1. Renovation, Modernization and Life Extension service of Power Plant
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 Industry Service slide 1 / Dan Rosca
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2. TÜV SÜD image presentation (Asia Pacific)
2017/4/12
Topics to discuss 1
TUV SUD: Corporate Overview 2
Lack of Technical Expertise for scope determination 3
Measurable benefits for the clients 4
Solution to overcome the problem for Lack of Technical expertise 5
Project References
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Department

3. Our heritage: 146 years of business success
12/04/2017
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
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
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TÜV SÜD Corporate Presentation

4. TÜV SÜD in numbers: Growing from strength to strength
12/04/2017 1
one-stop technical solution provider
150
years of experience
800
locations worldwide
1,820
million Euro in sales revenue 2012
18,800
Speakers notes
This slide provides you with a quick overview of TÜV SÜD in numbers. We are a 1 stop technical solution provider, powered by about 150 years of experience in the safety, quality and sustainable business. With 800 locations worldwide and a stable revenue of 1.7 billion Euros, our 17,200 employees act as process partners to our customers wherever their business is located.
employees worldwide
TÜV SÜD
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TÜV SÜD Corporate Presentation

5. Global expertise. Local experience.
12/04/2017
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
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TÜV SÜD Corporate Presentation

6. Technical expertise & broad industry knowledge
12/04/2017
Testing & product certification
Inspection
Auditing & system certification
Knowledge services
Training
Chemical, physical, mechanical, electrical and environmental testing and product certification.
Product, system, building, plant and infrastructure inspection.
Audits system certification in a variety of fields including quality, safety, energy, social compliance and environment.
Safety, quality, risk, environmental protection and regulatory advisory.
Training in work safety, technical skills, management systems and executive programs.
Speakers notes
Our technical expertise and broad industry knowledge enable us to provide the following technical services:
Testing & product certification
Inspection
Auditing & system certification
Knowledge services: Technical support such as design reviews and identification of resource optimization.
Training
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TÜV SÜD Corporate Presentation

7. INDUSTRY: Minimise risks. Optimise results.
12/04/2017
Chemical, oil & gas
Power & energy
Manufacturing & industrial machinery
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
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
Services for components manufacturers, contractors, installation providers, equipment & material manufacturers and operators include:
Component testing
Periodic inspection of equipment
Failure analysis
System certification
Training
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TÜV SÜD Corporate Presentation

8. CERTIFICATION: Achieve market success
12/04/2017
Manufacturing & industrial machinery
Consumer products & retail
Healthcare & medical devices
Telecommunications & IT
Services for components manufacturers, contractors, installation providers, equipment & material manufacturers and operators include:
Component testing
Periodic inspection of equipment
Failure analysis
System certification
Training
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
Services for medical device manufacturers and healthcare providers include:
Clinical approvals
Market approvals and certification
Testing
Evaluation
Quality control
System certification
Training
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
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TÜV SÜD Corporate Presentation

9. Blue solutions for a sustainable future
12/04/2017
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
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
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TÜV SÜD Corporate Presentation

10. 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 )
12 April 2017

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
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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
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13. Topic of Presentation
Lack of available technical expertise in Indian market for Scope Determination of R & M projects
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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
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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.
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16. Accuracy of the estimated costs
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
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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.
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18. Measurable benefits for the clients
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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
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20. Advisory services along the capital value chain
Investment
Operation
Feasibility
Planning
Procurement
Construction
Commissioning
In-service
Rehabilitation
Decommissioning
Refurbishment
Decommissioning
Owner´s Engineer
Technical Advisor
TDD
QA / QC
Plant Status
Assessment
Retrofit
Management
Compliance Certification
Plant
Optimization
Failure Analysis
(RCFA)
Licensing
Consenting
Pre-Qualification
Claim Management
In-service
Inspection
Efficiency
Consultancy
Tender & Contract
Management
Performance Tests
Asset life cycle project steps
Design Review
Design Approval
Noise / Vibration / Emissions Testing
Due Diligence
(TDD - technical, EDD - environmental)
Staff Training / Qualification I

21. Advisory services along the capital value chain
Investment
Operation
Feasibility
Planning
Procurement
Construction
Commissioning
In-service
Rehabilitation
Decommissioning
Refurbishment
Decommissioning
Owner´s Engineer
Technical Advisor
TDD
QA / QC
Plant Status
Assessment
Retrofit
Management
Compliance Certification
Plant
Optimization
Failure Analysis
(RCFA)
Tender & Contract
Management
Pre-Qualification
Claim Management
In-service
Inspection
Efficiency
Consultancy
Design Review
Design Approval
Performance Tests
Asset life cycle project steps
Noise / Vibration / Emissions Testing
Due Diligence
(TDD - technical, EDD - environmental)
Staff Training / Qualification
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22. Solution to overcome the problem for Lack of Technical expertise
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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.
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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.
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25. Performance evaluation tests (PET);
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)
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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
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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).
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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.
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29. Project References
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30. TÜV SÜD: References for Fluidized Bed Boilers
Year
Client
Location
Boiler technology /
Steam parameter
Fuel /
SOx emission limit
TÜV SÜD Services
ongoing
Bertsch. 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        
BASF, Germany
Ludwigshafen,
Germany
2x 80 MW(th)
Fuel mix: industrial sludge, coal, light oil
In-service inspections, Notified Body
UPM, Germany
Schongau,
Circulating fluidized bed
50 MW(th)
Paper waste
Kraftanlagen München, Germany / Foster Wheeler, Finland
Kladno ,
Czech Republic
326 MW(th)
Lignite
Design examination external piping and balance of plant (BoP)
Final assessment boiler and BOP assembly      
Stora-.Enso, Germany
Karlsruhe-Maxau, Germany
156 MW(th)
Fuel mix: paper waste, biomass, hard coal
Construction supervision, Nofified Body,
Site acceptance test
hse, Germany
Strambolijski,
Bulgaria
42 t/h (100 bar, 480°C)
Biomass
Design Examination              
Final assessment at workshop (Romania)
Final assessment on site Assembly          
Austrian Energy & Environment, Austria
Wittenberg, 
62 t/h (160 bar, 535°C)
Final assessment at workshop (Croatia)
Final assessment on site Assembly 
Alstom,
Canakkale,
2x160 MWe
Lignite,
Manufacturing supervision, Compliance certification, Design review , Design approval, Site acceptance test

31. TÜV SÜD: References for Lignite Fired Power Plants
Year
Client
Location
El. Output
Fuel ,
Combustion Technology
TÜV SÜD Services
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
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,
Canakkale,
Turkey
2x160 MWe
Manufacturing supervision, Compliance certification, Design review , Design approval, Final assessment on site
Boxberg (Block Q),
860 MWe
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
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
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

32. TÜV SÜD: References for Lignite Fired Power Plants
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
G.R. Sponge & Power Ltd
2014
Hira Power & Steel Ltd

33. TÜV SÜD image presentation Asia Pacific
2017/4/12
Thank you for your attention.
April 12, 2017
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     :
12 April 2017
Department