FEBRUARY 2006 – ISSUE NO.15

HIGHLIGHTS

  • INSSAN National Contest 2005Refer page 2
  • Highest ever monthly generation at Jojobera Refer page 3
  • Focus group visit to RELRefer page 4
  • Highest generation in the history of Tata HydroRefer page 5
  • Outage Help Desk Refer page 6
  • Strengthening of Bhira PenstocksRefer page 9

Savings:

  • Carnac – Rs.10,000/-Refer page 4
  • CSG Group – 36.18 lakhsRefer page 7,8
  • Corporate IT – Capex 24.00 lakhs and Opex 5.00 lakhsRefer page 8

IMPORTANT EVENTS AT VARIOUS DIVISIONS

TROMBAY

NEW

  • On 12.01.06 Supplier/ Partner Meet was held at Trombay.Around 44 suppliers participated in the Meet and have given their valuable feedback and suggestions for the improvement. They appreciated Tata Power’s initiatives and the honest working culture prevailing.
  • Eleven delegates from Tata Power, Trombay Thermal Power Station took part in Sixteenth Annual National Convention of INSSAN held in Mumbai on 20th & 21st January 2006. More than 50 organizations participated in the convention.
  • “Inssan National Contest 2005”

Tata Power, Trombay presented three case studies and one technical paper. Out of which the case study named “Resource utilization at Coal handling Plant” presented by Mr. P. D. Kulkarni of Coalyard and the Technical Paper based on the theme 'Value Creation Through Participation’ by Mr. Indranil Ghoshbagged ‘Encouragement Awards’. This is the 2nd consecutive year Mr. Indranil Ghosh received an award. Prizes were also distributed to Mr. R. S. Nikade of EMD B (First Prize for Marathi slogan) and Mr. B. D. Chive of Operation A (Encouragement Award for poster) for their performances in Inssan National Contest 2005. Congratulations to all the award winners.

  • Officials of our insurers, M/s New India Assurance and their reinsures from UK visited Trombay on 30.01.06. The program included a presentation on the strengths of Tata Power, discussions with Trombay Senior Management team and field visits to Unit 6, 7, Fire station and Load Dispatch. The presence and efforts of our employees from Planning, Operations, Load Dispatch, Fire, Safety and Security in making a positive impression on the visiting team (in view of Unit: 5 outage activities and the short notice) is highly appreciated.

BETTER

  • On Friday06.01.2005 YCMD Award Distribution program was held at Trombay. Mr. A. M. Paranjape, Divisional Manager (Value Engineering), Tata Motors, Pune and Managing Council member of INSSAN (Indian National Suggestion Scheme Association) were the Chief Guests. Mr. S. D. Deshpande , Mr. A P Wankhede and Mr. Thomson Koshi spoke on the occasion. Totally 33 awards were given. Congratulations to all the award winners.
  • Mr. Roshan George Sr. Technician of Instrumentation Department has been cleared by TQMS as a Certified Internal Assessor based on his performance in the recent training program (BECP) at VHRDC, Thane. Hearty Congratulations on this creditable achievement.
  • On 5.1.06, there was heavy gland leak from Boiler Feed Pump B discharge valve. The leak was sealed online and hence unit shutdown was avoided. The efforts put by employees from operation department in maintaining the process parameters and timely assistance given by employees of mechanical maintenance department in sealing of gland leak is appreciated.
  • On 20 the Jan 2006 in A shift after taking U5 out of service, while isolating 220 KV GT5, its bus side GOD (29A) power source tripped. GOD arms remained in skew position. Attempt was made to open GODs manually and GOD got stuck in arcing zone. Immediately 220 KV main bus-I was shut down. GOD was opened manually by de-linking the GOD drive mechanism by operation staff on duty before EMD help could arrive. Quick action by operation staff on duty is appreciated.

DIFFERENT

  • One Battery operated truck (Jambo) was lying unused at U#7 for a quite long time. Mr. Philip Noronha, Mr. S. M. Ali, Mr. Nitin Mahulkar, Mr. R. T. Gavand took initiative and repaired it in December 2005. Similar work now has been taken up by Mr. R P Mhandre, who has taken initiative to repair one unused Battery operated truck (Jambo) which belongs to MMD and make it working. Their efforts are appreciated.

JOJOBERA (NDB)

  • Jojobera achieved its highest ever-monthly generation of 262.5MU in January 2006.
  • Fly ash utilization was highest at 51538 MT in January 2006.
  • Export of power was 44.1 MU for January 2006.
  • Fourth Annual sports function was held at Moolgaonkar Stadium. Mr. D M Choudhary Chief, Electrical, of Tata Steel was the Chief Guest. Mr. Rakeshwar Pandey, President, Tata Electric Employees’ Union was the Guest of Honour. Employees, their spouses, children and the Contractor workmen also participated in the sports events.
  • Mr. Ashok Uppal, General Manager (ER) was given a fond farewell by the employees of Jojobera on 31/01/2006. Mr. Rakeshwar Pandey the Union President was also present. Mr. Uppal superannuated from the services of the Company on that day.

