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Company Presentation

Company Presentation. STEAG encotec. Experience Counts. STEAG encotec is the engineering arm of STEAG AG , a power plant owner and operator as well as Germany’s leading IPP. Overview. Introduction STEAG Profile STEAG Resources STEAG References in India

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Company Presentation

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  1. Company Presentation STEAG encotec.Experience Counts STEAG encotec is the engineering arm of STEAG AG, a power plant owner and operator as well as Germany’s leading IPP

  2. Overview • Introduction • STEAG Profile • STEAG Resources • STEAG References in India • STEAG References in Consultancy jobs • Scope & Methodology for Consultancy job of Sikka 2x250 MW Extn Project • IT Solutions for Power Industry

  3. Structure of the STEAG Group ARCELOR THYSSEN RWE E.ON -KRUPP REAL ESTATE DSK DEGUSSA German Mining Group

  4. IPP International • Total sales 2003251 EUR m • ProjectDevelopment • FinancialEngineering • Construction andOperation STEAG AG International Power Group No.1 Coal Mining Company inEurope Power Generation Gas and coal trading No.1 IPP in Germany • Total sales 2003856 EUR m • Electricity • District Heating • By-productManagement • Energy Services/Contracting • Total sales 20032.446 EUR m • Gas supply, transport and trading • Marketing, processing and transport of hard coal, coke or carbon by-products

  5. STEAG unites all energy activities in the RAG Group STEAG AG, Essen 100 % 100 % (2005) STEAG encotec GmbH STEAG Saar Energie AG 100 % 100 % SOTEC GmbH STEAG Fernwärme GmbH 76,88 % (To be sold in 2006) 100 % STEAG Saar Ferngas STEAG Entsorgungs-GmbH 74,8 % 51 % Minegas GmbH Iskenderun Enerji Uretim ve Ticaret A.S., 60 % 51 % Mingas-Power GmbH Compania Electrica de Sochagota S.A., 89 % 51 % STEAG State Power Inc., RAG Verkauf GmbH 51 % 100 % STEAG-EVN Walsum 10 Kraftwerksgesellschaft mbH RAG Trading GmbH

  6. Power Generation • Decentralized Energy Supply / Renewables • Foreign Power Plants • Gas Distribution • Coal Trading Employees: 4,996 STEAG as of 2006:A strong, highly profitable core energy division Sales EUR 5,708 million Project investmentEUR 369 million 18 % 4 % 6,5 % 21 % 50,5 %

  7. Power Generation Decentralized EnergySupply / Renewables ForeignPower Plants Gas Distribution Coal Trading • SalesEUR m 1,013 • Project investmentEUR m 232 • Employees2,773 • SalesEUR m 226 • Project investmentEUR m 61 • Employees915 • SalesEUR m 370 • Project investmentEUR m 49 • Employees639 • SalesEUR m 1,218 • Project investmentEUR m 23 • Employees149 • SalesEUR m 2,881 • Project investmentEUR m 4 • Employees303 STEAG as of 2006:Solid foundation for mastering the challenges of the future

  8. Communication Technology About STEAG Management Board Human Resources Business Development & Marketing Engineering Services Power Services Business Administration Energy Technology NuclearTechnology Operation & Maintenance Subsidiaries Wandelt STEAG KETEK IT GmbH 100 %STEAG LLC Durham, USA 100 %STEAG encotec do Brasil Ltda. 100 %STEAG encotec West Africa 97 %STEAG encotec (India) P Ltd. 100 %BTU STEAG O&M Services 50 %BZ Ahaus GmbH 45 % Process and Plant Technology Measuring &Performance Evaluation Civil Engineering Sales: 50 m €/a Employees: 360 I&C Technology

  9. About STEAG encotec GmbH • Wholly owned subsidiary of STEAG AG, Germany. • Germany’s largest IPP and one of the five largest IPPs of Europe. • Budgetary turnover of STEAG AG, €5,000 Million equivalent to Rupees 23,000 Crores. • Owns and operates around 11,000 MW of installed capacity of Coal, Gas and Refinery Residue based Power Plants. (90% of which is Coal based)

