Renovation, Modernization and Life Extension service of Power Plant TÜV SÜD Industry Serviceslide...

Renovation, Modernization and Life Extension service of Power Plant

TÜV SÜD Industry Service

slide 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 114-04-21 R & M and RLE

Topics to discuss

1 TUV SUD: Corporate Overview

2 Lack of Technical Expertise for scope determination

3 Measurable benefits for the clients

4Solution to overcome the problem for Lack of Technical expertise

5 Project References


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

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 20121,820

150 years of experience


Global expertise. Local experience.

Global Headquarters: Munich, Germany

INTERNATIONAL

Euro 690 mio8,600 staff

GERMANY

Euro 1,130 mio10,200 staff

Legend:

Countries with TÜV SÜD offices

Regional headquarters


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


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


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


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


April 18, 2023

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 )

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 12000 customers


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


Topic of Presentation

Lack of available technical expertise in Indian market for Scope Determination of R & M projects


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


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.


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


Regulator

The regulator is concerned about the justification of the expenditure on R&Mprojects and would like to ensure that the investment results in the leastadditional 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.


Measurable benefits for the clients


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


OperationOperationInvestmentInvestment

FeasibilityPlanning

FeasibilityPlanning ProcurementProcurement ConstructionConstruction CommissioningCommissioning In-serviceIn-service Rehabilitation

Decommissioning

RehabilitationDecommissioning

Performance TestsPerformance Tests

Noise / Vibration / Emissions TestingNoise / Vibration / Emissions Testing

Staff Training / QualificationStaff Training / Qualification

Claim ManagementClaim Management

Plant StatusAssessment


Due Diligence(TDD - technical, EDD - environmental)


Failure Analysis(RCFA)


PlantOptimization

PlantOptimization

QA / QCQA / QC RetrofitManagement

RetrofitManagement

Pre-QualificationPre-Qualification

Design ReviewDesign Approval


Tender & ContractManagement


LicensingConsenting

LicensingConsenting

Advisory services along the capital value chain

EfficiencyConsultancy


RefurbishmentDecommissioning


Owner´s EngineerOwner´s Engineer Technical AdvisorTechnical Advisor

TDDTDD

Compliance CertificationCompliance Certification

TÜV SÜD Romania Slide 2013-12-06 I

In-serviceInspection


http://www.geda.de/Permanentanlagen/Anwendungsgebiete/Kraftwerk

OperationOperationInvestmentInvestment

Performance TestsPerformance Tests

Noise / Vibration / Emissions TestingNoise / Vibration / Emissions Testing

Staff Training / QualificationStaff Training / Qualification

Claim ManagementClaim Management







PlantOptimization

PlantOptimization

QA / QCQA / QC RetrofitManagement

RetrofitManagement

Pre-QualificationPre-Qualification





Advisory services along the capital value chain





Owner´s EngineerOwner´s Engineer Technical AdvisorTechnical Advisor

TDDTDD

Compliance CertificationCompliance Certification




Solution to overcome the problem for Lack of Technical expertise


Need for standardization

The large fleet of 200/210 MW units which are coming up for R&M provides anopportunity to standardize documents for tendering for R&M to ensureacceptable levels of quality and to harmonize the requirements of all thestakeholders to a reasonable level of satisfaction to permit efficient execution ofprojects in this crucial programme to meet the power needs of India.


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.


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)


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


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).


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.


Project References


TÜV SÜD: References for Fluidized Bed Boilers

TÜV SÜD Industrie Service GmbH Folie 3018.04.23

Year Client Location Boiler technology /Steam parameter

Fuel /SOx emission limit

TÜV SÜD Services

ongoing Bertsch. Austria / Outotec, Germany

Çorlu, Turkey

Bubbling fluidized bed96 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

ongoing BASF, Germany Ludwigshafen, Germany

Bubbling fluidized bed2x 80 MW(th)

Fuel mix: industrial sludge, coal, light oilSOx < 50 mg/Nm³

In-service inspections, Notified Body

ongoing UPM, Germany Schongau,Germany

Circulating fluidized bed50 MW(th)

Paper wasteSOx < 50 mg/Nm³

In-service inspections, Notified Body

2011-2013 Kraftanlagen München, Germany / Foster Wheeler, Finland

Kladno , Czech Republic


Lignite Design examination boiler assembly Design examination external piping and balance of plant (BoP) Final assessment boiler and BOP assembly

2009-2010 Stora-.Enso, Germany

Karlsruhe-Maxau, Germany


Fuel mix: paper waste, biomass, hard coalSOx < 50 mg/Nm³

Construction supervision, Nofified Body,Site acceptance test

2008-2009 hse, Germany Strambolijski, Bulgaria

Bubbling fluidized bed42 t/h (100 bar, 480°C)

BiomassSOx < 50 mg/Nm³

Design Examination Final assessment at workshop (Romania) Final assessment on site Assembly

2007 -2008 Austrian Energy & Environment, Austria

Wittenberg, Germany

Circulating fluidized bed62 t/h (160 bar, 535°C)

BiomassSOx < 50 mg/Nm³

Design Examination Final assessment at workshop (Croatia)Final assessment on site Assembly

2003 - 2004

Alstom,Germany

Canakkale,Turkey

2x160 MWe Lignite,Circulating fluidized bed

Manufacturing supervision, Compliance certification, Design review , Design approval, Site acceptance test

TÜV SÜD: References for Lignite Fired Power Plants


Year Client Location El. Output Fuel ,Combustion Technology

TÜV SÜD Services

2011-2013 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 Lignite,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,Germany

Canakkale,Turkey

2x160 MWe Lignite,Circulating fluidized bed

Manufacturing supervision, Compliance certification, Design review , Design approval, Final assessment on site

1997-2000 Vattenfall, Germany

Boxberg (Block Q),Germany

860 MWe Lignite,Pulverized coal firing

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 Coal 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 Coal 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

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 Coal Energy Audit of a Power Plant

2012 G.R. Sponge & Power Ltd


2014 Hira Power & Steel Ltd


April 18, 2023

Thank you for your attention.April 18, 2023

Sapath Dutta GuptaTÜV SÜD South AsiaGeneral Manager - Business DevelopmentIndustrial Services - Power & Systems TÜV SÜD South Asia Pvt. Ltd.Solitaire, 4th Floor, ITI Road, Aundh,Pune - 411 007,Maharashtra, India. Boardline : +91-020-66841212Directline : +91-020-66841215Cell : +91-7767803522Fax : +91-020-66841261

E-mail : [email protected] : www.tuv-sud.in

mailto:[email protected]

http://www.tuv-sud.in/

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