T & D

NEW

  • Carnac - For augmented security monitoring, 12 nos. cameras commissioned at Carnac for CCTV system and same connected by WAN and accessed successfully from CCR at Dharavi.
  • Saki - Special arrangement has been made with a property management company- M/s. Total Solutions for power supply bill payment for 27 ONGC owned Flats in Hiranandani area.
  • Salsette - Learning center on 110 kV ELF breaker was inaugurated by GM (T&D) on 6.1.2006.
  • Salsette - Morning Exercises are started at Salsette after the union representatives have attended the Team building course held at Sinhagad.

DIFFERENT

  • Carnac - Aux. consumption reduction by 19MWH partly due to replacing FL lamps chokes by electronic chokes.
  • Parel - At Mahalaxmi s/s Quality Inspection of 22 KV Vacuum Circuit Breakers (connected on 22 KV Bus Section No. 2) carried out.
  • Saki - Maintenance practice for 10 MVA transformer OLTC is reviewed and redesigned so as to replace the oil once in every year as compared to monitoring BDV and oil filtration once in 6 months.
  • Salsette - The employees of Salsette visited Trombay unit # 5 for learning outage activities.
  • Saki - A breakthrough was achieved in our working relationship with REL when the Focus Group visited REL on 31.01.06 and made a small case study presentation on transformer repairs, during discussions. REL received the same enthusiastically and suggested a monthly joint meeting for knowledge sharing covering best practices in transformer / switchgear preventive maintenance and case studies, Relay setting co-ordination, SCADA issues, cable protection and common action plan to co-ordinate with MMRDA. REL also agreed to partner our efforts on process benchmarking.

BETTER

  • Borivli - Telk make CT repairs is being done in-house.
  • Carnac - Station Transformer No 3, 33kv bushing replaced departmentally without CCD or OEM help and saving Rs 0.1 lakhs.
  • Dharavi - CT of 110 kV Bus Section breaker was overhauled in house with the help/guidance from maintenance staff of Borivli R/S.
  • Mankhurd - At BARC power supply of Training school Hostel sub-station- 8 (800KVA) has been changed over to TPCL network on 22nd January 06.
  • Distribution - Out of eight cable faults, two were completed in one day each and four were completed in two days each.

PERFORMANCE HIGHLIGHTS

  • Borivli - 22KV/11KV Esselworld S/S was successfully taken on SCADA control.
  • Saki - Energy Sales has shown an increase of 11% as compared to corresponding month previous year.
  • Distribution - 2 x 500M cable was laid over-night in view of urgent road concreting work of MMRDA / PWD.
  • T & D -As per MERC directive TPC was advised to replace meters for consumers having load more than 20KW. Borivli, Saki & Distribution division have successfully completed phase I of replacing CT based meters with RS-485 port.

RECOGNITION FROM OUSIDE AGENCIES

CCR - A team offive members including3 officials from NDPL and2 officials from ABB visited CCR; mainly to see functioning ofDistribution Automation system of BKC area.AGM (CCR) Mr.V M Patankar also explained them over-all functioning of CCR. The team appreciated functioning of CCR resulting in increase in efficiency, cycle time reduction and proper utilization of manpower.

OTHER EXCELLENCE POINTS

  • Borivli - A knowledge sharing session on TELK CT was arranged at Borivli on 4/1/2006. Earlier in the month of May 05. TELK CT was repaired at Borivli in presence of TELK representatives. Knowledge sharing session was based on this experience. 9 employees of various divisions attended the session. A spare leaking CT was overhauled in their presence.
  • Borivli - Mr. K N Halarnkar and Mr. D M Khan from Borivli Division were deputed to Dharavi for helping the division to repair their CTs. Appreciation mail was received from Dharavi Division.
  • Borivli - Mr. N S Patil was deputed to Saki S/S for carrying out the breaker pole replacement of FC4 breaker during their emergency.
  • Carnac - 20 nos. suggestions received from employees on suggestions day.
  • Chembur - Mr. L. J. Mascarenhas conducted two workshops on increasing work efficiency & output by holistic approach at Carnac & Parel R/S. Practical knowledge of simple holistic exercise & breathing techniques was also imparted to participants. This will help in inculcating maximum agility overcoming lethargy & sluggishness.
  • Parel - Mr. S. Y. Karkar (Asst. Manager) received appreciation letters from NDPL, Mr. A. K. Sardana and Mr. V. C. Mathur for the contribution made by him during his 2 years stint with NDPL at Delhi.