  10. Supplier Consultant Plant Operator STEAG encotecmission STEAG encotec GmbH - Services as “Operating Engineer” Engineer Focussed on long term, efficient operation Development of new technologies Continous exchange of experience due to feedback from STEAG-plants Application of proven processes Over 65 years experience in realisation of small, medium and large scale power projects Operator

  11. GermanyRhein-Ruhr-Area• Bergkamen• Voerde• Herne• Walsum• Lünen• Bexbach• Weiher• Fenne• Cologne-Godorf• Leuna Bergkamen 747 MW Voerde 2.120 MW Herne 950 MW Walsum 600 MW Lünen 500 MW Bexbach 773 MW Weiher 707 MW Fenne 501 MW Germany Walsum 10 Philippines Mindanao TurkeyIskenderun ColumbiaTermopaipa STEAG-Power Plants Drawing on decades of experience. . . . . . breaking new ground in the power business GodorfRefinery 211 MW COD 2004 Iskenderun 1.320 MW COD 2003 Termopaipa 165 MW COD 1999 LeunaRefinery 158 MW. COD 1996 Mindanao 232 MW. COD 2006 Walsum 750 MWCOD 2010

  12. STEAG encotec (India) Ltd Engineering Services for the Indian Energy Industry Highlights • 100% subsidiary of STEAG encotec GmbH • Founded in 2001 • Number of Employees: 170 • Revenue in 2006: ~Rs 230 Million

  13. Organisation of STEAG encotec India Board of Directors Business Development Administration O&M Engineering IT Hazira Consultancy Online Optimization Gandhar IT-Development RLA & Audit Afam Power PlantEvaluation Simulator Haldia Goa

  14. About STEAG encotec India • STEAG encotec (India) Pvt. Ltd.(SeI) is wholly owned subsidiary of STEAG encotec GmbH, Germany. • SeI offers services in the field of: • Engineering Consulting Services • Power Generation • Operation and Maintenance • Renovation & Modernization • Information Technology for Power Plants • New Technologies for Power Plants

  15. Engineering Resources

  16. Key SeG Personnel • Mr. Achim Nietzschmann: • Over 20 years experience in Power Plants from preparation of Feasibility Reports to Erection of Power Plants throughout the world. • Was Project Leader in formulation of a Comprehensive Detailed Project Report for Kattupalli Power Plant, India • Mr. Kai Uwe Braekler: • Wide range of Experience in Power Plants all over the world including India. • Was involved in the preparation of DPR for the 2x250 MW Refinery Residue Plant for IOCL at Savli, Gujarat.

  17. Key SeIPersonnel Mr. Boben Anto: • Over 20 years experience in Power Plants • Head of Engineering Division • Ex NTPC & M.Tech.from IIT Delhi • Power Plant mapping and performance optimization study more than 10 plants in India Mr. Ravindra Mathur: • Over 30 years experience in Power Plants • Head of I&C Division • Ex TCE, B.Tech.(Electrical) from IIT Delhi • Wide experience in I&C Design, Engineering and Commissioning • Developed Simulator for CCPP Mr. Prabir Purkayastha: • Over 30 years experience in Power plant System Design • Head of IT Division • Ex Desein Head of I&C Division, BE(Mech) and ME(Comp Sc) • Experience in Thermodynamics and modelling related to power plants and I&C, 1997 2X650 MW Gas fired Steam Power plant in Egypt

  18. Key SeIPersonnel Mr. Arun Sarna: • Over 17 years experience in Power Plants • Ex ALSTOM/PPIL & M.Tech.from IIT Roorkee • Head of Technical Assessment & Audit Division • Certified Steam Path Auditor by Encotech Inc. • Experience of >15 RLA studies & 6 Steam Path Audits in India Mr. K D Paul: • Over 25 years experience in Power Plants • Head of Civil Division • Ex Desein, B.Tech.(Civil) from IIT Delhi • Wide experience in Civil Design, Engineering and Consultancy Mr. J. P. Sinha: • Over 30 years experience in Testing & Inspection • Ex CMERI, Durgapur & Wide experience in Consultancy

