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Renovation, Modernization and Life Extension service of Power Plant TÜV SÜD Industry Serviceslide 1 / Dan Rosca - Lack of available expertise in Indian.

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Presentation on theme: "Renovation, Modernization and Life Extension service of Power Plant TÜV SÜD Industry Serviceslide 1 / Dan Rosca - Lack of available expertise in Indian."— Presentation transcript:

1 Renovation, Modernization and Life Extension service of Power Plant TÜV SÜD Industry Serviceslide 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 R & M and RLE

2 Topics to discuss 1TUV SUD: Corporate Overview 2 Lack of Technical Expertise for scope determination 3Measurable benefits for the clients 4 Solution to overcome the problem for Lack of Technical expertise 5Project References TÜV SÜD South Asia Slide R & M and RLE

3 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) 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 R & M and RLE

4 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 , years of experience TÜV SÜD South Asia Slide R & M and RLE

5 Global expertise. Local experience. Global Headquarters: Munich, Germany INTERNATIONAL Euro 690 mio 8,600 staff GERMANY Euro 1,130 mio 10,200 staff Legend: Countries with TÜV SÜD offices Regional headquarters TÜV SÜD South Asia Slide R & M and RLE

6 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 R & M and RLE

7 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 R & M and RLE

8 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 R & M and RLE

9 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 R & M and RLE

10 19 April 2015 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 )

11 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 customers TÜV SÜD South Asia Slide R & M and RLE

12 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 R & M and RLE

13 Topic of Presentation Lack of available technical expertise in Indian market for Scope Determination of R & M projects TÜV SÜD South Asia Slide R & M and RLE

14 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 R & M and RLE

15 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 R & M and RLE

16 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 R & M and RLE

17 Regulator The regulator is concerned about the justification of the expenditure on R&M projects and would like to ensure that the investment results in the least additional 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 R & M and RLE

18 Measurable benefits for the clients TÜV SÜD South Asia Slide R & M and RLE

19 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 R & M and RLE

20 Operation Investment Feasibility Planning Feasibility Planning Procurement Construction Commissioning In-service Rehabilitation Decommissioni ng Rehabilitation Decommissioni ng Performance Tests Noise / Vibration / Emissions Testing Staff Training / Qualification Claim Management Plant Status Assessment Plant Status Assessment Due Diligence (TDD - technical, EDD - environmental) Due Diligence (TDD - technical, EDD - environmental) Failure Analysis (RCFA) Failure Analysis (RCFA) Plant Optimization Plant Optimization QA / QC Retrofit Management Retrofit Management Pre-Qualification Design Review Design Approval Design Review Design Approval Tender & Contract Management Tender & Contract Management Licensing Consenting Licensing Consenting Advisory services along the capital value chain Efficiency Consultancy Efficiency Consultancy Refurbishment Decommissioning Refurbishment Decommissioning Owner´s Engineer Technical Advisor TDD Compliance Certification TÜV SÜD Romania Slide I In-service Inspection In-service Inspection

21 Operation Investment Feasibility Planning Feasibility Planning Procurement Construction Commissioning In-service Rehabilitation Decommissioni ng Rehabilitation Decommissioni ng Performance Tests Noise / Vibration / Emissions Testing Staff Training / Qualification Claim Management Plant Status Assessment Plant Status Assessment Due Diligence (TDD - technical, EDD - environmental) Due Diligence (TDD - technical, EDD - environmental) Failure Analysis (RCFA) Failure Analysis (RCFA) Plant Optimization Plant Optimization QA / QC Retrofit Management Retrofit Management Pre-Qualification Design Review Design Approval Design Review Design Approval Tender & Contract Management Tender & Contract Management Advisory services along the capital value chain Efficiency Consultancy Efficiency Consultancy Refurbishment Decommissioning Refurbishment Decommissioning Owner´s Engineer Technical Advisor TDD Compliance Certification In-service Inspection In-service Inspection TÜV SÜD South Asia Slide R & M and RLE

22 Solution to overcome the problem for Lack of Technical expertise TÜV SÜD South Asia Slide R & M and RLE

23 Need for standardization The large fleet of 200/210 MW units which are coming up for R&M provides an opportunity to standardize documents for tendering for R&M to ensure acceptable levels of quality and to harmonize the requirements of all the stakeholders to a reasonable level of satisfaction to permit efficient execution of projects in this crucial programme to meet the power needs of India. TÜV SÜD South Asia Slide R & M and RLE

