ROLE OF C&I & IT IN THERMAL POWERROLE OF C&I & IT IN THERMAL POWER GENERATION

PM BhardwajDirector(P)Instrumentation LtdInstrumentation Ltd

Outline of Presentation

– Power Sector : Key to Economic Growth– India Energy Scenario : Demand vs Gap – Crucial Role of C&I– PLFs of Power plants– Benchmarking exerciseg– Trends on DCS – Broad Objectives of DCS– Integration of IT with C&IIntegration of IT with C&I– C&I – Role in making  Indian power plants world Class

– Benefits of IT solutions to Power Plants– Challenges of Today

Power Sector : Key to Economic GrowthGrowth

• Electricity - Critical infrastructure component for rapid y p peconomic growth

• Reliable and quality power at competitive rates is key to• Reliable and quality power at competitive rates is key to Industrial Growth .

• Importance of Energy for the Economy : President Barack Obama immediately on assuming office as US President signed an Executive Order Aimed at EnergyUS President signed an Executive Order Aimed at Energy Independence.

P C it ti f l t i it i I di (704 it ) i• Per Capita consumption of electricity in India (704 units) is very low compared to developed nations (17000).

Need to Increase Power Generation

• India’s GDP has taken a big jump and is growing at a rate of 7‐8%8%.

• The growth of the economy calls for a matching growth rate• The growth of the economy calls for a matching growth rate of infrastructure facilities, especially power.

• The growth rate for power in developing countries is  higher than GDP.

• Hence growth ratio of Generation should be minimum 11‐12 %. %.

India Energy Scenario : Demand vs Gap

• Indian Electricity Sector has made remarkable progress during the last five decades in the field of

GenerationTransmission and distribution Utilization of electricity.

• However, the demand of electricity has always been more than supply.

P tP t St tSt t•• PresentPresent StatusStatus::–– PerPer capitacapita consumptionconsumption 704704 unitsunits perper annumannum againstagainst world’sworld’s >> 1700017000

unitsunits–– InstalledInstalled CapacityCapacity 11 4747 457457 MWMW asas perper CEACEA datadata ofof 3131stst JanJan 20092009InstalledInstalled CapacityCapacity 11,,4747,,457457 MWMW asas perper CEACEA datadata ofof 3131 Jan,Jan, 20092009

• In FY08, the total power generation was 704 billion units as comparedto 663 billion units in FY07 ( 6 3% growth Year on Year basis)to 663 billion units in FY07, ( 6.3% growth Year on Year basis) .

• India is facing Power shortage in terms of energy and Peak shortage- Energy shortage is about 8%- Peak Energy shortage is about 13.8%.

• February 2008 recorded a Peak Shortage shortage of as high as• February 2008 recorded a Peak Shortage shortage of as high as 14.5%.

Projected power requirement and capacity addition by year 2012:Projected power requirement and capacity addition by year 2012:–– Per capita consumption about 1000 units per annumPer capita consumption about 1000 units per annum–– Installed capacity about 2,10,939 MWInstalled capacity about 2,10,939 MW

Installed Capacity in the country  at End of 10th Plan ( 31/3/2007)10 Plan ( 31/3/2007)

Coal based Power Plants are Backbone of Indian Power Sector forming 53% of theCoal based Power Plants are Backbone of Indian Power Sector forming 53% of the 

installed capacity of Power Generation as on 31/12/2008.

Demand Supply Gap can be bridged byDemand Supply Gap can be bridged by

•• Sustainable Large Capacity Addition Sustainable Large Capacity Addition ProgramProgramgg

•• Increasing efficiency of existing unitsIncreasing efficiency of existing unitsg y gg y g

•• Upgrading fleet of Old Power Stations Upgrading fleet of Old Power Stations pg gpg gwhich are inefficient and have poor which are inefficient and have poor availabilityavailabilityyy

Need to Improve performance of the Existing thermal power plants

• In the present scenario, apart from capacity addition, p , p p y ,there is an great need to improve the performance of existing units.