  19. Key SeIConsultants Mr. N. S. Venkateswaran: • Over 30 years experience in Power Plants • Ex Worthington & Wide experience in Pumps • Ex-Chairman of IPMA & Member of CII on Energy Panel Mr. O. P. Nanda: • Over 30 years experience in Power Plants Electricals • Ex BHEL & Wide experience in Commissioning Mr. D. Barua: • Over 30 years experience in Material Handling • Ex-BSBK, Ash and coal handling systems expert

  20. STEAG’s Experience • Conventional power plants using high ash coal (>36%) upto unit size of 740 MW. • Supercritical plants upto 750/800 MW. • Refinery residue based power plants. • Associated FGD and DeNox Systems. • Cumulative Engineering experience of all types of plants of about 100,000 MW. • Project Development in Germany, USA, Colombia, Turkey, Philippines etc.

  21. References in India • CONSULTANCY SERVICES – GREENFIELD PROJECTS Detailed Project Report, Technical Specifications, Short listing of EPC Contractors • for the 2x250 MW Refinery Residue Project for IOCL at Savli, Baroda. • for the 1000 MW LNG Plant for Chennai Power Generation Corporation. • Feasibility study for NLC for developing 10600 MW CONSULTANCY SERVICES – RENOVATION & MODERNISATION • Units # 3 & 4, GNDTP, Bathinda RLA AND LE STUDIES • 2x210 MW Units at GGSSTP, Ropar, PSEB • 4x110 MW unit of Koradi TPS of MSEB • 1x110 MW Unit of Panipat TPS of HPGCL

  22. PERFORMANCE TESTING • 210 MW Unit # 1 at Ropar of PSEB (under execution) • 110 MW Unit #1,2,3&4 at Bathinda of PSEB (supervision) • 156 MW CCP at Hazira of GSEG • CONSULTANCY SERVICES – ONLINE OPTIMIZATION OF POWER PLANTS (PADO) • PADO for 14x500 MW Units of NTPC at Simhadri, Ramagundam, Rihand, Talcher, Kahalgaon, Sipat & Vindhyachal Power Plants DIAGNOSTIC SERVICES – POWER PLANT SIMULATION using • Baseline study under Indo German Energy Efficiency Program using Ebsilon Software • §UPRVUNL – Panki, Parichha, Harduaganj, Anpara & Obra Thermal Power Stations. • §RRVUNL – Kota TPS • §MPGENCO – Satpura TPS • §NTPC – Badarpur TPS • §PSEB – Bathinda TPS Steam Path Audits using Encotech, USA Software References in India (Contd…)

  23. References in India (Contd…) O&M SERVICES • 10 Year Comprehensive O&M Contract for 156 MW Gas Based CCPP at Hazira Owner: Gujarat State Energy Generation Co. Ltd • O&M for 30 MW CCCPP at Gandhar Owner: ONGC • 6 Year Comprehensive O&M Contract for 116 MW CCCPP at Haldia for HPLCL Owner: HPL Cogeneration Limted (A subsidiary of L&T) • O&M Service for the V94.2 Siemens CCP of AFAM, Nigeria jointly with STEAG encotec Germany. Owner: Shell ØO&M Advisory services contract for Goa Energy Pvt. Ltd. Project at Amona in Goa for 30 MW WHRP using coke oven & blast furnace gas. Owner: Videocon

