Upload
eve-drakeford
View
227
Download
6
Tags:
Embed Size (px)
Citation preview
Renovation, Modernization and Life Extension service of Power Plant
TÜV SÜD Industry Service
slide 1 / Dan Rosca
- Lack of available expertise in Indian market for Scope Determination of R & M projects
Presented By: Sapath Dutta Gupta / GM – BD, Power & Systems TUV SUD South Asia Pvt Ltd, India
TÜV SÜD South Asia Slide 114-04-21 R & M and RLE
Topics to discuss
1 TUV SUD: Corporate Overview
2 Lack of Technical Expertise for scope determination
3 Measurable benefits for the clients
4Solution to overcome the problem for Lack of Technical expertise
5 Project References
TÜV SÜD South Asia Slide 214-04-19 R & M and RLE
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 South Asia Slide 314-04-19 R & M and RLE
TÜV SÜD
TÜV SÜD in numbers: Growing from strength to strength
1 one-stop technical solution provider
800 locations worldwide
employees worldwide 18,800
million Euro in sales revenue 20121,820
150 years of experience
TÜV SÜD South Asia Slide 414-04-19 R & M and RLE
Global expertise. Local experience.
Global Headquarters: Munich, Germany
INTERNATIONAL
Euro 690 mio8,600 staff
GERMANY
Euro 1,130 mio10,200 staff
Legend:
Countries with TÜV SÜD offices
Regional headquarters
TÜV SÜD South Asia Slide 514-04-19 R & M and RLE
Technical expertise & broad industry knowledge
Audits system certification in a variety of fields including quality, safety, energy, social compliance and environment.
Auditing & system
certification
Product, system, building, plant and infrastructure inspection.
Inspection
Safety, quality, risk, environmental protection and regulatory advisory.
Knowledge services
Chemical, physical, mechanical, electrical and environmental testing and product certification.
Testing & product
certification
Training in work safety, technical skills, management systems and executive programs.
Training
TÜV SÜD South Asia Slide 614-04-19 R & M and RLE
INDUSTRY: Minimise risks. Optimise results.
Chemical, oil & gas
Services for investors, operators and equipment manufacturers of upstream, midstream and downstream installations include: •Quality assurance and control•Periodic inspection•Owners’ engineer•Acceptance checks and tests•Material testing•Auditing •System certification•Training
Power & energy
Services for investors, owners, operators and equipment manufacturers of conventional, nuclear and renewable energy plants include: •Due diligence•Design reviews•Risk management•Owners’ engineer•Construction monitoring•Material testing•Periodic inspection•Regulatory compliance assessment•System certification•Training
Manufacturing & industrial machinery
Services for components manufacturers, contractors, installation providers, equipment & material manufacturers and operators include: •Component testing•Periodic inspection of equipment•Failure analysis•System certification•Training
TÜV SÜD South Asia Slide 714-04-19 R & M and RLE
CERTIFICATION: Achieve market success
Services for components manufacturers, contractors, installation providers, equipment & material manufacturers and operators include: •Component testing•Periodic inspection of equipment•Failure analysis•System certification•Training
Manufacturing & industrial machinery
Services for manufacturers, retailers, buyers and suppliers of electrical & electronics, food, health & beauty, hardlines, softlines, toys & children’s products: •Testing•Auditing•Inspection•Product certification•Knowledge services•System certification•Training
Consumer products & retail
Healthcare & medical devices
Services for medical device manufacturers and healthcare providers include: •Clinical approvals•Market approvals and certification•Testing•Evaluation•Quality control•System certification•Training
Telecommunications & IT
Services for equipment manufacturers and operators of infrastructure equipment and radio frequency wireless equipment include: •Design reviews•Testing•Software escrow•Product certification•System certification•Training
TÜV SÜD South Asia Slide 814-04-19 R & M and RLE
Blue solutions for a sustainable future
Renewable energy
Services for investors, manufacturers and operators of biomass, geothermal, hydropower, photovoltaic, solar thermal and wind components and plants include: •Feasibility & bankability assessments•Construction monitoring •Safety and licensing support services•Equipment and component testing and certification•Periodic inspection•Training
