RWE Technology International

Ready for Operation
Turning a Plant into a Business

Powering. Reliable. Future.

02 Operation and Maintenance Services

Team up with RWETechnology ­Internationaland our O & M experts toachieve your long-termbusiness goals.

Operation and Maintenance Services 03

04 Operation and Maintenance Services

Challenge

If you’re running a major energy facility, power plant, orfleet – chances are your operations would benefit from acheck-up. Volatile fuel prices, growing renewables, changing
workforce, and shrinking budgets – the operationallandscape has changed. The health of your facility, plant,fleet and business will be at risk. To be competitive, youneed to do more with less – less money and less people.
Still, your peoples safety must always come first.
Therefore, a careful set of priorities is key to success –making the most out of your resources. Our O & M experts
can show you how to keep your people safe – always.
We assist you to startup your generation safe, quick andreliable. We have extensive experience in O & M analysis andinterpretation to predict when your asset will need help andreduce losses and people.
Our specialists will determine suitable options formaintenance practices and support you in finding quick wins
to reduce costs. RWE can support you to get a heads up on
potential problems coming down the pike. Learn how you
can see anomalies before they become critical issues.
The following key figures highlight the main improvement
areas for any plant, based on our own project andoperational experience.

4  %
50  %
75  %
improvement in yearly operating hours
through a focused O & M strategy withsignificantly fewer losses due to failure.

reduction in ramp up time possible
through technical improvements.

of plant performance improvement isattributable to human and managerial
skills. This highlights the importance oftransfering the process know-how to thepeople involved in the operation.

Operation and Maintenance Services 05

6–8  %
10–20  %20–30  %is the world-class benchmark of­maintenance cost related to total sales,
to be achieved from small changes in­maintenance planning.

reduction in O & M cash costs by sharing
resources in your generation fleet andtaking advantage of process synergies.

cost reduction through proper Life-Cycle
Cost Management and improved availability
and flexibility of your plant system.

06 Operation and Maintenance Services

How we can help
RWE Technology International provides power plant operations and maintenance (O & M)
solutions for thermal and renewable power plants and fleets around the world. We haveexperience working across a wide range of technologies and energy sources, including
coal, oil, biomass, combined cycle gas turbine (CCGT), nuclear, open cycle gas turbine(OCGT), solar, hydro and wind.

Business Management
Our understanding of how an energy infrastructure businesschanges over its life cycle provides a critical perspective indeveloping effective operation management. Whether it is aplant, fleet, or a mixed infrastructure asset pool, we enable
you to learn how operations management and staff canmanage and monitor operations across your whole businessin a safe and efficient manner.

Performance and Efficiency Improvement
Through our competent advice for better operation andmaintenance practices, we help you find quick wins to lower
operating costs, enhance efficiency and improve
productivity. We make our own experience in operation
efficiency measures such as fleet synergies, improved ramp
rates, minimum load reductions, cluster management andbusiness process optimization available to your operations.

Mobilization and Commissioning
We support you both in early mobilization plans and enable
you to think ahead and become operational, faster. Our
project experts help you identify gaps and provide
recommendations to get you ready for commissioning
activities. We advise you in commissioning planning andsafety, provide expert support during execution andsupervise your commissioning and handover /takeoverprocesses.

Operational Readiness
Whether you build a new asset or make improvements to an
existing one, you want to know your operation will reachplanned capacity. We will help train your workforce, ramp-up
generation fast, enable your systems, and secure criticalspares. By translating your business targets into O & M
practices, we’ll ensure everything happens at the right time,from planning through to execution, with commissioning
and ramp-up as expected or faster.

Operation and Maintenance Services 07

Technical Support Agreement
Our O & M experts’ advice you in how to balance cost andreliability and risk. Our aim is to develop holistic solutions bycombining the health of an asset with operational impacts.
With best practice technical support we enable you to avoid
unplanned activities, reduce associated safety incidents andachieve your O & M targets.

Maintenance and Inspections
By performing our innovative Non-destructive testing (NDT)
inspections, we can help you reduce your plant downtime,
improve process safety and maintain mechanical integrity. In
addition our specialists offer support and guidance inoverhauling, repair and refurbishment activities, spare partmanagement and maintenance contracts.

Organization, Processes and IT Systems
Our focus is on optimizing plant availability and minimizing
maintenance costs, with a strong emphasis on safety. This isfacilitated by well-established systems, procedures, manuals
and work instructions. Our clients welcome this holistic
approach as it helps them to focus on the core areas of thebusiness.

Training
In order for a plant or fleet to operate effectively, staff must
be confident in their roles and be able to respond to any
situation. Our O & M experts prepare your people with afocus to ensure your staff has a detailed understanding ofthe plant, it’s O & M procedures and the commercial
landscape.

