Evonik Energy Services India: An Introduction

Evonik Energy Services (India) Pvt. Ltd. is a wholly owned subsidiary of Evonik
Energy Services GmbH, Germany (formerly STEAG encotec GmbH), which is
the Engineering and Nuclear technology division of Evonik Industries. Evonik Energy
is Germany’s largest IPP owning and operating over 11,000 MW in Germany and
elsewhere. Evonik has over 70 years of experience in the energy business, including
Operation & Maintenance of its own plants and of third parties. All power stations of
Evonik have been engineered, constructed, commissioned, rehabilitated,
modernized and operated by its own engineers. Evonik is proud to call itself as
the Consultant with Operational Experience.

Evonik Energy Services (India) Pvt. Ltd. (EESI) was set up in 2001 to provide cost-
effective consultancy services of international standards by integrating resources of
the parent company and those of EESI in India. EESI combines the best of the
technology and professionalism of its German principles and a thorough knowledge
and understanding of conditions in the power sector in India. It is thus able to
synergize its Indian experience with the technological and professional back up of
European standards and provide the best possible solutions and services to clients
in India and elsewhere.

Arising out of its vast experience in power plants, the Evonik Steag Group has also
taken up Independent Power Projects outside Germany. The Energy Services
division makes the necessary special know-how available for the Evonik Steag
power plants in Germany and abroad and handles the required technical project
work for hard-coal-fired power plant projects like 2x660 MW Iskenderun power plant,
232 MW Mindanao PP, 750 MW Walsum 10 PP and 750 MW Herne 5 PP or for the
refinery power plants of 158 MW at Leuna and 211 MW at Cologne-Godorf in
Germany.

From about 1965 the Energy Services division of Evonik STEAG assumed
responsibility for the planning and the owner's end of construction work on the

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Evonik power plants – 500 MW Lünen PP, 2120 MW Voerde PP, 747 MW
Bergkamen PP, 600 MW Walsum PP (750 MW under construction), 707 MW Weiher
PP, 773 MW Bexbach PP, 501 MW Fenne PP and 950 MW Herne PP (with one of
the first 500 MW Supercritical unit in operation) – in connection with the restructuring
of the capacities of pithead power stations to create state-of-the-art large-scale units.
Other tasks involved the planning and implementation of all necessary retrofitting
activities for air pollution control (FGD, DeNOx) at the Evonik plants. Based on the
extensive development work, special – also proprietary – technical and economic
know-how was acquired, which has since been applied at home and abroad.

In conjunction with the operating experience of Evonik Steag GmbH, since about
1970 the services of Energy Services division have been successfully offered in the
market without interruption. All told, the Energy Services division has participated in
the planning, engineering and building of power plants (including infrastructure) with
a total capacity of more than 200,000 MW in over 50 countries. In the waste-to-
energy field, it has realized plants like the RZR Herten waste incineration plant and
the Launa thermal waste treatment facility.

Evonik’s experience covers a variety of power plant sizes and technologies. These
include:

• Conventional power plants used 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, and Philippines etc.
• Renovation & Modernization of thermal power plants

Evonik Energy Services India are in the energy business particularly in the fields of
Operation & Maintenance services, Engineering Consultancy and IT related
solutions to Power Plants. Our Indian Experience includes:

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Energy Technologies

Consultancy Services : Greenfield Projects – Owner’s Engineer

¾ Consultancy services for setting up of 450 MW gas based power plant at
Sulemaniya, in northern province of Iraq for M/s Mass Global Co of Jordan
(BHEL is EPC contractor).
¾ Consultancy services for setting up of 1000 MW Coal based power plant in the
state of Chattisgarh from Concept to commissioning for M/s Moser Baer
¾ Consultancy Services for Phase II (2x330 MW or alternatively 4x135 MW) of
Matrishi Usha Jayaswal Mega Power Plant at Village Chitarpur, Dist. Latehar,
Jharkhand for Corporate Power Limited (Abhijeet Group)
¾ Detailed Engineering Services for Civil works for 2x600 MW coal fired power
project at Dist. Angul, Orissa for Jindal India Thermal Power Ltd.
¾ Consultancy Services as Owner’s Engineer for setting up of 2x150 MW Coastal
based Power Plant at Thamminapatanam, Nellore Dist., Near Krishnapatanam,
Andhra Pradesh for Meenakshi Energy Pvt. Ltd.

