Prem Prakash Rai

Senior Manager – Control & Instrumentation

APCPL (NTPC JV)

Jhajjar, Haryana

03.2010 - Current

Led commissioning & maintenance of C&I systems for 3x500 MW units including Boiler, Turbine, FGD, NOx control, biomass co-firing. Systems include Pressure, Temperature, Flow, Level, CEMS analyzers, Oxygen, Large video screens, flame cameras, Vibration sensors, Regulating and ON/OFF type pneumatic and electric actuators, Electromatic relief valves, GPS systems, Commissioning and maintenance of instruments over modbus, foundation fieldbus, Profibus, Hart protocols.
Led team for commissioning of Distributed control systems, Station LAN network Layer-3 switches, IPS/IDS firewalls etc. Expertise in networking concepts and syslog, IPS/IDS configuration, CISCO, Fortinet, Brocade network switches, routers and firewalls.
Experienced in commissioning, configuration and maintenance of OSI Soft PI system, designing of PI process books, PI Builder and PI Datalink.
Experience in OPC DA, OPC UA and tunneller software configuration.
Successfully tuned closed-loop control systems to help units pass performance guarantee tests, with strong expertise in Coordinated Master Control (CMC) tuning to improve process stability and efficiency.
Pioneered logic development for biomass pellet firing integration; adopted as NTPC-wide standard.
Designed and implemented the signal interfacing of retrofitting projects like FGD, DeNOx system, Cooling tower performance monitoring system to existing DCS systems.
Member of root cause analysis team for unit trips, also acted as external member of technical enquiry committee for unit outage.
Executed full HMI upgrade from Centum CS3000 to Centum VP including engineering, FAT, Commissioning & PG test; created SOPs for NTPC fleet. Upgraded maxDNA DCS HMI system.
Achieved 7+ years without C&I-related forced outages; led closed-loop tuning for 100% auto control.
Designed in-house online shift log and WO management systems, improving team productivity by 30%.
Site OT Cybersecurity Coordinator; ensured compliance to statutory requirements of OT system VA/PT audits and resolved audit findings.
Successfully led multiple unit overhauls with strong planning and execution skills, including implementation of innovative modifications for performance improvement.
Proactively manage spare parts planning and procurement for unit operations and overhauls, ensuring zero downtime due to material shortages; also lead maintenance contract lifecycle including initiation, execution, and payment processing.
Experienced in SAP Material Management & Plant maintenance modules.
Handling a team of 25 supervisors for routine preventive and breakdown maintenance. Coordinating and scheduling maintenance activities for Boiler C&I, DCS systems and OT networks to minimize downtime and to ensure smooth operation.
Implemented and developed operational standards, policies and procedures.

Similar Profiles

MD SHAHNAWAZ ANSARIMD SHAHNAWAZ ANSARI

Executive Engineer in Electrical Maintenance Department at Power Generation Company APCPL/NTPCExecutive Engineer in Electrical Maintenance Department at Power Generation Company APCPL/NTPC

Rohit ChoudharyRohit Choudhary

Engineer (Safety) at Utility Powertech limited (JV of Reliance infra and NTPC)Engineer (Safety) at Utility Powertech limited (JV of Reliance infra and NTPC)