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Company Presentation

STEAG encotec. Experience Counts


STEAG encotec is the engineering arm of STEAG AG, a power plant owner and operator as well as Germanys leading IPP

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

Structure of the STEAG Group

ARCELOR

THYSSEN -KRUPP

RWE

E.ON

DEGUSSA

REAL ESTATE

DSK German Mining Group

STEAG AG International Power Group


No.1 Coal Mining Company in Europe

Power Generation IPP International


Total sales 2003 856 EUR m Electricity District Heating By-product Management Energy Services/ Contracting Total sales 2003 251 EUR m Project Development Financial Engineering Construction and Operation

Gas and coal trading


Total sales 2003 2.446 EUR m
No.1 IPP in Germany

Gas supply, transport and trading


Marketing, processing and transport of hard coal, coke or carbon byproducts

STEAG unites all energy activities in the RAG Group


STEAG AG, Essen 100 %
STEAG encotec GmbH

100 % (2005)
STEAG Saar Energie AG
100 % SOTEC GmbH

100 %
STEAG Fernwrme GmbH

100 %
STEAG Entsorgungs-GmbH

76,88 % (To be sold in 2006)


STEAG Saar Ferngas

51 %
Iskenderun Enerji Uretim ve Ticaret A.S.,

74,8 %
Minegas GmbH

51 %
Compania Electrica de Sochagota S.A.,

60 %
Mingas-Power GmbH

89 %
STEAG State Power Inc.,

51 %
RAG Verkauf GmbH

51 %
STEAG-EVN Walsum 10 Kraftwerksgesellschaft mbH

100 %
RAG Trading GmbH

STEAG as of 2006: A strong, highly profitable core energy division


Sales EUR 5,708 million Project investment EUR 369 million

Power Generation Decentralized Energy Supply / Renewables

18 % 4% 6,5 %

Foreign Power Plants


Gas Distribution Coal Trading

21 %

50,5 %

Employees: 4,996

STEAG as of 2006: Solid foundation for mastering the challenges of the future

Power Generation

Decentralized Energy Supply / Renewables

Foreign Power Plants

Gas Distribution

Coal Trading

Sales

Sales

Sales

Sales

Sales

EUR m 1,013
Project investment

EUR m 226
Project investment

EUR m 370
Project investment

EUR m 1,218
Project investment

EUR m 2,881
Project investment

EUR m 232
Employees

EUR m 61
Employees

EUR m 49
Employees

EUR m 23
Employees

EUR m 4
Employees

2,773

915

639

149

303

About STEAG

Management Board

Business Development & Marketing

Human Resources

Engineering Services

Power Services

Business Administration

Energy Technology Process and Plant Technology Civil Engineering I&C Technology

Nuclear Technology
Wandelt

Communication Technology

Operation & Maintenance Measuring & Performance Evaluation

Subsidiaries 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 %

Sales: 50 m /a Employees: 360

About STEAG encotec GmbH

Wholly owned subsidiary of STEAG AG, Germany. Germanys 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)

STEAG encotec mission

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

Over 65 years experience in realisation of small, medium and large scale power projects

Application of proven processes

Operator

STEAG-Power Plants
Germany Rhein-Ruhr-Area Bergkamen Voerde Herne Walsum Lnen Bexbach Weiher Fenne Cologne-Godorf Leuna Turkey Iskenderun Columbia Termopaipa Philippines Mindanao Germany Walsum 10

Drawing on decades of experience. . .

Bergkamen Voerde 747 MW 2.120

Herne 950 MW

Walsum 600 MW

Lnen 500 MW

Bexbach 773 MW

Weiher 707 MW

Fenne 501 MW

MW
. . . breaking new ground in the power business

Godorf Refinery 211 MW COD 2004

Iskenderun 1.320 MW COD 2003

Termopaipa 165 MW COD 1999

Leuna Refinery 158 MW. COD 1996

Mindanao 232 MW. COD 2006

Walsum 750 MW COD 2010

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

Organisation of STEAG encotec India

Board of Directors

Business Development
O&M Hazira Gandhar Afam Haldia Engineering

Administration

IT

Consultancy RLA & Audit


Power Plant Evaluation

Online Optimization

IT-Development

Simulator

Goa

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

Engineering Resources

> 20 years
Mechanical Electrical I&C Civil Total 12 04 02 02 20

8 to 19 years
09 06 05 20

<8 years
12 06 09 1 28

Total
33 16 16 03 68

- List does not include operators and technicians manning plant operations and maintenance at Hazira, Haldia, Gandhar, Afam and Goa.

