In conjunction with the participation in A TEC Holding GmbH the market leader in dry-grinding technology Loesche GmbH, Germany, has entered into a close cooperation agreement with pyroprocess specialist A TEC Holding GmbH, Austria, in April 2012.

A great move for both companies: Loesche GmbH, the market leader in dry-grinding and thermal process solutions and A TEC Holding GmbH, the technology leader in cement pyroprocess technology, both are convinced to jointly provide an even stronger and better support to clients in the cement industry.

A compelling combination – combining technologies and sales organisation opens new interesting opportunities for certain types of projects, for example combined upgrading projects including grinding circuits and pyroprocess optimisation.

LOESCHE and A TEC will be partners for the realisation of plant improvement projects, environmental projects and will be in the position to offer complete process solutions.

The cooperation generates attractive synergies for both companies – R&D and joint technology developments will provide new innovative solutions to solve the issues of the cement production market in the future.

Loesche GmbH as well as A TEC Holding GmbH are well-known brands with unmatched reputation for quality and customer service.

The core business of both companies will remain unchanged:

Loesche supplies vertical roller mills and dry-grinding plants to process coal, cement raw materials, granulated slag, industrial minerals and ores. Process solutions and automation processes are being developed for each individual project by experienced engineers.

A TEC stands for worldwide leading pyroprocess engineering for reliability and operational safety and will be the partner for clinker and cement plant optimization.

Additionaly A TEC offers consulting services, also for new production lines including manufacturing and engineering supervision in China and other supply areas.

For A TEC, process optimization means to look at the whole pyroprocess, to calculate optimization potentials and to intervene at the right points. A TEC offers patented products and innovative cement process technology. More than 600 sucessfully completed projects are proof of strength and competence.

Source

Loesche has successfully sold its 63rd Loesche Mill for PCI for the project Trinecke Coal in the Czech Republic.

The order comprises a Loesche Mill type LM 23.2 D together with a Loesche hot gas generator type LF 16 with a multiple lance burner for blast furnace gas. The plant will be built by Paul Wurth S.A. in the steel and iron works of TRINECKÉ ZELEZÁRNY – MORAVIA STEEL Group in Trinec.

The Loesche Mill will have a capacity of 44 t/ at a product fineness of 20% > 90µm and will feed the blast furnaces No. 4 and 6.

Delivery is scheduled for the end of 2012.

About Loesche

Loesche is an owner-managed, export-oriented company, which was founded in Berlin in 1906. Today, the company operates from its head office in Düsseldorf and has subsidiaries, representatives and agencies around the world.

It was in 1928 that Loesche built the first spring-loaded air-flow mills, which even today are still known as Loesche mills. Nowadays, Loesche vertical mills form the core of many plants used to dry-grind coal, cement raw materials, granulated slag, industrial minerals and ores.

Thanks to its grinding plants with throughputs of 2 to 300 t/h for the cement industry and self-inert, central coal-grinding plants for hard and brown coal power stations, Loesche is the global market leader for vertical mills and turnkey grinding mills.

Loesche supplies turnkey plants, which are individually planned and built for the required process steps. This includes plants for processing, material storage, transportation and delivery, vertical mills, hot-gas generators, filter and separator systems, complete automation technology, plants for all aspects of construction above and below ground, steel construction and piping systems.

The company has EN ISO 9001 certification and the grinding plants themselves are compliant with national and international safety regulations.

At present, around 330 people are employed at the company’s head office in Düsseldorf, with around 600 employed worldwide. 

Source

Don’t miss this unique chance to hear the industry’s leading players discussing the latest developments in the coal business, both globally and in Russia & the CIS. Learn about the latest developments and trends in key export markets, government policy initiatives, and updates on how best to tackle the challenges of transportation and production efficiency.

Event website https://www.adamsmithconferences.com/erc15roge

Our 40+ strong Speaker Faculty features senior executives from the industry’s most influential players, including:

- Graham Chapman, General Director, Sharyn Gol Coal, Mongolia

- Dominique Fache, Country Manager & General Director, ENEL OGK-5*

- Andrey Churin, Managing Director, EN+ Group

- Ismail Khan, Joint Advisor, Planning Commission, Government of India

- Sergei Frolov, Investor Relations Director, Koks Group

- Natalia Bortsova, Director of Research and Marketing, Taltek Coal

- Giorgio Ruscito, Managing Director, Fuelmed Italy

- Anatoliy Starovoyt, Managing Director, Ukrkoks

- Alisher Ali, Chairman, Mongolia Development Resources

- Hong Gao, Vice General Manager, Fenwei Energy, China

- Mikhail Popov, Fuel Portfolio Director, Fortum Energy

- Yuriy Plakitkin, Deputy Director, Energy Research Institute, Russian Academy of Sciences

SUMMIT HIGHLIGHTS IN 2012:

Industry Leaders’ Debate – Top CIS coal producers in frank discussion

Keynote Overview: The Russian & CIS coal industries in a global context

Export Markets: Latest trends and forecasts

Rail & Sea Transportation and Infrastructure: How to overcome bottlenecks and capacity constraints?

Government Policy: Senior officials will outline Russia’s long-term coal strategies

New Coal Technologies: Cutting-edge technologies for modernising plants & optimising operational efficiency

PLUS! Pre-Summit FOCUS DAY on NEW COAL TECHNOLOGIES – Pioneering a cleaner, safer & more profitable coal industry for the 21^st Century, 22^nd May

With its topical and interactive programme, the 40+ strong line-up of expert speakers (from producers to traders, end-users and analysts) – as well as more networking opportunities than ever before, the CIS Coal Summit 2012 is guaranteed to be of real benefit to your business.

https://www.adamsmithconferences.com/erc15roge

As the leading supplier of the world’s largest vertical roller grinding mills, in November 2011 Loesche obtained a contract for the first ever 4-roller coal mill for the injection of pulverized coal into a blast furnace (PCI technology).

The Loesche Mill Type LM 43.4 D has a capacity of 120 t/h and will be installed in the iron and steel plant of SSI Redcar in Great Britain.

This will be, together with the Loesche Hot Gas Generator Type LOMA LF 28 with a maximum heat capacity of 17 MW, the world’s largest single coal grinding plant for PCI. A step forward in the development of the multiple lance burner (MLB) allows for operation of the hot gas generator with blast furnace gas as well as with coke oven gas also at maximum throughput of the mill.

The complete injection system will be implemented by Siemens VAI and is planned to start operation at the beginning of 2013.

Loesche ThermoProzess GmbH informs that, as of 1st April 2012, they have taken over the specialised department “Combustion Technology” of UCON AG Containersysteme KG, Gelsenkirchen.

For more than 60 years, this division of UCON AG Containersysteme KG has been well-known as “Küppersbusch Fachbereich Wärmetechnik”. A large variety of industrial combustion systems have been developed designed and delivered by them.

Loesche ThermoProzess GmbH is a subsidiary of Loesche GmbH Düsseldorf and – together with the department “Thermal Applications”- represents within the Loesche Group the section Thermo Process Technology for this field of international industry.

Loesche GmbH is a privately owned company with more than one hundred years of tradition in the world market of vertical roller grinding mills. Loesche develops and delivers plants for the processing and comminution of materials such as cement raw material, cement, coals, minerals, ores and enhanced products.

With thermo process technological solutions, Loesche covers another field of activities with related products e.g. industrial burners and hot gas generators.

The integration of the specialised department “Combustion Technology” of UCON AG Containersysteme KG, Gelsenkirchen, with their range of products is thus another component for the expansion of the Loesche Group’s portfolio.

In the future, the products of the new Loesche ThermoProzess GmbH will be available under the brand name “Loesche & Küppersbusch”.

Managing Director of Loesche ThermoProzess GmbH is Mr. Matthias Authenrieth while Mr. Günther Balgar has been designated as operational manager for the facility in Gelsenkirchen.

Source

TATNEFT continues planned works to clear power lines crossing the woodlands in the Company’s activity territory.

The actions to clear the overhead power line routes were prepared in 2011 jointly with the Forestry Ministry of the Republic of Tatarstan. According to the Program of OAO TATNEFT has to carry out clearance of overhead line long clade 522 miles on the area of 1264 hectares in 2012 to produce. To date, cleared 50 km transmission line clearings in the area of 124 ha.

The annual plan for clearing firebreaks formed on the basis of the schedules approved by the chief engineers NGDU. From the beginning, digged area of oil and gas departments’ Aznakaevskneft “,” Almetyevneft “and” Dzhalilneft. ” In the cleared areas by mulching is waste logging residues.

By holding these events have prompted the abnormal weather conditions in December 2010, when the trees sagged under the weight of ice. As a result, there were circuit and open circuit. Based on the analysis of the effects of anomalies in the Company’s December program designed to enhance the stability of the transmission line to the natural anomalous phenomena.

Source

How long has your Company been doing business in the region?
Sulzer Pumps has been designing, manufacturing and servicing pumps since 1834 and is recognized for delivering state-of-the-art product quality and performance reliability for a wide range of demanding applications. The Company has been active in the region for several decades and has a sales presence in Moscow and St Petersburg. Since 2010, we have established two service centers at Khimki (just outside Moscow) and Oktiabrisky (near Ufa) plus a small service Island in Yekaterinburg.  Russia is an important market for us and the target is to extend our presence with more service centers in the coming years.

Do you have a specific target markets in the region? (ie Russia, Kazakhstan, key regions or market sectors nuclear, coal, gas, hydro etc?)
Sulzer Pumps operate in the entire Russian pumps market, serving different customer types and operating in all of its core market segments of power generation and oil & gas. Our product range and service offerings are customized for the region. We see a clear need for replacement or retrofit of most of Russia’s infrastructure and industrial facilities and are confident that we can provide our customers with the right solutions.

What are your key products for the region and what are their benefits?
Majority of customers are under pressure to improve the efficiency of installed equipment and to implement energy-saving initiatives. Customers need to balance the initial capital expenditure against the longer-term benefits. However, like all our customers, they require products with high availability and on-time delivery of services that operate as promised. Sulzer Pumps is committed to deliver the same high quality pumps and service standards to this market that the company is known for around the world.

What potential is there for your products in the market?
In addition to the high quality new equipments, Sulzer Pumps offers upgrade and retrofit solutions to answer these challenges worldwide. This includes proven capabilities in Russia and on Russian pumps, in both the oil and gas, and power generation industries. The essence of all upgrades and improvements is to use the maximum amount of original equipment to maintain existing operational parameters to gain significant time and costs savings. It is possible to achieve notable benefits to the process with minimum or no impact on the original footprint area, the drive system, the utility supplies, site interfaces, control and instrumentation among others.

How do you compare and compete with existing Russian Technology?
Sulzer Pumps started in the 1990′s to analyze operational behavior of Russian-made Water Injection (WI), Main Oil Line (MOL) for the Oil & Gas sector and  Boiler Feedwater (BFW) pumps and circulating Pumps for the power sector. The goal was to develop a program of pump upgrades and retrofits to help end-users lower operations costs by increasing energy efficiency to save power and improve pump reliability. This is offered by using as much of the original equipment as possible, to increase meantime between maintenance (MTBM) and reduce maintenance costs and increase reliability.

Sulzer Pumps HPT radially split barrel casing pumps are specifically designed for boiler feed applications in thermal power stations. Copyright © Sulzer Pumps

How do you see the market developing over the next 5 years in your industry sector?
Russia’s economic situation, size, natural resources, and ambitious projects, particularly in the energy, hydrocarbon and oil and gas sectors provide an opportunity to support our customers’ by providing solutions that maximize operations and long-term values. The general growth in Russia creates a dynamic business atmosphere for all market segments. Furthermore, there is a large installed base of pumps that need to be significantly upgraded to improve efficiency and reliability, particularly in the power generation sector.  

Sulzer Pumps GSG radially split barrel casing pumps are used in boiler feed applications of steam and combined cycle power plants. Copyright © Sulzer Pumps

Do you have any new products being launched?
Sulzer Pumps has a vast range of innovations and product development running and in the pipeline, especially for the power generation, oil and gas and water industries. We are among the few companies measuring the ecological impact of its products over its lifetime.

Do you have any recent regional success stories?
We have several examples where we have completed major new business projects successfully in the region’s oil and gas upstream industry. Some highlights include the largest and most challenging pipeline projects in Russia, Azerbaijahn, Georgia etc, the world’s most powerful and highest pressure Water Injection Pumps, the world’s largest Multiphase pumps and the largest Boiler Feed pumps in Europe. The results in some of our retrofit/upgrade projects are really astounding. For example, we revamped some old Russian water injection pumps and increased the time between services from 8 000 to 45 000 hours as well as improving the power savings by up to 20%. We have similar examples for main oil line pumps.

In the power industry, we have also upgraded boiler feed pumps and thereby increased the pump efficiency from 72.5% to 84.0% with energy savings of 16 %. Furthermore, we increased pump operation between repairs from 15 000 to 50 000 hours. We have similar examples for circulating pumps successfully executed in our local service center.

Any further comments?
Sulzer Pumps is one of the world’s leading manufacturers of centrifugal pumps. The Company is dedicated to improving customers’ pumping solutions and operational reliability. Our Customer Support Services team responds to industry service needs and is focused on ensuring high performance for all makes of rotating machinery. The Swiss based company is a leader in the field of pumping equipment production, is consistently in the global top 3 of its core market segments (oil & gas, &hydrocarbon processing, power generation, pulp and paper as well as water) owning 22 integrated works facilities and over 60 service centers worldwide.  Our vision is to be a recognized leader in innovative, sustainable, engineered, and customized solutions for performance-critical applications in the markets that we serve.

Joachim Schulz, Vice President Market Support Functions, Sulzer Pumps Ltd
Joachim heads the global Market Support Functions of Sulzer Pumps based in the headquarters in Switzerland. He has over 30 years of experience in the industry and 11 years in the Power Generation market.

Mick Wigglesworth, Managing Director, Sulzer Pumps Ltd Russia
Mick heads the Sulzer Pumps operations in Russia. He has 38 years of service within Sulzer, mainly in Sulzer Pumps and Sulzer Turbo.

Alexander Sozinov
Project Management Department Head, OJSC “ VNIIG Vedeneev “

Today’s global hydropower development trends are based on principles of energy-efficient and environmentally friendly power facilities. Russia, being a major player in the global fuel and energy market, pays special attention to renewable energy sources, including hydroelectric power generation.

In current market conditions, the construction of new hydroelectric power plants is challenging due to the requirement of large investments, and is often only economically viable with a partnership of the state and the private sector. That being said, the majority of hydroelectric facilities currently in operation have been in service for over 50 years. The main buildings and structures are generally in an operable state and, after some repair work, could serve for another 50 years. As for the equipment, the situation is not so good. It could be said that the majority of equipment has reached the end of its operable life and is in desperate need of modernization.

The above mentioned factors forced Rushydro, the largest hydro power company in Russia, to commence a modernization program for all facilities that have been in operation for over 50 years.

The following major objectives need to be resolved as part of the reconstruction process:
»    extending the facilities’ lifetime;
»    increasing energy efficiency;
»    improving the safety standards for the facilities in service;
»    Implementation of modern technologies aimed at mitigating the influence of human error by creating automated process management systems (ASM TP), automated control systems for hydrotechnical facilities (SAK HTF), and introducing single center asset management technology.

As part of the program, the North Ossetia branch of OJSC “RusHydro” and its assets are to be reconstructed. Key facilities to undergo the reconstruction include: Ezminskaya HEPS, Gizeldonskaya HEPS, Dzaujikauskaya HEPS, Bekanskaya HEPS.

Ezminskaya HEPS (Photo 1). Location: Republic of North Ossetia-Alania, Chmi settlement, Terek river; distance from embouchement – 561 km. Mean annual runoff at power site – 0,860 km3/year. Installed capacity of HEPS – 45 MW. Mean energy capability – 231000 thousand kWh/year. Launch date for the first pump storage genset –24.11.1954. Major equipment:

Gizeldonskaya HEPS (photo 2). Location: Republic of North Ossetia-Alania, Vladikavkaz, Prigorodniy district, Koban settlement, Gizeldon river.  Mean annual runoff at power site – 0,106 km3/year. Installed capacity of the power site – 22,94 MW. Mean energy capability – 53400 thousand kWh/year. Launch date for the first pump storage genset– 29.06.1934. Major equipment:

Dzaujikauskaya HPP (Photo 3). Location: Republic of North Ossetia-Alania, Vladikavkaz. Mean annual runoff at power site – 0,85 km3/year. Installed capacity of HEPS – 9,2 MW. Mean energy capability – 39800 thousand kWh/year. Launch date for the first pump storage genset– 01.08.1948.
Major equipment:

Bekanskaya HEPS (photo 4). Location: Republic of North Ossetia-Alania, Ardonsky district, Bekan settlement. Installed capacity of HEPS – 0,504 MW. Launch date for the first pump storage genset– 25.12.45.
Major equipment:

The reconstruction is planned in three stages:
»    A review of all structures and equipment to determine the remaining life expectancy and volume of reconstruction required
»    Development of design and what expertise is required
»    Project realization

The most important stage is the review, which will entail the:
»    Which objects require demolition and what new building/facilities will be required
»    Which objects require reconstruction
»    Which objects requiring repair and restoration

During the review of mechanical and electric equipment, its remaining life expectancy will be assessed and it will then be classified as follows:
»    Equipment to be completely replaced;
»    Equipment that needs partial replacement;
»    Installation of new modern systems.

