Maintenance model

1. Utility O&M Outsourcing Model
Objective: To assign Thermax Limited for operation & maintenance of Utilities at YFCPL Lote site for operational excellence, equipment reliability, productivity and energy conservation.
Scope: Operation, Maintenance and Performance monitoring of
 Boiler House- Boiler, Ash handling system, Coal handling system, DM plant
 Cooling Tower System
 Centralized Utilities- Chilling System, Brine System, Air Compressor, PSA Nitrogen, Air Dryer, Liquid Nitrogen
 ECF plant Utilities- Chilling System, Brine System
Equipment Details :
Boiler Cooling Tower Air Compressor Unit ECF Brine Unit-Old
Capacity-12 TPH @ 10.57 kg/cm2 (g) Capacity : 850 TR Capacity-1218 CFM @ 7.5 Bar Capacity- 20TR/125TR
Type-Coal Fired, Combi-pack, AFBC Type- Wooden cross flow type Type- Screw Type Type- Vapor Comp.
Make-CBL Punjab Make- Paharpur Make-ELGI Temp- (-35|-10) Deg
Quantity- 1Unit Quantity- 5 Cell Quantity-2 Nos. Quantity-1 No | 3 Nos.
Coal Handling System BTF Brine Unit-New PSA Nitrogen Unit Air Comp-Old
Capacity-5 TPH Capacity-75 TR (-20|-16 Deg) Capacity-300 nm3/hr Capacity-250 CFM
Type- Hammer Mill Type Type-Vapor Compression Type-PSA Type-Screw
Make-Globe Engg Make-System & Component Make- Nuberg Make-
Quantity-1 Unit Quantity- 1 No. Quantity-1 Unit Quantity-1 No.
Ash handling System BTF Chilling Unit-New Air Dryer Unit BTF Brine Unit-Old
Capacity- 200 kg/hr Capacity- 100 TR (12|8 Deg) Capacity- 300 Nm3/hr Capacity-50TR | 20TR
Type- Pneumatic Conveying Type- Vapor Compression Type-Heatless Type-Vapor Comp.
Make-Ellora Green Make-System & Component Make-Mellcon Temp- (-20 Deg)
Quantity- 1 No Quantity- 2 Nos. Quantity-1 No. Quantity-1No. | 1No.
Utility Equipment Summary

2. Thermax Scope Matrix
Sr. Activity Description Boiler AHS CHS DM Plant CT ECF Utility BTF Utility Remark
1 Equipment Operation √ √ √ √ √ √ √
2 Equipment Maintenance-Direct √ √ √ √ √ χ χ Thermax to carry maintenance
3 Equipment Maintenance-Indirect ** ** ** ** ** √ √ Thermax to support OEM for
Maintenance
4 Electrical Maintenance Χ Χ Χ Χ Χ Χ Χ YFCPL Scope
5 Instrument Maintenance Χ Χ Χ Χ Χ Χ Χ YFCPL Scope
6 Housekeeping √ √ √ √ √ √ √
7 Spare, Consumable Supply Χ Χ Χ Χ Χ Χ Χ YFCPL Scope
8 QC Analysis from YFCPL Lab √ √ √ √ √ √ √ Thermax will submit sample in YFCPL lab
9 Flue Gas Online Monitoring √ ** ** ** ** ** ** Flue Gas monitoring will be Thermax
scope
10 Effluent Transfer to ETP √ ** ** √ √ ** ** Thermax to co-ordinate with YFCPL ETP
11 Waste Segregation and shifting √ √ √ √ √ √ √ Thermax to co-ordinate with YFCPL
12 Logbook, Record Up keeping √ √ √ √ √ √ √ Thermax will update data in given format
13 O&M data entry in SAP Χ Χ Χ Χ Χ Χ Χ Thermax to co-ordinate with YFCPL
14 General Tools & tackles √ √ √ √ √ √ √ Thermax Scope (Standard Tool Box)
15 Govt Liasoning and Fees Χ ** ** ** ** ** ** YFCPL Scope
√-Thermax Scope Χ-YFCPL Scope **-Not applicable