Goals of Power GenerationGoals of Power Generation– Lower Cost of Generation

Hi h Effi i & hi h t t (i i l– Higher Efficiency & higher output (increasing plant load factor and plant availability) 

– Good QualityGood Quality– Higher Reliability– Reducing transmission and distribution losses,

– Environment Friendly , Clean and Green Sustainable Power is need of the day.E S it– Energy Security

Crucial Role of C&I

• Globalization, Privatization and Liberalization has effected power sector also.

• It is gradually moving from a regulated to a non-regulatedIt is gradually moving from a regulated to a non regulated system with high competition.

• For achieving above in fast manner increasing the efficiencies of electric generating plants is critical.

• Power Plant’s efficiency is dependent on quality of its operations and maintenance and C&I has a crucual role in it.

• C&I has very important role in stabilization of various b t f P Pl t th hsubsystem of Power Plant through

– tuning and commissioning of various Loops – performance monitoring of various subsystems

optimal operation of the plant at the target performance level– optimal operation of the plant at the target performance level– Prevent Tripping and Forced shutdowns

• Use of Latest C&I systems has resulted in increase in PLF and decreasing the manpower required per MW.and decreasing the manpower required per MW.

ALL INDIA PLF (%) OF THERMAL POWER STATIONS

7 2 . 7

7 4 . 37 4 . 87 6 . 8

7 8 . 6

7 3

7 8C H A R T : 1 3

6 4 . 6

6 7 . 36 9 6 9 . 9

7 2 . 2

6 16 4 . 4 6 4 . 76 3

6 3

6 8

5 6 . 55 5

5 6 . 5

5 3 . 95 5 . 3

5 7 . 1

6 0

5 3 . 2

5 2 . 45 3

5 8

5 2 . 4

4 8

YY ears

Manpower per MWManpower per MW

Figures for NTPC Power Plants (Source NTPC annual Report)

Benchmarking ExerciseIn this benchmarking exercise data from 19 thermal power generating units was collected & comparison was made of the best figures in each parameter achieved by any Indian power plant over three years (2001 – 2004) with such

Performance of a B t P f i

Average Performance of f ll I di th l

figures for 2004 – 2005 of relatively high performing India power plants.

Best Performing Unit

of all Indian thermal Power Plants

Suratgarh

Forced outage % 4.44 8.84

Planned maintenance % 1.03 8.23

Operating availability factor % 93 6 82 93Operating availability factor % 93.6 82.93

Plant load factor 93.18 74.82 93.10

Specific fuel oil consumption 1 2 ml/unit 1 37Specific fuel oil consumption 1.2 ml/unit 1.37

Auxiliary power consumption % 7.53 8.57

Inferences from the comparisonInferences  from the comparison

• Performance figures of average Indian thermal power ti it d th fi f th b t f igenerating units and the figures of the best performing

power generating unit indicates that the potential for performance improvement is tremendous in Indian thermal power generating unitsthermal power generating units.

• If the availability factor of the existing thermal power generating units is increased by 10% from the presentgenerating units is increased by 10%, from the present level the capacity addition requirement will come down by approximately 12,000 MW. This will reduce the investment requirement of about Rs 50 000 Croresinvestment requirement of about Rs 50,000 Crores.

Trends in DCS  (Technology)Summary showing great

• 1988– 16000 Tags for the total system

Summary showing great improvement in following

CPU Power : g y

– Proprietary OS for operator stations and controllers– 16 bit CPU for Operator station– 8 bit for controller, 8 Mhz speed– Bus speed 1 MB or 2 MB

• 1998

Capacity of System in terms of NO. of Tags

– 16000 Tags for each controller,– 200000 tags for the system– Both ON/OFF & moudlating control in same controller– Integrated engineering and documentation functions– Windows or Unix OS for operator stations.

