Fuel Management_NTPC
Fuel Management_NTPC
Fuel Management_NTPC
on
Preface i
1 Introduction 1
2 Audit Framework 5
4 Import of Coal 19
Annexures 49
List of Abbreviations 57
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Executive Summary
INTRODUCTION
The installed electricity generation capacity in the country as on 31 October 2016 was
307278 MW out of which coal based capacity was 186493 MW (60.69 percent). NTPC
Limited is the largest power utility in the country, its coal based capacity being 40084 MW
(October 2016).
Coal cost constitutes 60 to 70 percent of the total generation tariff of a coal based power
station and has a major impact on cost of supply of power to consumers. Inefficiencies in
fuel management would increase the energy charges for the stations and cost of power to the
ultimate consumer. Keeping in view the significance of fuel management to affordable
power, the performance audit on fuel management of coal based power stations of NTPC
Limited was carried out. The performance audit covers fuel management of 13 out of 26 coal
based power stations of NTPC Limited and its Joint Ventures during the period from April
2010 to March 2016.
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coal shortage. During 2010-11 to 2015-16, 11 out of 13 stations covered in audit reported a
generation loss of 19546.26 million units of electricity with potential revenue loss of
`4299.80 crore. Further, Due to unduly positive presumption regarding coal receipt, four
power stations incurred generation fault penalty in the form of Unscheduled Interchange
charges amounting to `101.41 crore during the period from 2010-11 to 2015-16.
(Para 6.1, 6.2 and 6.3)
Storage capacity of coal yards at power stations
Storage capacity of six stations was less than the space required to store the normative
quantity for 15/30 days’ requirement prescribed under CERC Tariff Regulations. Shortage in
capacity as a percentage of requirement ranged from 2.60 percent (Rihand) to 53.62 percent
(Farakka). Further, imported coal warranted earmarking specific area for its storage limiting
the space for domestic coal.
(Para 6.4)
Storage of domestic coal along with imported coal
As per Local Management Instructions issued by stations, imported coal was to be stacked
separately in earmarked area in the yard. Physical verification reports (April 2010 to March
2016) of coal stock were reviewed in audit and it was observed that domestic and imported
coal were stored in the same yard. Availability of imported coal in excess of earmarked
capacity for it ranged between 6 and 158 per cent indicating that domestic and imported coal
were being mixed at the yard itself before they were actually blended.
(Para 6.5)
Railway logistics
The coal supplied through railway rakes was required to be unloaded within a stipulated
period known as ‘free time’, beyond which demurrage was levied by Railways. Stations
covered in audit had to incur demurrage of `129.67 crore on account of inefficiencies in
unloading coal within stipulated time during the period from 2010-11 to 2015-16.
Railways routinely divert rakes of coal consigned for one consumer to another, due to
congestion on a particular line or route. Audit noticed that the diversion was not always
between power stations of NTPC. In cases where rakes were ‘diverted in’ or ‘diverted out’
between stations of NTPC and other companies, there would be an adverse impact on NTPC
when high GCV coal of NTPC stations were being ‘diverted out’ and low GCV coal of other
companies were ‘diverted in’.
(Para 6.6.1 and 6.6.2)
Consumption of coal
Although yearly average Specific Coal Consumption of stations remained below 1 kg per unit
of power, Audit noticed significant monthly variations. Notably, the maximum SCC in some
cases was very high, at 3.21 kg in Mouda and 1.02 kg in Badarpur.
(Para 7.1)
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RECOMMENDATIONS
Based on the audit findings discussed in the report, the following recommendations are made
for efficient fuel management practices in NTPC coal based power stations.
For NTPC
1. The Company may review the procedures for procurement of coal above notified
rates such as incentive procurement, MOU, e-auction and imports.
2. The Company may invoke, wherever feasible, provisions in the existing Fuel Supply
Agreements for inter-station transfer of coal to tide over temporary coal shortages.
3. The Company may formulate a policy for import of coal. Action may also be taken
to ensure source and quality of imported coal.
4. Methods for measurement of GCV for procurement of coal and billing of energy may
be standardized in coordination with competent authorities.
5. Weighment of coal may be carried out at the time of receipt of coal at unloading
point to ascertain the actual transit loss and take remedial measures.
For Ministry of Power
6. Pricing of energy is based on Station Heat Rate, which, in turn, is based on quantity
and quality of coal (GCV) consumed by the stations. While quantity of coal received
is not weighed by the stations, quality assessment of coal has inherent as well as
manmade infirmities due to heterogeneous nature of coal and sampling errors. There
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is a need to appropriately review the method for energy pricing. Ministry may
coordinate with Central Electricity Regulatory Commission to examine this aspect in
the light of the audit findings.
7. The commercial terms in FSAs were not in accordance with New Coal Distribution
Policy and FSAs did not have safeguards for intra-year shortfall in deliveries.
Ministry may, therefore, review the terms of FSAs in consultation with Ministry of
Coal/ Coal India Limited to rectify these inadequacies.
The above recommendations were discussed in the Exit Conference held in October 2016 and
the Ministry/NTPC Limited were generally in agreement with the recommendations.
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Chapter 1
Introduction
1.1 Background
Electricity features in the concurrent list of the Constitution of India. Both the Central and
State governments are vested with the responsibility for development of power sector. In the
1970s, Central Sector Generating Stations (CSGS) were established to accelerate power
development in the country. The capacity of the CSGS was ‘shared’ among Beneficiary
States1, which were given allocations from the CSGS. The installed capacity in the country as
on 31 October 2016 was 307278 MW out of which coal based capacity was 186493 MW
(60.69 percent). The XII Five Year Plan document noted that, while the pace of addition to
generating capacity was commendable, there had not been comparable progress in delivering
fuel. Availability of both coal and gas to the new power stations was not assured. Resolution
of this problem was accorded high priority in the XII Plan.
1
Installed capacity of power stations under the Central Sector Generating Stations is shared among individual States and
these States are referred as ‘Beneficiary States’.
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2
Out of the 18 coal stations, nine are pit-head stations and nine are rail-fed (non-pit head) stations.
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3
Critical level – Coal stock above four days, but below seven days. Supercritical level – Coal stock below four days.
4
Station Heat Rate = Quantity of coal x Gross Calorific Value
No. of units of energy generated
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Chapter 2
Audit Framework
Framework
In addition, 36 out of 40 imported coal packages awarded during the period from April 2011
to March 2016 were examined. In respect of examination of coal linkages and monitoring of
coal stock including storage capacity, stations not included in the sample were also covered.
5
Indira Gandhi Super Thermal Power Station of Aravali Power Company Private Limited, Jhajjar, Haryana (JV of NTPC,
Indraprastha Power Generation Company Limited and Haryana Power Generation Company Limited with shareholding
of 50 percent, 25 percent and 25 percent respectively).
6
Vallur Thermal Power Station of NTPC Tamil Nadu Energy Company Limited (JV of NTPC and Tamil Nadu Electricity
Board with shareholding of 50 percent each)
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2.6 Acknowledgement
Audit acknowledges the cooperation extended by Ministry of Power and the Management of
NTPC and its JVs in smooth conduct of this performance audit.
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Chapter 3
Procurement of Domestic Coal
Coal is primarily procured by NTPC domestically through long term coal linkages from
subsidiary companies of Coal India Limited (CIL) and Singareni Collieries Company Limited
(SCCL). Any shortfall is met by domestic procurement through Memorandum of
Understanding (MOU) or e-auction and also by import. Coal is generally procured through
long term linkages at CIL/SCCL notified rates. For all other procurements (through MOU, e-
auction and import), the rates are higher.
Audit examined supplies through both domestic and imported sources. Observations
regarding procurement of domestic coal are summarized in this Chapter while those relating
to imported coal are at Chapter 4.
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2013, the Company took up the matter regarding tapering linkage7 for Barh-II only in April
2013. In September 2015, Ministry of Coal decided to supply coal at notified price, as a
special case, till decision regarding tapering linkage was taken. Two MOUs for supply of coal
were signed in October and November 2015.
The first unit of Barh-II was commissioned on 15 November 2014 and for the period from
November 2014 to November 2015, the Company tapped costly sources like e-auction and
imported coal for running the station, incurring extra expenditure of `527.43 crore. Audit
observed that the FSAs signed by the Company for other stations commissioned prior to 31
March 2009 allowed transfer of coal among stations wholly owned by the Company. But this
provision was not invoked to meet the coal requirement of Barh-II. Even, the initial
carpeting8 of the coal yard was done using costly coal by incurring extra expenditure of `5.28
crore.
Ministry stated (November 2016) that it was the first time Super Critical Technology based
660 MW thermal power plant was being installed by an Indian Company (BHEL), and during
the execution of the project it was felt that actual commissioning of the unit may take more
time due to various complex technological issues being faced at the station. Regarding inter-
plant transfer, Ministry stated that this was not possible from Barh-I and other stations
covered by new FSA9 . Ministry added that NTPC had requested MoC for tapering coal
linkage to Barh-II in April 2013 and as a as a special case, MoUs at notified prices were
agreed (September 2015) by MoC till grant of tapering coal linkage. Ministry further stated
that the station got approval for Bridge Linkage (earlier referred to as tapering linkage) in
March 2016 and MOUs with coal companies for supply were signed in August 2016.
