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EXECUTIVE SUMMARY 2
MARKET ANALYSIS 4
MANAGEMENT SUMMARY 12
FINANCIAL PROJECTIONS 13
EXECUTIVE SUMMARY
Gas turbine overhaul and heat recovery steam generator inspection will be the core
business based on potential revenue and is parallel with RMS expertise. For the first
five years beginning January 2007, gas turbine overhaul for Lumut and Prai power
plants can create total revenue of MYR 95.82 million and estimated gross profit of
MYR 21.84 million. HRSG inspection services for Lumut, Prai and Tanjung Bin
power plant will create estimated revenue of MYR 2.77 million with gross profit of
MYR 1.46 million, with the highest gross margin percentage at 52.8%. This
contributed to assessment work carried out by in-house expert inside RMS. Referred
to projected profit in five years (involvement mainly in plants inside Malakoff) a
steady stream of profit at average MYR 3.4 million per annum was estimated. Market
demand in Malakoff will maintain through out the year as it is based on machine
operating hours. In the long-term planning, with RMS focusing for market outside
Malakoff after 2011, this profit may double with the correct marketing strategy and
good manpower planning.
In realizing this plan, RMS will be set up as a company, a subsidiary of TJSB. This is
to ensure for proper marketing and for RMS to be more focus in business. RMS
vision is to be a leading company in power industry life-cycle asset maintenance in
Malaysia.
The key of success is to develop and create a strong brand name in the market.
Continuous staff development is essential to ensure a professional, competent and
motivated team in RMS. A good marketing strategy and ‘positive’ partnership must
RMS has involved in five ABB GT13E2 major (C) inspections, several minor (A&B)
inspections, one ABB GT13E2 tula1 re-blading and one ABB steam turbine major
(G) inspection.
From the five ABB GT major (C) inspections RMS had involved, RMS had managed
two, where previously was ‘lumped sum’ to Alstom Power, and had achieved service
cost saving of MYR 3.15 million to TJSB.
RMS has also outsourced skilled manpower to Prai Power Plant for a GE Frame 9FA
C-Inspection (minor) and turbine alignment work.
MARKET ANALYSIS
3.1 Market
3.1.1 In the Group
Recent years has seen a significant growth of power generation in the group. From a
single major power plant i.e. LPP – SEV of 1,303 MW in 2000, the group now own an
extension block of LPP of additional 640 MW, Prai Power Plant of 350 MW, 40% of
Kapar Power Plant of 2,420 MW and Tanjung Bin Power Plant of 2,100 MW that is
still under development and will be fully commissioned by 2008.
For short term planning, RMS targets to secure service contract with Lumut, Prai and
Tanjung Bin power plants that are operated by TJSB. Target market is to secure
service contract for RMS to manage overhaul of ST/GT, boiler, pump and BOP
equipments, which is parallel to RMS expertise. ST/GT and boiler are identified as
the two segments with the
highest market potential in Market analysis in Group
term of frequency of services
and revenue. A challenge for
RMS is to secure contract 10%
LPP-GT/ST
10%
with plant operator especially LPP-Boiler
40%
Lumut Power Plant with the 3%
PPP-GT/ST
highest number of gas PPP-Boiler
7%
turbine and boiler, and
TBPP-ST
eventually to be followed by 30%
TBPP-Boiler
Prai Power Plant and
Tanjung Bin Power Plant.
Market Analysis
Total 10 7 13 100%
As per Malakoff outage master schedule, almost 85% scheduled work is identified in
LPP. This contributed by the number of gas turbine and HRSG installed in LPP. The
services under RMS for GT and HRSG throughout 2007-2011 (5 years), is estimated
to generate revenue of MYR 88.9 million. For PPP, involvement of RMS in turbine is
quite limited due to LTSA signed with GE until first cycle of major inspection (MI),
due in 2009. A revision of LTSA after first MI will see more involvement of RMS in
turbine servicing work, however this is much dependent on the agreement achieved.
Service of GT alone for PPP referred to LTSA signed with GE can approximately
generate potential revenue of MYR 4.56 million per annum.
Apart from major machines i.e. GT, ST and HRSG, balance of plant (BOP)
equipments have also some market potential. There are approximately 100 major
pumps identified in all the three plants, a cooling tower (for rotating part i.e. fan and
gearbox) in Lumut PP, and other major auxiliary machines especially in Tanjung Bin
PP such as boiler fans, gas air heater, coal pulverizer and electrostatic precipitator.
Frequency of overhaul is limited to number of breakdown, which is less than 5%
Tenaga Nasional Berhad has the lion share of Malaysia power industry with
capability to generate power approximately 60% of peninsular Malaysia generation
capacity. Other major IPPs beside Malakoff Berhad are YTL Power Generation,
Powertek Berhad, Genting Sanyen Power and Teknologi Tenaga Perlis Consortium.
