13 February 2014

Integrating Plant Control Systems

with Business Applications

Confidential Slide

Index

2

About Reliance Power

Centralized Monitoring – the journey

Applications

Data Sources and IT systems

Integrated Visualization

Generation management and optimization

Predictive Diagnostics

Management Dashboards

Confidential Slide

Awarded Krishnapatnam

UMPP

(3,960 MW, imported coal)

Commissioned Rosa Stage 1

600 MW, Solar PV 40 MW

Formation of Reliance

Power

Launched India’s largest IPO

(Raised Rs 11,500 crore ie:

USD 2500 Mn)

Awarded Sasan UMPP

(3,960 MW, 707 MT coal)

Financial closure of Sasan

UMPP, largest project financed

debt in India (Rs 14,550 cr , ie:

USD 3200 Mn)

Awarded Tilaiya UMPP

(3,960 MW, 1,230 MT coal)

Won 3 out of 4 UMPPs

2006

2007

2008

2009

2005

2009

2010

2017

Reliance Power

Company with

largest coal

reserves in the

private sector in

India

Largest power

generation

portfolio under

development in

the private sector

in India

~25,000 MW

under

development

2011

2013

Commissioned

Rosa Stage II, 600 MW

Samalkot:2 Gas turbines

Commissioned

Buibori 600 MW,

Sasan Unit 2&3

3

Confidential Slide

Coal

Gas

Hydro

Butibori (600 MW)

Rosa (1,200 MW)

Tilaiya (3,960 MW)

Krishnapatnam (4,000 MW)

Chitrangi (3,960 MW)

Sasan (3,960 MW)

Goa (48 MW)

Kochi (165 MW)

Samalkot (220 +2,400 MW)

Urthing Sobla (400 MW)

Projects in Arunachal

Pradesh (4,220 MW)

Bharuch (4,000 MW)

Project phase Capacity

Operating phase 4193 MW

Construction

phase 6740 MW

Development

phase 12,580 MW

Total 23,513 MW

Reliance Power

Dahanu (500 MW)

4

Solar PV (40 MW)

Solar CSP (100 MW)

Satara /Vashpet (90 MW)

Aimangala / HD Pura (10 MW)

Solar

Wind

Confidential Slide 5

Centralized M&D – Why?

• Four plants at different locations

• 13 units getting operational in short span of time.

• Greenfield Projects

• New O&M team

Challenge was achieving sustained stable plant operations.

Confidential Slide 6

Centralized M&D – the Journey

To Monitor critical equipment to detect operational and

equipment problems early enough to mitigate damage

and manage the risk.

Objective of Fleet-wide Monitoring

Establish

Monitoring

Centre

Install

Historian

Condition

Monitoring

software

Remote

Vibration

Monitoring

Perf.

analyser &

optimizer

Business

analytics

Started in

2009

Headquarter OSI-PI / GE

Proficy

Smart signal FM / GE

Confidential Slide 7

PLANT HISTORIAN

DCS and SCADA

Performance

Monitoring &

Optimization

CONDITION

MONITORING Alarm

Management

Custom built applications

Business

Analytics and

Fleet wide

Optimization

Predictive

Analytics

Vibration

Analysis

Applications

EMS ABTGMS PLCs / Controllers

Confidential Slide 8

Site

Historian Interface

Historian server

LAN network

DCS Servers ABT GMS server Switchyard SAS

Historian Server

Clients

LAN network

Webserver

Firewall

Firewall

Clients Corporate

Switch

Typical Network

Business Application servers

Confidential Slide

9

SAP

FICO PM MM /QM SD HCM

WCM PS SRM

Website

KM Portal Mobile Accessibility

Dashboard

BI / BO

IT Systems - Enterprise

Operational

In - Process

BPC

Financial Performance Management Procurement & Inventory Management Project Management Maintenance (Preventive, predictive & breakdown) Sales & Accounting Business Planning & Consolidation Human Capital Management

Payroll E-Recruitment & Joining Performance Management E-Learning Employee Self service

