S.

No
EQUIPMENT

1 Generator

2 Generator Sync System

3 Power Transformer

4 Switchyard (Scada)

5 SWITCHYARD

6 Dry type Transformers

7 HT/LT MCC

8 Cable Galleries and Cable Trays

Oil Immersed Auxiliary

9 transformers
10 Motors

11

VFD s Healthiness

12 Emenrgency DG

Battery System
13

14 Fire Fighting System Healthiness

Breaker

15

16 Relays
16 Relays

17 HYDROGEN PLANT

18 PLANT LIGHTING

19 ONE YEAR SPARE PROJECTION

 ACTION PLAN TO IMPROVE RELIABILITY
Rotor Earth Fault Reading Monitoring Frequency increased to avoid tripping
rotor earth fault brushes monitoring and cleaning frequency increased
Stator Earth Fault Reading Monitoring Frequency increased
Modifications
Alarm configurations from Generator Relay to DDCMIS for rotor earth fault need to be provided
Two stage earth fault alarms setting to be set at 5 M ohms and 1 M ohms to alert at early stage of
deterioation of Insulation value
indications configured in DCS regarding feedback
SOP has been prepared for dummy synchronization
Digital synchroscope to be provided in DCS rather than synchroscope
Check Points pasted in the Panel
ST-1 Shutdown for carrying out manitenance activities, to avoid spurious and unwanted tripping, monsoon
preparation.
ST-2 Shutdown for carrying out manitenance activities, to avoid spurious and unwanted tripping, monsoon
preparation.

Spare GT bushing not available , in case of failure Machine will be down for long time
GT 1 B transformer to be replaced with spare GT during the opportunity shut down
GT 1 B transformer oil filtration to be carried out to reduce the Gasses to normal limits
GT/ UT/ UAT monsoon preparation during the opportunity
Extension switch yard maintenance needs addition manpower
WALK DOWN Checklist for BCU's , SCADA servers & PC's connectivity helathiness
SCADA Cards and Aux BCU and SPARE PC for Emergency restoration
Upgradation of the os and RAM of all scada servers and PC'S

Ensuring no DC earth fault in the system

Extension switch yard maintenance needs addition manpower

Water logging in the switch yard to be adressed
Compacting and gravel filling in switchyard to avoid vegetation growth
Kiosk - AC repair
132 KV switch yard pending commissioning to be completed to help during black out
Increasing the thermography frequency to 15 days during the summer period for early detection of
hotspots

Ambient temperature in trnsformer area to be improved

spare procurement of dry type transformers

Transformer Temperature monitoring frequency increased till monsoon

Supply fans and exhaust fans healthiness and maintenace
 MCC trenches water logging

arrangement of air presurrization system in FA silo MCC to avoid ash ingress in to MCC

Sealing of Duct entries for dust ingress

changing of damaged MCC feeder hinges to ensure proper closing of the feeder doors to avaoid any reptile
ingress
Healthiness of MCC changeover system during shutdown opportunity
Room Ambient temp monitoring
Fresh air ventiliation duct cleaning
H2 MCC shutdown to be taken,one section by another
Compressor house MCC shutdown maintenance, one section at a time

Boiler PMCC room temp@ 40 Deg

IDCT PMCC Incomer breaker temp going high , so Replecement to be done with higher capacity Breaker
Rodent entry blocking by ensuring the spare holes closed in the panel
Down Pit to be made in cable trenches inside the MCC room for collection of seepage water and complete
draining of the water.
procurement of industrial pedestal fans for meeting emergency in mcc rooms during summer

monthly Cleaning of Cable trays in boiler area specially PA ID , FD , Boiler , Bunker areas till monsoon start
sealing of coal dust entries and hot air entries in to Cable galleries to avaoid any fire incident
Monthly cable gallery cleaning
procurement of industrial pedestal fans for meeting emergency in mcc rooms during summer
Cable Gallery room temperature monitoring

Oil filtrations required in 32 nos of transformers and schedule plan attached here
T&R and Schneider transformer vital spares viz,- HT/LT Bushing , OTI,WTI,Bucholdzs etc
Monsoon preparation on all BOP transformers to avoid any supirious trippings

Availability of filtration machine for filtration of 84 no's of transformers with easily movable

Through fault stability of the remaining transformers like AWRS

Unarmoured Transformer Protection cable to be replaced with armoured and laid through cable tray

procurement of spare ESP transformers for immedetae replacement in case of failure of transformers

ESP rectiformer Vital -internal spares like HV winding /HV bushing/ RF choke /Feedback resistator

No arrangement for replacement of ESP rectiformers from one to one

MAINTAINING OF MINIMUM STOCKOF TRANSFORMER OIL AND SILLICON OIL FOR ESP RECTIFORMERS
REPLACEMENT OF NORMAL TRANSFOEMER OIL WITH SILLICON OIL IN ALL ILMS & SUSPENDED MAGNETS
AS PER OEM RECOMMEDATION
Spare ESP rectiformer repair & readiness

Increased the frequency of thermography monitoring of critical motors from monthly basis to fortnightly

