Digital Pathway For Asset Management

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Digital Pathway for Asset Management


NTPC - EOC

PROCESSES

ANALYTICS Presented by:-


-Gautam Upadhyay (OPN)
-Sobhit Maheshwari (EEMG)
BIG COMMISSIONING DATA
-Abhishek Joshi (C&I)
DATA -Vivek Kr Singh (OPN)
OPERATIONAL DATA

COPYRIGHT
Copyright 2018
© 2016 NTPC
Your LTD. All Rights Reserved.
Company 1
The Digital Transformation Imperative

 Many Industries have witness the Digital Disruption


 Transport – Uber, Ola
 Travel – Airbnb, Oyo
 Banking – Payment Wallets/Banks, E-Banking
 Amazon had the courage to disrupt itself. It launched the kindle e-book reader at expense of its
physical book sales. Now Amazon a leader in e-marketplace.
 Many such examples… Google, Facebook, Philips, Tesla

Holistic Digital Transformation – An opportunity for NTPC to


improve its bottom line & take the cutting edge.
 Digitalization – A way of institutionalizing Knowledge, Best Practices, Data Driven decision making
 Leveraging Technology before the competitors, to get the cutting edge.
 Price of Technology is insignificant compared to the benefits.

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Evolution of Technology

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ASSET :-Types Of Major Asset NTPC Managing
Sl.No. NO. OF PLANTS CAPACITY (MW)
NTPC Owned VARIATION AMONG ASSET
Coal 24 45,410
Gas/Liquid Fuel 7 4,017
Hydro 1 800
Small Hydro 1 8
Solar PV 11 870
Wind 1 50
Total 45 51,155
Owned By JVs/Subsidiaries
Coal 9 6,494
Gas/Liquid Fuel 4 2,494
Hydro 8 2,625
Small Hydro 1 24
Wind 2 113
Solar 1 5
Total 25 11,755
(JVs/Subsidiaries)

Total 70 62,910

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Super critical Units:-Variation among Asset
Supplier/Desi Doosan/ BHEL/Als BGRE/HP E Doosan/ BHEL/Alstom L&T MHPS BHEL L&T MHPS BHEL
gn Alstom tom Babcock
Furnace 2 pass, 2 pass, Single 2 pass, 2 pass, spiral 2 2 pass, spiral 2 2 pass, spiral
Type spiral spiral Pass, spiral wall pass,Vertical wall pass,Vertical wall
wall wall spiral wall wall wall
wall
Water wall T-22 T-22 T-12 T-12 T-22 SA-106C, SA- SA 213-T12 SA-106C, SA- SA213T12 & SA213T22
tubes 210C, SA- 210C, SA-
Material 213T12 213T12

Firing Corner Corner Front & Front & Corner fired Corner fired Corner fired Corner fired Corner fired
System fired fired Rear Rear (with two fire (with two fire
Fired Fired balls) balls)
No of PF 40 36 32 45 36 64 36 64 36
Burners
Start up & BRP BRP BRP with BRP BRP with (R/C BRP with (R/C BRP with (R/C BRP with (R/C BRP with (R/C

circulation without without (R/C & with & NPSH line) & NPSH line) & NPSH line) & NPSH line) & NPSH line)
system (R/C & (R/C & NPSH (R/C &
NPSH NPSH line) NPSH
line) line) line)
Primary Burner Burner Gas Bias Burner Tilt Gas Bias Burner Tilt Gas Bias Burner Tilt
RH temp Tilt Tilt Damper Damper Damper
control

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Challenge :-Balancing Cost, Risk and Performance
Why digitalization of Asset Management

Inefficient Asset distribution, Higher NMI, At last Recently IDFAN 2B Motor both Side Bearing
moment FIRE FIGHTING for arranging Spare, higher Damage. Arrangement of Spare took Two days extra
Equipment Outage
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Improvement in production

27%
the expected productivity
improvement in next 5 years,
compared to 21% improvement
in past 25 years

*Overall equipment effectiveness; **Sales, general and Source: Capgemini Digital Transformation Institute, digital
administrative expenses; ***Capital expenditure utilities survey, February-March 2017

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Reduction in cost of Production

$20Mn or ₹ 147
Cr
the production cost that can be
saved annually
in an average combined-cycle
power plant in US

Source: US Energy Information Administration (EIA)


Database, accessed in June 2017

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Huge reduction in CO2 emission
4.7%
the share of global annual
CO2 emissions that digital
power plants can eliminate
by 2025

NTPC recently upgraded RSTPP old


units (3*200MW) with state-of-the-art
turbines and the latest digital
technologies. It is expected to boost the
output of the plant by 10 MW and the
heat-rate by 14%. This implies that
CO2 emissions from the plant will
decrease by nearly 14%.