  24. West Power Plant, Unit I/II Project Name Herne * Cogeneration Plant, Unit IV Bergkamen Power Plant, Unit A Plant Capacity 1 x 500 MW coal 2 x 350 MW coal 1 x 747 MW el coal Scope of Service Owner's Engineer: Planning and design, construction management, and commissioning of a coal fired unit. Management, operation and maintenance Owner's Engineer: Planning and design, construction management, and commissioning of a coal fired unit. Management, operation and maintenance. Owner's Engineer: Planning and design, construction management, and commissioning of a coal fired unit STEAG AG Geschäftsbereich IPP Owner's/Client's Name STEAG AG Geschäftsbereich IPP STEAG und VEW Gemeinschafts-kraftwerk Bergkamen Frankfurterstr. 430, 46562, Voerde, Germany 02855-12-1091 Hertenerstr. 16, 44653 Herne, Germany 02323-202-299 Address/Fax Wetenhellweg 110, 59192 Bergkamen, Germany 02389-72-381 Year of Commissioning 1981 1970 / 1972 1989 1,300 Project Cost (m DM) 1,150 930 Iskenderun Power Plant 2 x 600 MW Engineer for Project Developer Group: Plant layout, turn-key specification, evaluation of proposal. Owner's Engineer: Technical Support and Construction Management Iskenderun Project Company Rüttenscheiderstr. 1-3, 45128 Essen, Germany 0201-801-1179 2003 2,600 References List of Projects: Complete Design Engineering, Tendering, Construction & Erection Supervision and Commissioning

  25. Voerde Power Plant, Unit A + B Project Name Walsum Cogeneration Plant, Unit 9 Plant Capacity 2 x 710 MW el coal 410 MW el coal Scope of Service Owner's Engineer: Planning and design, construction management, and commissioning of a coal fired unit. Management, operation and maintenance. Owner's Engineer: Planning and design, construction management, and commissioning of a coal fired unit. Management, operation and maintenance Kraftwerk Voerde STEAG-RWE oHG STEAG AG, Geschäftsbereich IPP Owner's/Client's Name Dr. -Wilhelm-Roelen-Str. 129, 47179 Duisburg, Germany, 0203-4996-203 Frankfurtestr. 430, 46562 Voerde, Germany 02855-12-1091 Address/Fax 1988 1982 /1985 Year of Commissioning 740 Project Cost (m DM) 2,400 Yang Liu Qing Power Plant 300 MW coal Conceptual design, technical specifications, bid evaluation, award of contract for two coal fired 300 MW units. Hua Neng Power Generation Corporation 11/F Hua Neng Build, No.A23, Fuxinglu, Beijing, Hai Dian District, 100036, China 1994 4,075 Herne Cogeneration Plant, Unit III 300 MW coal Owner's Engineer: Planning and design, construction management, and commissioning of a coal fired unit. Management, operation and maintenance. STEAG AG Geschäftsbereich IPP Hertenerstr. 16, 44653 Herne, Germany 02323-202-299 1966 480 References List of Projects: Complete Design Engineering, Tendering, Construction & Erection Supervision and Commissioning (Contd…)

  26. Power Plant Client Project Electrical Output Commercial Operation Patagonia, Argentina Federación de Trabaja-dores de Luz Operation and maintenance assistance of several gas-turbines in Patagonia 237 MW GT 1993 West Cogeneration Plant Stadtwerke Frankfurt/Main Owner’s Engineer: Basic design, preparation of permit documents, bid specification, evaluation of bids, approval of turn-key supplier’s documents, construction and commissioning supervision 100 MW GT/Cogen. 1994 Leuna STEAG Energieanlagen S.A. GmbH Owner’s Engineer: Planning, construction management, commissioning, operation and maintenance of a combined cycle cogeneration plant 129 MW CCGT/Cogen. 1994 Ikot Abasi, Nigeria Ferrostaal AG Construction supervision, commissioning, operation and maintenance services as well as training of the operation personnel of the gas turbine power plant 540 MW GT 1995 Schwarze Pumpe Sekundärrohstoff-Verwertungszentrum Schwarze Pumpe GmbH Conceptual design for the erection of the combined-cycle power plant including trial run and commissioning 80 MW CCGT 1995 Major References of STEAG in Gas Turbines / Combined Cycle