The reply is to be viewed against the fact that fuel tie-up was one of the pre-requisites for
project implementation. Hence the Company should have taken timely action for obtaining
tapering/bridge linkage or considered inter-plant transfer which was permissible under the
old FSAs. Audit also noticed that for supplies under Bridge Linkage for Barh-II, the
Company has agreed to coal prices demanded by the coal company which were 10 percent
above notified rates 10 , though notified rates were applicable for coal supplied under the
‘linkage’ route. The higher prices, agreed to (August 2016) by the Company would
correspondingly increase energy charges for the station.
7
Tapering linkage is the short-term linkage provided to those coal consumers who have been allotted captive coal blocks
for meeting their coal requirements of their linked end-use plant where production of coal from these blocks does not
synchronize with the requirements of the end-use plant.
8
It is a layer of compressed coal, which is spread on the yard to serve as a carpet upon which further heaps of coal are
placed.
9
As per this FSA, diversion for plants linked to captive coal blocks was not permissible.
10
Except for higher grade coal (Up to G5 grade and WCL coal).
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two units of Kahalgaon-II (2 x 500 MW), CEA stated (June 2009) that ACQ for these units
would be recommended separately as and when additional coal was available from the linked
mines or movement of additional coal was made possible by Railways. CIL, however,
clubbed the coal requirement of Farakka, Kahalgaon-I and Kahalgaon-II and the Company
signed (August/September 2011) FSAs for 15 MTPA for all the three stations. Though
NTPC took up the issue both with CEA, CIL/Ministry of Coal, it could not succeed in
enhancing coal allocation for these three stations. Finally, Ministry of Coal informed (March
2014) NTPC that the issue could not be decided at that point in time.
Audit observed that the coal companies actually supplied more than the ACQ but demanded
performance incentive (PI) at applicable rates, i.e., 40 percent over and above the notified
rates, which was the highest slab rate payable for supplies beyond ACQ. The station paid PI
amounting to `476.14 crore for coal supplies beyond ACQ, at 40 percent above notified rates
during the period from 2012-13 to 2015-16.
Ministry stated (November 2016) that the request to increase the ACQ was turned down by
CIL and it had no option but to sign FSAs with Eastern Coalfields Limited for ACQ of 15
MTPA. It was added that NTPC continuously took up the issue at different levels for an
upward revision in ACQ ever since ACQ was finalized but did not succeed. Ministry further
added that in the deliberations between NTPC and CIL in July 2016, CIL has agreed to
supply additional 3.69 Million MTPA to Kahalgaon under the FSA terms and conditions.
Ministry’s reply indicates that additional supply at FSA rates has been agreed to,
implementation of which would be watched in future audits. However, running two units of
Kahalgaon II having capacity of 1000 MW entirely on costlier sources of fuel for four years
(2012-13 to 2015-16) increased the fuel cost of the station which in turn was passed on to the
consumers through power tariff.
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quarterly basis from time to time. Ministry added that SECL and MCL mines were located far
away from the station. Ministry further stated that ACQ from MCL and SECL have now
been transferred to Singareni Collieries Company Limited (SCCL) on 21 January 2016 as per
the recommendations of New Inter-Ministerial Task Force (IMTF) and subsequently, NTPC
requested (March 2016) SCCL to revise the ACQ for Ramagundam as per approved linkage.
The reply is not tenable. FSA mechanism was prevalent even before NCDP. In the instant
case, NTPC had failed to sign the FSA with either WCL or SECL, when it had the approval
of Ministry of Coal (in September 1999), much before commissioning of the unit in March
2005. Subsequently, the Company had to sign the FSA for supply from the same distant
mines and agree to a lower ACQ, which resulted in extra expenditure.
3.1.2 Coal pricing done on cost plus basis for Mouda FSA
Mouda station was granted (21 June 2010) coal linkage of 1.78 MTPA from WCL mines for
Unit II of Stage-I. FSA was signed by the station in September 2013. At the time of
implementation of FSA, WCL stated that it was not in a position to supply coal at notified
rates and offered coal on ‘cost-plus basis’. Coal supplied under cost-plus agreement was
costlier than notified rates. Execution of another FSA on cost-plus basis was initially resisted
by the Company but eventually agreed to at a review meeting held on 30 August 2013 and
cost plus FSA for 0.6 MTPA was signed in January 2015.
Audit observed that NCDP envisaged supply of coal at rates declared/notified by CIL for
power utilities and there was no provision for coal supply on cost-plus basis. As such, the
Company’s acceptance of cost-plus prices was not in line with NCDP and has resulted in
extra fuel cost of `31.11 crore11 during the period from February 2015 till March 2016.
Ministry stated (November 2016) that the Letter of Assurance (LOA) dated 21.06.2010
issued by WCL provided that in case the quantity of normative requirement necessitates
opening of a dedicated mine, then coal shall be priced at the higher of the cost plus
reasonable return or such notified price. Ministry added that as WCL did not have coal
quantity available for supply at notified prices, it had identified New Majri mines from
which cost plus coal can be supplied to Mouda Unit 2 in terms of the LOA. Ministry further
stated that the issue was taken up with WCL/CIL, MoP/MoC for signing of FSA at
notified price after finalization of the model FSA-2012. However, MoC, vide letter dated
02 September 2013 communicated to MoP that WCL could supply coal from only cost-plus
mines and requested MoP to advise NTPC to sign cost-plus FSA with WCL. There was no
option available to NTPC but to sign cost plus FSA with WCL, as directed.
The reply is to be viewed against the fact that Standing Linkage Committee – Long Term, in
its meeting dated 30 April 2002, had decided that cost plus pricing should be resorted to only
in those cases where the consumer seeks supply from a specific mine. As in the present case,
NTPC did not seek supply from a specific mine, NTPC ought not to have agreed to cost plus
pricing. Moreover, NCDP provided for supply of coal at notified rates only and did not
envisage cost plus pricing for coal.
11
Cost plus price agreed by the Company was `1926.62 per tonne, while notified price was `1070 per tonne (G9 grade).
Quantity delivered was 3,63,213.55 tonne. Hence, excess cost is equal to `31.11 crore (`1926.62 – `1070 x 3,63,213.55).
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3.1.3 Additional fuel cost due to long time taken in signing Fuel Supply Agreement
Audit observed that there were significant time gaps between Commercial Operation Date of
units and signing of FSA by five stations in the audit sample. Two of these stations, viz.,
Farakka and Korba entered into MOU with coal companies but the MOU quantity was not
adequate to meet the requirement of the station. These stations were forced to procure coal
under ‘Performance Incentive’ provision in the existing FSA of older units, incurring
additional fuel cost as explained below:
Table-3.1: Performance Incentive paid due to long time taken in signing FSA
Name of the Details of Unit Coal procured PI paid for new units
station Commercial FSA date Time gap for new units during the period
Operation in signing against old between COD to FSA
Date (first FSA FSA `crore)
signing(`
unit) (months) (In Tonnes)
Farakka-III 01.04.2012 11.7.2013 15 1280471 90.74
Korba-III 20.03.2011 17.07.2013 27 2366031 7.51
Vindyachal-IV 01.03.2013 02.09.2013 6 931649 19.24
Rihand-III 19.11.2012 02.09.2013 10 1685772 37.35
Sipat-I 25.05.2012 01.09.2013 16 6425236 168.53
Total 323.37
Ministry stated (November 2016) that delay in signing of MOU was on the part of CIL
subsidiary. Ministry added that the model FSA was provided by CIL only in April 2012, with
many one sided provisions in CIL’s favour which led to protracted negotiations and
consequent delay. Ministry further stated that the time invested in negotiation with CIL
before signing of FSAs may not be deemed as delays since NTPC tried to protect the interests
of consumers only.
It needs to be highlighted here that the time gap in signing FSA led to extra expenditure of
stations for sourcing coal by paying incentive, which, in turn, was passed on to the
consumers. Moreover, protracted negotiations did not yield significant dividends in
commercial terms.
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resulted in increased fuel cost for the stations examined in audit. The incentive paid within
ACQ in case of 10 stations12 was ` 558.00 crore (2010-11 to 2015-16).
Ministry stated (November 2016) that NCDP authorizes CIL to declare/notify prices for coal
supplies, and during discussions held on 08 April 2009 between CEA, CIL, NTPC and other
power utilities, it was informed that in the coal shortage scenario, coal companies would be
motivated to produce more coal with the incentive provision. Ministry added that
Performance Incentive (PI) being applicable only for supplies above 100 percent of ACQ
might have resulted in higher notified prices and under such a scenario, even the coal
supplied below 80 percent ACQ would have attracted increased fuel charges. Ministry further
stated that it was a collective decision of CEA, CIL and power utilities including NTPC and
not a clause agreed to by only NTPC. Ministry further added that NTPC has taken up with
CIL for PI to be restricted to supplies beyond 95 percent of ACQ (@ 10 percent only) and
CIL/ECL have now withdrawn PI for the coal of G5 Grade and above.
The reply confirms that the commercial terms of FSA agreed to by NTPC were beyond the
rates specified by NCDP. As NCDP is the overarching framework for coal linkage, NTPC
ought to have stressed its implementation, particularly as the incentives agreed to in the
negotiated FSAs were not in the interest of the Company.
12
Dadri (` 1.85 crore), Vindyachal (` 130.18 crore), Talcher (` 15.14 crore), Sipat (` 27.76 crore), Rihand (` 60.85 crore),
Farakka (` 42.70 crore), Korba (` 63.72 crore), Ramagundum (` 150.88 crore), Badarpur (` 4.28 crore) and Kahalgaon
(` 60.64 crore). The incentive paid in case of Vallur and Jhajjar was Nil.
