Optimise plant performance with an integrated solution

Optimise plant performance with an integrated solutionBratin Roy Vice President - Industry Service TÜV SÜD South Asia

TÜV SÜD South Asia Slide 1 CPP Integrated Solution

Overview

1 Background

2 Steps to provide integrated solution

3 Benefit

TÜV SÜD Group – Conventional Power Plant Solution 4

TÜV SÜD South Asia Slide 2CPP Integrated Solution

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)


Overview

1 Background

2 Steps to provide Integrated solution

3 Benefit

TÜV SÜD Group – Conventional Power Plant Solution 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 AssessmentOperation & Maintenance – status assessmentsOperation & Maintenance – in-service inspectionRisk-based inspection and maintenancePerformance Measurement Efficiency and reliability improvement solutionsIntegrated plant retrofits along with comprehensive Renovation & Modernisation Program


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


Modern maintenanceand 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

Full up time of the plant ensuring 100% productivity, avoiding unnecessary force shut

down

Operation & Maintenance – status assessment

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Benefits

Plant status assessment


Operation & Maintenance - in-service inspection

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Destructive Tests

In-service inspection

Non-destructive Tests Systems and equipment

VE Visual Examination LP Liquid Penetrant

Examination MP Magnetic Particle

Examination UT Ultrasonic Examination EC Eddy Current Examination RX Radiographic Examination MR Metallographic Replication MPI Material Positive

Identification HM Hardness Measurements TD Tan-Delta Test HV High Voltage Test DM Dimensional Examination/

Measurement

Metallographic Testing Creep/Stress Rupture Testing Measurement of Mechanical

properties Microbiological analysis Metallurgical Chemistry Analysis

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


CPP solutions: Performance test for power plants and energy systems

Performance test for power plants and energy systemsAchieve 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


Risk-based inspection and maintenance

13-01-31TÜV SÜD South Asia Slide 10CPP Integrated Solution

Risk-based inspection and maintenanceAchieve 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

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%

Energy Efficiency assessment

Procedures

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


Combustion Control Optimisation Cooling System Heat Loss RecoveryFlue Gas Heat RecoveryLow-Rank Coal DryingSootblower OptimisationSteam Turbine Design Review Condenser optimizationImprovements 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

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 generationBy organising, an integrated program that incorporates various upgrades across the plant, matching thecapabilities of any combination of main components and associate parts it delivers maximum efficiency in most cost effective life extension solutionWith limited budget and timeline integrated retrofit solutions are a great way to explore hidden potential without the involvement of huge capital


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

Life Extension for another 15 to 20 years is possible

Increase of rated capacity 4% - 8%

Increase of efficiency 8%-10%

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

Renovation & Modernisation

Objective

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

Methods Expected Goal


Background

Steps to provide Integrated solution

Benefit

TÜV SÜD Group – Conventional Power Plant Solution


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Tangible benefits from integrated life cycle management

CPP Integrated Solution

Key

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Maximum yield over the entire life cycle Designed performance

Controlled risks

Return of investment

Lower costs, lesser risks

Stable cash flow

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Overview

Background

Steps to provide Integrated solution

Benefit

TÜV SÜD Group – Conventional Power Plant Solution


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Our heritage: 146 years of business success

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

1866

First vehicle periodic technical inspection (PTI)1910

1958 Development of a Bavaria-wide network of vehicle inspection centres in the late 1950s

1926 Introduction of the “TÜV mark / stamp” in Germany

1990s Conglomeration of TÜVs from the southern part of Germany to form TÜV SÜD and the expansion of business operations into Asia

TÜV SÜD continues to pursue a strategy of internationalisation and growth

Today

2006 Expansion of services in ASEAN by acquiring Singapore-based PSB Group

2009 Launch of Turkey-wide vehicle inspection by TÜVTURK


TÜV SÜD

TÜV SÜD in numbers: Growing from strength to strength

1 One-stop Technical Solution Provider

800 Locations Worldwide

Employees Worldwide 20,200

Million Euro in Sales Revenue 20131,900

150 Years of Experience

Note: Figures have been rounded off.


Global expertise. Local experience.

Global Headquarters: Munich, Germany

INTERNATIONAL

750 € mio9,800 staff

GERMANY

1,190 € mio10,400 staff

Countries with TÜV SÜD offices

Regional headquarters


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 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


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.

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Advisory services along the capital value chain


Feasibility & Planning

Refurbishment & Decommission

Procurement Construction Commission In-service

INVESTMENT OPERATION

Componentcertification




ISO 9001ISO 14001

ISO 9001ISO 14001

Feasibilitystudy

Feasibilitystudy

Riskanalysis

Riskanalysis

EIAEIA

CalculationSimulation

CalculationSimulation

Constructionsupervision

Constructionsupervision

Weldingsurveillance

Weldingsurveillance

HSEinspections

HSEinspectionsExpeditingExpediting

NDTNDT

Codecompliance

Codecompliance

Supplierevaluation

Supplierevaluation

Vendor qualityassurance

Vendor qualityassurance

Final acceptancetest

Final acceptancetest

NDTNDT

LTALTA

F4SF4S

Repairsupervision

Repairsupervision

O & Mmanagement

O & Mmanagement

AIM / RBIAIM / RBI

RegulatedRegulated

Non-regulatedNon-regulated

ISO 50001ISO 50001

IEE plant certification

IEE plant certification

Rehabilitation/modernizationmanagement

Rehabilitation/modernizationmanagement

QA/QCQA/QC

Claim managementClaim management

Compliance certificationCompliance certification

Design reviewDesign approval

Design reviewDesign approval

Licensing & consenting

Licensing & consenting

Staff training / qualificationStaff training / qualification

Technical due diligenceTechnical due diligence

Performance testsPerformance tests

Owner’s engineerOwner’s engineer

Tender & contractmanagement

Tender & contractmanagement

Technical advisorTechnical advisor

Plantoptimization

Plantoptimization

Plant status assessmentPlant status assessment

Pre-qualificationPre-qualification

Failure analysis(RCFA)

Failure analysis(RCFA)

In-serviceinspection

In-serviceinspection

Efficiencyconsultancy

Efficiencyconsultancy

Noise / vibration / emissions testingNoise / vibration / emissions testing

Due diligence(TDD - technical, EDD - environmental)

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

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.

Promote efficiency, reduce emissions

Our experts’ impartial perspective fosters cost

efficiency in your organisation, while their comprehensive

knowledge contributes to your emissions goals.

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.

Strengthenyour 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.

Your Business Benefits: Maximise Profits


Contact us today.

[email protected]


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Optimise plant performance with an integrated solution