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Subject: Minutes of 4
th
meeting of the Apex committee of HPGCL taken by MD/HPGCL
on 24.05.2014 at DCRTPP Yamunanagar regarding the performance of HPGCL
Power stations and various other issues.


The 4
th
meeting of the Apex Committee of HPGCL was held on 24.05.2014 at
DCRTPP Yamunanagar, under the Chairmanship of MD/HPGCL.

List of participants is attached as Annex-1

At the outset, MD/HPGCL expressed his concern that HPGCL is not considered a reliable
source of power by distribution companies, in view of frequent outage of its thermal generating
units. He stressed upon the need for HPGCL to improve and show its worthiness. MD HPGCL
exhorted upon Chief Engineers of thermal power stations to analyse the factors affecting
reliability and initiate appropriate action to handle them, so as to improve the reliability and
efficiency of generating units. He expressed hope that all the officers/officials will gear up, to
improve reliability and achieve reduction in cost of generation, so that the Units remain high
in merit order. During the meeting, following issues were discussed and decided:-

1. Performance of HPGCL Units viz a viz HERC targets and internal targets:

SE/Tech(HQ) gave a presentation on performance parameters i.e. PLF, Station Heat
Rate(SHR) , Auxiliary Power Consumption (APC), Specific Oil Consumption (SOC), Number
of trippings, cost of generation of HPGCL generating units viz a viz HERC targets and internal
targets.
MD HPGCL noted with satisfaction that the Unit -8 of PTPS Panipat has achieved a PLF of
more than 94 % and APC of 8.4% during April 2014. However, he desired that the APC of
Unit -8 may be further brought out down to 8.25%.
Regarding SHR of units 6, 7 & 8 PTPS Panipat MD HPGCL directed CE/PTPS-2 that all out
efforts may be made to bring down the further SHR of these units.
Regarding DCRTPP Yamunanagar, MD HPGCL stressed the need to bring down the APC and
SOC of unit -1.
MD HPGCL directed Chief Engineers of thermal power stations that the auxiliary power
consumption and heat rate may be monitored with respect to loading factor of the respective
generating unit.
While discussing the number of trippings MD HPGCL desired that the forced outage should
be benchmarked at 2% of the total availability of Unit. For achieving this, he emphasized
upon the need to improve quality of works and inspection during overhauling of the units.

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Cost of Generation:
SE/Technical (HQ) informed that due to optimization of blending of imported coal with
Indian Coal, the overall cost of generation has come down mainly due to reduction in
FPA. He further apprised MD/HPGCL that due to reduction in FPA, the RGTPP Units have
come up high in merit order above those of the CLP Jhajjar. MD/HPGCL directed
CE/RGTPP that the blending may be kept in the same range, so as to keep the variable
cost of generation below CLP and to get scheduled.
Perform Achieve and Trade (PAT):
MD/HPGCL expressed satisfaction over the achievement of PAT targets by PTPS,
Panipat and DCRTPP, Yamunanagar. CE/PTPS-1 informed about the appointment of M/s
Mitcom as consultant for achieving PAT targets.
Director/Generation directed CE/PTPS-1 to take up the matter with consultant for visit to
DCRTPP also, regarding PAT.
2. Main issues of ORT:
A. PTPS:
Condenser vacuum:
CE/PTPS-2 informed MD/HPGCL that condenser of Unit-6 & duct of Unit-8 have been
cleaned and it is expected that the vacuum of these Units will improve. As deterioration in
condenser vacuum impacts heat loss, frequent cleaning of the duct may be carried out,
as required.
Performance of Unit-7 after overhauling:
CE/PTPS-2 informed that the APH outlet temperatures have improved after overhauling
but they are still high.
