Microsoft PowerPoint - Cost-Effective Reliab

IMPLEMENTED INNOVATION Cost-Effective Reliability Enhancement through In-House Installation of Additional Seal Oil Pump A case study of innovation through self-reliance and engineering excellence Innovation through self-reliance.

2 Existing System Overview 1/2.

3 Existing System Overview 2/2 NE BUS A NE BUS B Backup DG set Seal oil to Generator AC Seal oil pump unit DC Seal oil pump unit Start command to DC pump DC BUS.

Problem Statement Our units are equipped with hydrogen-cooled generators that depend on a seal oil system for safe and efficient handling of hydrogen gas. The system lacks redundancy for the AC seal oil pump, leading to significant operational challenges. Seal Oil System Configuration MSOP Main Seal Oil Pump AC Driven ESOP Emergency Seal Oil Pump DC Driven Generator Hydrogen Cooled Single-Point Failure Risk System relies on only one AC-driven Main Seal Oil Pump (MSOP) for normal operation No redundancy means any MSOP failure immediately compromises generator safety Forced to use DC-driven ESOP for safe shutdown rather than continued generation Generation Loss Forced outages result in significant loss of generation hours and revenue impact Revenue Impact Unplanned shutdowns translate to direct financial loss and additional emergency costs Operational Inefficiency Limited flexibility during equipment failure and higher operational risk during peak demand.

Solution Approach To enhance operational reliability and flexibility of hydrogen-cooled generators, we proposed an in-house installation of an additional AC seal oil pump with auto-changeover capability, eliminating single-point failure risks and preventing unplanned outages. Proposed Redundant Seal Oil System MSOP Main Seal Oil Pump AC Driven ASOP Additional Seal Oil Pump Standby AC Pump Auto Changeover Automatic switching Redundancy Generator Hydrogen Cooled Solution Components Install additional AC-driven seal oil pump (Standby MSOP) in parallel with existing MSOP Configure system for auto-changeover between pumps in case of failure Ensure both pumps are sized for full load operation Introduce predictive maintenance tools for periodic health checks Enhanced Reliability Ensures 100% reliability of generator seal oil system Prevent Forced Outages Auto-changeover prevents unplanned outages due to MSOP failure Cost Optimization Reduces dependency on foreign OEM and lowers implementation costs.

Management Approval for implementation 6.

Implementation Strategy Our multi-phase approach ensured successful in-house implementation of the additional seal oil pump with minimal operational impact. Engineering & Design System study and capacity calculation Design drawings for pump selection, piping layout Electrical connections & control logic Bill of Materials (BOM) preparation Fabrication & Installation Systems preparation without requiring system outage Schedule installation during planned outage Pump foundation creation Pipe laying, valve fixing, and connections Control System Integration Multi DCS logic for auto changeover Addition of pressure transmitters Logic simulation before live implementation New alarms for system redundancy monitoring Electrical & Testing Identifying electrical power source Preparing hard wired electrical diagrams Conduct functional tests under various conditions Document commissioning results and update SOPs Implementation Timeline 01 Apr 24 Brainstorming 01 May 24 In-house Installation 01-10 May 24 Trail & Commissioning 31 Dec 2024 Installation Complete.

Technical Innovation Development of multi-DCS logic for seamless integration of Toshiba & Invensys platforms, enabling in-house control system innovation. Toshiba DCS Primary control logic Main drive control Signal Exchange Unified Logic Philosophy Invensys DCS Auxiliary drive support Auto-changeover functionality Custom Logic Development In-house logic for drive sequencing and synchronization Hardware Integration Signal exchange at electrical breaker end Cost Optimization Reduced vendor dependency.

9 Existing System with Additional Pump NE BUS A NE BUS B Backup DG set Seal oil to Generator AC Seal oil pump unit DC Seal oil pump unit Start command to Additional pump Additional Seal oil pump unit Start command to DC pump DC BUS.

Trail and Commissioning 10.

Key Challenges and Solutions Integration Challenges Existing hydrogen-cooled generator not designed for redundancy Risk of incorrect logic impacting generator safety Solutions Implemented Detailed system studies and drawing reviews Hydraulic calculations to ensure proper flow and pressure Control Logic Design System not designed for automatic changeover, alarms, and interlocks Need to maintain original safety philosophy Solutions Implemented Designed and simulated logic in stages Interlock checks for fail-safe operation Electrical Integration Limited space and coordination with existing protections Motor protection coordination within existing system Solutions Implemented Redesigned cable routing Coordinated motor protections.

Project Outcomes Operational Reliability Eliminated single-point failure in seal oil system Auto-changeover logic ensures uninterrupted operation Safety & Compliance Enhanced safety for hydrogen-cooled generators Reduced risk of hydrogen leakage incidents Cost Savings Avoided generation loss worth ₹1.8 Crore Saved startup resources worth ₹1.2 Crore Knowledge & Capability Strengthened internal engineering expertise Developed in-house capability for reliability projects.

Financial Impact The in-house implementation of the Additional Seal Oil Pump project has delivered significant financial benefits compared to the OEM approach. Cost Comparison: In-house vs OEM Total Cost Savings: ₹13.05 Crore Project Cost: ₹1.25 Crore (In-house) vs ₹10.05 Crore (OEM) Generation Loss Saved: ₹1.8 Crore Start-up Resources Saved: ₹1.2 Crore Additional Savings: Reduced maintenance costs and improved plant availability Direct Cost Savings Lower project cost by utilizing internal teams and avoiding external contractor overheads Revenue Impact Avoided generation loss worth ₹1.8 Crore and start up resources worth 1.2 Crore Long-term Benefits Enhanced plant reliability and reduced operational risk during peak demand periods.

Success Story Challenge A fault occurred on the NE bus, making it unavailable. The Main Seal Oil Pump (MSOP) was powered from this bus, so its supply was lost. NE Bus Fault MSOP Power Loss Auto Switchover Seamless Operation Innovation in Action The newly installed additional AC Seal Oil Pump automatically came into service Integrated control logic ensured seamless operation without manual intervention The generator continued running despite NE bus unavailability Prevented Emergency Shutdown Avoided emergency hydrogen purging and complete generator shutdown Saved Generation Loss Prevented generation loss and costly restart resources Time & Resource Savings Saved time and resources for hydrogen filling and machine startup.

Achievements and Recognition Our innovation in seal oil system reliability has been recognized for its excellence and impact. Gold Award Ahmedabad QC Chapter Recognition for innovation excellence Implementation of cost-effective solution Demonstrated reliability improvements Excellence Award NCQC Delhi Project implementation excellence Innovation through self-reliance Demonstrated financial impact Recognition Highlights Innovation Excellence Recognized for creative approach to reliability enhancement Self-Reliance Celebrated for in-house implementation without OEM support Financial Impact Acknowledeged for cost-effective solution with significant ROI.

16 Thank You! Website: www.tatapower.com.