Optimise plant performance with an integrated solution

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

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

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

Condition Assessment • Condition AssessmentThese 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 CPP Integrated Solution

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 13-01-31 CPP Integrated Solution

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 13-01-31 CPP 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 CPP Integrated Solution

Risk-based inspection and maintenance • 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 13-01-31 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 • SootblowerOptimisation • 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 CPP Integrated Solution

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 13-01-31 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

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

Tangible benefits from integrated life cycle management Maximum yield over the entire life cycle Return of investment Designed performance Lower costs, lesser risks Controlled risks Stable cash flow Peace of Mind Key Success Factors CPP Integrated Solution

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

Our heritage: 146 years of business success • 1866 • 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 • Today • TÜV SÜD continues to pursue a strategy of internationalisation and growth • Expansion of services in ASEAN by acquiring Singapore-based PSB Group • 2006 • 1910 • First vehicle periodic technical inspection (PTI) • Development of a Bavaria-wide network of vehicle inspection centres in the late 1950s • 1958 • Introduction of the “TÜV mark / stamp” in Germany • 1926 • Conglomeration of TÜVs from the southern part of Germany to form TÜV SÜD and the expansion of business operations into Asia • 1990s • 2009 • Launch of Turkey-wide vehicle inspection by TÜVTURK CPP Integrated Solution

TÜV SÜD in numbers: Growing from strength to strength 1 One-stop Technical Solution Provider 150 Years of Experience 800 Locations Worldwide Million Euro in Sales Revenue 2013 1,900 Employees Worldwide 20,200 Note: Figures have been rounded off. TÜV SÜD CPP Integrated Solution

Global expertise. Local experience. Global Headquarters: Munich, Germany GERMANY INTERNATIONAL Countries with TÜV SÜD offices 1,190 € mio 10,400 staff 750 € mio 9,800 staff 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 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 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 operationalsafety, reliability and overall performance of power plants for investors, engineering, procurement and construction contractors and operators. 13-01-31 CPP Integrated Solution

Advisory services along the capital value chain INVESTMENT OPERATION Feasibility & Planning Refurbishment & Decommission Construction Commission Procurement In-service Owner’s engineer Technical advisor Plant status assessment Technical due diligence QA/QC Rehabilitation/modernization management Repair supervision LTA Feasibility study Code compliance Welding surveillance Construction supervision Expediting HSE inspections Component certification F4S NDT Risk analysis NDT EIA Plant optimization Compliance certification Failure analysis (RCFA) O & M management Licensing & consenting Pre-qualification Final acceptance test Component certification ISO 9001 ISO 14001 AIM / RBI Tender & contract management Supplier evaluation Efficiency consultancy Claim management In-service inspection Vendor quality assurance Design review Design approval Regulated ISO 50001 Non-regulated IEE plant certification Performance tests Calculation Simulation Noise / vibration / emissions testing Due diligence (TDD - technical, EDD - environmental) Site assessment Staff training / qualification CPP Integrated Solution

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. 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. 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. Promote efficiency, reduce emissions Our experts’ impartial perspective fosters cost efficiency in your organisation, while their comprehensive knowledge contributes to your emissions goals. 13-01-31 CPP Integrated Solution

Contact us today. www.tuv-sud.ininfo@tuv-sud.in CPP Integrated Solution

Optimise plant performance with an integrated solution