Energy efficiency
Services for manufacturers, planners, owners and operators of buildings, products and equipment, production plants, power plants, municipalities and regions include: •Energy audits•Energy optimisation•Energy efficiency certification•Testing•Product certification•Compliance evaluation•System certification•Training
TÜV SÜD South Asia Slide 914-04-19 R & M and RLE
April 18, 2023
Credentials
TÜV SÜD South Asia is accredited by:
Central Electricity Authority (CEA) Bureau Of Energy Efficiency [BEE : Regulatory Body for Energy Efficiency, Ministry of
Power, Govt. of India.] Gujarat Energy Development Authority [GEDA] Ministry of New & Renewable Energy [MNRE] Petroleum Conservation Research Association [PCRA] Maharashtra Energy Development Authority [MEDA] Indian Green Building Council ( IGBC ) / Confederation of Indian Industry ( CII )
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 30 offices including 12 labs across India, Bangladesh and Sri Lanka
• Employee strength of over 1500
• Sales revenue of Rs.170 crore in 2013
• Over 12000 customers
TÜV SÜD South Asia Slide 1114-04-19 R & M and RLE
CPP Competency Hub at TÜV SÜD
• TÜV SÜD Conventional Power Plant Competence Hub is a complete solution in order to determine the necessary technical, regulatory, jurisdictional and economical viable measures for New Building / In-Service inspection / R & M / LE of Power Plants
• The Competence Hub has a highly trained and a highly qualified team of Experts, coordinated and managed from Munich, Germany
• The Competence Hub has a multinational, multicultural and very experienced team of Experts
• The Competence Hub has an international global approach, with local TÜV SÜD Experts & expertise involved
• The Competence Hub has an extensive international experience proved by the reference list, with similar jobs completed worldwide
TÜV SÜD South Asia Slide 1214-04-19 R & M and RLE
Topic of Presentation
Lack of available technical expertise in Indian market for Scope Determination of R & M projects
TÜV SÜD South Asia Slide 1314-04-19 R & M and RLE
Owner Operator of Power Plant
• Limited agencies to carry out R&M studies competently because of lack of technical expertise.
• Lack of internal expertise to evaluate actual condition of equipment and costs for repair / renovation
• Cost escalation on account of surprises found during project execution and the difficulty to build them into the contract
• Problems of ensuring expected and sustained plant performance after completion of R&M
TÜV SÜD South Asia Slide 1414-04-19 R & M and RLE
Bidders
• Time gap between study of RLA and actual initiation of R&M bidding process
• Uncertainty about the exact scope of work which makes it difficult to estimate the actual work to be undertaken
• Unforeseen items / surprises during execution and impact on cost – how to build them into the estimate and how to reduce risk on this account.
• Functional Guarantees which form part of the contract are often difficult to achieve owing to lack of clarity on how verification will be carried out.
• World Bank requires that the R&M Consultant shall do the energy audit / baseline assessment for the identified thermal power station.
TÜV SÜD South Asia Slide 1514-04-19 R & M and RLE
Funding Agencies
• Accuracy of the estimated costs
• Ensuring a strategy that takes care of unforeseen items / surprises and their impact on project cost and time for execution
• Delays in regulatory clearances
• Lack of appropriate infrastructure for project execution
• Ensuring that the study preceding the preparation of Detailed Project Report reflects actual conditions in the plant
• Credit worthiness of the utilities
• Material market fluctuations
TÜV SÜD South Asia Slide 1614-04-19 R & M and RLE
Regulator
The regulator is concerned about the justification of the expenditure on R&Mprojects and would like to ensure that the investment results in the leastadditional cost to the public for the power generated after R&M.
An objective judgment of the justified expenditure is complicated since it is difficult to establish which portion of the expenditure is based on genuine LE requirements and what is needed to make up for poor O&M practices.