Based on the preliminary evaluations that are made, the following can be concluded in relation to the condition of objects in need of reconstruction:
Hydrotechnical structures (HTS), including dams, dikes, intake chambers, discharge sluices, channels and penstock conduits – their overall condition can be deemed as satisfactory, with few units requiring repair and restoration work, including any reinforcement of the main structures. Also, all of the structures require additional retrofitting with measuring and control equipment and a relevant automation system.

The proposed instrumental revision will apply modern ultrasound flaw detection survey technology (a non-destructive control method), as well as sample taking (destructive control method); the technical condition of the structures will be assessed, including their sub water parts so that hidden defects will be revealed. During the revision for subsequent design work, 3D laser scanning will be used and its results will be applied to create a 3D model of the structure’s actual condition.

Equipment:
»    Hydropower and electrical equipment – preliminary estimates show that the equipment is to be completely replaced, as it’s worn out and outdated. Apart from this, the latest equipment is required to improve overall performance and automation

»    The hydromechanical equipment is severely worn out, and needs complete replacement

It should also be noted that the complex revision stage for the plants will include a revision of the equipment with participation of the original manufacturers.

During the reconstruction project, it is planned to implement pilot (for Russia) 3D modeling technologies. Development of the project will be done using three dimensional models which will be created at the revision stage using laser scanning.

Using 3D modeling technologies at the development stage will reduce time and save design documentation, save costs and decrease the likelyhood of any errors.

The 3D model, designed and updated during the construction period, will then be passed on to the operating company and be used as an instrument for managing the operating the asset. It will also be able to carry out additional functions, such as being a drill simulator for plant staff.

In order for the project to be undertaken successfully, with the latest equipment and best available project management, we plan to use the expertise of foreign equipment manufacturers. In this specific  case, we are looking to potentially work with Andritz Hydro, with the design and construction work being carried out by Russian companies with the RusHydro group.

Conclusions
»    The recent economic crisis has demonstrated the sad fact that Russia is now unable to use resources from the Soviet period and the time has come for global restructuring and modernization. Nothing but modern technologies implemented at hydropower facilities together with increased attention paid to secondary (and using the accepted terminology, basic) structures will enable us to reach sufficient levels of energy efficiency for hydropower facilities, and more imprtantly allow them to become fully capable of participating in the energy market.

»    The first step is for sure modernization the facilities, however it is also important to streamline the opration of the assets through automation and control, mitigating the risk of emergencies and environmental damage.

»    This program of innovation and modernization by RusHydro will see an implementation of new technologies and ideas which will be unparalleled any where in the world.

Telatek offers a wide range of services to the energy sector – what are your key market sectors in Russia?

Telatek works around the world in various industries such as power generation, timber and paper, shipbuilding, heavy engineering, mining and many others where the refurbishment demand of main equipment is an essential base to secure operational and production reliability, and ultimately extend equipment lifetime as well. One of our key markets however is Power Generation. We consider Russia and Ukraine as high promising and potential markets where our knowledge, expertise and know-how to repair the heavy-duty metal components of main equipment at power plants can be applied to extend its lifetime significantly.

Telatek has very extensive experience in the repair of a variety of types of turbines and boilers. Turbine component wearing is a continuous process that happens at all types of power plants. There are certain features of wearing however that depend on the type of power plant (thermal, nuclear or hydro) or turbine size and Telatek knows how to repair and improve the equipment efficiently. Some of our repair technologies would be more demanded at certain types of power plants like coal-fired units where boiler element wear is much higher than at gas-fired power plants. But anyway we consider nuclear, thermal and hydro energy companies as our high potential clients in the markets.

The Russian Government are insisting that power produces both increase efficiency in their operations, while also increasing power production to meet an ever growing demand. How can you help your customers achieve their efficiency and safety goals?

Of course that is possible if you apply a comprehensive approach and proven solutions. To increase efficiency means renew the main equipment to optimize operating parameters as well as reduce maintenance costs and breakdowns. Telatek´s long-term R&D program has made it possible to develop a wide range of materials which prevent all possible types of wear that occur during turbine, boiler, pump or valve operations at power plants. We also pay serious attention to repair technologies, including specially designed toolsets to provide all types of on-site repair techniques by machining and welding. The other important thing is quality control in order to secure the safety and reliability of the main equipment. All our projects are completed with close attention to quality and safety requirements throughout. It is worth emphasizing that all repair operations by Telatek are thoroughly inspected and accurately documented. Telatek Quality professional inspectors have extensive experience borne from many demanding projects. This high standard of work and measuring techniques ensure a reliable outcome. Quality assurance is one of the main reasons why Telatek can give substantial guarantees for its own work. We know Russian energy companies have approved large investment plans to “green-field” projects. These programs will help to replace old and inefficient power generation assets, but in spite of that fact probably 80% of existing units will remain in operation for a long time to come. The majority of power plant equipment was installed between 30 &40 years ago, meaning that energy companies have to constantly pay repair contributions in order to ensure reliability. I would say that operators would be eager to improve their existing equipment and reduce their repair budget and maintenance terms at the same time.

Many power plants are going through modernization and upgrading of their power producing facilities. The correct choice of coating for increasing equipment life is key – what should the operator look at when choosing a company to do such work?

Telatek has proven technologies and materials to meet clients’ expectations. We have bright success stories which demonstrate the level of our service, materials and techniques. One such example is Loviisa Nuclear Power Plant in Finland. The first coating of the horizontal planes of high pressure casing of K-220 steam turbine was done in 1982, and in 1990 the whole casing was coated against corrosion and erosion. After more than 20 years of operation the coating remains undamaged bringing serious lifetime extension to the unit. The latest maintenance of the power unit was done in 2010 and the return on investment was very quick, at about 6 months. This maintenance also increased the turbine capacity 1.5MW up. This lifetime extension and power increase has meant that the client got a clear cost saving.

What are your key clients in the region?

We launched our Russian business in 2006 with our main target being the Nuclear sector. In 2007 the company got its first order to provide on-site steam turbine repair services to Kola Nuclear Power Plant owned by Concern Energoatom. The services included thermal spraying for the high-pressure casing of K-220 turbine. We have also played an important role in modernizing and prolonging the life of an existing power unit at Leningrad Nuclear Power Plant at Sosnovyi Bor. In 2010 we collaborated in this project with Concern Titan-2 which took charge of the entire refurbishment project. Telatek’s role was to machine and coat K-500 turbine casings. Telatek installed at the NPP a uniquely designed horizontal boring and milling machine suitable for the client’s needs. All work was completed accurately and efficiently. In the final stage the turbine interiors were coated by thermal spraying using materials developed by Telatek. The client was pleased with both the results and the execution of the project and in particular appreciated the competent work and smooth and flexible collaboration. Our innovative solutions helped to extend the lifetime and maintenance intervals of the turbine. We are proud of our participation in the project which increased the performance of the turbine up to 15 MW.

Technology innovation in the power sector moves at a rapid pace. What specific products do you have that meet the strict requirements in this industry?

Telatek provides all types of repair services to power plant main equipment. The repair includes machinery, welding and thermal spraying of turbine and generator parts like division planes and sealing faces, guide vanes, casings, rotors, bearings, base plates; boiler parts such as wall and ceiling elements, superheaters, grates; pumps and valves like the main circulation pumps etc. We have several large and well-equipped machinery factories in Finland were we are able to manufacture any type of metal spare parts. But I think the main benefits we are able to provide all repair services on-site. Telatek has wide range of mobile machine, equipment and specifically designed toolset to do all types of machinery, welding and coating repair operations at power plant premises. The other important benefit is that we have spent a lot of time and effort to develop our own coating materials and specific repair technologies. Nowadays our proven patented materials cover all possible equipment damages and wearing cases and can be applied to any type of metal.

How do your products compete with local Russian companies?

Historically, nobody paid any serious attention to the cost of maintenance and spare parts. In today’s climate it is impossible for power producers to ignore. Also the reliability requirements remain very strong in Russia and other CIS countries. In order to fulfill the requirements and provide modern and proven repair technologies any research or maintenance company should invest significantly into materials and equipment. The fact is that just long term field observation on real equipment could help to create proven repair materials and techniques. I think for the time being such modern products and technology are mainly supplied by foreign companies that have a long history of demanding market competition. The other important thing is engineers, who should have strong experience within the industry and of using such technologies. Telatek has more than 30 years of success in the maintenance history, specifically for the power generation industry. Our developed materials and technologies have been strongly verified by decades of successful operations. It’s very important to emphasize that all of our maintenance experts and specialists are able to provide a broad range of repair operations by themselves, and to follow and manage the repair process for certain equipment wear and breaks from the very beginning to the final stage. In addition it reduces the maintenance costs to the clients.

What are you views on the energy sector in Russia at present, and how do you see the market evolving over the next 10 years?

We understand that maintenance is very conservative area, especially in power energy sector. The existing instructions and approved standard operations are continuously being done by local maintenance companies during every maintenance shutdown. But we look positively on the market share potential for our knowledge and services. The state of existing equipment and the cost saving programs that are being implemented mean that energy companies are looking for a new generation of refurbishment services. Currently, Telatek is developing a market strategy to establish a long term presence in Russian and CIS markets. We are open for the business with main industry players – both energy and maintenance companies.

Focusing on traditional power generation, what specific product offerings do you have, and what projects have you worked on in Russia?

If we refer to thermal power plants I think boiler coatings for coil fired power plants is quite a new product for the local market. The wearing of boiler wall, ceiling and superheaters pipes, areas around burners and air blowers, exhauster blades are very typical cases at such type of boilers. So far the local cost of new metal pipes and components hasn’t influence dramatically on maintenance budget. But now it becomes more and more expensive from one hand and also repair service price are growing faster. I think it could be attractive to the clients to protect the boiler elements for a long time and avoid emergency shutdown and thereby to reduce the maintenance costs essentially.

Telatek has invested serious resources to develop special type of materials which covers various types of boiler wearing like abrasive, adhesive, fretting, solid particle erosion and corrosion specifically occur at coal-fired medium and processes. Last year we got new mobile automated coating machine which had been specifically designed to our needs in cooperation between our engineers and producer. Such machine allows us to provide fast and high quality thermals spraying of different pipes and components inside boilers with very stable coating parameters across large repaired areas.

Here in Russia we are continue to work to nuclear power plants but currently look very positive on our negotiations with traditional power generation companies to apply our modern refurbishment technologies.

Do you have any further comments for our readers?

The world financial crisis has impacted every industry. With this in mind it becomes more and more important to find cost effective solutions which help energy companies to improve existing production and secure money to finance new projects. Finally it creates a good opportunity to introduce into your business a new generation products and technologies that ensure you are competitive in any economy climate.

Alexei Lobanov was born in Leningrad in 1965 and graduated in 1989 from the Leningrad Institute of Aviation Instrument Maiking, majoring in Design and Production of Electronic Equipment and Components. In 1996 he graduated from the Saint-Petersburg Electrotechnical University and majored with a PhD in Industrial Automation. Has worked with a number of companies in power generation,shipbuilding and heavy engineering industry., Has been employed at Telatek Group, Service as Regional Director since 2011

Provided exclusively to PowerTec Russia Magazine by ROSATOM

In September 2011Yukiya Amano, the head of the IAEA estimated that the total new build market for the Nuclear power sector to be at 350 new reactors.

After the tragic events at Fukushima-Daiichi nuclear power plant, questions were raised about the safety of Nuclear power and its long term viability. More than six months have passed however and although safety is more than ever at the forefront of our sector, the worse predictions have not come true. In fact, it is just the opposite – the majority of countries that have declared their intention to develop nuclear power have not abandoned their plans and indeed some countries, in particular Great Britain, have announced plans to build new NPP’s after the events in Japan.

ROSATOM is one of leading global players in the NPP construction market. The Russian state-run corporation has managed to become a clear world leader in the construction of nuclear power units overseas. Currently, 21 reactor construction projects are underway abroad at different stages of development, from a signed contract through pre-startup activities. These projects include plants in India, Bulgaria, Turkey, Armenia, Ukraine, Vietnam, China, Belarus and Bangladesh.

Growth in energy consumption and the need to cut carbon emissions in the energy sector has pushed many countries, including those new to Nuclear Power to have a positive outlook on the development of this sector. Over the last couple of years ROSATOM has signed nuclear construction agreements covering four new markets – Turkey, Vietnam, Belarus and Bangladesh.

Under an agreement signed in November 2011, two nuclear reactors with 1,000 MW installed capacity will be built on the Ruppur site in Bangladesh. Later on in the same month an agreement concerning the financing of NPP construction in Vietnam was also signed.

In December 2011 the House of Representatives of the National Assembly of the Republic of Belarus ratified a Russia-Belarus intergovernmental agreement Which gives the Belarus Government export credit for construction of NPPs in the Republic of Belarus. The agreement was signed in Moscow in November 2011. The project is planned to start in early 2012.

Construction of the first Turkish NPP is also already underway. The site is located near the Mediterranean seaport of Mersin in the Akkuyu Region. The plan is to build four 1,200-megawatt VVER reactors to Russian AES-2006 specifications. This is the world’s first nuclear power plant to be built using the “Build-Own-Operate” principle. The Russia-Turkey intergovernmental agreement signed in 2010 contains commitments from the Turkish utility TETAS to buy a fixed amount of electricity planned to be produced by the plant at a fixed price (70% from Units 1&2 and 30% from Units 3&4) for a period of 15 years, starting on the date of commercial operation of each power unit. The Russian company will sell the reminder on the free electricity market, on its own or through a retail electricity supplier.

Following the tragedy at Fukushima-Daiichi, the competitiveness of Russian NPPs has actually increased. In May, stress tests were carried out in Russia, with the results submitted to the Russian regulator Rostechnadzor. As well as this, a team of international experts from the World Organization of Nuclear Operators (WANO) conducted peer reviews. Russian NPPs were tested for threats such as earthquake, flood, loss of power supply, loss of ultimate heat sink, terrorist acts, and severe accident management capability. The stress tests confirmed the full reliability and safety of Russian NPPs.

The Tianwan NPP in China has been recognized as the the worlds safest and most successful NPP, and using this as an example the Russian NPPs that are planned or under construction will meet all existing safety requirements as well as being able to withstand the extreme events such as those encountered at the Fukushima-Daiichi NPP. In addition, they can withstand a heavy aircraft crash, they have a passive heat removal system, which keeps the plant safe in a blackout situation, and a core melt trap.

In 2011 the first reactor of Iranian Bushehr NPP was connected to the grid and in early 2012 two reactors at the Kudankulam NPP will be commissioned in India.

ROSATOM Chairman Sergey Kirienko stated that the Russian nuclear corporation intends to win, at least, 20% of the world’s nuclear construction market over the coming 20 years. In fact, within two decades ROSATOM wants to build up to 80 new nuclear power units of Russian design, of which only 30 will fall within the domestic market.

Vesa-Pekka Vainikka, Kari Kuisma

Finland is a country where ambient temperatures can drop down to as low as -40 C in winter whereas summer temperatures can peak at over +35 C. These conditions, combined with the nonexistence of domestic oil, gas and coal resources, have given the Finns a natural opportunity to develop sustainable energy solutions. In particular, Finland has been a front-runner for decades in the development of modern, energy efficient district heating and cooling (DHC) solutions, integrated with combined heat and power (CHP) production. For example, in Helsinki, over 90% of district heat is produced by CHP. Since the 1950’s Pöyry has been playing a vital role in developing these advanced CHP & DHC solutions, which have been later adapted in numerous other countries.

In most energy efficient solutions, including the one of Helsinki, the entire heat production and supply chain has been optimised.

Finland is the leading country in the world in terms of combined heat and power (CHP) generation. Almost 80 per cent of country’s district heat production is based on CHP generation. Correspondingly, one-third of electricity is obtained in CHP generation. No other country has such a great market share of CHP electricity. In the EU, combined heat and power generation amounts to only just over ten per cent of the total electricity production.

Pöyry is a leading designer and project manager of Combined Heat and Power plants for industries and communities in Finland and in Europe. Pöyry has designed over 8000 MW Combined Heat and Power capacity during the past 10 years only and this is why Pöyry has been ranked for several years in a row as the number one company in the field of engineering Combined Heat and Power Plants (Top 200 International Design Firms list, published annually in July by Engineering World Record).

“Our expertise covers particularly combined heat and power (CHP) plants for industrial and communities, be it based on gas-fired combined cycle power plants, solid fuel and especially biofuel-based power plants, diesel power, you name it,” says Vesa-Pekka  Vainikka, Senior Vice President of Pöyry for District Heating and Cooling.

“Combining the CHP expertise with the DHC know-how we are able to implement the most energy efficient energy solutions considering the entire district heat supply chain from heat production to distribution and supply to the end consumers, Mr Vainikka continues. The typical concept of a modern district heat supply chain is presented in Figure 1.

“In Russia there is huge energy efficiency potential related to optimisation of the entire district heat supply chain, claims Mr Vainikka. Taking full advantage of this potential is technically quite possible, but would require substantial investments, especially for consumer substations”, Mr Vainikka continues.

Pöyry’s experiences from District heat reconstruction projects
Mr. Veli-Matti Kivistö (pictured in Figure 2), Project Manager and Senior Adviser in District Heating and Cooling (DHC) at Pöyry, has more than 25 years of experience in DHC, covering Pöyry’s major DHC projects all over the world. He emphasises that modern DH systems must be constructed and operated based on sound economic criteria, using standardised, technically proven, and high-quality solutions.

