India Power Corporation (Haldia) Ltd – I-BOP Package Project
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India Power Corporation (Haldia) Ltd - I-BOP Package Project

  • Client : India Power Corporation (Haldia) Ltd
  • Industry : Power Generation

Project Background

India Power Corporation (Haldia) Ltd awarded Technisys Engineering Private Limited the EPC (Engineering, Procurement, and Construction) contract for the I-BOP package of their 3×150 MW Haldia Thermal Power Plant. This project aimed at enhancing plant efficiency, reliability, and environmental compliance through the integration of state-of-the-art instrumentation, control, and emission monitoring systems.

Scope of Work

The project encompassed a comprehensive scope of work, including:

Design and Engineering
  • DCS and Instrumentation: Comprehensive design and integration of Distributed Control Systems (DCS) and instrumentation for precise plant control.
  • Valves and Panels: Engineering and supply of control valves, motorized valves, and customized control panels.
  • CEMS & SWAS Systems: Design and implementation of Continuous Emission Monitoring Systems (CEMS) and Steam and Water Analysis Systems (SWAS) for regulatory compliance.
  • Field Instrumentation: Engineering and deployment of pressure, temperature, flow, and level sensors for plant monitoring.
  • Power Distribution & MCC Panels: Design and integration of Motor Control Centers (MCCs) and auxiliary power distribution panels.

Procurement and Supply

  • Instrumentation & Control Equipment: Supply of DCS systems, field instruments, sensors, and analyzers.
  • Valves & Actuators: High-performance control valves and actuators ensuring precision operation.
  • CEMS & SWAS Components: Stack monitoring analyzers, gas analyzers, and water analysis equipment for real-time emissions tracking.
  • Electrical & Control Panels: Manufacturing and delivery of PLC panels, relay panels, MCC panels, and marshaling cabinets.
  • Cabling & Accessories: Supply of power and signal cables, termination kits, and cable trays ensuring seamless connectivity.
  • Piping & Structural Steel: Supply of associated piping, supports, and structures essential for installation.
  • Quality Assurance: All components comply with industry standards and undergo rigorous quality checks.
Installation and Commissioning
  • System Integration: On-site installation and integration of all supplied systems with the existing plant infrastructure.
  • Field Wiring & Testing: Complete cabling, interconnection, and testing of instrumentation and control systems.
  • Performance Testing: Comprehensive functional and reliability testing to validate operational efficiency.
  • Regulatory Compliance: Ensuring the plant meets stringent environmental and safety standards.
Documentation and Training
  • Technical Documentation: Submission of detailed engineering drawings, test reports, and user manuals.
  • Operator Training: Conducting hands-on training sessions for plant personnel on system operation and maintenance.

Our Projects

Challenges Faced & Solutions Implemented

During the execution of the project, several challenges were encountered:

Technical Challenges & Solutions
  • Seamless Integration: Deployed expert engineers and advanced simulation tools to ensure flawless integration of new systems with existing infrastructure.
  • High-Voltage Safety: Designed robust safety measures to ensure secure handling of high-voltage equipment.
  • Complex Field Instrumentation: Implemented precise calibration and testing protocols to ensure accuracy and reliability.
Logistical Challenges & Solutions
  • Timely Material Delivery: Established a streamlined supply chain to prevent delays and ensure availability of critical components.
  • On-Site Coordination: Deployed dedicated project managers to oversee execution and manage stakeholder coordination.
  • Material Handling & Storage: Devised a structured approach for managing inventory and preventing equipment damage.
Regulatory Compliance & Solutions
  • Strict Adherence to Standards: Ensured full compliance with all statutory and environmental regulations through rigorous testing and certification.
  • Emission Control Measures: Implemented advanced monitoring solutions to meet stringent environmental guidelines.

Overcoming Challenges

To address these challenges, the following strategies were employed:

Technical Solutions
  • Expertise and Experience: Leveraging the expertise of experienced engineers and technicians.
  • Advanced Planning: Implementing advanced project planning and simulation tools to anticipate and mitigate potential issues.
Logistical Solutions
  • Robust Supply Chain: Establishing a robust supply chain to ensure timely delivery of materials.
  • On-Site Management: Deploying dedicated on-site project managers to oversee operations and ensure smooth execution.
Compliance Solutions
  • Regulatory Expertise: Engaging with regulatory bodies to ensure compliance with all applicable standards.
  • Environmental Best Practices: Implementing best practices for environmental management and sustainability.

Project Completion

The project was successfully executed within the stipulated timeframe, ensuring a fully integrated and operational I-BOP package. All supplied systems were installed, tested, and commissioned to meet performance expectations.

Provisional Acceptance Certificate (PAC)

  • Date of Issuance: Date of Issuance: [Insert Date]
  • Scope: The PAC was issued after successful completion of performance guarantee tests, confirming the system's readiness for commercial operation.

Final Acceptance Certificate (FAC)

  • Date of Issuance: [Insert Date]
  • Scope: The FAC was issued after the successful completion of the defect liability period, marking the formal acceptance of the project by MIDHANI.
Conclusion
The completion of this project reinforces Technisys Engineering Pvt Ltd’s expertise in delivering high-quality EPC solutions for the power generation sector. By overcoming technical, logistical, and compliance challenges, we have provided India Power Corporation (Haldia) Ltd with a reliable and efficient I-BOP system, further strengthening our commitment to excellence and client satisfaction.