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TRANSCRIPT
Optimise plant
performance with an
integrated solution Bratin 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 2 CPP 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 3 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 4 CPP 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 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 Slide 5 CPP 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 6 CPP Integrated Solution
Modern maintenance
and 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
TÜV SÜD South Asia Slide 7 CPP Integrated Solution
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 8 CPP Integrated Solution
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 Slide 9 CPP Integrated Solution
Risk-based inspection and maintenance
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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
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 11 CPP Integrated Solution
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
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
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 13 CPP Integrated Solution
Background
Steps to provide Integrated solution
Benefit
TÜV SÜD Group – Conventional
Power Plant Solution
TÜV SÜD South Asia Slide 14 CPP Integrated Solution
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2
3
4
Tangible benefits from integrated life cycle management
CPP Integrated Solution
Key S
uc
ce
ss
Fa
cto
rs
Maximum yield over
the entire life cycle Designed performance
Controlled risks
Return of investment
Lower costs, lesser risks
Stable cash flow Pea
ce
of
Min
d
Overview
Background
Steps to provide Integrated solution
Benefit
TÜV SÜD Group – Conventional
Power Plant Solution
TÜV SÜD South Asia Slide 16 CPP Integrated Solution
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2
3
4
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 17 CPP 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 2013
1,900
150 Years of Experience
Note: Figures have been rounded off.
CPP Integrated Solution
Global expertise. Local experience.
Global Headquarters:
Munich, Germany
INTERNATIONAL
750 € mio
9,800 staff
GERMANY
1,190 € mio
10,400 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 20 CPP 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 21 CPP 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 23 CPP Integrated Solution
Feasibility &
Planning
Refurbishment &
Decommission Procurement Construction
Commission
In-service
INVESTMENT OPERATION
Component
certification
Component
certification
ISO 9001
ISO 14001
Feasibility
study
Risk
analysis
EIA
Calculation
Simulation
Construction
supervision
Welding
surveillance
HSE
inspections Expediting
NDT
Code
compliance
Supplier
evaluation
Vendor quality
assurance
Final acceptance
test
NDT
LTA
F4S
Repair
supervision
O & M
management
AIM / RBI
Regulated
Non-regulated
ISO 50001
IEE plant
certification
Rehabilitation/ modernization management
QA/QC
Claim management
Compliance certification
Design review
Design approval
Licensing &
consenting
Staff training / qualification
Technical due diligence
Performance tests
Owner’s engineer
Tender & contract
management
Technical advisor
Plant
optimization
Plant status
assessment
Pre-qualification
Failure analysis
(RCFA)
In-service
inspection
Efficiency
consultancy
Noise / vibration / emissions testing
Due diligence
(TDD - technical, EDD - environmental) Site 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.
Strengthen
your 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
13-01-31 TÜV SÜD South Asia Slide 24 CPP Integrated Solution
Contact us today.
www.tuv-sud.in
TÜV SÜD South Asia Slide 25 CPP Integrated Solution