NTPC Consultancy

Noida

Technical Audit and Gap Analysis of

BPSCL Power Plant ( 11-15th Sep18)
Closing meeting
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Technical editand
Audit Master title style
Gap Analysis

•Field devices are maintained in good condition

•Identification of instrument is easy
•All the filed devices are protected from Dust, water and steam
•Tried to maintain the required system for operation through
stand alone controllers and relay based logic
•Preventive Maintenance is being done
•Laboratory Calibration records are well maintained

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Field Devices edit
and Master
Junction title style
Boxes

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Control and Protection Systems

•Control system does not exist in totality

•Controlling function is being provided through stand alone controllers
and relay logic
•Trip and root cause analysis is not carried out in depth
•First Cause of trip can not be identified as there is no SOE system
•Protections are to be checked from source /Field

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and Protection Systemstitle style

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Control and Protection Systems

•Status of unit protections not known for boiler

•Furnace pressure protection is vital for boiler safety
•Use of Protection bypass and authorization register is must
•Total C&I system is obsolete in TPP and CPP. Needs replacement
• Option1: R&M of Total C&I system ( DCS)
•Option2: R&M of C&I part wise( Individual PLC/DCS). Not
economical ,Difficult to Maintain.

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Observations Master title style
& Recommendations

•Measurement of Oxygen in Flue gas is available for one side only

•Regular calibration is not evident
•Auto Calibration system to be made available
•Extra sample points are needed for offline sampling
•Standard cylinders for zero and span calibration are to be made available.
Gas filling may be done from standard vendors
•Offline flue gas analyzer may be procured
•Accurate Oxygen value using High Temp. Oxygen measurement
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Observations & Recommendations

•Flame scanners are to be installed for sensing flame stability and to ensure
boiler safety.
•ASLD can be installed to detect steam leakages very fast.
•SWAS system is not functional in unit-9. AMC with Service Providers
•Air conditioners are to be provided in SOX,NOX analyzer rooms
•Dew point measurement for Hydrogen gas and instrument air should be
measured.

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Best Practices Master title style
be followed

•Replacement of capacitors in Power supplies, UPS etc. in every O/H

•Replacement of Fuses in Protection circuits, Power supplies in every O/H
•Usage of pen drives/USB port to be stopped. For backup CD/DVD may be
used
•Antivirus may be used for the unit-9 DCS
•.All cable glands and un used holes in the panels are to be covered to
stop the entry of rats,lizards etc.

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Best Practices Master title style
be followed

•Avoid using gauge cum switches as their malfunction rate is very high
•Local gauges are to be maintained in good condition
•Resistance mapping of solenoids to be done to avoid any malfunction
•Meggering and replacement of weak cable in every overhaul
•AMC with SWAS supplier/ Service providers
• All the oil hoses of hydraulic Governing system shall be replaced in every
O/H
•Regular/ Refresher training on PLC,DCS, SWAS
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THANK YOU

NTPC Limited
( A Government of India Enterprise)
www.ntpc.co.in

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