1. Optimise plant performance with an integrated solution
Bratin Roy
Vice President - Industry Service
TÜV SÜD South Asia
CPP Integrated Solution

2. CPP Integrated Solution
Overview 1
Background 2
Steps to provide integrated solution 3
Benefit 4
TÜV SÜD Group – Conventional Power Plant Solution
CPP Integrated Solution

3. 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)
CPP Integrated Solution

4. CPP Integrated Solution
Overview 1
Background 2
Steps to provide Integrated solution 3
Benefit 4
TÜV SÜD Group – Conventional Power Plant Solution
CPP Integrated Solution

5. 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
CPP Integrated Solution

6. CPP Integrated Solution
Condition Assessment
12/04/2017
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
Speakers notes
Supporting product quality worldwide
The Global supply chain is becoming increasingly complex. At the same time, the rapid turnover of fashion cycles places additional demand on clothing companies. TÜV SÜD recognises these difficulties and provides solutions to meet both customer and regulatory requirements in your markets.
CPP Integrated Solution
TÜV SÜD Corporate Presentation

7. and retrofit techniques
Operation & Maintenance – status assessment
Plant status assessment
Modern maintenance
and retrofit techniques
Benefits
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
SS IMAGE NO
CPP Integrated Solution

8. Non-destructive Tests
Operation & Maintenance - in-service inspection
In-service inspection
Destructive Tests
Non-destructive Tests
Systems and equipment
Metallographic Testing
Creep/Stress Rupture Testing
Measurement of Mechanical properties
Microbiological analysis
Metallurgical Chemistry Analysis
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
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
CPP Integrated Solution

9. CPP solutions: Performance test for power plants and energy systems
12/04/2017
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
Speakers notes
Supporting product quality worldwide
The Global supply chain is becoming increasingly complex. At the same time, the rapid turnover of fashion cycles places additional demand on clothing companies. TÜV SÜD recognises these difficulties and provides solutions to meet both customer and regulatory requirements in your markets.
CPP Integrated Solution
TÜV SÜD Corporate Presentation

10. Risk-based inspection and maintenance
12/04/2017
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
Speakers notes
Supporting product quality worldwide
The Global supply chain is becoming increasingly complex. At the same time, the rapid turnover of fashion cycles places additional demand on clothing companies. TÜV SÜD recognises these difficulties and provides solutions to meet both customer and regulatory requirements in your markets.
CPP Integrated Solution
TÜV SÜD Corporate Presentation

11. CPP Integrated Solution
Energy Efficiency assessment
Energy efficiency, productivity, reliability and stability – are intimately connected.
Fact
Procedures
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%
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
SS IMAGE NO
CPP Integrated Solution

12. Integrated Retrofitting
12/04/2017
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
Speakers notes
Supporting product quality worldwide
The Global supply chain is becoming increasingly complex. At the same time, the rapid turnover of fashion cycles places additional demand on clothing companies. TÜV SÜD recognises these difficulties and provides solutions to meet both customer and regulatory requirements in your markets.
CPP Integrated Solution
TÜV SÜD Corporate Presentation

13. CPP Integrated Solution
Renovation & Modernisation
Every R & M project is unique, requiring adaptation and system expertise that depends on extensive experience.
Objective
Methods
Expected Goal
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
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
Life Extension for another 15 to 20 years is possible
Increase of rated capacity 4% - 8%
Increase of efficiency 8%-10%
CPP Integrated Solution

14. CPP Integrated Solution1
Background 2
Steps to provide Integrated solution 3
Benefit 4
TÜV SÜD Group – Conventional Power Plant Solution
CPP Integrated Solution

