
his contractual responsibilities to rectify the plant deficiencies. The defect list / deviations are
enclosed. The defect with a time bound programme for sorting them out will be given by the
contractor. Further deviation if any will also be discussed with the contractor.
1. Description and location of plant.
2. Exceptions:
Subject to any observation you may wish to make overleaf, it is proposed to issue the taking
over certificate.
For NTPC Erection Deptt.
Signature-----------------------Designation--------------------Date-----------------------------Acceptance
* I agree to the issue of a taking over certificate.
* I have the following observations on the proposal to issue to taking over certificate.
For NTPC O&M Deptt.
Signature.
Designation..
Date..
* delete as appropriate
a)This certificate is to be issued after the satisfactory performance of equipment under
consideration.
b)After the issue of this certificate, maintenance is to be done by NTPC Breakdown due to
design deficiencies will be attended to by the contractor.
78
Simhadri Stage II
Annexure : H
.......................................SUPER THERMAL POWER PROJECT.

FINAL INTERNAL CONTRACT CLEARANCE CERTIFICATE.
Contract _________________Contract Ref. ________________Contractor __________
This is to certify that the ______________________ months maintenance period on the
following plant will be completed on (date) ______________ and omissions have been
cleared with the exception of the minor items listed below:
1
2
Description and location of the plant :

Minor work outstanding :
(Signature ) _________________
(General Manager)
Date_____________
Acceptance :
*
*
I agree that the plant meets all existing operational requirements.

I have the following observations in respect of operational requirements.
For NTPC O&M deptt.

______________
Signature
Designation_____________
Date ________________
delete as applicable.
79

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