Optimise plant

performance with an
integrated solution
Bratin Roy
Vice President - Industry Service
TÜV SÜD South Asia

TÜV SÜD South Asia CPP Integrated Solution Slide 1

Overview

1 Background

2 Steps to provide integrated solution

3 Benefit

TÜV SÜD Group – Conventional

4
Power Plant Solution

TÜV SÜD South Asia 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

1 Background

2 Steps to provide Integrated solution

3 Benefit

TÜV SÜD Group – Conventional

4
Power Plant Solution

TÜV SÜD South Asia 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

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

TÜV SÜD South Asia CPP Integrated Solution Slide 6

Operation & Maintenance – status assessment
Plant status assessment

Modern maintenance
Benefits
and retrofit techniques

 Preventive and Predictive maintenance

 Condition-oriented maintenance
– Inspection planning
– NDT program
– Monitoring methods Full up time of the plant ensuring 100%
productivity, avoiding unnecessary force shut
– Calculation methods (e.g. fracture down
mechanics calc.)
– Remaining life assessment
– Repair/replacement of damaged
components

TÜV SÜD South Asia 13-01-31 CPP Integrated Solution Slide 7

Operation & Maintenance - in-service inspection
In-service inspection

Destructive Tests Non-destructive Tests Systems and equipment

 Metallographic Testing  VE Visual Examination  Review of operation and maintenance

 Creep/Stress Rupture Testing  LP Liquid Penetrant Examination manual
 Measurement of Mechanical  MP Magnetic Particle Examination  Review of records
properties  UT Ultrasonic Examination  History of power plant
 Microbiological analysis  EC Eddy Current Examination  Hot and Cold Walk-down inspection
 Metallurgical Chemistry Analysis  RX Radiographic Examination  Civil, concrete and steel structures
 MR Metallographic Replication  Boiler
 MPI Material Positive Identification  Balance of plant
 HM Hardness Measurements  Generator, Transformers
 TD Tan-Delta Test  Turbine
 HV High Voltage Test  Motors, Switch Gear Panels, Circuit
 DM Dimensional Examination/ Breaker, Cables, UPS, Lightning,
Measurement 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  We base our qualitative and quantitative techniques
and risk assessments with information extracted on internationally accepted standards and
from expert judgment, physical models, and guidelines, and tailor the solutions to your specific
plant-specific and generic data 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 Procedures

 Around 70% of the world’s power plants use coal, Combustion Control Optimisation
natural gas, oil, biomass or solid waste to generate  Cooling System Heat Loss Recovery
electrical energy.  Flue Gas Heat Recovery
 Low-Rank Coal Drying
 7 -15 % of the power generated at fossil-fuel plants  Sootblower Optimisation
is consumed by the plant’s auxiliary systems.  Steam Turbine Design Review
 Condenser optimization
 Auxiliary systems are a major part of a power  Improvements and optimisation of other auxiliary
generation facility. They include all the drive power systems
applications (pumps, fans, motors, drives), electrical
balance of plant and instrumentation, control and A successful energy efficiency program would
optimization systems. require a detail technical and independent
evaluation of power plant and related system
 Much of this energy could be saved or sold to evaluation, and a cost vs. benefit analysis to obtain
generate higher plant revenues. By improving the reliable cost estimates for the options under
efficiency of each auxiliary, energy consumption of consideration, taking into account site-specific
an existing facility can be reduced by 10-30% 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,  Life Extension for another 15 to
Erection, first commissioning and 20 years is possible
O & M record/reports
 Energy Audit  Increase of rated capacity 4% -
 Performance testing 8%
 Hot and cold walk-down survey
of the plant  Increase of efficiency 8%-10%
 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

