BTPS_-IT

NTPC Limited

BADARPUR THERMAL POWER STATION,

Training Project Report

SUBMITTED BY UNDER GUIDANCE OF

Mr. P. L. RAJANIDGM (IT)BTPS- NTPC LimitedBadarpur, New Delhi-110044.

ACKNOWLEDGEMENT

I have great pleasure in acknowledging the help from all those who

favored me with giving shape to the present project.

Heartiest Thanks goes to my Project leader and guide Mr. P. L. Rajani

DGM (IT) for his help and support throughout the project.

I wish to express my grateful thanks to Ms Rachna Singh Sr.

Manager, EDC, BTPS for permitting me to do this project in their

organization.

The perfection of a man lies on her depth of gratitude. It’s not

only my duty but a matter of joy and pleasure to once again convey my

thanks to all.

Date : Name:

NTPC Limited

BADARPUR THERMAL POWER STATION,

To Whomsoever it may concern

This is to certify that Mr./Ms. , student of

has undergone Industrial Training in NTPC, Badarpur Division during the period

--------------------and contributed his/her effort in doing project on

------------------------------------------------------ He/she has performed his task in stipulated time

during his training under our supervision and guidance. During this period we found him/her

sincere and hardworking.

We wish him/her all success in his/her future assignments.

Date :

Mr. P. L. RAJANIDGM (IT)NTPC Limited, BTPSBadarpur, New Delhi-110044.

ABOUT NTPC

NTPC Limited is the largest thermal power generating company of India. A public sector company, it was incorporated in the year 1975 to accelerate power development in the country as a wholly owned company of the Government of India. NTPC ranked 317 th in the ‘2009 Forbes Global 2000’ ranking of the world’s biggest companies. Within a span of 34 years, NTPC has emerged as a truly national power company, with power generating facilities in all the major regions of the country. With a current generating capacity of 30,644 MW, NTPC has embarked on plans to become a 75,000 MW company by 2017.

VISION & MISSION

As laid down by the NTPC foundation, it’s vision is “A world class integrated power major, powering India’s growth, with increasing global presence”.

The organization aims to accomplish the following mission:-“Develop and provide reliable power, related products and services at competitive prices, integrating multiple energy sources with innovative and eco-friendly technologies and contribute to society.”

ROLE IN NATION BUILDING

NTPC is the largest power generating entity in the country. Apart from power generation from coal and gas, it has also diversified into hydro power, coal mining, power equipment manufacturing, oil and gas exploration, consultancy in the area of power plant constructions and power generation, power trading and distribution in the form of joint ventures with various other entities in India and abroad.

POWER GENERATION

Currently NTPC owns 15 Coal Based Power Plants with a generating capacity of 24,395 MW, and 7 Gas/Liquid Fuel Based Power Plants with a generating capacity of 3,955 MW.Apart from this it has 4 other Coal and Gas Based Power Plants with power generating capacity of 2,294 MW as joint ventures with other organizations.

Regional spread of Generating Facilities

REGION COAL GAS TOTALNorthern 7,035 2,312 9,347

Western 6,360 1,293 7,653

Southern 3,600 350 3,950

Eastern 7,400 - 7,400

Joint Ventures 814 1,480 2,294TOTAL 25,209 5,435 30,644

Hydro Based Power Projects

NTPC has increased thrust on hydro development for a balanced portfolio for long term sustainability. The first step in this direction was taken by initiating investment in Koldam Hydro Electric Power Project (800 MW capacity) located on Satluj river in Bilaspur district of Himachal Pradesh. Two other hydro projects under construction are Tapovan Vishnugad (600 MW capacity) and Loharinag Pala (520 MW capacity) in Uttarakhand. On all these projects construction activities are in full swing.

Performance

In terms of operations, NTPC has always been considerably above the national average. The availability factor for coal based power stations has increased from 89.32% in 1998-99 to 92.47% in 2008-09, which compares favourably with international standards. The PLF has increased from 76.6% in 1998-99 to 91.14% during the year 2008-09.