The market trend in Malaysia for services of major equipments i.e. GT and ST, is
dominated by machine OEM mainly Alstom, GE and Siemens. There is no yet a
reliable and trusted third part company been offered to perform major services for GT
and ST. Due to high requirement of machine availability as stated in PPA, most of
the IPPs in Malaysia rely heavily to the OEM which offers optimization of outage
window and guarantee in machine performance. While TNB having the comfort of
less aggressive environment has formed their own service company i.e. TNB
Remaco Sdn Bhd. TNB Remaco requires only minimum number of OEM specialist
for major services. Early this year they have proven themselves by performing major
overhaul of gas turbine ABB GT13D utilizing fully on their own personnel and
specialist.
The level of competition in Malaysia is high. Own heavily invested repair and
maintenance team will be the favourite choice of TNB plants for GT and ST
maintenance strategy. To secure contract with TNB plants is very slim. The potential
market is to attract and secure contract with IPPs that are currently enjoying good
services with OEM companies. To create a competitive market, RMS has to
establish a strong brand name in the market, a very competitive services fee and
forging strong partnership with other relevant companies i.e. technical and labour.
The projection of 8.1% growth per year until 2010 of Asia power demand is another
good potential market for maintenance and services industry. With the correct
marketing strategy and technical development / partnership, the potential to extend
our service overseas especially in Asia is enormous and very real.
RMS Vision
Strategizing RMS business is the first phase to reduce target and to ensure mission
achievement. There will be two business focus groups in RMS. Based on market
trend and opportunity, RMS core business will be gas turbine and HRSG-boiler
assessment and overhaul works. Steam turbine assessment and overhaul, ‘balance
of plant’ major equipments overhaul and condition based monitoring (CBM) of plants
equipment will be in the second business focus group. This is to ensure prioritization
of works in the group.
Second phase is the identification of resources available and new recruitment for
RMS. This exercise must be parallel with RMS target market in Malakoff and external
to ensure optimum resources intake and planning.
Third phase are to plan for continuous development of RMS personnel and forging
partnership with relevant local and international companies for support and new
ventures. By doing this, RMS will commit on continuously building up a strong brand
name in the market, local and international.
Mr. Izlan Ismail to lead RMS GT/ST team ensuring GT/ST overhaul efficiency and
workmanship quality, which is the main RMS core business. Mr. Chow Sak Choon
(I&C engineer) will lead RMS commissioning team specialized in ABB GT13E2 (9
units in LPP). He will lead LPP GT C-Inspection commissioning work and to give
technical support on GT13E2 operational issues. Mr. Izham Khalil (Mechanical
engineer), from LPP Engineering department, was identified to lead HRSG team,
one of the RMS core businesses. Mr. Izham has experience with assessment of
HRSG in LPP will continue his contribution in RMS HRSG team and to extend his
A b d R a h m a n R a d z i
H O D
A D M I N - S I T E
N o r J a s n i
S h a r a p
G T / S T G T C o m m i s s i o H n R i nS g G C B M B O P
I z la n C h o w S C I z h a m * Z a id i* o r H a lim *
M e c h M e c h
E n g in e e r 1 E n g in e e r 2 P l a n t s C B M P u m p
T e a m Z o lk a f li
B a k h t ia r
M e c h a n i c G a el n e r a t o r M e c h a n i c a l M o t o r
A r if f in Z a m r i * R o h im Z a m r i *
S a lim T a r m iz i Z a k a r ia * * T a r m iz i
C o o l i n g T o w e r
A z iz a n *
C o a l H a n d l i n g
R a h im in
The personnel plan layout is the foundation of RMS; having the key people in place
will enable the team to start with a solid foundation. Initial phase of recruitment
strategy is to engage experienced and competent personnel. This is to ascertain
proper set up of capable and motivated RMS team. Once initial set up completed,
RMS will recruit fresh manpower for support, on-job development and exposure of
good working culture inside RMS.
Competency
Position Job Description
Requirement
Gas Turbine Team
Supervisor OEM Chief Lead Engineer Lead GT mechanical overhaul work
Foreman / Technician OEM Mech / Generator Lead shift GT mechanical / generator
Supervisor overhaul work, assist Chief Lead
Engineer
Heat Recovery Steam Generator Team
Supervisor / Technician DOSH Steam Engineer 2nd Liaise with DOSH and supervise
grade, Welding inspector 3.1, boiler repair / inspection works
NDT competencies,
'Balance of Plant' Team
Supervisor / Technician Relevant competencies, Lead and supervise overhaul / repair
competency certificate from / inspection works
Suruhanjaya Tenaga,
knowledge in alignment,
vibration and lubrication
Below are the trainings require and have been identified to achieve required level of
competencies for RMS,
GT / ST
GT13E2 Commissioning
4.3 Partnership
Partnership, for turbine overhaul and service, is required for rapid set up of a strong
brand name in the market and development of technical capability to RMS. Correct
strategy of partnership can create an environment of less dependency to OEM and
to open opportunity of new ventures. Internationally, there are numbers of proven
and well known third party turbine overhaul and service company. Compare to OEM
companies, a third party company i.e. Wood Group, TSN or Turbocare, is more
ready to join and build a partnership with RMS to broaden their market opportunity.