TÜV SÜD South Asia Slide 1714-04-19 R & M and RLE
Measurable benefits for the clients
TÜV SÜD South Asia Slide 1814-04-19 R & M and RLE
Measurable benefits for the clients
• Performance assessment as per ASME standard and by using online calibrated inspection instruments. Cost reduction by using a single team of highly qualified Experts
• Our services add certain value measured by the client in terms of time reduction, cost savings, safety and quality
• TÜV SÜD Brand Name has a world wide recognition for technical competence, for independence, for impartiality and for reliability of the services provided
• TÜV SÜD Brand Name is recognized and accepted by Finance sector, by Insurance sector and by Jurisdictional authorities
TÜV SÜD South Asia Slide 1914-04-19 R & M and RLE
OperationOperationInvestmentInvestment
FeasibilityPlanning
FeasibilityPlanning ProcurementProcurement ConstructionConstruction CommissioningCommissioning In-serviceIn-service Rehabilitation
Decommissioning
RehabilitationDecommissioning
Performance TestsPerformance Tests
Noise / Vibration / Emissions TestingNoise / Vibration / Emissions Testing
Staff Training / QualificationStaff Training / Qualification
Claim ManagementClaim Management
Plant StatusAssessment
Plant StatusAssessment
Due Diligence(TDD - technical, EDD - environmental)
Due Diligence(TDD - technical, EDD - environmental)
Failure Analysis(RCFA)
Failure Analysis(RCFA)
PlantOptimization
PlantOptimization
QA / QCQA / QC RetrofitManagement
RetrofitManagement
Pre-QualificationPre-Qualification
Design ReviewDesign Approval
Design ReviewDesign Approval
Tender & ContractManagement
Tender & ContractManagement
LicensingConsenting
LicensingConsenting
Advisory services along the capital value chain
EfficiencyConsultancy
EfficiencyConsultancy
RefurbishmentDecommissioning
RefurbishmentDecommissioning
Owner´s EngineerOwner´s Engineer Technical AdvisorTechnical Advisor
TDDTDD
Compliance CertificationCompliance Certification
TÜV SÜD Romania Slide 2013-12-06 I
In-serviceInspection
In-serviceInspection
OperationOperationInvestmentInvestment
Performance TestsPerformance Tests
Noise / Vibration / Emissions TestingNoise / Vibration / Emissions Testing
Staff Training / QualificationStaff Training / Qualification
Claim ManagementClaim Management
Plant StatusAssessment
Plant StatusAssessment
Due Diligence(TDD - technical, EDD - environmental)
Due Diligence(TDD - technical, EDD - environmental)
Failure Analysis(RCFA)
Failure Analysis(RCFA)
PlantOptimization
PlantOptimization
QA / QCQA / QC RetrofitManagement
RetrofitManagement
Pre-QualificationPre-Qualification
Design ReviewDesign Approval
Design ReviewDesign Approval
Tender & ContractManagement
Tender & ContractManagement
Advisory services along the capital value chain
EfficiencyConsultancy
EfficiencyConsultancy
RefurbishmentDecommissioning
RefurbishmentDecommissioning
Owner´s EngineerOwner´s Engineer Technical AdvisorTechnical Advisor
TDDTDD
Compliance CertificationCompliance Certification
In-serviceInspection
In-serviceInspection
TÜV SÜD South Asia Slide 2114-04-19 R & M and RLE
Solution to overcome the problem for Lack of Technical expertise
TÜV SÜD South Asia Slide 2214-04-19 R & M and RLE
Need for standardization
The large fleet of 200/210 MW units which are coming up for R&M provides anopportunity to standardize documents for tendering for R&M to ensureacceptable levels of quality and to harmonize the requirements of all thestakeholders to a reasonable level of satisfaction to permit efficient execution ofprojects in this crucial programme to meet the power needs of India.
TÜV SÜD South Asia Slide 2314-04-19 R & M and RLE
Operational Goal
The management of a CPP rehabilitation / modernization (R&M) has to monitor the fulfillment of some important operational goals for entire plant, as:
– Plant load factor improvement;
– Plant heat rate increasing, as well as component individual efficiency;
– Plant availability and reliability increasing;
– Parts life extension;
– Environmental performances improvement.