Critical spare motors availability during the break downs

Critical Motor EPB feed back to PLC

Clinker grinder current feedback to PLC

ID Fan motor NDE temp is in increasing trend

Bearing stock availability of critical motors
procurement of Critical motors Spare parts like TBS , End covers , cooling fans
minor overhaul of the critical BOP/CHP/AHP motors to ensure stator and bearing healthiness
ID Fan motor Excitor Cable Termination monitoring on opportunity SD

AC/DC seal oil pumps of Unit #1 &2/HP Bypass pumps,APH motors,ID fan outlet gate blower motor,HPCF
motor, seal air fan motor /IDCT motors shifting down and UP/
HT motor rewinding contract has not been finalised
Trouble shooting charts to be prepared and pated in panel for faster identification of problem
ID fan cable to kept as spare for emergency
ABEL pump VFD spares procurement to be explored for fast delivery

repairing of Thyristor packs of VFD's by EDN bangalore

load test of DGs duringopportunity shutdown shutdown to ensure the healthiness of the DG and monitor
the temperatures

timely Replacement of fuel filters & lube oil filters

system failure alarms to DCS
Replacement of damaged batteriesin unit 1 &2 station batteries
Discharge test of Main plant battery bank which are completed during AOH period , Switchyard are
competed during the over hauling
Spare Batteries to be procured
standby Battery Chargers to be Procured
strengthening of Breaker maintenance practices like measurement of Contact resitance and replacement of
Jaw contacts

HT switch gear of CHP and AHP material need to be procured urgently

Breakers in IDCT to be upgraded to higher rating, Current reading 1800Amps, Breaker Rated:3200Amp.At
40% load temperature of breaker in IDCT is increasing
GRP
SEL
Alstom
ABB

58/120 HMI keyboard problems due to frequentcurrent monitoring by operation by pressing the keys

Thid party audit and inspection required for relay coordination to improve the system reliability
PROCUREMENT OF HYDROGEN PLANT SPARES AS PER RECOMMENDED LIST

PROCUREMENT OF COPPER SHORTINGJUMPERS FOR BYPASSING THE CELLS AS & WHEN REQUIRED
LIGHTING SPARES ARC WITH BAJAJ AND CROMPTON GREEVES TO BE FINALIZED FOR FASTER SPRE
PROCUREMENT
PENDING ERECTION LIGHTING TO BE COMPLETED ON FASTER BASIS TO IMPROVE THE PLANT LIGHTRING
TO AVAOID ACCIDENTS
ONE YEAR SPARE PROJECTION AS PER THE ATTACHED LIST FOR 100 % plf OF PLANT
 SUPPORT REQUIRED FROM
STPP/STEAG RESOURCES REQUIRED
None

None
None
MOC Approval None

Operation clearance

Operation clearance

stpp to explore faster despatch of

material
STPP TO GIVE CLEARANCE
SHUTDOWN TO BE PLANNED

STEAG 1 ENGR+2 TECH

MATERIAL TO BE PROCURED ON PRIORITY

LICENSES AND RAM TO BE PROCURED
Procurement of one more DC
earth fault locator

STPP TO INITIATE ACTION

STPP TO INITIATE ACTION
Spare Cards req Spare Cards, spare AC's required in spare

Improvement in AWU system by

Concerned

vital spares like WTI andHV/LV bushing and winding need to

be kept as spare
dewatering Pumps at all MCCS, to
drainout water

pressure grouting of the trenches

to be done to avoid seepage to
enter in to trenches during
mansoon
STPP
Civil Department, Cementing at
entries

Operation to facilitate

Operation Clearance
Operation Clearance
Exisitng fresh air ventiliation duct
system to be improved,Additional
cooling systems needs
improvement Air washer system
STPP Support Required

Pest treatment across all mcc's

Civil support required Pit to be Prepared

Civil support required Sealing of all dust ingress entries and other floor cutouts

NFA moved for procurement of Spares of filteration machine

PO done for Schneider
SHUTDOWN TO BE PLANNED

Procurement of additional
filtration machine for BOP
Transformers - 6KL Capacity

NFA to be approved as capital

item

ESP transformer shifting stand to

be provided
STPP to provide oil for
replacement
Rewinding and repairing of
rectiformer procurement of New HV winding Transformer

IDCT Fan motor,HPCF,VSF,TH compressor motor,S/R& Paddle

feeder radiator oil cooing motor,clinker grinder & vibro
feeder, vaccuum pump recirculation motor, dewatering p

MOC TO BE APPROVED
transducers and Cutrrent transformers required
OEM support required to identify
the Bearing Issue
Minimum stock to be maintained
STPP TO APPROVE THE NFA

high beams to be provided to

faccillitate the motor
replacement in case of failure
STPP to initate the action

ABEL pump ABB cards procuremrnt

STPP to initiate the work order
process

Operation to support the

changeover system

Filters available, letter sent for allocation of budget Lube oil

180AH, 200AH, 150AH, 100AH battery required

Megawin Switch gear procurement to be explored for fastre

delivery
Breaker of higher capacity
required
Spare relays received
PO DONE
Spare relays received
 Spare relays received

Data Concentrator to be
comissioned for viewing
parameters of drives
Third Party to be arranged for
auditing
PROCUREMENT OF SPARES

STPP

STPP

EXPLORE FAST PROCUREMENT