optimise plant performance with an integrated solution€¦ · · 2014-10-27optimise plant...

Optimise plant

performance with an

integrated solution Bratin Roy

Vice President - Industry Service

TÜV SÜD South Asia

TÜV SÜD South Asia Slide 1 CPP Integrated Solution

Overview

1 Background

2 Steps to provide integrated solution

3 Benefit

TÜV SÜD Group – Conventional

Power Plant Solution 4


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)


Overview

1 Background

2 Steps to provide Integrated solution

3 Benefit


Power Plant Solution 4


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


Condition Assessment

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


Modern maintenance

and retrofit techniques

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

Operation & Maintenance – status assessment

13-01-31

Benefits

Plant status assessment


Operation & Maintenance - in-service inspection

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Destructive Tests

In-service inspection

Non-destructive Tests Systems and equipment

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

Metallographic Testing

Creep/Stress Rupture Testing

Measurement of Mechanical

properties

Microbiological analysis

Metallurgical Chemistry Analysis

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 solutions: Performance test for power plants and energy

systems

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


Risk-based inspection and maintenance

13-01-31 TÜV SÜD South Asia Slide 10 CPP Integrated Solution

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

Fact

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%

Energy Efficiency assessment

Procedures

Energy efficiency, productivity, reliability and stability – are intimately connected.


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

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


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

Life Extension for another 15 to

20 years is possible

Increase of rated capacity 4% -

8%

Increase of efficiency 8%-10%

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

Renovation & Modernisation

Objective

Every R & M project is unique, requiring adaptation and system expertise that depends on extensive experience.

Methods Expected Goal


Background

Steps to provide Integrated solution

Benefit


Power Plant Solution


1

2

3

4

Tangible benefits from integrated life cycle management

CPP Integrated Solution

Key S

uc

ce

ss

Fa

cto

rs

Maximum yield over

the entire life cycle Designed performance

Controlled risks

Return of investment

Lower costs, lesser risks

Stable cash flow Pea

ce

of

Min

d

Overview

Background

Steps to provide Integrated solution

Benefit


Power Plant Solution


1

2

3

4

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 20,200

Million Euro in Sales

Revenue 2013

1,900

150 Years of Experience

Note: Figures have been rounded off.


Global expertise. Local experience.

Global Headquarters:

Munich, Germany

INTERNATIONAL

750 € mio

9,800 staff

GERMANY

1,190 € mio

10,400 staff Countries with TÜV SÜD offices

Regional headquarters


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


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


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.

13-01-31 CPP Integrated Solution

Advisory services along the capital value chain


Feasibility &

Planning

Refurbishment &

Decommission Procurement Construction

Commission

In-service

INVESTMENT OPERATION

Component

certification

Component

certification

ISO 9001

ISO 14001

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

NDT

LTA

F4S

Repair

supervision

O & M

management

AIM / RBI

Regulated

Non-regulated

ISO 50001

IEE plant

certification

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

management

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

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.

Your Business Benefits: Maximise Profits


Contact us today.

www.tuv-sud.in

[email protected]


optimise plant performance with an integrated solution€¦ · · 2014-10-27optimise plant...

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