13
As per FSA for stations commissioned after 31March 2009, the coal companies can offer imported coal up to a certain
percentage to meet their minimum supply requirements (80 percent of ACQ). Such imported component agreed was 15
percent of ACQ for the years 2012-13 to 2014-15, 13 percent of ACQ in the year 2015-16 and 5 percent of ACQ for the
year 2016-17 onwards. NTPC has the option to surrender the imported coal so offered, in which case it would be
considered as Deemed Delivered Quantity or DDQ.
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14
Farakka, Kahalgaon, Simhadri, Korba, Vindhyachal, and Rihand.
15
Rihand - ` 12.00 crore; Vindhyachal - ` 8.08 crore; Kahalgaon - ` 1.47 crore; Farakka - ` 9.29 crore; and Korba-
` 1.81 crore.
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FSAs provided for monetary compensation for both short delivery by coal companies and
short lifting by power stations when the annual supplies were below the specified trigger
level. Audit observed that the earning of incentive by coal companies were not affected as
long as there was no annual shortfall of supply. This led to a paradoxical situation where the
stations suffered generation loss due to coal shortage while paying incentives for additional
supplies made over the year. Review of records in audit did not indicate that the Company
escalated this issue with coal companies to seek a remedy, though intra-year/temporary
shortages forced the Company to tap costly sources of coal through e-auction, MOU and
imports.
Ministry stated (November 2016) that NTPC regularly monitors the level of coal supplies and
makes a very regular follow-up with coal companies for supplying coal. Ministry added that
in a scenario of coal shortages, NTPC had no option but to agree to this clause and that NTPC
shall again take up the issue with coal companies.
Considering that there was no disincentive in the FSA for short supply of monthly/quarterly
quantities and the significant impact such short supply had on power stations, there may be a
need to introduce safeguards in the FSA to enforce timely delivery of scheduled quantities,
including monthly and quarterly supplies.
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(iii) Jhajjar power station: During 2013-14 and 2014-15, there was supply deficit of
69.89 percent and 68.17 percent respectively vis-à-vis the ACQ. The compensation amount
of `58.27 crore was not recovered by the station from MCL with whom it had FSA.
(iv) Vallur power station: From 2013-14 to 2015-16, the level of delivery of coal by
MCL was short of ACQ by 36.31 percent (2013-14), 48.07 percent (2014-15) and 46.18
percent (2015-16). However, the Company did not claim any compensation from MCL.
Ministry stated (November 2016) that short supply of coal by the coal companies was on
account of less rakes supplied by Railways and hence, the power stations were not eligible for
the compensation. Regarding payment of PI, Ministry stated that the same was done in terms
of relevant clauses of FSA.
The reply points out reasons for short supply of coal by the coal companies. Audit, however,
has highlighted the payment of incentives to the coal companies by power stations despite
short supplies particularly as short supply of fuel as pointed out above has a significant
impact on functioning of the power stations.
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While entering into MOUs, NTPC compared the imported rates for coal. It was, however,
noticed that the procurement cost under MOU was in some cases higher than the cost of
imported coal. This was noticed in three stations, viz., Simhadri, Ramagundam and Talcher
Kaniha. Besides, in July 2014, the import parity criterion was waived off for other stations,
viz., Barh, Mouda, Dadri, Korba and Sipat, citing declining trend of imported coal prices,
which also resulted in high cost coal being procured under MOUs.
Ministry stated (November 2016) that the premium for MOU coal was mutually agreed based
on the premium realized by the coal companies in e-auctions in the past period and hence it
may be reasonably deemed as the price discovered through competitive procurement only.
Ministry added that alternatively, NTPC could have participated in the e-auctions conducted
by the coal companies, but in such cases there was no assurance of winning the bids and as
such coal security essential for running the power plant would not be available. Ministry
further stated that power stations were designed for domestic coal and there were technical
restrictions of blending imported coal with domestic coal and to avoid loss of generation,
stations had to tie-up domestic coal, in spite of prices being more than imported coal on some
occasions. Ministry also stated that coal companies with whom MoUs have been entered are
public sector entities.
The reply is to be viewed against the fact that there has been no price discovery in case of
MOUs and the premium payable under MOU procurement was decided only through
negotiation. Agreeing to significantly higher rates, even considering the maximum incentive
amount under FSAs would increase the power generation costs which would eventually be
passed on to the consumers. Moreover, MOU route of coal procurement was not envisaged in
the NCDP.
3.3 Procurement of coal through e-auction
The Company procured coal through e-auction to supplement the supplies under FSA. Audit
reviewed the e-auction process and noticed that the benchmark price used by NTPC for
bidding in e-auction was based on price of imported coal with GCV of 5700 kCal/kg. The
Company derived the price of the coal being auctioned (as per GCV of the offered coal)
based on this import price16. Audit noticed that there were significant differences between
the derived price and the actual import price for the grade of coal on offer in e-auction. In
such a situation, two scenarios could occur:
• where the import price for the grade of offered coal is lower than the derived price,
the bid amount would be on the higher side and the Company would win the bid by
quoting a higher amount for an inferior quality of coal.
16
For example, if the landed cost of imported coal of 5700 GCV was `5589 per MT, the landed cost of imported coal of
GCV 1000 kCal/kg was taken as `0.981 (5589 divided by 5700). `0.981 was multiplied by the GCV of domestic coal
being offered through e-auction and the prices were worked out backwards to achieve parity between domestic and
imported coal prices.
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• where the import price is higher than the derived price, the Company may be losing
the bid.
NTPC stated (April 2016) that since the quantity procured is very low, this assumption may
not significantly affect the fuel procurement for NTPC. Ministry noted the audit observation
(November 2016).
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Chapter 4
Import of Coal
The Company has been importing coal since 2005-06 to supplement domestic coal supplies.
Prior to 2011-12, The Company was importing coal through Public Sector Undertakings
(PSUs), viz., MMTC Limited and State Trading Corporation of India Limited. These PSUs
imported coal through suppliers and charged a service margin over and above their cost. The
New Coal Distribution Policy (NCDP) notified in October 2007 by Government of India,
Ministry of Coal (MoC) stipulated that CIL shall supply coal to meet the normative
requirement of consumers. NCDP provided that CIL could import coal and adjust its overall
price accordingly.
In April 2009, ACQ of stations was reviewed by CEA in consultation with CIL, NTPC and
power utilities. While the stations whose Commercial Operation Date (COD) was declared
prior to 31 March 2009 were given ACQ as per the extant level of supply; the new stations,
i.e., stations commissioned after 31 March 2009, got ACQ corresponding to normative
requirement, i.e.,85 percent Plant Load Factor (PLF). Hence for declaration of capacity17 of
stations above normative levels as well as for meeting disruptions in domestic coal supplies,
the Company resorted to import of coal. The Company did not exercise the option of import
of coal through CIL and imported coal on its own through tendering from November 2011
onwards.
The quantity of coal to be imported was fixed on a country-wide basis by Ministry of Power
(MoP) on the basis of domestic coal availability and generation level for the year as assessed
by CEA. A ‘target’ for import of coal was given to each generating utility. Details of import
of coal by NTPC during the last six years ending 2015-16 and price comparison with
domestic coal are tabulated in Table 4.1.
17
As per Indian Electricity Grid Code 2010, the generating stations shall make an advance declaration of their capacity
foreseen for the next day, based on which the beneficiaries schedule drawal of power from the stations.
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Actual import of coal registered an increasing trend during the period from 2010-11 to 2011-
12 and again during 2013-14 to 2014-15 but reduced in 2012-13 and 2015-16, however,
prices showed a mixed trend. The quantity awarded exceeded the ‘target’ in 2014-15. Audit
reviewed various aspects relating to import of coal and the observations are indicated below.
A. Splitting of packages
During the period from April 2011 to March 2016, the Company awarded 64 contracts (40
packages) for import of coal. 36 of the 40 packages18 {worth ` 22796.91 crore (approx.), for
18
Including two packages awarded as L2, due to spitting.
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36.79 million tonnes of coal accounting for over 75 percent of the procurement by value}
were awarded to a single entity, Adani Enterprises Limited. In the initial 17 packages
awarded from February 2012 to February 2013, the entire package quantity was awarded to
the L1 bidder and no splitting of quantity among qualified bidders was done. Subsequently, to
enhance participation level, the Company decided to split the quantity among the qualified
bidders. In the first tranche of 2013-14, NTPC envisaged splitting up the package quantity in
the ratio 50:30:20 for award amongst L1, L2 and L3 bidder respectively, at L1 prices for the
package quantity 1 MMT and above. It was decided that for package quantity between 0.5
MMT and 1 MMT, the quantity would be split in the ratio of 60:40 amongst L1 and L2
bidders respectively. However, these ratios were followed only for one tranche of three
packages awarded on 31 October 2013, and in subsequent eight packages, the ratio was
changed to 70 (L1):30(L2), but reasons for the change were not recorded. Subsequently,
splitting of contracts was dispensed with after ‘Reverse Auction’ was introduced in August
2014. Hence there was an inconsistency regarding the splitting mechanism adopted by the
Company across packages.
Ministry stated (November 2016) that in case of split ratio of 60:40/ 50:30:20, five to eight
bidders purchased bidding documents and only two bidders submitted their bids in each of
the packages. It was later decided to change the splitting ratio to 70:30 to keep parties
motivated to quote aggressively to become L1 bidder. With change of splitting ratio to 70:30,
15 to 24 bidders purchased the bidding documents and three to six bidders submitted their
bids in each of the packages. Ministry added that after changing the split-up ratio to 70:30,
better award prices were achieved and the same were also closer to the cost estimates. All
packages were awarded at L-1 prices only. Ministry also stated that Reverse Auction was
introduced to bring about highest level of transparency and further ensures that no bidder gets
any advantage vis-à-vis others on any ground other than the lower prices. Ministry further
stated that in order to have wider participation, NTPC has been floating tenders for each
package of procurement of imported coal on International Competitive Bidding (ICB) basis.
