Project Disha

Operation Department

OPERATING FRAMEWORK
O&M PROCESS-21
TOTAL STEPS- 886
IMPLEMENTED-17
1.
Strategic Planning
IMPLEMENTED-744
Strategy formulation & review
1.1

1.2 New Business Dev. (Greenfield)

1.3 New Business Dev. (M&A)

2. Fuel Mgmt.

.3Revenue Management

2.1
Sourcing (incl.
coal cost)

Sales Strategy & Planning 3.6 Customer Management

3.1
3.2 Bidding Process
3.7 Billing Process
3.3 Customer Acquisition (non- 3.8 Receivable Management
bidding)
3.9 Regulatory & Litigation
3.4 PPA Execution Setup
Management
3.5 Dispatch Management

2.2 Logistics

2.3 Quality
2.4 Planning
2.5 Handling

4.8. Fuel Oil Management

4.9 Safety and security
4.10 Ash handling and
utilization
4.11Environment &
compliance
4.12 Disaster Management
4.6. Process Data Acquisition 4.13 Water Management
4.7. In plant coal handling
4.14 Commissioning

5. IT and MIS

5.1. Energy Mgmt. System

5.2 MIS

.4Operation and Maintenance

Outsourcing strategy
4.1.
4.2. Maintenance Processes
4.3. Operation Processes
4.4. Performance
Optimization
4.5 Technical Audit

1.4 Risk Mgmt.

procedures
4.15 Contract Management
4.16 Inventory Management
4.17 Quality Processes
4.18 planning & Budgeting
4.19 knowledgeManagement
4.20 Statutory compliance
4.21 Operation modifications

6. HR

6.1. Organization Structure

6.2. Roles & responsibilities; KPIs
6.3. Training requirements

DISHA PROCESSES RELATED

TO OPERATIONS
OPERATION

FUEL OIL MANAGEMENT

WATER MANAGEMENT

ASH HANDLING

OPERATION
Process

Total steps

Fully
Implemented

15

15

08

08

Generation Sch
eduling

20

15

Changeover

12

11

55

49

Sub Process

Daily Load Plan

ning
Operation

Long-term Load
Planning

Total

OPERATION PROCESS KPI

S.
No.

KPI

KPI FORMULA

L1

04

L2

06

TARGE
T

LEVE
L

<675 gm/kwh

L1

No Target

L2

Equivalent Specific Coal

Consumption (gm/kWh)

Coal consumed / Total Generation

Coal Cost per KWh (Rs)

Coal consumption by stage x Coal price

/ Units Generated

% Difference between Actual

Generation and Scheduled
Generation

((Phase-wise Scheduled Generation) (Phase-wise Actual Generation))/

(Phase-wise Scheduled Generation)

<1%

L1

DC Revisions - Overall

Number of DC revisions (CUF) - Overall

<10

L2

DC Revisions - Coal Quality

Number of DC revisions (CUF) - Coal

Quality

<5

L2

Merit Order compliance (%)

% of compliance of load allocation as

per merit order

>95%

L1

Merit Order Non compliance (#)

No of instances of Non-Compliance

<15

L2

Loss due to Merit Order NonCompliance

(Actual Allocation - MO
Allocation)*Duration*Coal Cost

<5 Lacs

L2

Overall Changeover Compliance

(%)

Number of changeovers done on time /

Overall changeovers

>95%

L1

<5%

L2

10

Changeover Non-Compliance due 1 - (Changeovers delayed due to nonto technical reasons (%)
technical reasons/Total changeovers )

FUEL OIL MANAGEMENT

Process

Fuel oil
management

Sub Process

Total steps

Fully
Implemented

Demand Estimat
ion

17

15

In-Process Con
sumption and M
easurement

05

05

07

07

29

27

Variance Analys
is and Feedback
Process
Total

FUEL OIL MANAGEMENT PROCESS KPI

SR.
NO.

KPI

KPI FORMULA
Cumulative fuel oil consumption till given
month / cumulative generation till given
month

Station level SOC (YTD cumulative)

SOC variance (YTD cumulative) - Unit Actual cumulative SOC till given month /
1
Target cumulative SOC till given month
Sum of (actual fuel oil consumed for given
start-up calculated fuel oil requirement for
given start-up) / (calculated fuel oil
requirement for given start-up)*100 for all
start-ups

Deviation in actual vs. planned FO

consump / start-up (Unit 1)

SOC variance (YTD cumulative) - Unit Actual cumulative SOC till given month /
2
Target cumulative SOC till given month

L1

03

L2

04

TARGE
T

LEVE
L

<0.22 ml/kwh

L1

<1

L2

<10%

L2

<1

L2

<10%

L2

Deviation in actual vs. planned FO

consump / start-up (Unit 2)

Sum of (actual fuel oil consumed for given

start-up calculated fuel oil requirement for
given start-up) / (calculated fuel oil
requirement for given start-up)*100 for all
start-ups

HFO Inventory Level (% days

inventory level is below minimum
stock)

(Number of days closing stock is less than

minimum stock / Total number of days)*100

L1

LDO Inventory Level (% days

inventory level is below minimum
stock)

(Number of days closing stock is less than

minimum stock / Total number of days)*100

L1

WATER MANAGEMENT
PROCESS
Process

Water
management

Sub Process

Total steps

Fully
Implemented

Water Planning

21

14

07

07

12

12

40

33

Water Quality
Management
Performance Mon
itoring

Total

WATER MANAGEMENT PROCESS KPI

SR.
NO.

