As India accelerates its transition toward a sustainable and secure energy future, Steag Energy Services India (SESI) stands at the forefront. From optimizing legacy thermal plants to spearheading innovations in digitalization, renewable energy, and green hydrogen, SESI is redefining operational efficiency, decarbonization, and asset reliability. In this exclusive conversation with APAC Media and CXO Media, Debasish Patra, Group Executive Director, STEAG Energy Services (India) Pvt Ltd., shares insights into the company’s transformative projects, its use of advanced technologies, and its vision for powering India’s evolving energy landscape.
What are the key services that Steag Energy Services India provides in the Indian energy market?
Steag Energy Services India provides end-to-end energy solutions, covering:
Operation & Maintenance (O&M) Services for Coal, Gas:
- Comprehensive O&M
- Advisory O&M
- Commissioning Services
Digital Solution:
- Real Time Fleet Monitoring with Predictive Analytics (AI/ML Based) (CMS)
- Digital Twins—Ebsilon (Steady state Simulation), ProTRAX (Dynamic Simulation), Power Factory (Power System Simulation)
- Operator Training Simulator (OTS), including Flexibilization
- Boiler Tube Leakage Detection Systems (ALMA)
- Performance Analysis, Diagnostics & Optimization
- Advance Process Control (APC)Computerized Maintenance Management System (CMMS)
Engineering:
- Green Field: End-to-end engineering (Owner’s Engineering, FEED, detailed engineering)
- Brown Field: RLA, R&M, Flexibilization, Fuel Conversion studies,
- Environment: FGD, ESP Review Engineering
- Waste-to-energy and green hydrogen solutions
Project Development:
- Project Development Studies
- Support for development studies
- Due diligence and asset valuation
- T&D planning
Renewable Energies (New Energy Areas: GH2, Solar, Wind):
- Owner’s Engineering
- Project Management Consulting
- O&M Services
- Asset Management
- Due-Diligence
- Lender Independent Engineer
- Power System Studies
Technical Services:
- Performance Test (incl. PG Test)
- Testing Services (NABL Accredited)
- Energy Audits & Water Audits.
- Maintenance Audits
- Condition Monitoring
Training & Advisory:
- CEA recognized Institute
- Theory/Simulator Training (Online/Offline)
- Field/On-the-Job Training
- Competency Assessment and Training Need Analysis
Can you walk us through the technologies Steag uses in power plant optimization and performance monitoring?
STEAG leverages a suite of advanced digital technologies & solutions to optimize power plant performance and ensure operational excellence. Our AI-based Fleet Monitoring system employs predictive analytics to anticipate equipment failures and optimize maintenance schedules, minimizing downtime. Digital Twins, including tools like Ebsilon, ProTRAX, and Power Factory, enable real-time simulation and analysis of plant operations, enhancing decision-making and efficiency.
The Operator Training Simulator (OTS) ensures personnel are adept at handling complex scenarios, while the ALMA system detects boiler tube leaks early, preventing costly damage. For performance diagnostics, PADO/SR::EPOS provides deep insights into plant efficiency, enabling targeted improvements. Advanced Process Control (APC) systems fine-tune operations for peak performance, and our Computerized Maintenance Management System (CMMS) streamlines asset management, ensuring reliability. These technologies collectively drive sustainability, reduce costs, and extend plant lifespan, reflecting STEAG’s commitment to innovation in energy solutions.
Can you share examples of major projects Steag India has successfully delivered and the impact they’ve had?
STEAG India has consistently delivered operational excellence and engineering innovation across thermal and renewable energy projects.
O&M
- At Vedanta Jharsuguda (4X600MW), we have improved the reliability of the captive power to Aluminum and also improved availability from 71% to 83.5% by undertaking many engineering modifications through gap analysis.
- Singareni (2X600MW) has always been among the top 5 power plants in the country in PLF, implementing best O&M practices.
- HPL Haldia achieved 99.6% availability by state-of-the-art O&M practices.
- At HMEL Bhatinda, our O&M system has enabled the captive power plant to maintain reliability always above 99% in the last 5 years, matching international standards.
- Our O&M system at Talwandi Sabo (3x660MW) has improved plant availability (60%-90%) and asset reliability in a very short span of time.
- STEAG India also transformed BPC Botswana’s Morupule B 600 MW CFBC plant from an availability of 30 % to 65%.
Digital Projects
- Under the Indo-German Energy Project, our Ebsilon-based mapping of 85+ thermal power generating units identified a 6.92M ton coal savings potential (10M ton CO₂ reduction).