“Accordingly, investments shall be made based on an analysis of economic viability. The DH systems must be competitive compared with alternative heating methods, bearing in mind that the key issues to consider in design and operation are to provide heat to customers in all conditions and to maintain customer satisfaction,” Mr. Veli-Matti Kivistö emphasizes.

Mr Vainikka continues that Pöyry has participated in DHC projects for the improvement and development of energy supply systems, not only in several Finnish cities but also in Ukraine, Russia, Belarus, Kazakhstan, Mongolia, Bosnia and Herzegovina, Serbia, Estonia, Lithuania, Latvia, Hungary, Italy, Poland, Sweden, the UK, South Korea,
and China.

For example, in Seoul, South Korea Pöyry has a long history of cooperation with Korea District Heating Corporation (KDHC). KDHC is the owner and operator of the largest modern district heating and cooling system designed and constructed in accordance with the Western energy efficiency design principles. One of the major CHP plants in the Seoul DHC system, the Bundang Plant, is shown in Figure 3.

“Our district heating reconstruction assignments have included, for instance, the preparation of energy development plans, assistance in tendering and procurement processes, investment plans and financial assessments, project management, construction supervision, renovation of municipal heating systems, energy saving technologies and audits, studies on DHC, gas and steam distribution networks and environmental assessments,” Vainikka describes.

Mr. Vainikka continues that in most of the implemented DH reconstruction projects financing from various international organisations and financial institutions (such as EU, WB, IFC, EBRD and governmental agencies) has played an important role in making the projects happen.

The overall vision on DH reconstruction
Our criteria and approach to carry out the analysis and the recommendations for the minimum cost investment plan are based on the fundamentals briefly presented in this chapter.

Modernisation of a large DH system is a long-term process and requires considerable investments and technical know-how. Typically, technical, financial and institutional issues set limitations for the possible reconstruction actions. Based on Pöyry’s experience in Russia and other transition economy countries we have developed a methodology , which is proven to result in the minimum cost investment, both short term, and particularly for long term with optimised lifecycle costs (i.e. lowest annual costs considering both investment and operating costs). Quite simply, the key issue is to prioritise the available investment funds into the most feasible reconstruction components. According to our experience, the optimised lifecycle costs can be achieved in a typical DH reconstruction project by prioritising the reconstruction investments as follows:
»    Individual building level heat substations (ITPs): Gradual closure of the open Domestic Hot Water System (DHW) – if applicable – by ITPs equipped with heat exchangers and control valves for both space heating and DHW preparation (ITPs). ITPs have heat meters enabling invoicing based on real measured consumption. Installation of ITPs is also a key in the reconstruction of systems where the closure of an open DHW system is already done, but where consumer installations for space heating are still hydraulically connected to the DH network. Further more, building level ITPs enable the removal of Central block heat exchanger stations (CTPs) and particularly 4-pipe distribution DH pipe networks with short technical life time and high O&M expenses.

»    Pipes: Replacement of old and worn out DH network sections with new DH network sections applying  high quality bonded pre-insulated technique allowing excellent protection against external corrosion and reduction of leaks and heat losses.

»    Other: Reconstruction of pumps, water treatment, automation, remote control and monitoring equipment at production plants enabling variable flow operation and high quality treated DH water

The Introduction of ITP’s will allow hydraulic separation of consumers’ internal installations from the primary DH network and, respectively, the utilisation of purified DH water in the entire DH system.  The internal corrosion of DH pipes decreases, and the anticipated average technical life time of the DH network increases significantly in parallel with the progress of the hydraulic separation. Without the closure of the open DHW system and the hydraulic separation the average technical life time of the DH network remains low.  It should be pointed out that the share of the DH networks in reinvestment costs of heat transmission and distribution is estimated to be 70% – 80%. Currently, an average technical life time of more than 50 years is anticipated to be achieved in modern DH systems.

ITP’s and variable flow will enable more flexible, energy efficient and safe system operation from production to end customers. Customers equipped with ITPs will be capable of regulating their heat consumption, which results in savings in annual heat energy consumption. Furthermore, the quality and reliability of heat supply will eventually increase. Application of feasible standardised, technically proven high quality, but simple/cost efficient, solutions through transparent procurement process should be ensured, when rehabilitation measures with new ITPs are performed.

Reconstruction of District Heat systems in Russia – Will it happen?
It is no secret that in Russia there is a clear necessity to invest in DH reconstruction in order to improve the technical life time of the equipment, increase efficiency of operations (including CHP production) as well as to keep district heating competitive enough against other heating methods. For example, based  on our experience, the annual water leaks (losses) of a Russian DH system are typically high, between 8 – 30 (or even more) times of the total water volume of the DH network, whereas the corresponding figure in a modern Nordic DH network is only 1.

Furthermore, if the DH network is not upgraded and modernized the end customers may choose to disconnect from this network entirely in favour of other heating methods such as gas boilers/electric heating.

Pöyry has been involved during the past few years in several district heating reconstruction developments in Russia. “It is evident that the saving potential on a national level is enormous – not just related to energy but also to potential savings related to water, investment and operation costs of district heating systems,” says
Mr Kivistö.

Several Russian District Heating companies have already seen the potential and have started implementing reconstructions of their district heating systems. One of these companies is OAO Fortum, for which Pöyry carried out District heating system studies in Chelyabinsk, Tyumen and Surgut from 2008 – 2011 (Figure 4). The studies consisted of hydraulic analysis and simulations of district heat networks and recommendations for further actions in terms of future investments and other improvement measures. In Chelyabinsk, Pöyry teamed up with its Russian engineering partner JSC Cotes for the renewal of the district heating pumping system at CHP-3. “We are currently working together in several CHP/DHC projects in Russia and Kazakhstan, for example in Chelyabinsk, Blagoveshensk  and Astana (Figure 5) and our experiences when combining global technology know-how with local expertise have been very encouraging”, commented Mr. Dmitry Serant, CEO of JSC Cotes.

“The biggest obstacle for kicking-off the reconstruction projects in Russia is that the financial incentives and clear institutional guidelines are not yet there, either on the producer side nor on the consumer side and district heating is still considered as a side-product to electricity. A common ground needs to be found in terms of what needs upgrading and how to carry out these projects” says Mr Vainikka.

“But, it is clear that fundamental reconstruction of district heating systems will be needed in Russia in the future and it is not a question whether it will happen but when it will happen”, Mr Serant concludes.

Fiona Riddoch: Managing Director, COGEN Europe

Russia is naturally aware of the economic value of its primary fuel exports, particularly natural gas, and improving the efficiency of fuel production and consumption makes good economic sense. Improved efficiency frees up additional volumes of energy for export from Russia, while also enhancing the security of export supply. Within Russia itself, natural gas is the leading single primary fuel consumed representing 55% of primary fuel consumption. Coal is the second most used source at 20%, followed by hydro at 15% (see figure 1).

Primary energy supply in Russia (excluding electricity trade) runs at around 700,000 Mtoe with, 25% used in transport, around 30% in industry the remainder being in commercial, residential and agricultural use.

Russian industry is highly energy intensive. There was a dramatic decrease in energy consumption in Russia as a result of the decline in GDP growth over the market transition years of the 1990s where Russia saw its GDP fall by 50%. This low level of consumption has continued in the 2000s, showing a permanent shift in economic activity.

Russia uses CHP routinely within its heat and electricity supply. CHP accounts for around one third of the installed electricity generating capacity, hydroelectricity is 20%, nuclear is 10% and the rest is traditional thermal condensing generation. Due to the history of expansion of industry and of the urban areas and cities of Russia, there is an extensive use of district heating in Russia’s cities often supplied with the useable surplus heat from local industry as the source. Russia’s district heating network delivered 1,700 TWh of heat in 2007, supplying 80% of Russian residential buildings.

As mentioned above, Russia’s industry is highly energy intensive. Just over half of Russia’s 500 CHP plants are based in industry. Iron, steel, chemicals and petrochemicals make up over half of the industrial heat consumption in Russia. All these industries have been badly impacted by the structural change in the Russian economy and as the ability of CHP plants to deliver energy savings depends on their reliable operation “as designed” with all the electricity produced and all the heat produced being consumed, radical changes in either demand or supply have a potentially large impact on efficiency performance. Where a district heating network is accepting the heat from a process it is easy to see how a downturn in the industry has a knock-on effect on its role as a reliable heat supplier, sending customers looking for alternative or backup supply.

Considering the high penetration of both district heating and CHP in the Russian economy as a whole, it might be assumed that the areas of the economy involved would be highly efficient in their own right. However, those who have studied the sectors suggest that an absence of good data and underinvestment in the infrastructure mean that there is a huge opportunity for improving the energy performance in these areas.

Although Russia has over 50 GWe of CHP installed capacity there is little published data on the efficiency of these plants. Moreover, there is little direct policy structure around CHP despite its significant position in the economy and its considerable potential. District heating may be associated with CHP but it is not always the case and district heating relies heavily on the efficiency of its distribution network and on a CHP element to deliver significant primary energy savings compared to separate production.

District heating in Russia is suffering from several problems. The municipal heat network extends over 200,000 km. More than half of this length is estimated to have exceeded its technical lifetime of 20 years and 25-30% is considered to be in a critical condition according to the IEA. Raising the investment to replace, repair and maintain this immense network is the key challenge facing Russia’s district heating system network.

Estimates by the IEA suggest that raising the efficiency of Russia’s CHP plants and reducing the losses along its district heating network could yield energy savings through improved efficiency of 20-30%. Russia consumes the equivalent of about 150 billion cubic meters of natural gas a year in its district heating, savings of 30-50 bcm (roughly two thirds of Germanys total gas usage per annum) which could be achieved by action on CHP and district heating would release that gas for export rather than let it be wasted internally.

Energy efficiency has been a key element of Russian energy policy thinking for the past 15 years. Over the past 5 of these years legislators have moved to develop policy to create the necessary framework for action. Trends in the focus of energy efficiency legislation in Russia seem to be moving in a very similar direction to the European Union, with more focus on energy efficiency in general and providing a policy structure to deliver this as growing awareness of  the significant role of energy efficiency encourages more legislative action. The new Russian Energy Efficiency Law of 2009 focuses on energy end use with the declared aim of creating a legislative, economic and organisational stimulus for energy savings and increasing energy efficiency. Its effect extends to include water supplied, transferred and consumed using centralised water supply systems. The governing principals of the legal approach are:
»    efficient use of energy resources;
»    support and encouragement of energy savings and increased in energy efficiency;
»    a systematic and integrated approach to energy savings and energy efficiency program;
»    the planning and integration of activities increasing energy savings and energy efficiency;
»    use of resources with account to resource;
»    technological, ecological and social conditions.

Maybe driven by its economic strength as a supplier of energy, Russia’s growing attention to energy savings is visible for example in its focus on capturing all the areas of the energy supply and consumption chain under the legislation. An example is flaring of natural gas. Although the absolute level of flaring of associated gas in Russia is unclear, it is of concern to the government. Prime Minister Vladimir Putin brought focus to the issues in a 2007 presidential address. In response, the Russian energy and environmental ministries produced a set of proposals to reduce flaring and a decree published in 2009 sets the goal of using 95% of the associated gas by 2012. A further example, with implications for CHP, is the development of legislation around heat. Following the restructuring of the electricity market, the Russian authorities are now developing a new regulatory framework for the heating sector. The Federal Law 190-FZ on Heat Supply was adopted on the 27th of July 2010. In a similar way to the objectives pursued with the electricity reform, this law aims to modernise the sector which is currently characterised by the use of very old equipment and thus a high energy intensity. The European Union has toyed for the past decade with the idea of tackling the heat sector but failed to do so. Arguably this is a significant barrier to progress on CHP in Europe but one that Russia has already moved to address. With the extensive use of CHP in Russian industry and the relative contraction of that sector plus the age of the district heating network, there is considerable scope for improvement in efficiency through a focus on heat, its generation and use and how to efficiently adjust the existing system to the challenges of the current decade.

Both Russia and the European Union are beginning to consider the efficiency of the whole energy supply chain as being key to making progress. The European Parliament is currently discussing a proposed Energy Efficiency Directive which looks at the full energy supply chain. Until now European energy efficiency and savings legislation has been fragmented across several different directives. End use energy efficiency was promoted through the Energy Services Directive, CHP through the CHP Directive and other wide ranging measures through the Energy Efficiency Action Plan 2006. The interlinking network efficiency and particularly transformation efficiency itself were left to other instruments with a secondary impact on efficiency. The new Energy Efficiency Directive is ground breaking for Europe in the sense that it looks at the full energy supply chain, forcing consideration of all areas of conversion, supply and use and introducing the proposal for direct involvement of all primary energy using sectors, including the electricity sector.

One of the biggest differences between EU energy efficiency legislation and that of Russia is the absence in Russia of focused legislation addressing the economic and non-economic barriers to the wider uptake of efficient CHP. There are some learning experiences from the European Union which Russia might want to consider should it decide to move forward with legislation on CHP. The CHP Directive 2004/08/EC – though not successful in the promotion of CHP across Europe – was successful in raising policy-makers confidence in its energy savings and in giving the kind of policy background which allows investors to adequately calculate risks. The Directive did this by putting in place a transparent methodology for calculating the energy savings from CHP and introducing a threshold of efficiency performance for CHP (high efficiency CHP) which must be reached or exceeded if the CHP plant can benefit from particular Member State support schemes. The Directive was not so successful at introducing new statistical recordings for CHP, but this too is considered highly desirable in the implementation of an effective energy efficiency strategy.

District heating is a big existing and potential future heat customer for CHP in Russia. However, for district heating to deliver energy efficiency savings compared to individual installations the heat network itself must be highly efficient (achievable with modern distribution technology) and the overall efficiency of the system should be optimised. The main barriers which Russia’s district heating seems to face is a convincing business model which supplies the customers with the comfort and control level they expect, at  a price which is reasonable. Allowing adjustment of the heat tariff is a key element of any business model. If this can be achieved, investment in the heat network will follow based on the robustness of the plan. The emergence of a suitable environment for this will be the entry of third parties willing to support directly or jointly with others. For example, a recently announced large refurbishment of the Chelyabinsk district heating network by Fortum’s Russian subsidiary aims to reduce losses by 30% through automation and network upgrades and technical improvements at the power plants located in the Chelyabinsk region. A co-ordinated and long-term strategy and policy structure which enables the companies with experience in district heating to operate in confidence with a reasonable investment horizon, would drive this kind of investment forward. Examples of just such an approach in the European Union (Denmark, Germany and Flanders) have been successful.

There is considerable untapped potential for CHP in industry and space heating/hotwater delivery. The industries of paper, chemicals, refining, food, ceramics and more, use CHP routinely and effectively. At a time when industry is challenged by high labour and materials costs in Europe, it is possible to add an additional income stream of low carbon electricity sales to the profit and loss account if the policy structure in place removes the barriers for new players to enter the electricity market, and encourages and rewards high efficiency. Since the 2000 there has been increasing momentum in refurbishing existing boiler houses with smaller scale CHP units (<25 MW). These developments take CHP into new applications, smaller heat networks, smaller factories. There is an ever increasing range of CHP solutions for a widening range of capacity demands. In its district heating network Russia has both a challenge and a valuable opportunity. The existing network represents an investment which in planning and construction terms would be difficult to repeat today except in the rapidly expanding economies and cities. For district heating the challenge is to secure a solid business model which creates more customer demand for district heating, while providing adequate investment to upgrade the network and boiler house (to CHP) in a timely way.

Until the 1990’s, Russia was always at the forefront of the world’s hydropower sector. What is Russia’s position today in terms of hydropower, both domestically and on a global scale?

Today, I think that the Russian Hydro Power industry has not only been restored to its former state, but has also been able to create significant added value to its Soviet heritage. RusHydro does not only use existing assets efficiently, but we are also creating new capacity and putting an emphasis on research and development. It can’t be denied that in this day and age, development is impossible without an exchange of experience and technology. This is why RusHydro cooperates with the foreign industry majors to achieve its goals.

Do Russian Hydro Power companies have ambitions to export their expertise to the international markets?

This process has long been underway. Many Russian companies have already established strong positions in the international market. Unfortunately, many Russian companies these days are acting mostly as energy suppliers. At the same time however, I am convinced that our potential is not limited to this.

I believe that Platts recently ranked RusHydro as the fastest growing energy company in Russia. This is exciting news, but how will you sustain this growth in the coming years?
This fact creates a great opportunity for us. Currently, the level of development of water resources in Russia is only about 20%. Our potential however is not limited to the construction of HPPs in Russia. Over the next few years, we are planning to significantly raise our capitalization, through asset acquisition and management both domestically and abroad. In particular, substantial growth will be achieved by the acquisition of a 40% stake in IrkutsEnergo. Last year we also acquired “RAO ES of the East”, the Sevan-Hrazdan cascade in Armenia and a blocking stake in Krasnoyarskaya HPP.

With a lot of equipment out of date and obsolete in the regions HPP sector, it is clear that technology investment is key to the upgrading of existing hydro facilities. What investment programs are planned for the regions HPP sector?

The reliability and safe operation of Russian HPPs are the main priorities for RusHydro. This is why we are constantly investing in the renovation of our equipment. This modernization does not only allow us to provide uninterrupted operation of all our facilities but also increases their efficiency due to the implementation of advanced technology. Through this, we plan to reduce the wear rate from the current 40-45% to 10-15% by 2020.