3. Thermax Manpower Configuration
Sr. Position Qualification Experience Role & Responsibility Headcount
1 Facility Manager B.E. Mechanical 6-8 Years Site Co-ordination 1 No.
2 Boiler Operator-First Class Diploma/ITI/IBR Certified 3-5 Years Day to day Boiler operation 4 Nos.
3 Boiler Field Operator ITI/IBR Certified 3-5 Years Day to day boiler, ash handling, coal handling co-
ordination
3 Nos.
4 DM Plant Operator BSC-Chemistry 2-5 Years Day to day operation of DM plant 3 Nos.
5 Senior Fitter Diploma/ITI 2-5 Years Equipment Maintenance 4 Nos.
6 Utility Operator Diploma/ITI 2-5 Years Day to day Utility operation 7 Nos.
7 Helper ** Casual Housekeeping 4 Nos.
Total 26 Nos.
Terminal point of
Scope
Sr. Terminal Point Description
1 Fuel Bunker Inlet
2 Steam HP Header at Boiler
3 Exhaust Gasses Chimney Outlet
4 Bed Material Near boiler house
5 Storm water drain At Boiler boundary
6 Start up power At MCC room
7 Air Compressor At boiler house
8 Cooing Tower Discharge Pump header
9 DM Water At DM Feed Pump
10 IA and SA Air At Boiler house
Exclusion
All pending jobs related to erection, performance, completeness, design defect etc., are to be
made rectified by Owner to Operator’s satisfaction.
Fabrication /installation of further equipment other than the existing in coming up in sections
with items like canopies, junction boxes, panel cut outs etc. will be by done by YFCPL.
All modification work/new installation for improvement of plant is in YFCPL scope
Thermax will submit sample to YFCPL QC lab and YFCPL will provide reports for water, coal, flue
gas. Thermax will take actions for any deviation.
Electrical and Instrumentation Maintenance will be YFCPL responsibility.
Any issues related to Local authorities /bodies, political or labor union will be handled by
Thermax and YFCPL jointly.

4. 4
Key Performance Indicator (KPI)
Sr KPI UOM Basis Benchmark Remark
1 Overall Equipment Effectiveness % 1. Equipment Availability
2. Throughput
3. Quality
OEE = Availability X Throughput X Quality
90% Thermax to deliver all performance parameters as per OEM’s PG Trial run.
Boiler- S:F Ratio, Thermal Efficiency, O2 in Flue Gas, Specific power, TDS etc.
Cooling Tower- Specific Power, Supply-Return Temp, COC, Approach etc.
Air Compressor- Specific power, Flow rate, pressure etc.
Air Dryer- Flow rate, Dryness Fraction, pressure drop etc.
Nitrogen- Flow Rate, O2 content, pressure drop etc.
Chiller/Brine- Water Flow, Supply-Return Temp, Specific power etc.
2 PM Compliance (Maintenance) % PM Plan | OEM’s Schedule 95% Thermax to carry direct maintenance of following section (Mech.Equipments)
Boiler | Coal handling system | Ash handling system | DM Plant and storages |
Cooling Tower
Thermax to support OEM’s for following section
Chillers | Brine | Nitrogen | Compressor | Dryer
3 Specific Power Consumption % OEM Offer | PG Trial Run PG Test
Result
Specific power norms will be set for each utility after completion of PG trial run
and Thermax to maintain specified norms.
4 Manpower availability % 8 hours shift without any OT 100% Thermax to ensure all agreed manpower will be available at site all the time.
5 Complaint Notification % All complaints| Concern | Breakdown 100% Thermax to notify deviation in process immediately and submit CAPA of breakdown
within 72 hours.
6 Zero Accident % Safety Audit Report 100% Thermax to carry regular safety audit to identify unsafe conditions and submit
report
7 Statutory Compliance follow up % IBR | DISH | Labor Etc. 100% Thermax to ensure all statutory compliances guidelines.

