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Digital Pathway For Asset Management
Digital Pathway For Asset Management
Digital Pathway For Asset Management
PROCESSES
COPYRIGHT
Copyright 2018
© 2016 NTPC
Your LTD. All Rights Reserved.
Company 1
The Digital Transformation Imperative
Total 70 62,910
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
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
Copyright © 2016 Your Company All Rights Reserved. time. 6
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
$20Mn or ₹ 147
Cr
the production cost that can be
saved annually
in an average combined-cycle
power plant in US
*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
42%
the percentage of
utility companies that
have operational
digital plants
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 201
Industrial
CLOUD Internet of
Things
Industrial
Internet of
Things
(IIOT)
Information
Technology
Application
Layer
Wireless Infrastructure
24X7 Centralized OEM/Expert availability
Field
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
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
3
Conventional DCS system,
Maintenance Practices are not enough Converting Big data into Integrating All Information in
Own Dedicated Cloud
Big Information
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
Copyright © 2016 Your Company All Rights Reserved. 34
Operational Model
On
Vibr line se
Tools
atio n
n,Te sors fo Big Data
mp, r Business Analytics
Sou
nd
Cloud Computing
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
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
Copyright © 2016 Your Company All Rights Reserved. 37
C&M and Store Digitization model
Integrating Operational health
Index with Asset
STORE
Combining in Analytics Investment
NTPC VENDOR
Preset Present
value value
DEVIATION
OR HIGH
SEC. OIL
ROC
PR
ROC
OIL PR
Predictive Alarm
OR
Information
System
AND
MANY
MORE
Copyright © 2016 Your Company All Rights Reserved. 41
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
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)
• 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
Manpower sourcing –
A) In-house experts from different background
B) External experts in AI/ML Academics/
Industry
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