24 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 R & M and RLE

25 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 R & M and RLE

26 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 R & M and RLE

27 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 R & M and RLE

28 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 R & M and RLE

29 Project References TÜV SÜD South Asia Slide R & M and RLE

30 TÜV SÜD: References for Fluidized Bed Boilers TÜV SÜD Industrie Service GmbHFolie YearClientLocationBoiler technology / Steam parameter Fuel / SOx emission limit TÜV SÜD Services ongoingBertsch. Austria / Outotec, Germany Çorlu, Turkey Bubbling fluidized bed 96 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 ongoingBASF, GermanyLudwigshafen, Germany Bubbling fluidized bed 2x 80 MW(th) Fuel mix: industrial sludge, coal, light oil SOx < 50 mg/Nm³ In-service inspections, Notified Body ongoingUPM, GermanySchongau, Germany Circulating fluidized bed 50 MW(th) Paper waste SOx < 50 mg/Nm³ In-service inspections, Notified Body Kraftanlagen München, Germany / Foster Wheeler, Finland Kladno, Czech Republic Circulating fluidized bed 326 MW(th) LigniteDesign examination boiler assembly Design examination external piping and balance of plant (BoP) Final assessment boiler and BOP assembly Stora-.Enso, Germany Karlsruhe-Maxau, Germany Circulating fluidized bed 156 MW(th) Fuel mix: paper waste, biomass, hard coal SOx < 50 mg/Nm³ Construction supervision, Nofified Body, Site acceptance test hse, GermanyStrambolijski, Bulgaria Bubbling fluidized bed 42 t/h (100 bar, 480°C) Biomass SOx < 50 mg/Nm³ Design Examination Final assessment at workshop (Romania) Final assessment on site Assembly Austrian Energy & Environment, Austria Wittenberg, Germany Circulating fluidized bed 62 t/h (160 bar, 535°C) Biomass SOx < 50 mg/Nm³ Design Examination Final assessment at workshop (Croatia) Final assessment on site Assembly Alstom, Germany Canakkale, Turkey 2x160 MWeLignite, Circulating fluidized bed Manufacturing supervision, Compliance certification, Design review, Design approval, Site acceptance test

31 TÜV SÜD: References for Lignite Fired Power Plants TÜV SÜD Industrie Service GmbHFolie YearClientLocationEl. OutputFuel, Combustion Technology TÜV SÜD Services Kraftanlagen München, Germany / Foster Wheeler, Finland Kladno, Czech Republic 135 MWeLignite, Circulating fluidized bed Design examination boiler assembly Design examination external piping and balance of plant (BoP) Final assessment boiler and BOP assembly 2010Vattenfall, Germany Schwarze Pumpe, Germany 2x 750 MWeLignite, Pulverized coal firing Evaluation and optimization of the O&M scheme for the entire power plant (boiler, steam turbine, balance of plant, etc) 2003/2004Alstom, Germany Canakkale, Turkey 2x160 MWeLignite, Circulating fluidized bed Manufacturing supervision, Compliance certification, Design review, Design approval, Final assessment on site Vattenfall, Germany Boxberg (Block Q), Germany 860 MWeLignite, Pulverized coal firing Manufacturing supervision, Design review, Design approval, Construction supervision, Final assessment on site / Site acceptance test 2006Vemagiri Power Generation Limited, GMR Group (India) Vemagiri, AP India388 MWCombined Cycle Gas Turbine Power Plant Thermal Performance Test on Combined Cycle Power Plant Vemagiri, India, 2009RRVUVN Kali Sindh Thermal Power Project Kali Sindh & Chhabra India 2 x 600 MW and 2 x 25 MW CoalThird 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 2008Reliance Sasan Mega Power Project Sasan, India6 x 660 MWCoalThird 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, India1 x 250 MWCoalField Quality Assurance Services for Civil, Structural, Boiler & Piping, Electrical & C & I Works and Safety Services at 1 x 250 MW Santaldih ( Unit V) Project

32 TÜV SÜD: References for Lignite Fired Power Plants TÜV SÜD Industrie Service GmbHFolie YearClientLocationEl. OutputFuel, Combustion Technology TÜV SÜD Services 2011Essar Power Limited Hazira, Gujarat, IndiaCoalEnergy Audit of a Power Plant 2012Nalwa Steel and Power Ltd Raigarh, IndiaCoalEnergy Audit of a Power Plant 2012G.R. Sponge & Power Ltd Raigarh, IndiaCoalEnergy Audit of a Power Plant 2014Hira Power & Steel Ltd Raigarh, IndiaCoalEnergy Audit of a Power Plant

33 19 April 2015 Thank you for your attention. April 19, 2015 Sapath Dutta Gupta TÜV SÜD South Asia General Manager - Business Development Industrial Services - Power & Systems TÜV SÜD South Asia Pvt. Ltd. Solitaire, 4th Floor, ITI Road, Aundh, Pune , Maharashtra, India. Boardline : Directline : Cell : Fax : Website :


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