5. Sr. No. Position UOM Headcount
Thermax YFCPL
1 Facility Manager Nos. 1 1
2 Boiler Operator-First Class Nos. 4 4
3 Field Operator/Firemen Nos. 3 4
4 DM plant operator Nos. 3 2
5 Sr. Fitter Nos. 4 4
6 Utility operator Nos. 7 4
7 Utility Helper Nos. 0 4
7 Boiler Helper Nos. 4 4
Total Nos. 26 27
Sr Expenses Head UOM YEAR-1 YEAR-2 YEAR-3
Thermax YFCPL Thermax YFCPL Thermax YFCPL
1 Manpower Cost Rs.Lacs 93.630 90.864 102.993 99.950 113.292 109.945
2 Statutory Expenses Rs.Lacs 9.438 4.412 10.382 4.853 11.420 5.339
3 HSE Management Rs.Lacs 3.571 2.187 3.928 2.406 4.320 2.647
4 Tools Tackle Rs.Lacs 0.894 0.700 0.983 0.770 1.082 0.847
5 Amenities Rs.Lacs 13.640 6.194 15.004 6.814 16.504 7.495
6 Site office Expenses Rs.Lacs 1.530 1.436 1.683 1.580 1.851 1.738
7 Value Added Services Rs.Lacs 0.654 0.000 0.719 0.000 0.791 000
Total Expenses Rs.Lacs 123 106 136 116 149 128
Bonus-Penalty Criteria
KPI-1 Overall Equipment Effectiveness
Benchmark- 90%
Bonus- 2% of monthly contract value for every 1% higher OEE.
Penalty- 2% of monthly contract value for every 1% lower OEE.
KPI-2 Preventive Maintenance Compliance
Benchmark- 95%
Bonus- 2% of monthly contract value for every 1% of Higher PM compliance.
Penalty- 2% of monthly contract value for every 1% Lower PM compliance
KPI-3 Specific Power Consumption
Benchmark- Norms will be defined after PG trial run
Bonus- 0.5% of monthly contract value for every 0.5% for lower Aux. Power
Penalty- 0.5% of Annual Contract Value for every 0.5% higher Aux. Power
KPI-4 Zero Accident
Benchmark- 100%
Bonus- 0.5% of monthly contract value for no accident for operating manpower
Penalty- 0.5% of monthly contract value for any accident for operating manpower.
Maximum 5% Bonus or 5% Penalty of Annual Contract Value
Manpower Comparision
Costing & Projection
Microsoft Excel
Worksheet

6. 6
Boilers & Heaters Boiler+ Multi-utility
Sector
FMCG
Pharma
Distillery
Textile
Chemical
SCM Textiles Processing Mills
Auto & Solar
Reference Client List

7. Sr KPI UOM Benchmark FY18-19 FY19-20 FY20-21
1 Thermal Efficiency % 83 83.87 83.79 84.15
2 Plant Availability % 94 | 97 99.28 99.67 99.70
3 Auxiliary Power % 13 13.16 13.05 13.04
4 Zero Accident % 100 100 100 100
Case Study Results
Sudarshan Chemical-Roha
CPP Equipment Details
Captive Power Plant : 7.5 MW | Thermal power plant | Auxiliary Equipment's Model : CPP O&M
Boiler : Cheema | 62TPH | 65 Bar (g) | 490 Deg C | AFBC | Coal Fired | DCS Operated Started from : 2017
Turbine : Triveni | 7.5 MW No. of employees : 62
Auxiliary Equipment's : Air Compressor | Cooling Tower | Ash handling System | Coal handling system
KPI Summary
Remark:
Bonus-Penalty Criteria:
 Thermal Efficiency-
 Benchmark : 83%
 Bonus : 0.5% of Annual Contract Value for every 0.5%
higher Boiler efficiency
 Penalty : 0.5% of Annual Contract Value for every 0.5%
lower Boiler efficiency
 Plant Availability-
 Benchmark : 94% for First Year and 97% for Second Year
 Bonus : 1% of Annual Contract Value for every 1%
higher availability.
 Penalty : 1% of Annual Contract Value for every 1%
lower availability
 Auxiliary Power Consumption-
 Benchmark : 13% of Total Power Generation
 Bonus : 0.5% of Annual Contract Value for every 0.5%
for lower auxiliary power consumption
 Penalty : 0.5% of Annual Contract Value for every 0.5%
higher auxiliary power consumption
 Zero Accident-
 Benchmark : 100%
 Bonus : 0.5% of Annual Contract Value for no accident for operating
manpower
 Penalty : 0.5% of Annual Contract Value for any accient for the
reason attributable to operating manpower.

