Optimize plant efficiency and availability with an integrated

Optimize plant efficiency and availability with an integrated solution Bratin Roy Vice President - Industry Service TÜV SÜD South Asia TÜV SÜD Slide 1 05/10/15 Optimizing plant efficiency with an integrated solution

Overview TÜV SÜD Slide 2 05/10/15 1 Background 2 Steps to provide integrated solution 3 Benefit 4 TÜV SÜD Group – Conventional Power Plant Solution Optimizing plant efficiency with an integrated solution

Background § In today’s changing environment, fossil-fuel plant owners face significant lifecycle management challenges § Along with existing issues like fuel availability, price pressures due to market liberalization, 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 § Coal, Gas and oil power plant upgrades and retrofits are focused on improved efficiency, greater power generation capacity and better emission control systems TÜV SÜD Slide 3 05/10/15 Optimizing plant efficiency with an integrated solution

Overview TÜV SÜD Slide 4 05/10/15 1 Background 2 Steps to provide Integrated solution 3 Benefit 4 TÜV SÜD Group – Conventional Power Plant Solution Optimizing plant efficiency with an 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 § Performance Measurement § Energy Assessment/Audit § Integrated plant retrofits along with comprehensive Renovation & Modernisation Program TÜV SÜD Slide 5 05/10/15 Optimizing plant efficiency with an integrated solution

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 TÜV SÜD Slide 6 05/10/15 Optimizing plant efficiency with an 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. ) Full up time of the plant ensuring 100% productivity, avoiding unnecessary force shut down – Remaining life assessment – Repair/replacement of damaged components TÜV SÜD Slide 7 13 -01 -31 05/10/15 Optimizing plant efficiency with an integrated solution

CPP solutions: 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 TÜV SÜD Slide 8 05/10/15 Optimizing plant efficiency with an integrated solution

Performance Testing – Background Technical contents of Contract / Guarantees § Power Output at dedicated loads § Heat Rate (GJ/GWh) ⇨ Indication of power plant efficiency § Electrical Characteristics, e. g. • Auxiliary power, • Operation test within voltage and frequency limits, • Power factor range prescribed § § Water / Steam Parameters Emissions (Air, Sound Pressure) Vibrations Consumption of Water and Chemicals § Treatment of water and waste water TÜV SÜD Slide 9 05/10/15 Power Output Fuel demand Heat Rate Desired Condition Vibrations Consumptio n (Auxil. Water, Chemicals) Air and Noise Emissions Optimizing plant efficiency with an integrated solution

Performance Testing – Key Parameters Equipment : Measurement system • Accuracy Class of Instruments - RTD (PT 100) up to 150 °C < 0. 1 K - Differential pressure sensors < 1 mbar - Gauge and absolute pressure sensors < 0. 1 % - Powermeter < 0. 1 % • Accredited Calibration / QA TÜV SÜD Slide 10 05/10/15 Optimizing plant efficiency with an integrated solution

Energy Efficiency assessment/Audit Energy efficiency, productivity, reliability and stability – are intimately connected. Fact Success Factor § 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 fossilfuel 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. 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 § 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% TÜV SÜD Slide 11 05/10/15 Optimizing plant efficiency with an integrated solution

Energy Audit/Assessment – steps Energy assessment is key to decide a successful solution Scope § § § § Fuel Handling Plant Boiler Thermal Insulation Ash Handling Water Pumping Fans Steam Turbine Condenser Cooling Compressor Air System Motors Air Conditioning Lighting ESP TÜV SÜD Slide 12 Objective Expected Goal § To conduct energy § Process optimization analysis of the overall plant and determine the § Operational efficiencies and energy improvements losses of all the major components on the § Advance maintenance power plant. to reduce wastage § Select and develop the areas where energy § Capital investment ( up losses are being -gradation; retrofitting ; experienced. renovation & § Determine the costs modernization) and payback periods for the new technologies suggested for efficiency improvement. 05/10/15 Optimizing plant efficiency with an 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 TÜV SÜD Slide 13 13 -01 -31 05/10/15 Optimizing plant efficiency with an integrated solution

