The power industry is undergoing fundamental changes involving deÂcarÂbonisation, decentralisation and digitalisation, enabled by the integration of information technology (IT) with opÂerational technology (OT) alongside data analytics. Power plants are being diÂÂgiÂtalised with the aim to create an ecoÂsysÂtem with improved monitoring, anaÂlysis and prediction of plant operations. DigiÂtalisation optimises power plÂant opÂeraÂtions and maintenance (O&M), incÂreases safety and reliability, and reduÂces unexpected failure, thereby leading to operational excellence.
With digitalisation, the operating model of a genco becomes highly connected thÂÂrough sensors and smart devices. InÂternet of things (IoT) provides the building blocks of a digital plant, allowing collection, transmission, analysis and management of operations, processes and asset data. Advanced analytics, added to big data, provides tools to better anaÂlyse plant performance and help developers make informed decisions. Real-time visÂibility of demand/supply, coal cost and quality, and operating parameters ensurÂes fleet-wise despatch optimisation.
Due to the variable nature of renewable energy projects, power plants need to adopt flexibilisation measures. RenewÂable energy integration into the grid leads to lower plant load factors. There is thus a need to balance the grid. Digital solutions for advanced process control including combustion optimisation, temperature control, ramp rate improÂveÂment, frequÂency control and soot blowÂing optimisation; condition monitoring solutions such as boiler fatigue monitoring and turÂbine life monitoring; and frequency support through condensate throttling and automatic generation control are useful in maintaining power plant performance under flexible operations.
Apart from this, digital power plant solutions optimise O&M. Sensors, inÂdÂustrial IoT (IIoT) and other digital solutions can be used to obtain data on plant perforÂmÂaÂnÂce for condition monitoring, predictive asset analytics and asset performaÂnÂce maÂnaÂgement (APM). This allows deÂveÂloÂpÂers to maximise reÂtuÂrns on assets and inÂÂcÂreases their longevity and performance.
Powerful new technologies that are being adopted include low-cost sensors, analytics, IoT, the cloud, machine learning (ML) and artificial intelligence (AI). The use of ML, AI and reliability-centred maÂintenance (RCM) can improve the reliability of power plants by providing plant performance insights. Augmented reality (AR) and virtual reality (VR) are being deployed by power plant developers for employee/field staff training as well as virtual site visits. With the emerÂging digital twin technology, power generators can use simulation and modelling systeÂms to prevent outages and optimise daily power production. This tech allows deÂtailed modelling of burners and coal particle combustion, and analysis of oxygen concentration on the walls in a thermal power plant. Apart from this, digital technologies such as drones, 3D profiling and automated sprinklers are being used for stockyard management. Robotics is beÂing deployed for maintenance and insÂpection purposes.
Digitalisation initiatives by key gencos
NTPC Limited is implementing a digital strategy roadmap for generation performance optimisation and improved powÂer plant management. It has undertaken advance process control (for enabling flexible operation) and advancÂed monitoring of stockyard (for hotspot detection and 3D profiling of stockpiles) as a pilot project, and is now expanding it to other units. To enhance reliability of eqÂuipÂment and processes, the company is also undertaking initiatives for advanÂcÂed performance management (maintenÂanÂce optimisation suite), application of IIoT and asset information management (digital twin with life cycle documentation). The other digitalisation initiatives of the company include a water dashboard for real-time monitoring of water consumption at power plants; a centraÂlised system for monitoring of all renewable energy assets; adoption of robotic process autoÂmation, AI and ML in business processes; the strategic inÂformaÂtion management system; and an analytics platform for top management.
For capacity building of operating personnel, NTPC has completed a pilot AR/VR-based training project, and turbine training modules are under implementation. The company is developing full-fledged replica simulators for all available combinations of steam generator and turbine generator sets of supercritical units. A technology-intensive seÂcurity system with centralised control and multiple layers of security is being envisaged to replace manpower-intensive manual security. To this end, a pilot project has been completed at the Dadri station, and it is now being implemented at the company’s other projects.
Tata Power has undertaken maintenanÂce optimisation under the RCM approaÂch and APM analytics at Trombay. The company has recorded reduced oil waÂste generation through the RCM proÂcess and condition monitoring, alÂong with the use of additives and offline filtration to maintain oil quality at its JojoÂbeÂra poÂwÂer plant. The company is imÂpleÂmenÂting a host of other digital initiatives to enhance operational efficiency, including complete life cycle management of coal supply chain processes through the deployment of IT analytical applicatiÂons, improved IT-OT integration by enhancing the perimeter firewall under a unified PI project at all generation plÂants, and an automated asset maÂnageÂment process to achieve 95 per cent asÂset accuracy with digitalised assets.
Adani Power has been investing in cutting-edge technologies to enhance output and productivity, and strengthen its competitiveness. At Udupi, the company has initiated robotic desilting of the seawater intake pipeline. It is also setting up an Analytics Centre of ExcelleÂnÂce to enÂhance plant performance by leÂveÂraging digital transformation and analytics. The centre will strengthen goÂvernance throuÂgh its APM initiatives to improve asset reÂliability, availability and performance, implement RCM, optimise O&M costs, and imÂplement predictive analytics and earÂly warning systems to reduce forced outage and unÂplanned downtime.
Sembcorp Energy India Limited has unÂdertaken digital initiatives at its thermal power plants (TPPs) in Andhra PraÂdesh with a total capacity of 2,640 MW. It has adopted the use of drones for coal inÂvenÂtory management. PhotograÂmÂÂmetry software is used to generate a high resolution map, integrating point cloud and 3D modelling. This digital intervention has reduced inspection time, outage time and O&M cost.
Nabha Power Limited has undertaken digital initiatives at its 1,400 MW TPP in Punjab. It has implemented enÂterprise reÂÂsource planning (ERP) besides carrying out certain non-ERP enhancements (daÂshboards for O&M, commercial purposes, fuel sourcing, materials manageÂmeÂnt and procurement, finanÂce, and human reÂsource functions) and deploying analyÂtics-based solutions. It plans to use cognÂitive technologies such as AI, ML, IoT and robotic automation in plaÂnt processes.
Conclusion and way forward
Overall, the digitalisation of a power plaÂnt requires a defined roadmap and an imÂplementation strategy. Cost-benefit anaÂlyÂsis, manpower training (for the adoÂption of technology), undertaking well-deÂÂfined change management and strengÂthening the cybersecurity framework are necessary for successfully undertaking this transformational project.