*1 mature tree consumes, on average, 48 pounds or 21.78 kilograms of CO2 per year; **1 passenger
vehicle emits, on average, 4.7 metric ton CO2 in a year Source: Energy Information and Administration (EIA)
Database, accessed in June 2017

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Global initiatives in Asset Management Digitization

42%
the percentage of
utility companies that
have operational
digital plants

Source: Energy Information and Administration (EIA) Database,


accessed in June 2017

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Global initiatives in Asset Management Digitization

75%
the share of utility
companies from China
and India who will
have digital plants
within
3 years

Source: Capgemini Digital Transformation Institute, digital utilities survey,


February-March 2017

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Investment in digital initiatives: Global trend

Source: Capgemini Digital Transformation Institute, digital utilities survey, February-March 201

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Digitalization : Key Elements & Technologies
Data
Visualization Mobility
Big data
• Right Data, Right
(Data Volume/ Artificial Int &
Time, Right People
Machine
Velocity/ Learning
Variety)
Data
IIOT
Analytics
• Smart sensors,
flexible comm • Algo/data mining Virtual Horizontal and
interface for driving
insights
/Augmented TECHNOLOGIES vertical system
reality integration
Data
Integration

Industrial
CLOUD Internet of
Things

Digital Twin Digital Cyber Security


• Dimensional & Worker
Physical • Mobiles, AR/VR,
emulation Drones

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IIOT

 The Industrial Internet Consortium [6] defines how IIoT is


transcribed: ”The industrial internet is an internet of things,
machines, computers and people, enabling intelligent industrial
operations using advanced data analytics for transformational
Operation
business outcomes”. Technology

Industrial
Internet of
Things
(IIOT)

Information
Technology

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Main elements of IIOT
Visualization
Layer

Application
Layer
Wireless Infrastructure
24X7 Centralized OEM/Expert availability

IOT Platform HUB


Information Layer

IOT Gateway IOT Gateway IOT Gateway

DCS / SCADA Historian

Field

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Digital Twins

A digital twin is a dynamic virtual representation of a


physical asset, product, process, or system. It digitally
models the properties, condition, and attributes of the real-
world counterpart.
Using data from multiple sources, a digital twin continuously
learns and updates itself to represent the current working
condition of the object or process.
Decision-makers gain deep understanding, which they apply
to improve and optimize the performance of the modeled
asset and the larger systems it interacts with.

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Digital Twins: The Two models

 Operational/System Digital Twins


 Asset Digital Twins

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Operational Digital Twins

 Operational Digital Twins : It blends and correlates real-time streaming IoT


data together with other inputs. It then applies machine learning, AI, and
advanced modeling techniques to create a dynamic virtual representation
of the entire plant.
 Full visibility into the manifold and multi-layered interdependencies among
assets, processes, and operations.
 These unprecedented insights unlock the full business value of
manufacturing analytics, enabling:
1. Scalability to address the full range of production use cases and opportunities
2. Actionable intelligence to significantly reduce downtime, dramatically improve plant productivity
and efficiency, and avert problems before they happen

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Asset Digital Twins

 Asset Digital Twins: These are vendor-specific models of a single asset or


machine, which tap into operational data for the purpose of asset
optimization.
 They can be used for:
1. Enhancing performance and reducing operating costs
2. Field management of a large number of assets, such as trains or jet engines
3. Predictive maintenance
 While asset twins provide a window into single components, they offer no
visibility into the intricate and all-important relationships among machines,
workflows, and parts or batches.

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Practical inputs from future digital workers: Survey

 Survey was done to inculcate practical


inputs.
 Method: Online
 Total number of participants: 60
 Participants were from different
backgrounds and from different projects.

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Area of Concern

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 Asset of which areas has high potential of further digitization?