  27. Power Plant Gandhar, India Agua del Cajón, Argentina Stassfurt, Germany Client ONGC, Ankleshwar Kraftwerksgesellschaft mbH Stassfurt, Germany Capex S.A. Argentina Operation of an Open Cycle Gasturbine Plant, Commissioning of the water-steam cycle extension, Operation and Maintenance of the Combined Cycle Plant for a period of seven years Owner’s Engineer: Project management and site supervision for erection and commissioning of a combined cycle plant, supplied by the EPC-Contractor Project O&M of 30 MW Gas Turbine Electrical Output 120 MW CCGT 670 MW CCGT 30 MW CCGT 1999 2004 1996 Commercial Operation Haldia, West Bengal HPL Cogeneration Limited ((A subsidiary of L&T) Operation & Maintenance of Combined Cycle Cogeneration plant for six years, GT 2x38.5 MW, ST 1x34 MW Condensing, ST 1x14 MW Backpressure, 2 nos HRSGs, 2 nos. Service Boilers 116 MW CCCGT 2006 Cuiabá, Brazil Empresa Produtora de Energia, Ltda Enron International, Brazil Support of the Investor in plant commissioning, especially Gas turbine Siemens V84.3 a 270 MW CCGT 1998 Major References of STEAG in Gas Turbines / Combined Cycle

  28. Power Plant Kraftwerk Lausward, Germany Client Stadtwerke Düsseldorf, Germany Project Owner´s Engineer, Construction, Supervision and Commissioning of a Combined Cycle Plant Electrical Output 100 MW CCGT 2000 Commercial Operation Kraftwerk Burghausen Fortum, Germany Owner´s Engineer: EPC-contract, Planning-control, construction management, commissioning support 120 Mwel500 ME th CCGT 2001 Hazira, Gujarat, India Gujarat State Energy Generation Limited, India Ower’s Engineer: Planning, construction management, commissioning, operation and maintenance of a combined cycle power plant 156.1 MW CCPP 2002 Brazos Valley, Texas/USA STEAG Power LLC, Houston/ NRG Energy, Minneapolis Owner’s Engineer: Project development, conceptual design, basic design, economical calculations, financial engineering, specification, negotiation of all contracts for a combined cycle power plant 600 MW CCGT 2003 Mint Farm, Washington/USA AVISTA-STEAG, Spokane Owner’s Engineer: Project development, conceptual design, basic design, economical calculations, financial engineering, specification, negotiation of all contracts for a combined cycle power plant 250 MW CCGT 2003 Major References of STEAG in Gas Turbines / Combined Cycle

  29. The scope of services to be rendered within the framework of this contract can be broadly sub-divided into the following: • Preparation of RFQ • Preparation of RFP for Power-plant • Support towards order placement on successful Contractor: bid evaluation, discussions and recommendations • Review of Design & Engineering • Construction Supervision • Commissioning Supervision GSECL – SIKKA EXTN. PROJECT SCOPE

  30. Support Services Technical specifications • Detailed Scope of Supply of Main Plant & Equipment • Technical Particulars of Mechanical, C&I, Electrical & Civil Works • Scope of Supply of Balance of Plant Works • Defined Performance Parameters: Unit Heat Rate; Station Heat Rate; Auxiliary Power Consumption • Acceptance Tests • Procedures and Standards for Erection, Construction work, Testing & Commissioning Contd….

  31. Contract Support • Preparation of RFQ document • Preparation of RFP document • Support to Owner towards clarifying queries of bidders on Tender Specification • Technical Evaluation of the Bids • Post Bid meetings to bring all Bidders on a common technical platform • Techno-Commercial Evaluation of the revised bids • Final Bid recommendation after opening of Price Bid • Support towards order placement on successful bidder

  32. Cutting Costsin Plant OperationIT Tools STEAG KETEK IT - Information Technology For more than 15 years, STEAG KETEK IT has been developing and supplying intelligent system technology for use in the STEAG Group and for external customers. The worldwide references confirm the high quality and economic benefit for power utilities and industrial enterprises. The practical application of our systems systematically reduces the operating and energy expenses of customers and thereby their position in the market. Scope of Services: • O&M management systems • Energy management systems • Information management systems • System services and integration