8. 8
Comparative Statement
Sr KPI UNIT
LOIL Unit-I
(CPP)
Sudarshan-Roha
(CPP)
Prasol- Khopoli
(CPP)
LOIL Unit-II
YFCPL-Lote
(Proposed)
1 Thermal Efficiency-Boiler 82.20 % 83.93 %
73.04 %
(Part Load)
76.50 %
(Direct)
85 % (As per PG Test)
2 Plant Availability 98.98 % 99.55 % ** 95.80 % 100 % (Mechanical)
3
Auxiliary Power
Consumption 19.70 % 13.08 %
25.65 %
(Part Load) ** As per PG Trail
4 PM Compliance ** 100 % of PM Plan 70 % of PM Plan 100 % 95 % of PM Plan
5 OEE ** ** ** ** 90 %
Thank You !!!
Remark:
 We have visited at Prasol Chemical Khopoli and validated current year Operation and maintenance data, found in order.
 We checked with Sudarshan Chemical about Thermax performance in CPP and feedback was satisfactory.
 We will not apply KPI’s during stabilization phase of initial 6 month. After stabilization, KPI’s will be finalized based on actual performance parameters.
 We have flexibility to review manpower headcounts and adjust if required during yearly review.
 Performance Norms will be decided after completion of PG Test.
 KPI’s will be reviewed on yearly basis and may be changed if required.

9. Sr. No. Position UOM Headcount
Phase-I Phase-II
YFCPL Thermax YFCPL Thermax
1 Facility Manager Nos. 1 1 1 1
2 Boiler Operator-First Class Nos. 4 4 4 4
3 Field Operator/Firemen Nos. 4 3 4 3
4 DM plant operator Nos. 2 3 2 3
5 Sr. Fitter Nos. 4 4 4 4
6 Utility operator Nos. 4 4 4 7
7 Utility Helper Nos. 4 0 4 0
8 Boiler Helper Nos. 4 4 4 4
Total Nos. 27 23 27 26
Annual Cost Rs. Lacs 106 112 106 123
Phase wise costing
Utility Requirement for BTF plant (Phase-I)
Boiler, CHS, AHS
Cooling Tower-2 Cell
Air Compressor-2 Nos.
Dryer-1 No.
Nitrogen-1 No.
Chiller-2 Nos.
DM plant
DG Set
Utility Requirement for ECF Plant (Phase-II)
All above utilities
Brine Unit- 4 Nos.
DG Set-1 No.

10. Coal handling O&M Scope
Thermax scope of work:
 Coal unloading from truck and stacking at coal yard.
 Coal shifting from coal yard to grizzly hopper with JCB.
 Feeding coal at grizzly hopper
 Coal handling plant operation and equipment maintenance.
 Coal handling unit housekeeping as per 5S standard.
 Exclusion- Electrical & Instrumentation related activities.
Terms & Condition for JCB operation
 JCB will be available at site 24 hours.
 Diesel, Operator and JCB maintenance will be JCB owner’s scope
 JCB operator will be available from 9AM to 6PM at site and will be made available during silent hours if required.
 In case of JCB beak-down, JCB owner to made another JCB available with in 2-3 hours.
 JCB owner will be penalized if CHP operation is hampered because of any non-compliance of T&C agreed.
 24X7 availability of JCB operator is Owner’s responsibility.
 JCB owner will be paid @ Rs. 650 per hour for normal working hours (9AM to 6PM) and @ Rs. 800 per hours during silent hours (7PM
to 8 AM).
 JCB working hours will be documented by Thermax and approved by YFCPL.
 Tentative annual cost of JCB supply
 Total coal consumption : 20000 MT/year
 Total working hours of JCB : 5000 hours @ 4MT/hour CHP capacity
 JCB operation cost : 5000 hours x Rs. 650 per MT = Rs. 33 Lacs
 Thermax Invoicing with 10% profit : Rs. 36 Lacs