TÜV SÜD South Asia CPP Integrated Solution Slide 13

 1 Background

2 Steps to provide Integrated solution

3 Benefit

TÜV SÜD Group – Conventional

4
Power Plant Solution

TÜV SÜD South Asia CPP Integrated Solution Slide 14

Tangible benefits from integrated life cycle management

Maximum yield over

the entire life cycle Designed performance

Peace of Mind
Key Success
Factors

Lower costs, lesser risks Controlled risks

Stable cash flow Return of investment

CPP Integrated Solution

Overview

1 Background

2 Steps to provide Integrated solution

3 Benefit

TÜV SÜD Group – Conventional

4
Power Plant Solution

TÜV SÜD South Asia CPP Integrated Solution Slide 16

Our heritage: 146 years of business success

1866 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
1910 First vehicle periodic technical inspection (PTI)
1926 Introduction of the “TÜV mark / stamp” in Germany
1958 Development of a Bavaria-wide network of vehicle
inspection centres in the late 1950s
1990s Conglomeration of TÜVs from the southern part of
Germany to form TÜV SÜD and the expansion of
business operations into Asia
2006 Expansion of services in ASEAN by acquiring
Singapore-based PSB Group
2009 Launch of Turkey-wide vehicle inspection by
TÜVTURK
Today TÜV SÜD continues to pursue a strategy of
internationalisation and growth
TÜV SÜD South Asia CPP Integrated Solution Slide 17
TÜV SÜD in numbers: Growing from strength to strength

1 One-stop Technical
Solution Provider

150 Years of Experience

800 Locations Worldwide

1,900 Million Euro in Sales

Revenue 2013

20,200 Employees Worldwide

Note: Figures have been rounded off.

TÜV SÜD CPP Integrated Solution

Global expertise. Local experience.

Global Headquarters:
Munich, Germany

GERMANY INTERNATIONAL

Countries with TÜV SÜD offices 1,190 € mio 750 € mio

Regional headquarters
10,400 staff 9,800 staff

CPP Integrated Solution

Footprint in 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

TÜV SÜD South Asia CPP Integrated Solution Slide 20

TÜV SÜD CPP Global Competency Centre - India

 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

TÜV SÜD South Asia 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

INVESTMENT OPERATION

Feasibility & Refurbishment &

Procurement Construction Commission In-service
Planning Decommission

Owner’s engineer Technical advisor

Plant status Rehabilitation/

Technical due diligence QA/QC modernization
assessment management
Feasibility Repair
Component Code Welding Construction HSE LTA
study Expediting supervision
certification compliance surveillance supervision inspections
Risk F4S NDT
analysis NDT

EIA Plant Failure analysis

Compliance certification
optimization (RCFA)
O&M
Licensing &
Pre-qualification Component Final acceptance ISO 9001 management
consenting certification test ISO 14001
AIM / RBI
Tender & contract Supplier
management evaluation In-service Efficiency
Claim management
Vendor quality inspection consultancy
Design review assurance
Regulated ISO 50001
Design approval
Non-regulated IEE plant
certification

Calculation
Simulation
Performance tests

Noise / vibration / emissions testing

Due diligence
Site assessment (TDD - technical, EDD - environmental)

Staff training / qualification

TÜV SÜD South Asia CPP Integrated Solution Slide 23

Your Business Benefits: Maximise Profits

Increase availability, Promote efficiency,

optimize performance reduce emissions
Our experts’ impartial
TÜV SÜD’s experts help you obtain
perspective fosters cost
professional advice in performance
efficiency in your organisation,
optimization to reduce outage time
while their comprehensive
and increase your return on
knowledge contributes to your
investment.
emissions goals.

Strengthen
Minimise risk,
your competitive
improve reliability
edge
We help you to reduce the risk of
conventional power plant incidents, Leverage on our expertise in safety
enhance safety for people and the and statutory compliance for legal
environment, increase process certainty. Third-party certification by
transparency and eliminate TÜV SÜD demonstrates your
interface problems. commitment to quality.

TÜV SÜD South Asia 13-01-31 CPP Integrated Solution Slide 24

 Contact us today.
www.tuv-sud.in
info@tuv-sud.in

TÜV SÜD South Asia CPP Integrated Solution Slide 25