Standard OperatingSystem

Bus Speed– 16/32 bit CPU for controller– 66 MHZ Pentium or Unix based workstations. – Bus speed 100 MB

• 200832000 T f h ll

Bus Speed

Interfaces to Third– 32000 Tags for each controller– More than Million for the system– 400 MHZ Operator stations or Unix workstations. – industry Standard CPUs at controller level. – Gigabit Bus speed

Part Systems

Remote Connectivity

Communicationinformation security

OBJECTIVE OF C&I SYSTEMS

• Safe operation of plant Sa e ope at o o p a t• Better visibility,  close monitoring of Plant parameters and events for fault analysis p y

• Lower the cost of generation • Increase  equipment lifeq p• Minimize  environmental effect • Maximize efficiency y• Energy conservation 

Trends in DCS  (User Interfaces)• The first direct digital control (DDC) systems of g ( ) y

the 1970s offered Plant Mimics in semi graphics mode  like conventional BTG boards. Displays were ineffective because only part of the process was visible at any one time. Only a small number of variables could be shown on

Summary

Graphics : small number of variables could be shown on the low‐resolution monitors that were available. Operators were only able to view a very small number of plant variables at any time and were never able to get the complete i f l

Display Size

picture of a plant.• In the 1980s the  DCS started offering  larger 

displays . Historical information and trending  was available to see  process dynamics. Higher resolution screens and windowing

Display Resolution

Selection DevicesHigher‐resolution screens and windowing allowed more variables to be included on displays. Control was also included from DCS.

• By the mid 1990s supporting knowledge and

Simulation

operator guidance messages• By the mid‐1990s, supporting knowledge and 

operator guidance messages were included in most control systems.  Their was improvement in engineering  and simulation tools. Typically, an operator could now point at a process 

messages

Drill down capabilityp p p

object to retrieve associated information. Update Time

Present Day DCSPresent Day  DCS• Single Window to the process

• Open communication architecture, 3rd party subsystems can easily interface and integrateS hi i d P Pl E i i d O li• Sophisticated Power Plant Engineering and Online Documentation Tool for Asset Information Management

• Seamless interface with ERPSeamless interface with ERP • Ability to send information on laptops, PDAs and Mobile

devices• Remote Diagnostics• Remote guidance and operation

G hi l N i ti• Graphical Navigation

Present Trends in C&I

New technologies in C&I systems have been inducted for

• Improvement in plant performance and reduction in space and cost etc.

• These include adopting of microprocessor based controlThese include adopting of microprocessor based controlvalve positioners, wireless LAN, microprocessor based 24 V DC system, digital CCTV system,

• Large Video Screens as main operating tool,• Field‐bus based systems• Flame scannersFlame scanners• High level of diagnostics for early detection of problems and 

to facilitate proactive maintenance. 

The following aspects of C&I systems are i i i llimproving continually:

•  Standardization

• Speed of response

• Hardware

• Software compatibility

• User interface

• Memory

• Compactness

• Power requirement• Power requirement

• System integrity (reliability, availability, security)

• Control and logic algorithmsControl and logic algorithms

• Better Interfaces & Connectivity to other systems

Future of Control Rooms 

Old Control Room with many windows New Control room with large screens

Old Control Room Latest Control RoomOld Control Room              Latest Control Room

Integration of IT with  C&I

• Need to process e-information Intelligently in C&I systems is increasingday by dayW ld id j i h d t d ERP d Oth IT• Worldwide major energy companies have adopted ERP and Other ITsolutions and have benefited tremendously.

• Indian Energy companies are also upgrading their IT infrastructure andare going for solutions likeare going for solutions like

Integrating MIS with DCSStation wide LAN ,O ti i ti & Di ti ftOptimization & Diagnostics software .ERPE-Procurement software

IT in Energy Companies

• Companies with geographical spread units are tightly integrating

their units using the power of LAN / WAN and other IT technologiestheir units using the power of LAN / WAN and other IT technologies.

• This helps them to properly Monitor On-line various Real-time plant

parameters from different generating stations and improveparameters from different generating stations and improve

operational performance.

