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Digital Pathway for Asset Management

NTPC - SSTPS

PROCESSES

ANALYTICS Presented by:-

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

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Digital Pathway of Asset Management

Evolution of Technology
The Asset Management and its model
Why NTPC needs it?
Where do we stand right now
Digitization
Digital Power Plant – New Initiatives & their details

1. Advanced Process Control (APM)

2. Advanced Monitoring of Stockyard (AMS)
3. AR/VR Reality based Training (ART)
4. Asset Performance Management (APM)
5. Asset Information Management (AIM)
6. Application of IIOT in generating units (AIG)

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Why Asset Management in NTPC

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Evolution of Technology

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Asset management

Asset
Management

APM (Asset
Performanc
EAM (Enterprise Asset e
Management) Managemen
t
CLIMS
SAP
CMMS
Safety app
ERPMS
LOMS

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Asset management model
Management
Business layer integration Analytics

Operation & Maintenance Monitoring & Analysis

Maintenance Operation Maintenance Energy Performance Predictive Condition

optimization management management efficiency monitoring monitoring Monitoring

Data integration & management

Data integration

Measurements
Document
Mobility solution GIS … …
management
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Pic to be edited

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Pic to be edited

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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

Data Lake Analytics Centralized Connectivity

storage and
processing

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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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 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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NTPC– New Initiatives in 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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Digital Power Plant – New Initiatives
Advanced Process Advanced Monitoring of AR/VR Reality based
Control Stockyard Training
• Operations • Advanced monitoring • Creation of Augmented
Optimization & for coal stockyard like Reality (AR) based tool
Environmental hot spot detection etc. for Training in Work
compliance (NOx) procedures

APC AMS ART

Asset Performance Asset Information Application of IIOT in
Management Management Generating Units
• Maintenance • Digital Twin (3D • IIOT (Industrial Internet
Optimization through modelling software) of Things) for condition
RCM (Reliability with Lifecycle monitoring, other
Centered Maint), Documentation remote areas
Operator Rounds

APM AIM AIG

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New Digital Initiatives : Advance Process Control (APC)
Reliability
Business Heat Rate Flexibalization 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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 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 of SR Machines  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 : Asset Performance Management (APM)
 Reliability Centered Maintenance (RCM) Practice Major Benefits:
 Integrated Criticality Analysis  Maintenance Optimization
 Device best maintenance strategy mix – PM/CBM/OH  Reduction in Forced Outages
 Root Cause Analysis Libraries to prevent repeated Failures  System Driven Decision Making
 Life cycle costing analysis tools  Manpower Productivity

SAP Equipment Maintenance Maintenance

Maintenance
Master Data planning Execution &
Analysis
Documentation

RCM FMEA Optimize

strategies
Maintenance Risk Evaluation Strategy Strategy
Analysis Definition Evaluation
Establish Evaluation
RCM
Criteria

Condition Operator Rounds Operational

Performance
Monitoring Condition Monitoring Evaluation

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New Digital Initiatives : Digital Worker

SMART DEVICE for Field Operator Rounds, Filed Operator

Guides, Audio/Video upload, SOP access

DIGITAL HELMET for Remote Assistance/Monitoring, Remote

Access of SOPs, Procedure Videos

RTLS for Real time location tracking of Assets

Creating a workforce with digital skills

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 New Digital Initiatives : Application of IIOT in Generating Units
(AIG)
Augmenting today’s handheld
Visualization
based condition monitoring with Layer

Permanently mounted wireless

Wireless
vibration and skin temp sensors Application
Layer Infrastructure
on critical equipment 24X7 Centralized
OEM/Expert availability

 Portable wireless vibration and

IOT Platform HUB
skin temp sensors for need Information
Layer

based wireless assessment IOT Gateway IOT Gateway IOT Gateway

Humidity and Temperature
monitoring in remote equipment DCS / SCADA Historian

Voltage level and Lux level

sensors in remote pump houses
Field

Innovation using Information & Analytics is the new Mantra !!!