MD/HPGCL noted with concerned that the un-burnt carbon in bottom ash is still high and
has not improved much after recent overhauling. He observed that the high carbon content
in bottom ash indicates improper combustion. MD/HPGCL directed CE/PTPS-2 that the air
flow (primary and secondary) and O
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after APH may be checked and monitored. The flue
gas temperatures at LTSH and re-heater, left and right variation may also be checked as
the temperatures at economizer outlet are less. He also directed that a team may be
constituted to study the problem of combustion so as to reduce carbon in bottom ash. In
case required, the services of M/s Mechwell, expert in this field may also be obtained.
MD/HPGCL desired that ORT team may spend a day and study the parameters and come
out with a solution to the problem of improper combustion.
MD HPGCL also observed that the vacuum of Unit-7 has not improved much.
CE/PTPS-2 informed that duct is being cleaned.
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B. RGTPP:
MD/HPGCL noted with concern that the boiler efficiency of Unit-1 is almost 2% less than
the design efficiency. He directed CE/RGTPP to analyze the dry flue gas temperatures,
flue gas APH outlet temperature etc., and come out with a solution, so as to improve the
efficiency to desired level. He further directed that the running parameters be discussed in
daily plant meetings by all CEs of the plants.
Regarding variation in actual coal consumption and that indicated by gravimetric feeders.
MD/HPGCL directed SE/O&M-I that the gravimetric feeders may be calibrated regularly so
as to give the accurate value of coal consumption. MD/HPGCL also directed SE/O&M-1
RGTPP to make a team for analyzing the data for coal consumption and come out with a
recommendation in next 15 days. MD/HPGCL further directed Chief Engineer to discuss
the problem/ recommendations with him, after completing the study, within next 15 days.
Briefing MD/HPGCL about the Ash Handling system of RGTPP, CE/RGTPP informed that
the peak performance of said ash handling plant has not been achieved yet in case of
worst coal. Around 2000-2400 tonne per day dry ash is being evacuated daily.
MD/HPGCL directed CE/RGTPP to monitor the performance regularly and also the matter
may be taken up with EPC contractor to achieve desired performance.
Regarding Unit-2, CE/RGTPP informed that the Unit is expected to be boxed up by month
end. MD/HGPCL directed CE/RGTPP to get the boiler checked up thoroughly and ensure
that there is no tube leakage in the next 6 months.
C. DCRTPP:
CE/DCRTPP informed MD/HPGCL that the vacuum in Unit-2 has improved and is now
0.87 kg/cm
2
against the design limit of 0.89 kg/cm
2
. He further informed that helium leak
test is being got carried out to check for any leakage of air into the condenser.
MD/HGPCL noted with serious concern that the SWAS is not fully operational. He
observed that without SWAS the water chemistry parameters cannot be checked and
monitored. CE/DCRTPP informed that some of the SWAS parameters are available in
C&I system and the same are being hooked up in DCS. He further informed that enquiry
has been issued for making major SWAS parameters available. MD/HPGCL strongly
directed that SWAS should be made operational and maintained by C&I engineers, as is
being done at other thermal power stations.
MD/HPGCL also directed CE/DCRTPP that the healthiness of instrumentation required for
checking the water chemistry may be ensured within next 15 days. He further directed that
SE/O&M of each Unit of all the plants should check the daily log sheet and submit a
weekly report that no deviation in water chemistry parameters has taken place w.r.t the
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design limits, during the previous week, to Corporate Office every Monday under his
signature, without fail.
Stressing upon the importance of water chemistry, MD/HPGCL directed all Chief Engineer
of thermal power stations that strict action may be taken against the officers/officials
responsible for poor water chemistry and non availability of parameters.
Overhauling of Units of DCRTPP, Yamunanagar:
Unit-1:
CE/DCRTPP informed that the vendors for carrying out the works and spares required for
overhauling of Unit-1 have been arranged. MD/HPGCL directed CE/DCRTPP to discuss
the scope of work finalized for overhauling of boiler of Unit-1 with him.