TÜV SÜD South Asia Slide 2414-04-19 R & M and RLE
Energy Efficiency, Condition Assessment & RLA consultancy from a single source
Detailed Project Report (DPR) preparation, on which purpose, some studies and evaluations may be necessary, that means:
– Performance evaluation tests (PET);
– Energy audit (EA) on main CPP parts/systems;
– Residual Life Assessment (RLA) on all relevant parts, subjected to mechanical, thermal and chemical stresses;
– Condition Assessment (CA)
TÜV SÜD South Asia Slide 2514-04-19 R & M and RLE
RLA consultancy & Performance Guarantee from a single source
Technical Assistance
After DPR elaboration, the project Consultant will assist the customer /owner in preparing as follows:
– Preparation of Specification for EPC Contractor selection;– Bid documents and evaluation;– Preparation of Quality Plan;– Procurement supervision;– Erection & Commissioning supervision.– Performance Guarantee
TÜV SÜD South Asia Slide 2614-04-19 R & M and RLE
BTG & BOP consultancy for RLA from a single source
In case of a general R&M plant consultancy, the scope of works has to cover the following systems :
– Boilers and Auxiliaries;– Turbines and their Auxiliaries;– Generators and their Auxiliaries;– Power Transformers (generator, auxiliary units, switch yard);– Balance of Plant (cooling water, compressors, motors, piping, switch gear panels,
Hydrogen generation);– Instrumentation & Control (including distributed control system);– Coal & Ash Handling Systems (if the case);– Civil & Structures (RLA, concrete works, machine foundations, steel structures).
TÜV SÜD South Asia Slide 2714-04-19 R & M and RLE
Repair Supervision from a single source.
A CPP parts/systems repair process has to fulfill the following important Operation & Maintenance (O&M) goals:
– Plant availability and reliability increasing;– Parts life extension;– Minimization of maintenance costs;– Inventory optimization;– Environmental performances observance.
The parts repair / replacements occur typically during the plant overhauls, as regular scheduled maintenance activities. Repairs due to part damaging (causing unexpected breakdowns) are incidental cases, which will be treated as special interventions.
TÜV SÜD South Asia Slide 2814-04-19 R & M and RLE
Project References
TÜV SÜD South Asia Slide 2914-04-19 R & M and RLE
TÜV SÜD: References for Fluidized Bed Boilers
TÜV SÜD Industrie Service GmbH Folie 3018.04.23
Year Client Location Boiler technology /Steam parameter
Fuel /SOx emission limit
TÜV SÜD Services
ongoing Bertsch. Austria / Outotec, Germany
Çorlu, Turkey
Bubbling fluidized bed96 t/h (62 bar, 380°C)
Fuel mix: biological sludge, paper sludge, rejects, natural gas, etc.SOx < 50 mg/Nm³
Design examination boiler assembly Design examination external piping and balance of plant (BoP)Final assessment boiler and BOP assembly
ongoing BASF, Germany Ludwigshafen, Germany
Bubbling fluidized bed2x 80 MW(th)
Fuel mix: industrial sludge, coal, light oilSOx < 50 mg/Nm³
In-service inspections, Notified Body
ongoing UPM, Germany Schongau,Germany
Circulating fluidized bed50 MW(th)
Paper wasteSOx < 50 mg/Nm³
In-service inspections, Notified Body
2011-2013 Kraftanlagen München, Germany / Foster Wheeler, Finland
Kladno , Czech Republic
Circulating fluidized bed326 MW(th)
Lignite Design examination boiler assembly Design examination external piping and balance of plant (BoP) Final assessment boiler and BOP assembly
2009-2010 Stora-.Enso, Germany
Karlsruhe-Maxau, Germany
Circulating fluidized bed156 MW(th)
Fuel mix: paper waste, biomass, hard coalSOx < 50 mg/Nm³