There are two ways of approach for a successful RMS partnership. First is to support
RMS for existing business in Malakoff, which is quite a high risk as the OEM
companies might withdraw their support that have been given to us so far. Second
approach is purely on new ventures, where RMS can use the partnership to gain
trust and recognition from potential customer. Correct strategy for partnership
requires a thorough review, study and analysis to ensure a winning venture. The
strategy for RMS partnership won’t be elaborated in this business plan however it is
very important to be touched again in creating new business for RMS externally.
Pros & cons of JV with OEM / third party
Pros Cons
Gain trust / recognition from OEM withdraw support
customer / insurance
Potential market Profit sharing
Transfer of technology Limited to certain machine only
Established working system / Not totally independent
procedure
Strong technical support /
database
4.4 Milestones
MANAGEMENT SUMMARY
R o s li A b d H a m id
H O D
T J S B O p e r a t i o n s
& T e c h n i c a l
M
o k h t a r H a s M s ao nh d Y u s o f M o h d N o h
H O D H O D
T J S B M a r k e t i n Tg J* S B T r a i n i n g *
A b d R a h m a n R R a a h d i mz i i M d S h a r ip
H O D M a n a g e r
R M S R M S / T e c h n i c a l - K L H Q
* Departments under Operations & Maintenance Division, TJSB
TJSB Marketing department will assist and give support for RMS in identifying
potential market outside Malakoff and collaboration / partnership with relevant
parties. Marketing department will also advise and assist RMS for setting up as a
company in the mid-term planning (3 to 5 years). TJSB Training Department will
FINANCIAL PROJECTIONS
involve directly in technical development of RMS personnel. Continuous staff
development is vital to ensure achieving RMS vision as leader in power industry life-
cycle asset maintenance in Malaysia.
The following information presents a summary of RMS financial projections for five
years beginning January 2007. The financial details based on actual figures from
past experiences, estimation of cost by calculation of man hours and services
required, and on assumption based on experiences and actual data collected. Below
are the facts and assumptions taken into account used as basis for this financial
analysis.
7,000,000
6,000,000
5,000,000
4,000,000
3,000,000
2,000,000
1,000,000
-
2007 2008 2009 2010 2011
Financial forecast for the first five years are concentrated on the businesses inside
Malakoff. These are based on the services offered to Lumut, Prai and Tanjung Bin
EXPENSES
Salary 1,248,000 1,297,920 1,347,840 1,397,760 1,447,680
Technical Training 665,000 691,600 270,000 280,000 290,000
Tools 100,000 104,000 108,000 112,000 116,000
Total 2,013,000 2,093,520 1,725,840 1,789,760 1,853,680
PROFIT
Total 1,778,000 2,253,680 236,520 6,185,760 6,775,560
Profit / Revenues 8.46% 8.08% 3.31% 19.67% 22.34%
RMS has an exciting and profitable future. Based on pro forma profit and loss, 2007
– 2011, showed a steady stream of profit at average of MYR 3.4 million per annum. It
is expected to maintain the same profit after 2011 due to continuous demand of
machine overhaul. The profit can further increase by reduction of OEM specialist
during overhaul with continuous staff development and exposure. After 2011, as per
long-term planning, RMS to secure service contract with plant outside Malakoff,
which can double the profit obtained. RMS involvement not only can reduce TJSB
2% 6% 2%
GT
ST
HRSG
BOP
90%
For the total five years, involvement in gas turbine overhaul work produced almost
90% of gross profit, revenue versus direct cost. This contributed by frequency of
overhaul and requirement of highly expertise personnel for the service work. The
total gross profit for gas turbine was estimated at MYR 21.84 million. Second highest
gross profit estimated at MYR 1.46 million is HRSG inspection works. Even though
sharing the same number of inspection frequency as gas turbine, HRSG only require
assessment of parts instead of actual overhaul work. Steam turbine overhaul gross
profit at the second lowest at MYR 600,000 due to lower in frequency and steam
turbine overhaul work for PPP and TBPP were excluded due to lack of expertise
(manpower), information and data required. Future RMS involvement in steam
turbine overhaul works at PPP and TBPP may show increase in revenue. ‘Balance of
plant’ equipments overhaul estimated with the lowest gross profit at MYR 450,000 in
five years due to requirement of services only during breakdown which less than 5%
every year.