What new HPP construction plans do you have at RusHydro?

At the present time, the company is implementing a number of large projects. Among others we have: Boguchan HPP (3000 MW), Zagorsk PSHPP-2 (840 MW), Ust-Srednekan HPP (570 MW), Irganai HPP (400 MW), Zaramag HPP (342 MW) and Nizhne-Burey HPP (320 MW). Also, by 2014 we plan to complete the restoration of Sayano-Shushenskaya HPP.

With many international technology companies currently working in and looking to enter the Russian sector – how do you see integration between Russian and Western technology?

Today, we should take full advantage of the opportunities that the global economy grants us. Through collaboration with our western colleagues, we have an opportunity to exchange best practices, implement progressive innovations and sustain the qualification of our research and development divisions at the highest level. A good example of such hi-tech collaboration is a joint venture between RusHyrdo and Alstom, which has been manufacturing energy equipment for HPPs since 2010. In the summer of 2011 we also signed a number of agreements with Voith Hydro.

Hydropower is an efficient and clean form of power generation but its competing for funding with other generation sectors such as nuclear. Is this affecting the pace of development of the Hydro sector?

When comparing cost levels between the nuclear and hydropower sectors, the latter appears to be more profitable. It should be noted however that apart from the significant investment required at the initial design and construction stages, for which the level of costs is comparable in both sectors, there is also an issue of operating costs. And whereas for HPPs these are limited to sustaining the reliability and efficiency of a plant, the nuclear power engineers are compelled to budget immense funding for the purchases of nuclear fuel. When we also include the fact that generation from Hydro Power is among the lowest of all forms of power generation, it becomes apparent that we have a serious advantage.

Following the Fukishima tragedy last year and the bad press received by the Nuclear industry, do you foresee positive knock on effects for the Hydro Power industry?

We wouldn’t like to see the tragedy at Fukusima as an opportunity to further our cause. Humanity won’t be able to abandon nuclear power in the foreseeable future. The objective for today’s energy industry on a global scale is not to find a substitution for Nuclear Power, but to use it in the safest and most efficient manner. As for the efficient operation of nuclear power plants, hydropower engineers do have a number of interesting solutions. For example, it is known that NPP’s, due to their technological features, are not able to promptly respond to alterations in power consumption. A solution for this is to use pumped storage plants (PSHPP), which allow you to cover load peaks in the energy system.

With environmental awareness key to new project development, how does Hydropower fit in and compare with other power generation options?

Hydropower is first and foremost a clean form power generation. HPPs do not use fuel, which means no harmful emissions into the atmosphere. Water reservoirs built for HPPs provide safety from flooding for large territories while on the flip side, arid zones are provided with irrigation. HPP reservoirs also provide a water supply solution for the local communities.

It has been a pleasure to talk with you today; do you have any further comments for our readers?

In Russia today, there is probably not one single industry sector that provides as many opportunities as hydro power. The Russian Federation is the largest energy market in the world, and we have only scratched the surface of our Hydro Power potential. Our industry receives strong support from the Government and does not have any limitations for attracting foreign investment. At RusHydro, we are creating the future of energy, and are prepared to do this in cooperation with all our partners.

SUEK has recently undergone a major structural reform program to separate its coal mining and power generation divisions. Why did the company choose to do this and what benefits are you expecting from the change?

The decision to separate the power business from coal mining division was made due to a number of reasons. First of all, power generation and coal mining are two distinctly different businesses – they use different technologies, markets, and involve different risks. There is no real reason to combine them within a single company.

Secondly, we were not completely satisfied with the energy management structure. OJSC “SUEK”, which owned shares of OJSC “Kuzbassenergo” (TGK-12) and OJSC “Eniseyskaya TGK (TGK-13)”,  had the ability to formally influence the decisions of the TGK management through their Boards of Directors and shareholders’ meetings. This situation limited the manageability of the energy business. In the initial stages it worked for us, however with time the situation had to change. Lastly, the new company structure is more attractive to investors and ultimately provides better opportunities to raise funds for new projects.

As a result of these changes, we now have a new company – the Siberian Generating Company (SGK), which manages TGK-12 and TGK-13. SUEK acts as a supplier for SGK and we cooperate just as we would with any other partner.

With renewable energies being promoted as key to future energy sustainability, what long term future does the coal generating sector have?

Green energy has its obvious advantages, but is currently far too expensive for the consumer. The threat of renewables to our business does exist, however whether any significant headway is made will solely depend on its price and whether communities are prepared to pay higher tarrifs.

Today, coal is one of the cheapest energy resources in the world, and technologies mitigating the environmental impact of coal power plants are constantly improving.

If you discount hydropower, the share of renewables in Russia is very small and in the long term we don’t see renewbales taking over a large market share from coal generation.

What scope is there for SGK to grow as a regional power generator in Russia – can you enter new regions?

We are certainly prepared to consider acquisition (or exchange) of power plants in other regions, if we find them interesting and advantageous. Right now, however, there are no specific plans or decisions that I can discuss

Could you see a future where SGK becomes a net energy exporter to foreign countries?

This would only be possible if the import/export operations in the energy market were liberalized. At the present time this is not possible however. If things change in the future, we will review the situation.

What plans do you have regarding the construction of new generation facilities or retrofits to existing plants?

At the end of 2010, TGK-12 and TGK-13 signed electricity delivery agreements. For us, this was a land mark deal that we had been waiting for. The total investment needed to meet these agreements is in the region of 2 billion dollars. For the agreement with TGK-12, we need to facilitate an extra 280MW of new capacity, and modernize and upgrade a further 830MW of existing capacity, of which 100 MW has already been done.

For TGK-13, we have to facilitate an extra 305MW of capacity, and modernize a further 410MW.

In the first quarter 2012, TGK-13 will commission the Krasnoyarsk CHP-3, which is its first PDA project.

The PDA covers our largest projects. There are also some smaller projects that deal with increasing the operational efficiency which we’re also working on.

Coal fired power stations are often perceived to be causing long term environmental damage. How is SGK minimizing its environmental impact and emissions release?

SGK is constantly monitoring our policy on environmental safety at all of our power stations. We have a separate budget for this specific purpose. The underlying philosophy of our company is dynamic growth using an efficient, environmentally friendly approach. Being a responsible user of natural resources, we are seeking to gradually reduce our impact on the environment and we are consistently implementing, among others, the following measures:
»     complete compliance with environmental legislation;
»     increasing environmental safety of our operations;
»     decreasing emissions and discharges of polluting agents, disposal of waste in specially designated areas;
»     modernization, reconstruction and replacement of outdated equipment;
»     implementation of the best available technologies;
»     increasing the efficiency of natural resources and power source usage, energy conservation;
»     making management and investment decisions, taking in to consideration of environmental priorities and social factors.

OJSC “Kuzbassenergo” and OJSC “Eniseyskaya TGK (TGK-13)” are both carrying out environmental protection measures in a number of areas, including:
»     reducing emissions and mitigating their environmental impact. The Company is consistently implementing measures for the development, installation and reconstruction of gas purification equipment and the improvement of combustion technology, ensuring  current maintenance and overhauling of boiler units as well as the reconstruction of other technological equipment.

»     Regarding water usage, the company is developing and implementing programs on the design, construction and reconstruction of waste water treatment facilities, repairs to the hydraulic ash disposal systems, taking measurements to ensure correct observance of the sanitary protection zones, taking water protection measures in waste water receivers, ensuring the installation of metering devices for water consumption and discharge control

»     in order to decrease the volume of production waste generation (PWG), measures are being taken for technology advancement related to PWG treatment and the development of production control in this area; measures are being planned and implemented to resolve the problems of ash and slag waste (ASW) utilization through the construction of screening and dispatch units which would process ASW into consumable goods and ships it to the buyers.

What new technologies have been recently employed to improve your generation efficiency?

The Reliability Centered Maintenance method is now being implemented at two of our stations – Abakan CHP and Barnaul CHP-3. RCM allows a company to optimize its asset’s maintenance and repairs program. The actual results of implementing this system are better safety for both the staff and for the environment, an improvement in performance (volume of production and its quality), and better motivation for personnel. Using RCM allows fast and efficient phasing of new assets into application and their maintenance at the lowest possible cost.

I also have to mention the upcoming commissioning of the first power unit at Krasnoyarsk CHP-3 in the first quarter this year; this unit had been constructed using the latest available technologies. Thanks to this, a significant increase of energy efficiency at this Cogeneration plant will be achieved. This is the largest project we have fulfilled, and its scale becomes apparent when one mentions the volume of investments – over 13.5 billion rubles. Execution of the project for the construction of the first unit at Krasnoyarsk CHP-3 is a clear indication of how we fulfill our commitments to the government. This experience is not only significant for us as a company, but for the entire Krasnoyarsk region and for the country as a whole. Experience in the construction of coal-powered units is now of utmost importance, and we lead the way in Russia on this issue.

It’s been a pleasure speaking with you; do you have any further comments for our readers?

Today we are going through a very interesting time in our companies development. We are still young, but we have a number of reasons to be proud. We are steadily moving forward by executing our commitments to the Government and we hope that our upgrade and modernization programs, ensuring an increase in efficiency and capacity, will have a positive effect on power generation in the industrial, social and economical growth of Siberia.

In the next few years, three new power stations with a total capacity of 2.4 thousand MW will be finished in Eastern Siberia, including the Lensk TPP in Irkutsk oblast. This project is a joint venture between the largest private Russian energy company “EuroSibEnergo” (part of the En+ Group) and China Yangtze Power Company (CYPC). The details of this collaboration were presented by the president of En+ Group, Oleg Deripaska, in Irkutsk in September 2011. Whether the Siberians will be able to take advantage of this window of opportunity and become part of the rapid development of Asia-Pacific countries in this region is one of the most important issues on the regional agenda.

As stated by Andrey Kokoshin from the Russian Academy of Science, the economic development of these regions must be accompanied with closer cooperation between Russia and countries in the Asia Pacific countries. Oleg Deripaska agrees with the scientist; in his opinion, the main question that the authorities and large business should ask themselves is how they can integrate into the development of Asian countries: “The decision needs to be made as to how to handle the external market competition, which product to use, what depth of processing this product should have, what kind of infrastructure we require and what type of production we could create”, he comments.

Despite the common opinion that Siberia is the country’s storage room, the actual share of the Siberian Federal District in the county’s GDP is quite low – a little over 10%, Deripaska reminds us. The economy’s growth rate since 1997 has been behind that of the national average and there is a permanent rural migration of population from the regions. “The horse goes where its head is turned. If Moscow’s head is facing Europe, there are no incentives, expectations or opportunities we could use to move towards Asia. We have to review the ideology of our development very carefully”, Deripaska says.

The rapid industrial development of China, Korea and our other Asian neighbors creates demand for various resources that Siberia possesses. Including energy.

Let’s remind ourselves that last year EuroSibEnergo and CYPC founded a joint venture – YES Energo – for the realization of energy projects in Eastern Siberia. The matter in hand was the construction of up to 10 GW of new capacity. By 2020, two new power stations are planned for construction – the 660 MW Nizhne-Angarsk in the Krasnoyarsk Territory (to be launched in 2019-2020) and the 516 MW Transsiberian PP on Shilka river in Transbaikalia (planned to launch in 2014-2018). Besides these, Lensk TPP will be built near Angara, which is meant to run on associated petroleum gas. The capacity of this station will be 1260 MW and its launch is scheduled for some time between 2014-2018. The investments for the construction of the two HEPS will comprise $1.08 bln. and $1.55 bln., respectively, and the thermal power plant will cost about $2 bln.

The construction of energy infrastructure which would connect Siberia with Asia is also important for optimization of the regimes, Oleg Deripaska noted: “Collaboration with China will allow for optimization of today’s regimes and earning the financial means for the further the development of the energy infrastructure”. Thus far, such collaboration has been weak: only a single oil pipeline has been launched and two gas projects have been in discussion for some time now but with no concrete developments. Meanwhile, issues of pre-emptive infrastructure development in the region must be handled promptly. “Without a serious plan, without clear procedures and incentives, without forward investment into the infrastructure, these dreams will remain just that. But the cycle of economical development is not everlasting: in 15 years time, the Asian economies will make the transition to the next phase, with a different volume of resource consumption”, says Deripaska.

The development of Eastern Siberia is slow due to the absence of infrastructure, including not only networks and roads but also the social factor and a shortage of experienced manpower. “For the railway transport to comply with the types of projects that are under development in our region, the investments required over the next five year period are up to 60 billion rubles” – Deripaska stated. Investments only by “Russian Railways” just won’t suffice. Meanwhile, the current mechanism of creating investment from tariff alterations, when the consumer finances the monopolies’ investment programs will not work for Siberia, Deripaska believes. “The volume of investment that we require today cannot be shifted on to the consumers. The solution would be using external loans, federal budget and pension fund financing which would be placed into long-term securities” he reflects. Apart from the new financing mechanism for large investment projects, long-term tariffs for electricity and railroad transportation are needed, as well as transparent and steady regulations to entice foreign investors. “Long-term thought-out programs are needed, – Deripaska emphasized, – They [APAC] are already building new cities and we’re still believing they will always depend on our resources”.

Over the next 20 years, Asia will retain a high rate of economic grown due to continuing industrialization and urbanization. As for what this growth will be, there are a few viewpoints, noted Petr Shchelrovitskiy, deputy general director for strategic development of SC “Rosatom”. If the APAC countries follow the western example, then the demand for resources will grow exponentially. However, they might build their own resource portfolio and strive for the most rapid transition to effective consumption of resources, and then the economic growth will not require the same exponential consumption as with other earlier stages of development. One fact in favor of this method is that just about all the countries and large companies have adopted long-term programs on increasing the share of renewable resources. “Nowadays it is these Asian metropolises that demonstrate using the most modern solutions for energy-efficient buildings and urban mobility and are trying to adhere to international ecological standards” – the expert pointed out. It is entirely probable that Asian countries will become some of the world’s primary centers for the application of modern technologies and will possibly make a transition to a new technological energy platform over 15-20 years. “The window of opportunity for us to integrate into this system is quite narrow” – Shchedrovitskiy concluded.

By their own forces
Meanwhile, the 2 billion dollar expenditure for the construction of combined cycle Lensk gas power station will be shared between “EuroSibEnergo” and the Chinese corporation China Yangtze Power Company. The only thing required from the government is to facilitate the development of the infrastructure required for the station’s capacity to become available.

Last spring the tender was announced for the construction of Lensk TPP. Recently, the general director of En+ Group holdings, Artem Volynets, informed the journalists that development of the feasibility study should be completed in the first quarter of 2012. The final launch date for the station is to be established during the preparation of the documents, however, the general director of EuroSibEnergo, Evgeniy Fedorov, addressing the audience at the international conference “Europe – Russia – APR. Energy: integration and cooperation”, made a statement about “ the commissioning period in 2015”. He clarified, however, that this relates to the station’s first stage, when capacity output will be 400 MW, whereas the full station capacity will total 1.2 GW.

“Something I would like to emphasize – we’re not asking the government for any special preferences, we’re not requesting that these objects be included into the PSA list” – Fedorov pointed out. The construction expenses that he estimated at 2 billion dollars will be covered by “EuroSibEnergo” and the Chinese national corporation China Yangtze Power. As the investments return mechanism, the power engineers suggest an individual tariff for consumers of electricity from Lensk TPP. “We have almost agreed with the key consumers which will pay for electricity as per a dedicated tariff, although it will be higher than the current tariffs” – said the general director of EuroSibEnergo.

Some of the facilities to use energy generated at Lensk TPP include Udokan copper deposit, requiring 450 MW, Chineysk iron ore deposit (100 MW), Kholodninsky mining and processing complex (30 MW), the Eastern Siberia – Pacific ocean pipeline  (its power requirements after expansion of the second stage will be 80 MW) and Baikal-Amur Mainline. “The power requirements for priority projects is only 300 MW, – Fedorov noted. – As for BAM, its maximum traffic capacity now is 9-11 trains [per day], and if we launch as many as two or three large coal deposits in Tuva and Yakutia, the Mainline will simply come to a standstill. And even in the near future, its traffic capacity needs to double and allow for 20-24 pairs of trains per day. The only reason we are not able to do this is the lack of electricity”.

Construction of the Ust-Kut power station in itself will not resolve the problem, as the scheme of its power distribution needs to be arranged. Primarily, this applies to 500 kV power line from Ust-Kut to the “Chara” substation in the Zabaykalsky Krai. Its construction is included in the General scheme for the location of electric power objects through 2030 and the investment program of OJSC “Federal Grid Company of Unified Energy System”, however, it is only planned to be commissioning in 2020. “But if we do want to have Udokan in 2017 and the Chineyskoye deposit in 2018, if we want to resolve the problem of providing power for Bodaybo, then this line must be constructed by 2015” – Fedorov noted. And to emphasize his words, he went on to discuss the upsides of advanced commissioning of the power line: such as opportunities for attracting up to 10 billion dollars in private investments, the production of 70 tonnes of gold, 300 tonnes of silver, up to 500 thousand tonnes of copper and 236 thousand tonnes of zinc as well as utilization of up to 4 billion cubic meters of associated petroleum gas which would be used as fuel for Lensk TPP. “I will not repeat my conclusions, I will just say that in our view, the investment program of the FGC needs to be coordinated with our plans as soon as possible”
As the company develops, it upgrades the existing capacities. Thus, in September last year, a contract for delivery of six runners for Bratsk HEPS had been signed with the Austria’s Voith Hydro. The purpose of replacing the runners is to increasing the hydroturbines’ life and improve their performance. “The Austrian company will deliver us six runners before March 2016, the first one being delivered 25 months after the singing”, Evgeniy Fedorov stated. “We estimate that Voith Hydro runners, given the variable range of operation at Bratsk  HEPS, will be more efficient and will allow us to increase the average performance efficiency by 3-4%”. Evgeniy Fedorov also noted that the process of selecting the vendor was quite long and difficult; both Russian and foreign companies participated in the tender. The contract value is about 1 billion rubles.