Unit-2
CE/DCRTPP informed that APH baskets are required to be changed during the
overhauling, however, the same are not available. M/s BHEL have submitted the offer for
supply of APH baskets. However, BHEL has quoted higher rates for supply of middle
baskets and have refused to match the rates offered by SEC. MD/HPGCL directed
CE/DCRTPP to look into possibility of procuring the APH baskets from OEM, M/s SEC
directly.
Repair of ESP:
Chief Engineer DCRTPP apprised MD/HPGCL that BHEL has been approached for repair
of ESP and they would require 8 to 10 days for inspection to finalise the scope of work.
MD/HGPCL directed CE/DCRTPP to get the inspection of ESPs done through M/s SEC &
M/s BHEL at next available opportunity or during overhauling of the Unit. The tentative
time required for repair of ESPs may be finalized after the above inspection alongwith
spares availability.
High DM water consumption:
CE/DCRTPP informed that some measures have been taken due to which the total DM
water consumption has come down. Efforts are being made to further reduce the DM water
consumption. He further informed that NIT has been issued for carrying out the water
balance study at DCRTPP Yamunanagar.
Ash evacuation:
MD/ HPGCL enquired about the performance of ash handling system at DCRTPP, to
which CE/DCRTPP informed that there is no improvement in ash evacuation since last
meeting with M/s Indure. Director/Generation stressed upon the need to know the spare
consumption pattern, failure rate etc., so that the required spares are available in stores,
in time. He further desired that the problem of ash handling may be got identified through
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HPGCL engineers. MD/HPGCL directed CE/DCRTPP that the existing system may be set
right and if required they may also plan a visit to NTPC Dadri to study their vacuum based
ash handling system, being maintained by their own engineers.
Condensate Polishing Unit:
MD HPGCL observed that the all the parameters except conductivity of CPU are not
available on line, in both the units. He directed CE/DCRTPP to initiate immediate
necessary action for ensuring availability of all online parameters i.e., silica, sodium and
totalizer (flow) at site as well as in DCS.
3. Boiler tube leakages at DCRTPP and RGTPP:
DCRTPP:
XEM/BMD, DCRTPP gave a presentation on boiler tube leakage in Unit-1 and Unit-2 since
their commissioning during 2008. MD/ HPGCL observed that poor inspection after
overhauling may be the main reason for the frequent tube failures.
While discussing the report of water walls tube of Unit-2 got tested through BHEL Trichy,
MD/HPGCL noted that the failure has occurred due to hydrogen embrittlement. The reason
for this failure is low PH of DM water, which indicates problem in water chemistry.
MD/HPGCL again emphasized upon the importance of proper water chemistry and
directed CE/DCRTPP to immediately take corrective action to streamline the system,
failing which the action may be taken against the defaulting officers.
RGTPP:
A presentation on boiler tube leakage at RGTPP Khedar alongwith action plant to mitigate
the boiler tube leakages was given. MD/HPGCL directed to segregate the tube leakages
due to joint failure, erosion etc. SE/O&M-1 RGTPP apprised MD/HPGCL about the
inherent problem in economizer. MD/HPGCL directed CE/RGTPP to get the radiography of
balance economizer joints (not covered by SEC during 2010), carried out.
Regarding scope of work of boiler overhauling, MD/HPGCL directed CE/RGTPP that the
scope of work may be discussed with him before finalization.
In order to reduce the tube leakages MD/HPGCL directed all concerned engineers of
thermal power stations to adhere to the following steps/checks:
1. Segregate erosion failures.
2. Identify the location of failure on boiler layout diagram.
3. To improve quality inspection by building full height scaffolding with adequate platforms
up to boiler roof.
4. The works during overhaulings should be supervised on daily basis and responsibility
of delinquent officers/officials be fixed.
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5. Thickness measurement of tubes should be done in all overhauls in identified areas
and permanent records to be maintained.
6. To involve fully, operation engineers during overhauling of Unit.
7. To form separate groups for inspection of water walls and second pass during
overhauling. The second pass inspection should be more vigorous and meticulous.