08 Operation and Maintenance Services

Expertise & Services

There is no one-size-fits-all answer to a successful andsustainable asset operation and maintenance. It all depends
on the targets you define for your plant or fleet: Do you
want to reduce costs? Improve flexibility? Or Increaseavailability? From our experience, it’s usually a combinationof measures which will guarantee the greatest impact on
your asset’s O & M performance – ultimately reducing overall
costs and risks of your entire power plant fleet. RWE brings
knowledge of the entire field of O & M, starting with amobilization plan – one of the keys to successful startupof a new facility.
We provide a full range of tailored services across the lifeof power assets, from overall fleet management, throughplant mobilisation and commissioning, O & M lifecycle
management and eventual decommissioning. Our O & M
teams are supported by a large in-house team of engineers
and technical specialists, all with specific power sector
expertise.

Operation and Maintenance Services 09

10 Operation and Maintenance Services

Expertise & Services

Strategies and Systems

Mobilization

Effective operational management of power plants is key tomaximize the Return On Investment (ROI). By leveraging
RWE’s global operation and maintenance knowledge,
fleet-wide experience and best practice procedures andprocesses, you enable your plant staff to develop own O & M
as well as HSE strategies and practices, customized to local
requirements. Through our utility background we cansupport and guide you to optimize your assets in line withyour business objectives.

Preparing a new facility for commercial operation is one ofthe most challenging endeavors undertaken by a company.
To ensure that effective mobilization takes place requires
experienced O & M line managers working closely withowners, project and engineering teams, principal
contractors and OEMs.

• Fleet /plant optimisation studies• KPI evaluation and development• Cost management• O & M strategy and planning• Spare part concept• IT solutions and implementation support• LTSA optimisation• Benchmarks• Mobilization planning support• Support /participation in plant design reviews• Support /participation in negotiation of long-term service
agreement (LTSA)• Developing and installing management systems andprocedures• Developing the O & M plan and budget• Establishing the O & M organisation structure• Staff training and development• Participation /supervision in plant commissioning activities• Ensuring effective and structured hand over into
commercial operation

Operation and Maintenance Services 11

Generation
Building on the experience and knowledge provided by RWE, a utility with more than 100 years’ experience in power plants,
we make our owner and operator knowledge available to our clients.
Studies and Surveys

O & M Consulting• Fleet/plant optimisation studies• Due diligence• Pre-feasibility /feasibility• Plant health check• Plant technical audit• Plant integrity study• Engineering risk assessment (ERAP TM)• Operation risk assessment (OpRAP)• Operability RAMS study• Equipment /technology surveys• Fuel management strategy• Plant modifications /modernization• Overhauls /refurbishment /replacement• Plant condition monitoring /life extension• Life-cycle management• Safety assessment• Equipment reliability• Spare part management• Failure analysis /forensic investigation

On-Site• Expediting and Troubleshooting• Testing and commissioning support• Outage management, expertise and support• Specifying maintenance work scopes• Technical support of maintenance activities• Electrical support/fault investigation• Protection/control system support• C & I ExperienceTraining• O & M manager training• Operator training• Maintainer and outage training• Steam turbine, gas turbine and vibrationcompetency training• Outage training

Technical Support Agreement• Experienced engineer(s) onsite support• Technical back-up for troubleshooting• Training (e. g. on-the-job and theoretical)• Overhaul and maintenance supervision• Inspection management (e. g. NDT)
• Inspection management• Engineering design reviews• Spare part re-engineering• Metallurgy, stress analysis, welding
O & M Organisation• Organizational structure and review• People and roles• Staffing and recruitment• Customized training
Contract• Fuel management• Contract design /re-negotiation support• LTSA optimization advice• Tender assessment /warranty support

12 Operation and Maintenance Services

Projects
We have an international engineering consulting track record spanning over 50 years on
all continents, including countries in the Middle East, Asia, South-America, Africa andEurope. During this time, we have worked across many diverse cultures and technologies,
and have built strong relationships with our clients by working in partnership to solve
their technical and business challenges.