HYDROS

NEW

  • Hydro has achieved a highest generation of 1729 MUs in the history of Tata Hydro. The previous highest generation was 1636 MUs achieved in 1992.
  • Khopoli division also achieved the highest generation of 325 Mus. The previous highest generation was 308 Mus achieved in 1992.
  • At Bhira 25 MW sets were overloaded to 28 MW to enhance the old Ph capacity from 150 MW to 165 MW. The station capacity has been enhanced from 315 MW to 330 MW.
  • 25 MW Set # 1 completed 500 trip free days & Set # 5 completed 455 trip free days.
  • 24 MW Unit # 10 at Bhivpuri taken back into service on 16.01.2006 after completing annual overhaul.
  • On 8th January transfer stopping mode is commissioned for Unit 8 at Khopoli. This will reduce the starting time of machine from the current 333 Secs to 125 Secs.
  • On 8th January Morning Glory (overflow device) at Forebay taken in service thus providing additional protection to Forebay & an early warning system.

BETTER

  • Khopoli Division won the 1st prize in the cultural programme (Dance Competition) held at Trombay Sports Ground on 8th Jan 2006 at the Annual Athletic Meet.
  • Cricket match tournament was arranged for village youths of Maval Taluka at Somwadi from 27th Jan 06 to 29th Jan 06. VP (HR) inaugurated the match on 27th Jan 06 and Mr. S. N. Ogale, AGM (CSR) distributed the prizes to the winners on 29th Jan 06.
  • Cataract survey was carried out by Dr. P R Lingayat in the five villages around Bhivpuri PH area & identified 30 cases.
  • In an effort to improve employee health & morale, ‘YOGA’ classes for employees of Khopoli & Lonavla is being conducted at Khopoli Senior Club by Kaivalyadhama Experts from Monday the 23rd January 06.

VISITS

  • Mr. R K Singh, Chairman of DVC & Mr. Gupta, MD, DVC visited Bhira on 08-01-06.
  • Mr. Deshpande, Superintending Engineer, CDO, Nashik with 10 other technical members visited Bhira on 25-01-06.
  • 4 engineers from Rawalje Power House visited BPSU during the overhaul
  • 40 technicians & 2 engineers from Hydro visited Koyna powerhouse to know the best practices followed by MSEB.

CORPORATE SOURCING GROUP

NEW

  • Outage Help Desk:

Previous Arrangement: - To provide on the spot emergency materials assistance during Plant Outages, CSG had provided Local Help Desk at Trombay during previous Outages. Users used to communicate outage related emergency requirement to Local Help Desk which in turn jointly with Central Coordinator in CSG would meet the requirement.

New Arrangement: - For Trombay unit 5 Outage, CSG is extending these services to Trombay through Central Coordinator without being present locally at Trombay or initially visited frequently. Central Coordinator is accessible round the clock taking advantage of efficient communication system like Mobile, e-mail etc. Users from their respective work site communicate their requirement to Central Coordinator located at CSG. This has resulted in optimum manpower utilization without sacrificing requisite services desired by Internal Customers at Trombay.

  • Vendor Intelligence activities were newly started . Product wise market intelligence reports were prepared which includes the international and national vendors. The information contains the market demand, strength and weakness of vendors. New trends and technological changes were covered in the reports. The two reports on HT Cables and LT Cables are available for the users.
  • Complaint Management Help Desk: Sourcing group has formulated common help desk for registration of vendor’s complaints.
  • Glaring out come of CSG help desk: The emergency requirement of 200 drums of turbine oil was made available to user within 24 hours. Joint effort of Mr.Gopalkrishanan, Mr. Jana and Mr. Mane resulted in prompt sourcing of the same despite the day being weekend for the oil manufacturers.

DIFFERENT

  • Supplier’s meet 2006: Suppliers’ meet 2006 was arranged on 30th January 2006 at IMC, The tone for the suppliers meet was set by our ED (F) Mr. S Ramakrishnan, who emphasized the partnership concept and outlined the opportunities. This was followed by a brief presentation made by Corporate Sourcing Group, which outlined TPCs history and contribution to the Power sector. The presentation also included improvements made at CSG and gave a brief report to vendors on actions taken by CSG based on feedback received from Vendors.

Suppliers were educated on Maharashtra VAT and Tata ethics. Mr. Subramanium, Senior Manager of Deloitte Haskins & Sells, who are a Chartered Accountancy firm of international repute and consultants to TPC, gave a very detailed and lucid presentation on the newly introduced Service tax & VAT. They also outlined Future plans of the government to expand the ambit of the service Tax net, so as to make it parallel to what Excise duty is for materials.

