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)
TÜV SÜD South Asia Slide 3CPP 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 4CPP Integrated Solution
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
TÜV SÜD South Asia Slide 5CPP Integrated Solution
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 Slide 6CPP Integrated Solution
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
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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
TÜV SÜD South Asia Slide 8CPP Integrated Solution
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
TÜV SÜD South Asia Slide 9CPP Integrated Solution
Risk-based inspection and maintenance
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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.
TÜV SÜD South Asia Slide 11CPP Integrated Solution
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
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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
Renovation & Modernisation
Objective
Every R & M project is unique, requiring adaptation and system expertise that depends on extensive experience.
Methods Expected Goal
TÜV SÜD South Asia Slide 13CPP Integrated Solution
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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Fac
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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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Pea
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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 South Asia Slide 17CPP Integrated Solution
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.
CPP Integrated Solution
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
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 Slide 20CPP Integrated Solution
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 Slide 21CPP Integrated Solution
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
TÜV SÜD South Asia Slide 23CPP Integrated Solution
Feasibility & Planning
Refurbishment & Decommission
Procurement Construction Commission In-service
INVESTMENT OPERATION
Componentcertification
Componentcertification
Componentcertification
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
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