Rehabilitation & Modernization Every R & M project is unique, requiring adaptation and system expertise that depends on extensive experience. Objective § 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 TÜV SÜD Slide 14 Methods Expected Goal § Review /Study of Design § Life Extension for another basics, Erection, first 15 to 20 years is possible commissioning and O & M § Increase of rated capacity record/reports 4% - 8% § Energy Audit § Performance testing § Hot and cold walk-down § Increase of efficiency 8%survey of the plant 10% § 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 & 05/10/15 Optimizing plant efficiency with an integrated solution § Cost benefit analysis

TÜV SÜD Slide 15 05/10/15 1 Background 2 Steps to provide Integrated solution 3 Benefit 4 TÜV SÜD Group – Conventional Power Plant Solution Optimizing plant efficiency with an integrated solution

Tangible benefits from integrated life cycle management TÜV SÜD Lower costs, lesser risks Stable cash flow Slide 16 05/10/15 Designed performance Peace of Mind Key Success Factors Maximum yield over the entire life cycle Controlled risks Return of investment Optimizing plant efficiency with an integrated solution

Overview TÜV SÜD Slide 17 05/10/15 1 Background 2 Steps to provide Integrated solution 3 Benefit 4 TÜV SÜD Group – Conventional Power Plant Solution Optimizing plant efficiency with an integrated solution

Our heritage: 149 years of business success 186 6 191 0 192 6 195 8 1990 s 200 6 200 9 Toda y TÜV SÜD Slide 18 05/10/15 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 First vehicle periodic technical inspection (PTI) Introduction of the “TÜV mark / stamp” in Germany Development of a Bavaria-wide network of vehicle inspection centres in the late 1950 s Conglomeration of TÜVs from the southern part of Germany to form TÜV SÜD and the expansion of business operations into Asia Expansion of services in ASEAN by acquiring Singapore-based PSB Group Launch of Turkey-wide vehicle inspection by TÜVTURK TÜV SÜD continues to pursue a strategy of internationalisation and growth Optimizing plant efficiency with an integrated solution

TÜV SÜD in numbers: Growing from strength to strength 1 One-stop Technical Solution Provider 150 Years of Experience 800 Locations Worldwide 1, 900 20, 20 0 Million Euro in Sales Revenue 2013 Employees Worldwide Note: Figures have been rounded off. TÜV SÜD Slide 19 05/10/15 Optimizing plant efficiency with an integrated solution

Global expertise. Local experience. Global Headquarters: Munich, Germany Countries with TÜV SÜD offices Regional headquarters TÜV SÜD Slide 20 05/10/15 GERMANY INTERNATIONA L 1, 190 € mio 10, 400 staff 750 € mio 9, 800 staff Optimizing plant efficiency with an 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 operational safety, reliability and overall performance of power plants for investors, engineering, procurement and construction contractors and operators. TÜV SÜD Slide 21 05/10/15 Optimizing plant efficiency with an integrated solution

Advisory services along the capital value chain INVESTMENT Feasibility & Planning Procurement OPERATION Construction Commission Owner’s engineer Technical due diligence Feasibility study Technical advisor Code compliance Welding surveillance Risk analysis Construction supervision HSE inspections Expediting F 4 S Plant optimization Compliance certification Licensing & consenting Pre-qualification Tender & contract management Design review Design approval Component certification Supplier evaluation Final acceptance test NDT Failure analysis (RCFA) O & M management ISO 9001 ISO 14001 AIM / RBI In-service inspection Claim management Vendor quality assurance Repair supervision LTA NDT EIA Rehabilitation/ modernization management Plant status assessment QA/QC Component certification Refurbishment & Decommission In-service Regulated Non-regulated Calculation Simulation Performance tests Noise / vibration / emissions testing Due diligence (TDD - technical, EDD - environmental) Site assessment Staff training / qualification TÜV SÜD Slide 22 05/10/15 Optimizing plant efficiency with an integrated solution Efficiency consultancy ISO 50001 IEE plant certification

Your Business Benefits: Maximise Profits Promote efficiency, reduce emissions Increase availability, optimize performance Our experts’ impartial perspective fosters cost efficiency in your organisation, while their comprehensive knowledge contributes to your emissions goals. TÜV SÜD’s experts help you obtain professional advice in performance optimization to reduce outage time and increase your return on investment. 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. TÜV SÜD Slide 23 13 -01 -31 05/10/15 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. Optimizing plant efficiency with an integrated solution

Contact us today. www. tuv-sud. in Bratin. Roy@tuv-sud. in TÜV SÜD Slide 24 05/10/15 Optimizing plant efficiency with an integrated solution