“We’ve been working with “Irkutskenergo” since 2001 and the Bratsk HEPS is one of the world’s largest, so for us signing this agreement is a remarkable step, – the managing director and board member of Voith Hydro GmbH&Co. KG Josef Gashl said. – We will use state-of-the-art technologies during the development and production of this equipment, which, of course, will then help reduce operational expenses”.

At the end of 2010, installation of six new runners at Bratsk  HEPS which had been started in 2004 (the vendor was OJSC “Power Machines”), had been completed. The installation cost 700 million rubles and thanks to the realization of this project, the company was one of the winners at the first bid for the joint implementation under Kyoto Protocol.

For the very first time, a Loesche Round Table will take place in New Delhi, India, on February 28th – March 1st, 2012

More than 75 participants from the cement and allied industries are expected to participate in this event.

The Loesche India Pvt. Ltd., a subsidiary of Loesche GmbH, Duesseldorf, has been significantly involved in the planning and realisation of this Round Table.

The topics are widely spread and include the presentation of wellknown Loesche technology and also the latest corporate developments like e.g. the 500 t/h Loesche 4+4 cement mill. The Loesche Round Table India benefits from papers focussing on cement & allied industries.

Additionally, Loesche’s subsidiary in China– M/s. Loesche Mills Shanghai (LMS) has moved to a new location and will introduce its new manufacturing/ production facility in Shanghai.

The Madras Cement Ltd. will present operating experience of upgradation of Loesche Raw mill with new classifier / vortex rectifier and Coal mill for petcoke grinding at the facility in Alathiyur. Also Bharathi Cement will present the results of plant optimisation on Loesche Mills at the facility in Nallalingayapalli.

After these two days of theory, the participants will have the possibility to visit the cement plant at DadriThis plant is a stand-alone grinding unit wherein Loesche Clinker Mill Type LM 56.3+3C is in operation without use of hot gases. We are looking forward to a successful event, sharing a large amount of latest information with our clients.

For more information please contact:
LOESCHE GmbH
Hansaallee 243
D-40549 Duesseldorf
Mail: Loesche@loesche.de
www.loesche.com
Loesche India Pvt. Ltd.
D – 83, Sector – 2
Noida – 201301
U.P., India
Tel. +91 – 120 – 40 18 500
+91 – 120 – 24 44 205 – 207
Fax +91 – 120 – 40 18 590 – 92
+91 – 120 – 24 43 327
E-Mail: loesche@loescheindia.com
www.loescheindia.com

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Loesche launches mobile coal grinding plant to supply thermal processes with economical and environmentally efficient fuel.

Loesche presents the world’s first mobile coal grinding plant, which reduces energy costs for thermal processes by up to 60 percent.

Loesche concentrates decades of experience with large-scale plants into a few containers.

With the mobile, containerised coal grinding plant CGPmobile, which Loesche has developed and is now revealing to the professional world, operators of asphalt mixing plants and dry-grinding plants can reduce the energy costs for thermal processes by up to 60 percent.

The very first containerised CGPmobile plant (CGP = Coal Grinding Plant) was rolled out on 13 October as part of a customer open day at Linstal in Jasien, Poland. Among those participating in the event were industry professionals from South America, Africa and Asia, who had indicated their interest in the new system in the run-up to the launch. The plant is currently undergoing rigorous testing under realistic conditions. The new CGPmobile plant grinds coal into coal dust, which can then be used to power thermal plants much more efficiently than gas or oil. The coal dust can be burnt and used in asphalt mixing plants, in the cement industry, for drying processes and for decentralised power generation, in order to generate process heat or steam.

Coal dust reduces energy costs drastically, particularly in countries where there is a big difference in price between coal on one hand and gas or oil on the other. Here, these plants pay for themselves in less than two years.

An example calculation shows that fuel costs with coal dust furnaces are a mere EUR 630,000 to 830,000 per year in a typical asphalt mixing plant with a burner output of 16 MW and a capacity of 240 t/h. For gas, the equivalent figure would be as much as EUR 2.3 million, and for heating fuel oil as much as EUR 2.1 million. If conventional heating fuel oil is replaced by coal dust, the cost saving is around 60 percent.

Decades of experience crammed into a few containers

Loesche developed the CGPmobile plant for mobile use. The individual modules fit in just a few ISO sea containers, which can be transported on any container ship and carried by lorry on any road. The plant does not need any foundations and is simply assembled on compacted soil. In less than three weeks, it can be fully assembled and ready for operation on-site. At the end of the project, it takes just one week to disassemble. The new system became possible when Loesche and Lintec came together and pooled their specialist knowledge. Loesche brought their decades of experience in the construction of grinding plants and hot-gas generators to the table and combined this with Lintec’s expertise in the field of containerised, mobile plants.

All the plants are fitted with the necessary components as standard, including a complete set of measurement and control technology, and work as a stand-alone system. The modern plant controls also make them straight forward to operate. Production of the zero series is already underway, so Loesche can offer its customers a delivery time of three months. If we estimate three months for transportation, assembly of the first plants can begin on-site in six months.

Ideal for the world’s growing economies

Industries that need process heat and steam, but do not have a central grinding plant on-site, can all be considered as potential buyers of the mobile plants. The lack of this kind of facility may be due to the fact that there is no infrastructure in place for the transportation of coal dust over larger distances. Loesche devised CGPmobile first and foremost for countries where there are large differences between the price of coal and the price of gas and oil. This situation is most common in growth areas such as the CIS countries, India, Asia, Africa and South America. CGPmobile is also well suited for countries where coal is readily available, but oil and gas are hard to obtain.

Coal dust saves primary energy and preserves resources

In many parts of the world, there is a great need to substitute gas and oil with coal in order to make cost savings on primary energy. Burning coal in lump form is an inefficient method in the majority of situations. Grinding the coal into coal dust means that it burns very efficiently and also saves on resources. With good capacity utilisation, you can make a significant saving on primary energy. In many cases, the investment will pay for itself in less than two years. The various differences between the prices for coal and oil in the individual countries must be taken into consideration. These range from 1:3 to 1:5 depending on the specific fuel value. Furthermore, burning the coal dust under optimal conditions – like in the new plants – will also reduce the amount of CO2 polluting the environment.

Matthias Authenrieth, Head of “Thermal Applications & Automation” at Loesche GmbH, is an advocate of the use of coal under optimal conditions: “Either we look on indifferently as coal is burnt using inadequate technology in what is a more or less uncontrolled fashion, or we are proactive and support users by supplying state-of-the-art technology to burn coal in a highly efficient, optimal way, while keeping emissions to a minimum. By developing the CGPmobile, we evidently chose the second option. ”

Price stability is another benefit provided by coal. While prices for oil and gas fluctuate heavily, coal suppliers often agree to long-term contracts. For the user, this represents a significant competitive advantage because they can base their calculations on stable prices. What’s more, coal reserves are expected to last for a long time in many countries, whereas oil and gas are becoming scarce. Leasing is also an option for the plants. The monthly savings on energy costs alone make this financially worthwhile.

The technology in detail

Loesche devised CGPmobile for different types of coal, from brown coal to anthracite coal with grain sizes of up to 120 mm. At the core of each plant is the Loesche mill, with its throughput of 2 to 4 t/h. The coal is ground between the rotating grinding track and the grinding roller. The dust generated is transported up to a classifier by a hot-air flow, which dries the material at the same time. The finished product is discharged into a silo, while the larger grains fall back into the mill. With this reliable process, Loesche is thus able to achieve a uniform distribution of grain sizes. The fineness of the coal dust leaving the plant is between 5 and 45 percent R 90 μm. Loesche generates the hot gas required for the grinding process using the Loesche steel combustion chamber-based LOMA heater (LOMA = Lochmantel meaning ‘perforated jacket’), which the company developed in-house. Each plant is made of standardised components, is manufactured industrially and assembled by Linstal and is then tested extensively by the Loesche commissioning team. This standardisation is also beneficial in that it means wearing and spare parts are readily available. The emission values are compliant with TA Luft [German Technical Instructions on Air Quality Control], while the safety concept was designed in accordance with ATEX (optional NEC). Together these ensure that the approval procedures run smoothly on-site.

Asphalt

In road construction, asphalt mixing plants remain gas or oil operated by and large. Asphalt plants are mostly bought for a specific project and can pay for themselves across a project duration of 24 months, for example. Afterwards, they are sold on the second-hand market or used for other projects. The Loesche concept really suits this type of operation because the pay-back cycle is so similar. The cost saving is so big that the CGPmobile plant will completely pay for itself over a project lasting just 24 months. For instance, a new road could be built using several asphalt mixing plants, with a CGPmobile supplying all mixing plants. This would mean that the coal dust only needs to be transported short distances by lorry.

In road construction, fast availability is very important to avoid too much time being lost between when construction decisions are made and when the plants are ready for operation.

Decentralised energy supply

There is great demand worldwide for decentralised electrical power supplies in the several MW range. However, the only transportable diesel generators available are those with capacities of around 1 MW. If a higher capacity is required, these have to be cascaded, which involves a significant amount of investment. There is an urgent need for generators with a capacity of between 1 and 5 MW in regions such as India, South East Asia, Africa and Central and South America. The CGPmobile will bridge the gap here in future. Even with a conservative overall efficiency estimate of just 25 percent, an individual generator fuelled by coal dust will generate 5 MW of electrical power. Loesche is working intensively to find a complete solution in this area.

Drying

Coal dust can also be utilised for drying a diverse range of materials, including ores, minerals, tailings, slurries, waste, biomass and even food and animal feed. Comparably small coal grinding plants slotted in upstream of the processes will also reduce energy costs drastically.

Heating

The plants are also a perfect solution when it comes to heating industrial plants, mines and collieries, greenhouses, housing developments and industrial sites, because they convert the primary energy effectively and ultimately reduce heating costs.

Cement industry

Loesche used to build large-scale mills with throughputs of up to 300 t/h for the cement industry. However, many smaller sites in growth regions currently work with a capacity of 200–300,000 tonnes of cement each year, and will be able to significantly decrease their energy costs with the CGPmobile plants.

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Loesche Automation has – with LM_Master – introduced into its product portfolio a new product for increasing performance and for supporting the operators of Loesche vertical mills.

LM_Master provides for fully automatic control of the grinding process and continuously optimises regular plant operation. Online optimisation is achieved through precise depiction of the processes and increases throughput, energy efficiency and availability.

The most important component in putting such a project into practice is knowledge of all aspects of the process. Loesche has the necessary experience and the know-how from a diverse range of field such as, for example, automation,  commissioning and servicing, design, and research and development. This knowledge makes it possible to create models which reflect the process as accurately as possible in order to be able to derive the necessary calculations from them. These calculations show the future plant status with the aid of historic data and current process values, manipulated variables and disturbance variables.

The vertical mill is stabilised during regular operation by means of a continuous adaptation of the controller operating points. The plant is therefore operated as closely as possible to its specified limits. This in turn increases plant performance.

The software platform required for this purpose is, irrespective of the manufacturer of the automation system, installed on a separate industry PC. With only a few interventions in the existing automation system and low investment expenditure it is thus possible to increase the efficiency of the grinding plant.

Anyone wishing to operate their plant in line with the latest requirements should not just view LM_Master as an optional extra.

Target markets and applications:

Online process optimisation for Loesche vertical mills from all areas of material comminution. The application is intended for both new installations and existing grinding systems.

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New Industrial Energy Group and “True Energy” technology to address €1.45 billion global imperative

Emerson Process Management has announced the “Smart Energy Initiative”, a global programme designed to combine its unmatched industrial energy expertise with advanced energy management technologies. This will enable customers to leverage more renewable fuels, lower energy costs and reduce emissions.

Emerson is focused on an estimated €1.45 billion market that is poised for strong growth as refineries, manufacturers, and other industrial customers face increased pressure to adopt lower-cost fuels. With energy comprising 30 per cent or more of a facility’s overall operating costs – combined with higher prices for fossil fuels and new global emissions mandates – industrial customers are increasingly looking to waste fuels, biomass, and other renewable sources as a solution to these challenges.

Emerson’s new Industrial Energy Group will specifically focus on modernising and improving the performance of powerhouses, the onsite utilities that provide steam and electricity to power industrial operations, while also improving how the manufacturing process consumes energy. This holistic approach ensures the greatest efficiency in production of energy, plus reduced waste and inefficiencies where energy is used. Emerson technologies and expertise provide the industry’s only turnkey energy optimisation programme to help refiners, chemical producers, and other manufacturers significantly reduce energy costs and emissions.

“With industrial manufacturers consuming an estimated 50 per cent of the world’s energy, combined with rising fossil fuel prices and global mandates for reduced emissions, our customers need more than incremental efficiencies in energy management,” said Steve Sonnenberg, president of Emerson Process Management. “With our Smart Energy Initiative, Emerson is introducing a fundamentally new platform that can change energy economics globally.”

New patent-pending innovation

At the heart of Emerson’s integrated technology platform is its “True Energy” technology, a patent-pending innovation for calculating the actual calorific values of fuel sources, which makes reliable energy production predictable and repeatable.

“Our True Energy Combustion Control platform reinvents the current model of combustion management, which has been around since the 1920s and is still in practice today,” said Chip Rennie, director of Industrial Energy for Emerson. “This brings about nothing short of a reinvention of combustion models, which will make the prevalent use of low-cost fuels like biomass achievable and sustainable.”

For the first time, Emerson’s proprietary suite of software, combined with field control technologies, enables the powerhouse to interchangeably use the most available and affordable renewable or waste fuels – wood waste, food by-products, animal waste, or manufacturing by-products like petroleum coke or off-gases – to consistently create steam to power their operations. It also delivers 21st century combustion solutions for greater efficiency and reliability when using waste and other renewable fuels, which burn and deliver energy at variable and unpredictable rates.

Helping customers meet global emissions mandates

Modernising industrial powerhouses for greater sustainability not only reduces energy costs but also helps companies reduce emissions and meet global regulatory mandates. The European Renewable Energy Directive 20/20/20 seeks to reduce greenhouse gas emissions by 20 per cent and increase the share of renewable fuels in the European Union’s energy mix by 20 per cent by the year 2020. China, the world’s largest energy consumer, aims to reduce carbon emissions by 40 per cent to 45 per cent by 2020 and to use non-fossil fuels for about 15 per cent of its energy. According to the International Energy Outlook 2010 report, renewable energy is expected to grow by 1.8 per cent annually to represent 8 per cent of total energy use in the industrial sector.

“We have seen tremendous growth for certain projects, such as biomass-to-energy conversion, where we have many customers running on renewable fuels 95 per cent of the time,” Sonnenberg added. “Given our track record and energy management leadership, we anticipate 25 per cent to 35 per cent growth in industrial energy projects over the next five years.”

Recent applications of Emerson’s industrial energy solutions include increased steam production from scrap wood at a commercial power facility, more stable operation of a university’s utility boilers, and more stable and efficient consumption of by-product gases at a steel mill.

“Emerson’s work at our Port Talbot (UK) steel mill is helping us make better use of ‘indigenous’ fuels – such as blast furnace gas and coke oven gas – that are by-products of our manufacturing process,” said Andrew Rees, manager of a boiler upgrade project for Tata Steel. “The improved controls are part of a comprehensive energy management project that’s expected to reduce powerhouse energy consumption by 3 per cent to 5 per cent and help Tata Steel achieve its vision of becoming energy self-sufficient.”

New Emerson team combines expertise and critical technologies

Emerson’s new Industrial Energy Group is headed by Rennie, a 25-plus-year powerhouse operations expert. Emerson technologies that add real-time intelligent capabilities to the energy-generating process are Emerson’s SmartProcess™ Boiler and SmartProcess Energy Management software. These comprehensive solutions are designed to overhaul dated equipment and methodologies used by the majority of industrial powerhouses, as well as provide a new approach to “greenfield sites”.

Emerson’s innovative SmartProcess Boiler technology delivers a new and unique real-time combustion control solution to address the inconsistent nature of renewable and waste fuel sources, automating and simplifying management of sudden changes in calorific value or the availability of those fuels.

SmartProcess Energy Management is another sophisticated software application that runs in real-time, closed-loop control to balance steam systems, manage electrical demand swings and upsets, identify opportunities to buy and sell power, improve efficiency, and run an entire industrial utility at the lowest cost automatically.

“Improving energy efficiency at a customer site by just 1 per cent to 2 per cent can translate into hundreds of thousands of euros in savings, and substituting a waste fuel for a purchased fuel can save millions of euros annually,” Rennie said. “Opportunities like these are now too big to ignore. We look forward to helping our customers bring their powerhouse facilities up to 21st century performance standards.”

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Rolls-Royce, the global power systems company, has won an order for gas turbine and compression equipment for the Tapis oil and gas field, offshore Malaysia. The equipment will be utilized by ExxonMobil Exploration and Production Malaysia (EMEPMI) to expand and extend the production of the field.