Integrated IT Enablement of Business Processes for efficient plant management.

Information Any time, Any where.

IT ROLE & RESPONSIBILITIES @ BTPS

1.1. Development, Implementation & Support for Local Applications Development, Implementation & Support for Local Applications

2. Procurement & Maintenance of IT Infrastructure ( PCs, Printers, 2. Procurement & Maintenance of IT Infrastructure ( PCs, Printers, Servers & Network LAN,WAN etc)Servers & Network LAN,WAN etc)

3. Support to users for ERP & modules to supplement ERP. 3. Support to users for ERP & modules to supplement ERP.

4. Customization & Implementation support for BTPS Applications 4. Customization & Implementation support for BTPS Applications to other projects.to other projects.

I T Applications (BCOMIT) @ BTPS

Power Generation is a complex business. It involves operation and maintenance of more than 15,000 equipments. There are about 40,000 different materials and spares required for smooth operation of power plant apart from coal which is a major raw material, apart from Human Resources & Finance. In today’s, competitive environment, it is important to maintain high availability of the Power Plant at lower cost to survive and maintain profitability.

At BTPS, Information Technology has been used extensively for effective management of various business processes and resources.Major Innovation in this direction has been, in house Development & Implementation of an Integrated Suite of Online Applications BCOMIT on Oracle database, to manage following business processes;

1 Maintenance Management System 2 Materials Management System3 Financial Accounting System.4 Contracts Management System5 Operations & ABT Monitoring System6 Coal Monitoring & Accounting System.

7 Hospital Management System 8 HR, T/S & Training Management System 9 Office Automation & Communication System10 E-Samadhan complaints monitoring system

Some of the above applications replaced by ERP.

BCOMIT@BTPS Provides Online up to minute information and transaction ability, of all business processes, for efficient power plant management. It provides for Effective management of basic resources, i.e. Men, Machines, Materials & Money.

BTPS Applications BCOMIT Highlights

1 Single Login screen for all systems.2 Pass Word & Role based secured access. 3 G.U. Interface, Easy information retrieval & search facility.4 Information captured once at source. 5 Automation of routine activities. 6 Cost effective I T Infrastructure.7 Rapid response & change capability.8 Empowering People with decision support system.

Benefits of IT Innovations @ BTPS

1 OperationsImportant & critical parameters of Power Plant operation are monitored online to enable effective control on operation of various equipments and reduce down time. Online load analysis & Generation values are monitored to have optimum load balance of various units. Auxiliary power consumption monitored and controlled. Meritorial operation practicing enabled.

2 MaintenanceBetter control over maintenance cost by way of online information available through the system.Based on failure analysis and equipment history, modified maintenance strategy of Preventive, Predictive and Risk Based maintenance is implemented. Equipment spares planning are streamlined by way of Annual requirement, Vendor wise, linked to Equipment. Standardization of defects and repair codes for easy filling of Work Order Card, for future analysis.

3 MaterialsMaterial Planning and Procurement system streamlined, resulting in reduction in Administrative lead Time. Further, procurement on Annual Rate Contract basis enabled through the system. Ordering on actual need basis (just in time). This further reduces lead time and Inventory carrying.Detection of duplicate and obsolete items, standardization of material description and specification. Cleaning and Weeding of redundant data, resulting in overall system improvement and functionalities. Availability of coal stock status online, reduction in demurrages paid to railways.

4 Office Automation and Communication With implementation of e-Desk/e-broadcast, e-alerts, auto mail and BTPS website, information is available instantly to all and all time, resulting in tremendous reduction in paper communication and cost.

Concept to Implementation of IT Innovations @ BTPS

1. IT Infrastructure selectionAfter detail analysis and survey, Oracle 9i RDBMS on Intel Unix Platform with IDS as front end development tool was chosen, as it is latest and cost effective technology.