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Most Compelling issues at Store

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Challenges while digitization

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Survey favour Integration

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Survey Findings

Time,Cost,Quality,Manpower
and NMI reduction
Employee Favors Digitalization
Store
Material Management,
High NMI and Inventory
Digitalization
Store Department Need
digitization
Improvement
DATA SAP Data mismatch with
SECURITY Real time Inventory
Equipment Health Index,
More automation needed
in Plant Data security

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Model: Life Cycle of Asset

Data is already available to save

1
Asset are Interconnected
Massive amount of Data
is being generated every
seconds
our CRITICAL business process
mainly: O&M,C&M etc

2
Utilizing these digital data More Values from Asset,
Asset system behavior is Ensuring Availability at right time
analyzed in real time, for transforming asset
simulated and management
predicted

Digitizing Discrete information,

3
Conventional DCS system,
Maintenance Practices are not enough Converting Big data into Integrating All Information in
Own Dedicated Cloud
Big Information

Utilizing potential of IIOT/AI/Big

4
Creating Information Transparency
data and cloud computing Throughout ASSET Life cycle
within the Operators,OEM,Service
Providers
Accessing Right Information about Assets at
Right Time & Collaborate easily with each other
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Operational Model

On
Vibr line se
Tools
atio n
n,Te sors fo Big Data
mp, r Business Analytics
Sou
nd
Cloud Computing

Chemistry MIS , Daily sample


report

k IIOT Network/AI/Central server


ar I
chm LM
Ben its/ Data Collection
l / im
ir ca M l
isto a/OE Exchange
H at
d Analyse

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Safety Model

Digitizing Manual Isolation system with RFID BASE isolation of Module


Secure Permit System/Using Linking RFID Digital data with SAP permit system
Power of RFID

CCTV
Ne
Fi
na Geo ta twork, Setting UP IP Based CCTV Network
gging
lly Au Integrating Snapshot of area with IIOT system, Alarm and MIS,
In to J
te SA History data storage and comparison
gr ,Di
at Eq gita
io ui Sm liza
n pm a tion
al He en rt
li
nf lm t/S
or et m Digitalization of JSA,Linking with E&M Safety rules. Auto generation JSA
m s ar
at t Converting E&M Rule in searchable digital format and tags, Training
io Worker for JSA,safety
n
in
A
I/I Integration of All information in IIOT/BI/AI
IO
T/ Analyzing All information . Giving suggestion and benchmarking
B
I

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SMART Maintenance Model

Optimizing Predictive & Preventive OH Plans, General requirement


04 03
Maintenance . Modification ,Recommendations

ANALYTICS
IIOT/AI
Using Power of SAP ,Correct Defect
Listing, Analyzing Defects
02 BIG DATA 01
Equipment Health Index data

06
• Digitizing OEM Records,Limits,Recommendation 05 Manpower Skill mapping and Creating Repository
• Local Files and Data in Central servers

Smart Maintenance
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C&M and Store Digitization model
Integrating Operational health
Index with Asset

Prioritization of spare availability as per Digitizing Store Asset


Generation of AUTO PR
health index Using Power of RFID,Linking
AUTO PR in case of Threshold
RFID tag with Material Code
limit crossing

STORE
Combining in Analytics Investment

PR to PO time, Cost of UHF RFID tag is Rs.20.00/unit


Scrap Disposal Cost of RFID
Vender Survey reader/writer=Rs.40000.00/station
C&M Related ORT issues
Cost of RFID Antenna= Rs.15000.00/station
NMI

Using Power of SAP ANALYTICS Digitalization of C&M,Store Records


Managing Requirement from
Near by Plants or through Historical Old C&M Store Records and Direct
Central system on time bound Integrating all input in Central Servers
manner, these Data in AI
modules for
Deciding PR
generation
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Digital Model: an overview

NTPC VENDOR

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Digital Initiatives at NTPC Singrauli

1. Electro-Hydraulic control of Main Turbine & TDBFP

 Electro Hydraulic governing is used to control the opening of Control


Valve of Main Turbine and TDBFP based on electrical signal,
generated from Speed, Load and Pressure transducer.

 Any problem in EHTC circuit may disturb the opening of control


valve, thereby causing unit disturbance and may lead to Unit Trip.

 Even after proper observation, it is hard to predict EHTC failure.


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A Glimpse of AI Algorithm of EHTC Logic
LIFT OIL PR EHC OIL PR. CONTROL OIL PR
Adaptive Present Adaptive Present Adaptive Present
Preset value Preset value AND MANY MORE
value Preset value value value

DEVIATION DEVIATION DEVIATION


HIGH HIGH HIGH EHC BALANCE
VOLT

Preset Present
value value

DEVIATION
OR HIGH
SEC. OIL

ROC
PR

Watch dog Signal/Quality Signal


AND
AUX. SEC.

