TRENDS

IN
CONTROL & INSTRUMENTATION

(PROJECT-ENGG C&I)
NTPC LTD

C&I HOD WORK SHOP AT PMI-NOIDA

(9TH-11TH NOV-10)
10-NOV-2010
 PRESENTATION AGENDA
 C&I Engineering in a snapshot

 Strategies & Initiatives undertaken

 Engineering Process Standardization

 New Practices/ Concepts

 New Technologies
PRESENTATION AGENDA (Contd.)
 Security of C&I system

 Measures for reducing forced outages

 IPON implementation

 Expectations from site

C&I Engg activities in a snapshot
 Packages Owned
◦ Station C&I
◦ Instrumentation cable
◦ R&M packages of C&I systems
◦ Training Simulator packages (Stand
alone/part of main packages) for Thermal,
Hydro, Gas projects
C&I Engg activities in a snapshot
 Contribution to Mechanical Packages
◦ SG
◦ TG
◦ Gas projects
◦ Material handling
 AHP
 CHP
◦ Water system-
 DM/PT/CPU/ETP/AWRS/Desalination
 CW MU
 AC & Ventilation/Fire protection
◦ Main plant and off site Civil works package
◦ Hydro packages
C&I Engg activities in a snapshot
 In house engineering
◦ Station C&I package
 IO list/Drive list
 Logics
 HMIPIS inputs-(MIMICS, Logs ,Reports, LVS Annunciation, SOE
 Marshalling/panel termination assignment for DCS cabinets)
 Bought out items inputs for
 Field instrumentation
 LIE/LIR grouping
 JB grouping
 Locations for CCTV,PA system, Master Slave clock
 DCS System Testing
 System Design Features/Simulated and Integrated Testing
C&I Engg activities in a snapshot

◦ Cable Engineering
 Cable list
 Cable schedule
 Interconnection Schedule
 Control and power cable lists for AC/DC power distribution ,earthing
and grounding requirements.

◦ Layout Engineering
 Control Rooms layouts, Control equipment rooms, Battery Rooms, UPS
rooms, SWAS rooms etc
C&I Engg.
Engg Activities – a snapshot

◦ Projects Being Engineered Concurrently( In-

House)
 New -14
 R&M -3
 Diverse DCS Systems -6
 Functional testing in a year-10-12

 These figures will increase substantially for

projects to be engineered in future.
C&I Engg. Activities – a snapshot
snapsho

◦ Stringent targets
 C&I Specification preparation time w.r.t zero
date has come down from 6 months to
now -4 in bulk tendering projects)
 Documents review & approval time reduced
 Cost reduction in all packages including C&I
 Minimization of Project to Project Variants ( Eg,
C&I Layout)
 FAT time reduction though scope of testing
increased
 Tender Phase
◦ Two Stage Bidding ( Specification better tuned to
contemporary systems)
◦ Standard Specification Module ( Streamlining the
Specs. Preparation process)

 Engineering Phase
◦ Specialization based Dept. Structure ( Detailed
focus on specific area; continuity & consistency in
Engg.; single pt interface to sites)
◦ Standardization in Engg. Process.
◦ Pre-engineering of systems – UPS, 24V DC charger.
◦ All logics/ loops tested in laptops with the vendor
before Integrated test.
◦ Major Design Features test for DCS before FAT.
◦ Standardization of Documents (Interconnection
Drawing etc).
◦ Standardization of Control Room/ Control
Equipment rooms layout.
◦ Automation in Engg. Process (ICS generation for
main plant & offsite).
 In On-going Projects
Practice/ Concept

Uniform Control System for main plant as well as offsite ( DCS

Platform) for ease of maintenance, uniform HMI, optimized
operation.

Uniform Logics Philosophy/ Tagging for Offsites in line with main

plant.
Facility of remote operation of hydro plant from Corporate Centre.

Multiplexing of Programmer room hardware for space saving and
optimized usage.
 Contd..
 In On-going Projects
Practice/ Concept

Reduction in Control Hardware

Testing and Commissioning Tool of DDCMIS for site activities

PADO Results dissemination back to DDCMIS & to any PC on Plant

Intranet

Online Control loop tuning software in Station C&I package.

 In On-going Projects
Technology From

LED instead of UHP lamps for Bulk Projects

LVS
Modular Chargers Dadri-II
Field Bus for I/O intensive Simhadri-II ( Boiler Metal
areas Temperatures)
Microprocessor based Simhadri-II

Positioners
Technology

Online Coal Analyzer

GIUs for offsite areas for control in place of DCS

Field Bus for more areas

◦ Security policies and procedures for DDCMIS
included in the latest specifications.
◦ Circulated to all sites as OGN-31.
◦ Station LAN architecture modification -
Recommended architecture.
◦ Security audit.
◦ Government Initiative Example
◦ Training in Network Security - essential (included in
latest specifications for ongoing projects.
◦ Separate Cables for individual signals for tripping.
(Furnace Pr. Tx., PA Hdr Pr. Tx.)
◦ Separate UPS feeder for Flame Scanner and Ignitors.
◦ Separate JB for 24V DC.
◦ Triplex type T/C in Turbine Brg. Temp.
measurement with 2/3 on each such point.
◦ CW logic modification for operating any CW pump
from any unit.
◦ Power supply for offsite area control system
modified to include 2 charger- 2 battery system.
◦ Ignitor testing kit/ assembly included in scope.

◦ Proximity type limit switch for Hot Air Gates of Mill.

Performance report of Vendors on continuous basis
- w.r.t quality of work & support
- w.r.t their product performance
Project Completion report with objective feedback about
utilization of various systems.
Sharing of new technology adopted, if any at any site (e.g. trial
installations).
Similar
 sharing of best practices.
Training of site engineers.
THANK YOU….