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
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 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
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
and retrofit techniques
Benefits
 Preventive and Predictive maintenance
 Condition-oriented maintenance
– Inspection planning
– NDT program
– Monitoring methods
– Calculation methods (e.g. fracture
mechanics calc.)
Full up time of the plant ensuring 100%
productivity, avoiding unnecessary force shut
down
– 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
 Metallographic Testing
 Creep/Stress Rupture Testing
 Measurement of Mechanical
properties
 Microbiological analysis
 Metallurgical Chemistry Analysis
TÜV SÜD South Asia
Non-destructive Tests
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VE
LP
MP
UT
EC
RX
MR
MPI
HM
TD
HV
DM
13-01-31
Visual Examination
Liquid Penetrant Examination
Magnetic Particle Examination
Ultrasonic Examination
Eddy Current Examination
Radiographic Examination
Metallographic Replication
Material Positive Identification
Hardness Measurements
Tan-Delta Test
High Voltage Test
Dimensional Examination/
Measurement
CPP Integrated Solution
Systems and equipment
 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
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
TÜV SÜD South Asia
13-01-31
 We base our qualitative and quantitative techniques
on internationally accepted standards and
guidelines, and tailor the solutions to your specific
concerns
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%
TÜV SÜD South Asia
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
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
 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
TÜV SÜD South Asia
Expected Goal
CPP Integrated Solution
 Life Extension for another 15 to
20 years is possible
 Increase of rated capacity 4% 8%
 Increase of efficiency 8%-10%
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
Lower costs, lesser risks
Stable cash flow
Designed performance
Peace of Mind
Key Success
Factors
Maximum yield over
the entire life cycle
CPP Integrated Solution
Controlled risks
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
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
TÜV SÜD continues to pursue a strategy of
internationalisation and growth
Today
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
Countries with TÜV SÜD offices
Regional headquarters
GERMANY
INTERNATIONAL
1,190 € mio
10,400 staff
750 € mio
9,800 staff
CPP Integrated Solution
Footprint in South Asia
TÜV SÜD South Asia
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TÜV SÜD South Asia is a fully owned subsidiary of
TÜV SÜD AG
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Operating in India since 1995
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Extensive network of over 32 offices including 14
labs across India, Bangladesh and Sri Lanka
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Employee strength of over 1300
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Over 12000 customers
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
Feasibility &
Planning
OPERATION
Construction
Procurement
Commission
Owner’s engineer
Technical due diligence
Feasibility
study
Technical advisor
Code
compliance
Risk
analysis
Welding
surveillance
Rehabilitation/
modernization
management
Plant status
assessment
QA/QC
Component
certification
Refurbishment &
Decommission
In-service
Construction
supervision
HSE
inspections
Expediting
Repair
supervision
LTA
F4S
NDT
NDT
EIA
Licensing &
consenting
Tender & contract
management
Design review
Design approval
Plant
optimization
Compliance certification
Pre-qualification
Supplier
evaluation
Component
certification
Final acceptance
test
Failure analysis
(RCFA)
O&M
management
ISO 9001
ISO 14001
AIM / RBI
Efficiency
consultancy
In-service
inspection
Claim management
Vendor quality
assurance
Regulated
ISO 50001
IEE plant
certification
Non-regulated
Calculation
Simulation
Performance tests
Noise / vibration / emissions testing
Site assessment
Due diligence
(TDD - technical, EDD - environmental)
Staff training / qualification
TÜV SÜD South Asia
CPP Integrated Solution
Slide 23
Your Business Benefits: Maximise Profits
Promote efficiency,
reduce emissions
Increase availability,
optimize performance
Our experts’ impartial
perspective fosters cost
efficiency in your organisation,
while their comprehensive
knowledge contributes to your
emissions goals.
TÜV SÜD’s experts help you obtain
professional advice in performance
optimization to reduce outage time
and increase your return on
investment.
Strengthen
your competitive
edge
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.
TÜV SÜD South Asia
13-01-31
Leverage on our expertise in safety
and statutory compliance for legal
certainty. Third-party certification by
TÜV SÜD demonstrates your
commitment to quality.
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