Sop 03
Sop 03
Sop 03
Amendment History
PREVIOUS CURRENT
SL.N VERSION VERSION NO.
AMENDMENT DETAILS REASON
O. NO. / REV. / REV. NO. &
NO. & Date Date
2 Logo Change from Sesa Logo Change Rev 00, Dt. Rev 01, Dt.
Sterlite to Vedanta 24.05.2014 02.07.2015
3 Procedure reviewed and O&M Take over by Steag Rev 01, Dt. Rev 02, Dt.
reissued by Steag in 02.07.2015 01.12.2017
consultation with TSPL
INDEX
S.No Description Page No.
1 Purpose 4
2 Scope 4
3 Input 4
4 Output 4
5 Responsibility 5
6 Abbreviations 5
7 System Description 5
8 Equipment Details 5
9 Electrical Feeder Details 6
10 Starting Procedure 6
11 Reference 11
12 Records 12
13 Abnormalities 12
14 Quality & Efficiency. 13
15 Safety Measures &Environment 13
16 Annexure-1 For Coal PV checklist 14
17 Annexure-2 For Heap clearance format 15
18 Annexure-3. For PV Report. 16
1: Purpose
The purpose of this SOP is to carry out physical Coal verification –existence, location,
status &Condition of available coal stock.
Handling of coal and maintaining accurate stocks as per heap clearance policy.
To maintain accuracy in records of receipt, consumption and stock of coal for proper
inventory control.
Verification of stock with books stock by physical measurement survey of coal stock
heaps.
Certification of stock verification and reporting.
2 : Scope
3: Input:
Coal, Electricity, Competent manpower, third party surveyor and internal agency.
4: Output:
5: Responsibility:
6: Abbreviations:
PV :- Physical verification.
Coal supplied through rake from the source is being weighed at “ In motion weigh bridge “,
unloaded by wagon tippler & conveyed to stacker reclaimer&/OR tobunker. Coal conveyed to
bunker is further used in boiler. Remaining coal is being stacked in coal yard through stacker
cum reclaimer and dozers is used for formation of heap in trapezodial shape. Weighing of
conveyed coal being done at conveyor belt scale Display of which is available at Chp control
room PLC. Records of each weighing are maintained with relevant system and in SAP.
Available stock further used and maintaind in coal yard as per heap clearance system. Detail of
each transactions are maintained in coal stock report/heap clearance report. At the end of each
month, as per schedule defined by mutually agreed, a quantitysurvey being conducted through
an independent competent agency for physical verification of available stock of coal. Audit of
the coal stock process & survey reports is being done by a third party internal auditor through
company MAS & raised observation which are need to be complied according to management
discussion.
8: Equipment details:
9: Feeder details:
10.1 Coal Receipt : (For Detail technical Process refer SOP for In-motion weigh system:)
a) Coal supplied through rake is being weighed at In motion Railweigh Bridge& weigh report
certificate generated in computerized weigh system.
b) There will be Railway Receipt detail supplied by railway describing weight of coal supplied by
railway in that rake.
c) GRN will be made based on minimum of RR/Challan Quantity &TSPL Weigh system quantity.
d) Separate GRN will be made for excess quantity received at TSPL than RR quantity if any. Same
will be accounted separately in dummy vendor/PO @Rs1/mt for each material code separately.
No payment will be made for this excess receipt of coal.
e) GRN needs to be booked within 48hrs from receipt of coal.
Coal PV to be held on date 27th & 28th of each month, in case of any holiday, the change in date
to be decided in advance with consent of surveyor, auditor and plant PV in charge.
Information mail of coal survey date to be circulated to all concerned. (Auditor, PV in-charge,
head CHP, head operation, Head O&M, Finance team,MIS coordinators by PV coordinator
(TSPL).
Audit schedule will be supplied by auditor.
Representative of finance, operation and auditor should be available at location on time
(Normally 9.30 to 10.00 am on PV date).
