Optimize plant efficiency and availability with an integrated solution Bratin Roy Vice President - Industry Service TÜV SÜD South Asia TÜV SÜD Slide 1

Optimize plant efficiency and availability with an integrated solutionBratin Roy Vice President - Industry Service TÜV SÜD South Asia

TÜV SÜD Slide 1 Optimizing plant efficiency with an integrated solution05/10/15

Overview

1 Background

2 Steps to provide integrated solution

3 Benefit

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TÜV SÜD Group – Conventional Power Plant Solution 4

TÜV SÜD Slide 2Optimizing plant efficiency with an integrated solution05/10/15

Background

In today’s changing environment, fossil-fuel plant owners face significant lifecycle management challenges

Along with existing issues like fuel availability, price pressures due to market liberalization, 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

Coal, Gas and oil power plant upgrades and retrofits are focused on improved efficiency, greater power generation capacity and better emission control systems


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 Assessment Operation & Maintenance – status

assessments Performance Measurement Energy Assessment/Audit Integrated 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


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


Performance Testing – Background

Power Output at dedicated loads Heat Rate (GJ/GWh) Indication of ⇨

power plant efficiency Electrical Characteristics, e.g.

• Auxiliary power,• Operation test within voltage and

frequency limits, • Power factor range prescribed

Water / Steam Parameters Emissions (Air, Sound Pressure) Vibrations Consumption of Water and Chemicals Treatment of water and waste water

Technical contents of Contract / Guarantees

• Desired Conditio

n

• Heat Rate

• Air and Noise

Emissions

• Fuel• deman

d

• Consumption

• (Auxil. Water,

Chemicals) • Vibrations

• Power Output

05/10/15TÜV SÜD Slide 9Optimizing plant efficiency with an integrated solution

Performance Testing – Key Parameters

Equipment : Measurement system

• Accuracy Class of Instruments

- RTD (PT100) up to 150 °C < 0.1 K- Differential pressure sensors < 1 mbar- Gauge and absolute pressure sensors < 0.1 %- Powermeter < 0.1 %

• Accredited Calibration / QA

05/10/15TÜV SÜD Slide 10Optimizing plant efficiency with an integrated solution

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/Audit

Success Factor

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

TÜV SÜD Slide 11Optimizing plant efficiency with an integrated solution

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

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Fuel Handling Plant Boiler Thermal Insulation Ash Handling Water Pumping Fans Steam Turbine Condenser Cooling Compressor Air System Motors Air Conditioning Lighting ESP

Process optimization

Operational improvements

Advance maintenance to reduce wastage

Capital investment ( up-gradation; retrofitting ; renovation & modernization)

To conduct energy analysis of the overall plant and determine the efficiencies and energy losses of all the major components on the power plant.

Select and develop the areas where energy losses are being experienced.

Determine the costs and payback periods for the new technologies suggested for efficiency improvement.

Energy Audit/Assessment – steps

Scope

Energy assessment is key to decide a successful solution

Objective Expected Goal


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

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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

Rehabilitation & Modernization

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


Key

Su

cces

s F

acto

rs

Maximum yield over the entire life cycle Designed performance

Controlled risks

Return of investment

Lower costs, lesser risks

Stable cash flow Pea

ce o

f M

ind

Overview

Background

Steps to provide Integrated solution

Benefit


TÜV SÜD Group – Conventional Power Plant Solution


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Our heritage: 149 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 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

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.

Advisory services along the capital value chain


Feasibility & Planning

Refurbishment & Decommission

Procurement Construction Commission In-service

INVESTMENT OPERATION

Componentcertification

Componentcertification

ISO 9001ISO 14001

Feasibilitystudy

Riskanalysis

EIA

CalculationSimulation

Constructionsupervision

Weldingsurveillance

HSEinspections

Expediting

NDT

Codecompliance

Supplierevaluation

Vendor qualityassurance

Final acceptancetest

NDT

LTA

F4S

Repairsupervision

O & Mmanagement

AIM / RBI

Regulated

Non-regulated

ISO 50001

IEE plant certification

Rehabilitation/modernizationmanagement

QA/QC

Claim management

Compliance certification

Design reviewDesign approval

Licensing & consenting

Staff training / qualification

Technical due diligence

Performance tests

Owner’s engineer

Tender & contractmanagement

Technical advisor

Plantoptimization

Plant status assessment

Pre-qualification

Failure analysis(RCFA)

In-serviceinspection

Efficiencyconsultancy

Noise / vibration / emissions testing

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

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Increase availability, optimize performanceTÜV 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

edgeLeverage 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

13-01-31TÜV SÜD Slide 23Optimizing plant efficiency with an integrated solution05/10/15

Contact us today.

[email protected]


Documents

Optimize plant efficiency and availability with an integrated solution Bratin Roy Vice President - Industry Service TÜV SÜD South Asia TÜV SÜD Slide 1