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.

Key SeI Personnel

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

Key SeI Personnel

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

Key SeI Consultants

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

STEAGs 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.

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

References in India
(Contd)

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)

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 O&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

References

List of Projects: Complete Design Engineering, Tendering, Construction & Erection Supervision and Commissioning

Project Name

Plant Capacit y

Scope of Service

Owner's/Clie nt's Name

Address/Fax

Year of Commiss ioning

Project Cost (m DM)

Bergka men Power Plant, Unit A

1 x 747 MW el coal

Owner's Engineer: Planning and design, construction management, and commissioning of a coal fired unit

STEAG und VEW Gemeinsch aftskraftwerk Bergkamen STEAG AG Geschftsb ereich IPP

Wetenhellwe g 110, 59192 Bergkamen, Germany 02389-72-381

1981

1,300

Herne * Cogene ration Plant, Unit IV

1 x 500 MW coal

Owner's Engineer: Planning and design, construction management, and commissioning of a coal fired unit. Management, operation and maintenance Engineer for Project Developer Group: Plant layout, turn-key specification, evaluation of proposal. Owner's Engineer: Technical Support and Construction Management Owner's Engineer: Planning and design, construction management, and commissioning of a coal fired unit. Management, operation and maintenance.

Hertenerstr. 16, 44653 Herne, Germany 02323-202299 Rttenscheid erstr. 1-3, 45128 Essen, Germany 0201-8011179

1989

930

Iskende run Power Plant

2 x 600 MW

Iskenderun Project Company

2003

2,600

West Power Plant, Unit I/II

2 x 350 MW coal

STEAG AG Geschftsb ereich IPP

Frankfurterst r. 430, 46562, Voerde, Germany 02855-121091

1970 / 1972

1,150

References

List of Projects: Complete Design Engineering, Tendering, Construction & Erection Supervision and Commissioning
(Contd)

Project Name

Plant Capacit y

Scope of Service

Owner's/Clie nt's Name

Address/Fax

Year of Commiss ioning

Project Cost (m DM)

Walsum Cogene ration Plant, Unit 9

410 MW el coal

Owner's Engineer: Planning and design, construction management, and commissioning of a coal fired unit. Management, operation and maintenance Conceptual design, technical specifications, bid evaluation, award of contract for two coal fired 300 MW units.

STEAG AG, Geschftsb ereich IPP

Dr. -WilhelmRoelen-Str. 129, 47179 Duisburg, Germany, 0203-4996203 11/F Hua Neng Build, No.A23, Fuxinglu, Beijing, Hai Dian District, 100036, China Hertenerstr. 16, 44653 Herne, Germany 02323-202299 Frankfurtestr . 430, 46562 Voerde, Germany 02855-121091

1988

740

Yang Liu Qing Power Plant

300 MW coal

Hua Neng Power Generation Corporatio n

1994

4,075

Herne Cogene ration Plant, Unit III Voerde Power Plant, Unit A + B

300 MW coal

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.

STEAG AG Geschftsb ereich IPP

1966

480

2 x 710 MW el coal

Kraftwerk Voerde STEAGRWE oHG

1982 /1985

2,400

Major References of STEAG in Gas Turbines / Combined Cycle

Power Plant Client

Project

Electrical Output

Commercial Operation

Patagonia , Argentina

Federacin de Trabajadores de Luz

Operation and maintenance assistance of several gas-turbines in Patagonia

237 MW GT

1993

West Cogenerat ion Plant

Stadtwerke Frankfurt/Mai n

Leuna

STEAG Energieanlag en S.A. GmbH Ferrostaal AG

Owners Engineer: Basic design, preparation of permit documents, bid specification, evaluation of bids, approval of turn-key suppliers documents, construction and commissioning supervision Owners Engineer: Planning, construction management, commissioning, operation and maintenance of a combined cycle cogeneration plant Construction supervision, commissioning, operation and maintenance services as well as training of the operation personnel of the gas turbine power plant Conceptual design for the erection of the combined-cycle power plant including trial run and commissioning

100 MW GT/Cog en.

1994

129 MW CCGT/C ogen.

1994

Ikot Abasi, Nigeria

540 MW GT

1995

Schwarze Pumpe

Sekundrrohs toffVerwertungsz entrum Schwarze Pumpe GmbH

80 MW CCGT

1995

Major References of STEAG in Gas Turbines / Combined Cycle

Power Plant Client Stassfurt, Germany Kraftwerksges ellschaft mbH Stassfurt, Germany HPL Cogeneration Limited ((A subsidiary of L&T) Empresa Produtora de Energia, Ltda Enron International, Brazil Capex S.A. Argentina