The reply has to be viewed against the fact that the change in the splitting ratio increased the
quantity to be awarded to L1 bidder from earlier 50 / 60 percent to 70 percent. The increased
level of participation cannot be attributed to modification of splitting ratio alone as there
would be other factors including market conditions which would affect participation. Besides,
Audit noticed that key qualification requirements19 were also changed in tandem with the
change in splitting ratio, which may have affected the degree of participation. As such, it may
not be possible to come to a conclusion based only on one tender that the poor response was
due to the splitting ratio alone. It was also seen that prices were higher than cost estimates in
22 out of 36 packages examined by Audit.
19
(i) When splitting ratio was 50:30:20/60:40, minimum qualification requirement for a bidder to participate in the tender
was that he must had an experience of supplying 50 or 60 per cent of package quantity. However, when splitting ratio
was changed to 70:30, this was modified to 44 per cent of package quantity. (ii) Modified QR provided that a bidder
meeting the requirement of supply and handling attributes could also participate in bids after tying up with mine owner(s)
through a ‘Letter of Authority’ from them.
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B. Re-tendering/annulment of packages
A review of the import orders revealed that in 22 out of 36 packages examined by Audit, the
L1 rates obtained through the tender process were higher than the estimates20. Audit noticed
that the Company did not have a consistent approach in dealing with such cases.
• In 11 of these packages, the Company carried out re-tendering citing higher quotes
received from bidders.
• In six cases (including 3 re-tendered packages), the Company carried out post-bid
negotiations based on which the contracts were awarded.
• In the balance eight cases, the Company awarded the contracts without any
negotiations or resorting to re-tendering.
Ministry stated (November 2016) that re-tendering/ annulment was carried out keeping in
view NTPC’s commercial interest and applying due prudence by taking note of coal stock
position, demand for coal and coal prices arrived during tendering etc. Ministry added that all
these decisions have been approved by Board/Sub-committee, as the case may be. Ministry
further stated that higher expenditure would not reflect on the bottom line of NTPC since as
per the business model, fuel cost was pass through.
The reply indicates that there was a certain degree of subjectivity involved in these decisions.
20
Award values were more than cost estimates by 0 to 5 percent in 10 cases; 5 to 10 percent in 8 cases; 10 to 20 percent in
1 case; 20 to 30 percent in 1 case and 30 percent & above in 2 cases.
21
The list of mines submitted by bidders mentioned 340 mines-AEL consortium; 535 mines- Knowledge Infrastructure
System Private Limited (KISPL); 33 mines – MBG Commodities Private Limited (MBG) and 740 mines – Trimex
International FZE (TIF) Consortium (in respect of 1.3 MMT package for Simhadri and Ramagundam)
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Ministry stated (November 2016) that there are a number of small coal mines in Indonesia
and hence bidders used to declare a substantial number of mines in the above mentioned
format. Ministry added that once the source of coal mine(s) is declared by the successful
bidder, he is bound to supply the coal from only the declared mine(s), meeting the technical
specification of coal. It was also stated that the objective of obtaining assurance about the
quantity and quality of coal was fulfilled with source declaration.
The reason for non-participation of mine owners abroad was supply and handling of coal up
to station end. Instead of addressing this concern, the Company relaxed the requirement of
declaration for specific mine (s). Though declaration of specific mine(s) would have caused
some inconvenience to the bidders, the same would have provided assurance to the Company
about quantity and quality of coal being procured by the bidder.
22
(i) CERC methodology (which comprised of indices for the Richard Bay API4 for 6000 kCal/ Kg NCV, Newcastle
Export Index (NEX) for 6700 kCal/ Kg GAD and Global Coal New Castle (GCNEW C) for 6000 kCal/ Kg NCV with
weightage 50:25:25); (ii) Methodology using the Indices for the Country of Origin of Coal (in this case one of the
indices considered was Indonesian Coal Index (ICI) 6500 GAR).
23
For example, in the bid opened on 3.2.2012, the bidder quoted 97.35 $ per tonne for coal of GCV 6300 (GCV to be
assessed on ADB basis). The market price of coal as per Indonesian Coal Index 6500 (GAR basis) at that time was 113
$. The quoted price, which was accepted, was lower than the market price as per this index. However, the market price
as per Indonesian Coal Index 5800 (GAR basis), which was the appropriate index at that time was 94.25 $ but the quoted
price was higher than this value. The same analogy was applicable during price settlement at the time of actual delivery
also.
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particular index number used. Ministry added that indices were used only for the payment of
price escalation.
The reply is to be viewed against the fact that adoption of appropriate index was crucial for
payment purpose, including escalation with reference to base date, since coal pricing varied
according to moisture and basis of reporting (ADB or GAR).
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Chapter 5
Assessment of Quality and Quantity of Coal
In coal fired power stations, coal of appropriate quality is essential for proper combustion and
operational efficiency of the boiler. Pricing of coal also depends on its quality or ‘Grade’.
Accurate assessment of quality and quantity of coal is crucial to appreciating the adequacy
and efficiency of inputs of the power station. Audit examined assessment of coal quality as
well as weighment of coal and the findings are detailed below.
24
(i) Total Moisture Basis – GCV is reported taking into consideration the total moisture, i.e., moisture inherently present in
coal and surface moisture present in the sample. (ii) Equilibrated Basis – The sample is brought to standardized moisture
and humidity levels and GCV of the resultant sample is reported. (iii) Air Dried Basis - The given coal sample is air dried,
as per procedure given by the Bureau of Indian Standards and the GCV is measured thereafter.
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B. Quantity of coal
The method of estimation of quantity of coal did not provide adequate assurance regarding its
accuracy:
(i) The collection of samples was done by private agencies at the stations and control
mechanisms such as witnessing of the sample collection by Company’s employees and
maintenance of log book for collection was not found on record. The significance of
representative sampling can be gauged from the fact that a 1000 MW station requires around
25000 tonnes of coal per day and GCV of this quantity of coal is assessed once daily, by
placing one gm of the processed coal sample in the Bomb Calorimeter (device used to
measure GCV).
(ii) GCV test results given by the Bomb Calorimeter were manually entered into a
register maintained for the purpose, and thereafter entered into the computerized system.
There was an option to print the GCV test results carried out by the Bomb Calorimeter but
such printed results were not maintained by the stations.
Ministry stated (November 2016) that total moisture based GCV is the standard industry
practice. Ministry further stated that payment for domestic coal was as per the provisions of
FSA and for imported coal it was on the basis of competitive bidding and hence did not result
in any undue advantage inter-se to any-one supplier over the others. Ministry added that in
case of imported coal, GCV is measured on ADB basis, however, adjustment is made for
excess moisture. Regarding collection of samples, Ministry stated that this was highly labour
intensive and hence outsourced but appropriate supervision was undertaken by NTPC
personnel.
The reply is to be viewed against the following:
(i) Total moisture method, though adopted by power utilities, was not expressly
provided for in CERC regulations. GCV reported under total moisture method was
lower by around 280 to 350 kCal/kg25 when compared to EB. CEA has stated that
reduction in GCV by 100 kCal/kg would increase consumption by three percent.
Hence there may be a need for standardising the method of reporting GCV.
(ii) Regarding adjustment for excess moisture in imported coal, it was seen that the
specified moisture level, as per contract was 25 percent and tolerance limit for
rejection was 32 percent. Supplies in the range of 25 to 32 percent moisture were
accepted with reduction in quantity for excess moisture. Hence adjustment carried
out for ’excess’ moisture vis-a-vis tender specification, did not address the loss of
heat value due to determination of GCV on ADB, for payment of imports.
(iii) Though Ministry has stated that appropriate supervision of collection of samples
by outsourced agency was undertaken by NTPC personnel, Audit noticed that
payment to the agency was made based on quantity of coal brought to the lab.
Maintenance of records to ensure integrity of sample collected such as logbook for
25
As per Fuel Audit Report of Central Power Research Institute uploaded on the web site of Punjab State Electricity
Regulatory Commission.
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As can be seen from the above table, except in Vindhyachal, the difference in GCV between
‘as billed’, ‘as received’ and ‘as fired’ was significant irrespective of whether the station was
pithead or non-pit head (it is expected that the difference in case of pithead stations would be
much lesser than non-pit head stations owing to the shorter transportation of coal). The above
26
During these months GCV figures were available for the three locations, i.e., at the loading point (‘as billed’), at the
unloading point at the station (‘as received’) and at the boiler (‘as fired’). GCV ‘as received’ was not measured by the
stations in other months. Beyond July 2014, the location for collection of sample for measurement of GCV was changed
to ‘secondary crusher’ from the ‘bunker/firing’ stage, hitherto adopted, for billing of energy charges.
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27
Station Heat Rate = Quantity of coal x Gross Calorific Value
No. of units of energy generated
28
GCV ‘as received’ was reduced by storage loss as envisaged by CEA, i.e. 0.08 percent for 10 days. For pit head stations
storage loss was calculated for 15 days and for non pit-head stations storage loss was calculated for 30 days, as per CERC
norms for coal stock.
29
The only period when the stations measured GCV ‘as received’.