Consultancy Services : Greenfield Projects - Due Diligence

¾ Due Diligence for Lanco Power for 2x300 MW coal based Power Plant.
¾ Due Diligence for Mott MacDonald for international developer for 2x520 MW coal
based Power Plant.
¾ Due Diligence for Moserbaer for 2x300 MW coal based Power Plant.
¾ Due Diligence for the Consortium of GMR Energy, India, Macquire, Singapore &
NAK, Kuwait for acquisition of TUAS Power Asset of 2x600 MW oil fired Steam
Turbine Sets & 4x367.5 MW gas fired CCGT.

Advisory Services :
¾ Central Electricity Regulatory Commission (CERC): Consultancy Services for
developing benchmarks of capital cost for thermal power stations and
transmission system elements.
¾ GTZ GmbH - Assessment of tendering procedures followed by Public Utilities and
review of documents of Standard R&M Projects

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Renewable Energy:
¾ NTPC Limited: Consultancy Services for Solar Upgrading of Anta Gas Power
Plant, Rajasthan.
¾ ACME Tele Power Ltd.: Consultancy services for preparation of Detailed Project
Report for setting up of 10 MW Solar Thermal Power Project in the State of
Rajasthan.

Consultancy Services : Greenfield Projects - DPR

Detailed Project Report, Technical Specifications, Short-listing of EPC Contractors
¾ for the 500 MW Refinery Residue Project for IOCL at Savli, Baroda.
¾ for the 1000 MW LNG Plant for Chennai Power Generation Corporation.
¾ Preparation of Master plan for Neyveli Area and performing power development
studies – Under this study sites for ST-CMS (1x250 MW), TPS –II extension (500
MW), TPS-I extension (2x210 MW), Station B (4x500 MW), Station III (3x500
MW), Jayamkondam I (3x500 MW), Jayamkondam II (3x500 MW), Vellar (3x500
MW) and Behur (3x500 MW) were identified for development.
¾ Consultancy services for setting up of 1000 MW Coal based power plant in the
state of Chattisgarh from Concept to commissioning by M/s Moser Baer -
Feasibility report under preparation as first phase of the job.
¾ Consultancy services for setting up of 1000 MW imported coal based power plant
at Tuticorin by M/s Coastal Energy.
¾ Consultancy services for preparation of Detailed Project Report for coal based
thermal power station at Yermaras in Karnataka by Karnataka Power Corporation
Ltd (KPCL).
¾ Consultancy services for preparation of Detailed Project Report for coal based
thermal power station at Yadgir in Karnataka by KPCL.
¾ Consultancy services for setting up of 1300 MW coal based power plant at
Belgaum District in Karnataka by M/s Power Company of Karnataka (formerly
SPPCC)
¾ Consultancy services for setting up of 1300 MW coal based power plant at
Jewargi District in Karnataka by M/s Power Company of Karnataka (formerly
SPPCC)

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¾ Consultancy services for setting up of 1000 MW imported coal based power plant
in the state of Andhra Pradesh by M/s CMR Power
¾ Consultancy Services for preparation of Feasibility Study Report for setting up of
1000 MW coal based power project either in Maharashtra, Chhattisgarh &
Jharkhand by M/s. Farouk Sodagar Darvesh & Co.
¾ Consultancy Services for preparation of Pre-Feasibility Report, Feasibility Report
and Detailed Project Report for setting up of 1000 MW coal based Power Project
in the State of Chhattisgarh by M/s. Bhushan Energy Ltd.
¾ Consultancy Services for preparation of Detailed Project Report for 1x250 MW
Panki TPS Extension project by UPRVUNL.
¾ Consultancy Services for preparation of Feasibility Report for setting up of 1000
MW coal based power project at Tuticorin, Tamil Nadu by M/s. SLS Energy Pvt.
Ltd.
¾ Consultancy Services for preparation of Pre-Feasibility Report and Detailed
Project Report for setting up of 1000 MW coal based power project in
Vijayawada, Andhra Pradesh by M/s. Machilipatnam Power Pvt. Ltd.
¾ Consultancy Services for preparation of Detailed Project Report for setting up of
1600 – 1800 MW thermal power project at Kovaya in Gujarat by M/s. GSPC
Pipavav Power Company Ltd.
¾ Consultancy Services for preparation of Detailed Project Report for Harduaganj
Thermal Power Station Extn-II (2x250 MW) by UPRVUNL.
¾ Consultancy Services for preparation of Feasibility Study Report and Detailed
Project Report for 500 MW/660 MW (Supercritical) Units as Anpara Expansion
Project by UPRVUNL.
¾ Consultancy services for feasibility study and preparation of DPR for the
proposed 1x660 MW Power Station at Lohara, at Tahsil & District Yavatmal by
Maharashtra State Power Generation Co. Ltd.

