Presentation SMCCS NRHQ

7/31/2019 Presentation SMCCS NRHQ

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Materials Classification

Codification andStandardization (SMCCS)

By:

C. Ballabh (IT & MS Deptt., CC)


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OBJECTIVE OF THEPROJECT

1. Unique item code for easy identification.

2. To establish commonality for criticalitems located at various stations foroptimal resource utilizations.

3. Standardization & Varity reduction.

4. Ease of retrieval & storage.5. To evolve common description/language.


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Carried out Initial Study

MATERIAL CODE STRUCTURE

NTPC- 10 DIGITS KARDEX

1 2 3 4 5 6 7 8 9 10

1,2 - Main Group

3,4 - Sub-group

5,6 - SUB- System

7,8,9- Serial No.

10- Check Digits

For equipment

spares.


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Material Code Structure And

Codification Schemes

STATUS OF MATERIAL CODIFICATIONSCHEME

TOTAL NO. OF SCHEME (INCLUDING 660 MW TG,SG AND HYDRO POWER PROJECTS): 65


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Break up of Codification Schemes.DESCRIPTION MAIN

GROUP

NO. OF

SCHEMES

DETAILS

Primary Materials 01-05 5 Ferrous, non ferrous and packing material

Chemical and oils 07,10,11 3 Paints, Chemicals, Fuels and Lubricant

Medicines andAllied

13 1 Medicines & Surgical Instruments

MachineElements

15-24 10 Fasteners, Pipes, Bearings ,Tools, ElectrodesBuilding Material And power TransmissionsEquipments

Laboratory items 26 1 Lab apparatus & measuring instruments

Furniture 27 1 Table, chair Etc

Stationery items 28 1 Office Stationery

CSR, Welfare,Corporate gifts

29 1


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ContinuedRotating equipments 31,32,34,35 4 Pumps, Blowers, Fans (industrials)

SG and TG 660 MW 43,44 2 TG, SG

SG 45,46,47 3 100,200,500MW

TG and GTG 49,50,51,52 4

Aux. system spares 53-59 7 CHP, AHP, WTP, CW, Hydrogen generationplant

Supporting Systems 62,63,65,66,68 5 Auto base, workshop, AC, Lifting & materialhandling & fire fitting system

MGR System 70,71,74,75 4 Engines, Locomotives wagons & rail trackssystem

Hydro powerprojects

76 1

Electrical items 81,82,83,85,86,

87,90,92,94,95,

96,97,98

12 Cables, fittings, components, motors, switchgears, relays, DAS, communication, computers& control instruments,Simulator


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Appointment Of Consultant

1. An award for consultancy services forimplementation of MCCS at

RSTPP,FGPP,KOLDAM & CC was placed onM/S system incorporates Kolkata on 1stDec.2006 for pilot Projects

2. Subsequent order for remaining 19 Projectswas placed on the same consultant vide LOAdated 24.08.07. LOI was released on 12th June2007.


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Salient feature of scope of work1. Material and services codification at the above locations

2. Finalization of material service codification schemes afterdiscussion with users.

3. Standardization of material description

4. To create short description in 40 characters in addition to longdescription

5. Cleaning of data and identification of duplicate codes

6. To provide web based package and templates for generatingmaterial and service codes and integrate with SAP ERP systems

7. To maintain link table of old and new codes.


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MCCS Issues & Restraints Diversity & complexity of equipment

procurement. Inadequate attention on spares tech,

specification during initial procurement.

Supplier reluctance to furnish tech information /

specification. Perception mismatch between end users and

material managers.

Subsequent procurement difficulty due to nonavailability of tech information.

Lack of adequate guide line on tech descriptionof spare parts.

Technological Development.


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Inventory Composition inThermal Power Plant

i. Primary Materials

ii. Chemicals and Oils

iii. Healthcare Items

iv. M/C Elements andH/W

v. General Items

vi. Rotating and StaticEquipment

vii. Aux. System SupportSpares

viii. Electrical/Electronics

ix. C&I, DAS, Computer& Communication

items

3%2%2%

17%

10%

15%11%

21%

19%1

2

3

4

5

6

7

8

9

FIGURE INDICATED IS %AGE POPULATION OFTOTAL INVENTORY


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SPARES OUT OF TOTAL

INVENTORY

CONSTRUCTION INV

12%

SPA RES INV

80%

OTHERS

8%

CONSTRUCTION INV SPARES INV OTHERS


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Constraints at ProjectsExecuted

1. High volume of work with large variety of items frommulti source of supply.

2. Retrieval of technical information at old Power Stationis difficult.

3. Retrieval of technical information of various items is acumbersome and time consuming process

4. Inadequate deployment of man power by theconsultant

5. Dedicated services of users are required6. Difficult to retrieve technical information for absolute

items.