All representatives to be sign the format of presence given by auditor.
Documents to be provided to auditor duly signed by PV in charge, finance representative before
PV as per predefined checklist.
Summary of all available coal with heap detail, including any coal available in wagon tippler
Hopper or elsewhere for the beginning of PV day, should be provided by CHP operation I/C
before PV.
Detailed report of coal receipt, stocking and consumed day wise and heap wise should be
available.
Stock detail as per SAP (T code - MC.9 & MB5B for all consumption and receipt movements like
261/262,101/102) for the beginning of the PV day should be available.
Detail of any pending entry of consumption as well as Receipt GRN should be available.(Store
report)
Belt weigh scale readings at beginning of day (at 00:00 hrs) to be noted down as per CHP
logbook and to be provided to auditor and surveyor.
If heap is small (Approx quantity <1000mt), take readings for 3 samples otherwise take 6
readings
Average of all readings of a single heap to be considered for calculation purpose of that heap
only.
For different heap, use bulk density reading which is taken for respective heap.
For carpet, readings to be taken from different yards by compact method only. If any yard is full
with coal, take more readings from available yards.
For readings at different places by digging the carpet till coal bed disappear, use these material
for taking bulk density with compact method.
Take minimum 6 readings for each yard.
Take average value of all readings taken for carpet from all areas. Use this bulk density as final
bulk density for quantity calculation of carpet.
On 1st of next month of PV date, a reconciliation statement showing coal stock at the end of
month based on Surveyor report and as per Book stock to be prepared in the format as per .
Also it should include detail of opening stock of the month, total receipt, total consumption and
balance of stock compared with PV stock and difference between.
This report should be e-mailed to auditor and all concerns department heads, plant head,
Business controller, finance head with forwarded surveyor report.
Auditor will audit all documents, surveyor report and PV report with book stock data and give
their observations&/noncompliance of policy, error of process, or suggest improvement if any
scope.
Accordingly Management improvement plan for each observation to be submitted by PV
owner.
Final audit report to be submitted by auditor for management review.
No adjustment should be given in SAP for PV survey results. This method is just for cross check
only. The differences as calculated with the heap clearance process will be adjusted in SAP
during the same month before SAP period closing.
Stone write-off policy will be separately dealt with if any required.
Consumption SOP will be dealt with material from plant to be covered under closing stock
11 : Reference:
PREPARED BY: ISSUED BY : REVIEWED BY: APPROVED BY :
STEAG TSPL
Date: Date: Date: Date: Date:
TALWANDI SABO POWER LIMITED
3 x 660MW POWER PLANT, MANSA.
Standard Operating Procedure
12 : Records:
CHP logbook,
Belt scale reading register/reports,
Coal consumption sheet with belt scale readings.,
SAP records for coal data for receipt, consumption & stock.
Heap clearance records.
Belt scale deviation records.
Belt scale calibration reports.
These records needs to be available to all concerned person who are part of PV
process including auditors , finance ,Operations and person deems fit by management.
9. Surveyor readingssheet: -
Details from the surveyor to calculate the volume
8 total station reading , Bulk
before leaving the place of entity
density,.
Reconciliation of PV Vs. Physical stock (Heap
10. On date Stock
9 wise) should be done as on the date of PV to get
reconciliation report for PV.
a better picture.
Details of Surveyor with names who had done the
10
PV in last 6 months to ensure if any rotation 11. Statement from surveyor
happened or not.
17 : ANNEXURE -2 : COAL HEAP CLEARANCE FORMAT
Remarks Reconciled
Bunker level at 13:00 hrs. on PV date(AS per Note:- There was no movement in Heaps during PV
PV) Read Nos in Bracket as-VE
Feeding to Bunker up to 10:00 hrs. on PV
date(As per PV report) Direct from rake and
from yard
Bunker level at 06:00 hrs. on PV date