Consultancy Services : Renovation & Modernization – Owner’s Engineer

¾ 110 MW Units # 3 & 4, GNDTP, Bathinda
¾ 210 MW Unit # 5, Bandel TPS of WBPDCL
¾ 210 MW Unit # 6, Koradi TPS of MAHAGenco

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¾ Consultancy Services for preparation of Techno-commercial specifications,
Evaluation of bids and detail engineering etc. for Renovation & Modernisation of
4x210 MW units of Hasdeo TPS, Korba West of CSEB
¾ Consultancy Services for Preparation of DPR, BOQ preparation, tender
evaluation & supervision during RM&U works of Unit No.7 & 8 (110/105 MW
each) at PTPS of JSEB
¾ Central Electricity Authority (CEA): Consultancy assignment for preparation of
Feasibility Report of three power plants under Energy Efficiency Programme
(EEP) in India for Nashik TPS (1x210 MW) of MAHAGENCO; Kolaghat TPS
(3x210 MW) of WBPDCL; Bokaro ‘B’ TPS (3x210 MW) of DVC

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Projects – Plant Services
O&M Services:
¾ 10 year comprehensive O&M contract for 156 MW Gas based CCPP at Hazira
for GSEG.
Owner: GSEG Gujarat State Energy Generation Ltd.
Fuel: Natural Gas
Gas Turbines: 2 x 50 MW GT8C2 – Alstom
Steam Turbine: 1 x 50 MW - Alstom
Control System: Advant
DM Plant – 30 M3/hr per stream (Total 2 stream)

¾ O&M for the power island for 30 MW CCP at Gandhar for ONGC.
Owner: ONGC (Oil and Natural Gas Corporation Ltd.)
Fuel: Natural Gas
Gas Turbine: 1 x PG 5371 PA – GE Frame 5 (21 MW)
Steam Turbine: BHEL NK/40/56/25-3 (11 MW)
Control System: Mark V

¾ O&M contract for 116 MW Co-generation Plant at Haldia by L&T.

Owner: HPL Cogeneration Limited (A subsidiary of Larsen & Toubro Limited)
Site: Haldia, Midnapur District, West Bengal, India
Fuel: Naphtha
Responsibility: a) Power Generation Rated capacity 116 MW
b) Process steam export to Haldia Petrochemicals Limited at four pressure levels
viz.
SHP at 12 Kg/cm2(a) & 540 degC
HP at 43.5 Kg/cm2(a) & 415 degC
MP at 18.5 Kg/cm2 (a) & 310 degC
LP at 6 Kg/cm2 (a) & 21 degC
Gas Turbine: GE Frame 6551B Model, 2x34.5 MW
Condensing Steam Turbine: 1x33 MW
Back Pressure Steam Turbine: 1x14 MW with dual extractions
HRSG, 2 Nos: 120 TPH of SHP steam and 22 TPH of MP steam
Service Boiler, 2 Nos.: 120 TPH of SHP steam
O&M Period: Six years starting from September 1, 2006

¾ 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
Steam Turbine: One cylinder non-reheat turbine with one stage regenerative
heater (steam parameters: 64 ata, 480°C)
Two waste heat recovery boilers: 64 t/hr steam

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Field Supervisory Services
¾ GSEG Hazira – Pre-commissioning and commissioning of 156 MW Gas based
CCPP at Hazira for GSEG.
¾ Cairn Energy - Field Supervisory services for commissioning testing, Reliability
Test, PG Test and O&M Support for captive power plant at Barmer, Rajasthan (in
progress)
¾ VS Lignite Power Private Limited (KSK Group) - Expert field supervisory services
for Commissioning, Testing, Reliability test and PG test of 135 MW Lignite based
power plant at Gurha, Bikaner Dist., Rajasthan (in progress)
¾ Wardha Power Company Limited (KSK Group) - Expert field supervisory services
for Commissioning, Testing, Reliability test and PG test of 540 MW Coal based
power plant at Warora, Wardha, Maharashtra (in progress)

Consultancy Services : Renovation & Modernization / RLA /CA Study

RLA and R&M Studies of
¾ 4x210 MW Units at HTPS, Korba (West), CSEB
¾ 2x210 MW Units at GGSSTP, Ropar, PSEB
¾ 4x120 MW Units of Koradi TPS of MSEB
¾ 1x110 MW Unit of Panipat TPS of HPGCL
¾ Six nos Boilers of IndoGulf Fertilizers (Aditya Birla Group Company) Jagdishpur
¾ RLA of 2 nos. Boilers at Essar Power, Hazira
¾ RLA studies of 200 MW (Unit # 2) of Ramagundam STPP of NTPC.
¾ RLA studies of 210 MW Turbine (Stage-1) of Kahalgaon STPP of NTPC.