2. Application Development Design and development of New Applications, was taken up in house. This involved understanding various business processes, interaction with user groups of various department, defining computerization needs, development and trial of the applications, considering company policies and procedures.

3. Procurement of Hardware & Software.Intel LAN Server with Oracle 9i RDBMS software and Pentium IV Computers were procured and deployed in various departments of BTPS to provide appropriate IT Infrastructure. All PCs were connected in Plant wide Local area Network using cost effective technology.

4. Implementation of ApplicationsVarious Online Applications as mentioned above were developed tested and implemented in phased manner over a period of time. Any innovation involves major change over and disturbance during transition phase. This was managed with support of management, commitment and expertise of IT team and cooperation of users.

5. Training For effective implementation and utilization of new IT Applications, major thrust was given on training and retraining. Everybody from Operator to General Manager was covered. Young Computer Professionals were deployed for short period to provide on the table training to users on need basis to supplement IT department efforts.

6. Data MigrationData Migration from old legacy systems of various departments was a major exercise for effective implementation of new systems. Old historical data is valuable for reporting, analysis and decision support system. It was handled effectively by IT team in association with users.

Overview of Online Applications at BTPS

Maintenance Management system, Anurakshan @ BTPS1 Work Order Card registration for PM, BD & OH.2 Permit to Work Issue, Closure of WOC with detailed feedback.3 Daily Plant Meeting and CHP Meeting minutes generated online.4 Trends of defects priority wise /department wise for a period.5 Equipment history with detailed WOC feedback available.6 Analysis of repeated equipment failure for corrective action.7 Standardization of defects & repair codes.8 Interface with Materials Management System & CMS for WOC cost.

ABT & Operation Performance Monitoring System (With Frequency trend analysis)

Materials & Contract Management System (CMS)1 Initiation and approval of Contract Proposal.2 Preparation of Tender Documents and approvals.3 Bids Evaluation and preparation of CS.4 Issue of LOI, LOA and Approvals.

5 Preparation of MB and processing of Bills.

FINANANCIAL ACCOUNTING SYSTEM (FAS)1 Proactive Payroll Process. Transactions effect visible in provisional pay slip. 2 Status of Income Tax Details, PF slip, Leave, Accrued Interest, Earning Card available

online. 3 Fund Flow Statements & other Reports for day to day functioning. 4 Bank Reconciliation.5 Automatic maintenance of Trial Balance, GL, Sub ledgers and schedules from

vouchers.

Coal Accounting System (CAS)1 Online uploading of Wagon wise Weight from Wagon Tipplers.2 Linkage of Coal Bills to GRS Weight.3 Coal and Rail Freight bill payments accounting & reconciliation.4 Tariff Summary, coal accounting and MIS reports generated from the system.

REWARDS & RECOGNITION

Badarpur has achieved unique distinction of being, First site in NTPC, with independent initiative of Development & Implementation of new Oracle based integrated online Applications, with in house effort. This has been appreciated by NTPC higher management.

BTPS Received Golden Peacock award for IT Innovation in 2004.Adoption of Best Practices : BTPS IT strives to provide value added services and features thru best practices, to support management initiatives & users reqmt.

Conclusion: The BTPS IT has come a long way to leading position in IT enablement among NTPC power stations. IT Vision realized, making BTPS highly Information enabled Plant.

Success FactorIn house development using latest technology, effective change management, training & using synergized force of People of BTPS (Management, IT Team & Users).

Saga of IT Turnaround at BTPS

Realization of IT vision of making BTPS highly IT enabled Plant with Online up to date information and transaction ability.Cost effective I T Infrastructure.Adopting latest technology & skills.Developed by dedicated & motivated IT Team in house. Continuous learning thru training, workshops, Internet.Continuous improvements thru user feedback & Innovations. On the Desk User training from operator to senior executives.IT Evolution as People’s Movement.Synergized force of BTPS (Management, IT Team & Users ).Effective Change Management.User friendly Applications & Services. Achieving User satisfaction & affection.