ROC
OIL PR

Predictive Alarm

OR
Information
System
AND
MANY
MORE
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2. Asset Health Index
MILL HEALTH INDEX
Health Index Qualifications (Mill Fineness)[A] Specific Power Consumption [B] Air/Fuel Ratio[C] Vibration & bearing Temp[D] Total[(A+B+C+D)/19*100]
MAX Score 10 5 2 2 100
U6-MILL-A 8 4.9 1.8 1.92 87.5
U6-MILL-B 10 4.88 1.88 1.94 98.4
U6-MILL-C 10 5 1.93 2.0 99.6
U6-MILL-D 10 4.88 2 2.0 99.3
U6-MILL-E 10 4.97 1.82 2.0 98.9
U6-MILL-F 10 4.78 1.83 1.95 97.7
U6-MILL-G 10 5 1.98 1.94 99.6
U6-MILL-H 8 4.55 1.8 1.92 91.5

Multidimensional
Multidimensionalmeasure
measureof
ofAsset
AssetCondition
Condition

Computed
Computed by
bycombining
combining several
severalparameters
parameters with
with weights
weightsto
toeach
eachparameter
parameter

Benchmarking
Benchmarkingtool
toolfor
forsimilar
similarequipment
equipment

Continuous
Continuous monitoring
monitoringtool
tool

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Asset Health Index
TDBFP HEALTH INDEX
Health Index Category Pump Efficiency (Hydraulic Turbovisory performance (Brng Temp, Maintenance Factors Weighted factor
Power) [A] Vibration etc) [B] (Liabilities) [C] [(A+B+C)/8*100]
MAX Score 3 3 2 100
U-6_TDBFP 6A PUMP 2.99 2.75 2 96.8
U-6_TDBFP 6b PUMP 2;91 3 2 98.9
Health Index Category Turbine Efficiency (Hydraulic Turbovisory performance (Brng Temp, Maintenance Factors Weighted factor
Power) [E] Vibration etc) [F] (Liabilities) [G] [(E+F+G)/8*100]
MAX Score 3 3 2 100
U-6_TDBFP 6A TURBINE 2.82 3 2 97.8
U-6_TDBFP 6b TURBINE 2.63 3 2 95.4
Health Index Category Efficiency [X=(A+E)/2] Turbovisory Performance Maintenance factors Weighted Health Index
[Y=(B+F)/2] [Z=(C+G)/2] {(X+Y+Z)/8*100}
MAX Score 3 3 2 100
U-6_TDBFP 6A OVERALL 2.905 2.875 2 97.25
U-6_TDBFP 6b OVERALL 2.77 3 2 97.125

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3. Digital Twin to Integrate Legacy system

Digital twin Model


Metadata, Monitor,
Analytics, Solutions

Total Cost savings = Rs 79 lakhs ( approx)

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Budgetary Offer for LP dosing Pump

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Budgetary Offer for Auto Control of LP dosing System

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New Digital Initiatives : Advanced Monitoring of Stockyard (AMS)

 Stockyards challenges are:


Frequent hot spot formation.
Manual assessment and Record Keeping.
GCV Measurement is Manual in laboratory.
 As per A.T. Kearny a proper management
framework could reduce 7% to 12% of the total
coal costs.
This part of power plant is completely manual and need
complete automation for effective stockyard management
Digital Solutions: Operator can visualize
o 3D Profiling of Coal Stockyard for volumetric
 Exact replica of the coal heap
analysis
 Cross sectional volume and other details available in a
o Hotspot detection
particular heap of coal.
o Automatic Sprinkler Operation
o Enabling Man less operation.  Different Color Gradient indicates the different
thermograms or temperature zones of the stock yard.

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New Digital Initiatives : Augment/Virtual Reality Based Training
(ART)
Virtual Reality based Training Module
• Interactive computer generated experience
• Simulation of real environment
• Workplace occupational safety and health purposes,
• educational purposes, and
• training purposes
• Currently widely used in Aviation, Medicine and Military

 Technology Pilot Completed – HP Turbine Front Pedestal Bearing assembly/disassembly


 BUSINESS PROPOSAL UNDER APPROVAL - Joint Development with Siemens for complete Turbine
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New Digital Initiatives : Digital Worker

SMART DEVICE for Field Operator Rounds, Field Operator


Guides, Audio/Video upload, SOP access

SMART HELMET for Employees and Workers

RTLS for Real time location tracking of Assets

Creating a workforce with digital skills

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Areas of Asset Management

BUSINESS IMPROVE OPRN. REDUCE DIGITIZE


EMPOWERED OPTIMIZE MAINT.
EFFICIENCY PREVENTABLE
OBJECTIVE WORKER COST
LOSSES
ASSET & DOC

Operation Improved Worker Maintenance Improved Process Digital Twin of


FOCUS AREA Efficiency
Efficiency
Heat Rate Flexible Online
ProductivityDigital Minimize
Right mix of
Visibility 3-D Plant
One Stop
expert
Virtual
Operator unplanned Real time IIOT for Walkthrou Document
Improveme Operation Training PM/CBM/OH Coal Stock monitoring
nt Support guidance Rounds Outage gh ation