8. To check overheat signs on tubes during overhauling.
9. Selection of good vendor having adequate number of IBR qualified welders and staff.
10. Provision of penalty on vendor in case of tube failure within a certain duration after
overhaul say 3 months and 6 months.
11. The tube built up during normal failure should be replaced during the overhauling.
12. Radiography of stub joints of DCRTPP should be taken up in view of lot of joint failures.
13. Identify failure rate within one month of overhaul, 6 months of overhaul and so on.
14. To calculate failure rate per thousand hours of actual operation of the Unit, as a
performance indicator.
Remedial measures:
1. DPT of welded joints.
2. TIG welding followed by arc welding.
3. Radiography wherever required.
4. Provision of protective shields and shrouds.

He further directed Chief Engineers of thermal power stations that the performance
parameters of previous day should be discussed alongwith the action to be taken in the
daily plant meeting without fail.
MD/HPGCL also directed CEs thermal power stations to work out the cost of overhauling viz a
viz the estimates, and to work out a payback period, in view of efficiency improvement
achieved. Accordingly, the efficiency improvement should be related to cost of overhauling for
the next coming overhauls.
4. O&M Issues:
a. MD/HPGCL desired that the C&I audit of RGTPP may be got conducted through the team
of C&I officers of PTPS-2 Panipat and DCRTPP Yamunanagar. The team may also
discuss the methodology of carrying out the audit with Sh. Lal Ji Aggarwal, ex- NTPC
expert.
b. & c. MD/HPGCL desired that the existing practice of checking of DG set and DC
emergency auxiliaries in each shift, may continue to be followed.
d. He further directed that a committee comprising ORT coordinator of respective station
may be constituted for giving recommendations regarding tests and interval of test
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required for GT, ST, UAT, CT, PT etc., so that the testing are standardised at all HPGCL
thermal power stations.
5. Fire Fighting System:
DCRTPP:
CE/DCRTPP informed that the fire fighting auto system is not working. He further briefed
about the visit of vendor for inspection of fire fighting system. MD/HPGCL directed that the
problems may be analysed thoroughly, before taking a final decision in the matter.
PTPS:
CE/PTPS-2 apprised MD/HGPCL about the progress achieved in fire fighting system of
Unit-5.
MD/HPGCL directed Chief Engineer/PTPS-2 that the emergency fire fighting system of
Unit-5 & 6 should be made ready by 30.06.2014. He further desired that the action plan for
making the emergency fire fighting system of Unit-5 & 6 may be reviewed by CE/PTPS-2
on weekly basis. He also desired that the status of fire fighting system should be
incorporated in the ORT format and status of NITs and the progress achieved should be
discussed at length during ORT.
6. Assessment of O&M practices of thermal power stations:
Chief Engineer planning apprised MD/HGPCL about the progress of standardization
SOPs/SMPs submitted by Steag Energy Services India Pvt. Ltd. Director/Generation
informed that on the basis of SOPs/SMPs being followed at HPGCL thermal power stations,
the World Bank would disburse loan for strengthening the operating practices in HPGCL.
MD/HPGCL directed Chief Engineer/ Planning that the SOPs/SMPs should be finalized by
forming a group of engineers of Planning department, who will visit each thermal power
station and finalize the SOPs/SMPs in association with plant engineers in a time bound
manner. MD/HPGCL also directed Chief Engineers of thermal power stations to extend full
support to the team of CE/Planning for finalizing the same.
7. Standardization of sampling and testing procedure of Indian and imported coal:
CE/Fuel apprised MD/HPGCL about the progress of implementation of directions of
MD/HPGCL issued during the meeting on 05.04.2014 regarding standardization of sampling
and testing procedure of Indian and imported coal. Director/Generation directed CE./Fuel that
a status report may be submitted in this regard for the information of MD and Directors.
MD/HPGCL directed CE/Fuel to ensure in next one month that there is no variation in
methodology of sampling and analysis of coal, at HPGCL thermal power stations. He further
directed CE/Fuel that the exception report may be discussed in the next Apex meeting.

