TÜV SÜD South Asia

Optimise plant performance with an integrated solution

Bratin Roy Vice President - Industry Service TÜV SÜD South Asia

CPP Integrated Solution Slide 1

Overview

TÜV SÜD South Asia

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Background

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Steps to provide integrated solution

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Benefit

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TÜV SÜD Group – Conventional Power Plant Solution CPP Integrated Solution Slide 2

Background

 In today’s changing environment, fossil-fuel plant owners face significant lifecycle management challenges  Along with existing issues like price pressures due to market liberalisation, new concerns of climate change and other environmental issues have further impacted the industry  Operation and maintenance cost reductions are needed along with performance improvements along the entire lifecycle  As a result, fossil fuel power plants need to be more flexible, reliable and efficient, while cutting emissions. In some countries, government has initiated fuel-saving or energy efficiency program, which constitutes further Market Based Instruments(MBI) for plant operators to improve efficiency and reduce their fuel consumption  In India, Govt. has already approved MBIs like PAT ( Performance, Achieve & Trade Scheme) TÜV SÜD South Asia CPP Integrated Solution Slide 3

Overview

TÜV SÜD South Asia

1

Background

2

Steps to provide Integrated solution

3

Benefit

4

TÜV SÜD Group – Conventional Power Plant Solution CPP Integrated Solution Slide 4

Steps to provide integrated solution

Taking an integrated approach from beginning delivers greater benefits than the traditional project stage specific approach Integrated solutions focus on operational and implementation synergies with due consideration of plant and market needs and demand, which often get missed in traditional component/ equipment specific approach        Condition Assessment Operation & Maintenance – status assessments Operation & Maintenance – in-service inspection Risk-based inspection and maintenance Performance Measurement Efficiency and reliability improvement solutions Integrated plant retrofits along with comprehensive Renovation & Modernisation Program TÜV SÜD South Asia CPP Integrated Solution Slide 5

Condition Assessment

TÜV SÜD South Asia

Condition Assessment

These evaluations focus on establishing the current condition of assets for more precise planning of refurbishment or optimisation.

    Condition assessments provide a comprehensive review of the status of all plant equipment Risk assessments review factors influencing the operational reliability of plant components and assist in planning of refurbishment activities Damage assessments are used after an incident to identify affected equipment and guide repair efforts Component assessments provide an up-to-date condition status of all components and systems CPP Integrated Solution Slide 6

Operation & Maintenance – status assessment

Plant status assessment

Modern maintenance and retrofit techniques

  Preventive and Predictive maintenance Condition-oriented maintenance – Inspection planning – NDT program – Monitoring methods – Calculation methods (e.g. fracture mechanics calc.) – Remaining life assessment – Repair/replacement of damaged components

Benefits

Full up time of the plant ensuring 100% productivity, avoiding unnecessary force shut down TÜV SÜD South Asia 13-01-31 CPP Integrated Solution Slide 7

Operation & Maintenance - in-service inspection

In-service inspection

Destructive Tests

     Metallographic Testing Creep/Stress Rupture Testing Measurement of Mechanical properties Microbiological analysis Metallurgical Chemistry Analysis

Non-destructive Tests Systems and equipment

           

VE LP MP UT

Visual Examination Liquid Penetrant Examination Magnetic Particle Examination Ultrasonic Examination

EC RX MR

Metallographic Replication MPI Material Positive Identification

HM

Eddy Current Examination Radiographic Examination Hardness Measurements

TD HV DM

Tan-Delta Test High Voltage Test Dimensional Examination/ Measurement           Review of operation and maintenance manual Review of records History of power plant Hot and Cold Walk-down inspection Civil, concrete and steel structures Boiler Balance of plant Generator, Transformers Turbine Motors, Switch Gear Panels, Circuit Breaker, Cables, UPS, Lightning, Switchyard, Control and Instrumentation TÜV SÜD South Asia 13-01-31 CPP Integrated Solution Slide 8

CPP solutions: Performance test for power plants and energy systems

Performance test for power plants and energy systems

Achieve guaranteed performance and maximise efficiency

    Independent assessment of technical condition of plant, e.g. at the end of O & M Contract; during operation before taking decision of retrofitting or renovation Identification of shortfall/deficiencies in the efficiency and capacity of plant Follow international practice and test procedure like ASME, VDI Assess results and prepared detail plan of implementation for technical mediation and moderation to attain maximum efficiency and reduce operation costs TÜV SÜD South Asia CPP Integrated Solution Slide 9