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New Digital Initiatives : Asset Information Management (AIM)
 Featured in Gartner’s Top 10 Strategic Technology Trends for 2017

Real Space Virtual Space

Dimensional • DIMENSIONAL DIGITAL TWIN

Model • Walk Through
3D model + • One Stop Documentation
• Training / Maintenance Planning
Life cycle
documentation
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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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 Status of Digitalization projects
Initiatives Responsibility Status/ Action Plan

PE-C&I  NIT by May 2020 Award: July’20 

Advanced Process Control (APC) Phase-2
PE-C&I  NIT  by May ‘20    Award: July 20 
Advanced Monitoring of Stockyards (AMS) Phase-2
PE-C&I  Price bid opening by 10th April
Integrated Security System Phase-1 (5 Projects) Award by 30th  April 20
PE-C&I NIT  by April’20; Award July’20
Integrated Security System Phase-2 Lot A (5 Projects)

PE-C&I ACC & Pipe Conveyor completed

AR/VR based models-ACC, Pipe Conveyor, Boiler Boiler in progress. By June 20
PE-C&I Earlier Tender annulled.
Advanced Asset Management  EOI floated – Scheduled
submission by 24 Apr'20
PMI    Award by Aprl'20
AR/VR based Training –Siemens 660/ 800 MW Turbine with PE-C&I

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 Status of Digitalization projects
Initiatives Resp Status/ Action Plan
Rail Asset Management: Capture and Standardize Rail Asset Maintenance - Development completed
• Digitize complete rail asset maintenance lifecycle & Standardize procedures across DI on 27th Mar 20. 
NTPC - User Training and
• Capture KPI of asset utilization, frequent failures to enable better utilization Data config going on

Advanced Pattern Recognition Package: (AI/ML Application) Predictive Maintenance , - NIT 10th Jan 20

Forced Outage reduction  - Revised QR finalized on
• Provide early warning of impending equipment faults much before DCS alarms DI Apr 20
along with probable causes of the early warning along with ranking in order from - Award by July 20
most probable to least probable

RFID based Store Management: Store Inventory tracking, easy identification and

reduce inventory loss - PR with SSC-SR
DI 
• RFID tagging for seamless material entry, exit and reconciliation - Award by Jun 20
• Material 2D image linking to RFID and location tracking with RFID and GPS

Partnership with Startup for BTL analysis & prediction tool: (AI/ML - Proposal under approval

Application) Prevent BTL using data based modelling and failure DI - Pilot for one type of
pattern identification BTL by July 20

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 Status of Digitalization projects
Initiatives Resp Status/ Action Plan
- Discussing with IIIT NR
Partnership with IIIT-NR for development of IIOT and AI/ML based solution
and IIT Kanpur
• Ash Slurry Pipeline leakage detection system  DI
for collaboration
• Ash dyke monitoring through drone
- Pilot completion by Nov 20
Coal Management: (Application of Analytics) Integrated application to digitize, support DI - Under Scope finalization
decision making and automate coal planning & coal transport. - Roll-out by Nov 20
Asset Management for Operation Services Group: (Application of Analytics) Asset
- Under Scope finalization
health index by combining all asset data (Design, Operation, Maintenance, OH, DI 
- Award by Dec 20
Chemistry)

Safe Work Process Management: (AI/ML Application)  - PR to be released

• Safety tool (with desktop application, mobile app) to bring pro-activeness, to safety DI in next week.
process and ensure 100% compliance and improve the productivity in safety process - Award by Sept 20
execution.

Chatbot for O&M: (AI/ML Application) Virtual expert operator 

DI - Under Scope finalization
providing voice based assistance for Operation and Maintenance functions - Roll-out by Nov 20

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 Copyright
Emerson © 2016
Confidential Your Company All Rights Reserved. 35
Practical inputs from future digital workers: Survey

Departments  Survey was done to inculcate practical

inputs.
8%  Method: Online
13%
5%  Total number of participants: 60
5% AHD  Participants were from different
EMD backgrounds and from different projects.
5% OPERATION
HR
EEMG
C&I

65%

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Way forward

Formation of  a team for Digitalization under ED Engg

 Manpower sourcing – A) Inhouse experts from different background

                                   B) External experts in AI/ML   Academics/ Industry
 Business analytics for current business environment

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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

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

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