  33. SR1 Lifetime Monitoring SR2 Energy Management SRv DataValidation SRp Statistic Forecast SRx Energy Data Management SR3 Energy Controlling SRk Power Cycle Evaluation SR4 Power Plant Optimisation SR5 Power Trade System Cutting Costsin Plant OperationIT Tools Introduction of Energy Management Systems

  34. Cutting Costsin Plant OperationIT Tools SR2 - Plant Portfolio Optimisation • You have a varying demand of electricity, steam, • hot and chilled water, compressed air, etc. ? • You have alternative means of generating and supplying these energies ? • You have various buying and selling contracts • for your moving energies ? SR2 optimizes your plant operation and reduces your energy bill - typically by 2-5 % ! SR2 returns your investment shortly - often within the first year !

  35. Cutting Costsin Plant OperationIT Tools Concept:comparing the actual status of plant operation with the „best“ status by simulating the entire process identifies potential cost savings to be realized immediately for the operator SR4 – Unit Optimisation • online optimization-system for operation monitoring of large units • periodical data validation (each 5 min.) based on avarage measurements • calculation of important process / component-parameters and consequent appraisal • Identification of sources of economical losses (shown in currancy/hour) ROI < 2 years!!

  36. SR4 – Unit Overview Simhadri

  37. SR4 – Optimal Time for Waterwall Sootblowing Generator Power Waterwall effectivity (fouling) Economic Loss from soon or late sootblowing Optimum Waterwall Sootbl. Signal

  38. SR4 –Turbine Section Simhadri

  39. Cutting Costsin Plant OperationIT Tools Computer-Based Coal Evaluation with SPICE® SPICE®:STEAG Program for Import Coal Evaluation • Recognizing problems of coal use before coal is procured will result in an improvement of availability • A generating cost difference of 1 € for coal grades of equal price results in a profit increase of 500,000 €/a for a 350 MW unit which consumes 500,000 t/a • Constant use of the SPICE® program creates a learning expert system Compatibility of coal blends Difference in power generation costs

  40. S O F B I D Essen Frankfurt Frankfurt Zwingenberg Software for the Power Industry Plant optimization offline with Performance Monitoring online with EbsilonProfessional EPOS Our clients: more than 100 utilities and manufacturers ABB, ALSTOM, BABCOCK, BEWAG, Blohm + Voss, BMW, CEE, Colenco, DSD, ECH, Envi Con, E.ON, Electrowatt Hamburg und Zürich, enertech, ENERGOPROJEKT, EVH, EVT, GKWeser, GEW Rheinenergie, gtz China, gtz India, HEW, IBT, LAUBAG, Lurgi, Mannesmann Seiffert, Mitsubishi HI, Ramboll, MVV, NEM, Schering, PCE ENERTEC, PEF, RAB, Rheinbraun, RWE, Saarberg, Siemens, SIK, Stadtwerke Chemnitz, Stadtwerke Hannover, Standardkessel Lentjes-Fasel, STEAG, TEAG, Technip, TÜV Nord, VA TECH, VEAG, Weig GmbH, ZBP INWAT

  41. Offline process simulation EbsilonProfessional Modellierung Mills • Graphical modelling with tool box • Standard libraries for • fuels (coal, oil, gas) • oxygen carrier • gas turbines • water-steam • user defined and extensible • Error analyzer • English, French, German, Spanish, • multilingual Fluegas path

  42. EbsilonProfessional Interactive offline process calculation Input air temperature Start of the calculation Demo example CCP Total power 10.382 MW Efficiency 38.09% Input of process parameters

  43. Offline process simulation with actual, historical or manipulated data EbsilonProfessional EPOS Choice coal mixture Determination overheads of a power plant water-steam-circuit air path mills fluegas path fluegas desulphurization unit

  44. Summary • Consultant with Operation experience • Local experience in providing Owner Engineer services for large size Power plant • Technical and financial evaluation using Ebsilon software on the working model of proposed plant • Simulation capabilities to optimize efficiency through use of Ebsilon, SR4, eSTPE & other Software tools • PET experience • Full technical backup support from parent company to ensure International standards

  45. Thanks

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