Risk-based inspection and maintenance

Risk-based inspection and maintenance

Achieve safe and cost-efficient operation of your power plants

 Our TÜV-RoiM strategy combines reliability and risk assessments with information extracted from expert judgment, physical models, and plant-specific and generic data  We base our qualitative and quantitative techniques on internationally accepted standards and guidelines, and tailor the solutions to your specific concerns TÜV SÜD South Asia 13-01-31 CPP Integrated Solution Slide 10

Energy Efficiency assessment

Energy efficiency, productivity, reliability and stability – are intimately connected.

Fact

 Around 70% of the world’s power plants use coal, natural gas, oil, biomass or solid waste to generate electrical energy.

 7 -15 % of the power generated at fossil-fuel plants is consumed by the plant’s auxiliary systems.

 Auxiliary systems are a major part of a power generation facility. They include all the drive power applications (pumps, fans, motors, drives), electrical balance of plant and instrumentation, control and optimization systems.

 Much of this energy could be saved or sold to generate higher plant revenues. By improving the efficiency of each auxiliary, energy consumption of an existing facility can be reduced by 10-30%

Procedures

 Combustion Control Optimisation Cooling System Heat Loss Recovery   Flue Gas Heat Recovery Low-Rank Coal Drying     Sootblower Optimisation Steam Turbine Design Review Condenser optimization Improvements and optimisation of other auxiliary systems

A successful energy efficiency program would require a detail technical and independent evaluation of power plant and related system evaluation, and a cost vs. benefit analysis to obtain reliable cost estimates for the options under consideration, taking into account site-specific conditions

TÜV SÜD South Asia CPP Integrated Solution Slide 11

Integrated Retrofitting

Integrated retrofitting

Optimise availability and reliability over the long term.

    Component/part retrofitting is not sufficient specially when ultimate goal is total asset optimisation and highest possible generation By organising, an integrated program that incorporates various upgrades across the plant, matching the capabilities of any combination of main components and associate parts it delivers maximum efficiency in most cost effective life extension solution With limited budget and timeline integrated retrofit solutions are a great way to explore hidden potential without the involvement of huge capital TÜV SÜD South Asia 13-01-31 CPP Integrated Solution Slide 12

Renovation & Modernisation

Every R & M project is unique, requiring adaptation and system expertise that depends on extensive experience.

Objective Methods Expected Goal

     Achieve rated output/higher than rated Output Better availability of generating equipment Improved performance / efficiency and life extension of unit Facilitate adoption of improved operations and maintenance practices.

Improvement in emission levels from thermal power plants          Review /Study of Design basics, Erection, first commissioning and O & M record/reports Energy Audit Performance testing Hot and cold walk-down survey of the plant Interaction with O & M staff Non-destructive tests (Mechanical tests and Electrical tests on critical components, Dynamic behavior tests) Evaluation and analysis of test results Preparation of R & M proposal & Cost benefit analysis   Life Extension for another 15 to 20 years is possible Increase of rated capacity 4% 8%  Increase of efficiency 8%-10% TÜV SÜD South Asia CPP Integrated Solution Slide 13

TÜV SÜD South Asia

1

Background

2

Steps to provide Integrated solution

3

Benefit

4

TÜV SÜD Group – Conventional Power Plant Solution CPP Integrated Solution Slide 14

Tangible benefits from integrated life cycle management

Maximum yield over the entire life cycle Lower costs, lesser risks Stable cash flow Designed performance Controlled risks CPP Integrated Solution Return of investment

Overview

TÜV SÜD South Asia

1

Background

2

Steps to provide Integrated solution

3

Benefit

4

TÜV SÜD Group – Conventional Power Plant Solution CPP Integrated Solution Slide 16

Our heritage: 146 years of business success

TÜV SÜD South Asia

1866 1910 1926 1958 1990s 2006 2009 Today

Establishment of a Mannheim-based steam boiler inspection association by 21 operators and owners of steam boilers, with the objective of protecting man, the environment and property against the risk emanating from a new and largely unknown form of technology First vehicle periodic technical inspection (PTI) Introduction of the “TÜV mark / stamp” in Germany Development of a Bavaria-wide network of vehicle inspection centres in the late 1950s Conglomeration of TÜVs from the southern part of Germany to form TÜV SÜD and the expansion of business operations into Asia Expansion of services in ASEAN by acquiring Singapore-based PSB Group Launch of Turkey-wide vehicle inspection by TÜVTURK TÜV SÜD continues to pursue a strategy of internationalisation and growth CPP Integrated Solution Slide 17