Client /ProjectCountry

Project Details

Date

O & M Service Company

Egypt

Drafting O & M contracts and negotiation
supportongoing(2017)

O & M Service Company

Egypt

LTSA for O & M support

ongoing(2017)

O & M Service Company

UAE

Operability review and O & M quality needs

ongoing(2016)

O & M Service Company

UAE

Mobilisation concept and supportongoing(2016)

O & M Service CompanyUAE

Commissioning and Handover /Takeover
support in preparing a new facility forcommercial operation support

ongoing(2016)

O & M Service Company

UAE

LTSA for warranty management and O & M
supportongoing(2016)

Local Power Developer

Pakistan

O & M support contract and mobilisation
supportongoing(2016)

Utility

Pakistan

Independent Advisor in O & M contractor
selectionongoing(2016)

Utility

Pakistan

Preparation of tender and contract
documents, negotiation support

ongoing(2016)

Independent Power Producer (IPP)

Malaysia

Review of mobilization activities

ongoing(2015)

Independent Power Producer (IPP)

Malaysia

Provision of power plant manager, andengineering services for improvement ofplant performance & availability

ongoing(2014)

Independent Power Producer (IPP)

Malaysia

Failure analysis for GT compressor

2016

Utility

KSA

Optimisation of workshop infrastructure

2016

Independent Power Producer (IPP)

Malaysia

O & M competency review of new
operational staff

2016

Independent Power Producer (IPP)

Malaysia

Compressor failure root cause analysis

2016

Independent Power Producer (IPP)

Malaysia

Technical review of milling plant

2016

Independent Power Producer (IPP)

Malaysia

CCGT gap analysis

2015

Independent Power Producer (IPP)

Malaysia

Emergency procedures workshop

2015

Independent Power Producer (IPP)

Malaysia

Training and support for implementation ofprocess safety management

2015

ERAP™ = Engineering Risk Assessment Process; OpRAP = Operational Risk Assessment Process;Operation and Maintenance Services 13

Client /ProjectCountry

Project Details

Date

Independent Power Producer (IPP)

Malaysia

Gas leakage analysis (increased generationand change of maintenance practice led
to review of historic generator transformerdata)

2015

Independent Power Producer (IPP)

Malaysia

Review and advice on super heater outletissues

2015

Independent Power Producer (IPP)

Malaysia

Coal handling (unloading and reclaiming)

2015

Major Energy Utility

Malaysia

Delivery of ERAP™ (plant failure scenarios)

2015

Major Energy Utility

Malaysia

Delivery of OpRAP(risk based identificationof areas for improvement in safety,
commercial optimization & organizationalculture)

2015

Major Energy Utility

Malaysia

Power plant review (long term serviceagreement)

2015

Independent Power Producer (IPP)

Malaysia

Identification of operational safety issues

2015–2014

Public Service Infrastructure Company

UAE

Engineering consultancy services at coalfired power station, site infrastructuredevelopment study – clean coal generation

2015–2014

Independent Power Producer (IPP)

Malaysia

Mill and combustion optimization services

2015–2014

Independent Power Producer (IPP)

Malaysia

Delivery of ERAP™ with a focus on boiler
plant & fuel handling /storage

2014

Independent Power Producer (IPP)

Malaysia

Technical due diligence of boiler & fuelmanagement

2014

Independent Power Producer (IPP)

Malaysia

Operations & Maintenance review (deliveryof OpRAP

2014

Independent Power Producer (IPP)

Malaysia

Health Check with focus on asset integrity
and a review of safety procedures

2014

Independent Power Producer (IPP)

MalaysiaBoiler assessment (plant operational
integrity in case of potential water cannon
implementation)

2014

ERAP™ = Engineering Risk Assessment Process; OpRAP = Operational Risk Assessment Process;14 Operation and Maintenance Services

Utility Background
PeopleOur people define what we do. As part of a power utility, we have extensive experience and in-house expertise within
Engineering, Procurement, Construction, Operation, Maintenance and Innovating of power plants. Within this framework,
our O & M experts, engineers, and consultants bring together the knowledge, know-how, technology, and creativity neededto meet both your daily operation and overall business challenges. Our heritage enables us to understand our client’scommercial objectives and how to support them through effective power plant O & M.

Operational ExpertiseRWE is an experienced operator of a well-managed and integrated power generation portfolio.

Generation Capacity (2016)5  % 1  %
OCGT

Other

26  %
Lignite31  %

41.9 GW

CCGT

10  %
Nuclear

6  %
Hydro

21  %
Hard CoalOperation and Maintenance Services 15Learn from our ExperienceAs a power utility, RWE is naturally looking to maximize the returns on its asset investments by optimizing operations andmanaging risks. We learned that O & M organizations and business processes are often a major key performance driver tocash improvements. We early recognized that shared learning between power plants across the portfolio improves theoverall fleet performance. Today we share our Best-in-class O & M structure and continuous improvement culture successfully
with our clients.

Production volumes (2016)

4  %
Other 1

21  %
UK

63  %
205 TWh11  %Netherlands/Belgium

Lignite power plant
Nuclear power plant
GasHydroHard Coal
Other

1

Including Denizli and Mátra

Germany

RWE Technology
International GmbH
Ernestinenstraße 60
45141 Essen
Germany
T +49 201 12-28742
E re@rwe.com
I www.rweti.com