Corporate Website

Knowledge Management & Internal Communications

Purchase Request Tracker

Role Based Dashboard

Performance Dashboard

Project Dashboard

Mobility for employee productivity

Mobility for operation & maintenance

Contract Management

PR Tracker Contract Management

Confidential Slide

PrAn – Smart Signal

Predictive Analytics

10

IVGI - Integrated Visualization

of Generation Information PADO

NPOC – National Power Operations Centre

Historian Application

GE Proficy & OSI PI

DCS

ABT GMS

Schneider

iMMS for Coal Mine

Modular

Alarm Management System

Honeywell

RVMS

FM,GE System1

EMS

Envision

Minex

IT Systems - Plant Optimization

Operational

In - Process

Future Plan

Distributed Control System Historian for plant monitoring Grid Frequency Management (ABT) Condition Monitoring , Alarm & Event Processing Integrated Mine Management Mine Planning (Minex)

Performance dashboard (IVGI) Energy Management System (EMS) Predictive Analysis – Smart Signal

Performance Analysis , Diagnostics &Optimization

Confidential Slide

11

EDMS

Enovia CMS- Legatrix

Primavera 3D AutoCAD, StaadPro CCTV Surveillance Systems

Mail &

Mobility

IT Systems – Back Office

Information Security

Operational

Electronic Document Management System Compliance Management System (Legal &

Statutory) Project Management Surveillance Email & Collaboration Design & Engineering Information Security Management

Data Leakage Prevention Antivirus

Confidential Slide 12

IVGI - Integrated Visualisation of Generation Information

GE RTIP with GE Proficy & OSI PI

IVGI – Integrated Visualization

Confidential Slide 13

IVGI Dashboards

Confidential Slide 14

IVGI Dashboards

Confidential Slide 15

IVGI Dashboards

Confidential Slide 16

Real time Generation Management

Confidential Slide 17

Predictive Analytics

• Equipment and process models are built based upon historical data (SBM - empirical correlation)

• The online data is continuously compared with model predicted values

• Deviation between model predicted and actual value indicates equipment health.

• Gradual equipment degradation is identified before the value reaching set alarm threshold

• Rule based diagnostic

It’s like having your best operator on 24/7, looking at every piece

of equipment in the fleet every five minutes

Confidential Slide

Predictive Analytics Catches LP Heaters extraction Pressure connected

wrongly

18

•

Predictive Analytics

Confidential Slide 19

96.8%

79.1% 78.8%

91.7%

86.6%

90.9%

75.8% 74.5%

80.7% 80.5%

50.0%

55.0%

60.0%

65.0%

70.0%

75.0%

80.0%

85.0%

90.0%

95.0%

100.0%

Q1 Q2 Q3 Q4 Annual

Availability PLF

5.88

6.23

7.41

Annual PLF Loss (Total Loss 19.53 %)

Forced Outage

Backing Down

Planned Outage

1,023

208 132

1,169

238 150

1,931

744

335

0

500

1,000

1,500

2,000

2,500

Revenue EBITDA PAT

FY11 FY11 adj FY12

Management Dashboards

Business

Analytics

Confidential Slide 20

Parameters

May- 12 – Station YTD -12-13 Station

Budgeted Actual Budgeted Actual

DC (%)

PLF (%)

Gross Gen. (MU)

Gross Heat Rate

(Kcal/KWh)

Aux Power (%)

Sp. Oil cons.(ml/KWH)

Sl

No Description

Annual

Budget May-12 YTD 2012-13

Budgeted Actual Budgeted Actual

1 Spares and Materials

2 Services and

Contracts

3 Employee Cost

4 Station Overheads

5 Insurance

6 Water

7 Chemical

8 Security

TOTALS Parameters Annual Bud

May 2012-13 YTD 12-13

Bud Act Bud Act

Fixed Charges

Energy Charges

Incentive

Other Income

Revenue

Fuel Cost

O&M Expenses

EBIDTA

Depreciation

Interest

PBT

Management Dashboards

Plant

Performance

Cost sheets

P & L

Improved

Decision

Making

Confidential Slide 21

Vibration

Diagnostics

Performance

monitoring &

Optimization

Expert Services

DSS for

Merchant sale

and Fleet wide

optimization

Condition

monitoring and

Early warning

The Cutting edge for Business Excellence

National Power

Operations

Centre

13 February 2014

Thank You