TÜV SÜD in numbers: Growing from strength to strength

1 150 800 1,900 20,200

One-stop Technical Solution Provider Years of Experience Locations Worldwide Million Euro in Sales Revenue 2013 Employees Worldwide Note: Figures have been rounded off. TÜV SÜD CPP Integrated Solution

Global expertise. Local experience.

Global Headquarters: Munich, Germany

Countries with TÜV SÜD offices Regional headquarters

GERMANY 1,190 € mio 10,400 staff INTERNATIONAL 750 € mio 9,800 staff

CPP Integrated Solution

Footprint in South Asia

TÜV SÜD South Asia  TÜV SÜD South Asia is a fully owned subsidiary of TÜV SÜD AG  Operating in India since 1995  Extensive network of over 32 offices including 14 labs across India, Bangladesh and Sri Lanka  Employee strength of over 1300  Over 12000 customers CPP Integrated Solution Slide 20

TÜV SÜD CPP Global Competency Centre - India

TÜV SÜD South Asia  TÜV SÜD’s Global Competence centre extends holistic advisory services to approach technical, regulatory, jurisdictional and economical viable measures for new and existing plant such as owners engineering in-service inspection / R&M / LE  The competence centre has highly trained and qualified team of experts, coordinated and managed from Munich, Germany  The competence centre has an international global approach, with local TÜV SÜD experts & expertise involved  The competence centre has an extensive international experience proved by the reference list, with similar jobs completed worldwide  Our empanelment by CEA as a consultant for preparation of DPR report for Renovation & Modernisation, will further assist us to deliver world class services to the industry CPP Integrated Solution Slide 21

Holistic solutions across the value chain

From feasibility and planning through to procurement, construction, commissioning, operation, maintenance, and decommissioning, TÜV SÜD conventional power services ensure improved operational safety, reliability and overall performance of power plants for investors, engineering, procurement and construction contractors and operators. 13-01-31 CPP Integrated Solution

Advisory services along the capital value chain

Feasibility & Planning

Technical due diligence

Feasibility study Risk analysis EIA

Licensing & consenting Tender & contract management Design review Design approval

Calculation Simulation

Site assessment

INVESTMENT OPERATION

Procurement

Owner’s engineer

Component certification

Code compliance

QA/QC

Welding surveillance NDT Construction supervision Expediting

Compliance certification

HSE inspections

Pre-qualification

Supplier evaluation Vendor quality assurance

Construction Commission Component certification

Final acceptance test

ISO 9001 ISO 14001 Claim management In-service Refurbishment & Decommission Plant status assessment

LTA F4S

Plant optimization

O & M management AIM / RBI

Technical advisor Rehabilitation/ modernization management

Repair supervision NDT

Failure analysis (RCFA) In-service inspection

Regulated Non-regulated

Efficiency consultancy

ISO 50001 IEE plant certification

Performance tests Noise / vibration / emissions testing

Due diligence (TDD - technical, EDD - environmental)

Staff training / qualification

TÜV SÜD South Asia CPP Integrated Solution Slide 23

Your Business Benefits: Maximise Profits

Increase availability, optimize performance

TÜV SÜD’s experts help you obtain professional advice in performance optimization to reduce outage time and increase your return on investment.

TÜV SÜD South Asia

Minimise risk, improve reliability

We help you to reduce the risk of conventional power plant incidents, enhance safety for people and the environment, increase process transparency and eliminate interface problems.

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Promote efficiency, reduce emissions

Our experts’ impartial perspective fosters cost efficiency in your organisation, while their comprehensive knowledge contributes to your emissions goals.

CPP Integrated Solution

Strengthen your competitive edge

Leverage on our expertise in safety and statutory compliance for legal certainty. Third-party certification by TÜV SÜD demonstrates your commitment to quality .

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TÜV SÜD South Asia CPP Integrated Solution

Contact us today.

www.tuv-sud.in

[email protected]

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