• Indian Companies like NTPC, GEB, RRVUNL etc. have gone forIndian Companies like NTPC, GEB, RRVUNL etc. have gone for

latest systems like PADO & state of the art ERP systems to adopt

best practices in Power Generation.p

• Several Discoms have also taken large initiatives in field of

networking. E.g. AVVNL, JVVNL , RRVUNL has taken large ITg g g

initiatives for improving IT infrastructure.

C&I – Role in making  Indian power plantsworld Class

• C&I can play an Important role in making Indian Power plants• C&I can play an Important role in making Indian Power plantsworld Class – How ‐

• Adopt Best practices followed by Power Plants worldwide• Identify the state of the art DCS and C&I technologies adopted in y g p

international power plants• Identify and adopt the best practices in Indian power plants which can 

suitably be fine tuned and used in various power plants. • Try to reach Best operating parameters of coal based thermal power• Try to reach Best operating parameters of coal based thermal power 

plants for each size of unit• Adoption  of the best operating and maintenance practices from various 

high performing thermal power generating units will help the power i i d h b h kigenerating units to move towards the benchmarking

• Monitor  Green house gas emissions 

Performance Analysis, Diagnostic and Optimization (PADO)Optimization (PADO)

• PADO compares the actual status of plant operation with the “best” status by simulating the entire process and identifying 

i l i b li dpotential cost savings to be realized.

• Also includes a life time monitoring package that computes• Also includes a life time monitoring package that computes continuously the residual life of the plant.

• Being Implemented by IL at Chhabra TPS of RRVUNL.

Benefits of IT solutions to Power PlantsBenefits of IT solutions to Power Plants

• Benefit through adoption of best business practicesBenefit through adoption of best business practices • Increase in the useful life of the power generation Plants• Increased efficiency in operation & maintenance system • Reduction in inventory carrying costs (inventory requirement forecasting , y y g ( y q g

analysis & replenishment)• Improvement in manpower productivity (competency management, 

planning, removing non‐value added activities etc.) and help in reducing  workload on top management.workload on top management. 

• Controlling time and cost overruns of projects (through exception based project management) Powerful executive information system to facilitate proactive decision making processI d bilit t d t th h i d d d d f• Increased ability to respond to the changing needs and demands of customers

• Generation of most competitive power

Costs after Implementation of IT solutions in P PlPower Plants

• Inventory CostsInventory Costs 

• Procurement Costs

Sh t C t• Shortage Costs

• Manpower Costs

• Communication Costs

• Decision Costs

• Maintenance costs

IL’s Path to Software Solutions

Challenges of Today• Due to Globalization, Privatization and Liberalization, today’s

industries face continuous need to lower operational costs• Ensuring sustained availability of plant at higher performance levelEnsuring sustained availability of plant at higher performance level • Need of increased information sharing• Real-time Optimization• Merging of earlier isolated optimization tasksg g p• Low-level vs. high-level objectives into overall organization

objectives • Earlier manually solved problems and now optimized and

l d i l b l ti & C l ti i ti tsolved using global expertise & Complex optimization systems.• C&I and related ERP systems require extensive support and

expertise. Hence we should look after companies with good f t ti li i t ll ti t i ft lreferences, reputation, live installations, staying power, after sales

support. • Integrated C&I , software and hardware providers can provide real

t k l ti i b t iblturnkey solutions in best possible manner.

Conclusions

• The market-oriented competitive environment has made it necessary forced many power plants to become more conscious of the role ofof the role of

• proper C&I systems, • maintenance and optimization management tools

• Good C&I system coupled with IT products like ERP , Optimization Packages, Fuel management software, equipment maintenance practices and tools can improve the reliability of the power system;

• Use of IT along with latest C&I systems can help to zero in on the optimum methods & management practices in order to improve the overall effectiveness of the operations andimprove the overall effectiveness of the operations and maintenance of the plant.

• IT can help to reduce the work burden by automating tediousIT can help to reduce the work burden by automating tedious and monotonous tasks.