General Manager Mr. U S Bapat gave a brief, but very appropriate talk on the Tata Code of conduct, besides the overview, he impressed upon the vendors the need for Tata Companies to produce Goods and Services, which are at least on par with the best available nationally, while aiming to be of International standards. Towards this end, he highlighted the important role to be played by the Supplier partners. Feedback from suppliers is very good and interactive.

  • Site offices requested to place the order at landed price Rs.62 lacs. CSG sourced the equipments from direct dealer of manufacturer. The quotations for supply of CCTV and Thermo vision camera was submitted by the Indian representatives as per normal sale in country, however during negotiations Mr.V.L.Gopalkrishnan and Mr.B.D.Pande sourced the material on high sea sale basis, which in turn saved Rs.29.77 lacs in CCTV sourcing and Rs.3.6 lakhs in Thermo vision Camera. The equipments are under use during current outage.

BETTER

  • Mr Rahul Rao conducted 4 sessions on ‘Save Power’ on 24th Jan 2006 at SwamiVivekanandSchool, Chembur. Over 1,000 children from classes V to IX attended these sessions.
  • Mr. Negi S S has avoided placing of order on L-2 bidder, by pointing out the mistake in proposal and saved Rs.02.42 lakhs.
  • Vendor Survey was carried out departmentally and by outside agency i.e. AcNielsen, as per survey report TPCL is perceived as the best company far better than other companies in the industry. TPCL has established very high brand image among its vendors.
  • In the negotiation of Jetty and conveyor, CSG groups got substantial reduction in cost. Similar effort for Ethernet base ESTV resulted in reduction of cost.

Corporate IT

NEW

  • Company Information Map has been defined in terms of KPMs and mapping with Source Systems, with the help of consultants, as part of a comprehensive Business Information Warehouse project.
  • Web based Access Portal ( launched for access to Company applications from anywhere outside Company premises; currently available for Email, Holiday Home Booking, PMS, Hard Furnishings System, Leave Management System, Retirement Benefits, Salary Query and LTA.
  • E-muster system to replace the aging swipe card system has been launched effective 1st Jan 2006. eMuster has been introduced for officers through a computer login.
  • Since the card readers have out lived its life, the cost of replenishing them would be around Rs.24.00 lakhs. This system has facilitated saving of Capex of 24.00 and Opex of 5.00 lakhs. Since the eMuster is interfaced with Leave System, absenteeism can be tracked and a system-generated email can be activated to inform the officers who have not signed in to submit leave applications.

BETTER

  • Email system has been revamped by updation of directory and increase of capacity of individual mailbox sizes.
  • The full range of IT policies have been comprehensively reviewed and re-vamped.

Civil Construction & Central Construction Dept.

Job: Strengthening of Bhira Penstocks.

Introduction:

Bhira Power station (6 x 25MW) was commissioned in year 1927. It has six Penstock pipes starting from Valve House which bifurcate to 12 pipes after Anchor Block No7.

The Penstock diameter varies from 1480mm at the Valve House to 914mm near the Power House and traverses a length of approximately 1800meter.

A review of the structural safety and RLA study of these penstock pipes was carried out.

Thickness measurements of pipe shells were taken along the entire length of the penstock pipe at 1 meter interval. The analysis carried out and (based on RLA study) it was decided to introduce an additional Anchor Block (AB) with an Expansion Joint (EJ) to achieve the required factor of safety in span of AB15 to AB16 – being the longest span of almost 200 meters.

Civil and Construction Division executed the above work in a record time of 33 days as against scheduled 53 days.

The power station was in operation during the construction time and outage of one Penstock was given at a time.

Special precautions, procedure and sequencing of work was planned to ensure the Safety of the Penstock pipes as well as to achieve the desired results.

SPORTS / CULTURAL ACHIEVEMENTS

The 68th Tata Sports Club Athletic Meet concluded in Mumbai at the University Stadium on the 21st and 22nd January 2006 which witnessed 220 athletes from 17 Companies of the Tata group participating. Mr R.Gopalakrishnan, Executive Director, Tata Sons presided over the prize distribution function and Mrs Geeta Gopalkrishnan gave away the prizes.

Tata Steel retained the team championship for Men with a whopping 120 points to win the Tata Sons Challenge Shield while Tata Motors finished second with 62 points to retain the A.P.Sabavala Memorial runner up Challenge Shield. Tata Power retained the third place with 8 points to win the Hardlines shield. In the Women’s section Tata Steel (Wire Division) annexed the J.D.Engineer Challenge shield for women for the first time with 49 points while Titan won the newly instituted TSC challenge runner up shield with 16 points and were closely followed by Voltas with 15 points. Tata Power finished fourth with 8 points.