The order includes two Rolls-Royce RB211-GT61 gas turbines, each driving twin Rolls-Royce RCB and RBB multi-stage barrel gas compressors. Each gas turbine compressor set will produce 27MW of power, enough to deliver up to 390 million standard cubic feet of natural gas per day.

Rolls-Royce will begin to deliver equipment to EMEPMI in the third quarter of 2012, supporting the operator in developing the long-term potential of the Tapis field.

Tony Ruegger, Rolls-Royce, Executive Vice-President – Oil & Gas said: “The reliability and efficiency of the Rolls-Royce equipment will help our customer in this important offshore field. The combination of Rolls-Royce RB211s and our gas compressors matches the demanding requirements of this important installation.”

The Rolls-Royce equipment will be installed at the Tapis Enhanced Oil Recovery Project, featuring a central processing platform with a new integrated deck.

Forty-two Rolls-Royce RB211s and five Avon engines are already in offshore service in Malaysia, working for leading operators including ExxonMobil, Shell and Petronas. A total of more than 500 Rolls-Royce gas turbines are installed worldwide, serving offshore operations, often in harsh environments.

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Wood Group GTS has been awarded a multi-million dollar contract by MC Systems Energy of Moscow for Surgutneftegas OJSC in Western Siberia, Russia to provide overhaul services for two Siemens SGT-200-1S (Tornado) gas turbines.

Under the MC Systems Energy contract Wood Group GTS will provide all gas turbine parts, component repair and technical services to fully overhaul two 6.75 megawatt gas turbine generators fitted with Dry Low NOx (DLE) combustion systems. These machines provide local power for the Tyanskoye oil field in Western Siberia and are fueled by well head gases, reducing the need to flare gas into the atmosphere. This contract will enable oil and power production to continue whilst meeting local environmental standards.

Wood Group GTS will support the Siemens gas turbine generators from its Aberdeen facility, providing complete in-house repair, overhaul and test solutions under one roof.

Vladimir Vladimrov, managing director of MC Systems Energy commented “Wood Group GTS has worked with us over many years and has proven to be a reliable partner. We are very happy with their performance and the value of service they deliver.”

“This latest award enhances our position as a key service provider for oil & gas producers in Russia. Combining our full range of services into this overhaul contract enables Wood Group GTS to deliver a cost-effective maintenance plan, reliable power supply and compliance with local environmental legislation,” said Mark Papworth, CEO, Wood Group GTS.

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For the very first time, a Loesche Round Table took place in Daejeon, Republic of Korea.

88 participants from the cement industry as well as the power generating, iron and steel industries joined this event.

Next to Loesche GmbH with its headquarters in Germany the Loesche agency Seil Trading Co. Ltd. was significantly involved in the planning and successful realisation of this Round Table.

The topics were widely spread and included besides the presentation of the well-known Loesche technology also the latest corporate developments in the cement, industrial minerals and power generating industries. Thereby, the Chinese Loesche subsidiary, Loesche Mills Shanghai, introduced its new production site in Shanghai.

The company Icheon Material presented operational experiences of a Loesche mill LM 46.2+2 S, which were collected so far at the facility in Dangjin.

To complete these two days the participants had the possibility to join a wine tasting of the still quite unknown local wine in the very first Korean vineyard.

The next Round Table is already planned for the year 2013.

COPA-DATA presents its HMI/SCADA software zenon at the SPS/IPC/DRIVES 2011, for the first time with comprehensive Multi-touch support. The operating of touch panels with several fingers simultaneously offers numerous advantages for the user: usability is improved, thus making daily use more efficient. At the same time, the Multi-touch technology allows for maximum security in industrial applications.

Multi-touch control concepts are making strong advances into industry and manufacturing. More and more machine and plant engineers require Multi-touch solutions from both hardware and software suppliers. The consumerization of IT, and Multi-touch support in Windows 7, are pushing this development and increasing the demand further still. COPA-DATA is one of the first suppliers able to comprehensively implement this technology in a HMI/SCADA solution. It is presenting its software zenon with full Multi-touch support at this years` SPS/IPC/DRIVES trade fair in Nuremberg, Germany.

“With the increased use of smartphones and tablet-PCs, Multi-touch has already become a trusted form of technology and can also offer many advantages outside of IT. We have intensively addressed and redefined the technology so that Multi-touch is also perfectly suitable for machine operation in industrial applications”, explains Thomas Punzenberger, COPA-DATA’s CEO. “First inquiries from machine manufacturers in this area confirm our thoughts. Usability is an important success factor for our customers and a modern, intuitive control concept is an essential part of this. We recognized this demand early on and have already integrated Multi-touch functions in zenon.”

The HMI/SCADA solution, zenon, can fully recognize and process touch movements involving various contact points. Among these standard touch gestures are tap, swipe and zoom movements. These can be used directly in zenon. With this, zenon allows the user to comfortably page through function overviews, lists, directories and documentation. Users can also very easily navigate in display pages as well as overview and process screens. Screens can be easily moved, and display screens enlarged or reduced as needed. Thanks to the open interfaces it is also possible to define individual touch gestures which then trigger predefined actions. Hence, the user can, for example, place a tick on the screen to acknowledge an alarm and with that confirm the action. With the input of an S, for example, they are brought directly back to the start screen.

Thanks to Multi-touch the navigation structure within projects is easier to manage by replacing menus and submenus with so called docks. This is achieved by a toolbar which evenly arranges the central symbols of a project enabling speedy access to the most important screens or applications. The symbols can be arranged as required within a dock using the drag and drop capabilities of Multi-touch. The user can achieve a simple overview across the entire dock by scrolling. The objective function can be reached more quickly than before, thus reducing search time.

The drag and drop capabilities can also be used in process and overview screens. The user can put them together on the HMI according to their individual requirements. It is therefore possible to bring a standard process screen out of a menu and to position it at a particular point on another screen. This configuration can also be saved: enabling the user to find his personal, individual work space at their next login.

Users of the Multi-touch technology profit from better usability, an optimum overview on the HMI and intuitive handling. Efficiency in the handling of the machines and plants is greatly improved. Professionals – as well as new or inexperienced employees – can work with zenon quickly, easily and with little training work with zenon, thanks to the Multi-touch technology.

Particularly important in industrial applications: users must use an additional button for unlocking commands when making safety critical actions. Thanks to this two-handed operation it is ensured that unwanted touches don’t result in an operation to switch or change values. In addition, the login process is simplified as users can authenticate and register via a gesture-based login.

Over more than 100 years Loesche has built up a wealth of experience in the grinding of coal, cement raw material, clinker, slag, ores and various industrial minerals.

The quantities of finely ground industrial minerals lie in the range 5 t/h to 80 t/h, with a main throughput of 5 t/h to 25 t/h. To accommodate these customer needs, Loesche has developed a special series of “compact mills”, which not only offer the usual high quality of Loesche mills but are also of a compact size that minimises time-consuming planning and assembly work.

On the occasion of the POWTECH, Loesche had the opportunity to present this special mill type to a wide audience and explain the technical details to their customers – who where invited to an ambiente similar to the inside of the LOESCHE mill.

The smallest mills in this series – LM 12.200 and LM 15.200 – are delivered to the customer complete or semi-complete within a short delivery time offered to the customers.

Mr. Thomas Leppak and Mr. Pierre Wlodarzyk in discussion with customers

Mr. Michael Schmidt and Mr. Pierre Wlodarzyk „inside the mill“

For more information:
www.loesche.com/en/home/products/dry-grinding-plants/industrialminerals

Charles Hendry MP, Minister of State at the Department for Energy and Climate Change visited Tidal Generation Limited (TGL), the Bristol based Rolls-Royce subsidiary which is pioneering tidal energy technology with an innovative subsea project off the Orkney Islands, Scotland.

Harnessing the reliable and predictable energy of tidal streams, the Rolls-Royce tidal turbine unit has successfully generated and fed over 100 megawatt hours (MWh) of electrical power into the national grid.

Charles Hendry MP commented: “The UK is leading the global renewables industry in the development of pioneering tidal energy technology. Our proposals to support the technology, under the Renewables Obligation, show that we are serious about getting marine into the mainstream.”

“I am delighted that Rolls-Royce is playing a lead role by transferring technology know-how from its wider power generation businesses to its successful Orkney Islands pilot project. This and similar projects will be instrumental in enabling cleaner, greener tidal power to fulfil its potential as part of a diverse UK energy mix.”

Source

LOESCHE’s brand new solution to reduce operating costs by substituting coal instead of oil or gas in various thermal applications.

The presentation of the latest development of companies LOESCHE & LINTEC, at Linstal in Poland on the 13th October 2011, was highly successful. To an international audience LOESCHE presented their latest development based on long-term experience in coal grinding technology and plant engineering. The first containerized Coal Grinding Plant (CGP) is fully automated, ready for operation.

By integration of the Coal Grinding Plant into 100 % ISO sea containers the plant is mobile and enables low transport charges for worldwide operation.

LOESCHE have packed more than 100 years of experience in coal grinding technology and plant engineering into a few seaworthy containers, representing a very compact and efficient Coal Grinding Plant. LOESCHE has designed the new CGP for the grinding of all types of coal possible, from dried, lignite to anthracite with a grain feed size from 5-30 mm. The fineness size range of coal dust will be from 5%R 90μm to 45%R 90μm with a possible production of 2-4 t/h coal dust.

The emission values correspond to TA air (German regulations) while the safety concept was designed according to ATEX (optional NEC).

The new CGP plant can be installed for our customers worldwide, as it may be installed at environmental temperatures between -30 and +40 °C. Some of the advantages of this plant include standardized plant design, simplified approval procedure, delivery period of 6 months, installation and commissioning of 3 weeks, adaptation to the required output at the location, high on-site mobility, short implementation, investment can be financed or leased, high economic efficiency through substitution of gas or oil with coal, fast amortization, low transport costs, no foundation required, weather protection for plant components, full factory trial run before delivery and short supply times for spare parts due to standardization.

For further details please contact:

LOESCHE GmbH
Hansaallee 243, D-40549 Düsseldorf, Germany,
Phone: (+49-211) 53 53-113, Fax: (+49-211) 53 53-500,
Mail: CGP@loesche.de, Internet: www.loesche.com

“There is a huge potential for smart grid and smart demand initiatives in Russia, as there is a pressing need to save energy, reduce emissions and modernize the network for greater efficiency. Smart Utilities Russia comes at no better time to discuss the energy future in Russia”

Dr Philip E Lewis, CEO and Founder of the VaasaETT Global Energy Think Tank

 
Smart Utilities Russia 2011 is taking place in less than 2 weeks. Join Philip plus 200 top level energy names from Russia and their European peers in Moscow. Delegations from the following top-level UTILITIES have already confirmed their participation:
•    Alliander / Liander Infostroom
•    Altayenergosbyt
•    Enel Italy
•    Enel Russia
•    Energa SA
•    Energomera
•    Energy Forecasting Agency
•    Energosbit Barezh
•    Energostream
•    ESB Networks Ireland
•    Federal Grid Company
•    IDGC Holding JSC
•    IES Holding
•    Inter RAO UES
•    JSC Interregional Distribution Grid Company of North-West
•    JSC Moesk
•    Lenenergo
•    MES Centra
•    Mosenergosbyt
•    MRSK Holding
•    OJSC IDGC of Urals
•    PSK Energo
•    St Petersburg Electricity Company
•    Tymenenergo
•    and many more…!

Don’t miss this rare chance to meet them under one roof over 2 days in Moscow to learn, debate and forge new relationships. Find out about new energy efficiency pilots and actual rollouts and what contributions you can make to this thriving industry.
 
Register online today to secure your place.

We have brought together the most expert speakers, sourced the best topics and attracted the 200-strong top level audience - why not make these into 2 most effective working days of your year!

Highlights of this year’s event include:
•    This is the most time efficient way to build relationships that matter - 200+ Russian and international electric power experts will be here– meet everyone who’s anyone in the Russian smart utility industry!
•    Get the first-hand, top intelligence on policy, financial mechanisms, drivers and barriers to the smart grid from Energy Forecasting Agency, ATS Metrology Department, Halycon Russian and i2bf
•    Real-time updates on the current projects and what is in the pipeline. Hear from MRSK, Federal Grid Company, Lenenergo, Energostream, Saint Petersburg Electricity Company, PLUS international experiences from Enel, ESB Networks,  Alliander and IDC Energy Insights
•    Looking for a local partner or distributor? Forge strategic alliances with numerous solution providers at the exclusive supplier pavilion, including Gazprom, Matrix, ProSoft Systems, Fujitsu, Landis+Gyr, Teradata, Sanxing, RVS, Iskraemeco, Maxim, Ericsson and Rusinvest.

Do not miss the chance to meet 300 industry experts that will change the Russian utilities industry forever! And use this opportunity to gain critical updates as to how. We strongly advise you to register before November 15th to benefit from our attractive discount and SAVE up to €100.

Source: http://www.synergy-events.com/

What is your position in the company and how long have you held this position?

I am the chief representative of the Moscow office of Bopp & Reuther Sicherheits und Regelarmaturen GmbH and have held this position since August 2009.

How long have you been in business in Russia and the Caspian?

The representative office was established in 2002. However the first project to be undertaken by the company was before this – type Si 63 DIN safety valves and spares were supplied to the Ryazan and Tyumen refineries in the year 2000. Following this, over 10 further projects were undertaken in the nuclear, process and power plant industries.

What companies have you worked with in the Region?

B&R is currently working with Rosenergoatom, specifically the Kola, Kalinin, Novovoronezh and Balakovo NPPs in Russia. Our products have also been supplied to the South-Ukrainian NPP in Ukraine.

Our client list also includes TEK Mosenergo, Atomstroyexport, E4 Group and Technopromexport, and we have worked with design institutes such as TEP, MEP on issues related to power plants.

Rosneft, Gazpromneft, Slaftneft and Lukoil could be considered as our partners for the process industry. We are also currently trying to forge a partnership with Stroytransgaz.

What is your most recent success in the market?

We have recently delivered pressurizer pilot operated safety valves to the Rosenergoatom NPP at Kola, and safety valve units and switchover devices have also been delivered to Kstovo as part of our cooperation with OOO LUKOIL-Nizhegorodnefteorgsintez in 2009/2010.Our contract to supply turbine bypass systems to the Yuzno-Uralskaya PP is without doubt success in process industry.

Have you had any recent product launches for the region?

The majority of our product launches have focused on the nuclear industry. We also have plans to launch safety valves in to Russia with position indicators and removable pressure pilots. Control valves with emergency vibration dampers for the cooling systems at the South-Ukrainian NPP can also be considered as a recent success, as well as our high pressure gate valves for conventional power plants. We also plan to provide type Si 11/13/14 safety valves to the process industry in the near future.

What is your favorite band and track?

My favorite band is The Beatles, but my favorite track is The Hotel California by The Eagles. I prefer the old style as opposed to modern music. The new techno/club style music is not my scene!

Where in the world would you most like to visit and why?

I would like to visit Rio de Janeiro for the carnival. This event, from my point of view seems very grandiose and I hope to attend one day.

I would also like to see Seven Wonders of the World; to see them I believe would be like touching ancient civilizations. I have never visited Lake Baykal either, so this is high on my list, as are places like Persepolis although I have been there before.

What is your favorite sport, and what team do you support?

My favorite sport is soccer; indeed I am a fan of any ball games such as soccer, basketball and volleyball. When I was younger I played hand ball and hockey; any sports that involved a goal, I was a goalkeeper! During my visits to the factory in Mannheim I try to play soccer, time permitting. My favorite team is Spartak Moscow, and when I have time I try to go to the stadium to cheer them on. Unfortunately I have not gone to a live game this year because I have been working a lot! However I always catch the games on TV.

What are your thoughts on the Russian power market through to the end of this year and beyond?

The Russian Power Sector looks to be in great health, with many large construction programs in both the Nuclear and Conventional sectors either underway, or planned. The NPP(s) that have recently been completed in Russia are the Rostov NPP, Units 3 and 4 and the Leningrad NPP Stage II. The second stage of the Novovoronezh NPP is also under construction.

In terms of new NPP Units there are plans in both Russia and Turkey. Several conventional power plants under construction, such as the Nizhnevartovskaya, Berezovskaya and Kirishskaya power plants.

Philipp Stolzenburg, LOESCHE GmbH
Dr. Holger Wulfert, LOESCHE GmbH

Introducing new products has long been the tradition of the Dusseldorf-based company Loesche. In keeping with their motto “Innovative Engineering” the first coal dust-operated LOMA® Hot Gas Generator with an output of 30 MWth was delivered to a client in Bangladesh.

The combustion chamber without refractory lining has a coal burner which is operated without a supporting flame – a first in hot gas generator technology.

The basis for this development was a research project with a European university.

To meet all the requirements in the combustion of solid fuels from different sources for large industrial plants, Loesche has a 1 MW test plant which is connected to a Loesche coal mill. All parameters, including the fineness of the coal can be analysed and optimised during the combustion of solid fuels.

A new energy consciousness and the scarcity of precious energy sources has led to the development of hot gas generators which use cheaper fuels, such as solid fuel and gaseous industrial by-products. The cost-saving potential lies between 50% and 70%.

Loesche technology — always one step ahead
For over one hundred years Loesche GmbH has been successfully building machines, such as mills, classifiers,
hot gas generators,rotary gates etc., and been involved in plant construction around the world. Loesche develops, plans and delivers plant components and complete grinding plants to the cement, iron & steel, power station, industrial mineral, ore and wood industries and for nonferrous metallurgy applications.