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Audit also worked out the difference in energy charges considering the ‘as received’ and ‘as
fired’ stage for the same period (October 2012 to September 2013). It was seen that during
this period, Energy Charge Rate (ECR) worked out on ‘as fired’ basis was higher than ‘as
received’ basis by `0.03 to `0.96 per unit of electricity for the different stations, as per details
given below:
Table-5.2: Summary of higher energy charges due to GCV difference
Sl. No. Station Name* Range of difference Total impact
in ECR `in crore)
(`
1 Dadri Stage– I (-)0.06 -0.43 135.64
Dadri Stage – II (-)0.07 -0.46 165.06
2 Badarpur 0.58 -0.96 324.73
3 Korba Stage -I&II 0.05 -0.18 161.01
Korba Stage – III 0.03 -0.16 32.65
4 Vallur 0.06-0.45 58.25
5 Sipat 0.04 -0.23 144.36
6 Rihand Stage I 0.09 - 0.17 87.26
Rihand Stage II 0.11 -0.21 121.90
Rihand Stage III 0.05 -0.25 30.89
7 Talcher 0.09-0.11 31.97
8 Farakka I & II 0.17-0.38 110.23
Farakka III 0.17 -0.38 36.38
9 Vindhyachal Not calculated as GCV differences were minor
Total 1440.33
Overall, for the eight stations studied in Audit, energy charges billed on ‘as fired’ basis was
higher by `1440.33 crore for a one year period (October/November 2012 to September
2013).
Ministry stated (November 2016) that during the period (October/November 2012 to
September 2013) CERC Tariff Regulation did not envisage GCV ‘as received’ for ECR
computation. Ministry added that the formula for calculation of energy charges as per CERC
Regulations provided for using GCV on ‘as fired basis’ and billing was made accordingly.
Ministry further stated that Dadri and Badarpur stations also used washed coal in significant
quantities but GCV ‘as received’ was not measured for the same and added that GCV was not
determined for ‘diverted in’ and e-auction coal also. Ministry also stated that ‘as received’
GCV measured to take up with the coal companies was on Equilibrated basis (EB) while
GCV ‘as fired’ was on Total Moisture (TM) basis and the two values would be different
depending on the total moisture.
The reply is to be viewed against the following:
(i) Though CERC Tariff Regulations provide for energy billing on GCV ‘as fired’
values, measurement of GCV on TM basis was not expressly mentioned in the Regulations. It
is pertinent to note that TM method gives lower GCV values and correspondingly increases
energy charges.
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(ii) CEA, in its ‘Recommendations on operation norms for thermal power stations, tariff
period 2014-19’ stated that “any arbitrary practice of using as fired GCV for SHR
computations without proper guidelines for determining the same would only lead to inflated
claims of coal consumption”. This is reflected in the SHR worked out considering GCV ‘as
received’ by Audit.
(iii) The Company has not clarified whether GCV was less for the types of coal
mentioned- washed coal, coal procured through e-auction and ‘diverted in’ coal. Besides,
their effect on the overall GCV would be minimal considering that their quantities were
marginal.
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Railway Receipt (RR). Further, out of total 353 rakes of imported coal received
during 2014-15, only 208 rakes were weighed.
(ii) One Wagon Tippler associated with Vindhyachal-III commissioned on 31 December
2014 was without ‘in-operation’ weighing arrangement. As such, quantity of coal
unloaded using this wagon tippler was being accepted based on quantity indicated in
RR. Second set of in-motion weigh bridge was commissioned only in July 2015.
Management stated (April 2016) that a lot of efforts were taken up at Vindhyachal station to
stabilize the weigh bridge operation at the station end which included various modifications
in the weigh bridge in consultation with the supplier and commissioning of the second
weigh-bridge in July 2015.
The corrective steps taken by the Company are noted. The fact remains, however, that even
imported coal, which was required to be weighed at station for payment purpose, was not
weighed in Vindhyachal nearly half the time (imported coal was not weighed for 840 days
during five years ended 31 March 2015).
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(ii) Inaccuracy of the transit loss ascertained using this method was further evidenced by
the fact that coal physically verified at the coal yard at the following stations was even
more than the storage capacity of the yard.
Table-5.3: Coal stock in excess of coal yard capacity
Sl. Name of Physical quantity of coal more than the Excess coal
No. station@ storage capacity of the yard * stored above
storage capacity
Quarters (in No.) Quarters
(in percentage)
1 Badarpur 6 Q II (2013-14) 17
Q IV (2013-14) 6
Q IV (2014-15) 30
Q I (2015-16) 114
Q II (2015-16) 94
Q III (2015-16) 48
2 Sipat 1 Q I (2015-16) 37
3 Mouda 5 Q III (2014-15) 18
Q IV (2014-15) 22
Q I (2015-16) 41
Q III (2015-16) 37
Q IV (2015-16) 23
4 Rihand 5 Q IV (2010-11) 9
Q I (2015-16) 36
Q II (2015-16) 31
Q III (2015-16) 28
Q IV (2015-16) 17
5 Ramagundum 3 Q IV (2012-13) 1.7
Q IV (2014-15) 23
Q I (2015-16) 5
6 Vindyachal 2 Q IV (2014-15) 16
Q I (2015-16) 30
7 Farakka 2 Q IV (2013-14) 13
Q IV (2015-16) 38
8 Korba 5 Q I (2010-11) 13
Q I (2011-12) 1
Q II (2011-12) 2
Q IV (2014-15) 11
* Calculated based on the data regarding storage capacity provided by Corporate Office.
@ Jhajjar did not provide data and Vallur did not provide quarter-wise data. Instances as mentioned above
were not seen in the case of Dadri, Talcher and Barh.
In all the above mentioned stations, coal quantity physically verified at the yard was
more than the storage capacity in the yard. Notably, at Badarpur station, during two
quarters in 2015-16, physical quantity of coal as per the verification reports was 94 to
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114 percent more than the storage capacity of the yard. This raised doubts on the
correctness of coal stock and transit loss reported by the stations.
(iii) Despite investing in facilities like ‘in-motion weighbridge’, the stations have not been
using the same for weighing coal receipts and ascertaining actual transit loss. Local
Management Instructions were silent regarding ascertaining transit loss.
(iv) Since the actual transit loss was not properly ascertained, the station did not take up the
issue/lodge claim with Railways regarding en-route theft/pilferage, if any, of coal
from wagons.
Ministry stated (November 2016) that weighment of coal by volumetric method was being
done as per the practices prevalent in the power industry in the country.
The reply is to be viewed against the deficiencies of volumetric method as pointed out above.
Since the Company had the resources to ascertain the actual transit loss at the time of receipt
of coal itself, the same should have been used.
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Chapter 6
Coal Supply Management
One of the important functions in operating a power station is to ensure uninterrupted supply
of coal so that generation loss due to coal shortage does not arise. Coal was required for
‘declaration of capacity’ (DC) of stations, even though the beneficiaries may not schedule
power from the station. The Company operated nine pithead power stations where coal was
moved from mine to the power station through the Company’s own rail network and wagons
called Merry Go Round (MGR) system. In the nine non-pit head stations, coal was
transported in wagons from the linked mines to the power station through the Indian Railway
network. Imported coal was transported by shipping vessels and upon reaching the ports, coal
was shifted to railway rakes for onward transportation to designated stations. Audit reviewed
various aspects relating to coal supply management and observed as under:
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Audit also noticed that domestic coal stock dropped to zero level at various stations during
2012-13 to 2014-15 as per details given in Annexure 6.1. It can be seen from the above table
that during 2012-13, the stock level was at super critical position in seven stations for more
than six months. Similar situation prevailed in four stations during 2013-14. There was some
improvement in 2014-15 but three stations reported super critical stock levels for more than
six months. During 2015-16, the situation improved significantly at all stations except
Korba, Farakka and Kahalgaon where coal stock level was super critical for 26 days, 15 days
and 76 days respectively.
Ministry stated (November 2016) that coal stock at various stations was closely monitored
and the matter was continuously pursued with coal companies, MoP, MoC and Railways at
various forums. Ministry added that the actual coal supply was the responsibility of coal
companies and the short supply might be due to various reasons including less production
from mines or railway constraints etc. Ministry further stated that during negotiations over
FSA terms, coal was supplied to NTPC stations under short term MoUs.
The reply needs to be seen against the fact that during 2012-13 and 2013-14, supply of coal to
stations was disrupted due to delay in signing of FSA and payment dispute with coal
companies. Import of coal also did not significantly mitigate fuel shortgage since imported
coal could only be blended up to 30 percent. Hence the Company resorted to costly options
for procuring domestic coal such as MOU at premium rates, involving higher costs.
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Audit observed that while the stations suffered generation loss due to coal shortage on the
one hand, they paid performance incentive to coal companies for excess supply of coal
beyond ACQ on the other. Audit also noticed that the FSA allowed transfer of coal meant for
one station to another station, if both stations were wholly owned by the Company.
However, this provision of transfer was used sparingly.
Ministry stated (November 2016) that in spite of best efforts, coal shortages were there in the
country on some of the occasions due to unavoidable problems in mining, natural calamities,
seasonal issues etc. Regarding inter-station transfer of coal to address shortages of coal,
Ministry stated NTPC has used the provision on many occasions during the period under
audit, as per FSA terms.
Though Ministry has stated that provision for inter-station transfer of coal was used to address
shortages, the fact remains that the efforts taken by the Company to tide over coal shortages
proved inadequate as 11 stations suffered generation loss of 19546.26 million units due to
shortage of coal.