Construction supervision, Nofified Body,Site acceptance test
2008-2009 hse, Germany Strambolijski, Bulgaria
Bubbling fluidized bed42 t/h (100 bar, 480°C)
BiomassSOx < 50 mg/Nm³
Design Examination Final assessment at workshop (Romania) Final assessment on site Assembly
2007 -2008 Austrian Energy & Environment, Austria
Wittenberg, Germany
Circulating fluidized bed62 t/h (160 bar, 535°C)
BiomassSOx < 50 mg/Nm³
Design Examination Final assessment at workshop (Croatia)Final assessment on site Assembly
2003 - 2004
Alstom,Germany
Canakkale,Turkey
2x160 MWe Lignite,Circulating fluidized bed
Manufacturing supervision, Compliance certification, Design review , Design approval, Site acceptance test
TÜV SÜD: References for Lignite Fired Power Plants
TÜV SÜD Industrie Service GmbH Folie 3118.04.23
Year Client Location El. Output Fuel ,Combustion Technology
TÜV SÜD Services
2011-2013 Kraftanlagen München, Germany / Foster Wheeler, Finland
Kladno , Czech Republic
135 MWe Lignite,Circulating fluidized bed
Design examination boiler assembly Design examination external piping and balance of plant (BoP) Final assessment boiler and BOP assembly
2010 Vattenfall, Germany
Schwarze Pumpe,Germany
2x 750 MWe Lignite,Pulverized coal firing
Evaluation and optimization of the O&M scheme for the entire power plant (boiler, steam turbine, balance of plant, etc)
2003/2004 Alstom,Germany
Canakkale,Turkey
2x160 MWe Lignite,Circulating fluidized bed
Manufacturing supervision, Compliance certification, Design review , Design approval, Final assessment on site
1997-2000 Vattenfall, Germany
Boxberg (Block Q),Germany
860 MWe Lignite,Pulverized coal firing
Manufacturing supervision, Design review , Design approval, Construction supervision, Final assessment on site / Site acceptance test
2006 Vemagiri Power Generation Limited, GMR Group (India)
Vemagiri, AP India 388 MW Combined Cycle Gas Turbine Power Plant
Thermal Performance Test on Combined Cycle Power Plant Vemagiri, India,
2009 RRVUVN Kali Sindh Thermal Power Project
Kali Sindh & Chhabra India
2 x 600 MW and 2 x 25 MW
Coal Third Party Inspection of structural steel fabrication and erection of main power house building and mill building of 2 x 600 MW Kali Sindh Thermal Power Project and 2 x 250 MW Chhabra Thermal Power Project
2008 Reliance Sasan Mega Power Project
Sasan, India 6 x 660 MW Coal Third Part Inspection services of all the pipelines of the Balance of Plant for 6 x 660 MW Sasan Mega Power Project
2005 to 2008
BHEL Santaldih ( Unit V) Project
Santaldih, India 1 x 250 MW Coal Field Quality Assurance Services for Civil, Structural, Boiler & Piping, Electrical & C & I Works and Safety Services at 1 x 250 MW Santaldih ( Unit V) Project
TÜV SÜD: References for Lignite Fired Power Plants
TÜV SÜD Industrie Service GmbH Folie 3218.04.23
Year Client Location El. Output Fuel ,Combustion Technology
TÜV SÜD Services
2011 Essar Power Limited
Hazira, Gujarat, India Coal Energy Audit of a Power Plant
2012 Nalwa Steel and Power Ltd
Raigarh, India Coal Energy Audit of a Power Plant
2012 G.R. Sponge & Power Ltd
Raigarh, India Coal Energy Audit of a Power Plant
2014 Hira Power & Steel Ltd
Raigarh, India Coal Energy Audit of a Power Plant
April 18, 2023
Thank you for your attention.April 18, 2023
Sapath Dutta GuptaTÜV SÜD South AsiaGeneral Manager - Business DevelopmentIndustrial Services - Power & Systems TÜV SÜD South Asia Pvt. Ltd.Solitaire, 4th Floor, ITI Road, Aundh,Pune - 411 007,Maharashtra, India. Boardline : +91-020-66841212Directline : +91-020-66841215Cell : +91-7767803522Fax : +91-020-66841261
E-mail : [email protected] : www.tuv-sud.in