Diagnostic Services – Power Plant Simulation & Base line Studies:

¾ Baseline studies under the Indo-German Energy Efficiency Program:
ƒ UPRVUNL
¾ Panki 110 MW
¾ Parichha 110 MW
¾ Harduaganj 110 MW
¾ Anpara 210 MW &
¾ Obra 200 MW
ƒ RRVUNL
¾ Kota 110 MW
ƒ MPGENCO

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 ¾ Satpura 210 MW
ƒ NTPC
¾ Badarpur 200 MW
ƒ PSEB
¾ Bathinda 110 MW

¾ Baseline studies of 85 Units capacity range from 100 MW to 210 MW by

Central Electricity Authority under the Indo-German Energy Efficiency
Program

¾ Steam Path Audits using Encotech, USA Software

ƒ PSEB
¾ 2 x 210 MW Units 1 & 2 at Ropar
ƒ CSEB
¾ 210 MW Unit 2 at Korba (West)

ƒ NTPC
¾ 200 MW (Unit # 2) of Ramagundam STPP.
¾ 210 MW Turbine (Stage-1) of Kahalgaon STPP.
¾ Steam Turbine of Rajiv Gandhi CCPP, Kayamkulam (Kerala)

Performance Testing:
¾ 210 MW (Unit # 2), Hasdeo TPS, Korba (West), Chhattisgarh (CSEB)
¾ 210 MW (Unit # 1), GGSSTP, Ropar, Punjab (PSEB)
¾ 156 MW CCP at Hazira (GSEG)
¾ Supervision of PG Test for 2x110 MW units of GNDTP, Bathinda, Punjab (PSEB)
¾ 210 MW (Unit # 6) of Koradi TPS (MAHAGENCO)
¾ 210 MW (Unit # 5) of Bandel TPS (WBPDCL)
¾ 460 MW Combined Cycle Gas Power Plant at Ravulapalem of Konaseema Gas
Power Ltd. (2 Nos. V94.2 Gas Turbines)

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Projects – System Technologies

Online Optimization of Power Plants (PADO Systems):

PADO for following NTPC Power Plants:
¾ Simhadri 2x500 MW (In operations)
¾ Ramagundam 1x500 MW (SAT done)
¾ Rihand 2x500 MW (SAT done)
¾ Talcher 4x500 MW (FAT done)
¾ Kahalgaon 3x500 MW (FAT done)
¾ Sipat 2x500 MW (FAT done)
¾ Vindhyachal 2x500 MW (FAT done)
¾ Dadri 2x500 MW
¾ Farakka 1x500 MW
¾ Khaparkheda 1x500 MW
¾ Bhusawal 2x500 MW
¾ Simhadri 2x500 MW
¾ Jhajjar 3x500 MW
¾ Bellary (KPCL) 1x500 MW
¾ Marwa (CSEB) 2x500 MW
¾ Korba Extn 1x500 MW

Training Simulators:

¾ Training Simulator for a Combined Cycle Power Plant supplied to NPTI

Faridabad, India.
¾ Supply of 500 MW coal fired Training Simulator to our parent company in
Germany.
¾ Supply of 500 MW Combined Cycle Training Simulator to our parent company in
Germany (under execution).
¾ Supply, installation, testing & commissioning of Hydro Power Plant Training
Simulator for NPTI, Hydro Power Training Centre, Nangal (Punjab). (under
execution).

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Our personnel are trained in the use of Ebsilon Software (product of SOFBID which
is now owned by parent company). This is a useful tool for baseline mapping of
power plants and auditing of plant performance. Likewise, we have US-trained
Steam Path Auditors for using the Steam Path Audit Software.

With the above engineering capabilities and software tools, Evonik Energy Services
India are in a position to provide international quality of services for power plant
technology, with the full technical and financial backing of our parent company
Evonik Energy Services GmbH, Germany.

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