- 130 online performance monitoring and optimization commissioned projects helped various utilities to improve heat rate (by 0.5–1%), reduce Metal temperature excursion, and improve imbalances.
- With 35 high fidelity operator training simulators, including the Flexibilization Simulator, enabled utilities/Training institutes to build the capacity of operators for now and the future.
In renewables, we conducted grid compliance studies and dynamic modeling for Sterling & Wilson’s solar projects in Morocco (65 MW Laayoune, 55 55MW Ouarzazate, and 15 MW Boujdour) using DigSilent PowerFactory. We also supplied PowerGrid Corporation with PowerFactory software and AMC support, reinforcing our expertise in grid integration.
Steag has been providing comprehensive services from concept to commissioning of all kinds of power plants in India and abroad for the last few decades. With our vast experience and German engineering, we successfully completed many projects with a total capacity of more than 2 GW globally.
With 100+ training modules upskilling professionals across 50+ organizations, STEAG doesn’t just operate plants—we transform them into benchmarks of efficiency, reliability, and sustainability.
How do you ensure reliability and efficiency in legacy power plants?
Ensuring reliability and efficiency in legacy power plants demands a hands-on, experience-driven approach that combines rigorous operational practices with targeted engineering upgrades. At STEAG, we begin with Comprehensive O&M Services, where our seasoned teams implement disciplined maintenance routines, real-time equipment monitoring, and corrective actions to prevent performance degradation.
For structural improvements, our Energy Technologies (Engineering) division conducts RLA (Remaining Life Assessment) studies to evaluate critical components, followed by Retrofits & Modernization (R&M) programs that upgrade aging systems without full replacement. Fuel conversion studies and flexibilization enable older plants to adapt to alternative fuels and load-cycling demands, enhancing both efficiency and operational flexibility.
Technical services play a key role—performance testing and NABL-accredited testing services benchmark plant output, while energy audits and maintenance audits identify inefficiencies in heat rate, auxiliary power, and workflow gaps. Condition monitoring ensures early detection of mechanical wear, allowing proactive interventions.
Finally, our CEA-recognized training programs upskill plant personnel in best practices for legacy systems, ensuring operational excellence. This holistic O&M and engineering approach maximizes the lifespan, reliability, and cost-effectiveness of older power plants.
How is Steag India aligning with India’s national goals for renewable energy and carbon neutrality? What steps is the company taking to reduce the environmental footprint of thermal power generation?
STEAG India is at the forefront of supporting India’s renewable energy transition and carbon neutrality goals through a dual strategy—modernizing thermal power while scaling up green energy solutions.
For thermal power plants, we enhance efficiency and reduce emissions via Performance Optimization (PADO/SR::EPOS), Fuel Conversion Studies, and Flexibilization, enabling cleaner coal operations. Our AI-driven Fleet Monitoring and Condition Audits minimize energy waste, while R&M (Retrofit & Modernization) extends plant life with lower emissions.
In renewables, our partnership with IQONY Solutions GmbH drives innovation in green hydrogen (GH2), ammonia, methanol, and Battery Energy Storage (BESS). We provide end-to-end Owner’s Engineering, project management, and O&M for solar, wind, and hybrid projects. Additionally, our Due Diligence and Power System Studies ensure seamless grid integration of renewables.
By integrating CCUS-ready solutions, Waste-to-Energy systems, and Hydrogen/Ammonia feasibility studies, STEAG India is bridging the gap between conventional and decarbonized energy, aligning with India’s 2070 net-zero vision while ensuring energy security.
How do you see the Indian energy landscape evolving over the next 5 years?
The Indian energy landscape is poised for a transformative shift over the next five years, driven by renewable expansion, grid modernization, and strategic decarbonization of fossil fuel-based assets.
India will aggressively scale up solar, wind, and hybrid projects, supported by advanced Battery Energy Storage (BESS) and green hydrogen/ammonia solutions to stabilize intermittent supply. STEAG, in collaboration with IQONY, is already spearheading feasibility studies, project management, and O&M for these technologies, ensuring seamless integration into the grid.
Simultaneously, thermal power will transition toward flexibility and lower emissions through AI-driven optimization, fuel switching, and R&M upgrades, extending plant life while reducing carbon intensity. CCUS and waste-to-energy solutions will gain traction as interim measures.
Regulatory push for renewable purchase obligations (RPOs), carbon pricing mechanisms, and green financing will accelerate this transition. STEAG’s expertise in performance optimization, hybrid asset management, and decarbonization engineering positions us as a key enabler of India’s dual goals: 50% non-fossil capacity by 2030 and sustainable energy security.