15. Tangible benefits from integrated life cycle management
12/04/2017
Maximum yield over the entire life cycle
Designed performance
Speakers notes
TÜV SÜD provides tangible economic benefits for your business:
Increased market access: TÜV SÜD’s wide scope of accreditations, comprehensive laboratory network, technical expertise and understanding of buyers specifications worldwide enable us to provide one-stop testing and certification services that facilitate entry to multiple markets.
Increased productivity & profit: Through plant, building, product and process improvement that will lead to more operational uptime, greater efficiency and more marketable products.
Increased brand reputation: Product recalls and scandals due to environmental, quality and safety issues can have a long-lasting impact on your reputation and your bottom line. Working with an independent, world renowned safety partner will enable you to pinpoint problems at an early stage. Ensuring your reputation stays intact.
Reduced costs and inefficiencies: Periodic inspections, quality and safety testing, employee training and system audits & certification will enable you to reduce costs of operation, product development and distribution as well as running your operations more efficiently.
Reduced time to market: TÜV SÜD’s one-stop services enable you to fulfill all your compliance needs through a single partner. Furthermore, our experts are able to provide technical support from the onset of your project to ensure reduction in time consuming rework.
Reduced business risks: We partner you to identify potential problems / issues in a preventative manner to minimise risk of operational failure or product flaws that could lead to environmental damage; loss of human life and/or operational downtime.
Lower costs, lesser risks
Controlled risks
Peace of Mind
Key Success Factors
Stable cash flow
Return of investment
CPP Integrated Solution
TÜV SÜD Corporate Presentation

16. CPP Integrated Solution
Overview 1
Background 2
Steps to provide Integrated solution 3
Benefit 4
TÜV SÜD Group – Conventional Power Plant Solution
CPP Integrated Solution

17. 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

18. CPP Integrated Solution
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
1,900
Million Euro in Sales Revenue 2013
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 1.8 billion Euros, our 18,800 employees act as process partners to our customers wherever their business is located.
20,200
Employees Worldwide
Note: Figures have been rounded off.
TÜV SÜD
CPP Integrated Solution
TÜV SÜD Corporate Presentation

19. Global expertise. Local experience.
12/04/2017
Global Headquarters: Munich, Germany
Speakers notes
Headquartered in Munich, Germany, TÜV SÜD is a multi-national corporation with a vast office and laboratory network in over 800 locations around the globe. Clients benefit from the winning combination of German technical excellence and local in-country experts familiar with local market standards and regulations.
Our regional headquarters:
North America: Peabody, USA
South America: Sao Paolo, Brazil
Germany: Munich, Germany
Central & Eastern Europe: Czech Republic
Middle East & Africa: Cape Town, South Africa & Dubai, UAE
South Asia: Puna, India
Greater China: Shanghai, China
Korea: Seoul, South Korea
Japan: Tokyo, Japan
ASEAN: Singapore, Singapore
Additional notes
To edit map:
Click on any object on slide
Click on Format on the ribbon
Click on “Selection Pane”
A list of countries and objects will appear
Click on the countries which you would like to select (hold on to ctrl key while clicking for multiple selection)
Change the colours of the selection
Countries are already grouped into those with TÜV SÜD offices and those without
Countries with TÜV SÜD presence: Blue
Countries without TÜV SÜD presence: Grey
INTERNATIONAL
750 € mio
9,800 staff
GERMANY
1,190 € mio
10,400 staff
Countries with TÜV SÜD offices
Regional headquarters
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TÜV SÜD Corporate Presentation

20. 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 customers
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21. 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
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22. Holistic solutions across the value chain
12/04/2017
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.
CPP Integrated Solution
TÜV SÜD Corporate Presentation

23. Advisory services along the capital value chain
INVESTMENT
OPERATION
Feasibility &
Planning
Procurement
Construction
Commission
In-service
Refurbishment & Decommission
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
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
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
LTA
F4S
Repair
O & M
management
AIM / RBI
Regulated
Non-regulated
ISO 50001
IEE plant certification
Component
certification
ISO 9001
ISO 14001
Asset life cycle project steps
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24. Your Business Benefits: Maximise Profits
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.
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25. www.tuv-sud.in info@tuv-sud.in
Contact us today.
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