The first Loesche hot gas generators were developed, built and delivered in 1960, and were available both with and without refractory linings. Which hot gas generator was used depended on the desired outlet temperature for the downstream processes and on the dust content of the process gas to be heated.

Since then these hot gas generators have been subject to continuous further development, always represent the latest know-how and conform to the current technical standards. They are characterised by a clean, complete burning process and low emissions.

Loesche hot gas generators are ideally suitable for direct drying processes and are used for example in conjunction with:
» grinding plants
» drum-type driers
» fluidised-bed furnaces/driers
» flash driers
» spheroidisers

The hot gas generators can run on a wide range of different fuels:
» Gas (such as e.g. natural gas, biogas, coke gas, blast furnace gas, lean gas, synthesis gas and LPG)
» Light crude, diesel and heavy oils, and other liquid refinery waste
» Wood dust, pulverised lignite, pulverised hard coal, pulverised petroleum coke

Loesche combustion chambers come in two different versions: The LOMA® heater, a combustion chamber made from high temperature steel for maximum hot gas outlet temperatures up to 750 °C.

This steel combustion chamber is — thanks to its industrial, economical and ecological advantages — used in most cases. The LOMA® heater is adapted to the relevant combustion and technological requirements, i.e. there are design variants depending on the fuel used and depending on the respective burner type on account of different flame geometries.

This high flexibility on the part of the Loesche combustion chamber demonstrates the innovative approach of Loesche and has been utilised around the world in more than 600 plants with thermal output figures of between 0.1 MW and 60 MW.

The LOMA® heater
The perforated jacket heater developed by Loesche back in 1960 – a steel combustion chamber made of high-temperature steel and a burner muffle — was launched onto the market under the name LOMA® heater. For decades the LOMA® heater has been used around the world in a wide range of thermal processes in order to provide an optimum thermal configuration of the process. It is used to heat:
» Fresh air
» Return gases
» Cleaned exhaust gases
» Hot blast furnace gases
» Process gas with low dust content

These gases to be heated can be introduced at temperatures of up to 350 °C into the spiral housing.

Features of the LOMA® heater
» Combustion chamber manufactured from high-temperature steels, no refractory lining necessary (outlet temperatures up to 750 °C)
» Minimal heat losses on startup of the hot gas generator due to the absence of heating of a refractory lining, therefore startup at full load possible
» Virtually delay-free adaptation of output in the case of rapid load changes
» High combustion chamber cooling rate, preventing thermal overloading of downstream components
» There is no need for an EMERGENCY STACK in EMERGENCY SHUTDOWN SITUATIONS and during startup up and shutdown
» Short-term accessibility for inspections
» Longer service life than plants with refractory linings
» Short installation times, low weight, minimal space requirements, can be installed in existing plants, complete pre-assembly also for larger LOMA® heaters
» Horizontal and vertical erection possible
» Combustion chamber virtually adiabatic – more than 99 % of the heat can be utilised for the process
» Operates both in vacuum and overpressure modes
» No moving parts in the combustion chamber
» Low susceptibility to faults/repairs
» Optical monitoring of perforated jacket temperatures
» Customised plants for individual applications Operational reliability and economic efficiency considerations play amajor role in layout, design and manufacture.

Methods of operation
The flow of process gas entering via the spiral housing ➂ cools the protective jacket ➄, the burner muffle ➁ and the perforated jackets as a result of flow control. The process gas passes through the ring slots ➃ and holes in the perforated jacket into the interior of the combustion chamber, where it mixes with the hot smoke gases from combustion. The combustion chamber geometry and flow control protect the perforated jacket against the flame and the hot smoke gases. The combustion chamber has an overall pressure loss of 2 – 3 mbar.

When process gases with a light dust content and powdery fuels are used, a vertical arrangement of the LOMA® heater is always chosen.

In processes which require a highly uniform temperature profile, specially shaped swirl constructions (e.g. baffle plate) with very low pressure losses (< 1 mbar) are installed in the area of the outlet  ➆ or at a short distance behind this area. This results in a highly uniform temperature distribution after only a distance of 1.5 to 2 times the duct diameter.

Hot gas generators for lean gases
The Loesche steel combustion chamber in combination with a multiple-lance burner (MLB) constitutes a special development for burning lean gases and is characterised by the following features:
The multiple-lance burner comprises a number of individual nozzles for lean gas and combustion air, thereby enabling lean gas to be fully combusted without a supporting flame. Both media strike one another within the nozzle system at high velocity. This provides for an intensive mixing of the media, and thereby ensures that the basic requirement for efficient combustion is achieved. The hot smoke gases emerging from the burner muffle mix in the area of the perforated jackets with the process air to be heated and which is fed to the LOMA® heater via the spiral housing. The high proportion of inert gases of sometimes over 75 % in lean gases results in a low flame temperature. For this reason, a start burner installed coaxially in the main burner is used to start the LOMA® heater. The function of this start burner (run on natural gas, coke gas, other burnable gases but also light crude oil) is on the one hand to heat up the interior wall of the burner muffle to a specific surface temperature in order to ensure that the lean gas is safely ignited (the ignition temperature of e.g. CO is 605 °C).

On the other hand, the start burner is dimensioned in terms of its output in such a way that the entire plant can be heated up  above the dew point. The start burner is switched off after the main burner has started. The output ranges of the main and start burners are designed to overlap so as to provide continuous operation. The main burner has a control range of 1:10, the start burner has a control range of 1:5 to 1:8. Every necessary operating point within the control range of 1:40 to 1:70 can therefore be easily achieved.

The excellent control performance of the multiple lance burner is a significant benefit to the downstream processes. More than 50 of these hot gas generators developed and patented by Loesche are deployed in conjunction with Loesche vertical roller mills and mills of other manufacturers around the world in dry-grinding plants (e.g. PCI plants) and coal gasification plants for preparing coal for the purpose of smelting iron ore.

Main features of lean gas combustion:
» Combustion of lean gases from a calorific value of 2800 kJ/m3 (standard conditions) without a supporting burner
» Thermal output of 0.5 MW to 60 MW
» Wide control range
» Short flame and stable combustion
» Low CO and NOx content in the exhaust gas

Hot gas generators for solid fuels
Since 1986 the Loesche-developed steel combustion chamber (LOMA® heater) has been successfully used in combination with multifuel burners of different manufacturers to burn wood dust and pulverised lignite. This steel combustion chamber is the prototype of all these combustion chambers which are used for different thermal processes around the world.

Since 1988 Loesche has supplied a large number of hot gas generators with outputs of up to 60 MW to burn wood dust from the chipboard industry. LOMA® heaters run on pulverised lignite are also successfully used. In order to burn solid fuels, a vertical arrangement of the combustion chamber should wherever possible be adopted so as to avoid slag caking.

In view of the increasing scarcity and thus increasing cost of rare energy sources, such as light crude oil and natural gas, customers are increasingly expressing a desire to use hard coal, brown coal or petroleum coke to generate process heat. Loesche has taken up this challenge by instigating an appropriate research programme in conjunction with university institutes, since pure steel combustion chambers for burning hard coal and petroleum coke are barely available on the market. The purpose of this programme has been to gain initial experience of burning solid fuels with a 400 kW dust-fired LOMA® heater.

The Loesche Technology centre also houses an HGG test rig for solid fuels with a heater output of 1 MW. What is unique about this test rig is that it is directly coupled to a Loesche mill. This rig enables Loesche to analyse customer-specific coal of all kinds and origins under real conditions and to determine the combustion parameters.
On the basis of the positive research results and the ensuing development of large-scale plants, it has been possible to successfully implement in Asia the first LOMA® hot gas generator run on pulverised hard coal with an output of 30 MW (pulverised hard coal as the primary fuel, heavy oil as the secondary fuel).

Loesche hot-gas generators for solid fuels are characterised by the following features:
» High degree of mixing between dust and combustion air
» Total combustion
» Pulsation-free flame
» Monitored flame temperature
» No caking on the combustion chamber walls
» Gases and oils can be used as the second fuel
» Complete redundancy with secondary fuel
» No heat-up phase required
» Pulsation-free dosing

Energy drives the economy. In order to secure its supply, safety is of utmost importance. This is especially true when critical media are involved during power production and transport. When it comes to feeding electricity through the containment structures of gas-cooled power generators, liquefied natural gas applications and even nuclear power plants, SCHOTT’s glass-to-metal sealed hermetic cable penetrators are the safest solutions available.

Russia and the Commonwealth of Independent States (CIS) have experienced continued economic growth. This has boosted the energy demand and put corresponding strains on networks and the environment. National policies increasingly focus on energy security and sustainable development. The aim is to reach a better quality of the fuel and energy mix and enhance the competitive ability of the energy production and services in the world market.

The region continues to rely on an energy mix based on its rich natural resources: natural gas, coal, oil, water and uranium. According to the International Energy Agency (IEA, 2008), roughly 68% of Russia’s electricity is generated by thermal plants, 16% by hydropower and 16% comes from nuclear reactors. The domestic production greatly exceeds domestic demand. Russia is the world’s leading net energy exporter and an important technology supplier.

However, the objectives of the Russian energy strategy for the period of up to 2020 have been set: Energy safety, energy effectiveness, budget effectiveness and ecological energy security have clearly moved into focus. SCHOTT’s hermetic glass-to-metal sealed electrical penetrations contribute to reaching these goals. As the world’s safest solution for power, control and instrumentation feedthroughs, they are employed in advanced power producing and processing applications.

Gastight penetrations are required in highly efficient hydrogen-cooled generators that are increasingly being used in thermal and hydroelectric power plants. These generators typically operate at a high voltage. SCHOTT’s power feedthroughs safely maintain the hermetic boundary between the electrical system and the closed hydrogen gas cycle. Leading generator manufacturers rely on SCHOTT’s ATEX- and IEC-certified cable penetrations.

Thanks to their unique design, feedthroughs from SCHOTT offer an extremely high level of security. They consist of metal conductors, a non-aging, inorganic glass sealant and a metal housing. The preassembled component is heated up to a temperature at which the glass melts to the metal. During the cooling process, the metal housing contracts to a much greater extent than the glass does. This compression creates a highly pressure-resistant and hermetically sealed unit.

Another major application for glass-to-metal sealed feedthroughs is the transport of liquefied natural gas (LNG). In order to unload the liquefied gas, most LNG storage tanks contain powerful electric pumps. Since they are completely immersed in liquefied gas at -162° Celsius, the pumps are protected against this harsh environment by a chassis. Here, SCHOTT’s terminal header assemblies are used for the three-phase electrical power, as well as the control and instrumentation conductors.

The LNG industry is growing, especially around the Northern and Baltic Sea that has become the world’s first Emission Control Area (ECA). The tight international regulation of pollution is increasingly driving the development of new eco-friendly LNG-fueled applications such as ship propulsion. Major LNG pump manufacturers bet on glass-to-metal sealed feedthroughs to safely maintain the hermetic pressure boundary between LNG and surrounding air.

Nuclear power plants, however, are the most demanding applications for hermetic feedthroughs. Thanks to their glass-to-metal compression seal that does not age, Electrical Penetration Assemblies (EPAs) from SCHOTT remain gas and radiation tight for more than 60 years. They enable the energy supply for pumps and electronic devices inside the power plant’s containment structures and provide the pass-through for control and instrumentation signals.

Russia is a leading nuclear technology developer. Like many other countries, the nation is planning to increase the number of nuclear power plants – from 31 to 59 by 2020. SCHOTT is able to enhance the safety of both existing and future nuclear power plants. More than 12,000 of SCHOTT’s EPAs have already been installed in about 100 nuclear power plants around the world. Among these are the two Russian nuclear icebreakers as well as Hungary’s only nuclear power plant in Paks that is currently upgrading to SCHOTT’s EPAs.

Gazprom Global Energy Solutions has a diverse portfolio of services for the gas and electricity sector – what specific services are you currently offering in Russia?

Gazprom Global Energy Solutions is a global brand leader in the smart metering & smart grid sectors, offering a completely managed end to end solution for all smart metering and demand side management applications. As well as this totally integrated solution Gazprom Global Energy Solutions has developed a range of products which are being used extensively for monitoring, targeting and control purposes in primary and sub metering applications for Gas, Water and Electricity.

As a 100% owned subsidiary of Gazprom Marketing and Trading, what is your history in the Russian market place specifically?

As a group we have a rich heritage in delivering energy solutions in the Russian market. Gazprom Global Energy Solutions has more recently worked with a number of Utilities in Russia and CIS to design, engineer and deploy smart metering systems across gas, water, and electricity sectors. We have successfully deployed a number of systems in Russia and have arrangements in place with a number of Utilities to roll out smart grid systems in 2012.

The Government has announced large investment programs with the aim of developing an intelligent, or Smart Grid network in Russia. What part will Gazprom Global Energy Solutions play in this exciting future?

As a smart grid solutions provider we hope to play a key role in driving this market forward. We are working in partnership with Network Operators and Major Utilities across Russia and CIS in order to deliver best in class solution.

What benefits will smart grid technology bring to both the Utility companies in Russia, and ultimately the end user?

The smart grid market is predicated on developing the capability to contrast the demand for and supply of energy and then acting on findings, either by reducing consumption or rescheduling it. The Gazprom Global Energy Solutions suite of smart grid solutions will provide all the tools that a utility requires to enable more efficient and effective network and portfolio management. Our smart grid solution provides a Utility with detailed insight into real time consumption on the network, the system also empowers the Utility to remotely control all electricity loads on the network which in turn allows for a more effective balancing and forecasting regime and eliminates the requirement for expensive back up generation capability. There are also a number of benefits  realized by the consumer by implementing smart grid systems. Firstly, the first steps in an energy management program should be to roll out smart metering as you cannot manage what you cannot measure. The consumer requires the data provided via a smart meter to understand when energy is consumed and as such start to identify inefficiencies, eliminate waste and change human behaviors. Through effective use of the smart meter system the end user should see a reduction in their energy spend.

Energy Efficiency is a hot topic in Russia – it is clear that there are huge inefficiencies in the system from the loss of heat through the heating networks, to the loss of electricity from the ageing grid network. What solutions do Gazprom Global Energy Solutions bring to help companies and individuals manage their energy use better?

We provide Utilities and Network Operators across the gas, electricity and water sectors with turnkey smart grid solutions, from design and development of smart grid hardware, firmware and communication protocol, right through to provision and installation of bespoke meter data management systems (MDM) and installer commissioning software.
In the consumer market we provide a web based M&T platform that enables consumers to analyze, benchmark and report on energy performance. This platform allows consumers to realize the value of smart metering data.

I understand you have recently attended the Smart Utilities Europe event in Amsterdam. How do you compare the Russian market to the rest of Europe, and how do you see this market developing over the next 10 years?

I first attended the smart metering Europe event 6 years ago, it was held in a hotel conferencing room in Barcelona, there were approx 200 delegates and 20 exhibitors. This year the event was held in an international conferencing arena in Amsterdam with 5000 delegates and 400 exhibitors in attendance. The smart metering market within Europe has grown immeasurable in such a short period of time, primarily driven through policy change, regulation and rising energy prices. The story boards has already been written, the Smart Utilities Russia event this year is held in a hotel conference room with 200 delegates and 20 or so exhibitors, I fully expect in 5 years time to be attending this conference with over 5000 other delegates as the interesting point to note is that in terms of size and potential the Russian market is a bigger market than the all of EU states combined.

As I understand, you are in charge of “smart-grid” development within the Russian Federation. Russia has a comprehensive, but somewhat “ageing” grid system – but what is the true current state of the regions transmission grid?

Due to a shortfall in funding for the renovation of electric power sector assets for about 10-15 years in the early 90s, we’re now seeing critical wear of the substation equipment fleet. The guideline equipment life (25 years) has ended for 54.7% of these assets and total excess life (35 years) has been surpassed for 22.2% of equipment.

Considering the longer lifetime for HV power lines, on average 40 years, the wear of power transmission line equipment comprises the following – guideline life (40 years) has ended for 29.2%, total excess life (50 years) has been surpassed for 8.9% of equipment.

Industrial development and the implementation of new high-tech equipment in Russia will lead to new requirements for reliable, cost-effective and high quality power supply (“digital” demand for reliability and quality). The current state of the grid system and the slow approach to modernization and development of the power grid system has gone a long way to impeding the ongoing problems we are facing and the long term development of the sector. The solution has to be a whole new innovative approach to the development of the existing grid network– which would involve the creation of a new system which will meet the economical challenges of both the present and future, and create a solid foundation for future growth.

The term “Smart Grids” has many interpretations, but what does developing a “smart grid” actually mean for the Russian distribution sector?

The term “smart grid” covers one of the most important trends in the development of the electricity sector, and the new technologies that are available in the transmission and conversion of electric power. I am referring to technologies that are capable of making the power grid, and its load, as manageable as possible.

In our opinion, the smart or actively adaptive grid is a whole new type of grid system built on the latest solutions, principles and technologies of power transmission. This allows for the following:
»    Real-time alteration of parameters and grid topology based on the current conditions, so eliminating accidents, based on equipment with alterable parameters (FACTS, STATKOM, USHR), and high-T superconductivity equipment, out-of-phase connection insertions, phase reverser devices, active filters, short-circuit current limitation equipment;

»    Integration of all types of power generation (including small generating stations) and all types of end users(from households to large scale industry) to enable the management of their power demand;

»    Providing expansion of market opportunities for the infrastructure by having a wide range of services to be interchanged between the market entities and the infrastructure;

»    Minimizing losses and implementing “self-diagnostics” and “self-recuperation” of systems while maintaining reliability and quality of the supply;

»    Integrating electric grid infrastructure with IT infrastructure to create a fully integrated management system and full-scale information support.