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Ministry stated (November 2016) that imported coal was stored separately in the yard and
that any portion of the yard could be earmarked for storing imported coal based on
requirement.
The reply is to be viewed against the overall shortage in the storage capacity of coal.
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The demurrage had to be paid on account of inefficiencies of the stations in unloading coal
from railway rakes.
Ministry stated (November 2016) that all efforts were made to reduce the demurrage but
some of the times, it became unavoidable due to reasons beyond the control of the company
e.g. bunching of rakes, maximum permissible free time allowed by Indian Railways being
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Report No.35 of 2016
inadequate for long sidings etc. Ministry added that demurrage has decreased during 2011-12
and on company-wide basis, demurrage has decreased over the last two years.
The reply is to be viewed against the fact that demurrage was not recoverable from tariff and
hence there is a need to avoid payment of demurrage.
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Chapter 7
Consumption of Coal by Power Stations
Coal is the primary fuel for the coal fired power stations while oil (High Speed Diesel and
Light Diesel Oil) is the secondary fuel. Coal is used to boil water which is converted into
steam. The steam, in turn, drives turbine generators to produce electricity. For producing one
unit of electricity, 500 gm to one kg of coal and around one ml of oil is consumed. Audit
analysed various aspects relating to consumption of coal by the 13 stations selected for audit
and the following position emerged:
The above data shows that the average coal used annually to produce one unit of energy
ranged between 0.59 kg to 0.89 kg in the sample reviewed during the period from 2010-11 to
2015-16. Although yearly average SCC remained below one kg, there were significant
monthly variations as can be seen from the range of minimum and maximum monthly SCC.
Notably, the maximum SCC in some cases was very high, at 3.21 kg in the case of Mouda
and 1.02 kg in the case of Badarpur. Keeping in view the fact that the stations were required
to meet their coal requirements from the ACQ allocated to them, SCC beyond a limit ought to
be monitored by the power stations for their smooth operation.
Ministry has noted the Audit observation (November 2016).
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31
Subsequently, vide Notification No.-GSR- 02(E) dated 02 January 2014, these Rules were made applicable for 750-1000
Kms. w.e.f. 01 January 2015 and for 500-750 Kms. w.e.f. 05 June 2016.
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Note: Among other five non-pit head stations in the audit sample viz.,Vallur and Jhajjar procured 4957858.60
MT and 15543135 MT of coal respectively during the period of audit, out of which washed coal
quantity was ‘nil’. Data in respect of Mouda, Farakka and Barh were not made available.
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Chapter 8
Conclusion
Conclusion and Recommendations
8.1 Conclusion
The installed electricity generation capacity in the country as on 31 October 2016 was
307278 MW out of which coal based generation capacity was 186493 MW (60.69 percent).
Coal cost constitutes 60 to 70 percent of the total generation tariff of a coal based power
station. Audit of fuel management in the power stations indicated inefficiencies which
increased fuel cost of the power stations and cost of energy to the ultimate consumers.
Supply of domestic coal to power stations was governed by National Coal Distribution Policy
(NCDP) notified by Ministry of Coal. Domestic coal was supplied to power stations by coal
linkages established through Fuel Supply Agreements (FSAs) at prices notified by Coal India
Limited (CIL). However, inadequate coal linkages of power stations, delay in signing of
FSAs and intra year shortfall in supplies led to procurement of coal at prices higher than the
notified rates. Power stations also incurred additional cost by way of performance incentives
even for quantities within Annual Contacted Quantity (ACQ) and on deemed delivered
quantities, premium on MoU procurement, e-auction etc. Besides, the power stations paid
performance incentives for additional annual supplies even as they suffered generation loss
due to intra year shortfall in coal supply. The Company incurred additional expenditure of
`6869.95 crore over 2010-16 in procurement of domestic coal even as it lost an opportunity
to generate revenue of `4299.80 crore due to full or partial outages of stations on account of
shortage of coal.
Though the Company has been importing coal since 2005-06, no comprehensive policy for
import of coal had been designed resulting in non-uniform decisions regarding splitting of
packages among bidders, qualification requirements, re-tendering and annulment of
packages. Imported coal having higher Gross Calorific Value (GCV) compared to domestic
coal but was stored in the same yard affecting the blending ratio of domestic and imported
coal. Besides, Audit noticed that despite the very significant quality difference (GCV
difference) between domestic and imported coal, the specific coal consumption of the power
station was not significantly affected by a change in the quantity of imported coal blended.
Fuel price depends on the quantity and quality of coal. To accurately determine the ‘quantity
of fuel procured’, proper weighment of coal was necessary. Weighment of domestic coal was
not carried out regularly when the rakes arrived, despite the provision of in-motion weigh
bridges. Instead of ascertaining transit loss of coal (difference between quantity of coal
dispatched from the mines and quantity of coal received by stations) by weighing the railway
rakes, an indirect method called ‘volumetric method’ was used. There were also concerns
regarding accuracy of the stock reported at the stations, considering that some stations
reported larger stocks than the storage capacity of yard.
The quality of coal (represented by GCV) was measured by three different methods; while
paying for coal imports, Air Dried Basis (ADB) method was used, while paying to domestic
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Report No.35 of 2016
coal companies for supplies Equilibrated Moisture (EM) method was used and for energy
billing Total Moisture (TM) method was used. ADB method gives the highest value of GCV
while TM gives the lowest. As fuel cost is directly proportional to GCV, working out GCV
on ADB and EB method increased the fuel cost for the power stations. Energy charges are
however inversely proportional to GCV and employing the methodology to generate the
lowest GCV value (TM method) increased energy charges recoverable from consumers.
Besides, there were significant differences in GCV of coal ‘as received’ in the power stations
and ‘as fired’ by them. Such significant differences were not technically expected and were
within the control of the power stations. The energy charges were worked out on the basis of
GCV ‘as fired’. Audit worked out the energy charges on the basis of GCV ‘as received’ for a
one year period (October/ November 2012 to September 2013) and noted that energy charges
would have been lower by `1440.33 crore had it been worked out on GCV ‘as received’
basis.
Audit of fuel management of coal based power stations in NTPC indicated inefficiencies in
coal procurement (domestic procurement and import), storage, supply and consumption
which led to higher fuel cost of the stations which were passed on to the final customer
through higher energy charges.
8.2 Recommendations
8.2.1. In order to undertake corrective measures for overcoming the deficiencies in fuel
management, following recommendations are made for implementation by NTPC:
1. The Company may review the procedures for procurement of coal above notified rates
such as incentive procurement, MOU, e-auction and imports.
2. The Company may invoke, wherever feasible, provisions in the existing Fuel Supply
Agreements for inter-station transfer of coal to tide over temporary coal shortages.
3. The Company may formulate a policy for import of coal. Action may also be taken to
ensure source and quality of imported coal.
4. Methods for measurement of GCV for procurement of coal and billing of energy may be
standardized in coordination with competent authorities.
5. Weighment of coal may be carried out at the time of receipt of coal at unloading point to
ascertain the actual transit loss and take remedial measures.
8.2.2. The Company is the largest power generating utility in the country and the
inadequacies noticed by Audit also require intervention at the Ministry/Regulatory level for
appropriate remedial action for the power sector as a whole. The following recommendations
are, therefore, suggested to Ministry of Power:
6. Pricing of energy is based on Station Heat Rate, which, in turn, is based on quantity and
quality of coal (GCV) consumed by the stations. While quantity of coal received is not
weighed by the stations, quality assessment of coal has inherent as well as manmade
infirmities due to heterogeneous nature of coal and sampling errors. There is a need to
appropriately review the method for energy pricing. Ministry may coordinate with
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Report No.35 of 2016
Central Electricity Regulatory Commission to examine this aspect in the light of the
audit findings.
7. The commercial terms in FSAs were not in accordance with New Coal Distribution
Policy and FSAs did not have safeguards for intra-year shortfall in deliveries. Ministry
may, therefore, review the terms of FSAs in consultation with Ministry of Coal/Coal
India Limited to rectify these inadequacies.
The above recommendations were discussed in the Exit Conference held in October 2016 and
Ministry/NTPC Limited were generally in agreement with the recommendations.