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8. FPA:
A presentation regarding calculation of FPA was given by FA/HQ. MD/HPGCL directed FA/HQ
and FAs and CAOs of thermal power stations that the FPA should be calculated on the same
lines so that it is standardized and there is no variation in FPA calculated at power stations
and that calculated at Head Quarter.
9. AMC/ARC:
MD/HPGCL desired SE/Projects that the quantum of AMCs/ARCs in place at each thermal
power station should be compared to streamline and reduce the AMCs/ARCs to bare
minimum.
10. ERP Implementation:
CE/PTPS-1 apprised MD/HPGCL about the progress made and informed that the preparation
of RFP for selection of implementation partner is under progress.
11. E-tendering:
CE/PTPS-1 informed MD/HPGCL that sign off to the Functional Specification Document
submitted by M/s Next tenders has been issued on 26.05.2014. The firm shall start online
training regarding e tendering, to HPGCL nodal officers within a week.
12. Performance Management System:
CE/PTPS-1 informed MD/HPGCL that the KPAs/KRAs are being finalized as discussed during
the meeting with Chairman HPGCL on 17.04.2014.
13. Shortage of Manpower:
CE/DCRTPP informed that out of 15 AE/AEEs and 9 officials posted at DCRTPP
7 AE/AEEs and 4 officials have not yet joined, and requested MD/HPGCL to post additional
AE/AEEs for performing shift duties.
Regarding shortage of staff at PTPS-2, MD/HPGCL directed CE/PTPS-2 to consider Unit-5 to
8 as a single Unit and utilize the available man power in any of the Units, depending upon the
requirement.
14. Inventory Management:
MD/HPGCL noted with concern the high level of inventory in main store and site stores at
HPGCL thermal power stations and directed Chief Engineers to reduce the same in a phased
manner. Director/Technical directed CE/PTPS-2 that the items available in the site store may
be identified at the earliest so as to reduce the inventory in site store (MAS). MD/HPGCL
directed CE/PTPS-2 to reduce the inventory in site store from the existing level of Rs. 38 crore
to Rs. 30 crore in the next three months.
MD/HPGCL directed CE of thermal power stations to examine the possibility of starting a
night store at respective thermal power station which shall remain open upto 10:00 PM.
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15. Budget:
FA/HQ gave a presentation on the annual budget of 2014-15, to sensitise the officers.
MD/HPGCL directed CEs that the expenditure may be monitored regularly w.r.t. the budget
allocated to respective power station/divisions.
16. Internal Audit:
MD/HPGCL directed CAO to circulate the observations of Internal Audit to all concerned and
desired to discuss the same during the next Apex meeting.
17. General issues:
Regarding heat rate calculation, MD/HPGCL desired that the difference in turbine heat rate
calculated on the basis of GCV and that calculated on basis of parameters should not be
more than 50-60 kcal/kwh.
MD/HPGCL also desired that the similar exercise may also be taken up by SEs of PTPS,
DCRTPP and RGTPP.
Regarding proposal of 660 MW Super Critical Unit at PTPS Panipat, Director/Technical
directed CE/Planning to check the feasibility of selling up an 800 MW Ultra Super Critical
at PTPS Panipat in a time bound manner so that further action for implementation of the
same may be decided.
MD/HPGCL directed SE/Projects that the CE/Projects should coordinate with CE of
thermal power stations for closing the pending contracts.
During the visit to Ash silo at DCRTPP, MD HPGCL observed the register being
maintained for lifting of fly ash is not being signed by any HPGCL officer/official. He
directed CE/DCRTPP that signing of ash lifting record register by concerned JE on daily
basis may be ensured and send the monthly record at the end of the month to Head
Quarter. Regarding water logging in the ash silo area, he directed to get the area cleaned.

