Rectification/Improvement Of Wagon Tippler Control System Of CHP Stage-I Of NCPS, Dadri
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RECTIFICATION/IMPROVEMENT OF WAGON TIPPLER CONTROL SYSTEM OF CHP STAGE-I OF NCPS, DADRI
- Client : NTPC Limited
- Industry : Power Generation
Project Background
JK Tyre & Industries Ltd, a leading name in the automotive and tyre manufacturing sector, entrusted Technisys Engineering Pvt Ltd with the task of expanding and modernizing its utility infrastructure. The project aimed to enhance operational efficiency, optimize resource utilization, and implement advanced monitoring capabilities within the Chennai tyre plant.
Scope of Work
The project encompassed a comprehensive scope of work, including:
- Supply of PLC to NTPC for automation and control.
- Ensuring seamless integration with existing plant operations.
- Enhancing system efficiency and reliability.
- Rectification and improvement of the Wagon Tippler Control System for CHP Stage-I at NTPC National Capital Power Station, Dadri.
- Upgrading control mechanisms to improve operational efficiency.
- Ensuring smooth coordination with coal handling processes.
Project Execution & Maintenance
- The project was successfully completed on time, meeting all quality and performance standards.
- Since 2017, we have been maintaining NTPC’s plant, ensuring the continuous and efficient operation of the supplied systems.
Project Name
Design, engineering, manufacturing, supply, supervision of erection and commissioning of PLC for Vandana Vidyut Project 2X135MW TPS (PH-1) & 2X330MW (PH-1), Korba
Client Name
- Vandana Vidhyut Ltd
- Industry : Conveyor Systems and Material Handling
Scope of Work
- Design and Engineering:
- Design and engineering of the PLC system
- Software development and testing, including Factory Acceptance Test (FAT).
- Supply of PLC System:
- o Supply of Honeywell make redundant PLC (ML200R) system.
- I/O modules, OS-1, OS-2, and printers.
- PLC panel, control desk cum MIMIC panel, hardware, and PC desk
- Supervision and Commissioning:
- Supervision of erection and commissioning at the site.
- 45 free man-days of support, with lodging, boarding, and transportation arranged by SCS.
- Additional Components:
- RADAR Level transmitter, Pull Chord Switches, Belt Sway Switch, Sensor modules, Belt Slip Switch, Chute Jamming, RF type Level Sensor, Dual Channel Belt Watch System & Indication Module.
- Cables and Accessories:
- Various types of cables and cable trays
- Structural steel for support (angles/channels).
- Erection and Commissioning:
- Erection and commissioning of supplied instruments, cables, trays, etc.
- Transportation, storage, and handling of materials.
- UPS System:
- Supply of Hitachi HI-Rel make ON-LINE 2xSKVA Parallel Redundant UPS system.
- 2 sets of Ni-cd pocket pallet battery bank for 1-hour backup.
Our Projects
- SAIL Bhilai Plant
- SAIL Barsua Iron Mines
- IRCON International Ltd- Sector 43 Mall (Noida)
- IRCON International Ltd- Sector 48 Mall (Noida).
- Gail India Ltd- Kailaras
- Indian Oil Corporation Ltd- Assam
- SAIL Gua Ore Mines
- Deendayal Port Authority- Kandla
- Balmer Lawrie Co Ltd- Kolkata
- SJVN Ltd- Jhakri.
- NTPC Ltd- Koldam
- Nabinagar Power Generating Company
- Power Grid Corporation India Ltd-Shivpuri
- Rites Limited-Kalaburagi
- Power Grid Corporation India Ltd-Madurai
- Steel Authority of India Limited (SAIL) – Rourkela Steel Plant, Barsua Iron Mine.
- NLMK INDIA Coating Pvt Ltd.
- Power Grid Corporation of India Limited (PGCIL)-Poducherry
- GAIL (India) Limited-Faridabad
- Indian Oil Corporation Limited (IOCL)-Vijaywada
- Mishra Dhatu Nigam Limited (MIDHANI)-Hyderabad
- Steel Authority of India Limited (SAIL), Rourkela Steel Plant, Barsua Iron Mines
- Mishra Dhatu Nigam limited-Rohtak
- India Power Corporation (Haldia) Ltd – I-BOP Package Project
- Aravali Power Company Private Limited (APCPL)
- JK Tyre & Industries Ltd
- Rectification/Improvement Of Wagon Tippler Control System Of CHP Stage-I Of NCPS, Dadri
Challenges & Solutions
During the execution of the project, several challenges were encountered:
- Technical Complexity:
- Challenge Designing and integrating a complex PLC system.
- Solution Employed experienced engineers and conducted thorough testing
- Coordination and Communication:
- Challenge: Ensuring clear communication and timely approval.
- Solution: Established regular communication channels and provided detailed drawings.
- On-Site Commissioning:
- Challenge: Handling technical issues during on-site commissioning
- Solution:Provided 45 free man-days of on-site support with skilled personnel.
- Compliance and Documentation:
- Challenge: Ensuring compliance with industry standards and proper documentation.
- Solution: Ensured all prices included necessary charges and provided proper documentation.
- Timely Delivery:
- Challenge: Meeting the delivery schedule and commissioning deadlines.
- Solution: Committed to early delivery and successfully commissioned the project.
- Project Completion: The project was successfully completed on time.
Technical Challenges & Solutions
- Complex System Integration: : Leveraged expert engineers and cutting-edge simulation tools for seamless compatibility.
- Harsh Environmental Conditions: Designed robust components to withstand extreme industrial environments.
Logistical Challenges & Solutions
- Timely Material Delivery: Strengthened supply chain coordination to prevent delays.
- On-Site Execution Management: Deployed experienced project managers to streamline installation and coordination.
Compliance & Quality Assurance
- strong>Regulatory Adherence: Ensured strict compliance with safety and quality standards.
- Sustainable Execution: Implemented best practices for minimal environmental impact.
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 & Impact
The successful execution of this project reinforced Technisys Engineering Pvt Ltd’s capability in delivering turnkey utility expansion solutions. By overcoming technical and logistical challenges, we provided JK Tyre with a future-ready infrastructure, ensuring enhanced efficiency and reliability in their manufacturing processes.
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.