KPI

KPI FORMULA

Variable cost of water production DM

Variable cost of production of DM water

(chemicals, power, etc.)/ KL of production

Specific Power Consumption by DM

Plant

Power Consumed by DM Plant / KL of DM

Water

Specific chemical consumption (DM) Dosing Chemical Consumed (Kg) / Amount

(Hydrochloric Acid +Sodium
of water processed (m3)
Hydroxide )

Total Quantity of DM Water Generated

OBR (Output between regeneration) between two consecutive regenerations existing DM plant m3 (3*45m3/Hr.)
(Sum of all Phases)

Total Quantity of DM Water Generated

OBR (Output between regeneration) between two consecutive regenerations additional DM plant m3 (2*90m3/Hr.)
(Sum of all Phases)

Volume of DM water water consumed Volume of DM water consumed

Other DM Consumption (Station)

(m3)

Sum of phase-wise consumption (m3)

Specific chemical consumption For

RO Water - (Antiscalant+SMBS+HCl)

Dosing Chemical Consumed (Kg) / Amount

of water processed (m3)

L1

02

L2

14

TARGE
T

LEVE
L

<16.00 Rs/KL

L1

<2.2 kWh / KL

<0.57 Kg / m3

>2160 m3

>4320 m3

<24000 m3

<9000 m3

<0.030 Kg / m3

L2

L2

L2

L2

L2

L2

L2

WATER MANAGEMENT PROCESS KPI

SR.
NO.

KPI

KPI FORMULA

L1

02

L2

14

TARGE
T

LEVE
L

>75%

L2

<41250 KL

L2

Average Recovery (%) of RO plant

((2*45+1*90)m3/Hr.)

Permeate Quantity / Feed Quantity

10

Volume of RO water water consumed

Volume of RO water consumed

11

Specific Power Consumption by PT

plant

Power Consumed by PT Plant / KL of PT

Water

<0.03 kWh / KL

12

Specific Chemical Of UF Plant ( Sodium Hypochloride+Sodium

Hydroxide+Hydrochloric Acid )

Dosing Chemical Consumed (Kg) / Amount

of UF water processed (m3)

<0.15 Kg / m3

13

HW Makeup % - Overall

Hot-well makeup rate / Boiler BMCR Feed

Flow

<0.6%

L1

14

HW Makeup % - Unit 1

Hot-well makeup rate / Boiler BMCR Feed

Flow

<0.6%

L2

15

HW Makeup % - Unit 2

Hot-well makeup rate / Boiler BMCR Feed

Flow

<0.6%

L2

16

Extent of Deviation in Water Quality

by Location

(% of deviation x duration of deviation in

hours) / Total duration in hours

0.0%

L2

L2

L2

ASH HANDLING PROCESS

Process

Sub Process
Ash Planning

Ash
management

Main Ash Handl

ing
Ash Bagging

Ash Performance
Monitoring
Total

Total steps

Fully
Implemented

17

14

12

07

15

00

05

02

49

23

ASH HANDLING PROCESS KPI

L1

02

L2

04

SR.
NO.

KPI

KPI FORMULA

TARGE
T

LEVE
L

Ash Sale (%)

Quantity of fly ash sold / Quantity of fly ash

generated

>95%

L1

% Days of non-adherence to Ash

Planning

(No. of days day ahead ash planning

communication was not sent / total number
of days)*100

<0%

L2

Variance in ash %

(((Actual fly ash generated - forecasted fly

ash generated) for all days of the month)/
(Average of actual fly ash generated in the
month

No Target

L2

Ash Management Profitability

(Revenue - Variable Cost) / Per ton of fly ash

sold

To be set

L1

Ash Sales Realization

Revenue from sales of fly ash/ volume of fly

ash sold

>200 Rs/MT

L2

Variable cost per ton of ash handled

Variable cost of ash handling per ton of ash

generated (includes maintenance and any
other variable cost)

To be set

L2

OTHER PROCESSES
PROCESS

Maintenance

In
Plant Coal Handlin
g
Statutory
compliance

PDA

SUB PROCESS

TOTAL
STEPS

INVOLVEMENT
IN STEPS

RCA

30

05

PM

23

07

CBM

19

06

Work order management

48

43

Coal planning

11

02

Coal quality management

08

01

Statutory requirements identification

08

02

Statutory requirement achievement

21

07

Process Parameters Guidelines Definition

10

10

Process Data Monitoring

03

03

06

06

07

04

Technical audit execution

09

02

Technical Audit Reporting

07

02

Technical Audit Roll out

08

02

Deviations Data Analysis Process

Knowledge Manag
ement

Technical audit

Knowledge Capture

OTHER PROCESSES
PROCESS

Disaster managem
ent

Safety & security

Quality

Planning
& Budgeting

Operations
Modification

SUB PROCESS

TOTAL
STEPS

INVOLVEMENT
IN STEPS

Emergency Preparedness

14

01

Compliance Tracking

11

03

Access Rights Definition Process

10

01

Access Control Management Process

11

04

Safety and Emergency Training Process

11

01

Near-Miss Reporting Execution

11

04

1. Pre-dispatch quality inspection

19

02

3. Field Quality Inspection

17

02

Materials consumption budget for Other

depts

23

03

Review and Approval Process (Governance

Mechanism)

08

01

. Tracking and Variance Analysis

09

03

Opportunity Identification

09

03

Project Definition

08

06

Governance & Close Out

16

04