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Annexure- 1

List of participant of 4
rd
Apex Level Meeting held on 24.05.2014 taken by
MD/HPGCL at DCRTPP, Yamunanagar:
Sr. No. Name of officers/officials Designation
1. Sh. J.P. Agrawal Director/Technical
2. Sh. S.C. Jain Director/Generation
3. Sh. S.S. Dalal CE/PTPS-2
4. Sh. A.K. Sood CE/PTPS-1
5. Sh. V.B. Bansal CE/DCRTPP
6. Sh. Rajesh Kuchchal CE/Fuel
7. Sh. Tarun Choudhary CE/RGTPP
8. Sh. S.K. Khungar CE/Planning
9. Sh. B.B. Gupta FA/HQ
10. Sh. Vikas K. Gupta, CAO, HQ
11. Sh. Sharad Bhatnagar SE/Technical (HQ)
12. Sh. N.K. Wason SE/O&M RGTPP
13. Sh. V.K. Mirzapuri SE/Projects, Panchkula
14. Sh. Sunil Sharma SE/Planning, Panchkula
15. Sh. S.L. Pruthi SE/O&M-I, DCRTPP
16. Sh. Kalvinder Singh SE/O&M-II, DCRTPP
17. Sh. R.K. Jangra SE/O&M-I, PTPS
18. Sh. Ashok Singla SE/O&M-II, PTPS
19. Sh. L.N. Dua SE/Unit-5, PTPS
20. Sh. H.S Saini SE/Unit-7 , PTPS
21. Sh. Balwan Singh SE/Civil, DCRTPP
22. Sh. Sanjeev Gupta SE/M&T, DCRTPP
23. Sh. V.K. Sethi, SE/Fuel, DCRTPP
24. Sh. H.D. Jangara SE/O&M-1, PTPS
25. Sh. D.K. Sharma SE/MM & Store, DCRTPP
26. Sh. Rohitas K. Bansal FA&CAO/PTPS
27. Sh. Sanjeev Arora FA&CAO/DCRTPP
28. Sh. Rajesh Goyal FA&CAO/RGTPP
29. Sh. Surinder Mittal OSD/(Technical) to MD/HPGCL
30. Sh. Ashok Garg Dy. Secy./Generation
31. Sh. Rajesh Arora Xen/BMD-I, DCRTPP
32. Sh. Rajesh Garg Xen/Unit-7, PTPS
33. Sh. Jasmer Singh Xen/BMD-II, RGTPP
34. Sh. J.P. Dhiman Xen/BMD-II, DCRTPP
35. Sh. J.K. Taneja Xen/Proc-I, DCRTPP
36. Sh. R.A. Khan Xen/Proc-II, DCRTPP
37. Sh. P.K. Nigan Xen/CHP, DCRTPP
38. Sh. V.K. Gautam Xen/Fuel, DCRTPP
39 Sh. Mohinder Singh Xen/Works, DCRTPP
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40. Sh. Amit Uppal Xen/C&I-8, PTPS
41. Sh. L.S Virdi Xen/ BMD-2, RGTPP
42. Sh. Atul Khanna Xen/Efficiency, DCRTPP
43. Sh. Ajay Amber Xen/Store, DCRTPP
44. Sh. Parveen Arora Xen/ORT, Panchkula
45. Sh. Himanshu Gupta Xen/ORT, Panchkula
46. Sh. Pardeep Kumar Bhanwara, AEE O/o CE/Admn.
47. Sh. Deepak Phogat, AEE O/o CE/Admn.
48. Sh. Puneet Arora AEE/Efficiency
49. Sh. Manish AEE/Efficiency
50. Sh. Dharambir Rathore AEE/Efficiency
51 Sh. J.S. Kushwaha Sr. AO Accounts , DCRTPP
52. Sh. Mohinder Pal AO Accounts
53. Sh. V.K. Mahajan Chief Chemist, PTPS
54. Sh. Ashok Basra Dy. Chief Chemist, DCRTPP
55. Sh. Ashwani Gupta Chemist, PTPS