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Annexure 3.1
Range of monthly and quarterly deviation in actual vis-à-vis scheduled supplies
(Referred to in para 3.1.5.1)
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Annexure-5.1
Comparison of SHR reported by stations using GCV ‘As Fired’ and SHR worked out using GCV ‘As Received’
(Referred to in para 5.2.1)
(Figures in kCal/kWhr)
Name of station Range of SHR reported Range of SHR worked out Range of difference
by stations (using GCV using GCV 'as received'
'as fired')
1 2 3
Dadri Stage I 2376 - 2411 2416 - 3198 6-803
Dadri Stage II 2356 - 2408 2350- 2951 (-)47 - 568
Talcher 2804 -2828 3429 -3510 625 - 682
Badarpur 2614 - 2765 3187 - 3572 477 - 828
Korba Stage I & II 2371 - 2398 2488 -2870 102 - 499
Korba Stage III 2347 - 2481 2472 - 2852 29 -501
Vallur 2417 - 2659 2765 - 3656 110 -1103
Rihand stage I 2318 - 2368 2728 - 2900 360 - 572
Rihand stage II 2338 - 2384 2724 - 2996 375 - 652
Rihand stage III 2321 - 2530 2536 - 3848 215 - 1124
Sipat 2279 - 2375 2079-2972 (-)44 - 611
Farakka 2395 - 2406 3244 - 3667 848 - 1261
50
Report No.35 of 2016
Annexure-6.1
Details of stations which had zero stock of coal
(Referred to in Para 6.1)
2012-13 2013-14 2014-15
Month Stations having zero Month Stations having zero Month Stations having zero
domestic coal stock domestic coal stock domestic coal stock
Stations No. of days Stations No. of days Stations No. of days
April - - Dadri 20 April - -
April
May - - Badarpur 3 May - -
Unchahar 2 Dadri 14 June - -
June May
Dadri 1 Farakka 1 July Vindhyachal 2
Farakka 2 June - - August - -
Unchahar 16 July Ramagundum 6 September Ramagundum 7
July
Kahalgaon 1 August - - Rihand 2
Dadri 4 September - - Unchahar 26
August Unchahar 8 October Ramagundum 1 October Tanda 9
Vindhyachal 5 Rihand 1 Badarpur 21
September Tanda 1 November Unchahar 7 Dadri 1
Dadri 5 Talcher Kaniha 1 Vindhyachal 20
October
Sipat 10 Unchahar 14 Badarpur 10
December November
Dadri 13 Ramagundum 1 Tanda 23
November
Sipat 29 Unchahar 18 Unchahar 30
January
December - - Ramagundum 1 Singrauli 16
Dadri 15 February Unchahar 16 December Unchahar 31
January
Sipat 1 March - - January Unchahar 3
February Dadri 2 February - -
March Dadri 28 March - -
51
Report No.35 of 2016
Annexure – 7.1
Specific Coal Consumption of Stations from April 2010 to March 2016
(Referred to in Para 7.1)
(in Kg.)
Month Dadri Farakka APCPL Mouda Ramag- Rihand Sipat Talcher NTECL Vindhy- Badarpur Korba Barh
Jhajjar undum III Thermal Vallur achal IV
Apr-10 0.64 0.77 0 0 0.57 0.67 0 0.81 0 0.71 0.80 0.75 0
May-10 0.67 0.77 0 0 0.56 0.67 0 0.81 0 0.70 0.77 0.72 0
Jun-10 0.64 0.70 0 0 0.57 0.67 0 0.81 0 0.71 0.78 0.75 0
Jul-10 0.64 0.81 0 0 0.60 0.68 0 0.81 0 0.69 0.81 0.80 0
Aug-10 0.67 0.66 0 0 0.63 0.64 0 0.82 0 0.64 0.80 0.79 0
Sep-10 0.69 0.64 0 0 0.62 0.63 0 0.84 0 0.65 0.80 0.74 0
Oct-10 0.67 0.63 0 0 0.61 0.60 0 0.82 0 0.67 0.81 0.68 0
Nov-10 0.68 0.63 0 0 0.59 0.63 0 0.82 0 0.65 0.81 0.76 0
Dec-10 0.71 0.60 0 0 0.58 0.62 0 0.82 0 0.66 0.80 0.75 0
Jan-11 0.63 0.59 0 0 0.57 0.62 0 0.81 0 0.67 0.85 0.70 0
Feb-11 0.64 0.00 0 0 0.58 0.63 0 0.82 0 0.68 0.87 0.72 0
Mar-11 0.65 0.58 0.70 0 0.58 0.60 0 0.82 0 0.68 0.84 0.72 0
Apr-11 0.63 0.61 0.78 0 0.58 0.63 0 0.81 0 0.69 0.84 0.74 0
May-11 0.63 0.66 0.71 0 0.61 0.64 0 0.81 0 0.68 0.83 0.72 0
Jun-11 0.65 0.65 0.77 0 0.62 0.68 0 0.82 0 0.70 0.84 0.71 0
Jul-11 0.65 0.66 0.93 0 0.57 0.69 0 0.82 0 0.70 0.83 0.73 0
Aug-11 0.69 0.69 0.91 0 0.57 0.68 0 0.82 0 0.72 0.87 0.72 0
Sep-11 0.67 0.69 0.84 0 0.50 0.69 0 0.83 0 0.65 1.02 0.67 0
Oct-11 0.71 0.67 0.75 0 0.55 0.64 0.64 0.82 0 0.67 0.99 0.68 0
Nov-11 0.69 0.72 0.80 0 0.59 0.67 0.64 0.82 0 0.70 0.89 0.71 0
Dec-11 0.67 0.72 0.77 0 0.65 0.70 0.63 0.81 0 0.69 0.94 0.74 0
Jan-12 0.67 0.71 0.78 0 0.61 0.69 0.60 0.80 0 0.69 0.89 0.74 0
Feb-12 0.68 0.77 0.71 0 0.63 0.67 0.69 0.81 0 0.71 0.86 0.73 0
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Report No.35 of 2016
Month Dadri Farakka APCPL Mouda Ramag- Rihand Sipat Talcher NTECL Vindhy- Badarpur Korba Barh
Jhajjar undum III Thermal Vallur achal IV
Mar-12 0.66 0.73 0 0.59 0.68 0.67 0.82 0 0.70 0.87 0.71 0
Apr-12 0.69 0.70 0.70 0 0.63 0.70 0.63 0.82 0 0.70 0.87 0.73 0
May-12 0.66 0.72 0.72 0 0.62 0.70 0.62 0.82 0 0.71 0.92 0.72 0
Jun-12 0.67 0.67 0.73 0 0.59 0.70 0.67 0.82 0 0.73 0.93 0.75 0
Jul-12 0.73 0.73 0.79 0 0.59 0.73 0.73 0.82 0 0.76 0.90 0.69 0
Aug-12 0.76 0.89 0.76 0 0.58 0.68 0.63 0.82 0 0.77 0.90 0.73 0
Sep-12 0.74 0.84 0.76 0 0.58 0.66 0.65 0.82 0 0.74 0.92 0.76 0
Oct-12 0.70 0.85 0.80 0 0.69 0.66 0.60 0.82 0 0.72 0.89 0.82 0
Nov-12 0.65 0.78 0.71 0 0.63 0.68 0.58 0.82 0.86 0.69 0.88 0.69 0
Dec-12 0.67 0.79 0.68 0 0.64 0.67 0.62 0.81 0.87 0.73 0.87 0.77 0
Jan-13 0.67 0.88 0.66 0 0.64 0.67 0.67 0.81 0.78 0.72 0.85 0.75 0
Feb-13 0.67 0.87 0.63 0 0.65 0.71 0.62 0.81 0.74 0.71 0.82 0.77 0
Mar-13 0.69 0.85 0.67 0 0.62 0.67 0.63 0.81 0.70 0.74 0.81 0.79 0
Apr-13 0.66 0.79 0.66 0.00 0.65 0.67 0.61 0.81 0.68 0.72 0.85 0.77 0
May-13 0.63 0.77 0.80 0.00 0.67 0.67 0.67 0.82 0.66 0.68 0.86 0.74 0
Jun-13 0.62 0.77 0.80 3.21 0.66 0.69 0.68 0.82 0.60 0.67 0.86 0.78 0
Jul-13 0.62 0.74 0.78 1.30 0.64 0.70 0.66 0.82 0.62 0.70 0.85 0.71 0
Aug-13 0.68 0.75 0.72 1.17 0.66 0.73 0.64 0.82 0.68 0.71 0.87 0.67 0
Sep-13 0.68 0.77 0.70 1.20 0.72 0.69 0.66 0.82 0.67 0.68 0.88 0.67 0
Oct-13 0.70 0.77 0.76 1.52 0.70 0.73 0.64 0.82 0.71 0.67 0.87 0.69 0
Nov-13 0.70 0.69 0.71 1.08 0.69 0.72 0.63 0.82 0.69 0.65 0.88 0.70 0
Dec-13 0.69 0.66 0.71 1.02 0.68 0.75 0.58 0.81 0.73 0.72 0.84 0.74 0
Jan-14 0.68 0.70 0.68 0.86 0.66 0.72 0.62 0.81 0.69 0.71 0.83 0.74 0
Feb-14 0.68 0.67 0.72 0.61 0.66 0.71 0.60 0.81 0.69 0.71 0.83 0.74 0
Mar-14 0.71 0.72 0.76 0.56 0.67 0.72 0.62 0.81 0.68 0.70 0.85 0.81 0
Apr-14 0.70 0.77 0.75 0.56 0.68 0.72 0.59 0.81 0.65 0.71 0.81 0.70 0
53
Report No.35 of 2016
Month Dadri Farakka APCPL Mouda Ramag- Rihand Sipat Talcher NTECL Vindhy- Badarpur Korba Barh
Jhajjar undum III Thermal Vallur achal IV
May-14 0.68 0.75 0.74 0.58 0.68 0.69 0.65 0.81 0.66 0.71 0.81 0.73 0
Jun-14 0.67 0.77 0.78 0.67 0.70 0.70 0.61 0.81 0.68 0.71 0.82 0.74 0
Jul-14 0.71 0.74 0.82 0.78 0.74 0.71 0.57 0.82 0.67 0.72 0.85 0.78 0
Aug-14 0.71 0.77 0.86 0.79 0.75 0.72 0.62 0.82 0.73 0.71 0.87 0.75 0
Sep-14 0.72 0.74 0.83 0.75 0.70 0.70 0.59 0.82 0.66 0.72 0.87 0.69 0
Oct-14 0.73 0.74 0.87 0.73 0.66 0.68 0.62 0.82 0.69 0.68 0.87 0.67 0
Nov-14 0.72 0.72 0.80 0.68 0.66 0.71 0.59 0.82 0.71 0.68 0.81 0.78 0.57
Dec-14 0.74 0.70 0.72 0.74 0.67 0.69 0.59 0.82 0.70 0.69 0.81 0.76 0.59
Jan-15 0.72 0.69 0.71 0.72 0.71 0.66 0.62 0.66 0.69 0.70 0.77 0.71 0.59
Feb-15 0.71 0.72 0.72 0.73 0.68 0.67 0.56 0.81 0.67 0.70 0.76 0.69 0.60
Mar-15 0.71 0.67 0.72 0.71 0.67 0.65 0.57 0.81 0.63 0.70 0.76 0.67 0.65
Apr-15 0.63 0.82 0.71 0.68 0.69 0.66 0.67 0.81 0.64 0.71 0.80 0.69 0.66
May-15 0.61 0.79 0.65 0.70 0.70 0.67 0.66 0.82 0.65 0.69 0.77 0.78 0.64
Jun-15 0.62 0.78 0.69 0.69 0.71 0.71 0.64 0.82 0.66 0.72 0.77 0.73 0.62
Jul-15 0.66 0.78 0.68 0.71 0.69 0.68 0.62 0.82 0.64 0.71 0.78 0.77 0.65