AMS (Advanced
ART (AR/VR based APM (Asset Monitoring of AIM (Asset
APC (Advance Trainings) Performance Stockyard) Information
INITIATIVE Process Controls) DIGITAL WORKER Management) AIG (Application of Management)
IIOT in Generation)

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New Digital Initiatives : Advance Process Control (APC)
Reliability
Business Heat Rate Flexibilization Stable Min.
(Reduce
Improvement (Upto 5% Load (50%
Requirement Excursion Upto
(Upto 0.5%) Ramp) Load)
50% )

Focus Area Parameter Ramp Rate


Parameter
Control loop
Excursion
Optimization Improvement Optimization
Reduction

Combustion & Model Predictive


Soot Blowing Model Predictive
Solution Optimization Closed loop
Envisaged Closed loop SH/RH Auto-tune blocks
Model Predictive
& Neural Net Pressure Control Temperature
Control Control

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DIGITALIZATION – Benefits, Cost, Payback & Vendor base
Initiatives Benefits Approx. Payback Vendors
Cost
- Support Flexibalization Siemens, Emerson
APC - Stable operation at Technical Minimum 13.6 Cr 2 Years BHEL/Steag,
- Heat Rate Improvement Schneider Electric
- Prevent wastage of coal by early detection of hotspot Siemens, FLSmidth,
- Online info of Coal Stock – Volume & Storage Profile ABB,
AMS - Enabling Man-less operation of SR
19.55 Cr 4 Years
NextGen, EIP Enviro

- Hands on experience of Virtual Reality based training 4 Years OEMs


ART - Learning by Doing 4.5 Cr
(Emp. Training)
- Maintenance Cost optimization Siemens, TCS, Wipro,
APM - Reduction In Forced Outages GE, Aveva
- Manpower Productivity improvement
- More visibility into Un-monitored/ In-accessible areas. Siemens, TCS , Wipro,
AIG - Supporting condition monitoring with real time data 38.12 Cr 7.1 Years Honeywell, Emerson

- Walk Through of Plant in 3-D Model TCS, Wipro, Aveva,


- One click documentation of all plant assets Bentley
AIM - Easier familiarization/Training of Plant personnel's

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SWOT Analysis

• Lack of Digital
Maturity Model for
• High Productivity Power/Process
• Reduced emission industries
• Reduced ECR • Lack of
implemented cases
in many Areas

Strength Weakness

Threats Opportunity

• Culture & Mindset • Consultancy to other


• Aversion to Change Utilities
• Cyber Security • Data Monetization
• To be the world’s
leading power
company

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Way forward

Business analytics for current


business environment

Manpower sourcing –
A) In-house experts from different background
B) External experts in AI/ML   Academics/
Industry

Formation of  a team for Digitalization at each station

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Conclusion
 Digital is the new normal….Its an era
 Digitalization of the entire power sector Value Chain holds the key to improving efficiencies
 Digital initiative should be linked to business outcome - Contracts to be performance based
 Quick wins with high business impact will lead the way
 Enterprises should create an digital transformation road map with a phased approach
 Scalable Digital platform to support innovation & meta data integration
 Digital Transformation can create new revenue streams in future
– Consultancy to other Utilities
– Data Monetization
 Digitalization is no longer an option… but a necessity

“ The best way to predict the future is to create it yourself ”


Peter H. Diamandis

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Thank You

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References

 PRADIP-Paperless e-Office Solution. Business Requirement Document for Legacy Document Digitization Process (NTPC-PRADIP-
BPD-Digitization, Version:1.3), 2019
 A Practical Guide to Digitization for the Power Industry, 2017
 Digital Twins for Industry 4.0 by Rajendra Sapre
 The Digital Utility Plant: Unlocking value from the digitization of production by Capegemini Consulting, 2017
 https://www.arcweb.com/events/arc-industry-forum-india-2018/speakers-2018/r-sarangapani
 https://www.ge.com/news/press-releases/ntpc-ge-joint-venture-and-ge-wins-contract-6451m-rm-steam-turbine-3x200-mw-ntpc-ltd
 Wikipedia: Digital Twin
 https://www2.deloitte.com/us/en/insights/focus/industry-4-0/overview.html

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