A Presentation On

Industrial Training
At

Projects India Limited

Maneja , Vadodara ,Gujarat
 Company Profile
 Global Leader In Power Generation and Rail transport
 World Leader in Hydroelectric Power Generation
 Listed In Paris Stock Exchange having Annual Sales of 17 billion
Euros , employees 76000 people in 70 countries.
 Engineered and built World’s Fastest Train and The World’s Highest
Capacity Automatic Metro
 Producer Of Very High Speed Trains AGV ,TGV and EUROSTAR as
well as CITADIS trams.
 Also present in Urban Transport Market, Regional Train Models and so
many associated services.
 In Power Generation , associated with manufacturing of :
 Boilers
 Steam Turbines and Gas Turbines
Turbo Generators and Hydro Generators
Air Quality Control Systems
Monitoring and Control Systems For Power Plants
In Rail Transport : -
Rail Vehicles
Rail Infrastructure
Turnkey Systems
 Services
ALSTOM PRODUCTS
 ALSTOM Projects India Ltd.
Legal Entity in India , Listed at Bombay Stock Exchange.
Turnover of around 1596crore and employees about 4000
people all over India.
APIL has its Offices at : -
New Delhi :- Corporate Office , Turbo Machinery Group ,
Power Services , Plant Business ,Transport
Vadodara :- Hydro Business, Research & Development ,
Power services Workshop , Plant Hub & Power services.
Kolkata :- ECS and Power Service Office at Salt Lake.
Durgapur :- Manufacturing Unit for Boilers
Shahabad :- Manufacturing Unit for Boilers
Coimbatore :- Manufacturing Unit for Boilers
ALSTOM Vadodara Plant Overview
 ALSTOM Vadodara Plant Overview

From 2004 as an Autonomous Project Execution

and Manufacturing Facility.
Objectives :---
1. to participate in the expansion of the Indian
domestic market for Hydro Power.
[Link] execute export hydro projects from India, as
leader or partner of other ALSTOM Units.
 Various Departments
Industrial Sourcing Deptt.
Design Deptt.
Planning Deptt.
Industrial Engineering Deptt.
Manufacturing Deptt.
Inspection & Quality Control Deptt.
Store Deptt.
Maintenance Deptt.
Research & Development Deptt.
Human Resource Deptt.
 Lean Manufacturing

. Manufacturing Practice being used by

many companies
. considers the expenditure of resources for
any goal other than the creation of value
for the end customer to be wasteful
. Variation on the theme of efficiency based on
optimizing flow
. Increasing Efficiency
. Decreasing Waste
. First Implemented by Toyota in 1960s
3 Major types of waste of any company by TOYOTA:-
MURI (Overburden)
MURA (Unevenness )
MUDA (Wasteful Activity)
General 7 types of wastes are in Lean Manufacturing :-
TIMWOOD
T:- Transportation
I:- Inventory
M:- Motion
W:- Wait
O:-Over-Processing
O:-Over-Production
D:- Defect
 Methods to Reduce or eliminate waste
5 S Concept(Seiri, Seiton, Seiso, Seiketsu and
Shitsuke)
5 Japanese words start with “S” which mean :- ( Sorting ,
Setting in order , Shine , Standardizing , Sustain)

Total Productive Maintenance (TPM)

KANBAN (Lean, Just In Time {JIT} Production)
Continuous Improvement
 Kanban Method

[Link] from Japanese word

“Katanaka” means SignBoards
or BilliBoards.

[Link] Boards to track the

Progress of workstation ,
need of any item , work
completed everything is
check by cards only…
 Some Projects At ALSTOM
Bujagali
NamNgum
Wimalasurendra
Subansiri
Chamera
Uri
Chuzachen
 Alqueva
 Major Components Of Hydro Electric Projects
River Diversion Structures
Dam
Spillway
Desilting Arrangements
Power Intake Structures
Headrace Tunnel/Channel
Surge shaft
Penstock
Powerhouse
Trailrace Tunnel/channel
Hydro mechanical works such as Gates, hydraulic hoists
Electromechanical works
Switchyard works
View of Hydro Power Station
 Control Systems


In Control SCADA ( Supervisory Control And Data Acquisition)
system
4 control and monitoring systems are defined
Due to Interlock mechanism only one control level become active at each time


LEVEL O :- Drive Control Panel

LEVEL 1 :- Local Control Panel

LEVEL 2 :- Central Control Room Level

LEVEL 3 :- Remote Supervision Level


 Level 0 :- Drive Control Level

Local Control
Equipments Operated from Local Control Cubicle ,
Motor Control Center(MCC) , Switchboards etc,
Individually and Manually Controlling of Equipments
Only Electrical Protections will remain active for Speedy
Detection and Isolation Of Faults.
 Level 1 :- Local Control Level

Local level Control board (LCB)

LCB Controlled through Local Human Machine
Interface (HMI) & Automation Cell.
Local HMI has access to all information about the
process
HMI Selection from LCB then Commands from control
room is inhibited
All Interlocks and Protections will remain active for this
level.
 Level 2 :- Central Control Room Level
Normal Operating Level
Remote Control and Monitoring Operations for Whole
Power Station provided from Central Control Room.
Individual Control Mode:- Set Up for Active and Reactive
Power
Monitoring/Automatic Control Mode :- Manage the
operation of plant form the software
Used for Data management, Data logging, Trending,
Function Curves , Alarm Management
All Interlocks and Protections will remain active for this
level.
 Level 3 :- Remote Supervision Level
Remote Supervision Level
Used for Monitoring of a power plant from load dispatch
center for energy networks global management
All Interlocks and Protections will remain active for this
level.
 DESCRIPTION CONTROL MONITORING
Unit generator Y Y
Unit excitation and voltage regulator Y Y

Governor OPU Y Y
Brg. Oil OPU Y Y
Various Unit turbine Y Y

Equipments GSU transformers Y Y

Station auxiliary transformer Y Y
with their
Status Unit protection system N Y
Bus bar and bus coupler protection N Y
system

N Y
Line protection

Neutral grounding transformer N Y

Fire detection system N Y

Fire protection system Y Y
HVAC N Y
220 VDC distribution system N Y

48 VDC distribution syste N Y

415 VAC distribution system (RB, Y Y
SAB)

415 VAC distribution system Y Y

(UAB)

Diesel generator sets Y Y

Inverter distribution system N Y

HP compressed air system Y Y

LP compressed air system N Y

ST Y Y

Drainage and dewatering system Y Y

Cooling water system Y Y

Intake gates N Y

Draft tube gates N Y

Tail race water level Y Y

Switchyard unit bay Y Y

Switchyard line bay Y Y

Bus PT Y Y
Heating , Ventilation and Air
Conditioning System
(HVAC System)
 Some Turbines used in Hydro Power Plant

Pelton Turbine Fransis Runner

 Presented By :-
Vishvendra Singh
[Link] (Final Year)
Deptt. Of ECE
MNIT , JAIPUR
2007UEC165