Aug-15 0.68 0.75 0.71 0.73 0.70 0.67 0.64 0.83 0.67 0.69 0.76 0.79 0.64
Sep-15 0.69 0.72 0.70 0.71 0.69 0.66 0.67 0.83 0.73 0.71 0.79 0.74 0.65
Oct-15 0.65 0.72 0.69 0.70 0.68 0.65 0.59 0.83 0.69 0.69 0.73 0.65 0.66
Nov-15 0.64 0.71 0.64 0.74 0.67 0.65 0.61 0.83 0.70 0.70 0.70 0.64 0.66
Dec-15 0.65 0.74 0.72 0.72 0.66 0.63 0.60 0.83 0.68 0.71 0.74 0.68 0.61
Jan-16 0.66 0.72 0.74 0.00 0.65 0.67 0.63 0.82 0.64 0.67 0.74 0.63 0.60
Feb-16 0.65 0.71 0.75 0.73 0.61 0.63 0.62 0.82 0.66 0.67 0.74 0.66 0.57
Mar-16 0.61 0.74 0.71 0.72 0.62 0.63 0.61 0.82 0.69 0.66 0.74 0.61 0.60
54
Report No.35 of 2016
Annexure-7.2
Impact of blending of imported coal on Specific Coal Consumption (SCC)
(Referred to in Para 7.2)
Sl. Station SCC (in kg) Month (blending ratio)
No. (Difference of 6% and above taken into account)
1 Badarpur 0.80 December 2010 (8%) August 2010 (21%)
0.81 October 2010 (4%) July 2010 (14%)
0.87 August 2011 (0.01%) February 2011 (7%)
2 Rihand 0.63 November 2010 (2%) September 2010 (10%)
0.66 September 2012 (0%) January 2015 (7%)
0.67 February 2012 (0%) June 2010 (9%)
0.68 August 2012 (0%) August 2011 (15%)
0.69 January 2012 (1%) September 2011 (12%)
0.70 May 2012, June 2012 and September 2014 (13%)
April 2012 (0%)
0.71 February 2014 (0%) November 2014 (8%)
0.72 November 2013, January August 2014 (6%)
2014 and April 2014 (0%)
0.73 July 2012 and December August 2013 (11%)
2013 (0%)
3 Dadri 0.63 April 2011 (9%) May 2013 (25%)
0.64 February 2011 (7%) July 2010(22%)
0.65 March 2011 (3%) July 2011 (25%)
0.66 April 2013 (6%) March 2012(21%)
0.67 February 2013 (8%) June 2012 (30%)
0.68 February 2014 (1%) August 2013(22%)
0.69 March 2013 (1%) August 2011 (23%)
0.71 December 2010 (2%) March 2015 (28%)
0.72 September 2014 (11%) January 2015 (24%)
0.74 September 2012 (1%) December 2014 (23%)
4 Sipat 0.58 December 2013 (5%) November 2012 (16%)
0.59 April 2014 (4%) September 2014 (15%)
0.61 April 2013 (3%) June 2014 (9%)
0.62 May 2012 (1%) August 2014 (13%)
0.63 March 2013 (4%) August 2012 (15%)
0.64 October 2011 (4%) August 2013 (12%)
0.65 May 2014 (8%) September 2012 (22%)
0.67 June 2012 (5%) May 2013 (14%)
5 Vindhachal 0.65 November 2013 (1%) September 2011 (13%)
0.67 October 2010 and October October 2011 (8%)
2013 (2%)
0.68 March 2011 (2%) October 2014 (9%)
0.69 December 2014 and July 2010 (7%)
January 2012 (0%)
0.70 January 2015, March 2012 March 2015 (7%)
and April 2012 (0%)
0.71 February 2014, May 2012, June 2010 (7%)
February 2012, February
2013 and January 2014
(0%)
55
Report No.35 of 2016
Sl. Station SCC (in kg) Month (blending ratio)
No. (Difference of 6% and above taken into account)
0.72 January 2013 and August 2011 (8%)
December 2013 (0%)
6 Vallur 0.66 May 2013 (30%) September 2014 (49%)
0.67 September 2013 (20%) July 2014 (52%)
0.68 April 2013 (20%) March 2014 (38%)
0.69 January 2015 (32%) October 2014 (43%)
0.70 March 2013 (35%) December 2014 (55%)
October 2013 (13%),
0.71
November 2014 (53%) November 2014 (53%)
Jhajjar 0.70 March 2011 (9.40%) September 2013 (28.65%)
7. 0.71 May 2011 (5.42%) January 2015 (38.21%)
0.72 May 2012 (17.76%) March 2015 (41.25%)
0.75 April 2014 (16.92%) October 2011 (24.05%)
0.76 March 2014 (14.68%) August 2012(38.01%)
0.77 June 2011 (5.01%) December 2011 (17.18%)
0.78 April 2011 (9.88%) June 2014 (32.76%)
0.80 November 2011 (16.38%) October 2012 (31.22%)
8 Ramagundam 0.58 September 2012 (0%) December 2010 (8.55%)
0.62 May 2012 (1.55%) September 2010 (7.59%)
0.63 November & April 2012 August 2010 (10.30%)
(0%)
0.64 December 2012 (0.85%) July 2013 (22.90%)
0.65 December 2011 (0%) February 2013 (9.68%)
0.66 February 2014 (0.86%) October 2014 (22.20%)
0.67 May 2013 (0.60%) March 2015 (25.42%)
0.68 December 2013 (6.34%) May 2014 (21.82%)
0.70 October 2013 (0%) September 2014 (8.28%)
9. Talcher 0.81 February 2014 (0%) April 2010, May 2010,
July 2010, June 2010 (4%)
0.82 November 2012 (0%) August 2010 (1%)
10. Korba September 2011, March
0.67 October 2014 (1%)
2015 (4%)
0.69 November 2012 (1%) September 2014 (8%)
0.71 March 2012 (1%) January 2015 (6%)
0.72 May 2010 (1%) May 2011 (6%)
July 2011 and August
0.73 May 2014 (3%)
2012 (5%)
April 2011, December 2013
0.74 May 2013 (8%)
(1%)
June 2012 and August
0.75 December 2010 (1%)
2014 (5%)
0.76 November 2010 (3%), September 2012 (9%)
0.78 July 2014 (5%) June 2013 (8%)
56
Report No.35 of 2016
List of Abbreviations
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Report No.35 of 2016
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Report No.35 of 2016
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Report No.35 of 2016
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Report No.35 of 2016
27. Pit Head Station Generating station located near coal mine is referred to as Pit
Head station.
28. Plant Load Factor PLF is the ratio of the total number of units of electricity
(PLF) supplied by a generating station to the total number of units
which would have been supplied if the generating station had
been operated continuously at its maximum continuous rating.
29. Secondary Secondary crusher is a large machine deployed at power
Crusher stations to crush coal supplied by coal companies. It is referred
to as ‘secondary’ since ‘primary crusher’ is used by coal
companies to crush coal to some extent before loading.
30. Specific Coal Coal used to produce one unit of energy is termed as ‘Specific
Consumption Coal Consumption’.
(SCC)
31. Station Heat Rate Operational efficiency of power stations is regulated through a
(SHR) parameter called ‘Station Heat Rate’, which denotes the input
heat value incurred by the station to produce one unit of energy.
32. Surface Moisture Surface moisture in coal results from water held on
the surface of coal particles. This is normally due to exposure
to rain, humidity etc.
33. Tapering Linkage Tapering linkage is the short-term linkage provided to those
coal consumers who have been allocated captive coal blocks for
meeting the coal requirements of their linked end use plants, in
cases where the production of coal from these blocks does not
synchronize with the requirement of the end use plants.
34. Total Moisture Total moisture means the sum of surface and inherent moisture
(TM) content in coal, expressed as a percentage.
35. Unscheduled UI charges are a commercial mechanism to maintain grid
Interchange (UI) discipline. The UI charges are payable by generators and
charges distributors who deviate from the schedule given by Load
Despatch Centers for injection/drawl of electricity on a day to
day basis.
36. Volumetric A method through which quantity of coal is determined based
Method on the dimensions of coal heaps kept in the yard using
mathematical formula, i.e., Weight = Volume x Density of coal.
37. Wagon Tippler Wagon Tippler is a machine used for emptying coal from the
loaded railway wagons that arrive at power station. The
machine holds each wagon from the top as well as sides by
using clamping devices and topples the wagon sideways to
empty the cargo of coal to underground chambers.
61