Project Owners Engineer: Project management and site supervision for erection and commissioning of a combined cycle plant, supplied by the EPC-Contractor 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 Support of the Investor in plant commissioning, especially Gas turbine Siemens V84.3 a

Electrical Output 120 MW CCGT

Commercial Operation 1996

Haldia, West Bengal

116 MW CCCGT

2006

Cuiab, Brazil

270 MW CCGT

1998

Agua del Cajn, 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 O&M of 30 MW Gas Turbine

670 MW CCGT

1999

Gandhar, India

ONGC, Ankleshwar

30 MW CCGT

2004

Major References of STEAG in Gas Turbines / Combined Cycle

Power Plant Client Kraftwerk Lausward, Germany Stadtwerke Dsseldorf, Germany

Project Owners Engineer, Construction, Supervision and Commissioning of a Combined Cycle Plant

Electrical Output 100 MW CCGT

Commercial Operation 2000

Kraftwerk Burghaus en

Fortum, Germany

Owners Engineer: EPC-contract, Planning-control, construction management, commissioning support

120 Mwel 500 ME th CCGT 156.1 MW CCPP

2001

Hazira, Gujarat, India

Gujarat State Energy Generation Limited, India STEAG Power LLC, Houston/ NRG Energy, Minneapolis AVISTASTEAG, Spokane

Owers Engineer: Planning, construction management, commissioning, operation and maintenance of a combined cycle power plant Owners Engineer: Project development, conceptual design, basic design, economical calculations, financial engineering, specification, negotiation of all contracts for a combined cycle power plant Owners Engineer: Project development, conceptual design, basic design, economical calculations, financial engineering, specification, negotiation of all contracts for a combined cycle power plant

2002

Brazos Valley, Texas/US A

600 MW CCGT

2003

Mint Farm, Washingto n/USA

250 MW CCGT

2003

GSECL SIKKA EXTN. PROJECT SCOPE

The scope of services to be rendered within the framework of this contract can be broadly subdivided into the following: a) Preparation of RFQ b) Preparation of RFP for Power-plant c) Support towards order placement on successful Contractor: bid evaluation, discussions and recommendations d) Review of Design & Engineering e) Construction Supervision f) Commissioning Supervision

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.

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

Cutting Costs in Plant Operation IT 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

Cutting Costs in Plant Operation

IT Tools

Introduction of Energy Management Systems


SR1 SRv
Data Validation
Lifetime Monitoring

SR2
Energy Management

SRp
Statistic Forecast

SRx
Energy Data Management

SR3
Energy Controlling

SRk
Power Cycle Evaluation

SR4 SR5
Power Trade System Power Plant Optimisation

Cutting Costs in Plant Operation IT 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 !

Cutting Costs in Plant Operation IT 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!!

SR4 Unit Overview Simhadri

SR4 Optimal Time for Waterwall Sootblowing


Waterwall effectivity (fouling)

Generator Power

Economic Loss from soon or late sootblowing

Optimum

Waterwall Sootbl. Signal

SR4 Turbine Section Simhadri

Cutting Costs in Plant Operation IT Tools

Computer-Based Coal Evaluation with SPICE


SPICE: STEAG Program for Import Coal Evaluation

Compatibility of coal blends

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

Difference in power generation costs

SOF BID

Software for the Power Industry


Performance Monitoring online with

Plant optimization offline with

EbsilonProfessional

EPOS

Our clients: more than 100 utilities and manufacturers


Essen

Frankf urt
Zwingenberg

Frankfurt

ABB, ALSTOM, BABCOCK, BEWAG, Blohm + Voss, BMW, CEE, Colenco, DSD, ECH, Envi Con, E.ON, Electrowatt Hamburg und Zrich, 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, TV Nord, VA TECH, VEAG, Weig GmbH, ZBP INWAT

Offline process simulation Modellierung


Mills

EbsilonProfessional

Graphical modelling with tool box Standard libraries for


fuels (coal, oil, gas) oxygen carrier gas turbines water-steam user defined and extensible

Fluegas path

Error analyzer English, French, German, Spanish, multilingual

Interactive offline process calculation

EbsilonProfessional

Input air temperature


Demo example CCP Total power 10.382 MW Efficiency 38.09%

Start of the calculation

Input of process parameters

Offline process simulation with actual, EbsilonProfessional historical or manipulated data EPOS

Choice coal mixture

Determination overheads of a power plant


water-steam-circuit air path mills fluegas path fluegas desulphurization unit

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