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UNIQUE CODIFICATION OF NEW 500 MWUNITS

1. PROPOSED CODIFICATION AT TALCHER, SIMHADRI,

SIPAT, RIHAND, RAMAGUNDAM AND VINDHYACHAL

2. ALL THE UNITS ARE BEING SUPPLIED BY BHEL

3. APPROVAL TAKEN FOR COMMON CODIFICATION OF

ITEMS IN THESE PROJECTS

4. INDENTIFICATION OF SPARES FOR TG & SG HAS BEEN

COMPLETED.5. MEETING TO BE HELD WITH BHEL ON RECEIPT OF

DETAILS FROM SITES


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Common Interchangeable Spares for TG & Auxilieries for 500 MWUnits Supplied by BHEL

S. No Common Code Item Description BHEL Code Common At

1 LP SHAFT 0103010200000 00 R4, V7

2 LP SHAFT 0103014100000 00 R7, Rh3, Rh4, Sm1, Sp4, Sp5,

3 LP ROTOR BLADING-FORGEDBLADES

0103070500000 00 R4, V7

4 LP ROTOR BLADING-MODULESTAGES

0103074100000 00 R7, Rh3, Rh4, Sm1, Sp4, Sp5,

5 HP CASING ASSEMBLY 0105010900000 00 R7, Rh3, Rh4, Sm1, Sp4, Sp5,

6 HP INNER CASING 0105020900000 00 R7, Rh3, Rh4, Sp4, Sp5, V10,V9

7 HP SHAFT SEALING FRONT 0105050900000 00 R7, Rh3, Rh4, Sp4, Sp5, V10,V9

8 HP SHAFT SEALING REAR 0105060900000 00 R7, Rh3, Rh4, Sp4, Sp5, V10,V9

9 IP CASING ASSEMBLY 0106012750000 00 R7, Rh3, Rh4, Sp4, Sp5, Tk3,

10 IP INNER CASING 0106022700000 00 R7, Rh3, Rh4, Sm1, Sp4, Sp5,

11 IP SHAFT SEALING 0106062700000 00 R7, Rh3, Rh4, Sm1, Sp4, Sp5,

12 IP INLET ASSLY. 0106122700000 00 R7, Rh3, Rh4, Sm1, Sp4, Sp5,

13 INNER CASING ASSLY LPC 0107430200000 00 R4, V7

14 EMERGENCY STOP VALVE 0112020500000 00 R7, Rh3, Rh4, Sm1, Sp4, Sp5,


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ANALYSIS OF PRESSURE PARTS FOR 500 MW NTPC UNITS

[BASED ON THE PRODUCT DRAWINGS]

Sl.No.

System Description

Simhadri 2X 500 MW;Cust nos:

0614 & 0615

Talcher 4 X500 MW;Cust nos:

0616 to0619

Ramagundam 1 X500MW;

Cust nos:0622

Rihand 2 X500 MW;Cust nos:

0620 & 0621

Vindhyachal 2 X 500

MW; Custnos: 0624 &

0625

Sipat 2 X500 MW;Cust nos:

0630 & 0631

1 Economiser VAR 01 VAR 02 VAR 03 VAR 04 VAR 05 VAR 03

2 LTSH VAR 01 VAR 02 VAR 03 VAR 03 VAR 04 VAR 03

3 LTSH Terminals VAR 01 VAR 02 VAR 03 VAR 03 VAR 04 VAR 03

4SH Div. PanalleteCoils

VAR 01 VAR 02 VAR 03 VAR 03 VAR 03 VAR 03

5 Platen SH Coils VAR 01 VAR 02 VAR 03 VAR 03 VAR 03 VAR 03

6 RH Front Coils VAR 01 VAR 02 VAR 03 VAR 03 VAR 04 VAR 04

7 RH Rear Coils VAR 01 VAR 02 VAR 03 VAR 03 VAR 04 VAR 04


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PRODUCT ENGINEERING (FB)/ BOILER MOUNTINGS

ANALYSIS ON BWCP

DataDescription

UnitSimhadri

2X500 MWTalcher

4X500 MWRamagundam

1x500 MWRihand

1x500 MWVindhyachal2x500 MW

Sipat2x500 MW

Design Pressure Kg/Cm2(g) 209 211 212 216 213.5 214

DesignTemperature 0C 368 369 370 370 370 370

Flow Per Pump M3/Hr 3018 3133 3019 3019 3021 2975

SuctionPressure Kg/Cm2 195.4 195.24 196.4 196.4 198 198.6

NPSH Required M 14 14 19 19 15 17

Pump Head M 32.3 31.1 31.05 30.17 29.91 31.35

Specific Gravity 0.545 0.565 0.565 0.582 0.588 0.561

Voltage Rating Kv 3.3 3.3 6.6 3.3 3.3 3.3

Power Rating Kw 354 354 350 350 350 365

Vendor M/s HT/UK M/s HT/UK M/s KSB M/s KSB M/s HT/UK M/s HT/UK

ModelPump

(2X13)X16X19H (2X13)X16X19HLUVAC 2X300-475/1 LUVAC 2X300-475/1

(2X13)X16X19M (2X13)X16X19M

Motor LUV 5/4 HQ 35-335 LUV 5/4 HQ 35-335


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Status Material Codification For ERPRoll out Projects

Name of

Project

Total No. Of

Items

Total No. Of

Stock Items

Total No. Of

Obsolete Items

Total No. Of

Items Codified

Responsibility

RAMAGUNDAM 72,000 53,600 5,500 53,600 Consultant

SIMHADRI 28,877 18,658 Nil 18,658 In House

KORBA 58,000 58,000 2,900 57,200 consultant

VINDHYACHAL 53,000 42,000 3,000 43,000 Consultant

SIPAT 16,249 2,882 Nil 15,609 In House

RGCCPP 15,890 14,600 311 15,890 In House

AURIYA 13,082 13,082 NA 13,082 Consultant

GANDHAR 17,700 16,100 NA 17,700 Consultant

KAWAS 15,528 14,088 NA 15,528 Consultant

ANTA 16,000 14,600 NA 16,000 ConsultantKOLDAM 2100 2100 NA 2100 Consultant

WR (HQ) 354 - - 354 Consultant

ER HQ) 184 - - 184 Consultant

NCR-CC-Hy.HQ

6,600 6,600 - 6,600 Consultant


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Status Material Codification For ERP


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Presentation SMCCS NRHQ

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