As a result, the grid system infrastructure becomes truly intellectual (or smart) not only including communication infrastructure based on IT, but also brand new technologies and methods of power generation, accumulation and consumption of power.

The Federal Grid Company announced in 2010 a huge investment into “smart grid” development. When will we see the impact of that investment?

Individual technologies and solutions are created after extensive R&D and are later trialed and perfected in separate power grid assets of OJSC “FGC UES”. The R&D process includes an entire chain of events, from the initial idea to the implementation of actual specific equipment. A number of projects are already underway at some of our facilities. As an example, a STATKOM unit has been installed at the Vyborg converter complex, a synchronous compensator has been installed at the Beskudnikovo substation (Moscow), and an overhead power line with multi-chamber insulator arresters is undergoing pilot operation in Rostov oblast. As an idea, The Federal Grid Company is planning to spend 19 billion rubles for research and development in between now and 2014.

An important transition from pin-pointing a specific technology area that needs attention and the subsequent development or technology purchase is the implementation of complex pilot projects and the creation of power clusters. The implementation of power clusters is necessary for the development of intellectual, or smart, grids (detection of faults and upsides, synergy effect from using various technologies) for future duplication across UES Russia.

As part of smart grid implementation in UNPG in the East and ESD in the North-West, pilot projects are being implemented. During 2011-2012 we are planning to complete pilot programs for smart grids in the Far East and North West regions, where large-scale implementation is planned for the “Elgaugol” power cluster in a branch of OJSC “FGS UES” – PTS East.

To implement a smart grid in this power cluster, we are planning to install “digital” compactly designed substations (the first digital substation was launched in December 2010) which include the latest technology such as a new type of reactive power compensation and voltage maintenance system, and active harmonic filters which use equipment monitoring and diagnostics systems

Innovations such as these are also planned for two other power clusters in the Far East – “Vanino” and Primorsky kray, which will lead to a more reliable power supply for track substations at the Khabarovsky Kray electric railroad and provide a reliable power supply for the southern part of Primorsky Kray.

The second territory planned for smart grid implementation is the North-West region. Here, the focus will be on the power clusters of the Karelia energy grid, that of the Komi Republic and Arkhangelsk, and the both the “Large” and “Small” grid rings of St.Petersburg.

In order to help aid in the implementation of new solutions and technologies within the next 2 x years, we are working hard to resolve the problems of power output limitations by the generating stations, and to improve the reliability of power supply to the consumers.

Will government and regional regulation have an impact on the speed of “smart grid” implementation?

A general concept and overall vision of intellectual power system with an actively adaptive grid is presently being developed by the all participants (power companies, ministries and equipment manufacturers).

It is apparent that creating a smart grid is impossible without the proper support from ministries, legislators, equipment manufacturers, science institutes, universities, etc.
This is why FGC initiates open discussions for the issues of smart grid development (round tables at St.Petersburg international economic forum (SPIEF) in 2010 and 2011, various conferences and expos with participation of all interested parties.

The latest round table at SPIEF that took place on the 16th of June 2011, where various aspects of “smart grid” development in Russia were discussed; top managers of Russian and foreign power companies, managers of power equipment manufacturers, telecom companies, business executives, legislators and executive government officials attended.

During the round table, the representatives of legislation and executive authorities had expressed their readiness to provide the necessary support for future development. This support not only includes preparation and approval of corresponding legislation initiatives (such as the Grid Code), but also creating unified strategic plans for development among the power companies.

And doesn’t a successful “smart grid” also need support from the generation facilities? Including serious investment and modernization within the plants?

Obviously, creating a smart grid depends on many factors – from the state of scientific research to production of modern equipment. FGC is already building this network, thus forming the foundation for future changes.

The company is expanding its cooperation with scientific research and design companies (some of them as part of earlier cooperation agreements), including institutes of RAS, SB RAS, FSUE ARETI, OJSC “HVDCPTRI”, OJSC “ENIN”, OJSC “Institute Energosetproekt” among others, pushing them to undertake scienctific research, experimental design and technological works (R&D), including that within the framework of the “Intellectual energy system” technology platform where OJSC “FGC UES” is both the initiator and a participant.

The special focus is on personnel training (“support” universities – MEI, SPBSPTU, ISPU). As part of the expansion of innovative ideas and activities, OJSC “FGS UES” will expand the Russian science and engineering base, including by attracting foreign partners and collaboration with Russian higher education institutes.

FGC had adopted a Program for the support and motivation of local manufactures, and also, considering earlier cooperation agreements, has formed a system of long-term partnership between OJSC “FGS UES” and equipment manufacturers, including foreign ones, which will provide:
»    mutually beneficial cooperation of FGC with the equipment manufacturers;

»    increased quality and competitive ability of locally produced energy equipment;

»    localize the production of modern energy equipment in Russia and increase the share of equipment purchased by FGC in Russia;

»    Reduce the delivery time, registration and attestation time for equipment required by FGC.

As part of this program, requirements are established for long term contracts for equipment delivery, including full service support by the equipment manufacturer for the entire equipment lifetime.

In order for the these programs to be implemented, long term programs of compulsory adaptation need to be put in place. To ensure that all participants are “reading from the same page” for the creation of a smart grid, all participants from related industries such as  electrical technology, construction, design, science education, service, repair and engineering need to be on board.

And what incentives are there for operators to upgrade their facilities? Who will pay for their modernization?

Currently, contracts for capacity supply (CCS) for the bulk energy market are being signed, which state the commitment of the generating company to introduce new capacity in a timeframe stipulated by the investment program. Generating equipment will be upgraded within the framework of these agreements.

And what benefits will the end user get from a smarter grid system?

The transmission grid consumers will be provided with reliable and uninterruptable power supply with reliability and quality factors required by the consumers (digital indicators), which subsequently will decrease expenses for technological failures and losses, prevent cost escalation for infrastructure maintenance as well as provide new services from the grid (such as energy accumulation, IT and telecom services).

I presume the end users will pay for this development through higher energy tariffs?

New RAB tariff regulation parameters were approved in 2010. Changing from a 3 year to 5 year planning stage had allowed the financing of a long-term FGC investment program that created a solid foundation for future reforms.

RAB is the system of long-term tariff regulation, aimed at providing an internal rate of return comparable with the market conditions, and subsequently capable of providing investments for the construction and modernization of the grid infrastructure. The basis of this method is a system of tariff calculation which allows the gradual return of invested funds, including the interest on the borrowed capital. Because the investment is returned over a longer period, the tariffs can be maintained at a reasonable level.

Therefore the implementation of both individual projects as well as development of the smart grid as a whole will not affect the consumers outside of the current tariff proposals.

So, we should soon see some big developments within the grid itself, but how about the “smart- home”? When will we see Russian consumer adopting smart systems within their properties?

The creation of a smart grid is a complex, relevant and important task for both the energy industry and economy of Russia as a whole. To maintain our leading position among the global community and to create an smart grid power system in Russia, the participation of all the companies and entities I have discussed in this interview is necessary, as well as a combined effort and support from the energy industry players, consumers, equipment manufacturers, science community and related industries.

Regarding smart homes, this needs a smart grid on the one hand, and the installation equipment and systems to facilitate this in the consumers home. There are currently a number solutions available; they are however quite expensive. These will decrease in  price though once the we reach the COMPLETE SMART GRID!

Dimitri Tyuhtin

In 2011 IDGC Holdings and Integrated Energy Systems, two of the leading Russian energy companies, jointly commenced a Smart Metering pilot project in the area serviced by IDGC of the Urals. The project was launched under the “Count. Save. Pay” federal program drawn up by the “Technology Development and Update Commission” attached to the office of the Russian President.

A joint working group created to implement the project was formed by representatives from IDGC Holdings OAO, IDGC of Urals OAO and also Integrated Energy Systems ZAO. The key focus lies in determining the best technologies used for arranging retail market metering, the recognition of potential problems, generating strategies to solve problems, decrease energy loss and operating expenses as well as improving customer service.

As a part of the project, the energy companies intend to create a metering automated control system (or ACS). It will include boundary meters for domestic consumers and small businesses (installed, if needed, at consumer facilities), data-collection units installed on transformer substations as well as a data acquisition and processing center.
The project will be launched at Permenergo in 2011-2012. The Company intends to replace and mount approximately 50,000 intelligent meters in the Perm region (Sadovyi urban district) and integrate them into a unified ACS.

“Certainly, it is a rather painstaking project, but it will have significant repercussions because it is aimed at teaching our customers how to manage their own energy consumption”, said Oleg Zhdanov, Permenergo director. “The project is designed to create an open system, and any consumer can sign-in and see their own consumption and payments. The use and analysis of such information should help our customers to take deliberate energy-saving measures”.

A new Smart Metering system will provide the transparency and operability of the following processes: record of readings, data transition to billing systems, meter monitoring, on-line configuration of network distribution and consumption as well as possible remote customer curtailment based upon requests from retail suppliers.

Over 50 Russian meter producers showed interest in our project. Technical expertise has determined the short list, and after negotiations they received an offer to generate technical solutions for a particular Perm urban district. The participants are Russian leaders in ACS development and implementation. They are very experienced, highly innovative and use cutting-edge energy technologies.

The installation of new meters began on June 06, 2011. Five sites on the pilot territory are equipped by devices produced by both Russian (Incotex, Energomera, Matrix) and foreign (Echelon, SAGEM) manufacturers. 150 apartment buildings are currently being equipped with the devices, with the overall quantity of the assembled meters exceeding 15,000. The devices may use several tariffs, meter both consumption volume and capacity (the latter being important for network prameters calculation) as well as being able to send feedback remotely. Inhabitants of the area are satisfied with the innovations: “A 3-tariff meter is very convenient for us, since we are out during the day-time. We manage our household duties, like garment washing, cleaning and cooking, in the evening when the tariff is low”, they comment. “We also like the design of the meters and it is easy to use them“, said one customer.

IDGC of the Urals has also arranged a tender to choose a contractor for developing a top-level ACS based on Smart Metering technology. Sixteen of the largest IT firms showed interest in the tender. Seven companies, including four foreign ones, have submitted their offers during the negotiations.

Synchronously with the pilot project, the working group intends to work out proposals stipulating amendments to the Russian legislation, standardization of financing sources and mechanisms as well as exploitation with a view to replicate the project all over Russia.

There are also plans to determine the efficiency the project. A possibility to update business processes related to metering by gridcos and retail suppliers will appear after implementation and a full review of the pilot project.

Energy-Efficient Technologies in the Urals Grids
IDGC of the Urals is a united operating company of the Urals region dealing with the transfer and distribution of energy in the Sverdlovsk, Chelyabinsk and Perm regions.
Our operations are aimed at increasing the efficiency of grids. The Company pursues a policy of elaborating and implementing programs dealing with the increase of supply reliability, energy-efficient technologies, investment attraction and network development.

We have reseached and implemented our program for increasing energy efficiency increase, comprising several actions including increasing metering quality, reactive capacity compensation, implementation of cutting-edge lighting and heating technologies as well as the optimization of the current supply chain.

We intend to spend over US$ 120 mln on these key programs in the Sverdlovsk, Chelyabinsk and Perm regions between 2011-2015.

Invensys are into key areas of power generation all around the world. Specifically within Russia, what are your key focus areas?

Paul DaCruz: Historically, our footprint in Russia has always been the oil and gas market. We’ve been a very big player in providing automation solutions for the oil and gas sector. However, our big strategic area of development is the power sector.

The grid network in Russia is ageing and in need of modernization. What products & technology does Invensys offer to help upgrade the system and achieve higher efficiency?

Paul DaCruz: Well, we have some very interesting solutions from generation and transmission to distribution and metering. We also offer solutions to upgrade power plants, upgrade networks and also to build new, more efficient assets. But you can’t just look at new assets because these are only adding to the existing systems, and you need to have an overall view of the general situation.

An interesting solution we provide is one that enables all electrical systems to communicate with each other in real time. From a (power) generator point of view, this means knowing what the consumption is going to be. From the consumers point of view this means knowing in advance what the potential prices are going to be so you can better manage your consumption.

One of the main focus areas in the Russian Power sector moving forward is safety and reliability of supply. What is Invensys Operations Management doing to help their customers in this area?

Paul DaCruz: One thing that we’re focusing on as a company is to provide what we call control and safety solutions. This includes protection of the assets, protection of the environment and protection of the people. We don’t consider this to be just a technology offering, but more of a philosophy; we are however totally committed to the technology side as well. In fact our control and safety systems are considered the best in the industry. They probably are the most widely used systems for nuclear power stations around the world. In Russia, I reckon that one of the major problems is not just the lack of Control and Safety systems that are deployed, but also the necessity to develop best practices that help in the overall culture of safety.

We also provide systems that can help companies simulate what-if scenarios: thus showing potential outcomes based on the practices that have been implemented.

With the solutions we provide we not only try to offer our clients the best control and safety technology but we also aim at giving them the tools to develop a safety culture within their working environment.

Focussing on the local market, are there any Russian companies that you are competing and/or working with?

Paul DaCruz: Russia is a very complicated market because there are many stakeholders, and the code system is quite complex. But what we tend to do is to build on local expertise. We develop local partnerships; for example we are currently collaborating with INVEL, which has turned out to be very beneficial for us so far. It has given us the opportunity to liaise with different local companies we would like to work with.

On the other hand, the market is well covered by our multinational competitors. Russia is a very dynamic market thanks to the fast growing economy, and for sure the infrastructure will have to be modernised.

You mentioned your partnership with INVEL – what specific benefits does this bring to yourselves and them, and the market as whole?

Paul DaCruz: INVEL’s Executives and stakeholders enlist some of the key power companies in Russia. Its main goal is to bring innovation to the market place both in Russia and abroad. Invensys can help them by providing the innovative solutions they’re looking for, meaning it definitely is a win-win situation for all involved

Significant investment is needed in this sector to achieve goals set out by the Government. How do you see the market moving forward over the next decade?

Paul DaCruz: All the projections today show that by far the biggest energy investments is going to be in the electricity sector.

The electricity sector corresponds to about 50% of total capital investment in Russia and this is more or less equally spread between electricity generation and electricity transmission and distribution. So I think if I recall correctly the International Energy Agency forecasts $26 trillion of total investment up until 2030, with the power sector representing $13 trillion. I know you guys publish ROGTEC (Russian Oil & Gas Technology) Magazine, but I have to say that investment in the Power sector significantly trumps that of oil and gas! Obviously these investments are not just going to be new assets, they’re going to be put into much needed upgrade and modernisation projects. When you have such old assets there is a real necessity to shift from maintaining the asset to potentially thinking about upgrading or replacing it. Currently in Russia there are many modernization projects taking place for this reason.

One of the major challenges faced in the electricity market in Russia is that the largest consumer of electricity is the “loss”. What can Invensys do to stop this worrying trend?  

Paul DaCruz: Operators can sometimes fall into a comfort zone in terms of the asset at their disposal and the efficiency and generation they are achieving. The “comfort zone” is going to happen whoever the operator is, no matter what their ability or capability. Now, if you put some Intelligence into the control of this asset using advanced process control, predictable control, neuron networks and other such clever stuff you can achieve large cost savings and huge increases in efficiency and power generation. The problems an operator has to face are quite complex, so by trying to model the optimum way of operating the assets, we can generate some fantastic benefits. As an example, we achieved improved efficiencies of about 2% on a boiler for a coal fired power station, which is significant. The problem in the boiler was an excess of oxygen; the operator was adding more oxygen to increase combustion, but this excess of oxygen led to huge inefficiencies. So, if you reduce this excess of oxygen you increase the efficiency immediately. And in power generation, increasing efficiency equals a reduction in emissions.

In Russia specifically, do you target the conventional or nuclear sector, or do you look at the Power Generation sector as a whole?

Paul DaCruz: We are currently enabling 20% of world power generation through our automation and control solutions, functional systems, functional room sensors and instrumentations. There are 5,500GW around the world, so we enable roughly 1,000GW around the world. That’s power generation as a whole: nuclear, conventional and renewable. We have today, for example, contracts in our hands for several control systems in Asia-Pacific for 140GW. As an idea, 140GW is twice the size of the available generation of the UK! In the nuclear sector there are 440 reactors around the world and our functional and safety solutions are in 160 of those systems.

We are in early discussions with a number of nuclear power plants at present, and we believe Russia is a very interesting nuclear player. Together with China, they are by far the countries that are developing extensively their industry not only for domestic usage, but also for export.

It has been great to speak with you on this exciting market sector. Do you have any further comments for our readers on Smart Grids?

Paul DaCruz: The big question here is what is and what isn’t a smart grid. The concept of a “Smart Grid” is very interesting. It is also very broad! When looking at this concept we have to consider the overall chain from generators to stakeholders, politicians, regulators etc.

From a regulator point of view, monitoring what’s going on in the system is important. So I would just make sure that people realise that smart grid isn’t just smart meters, it’s not just grid. It’s also the generators and a “total value chain”.

Another important point is that we are now moving into an era where energy is expensive. Historically it has been relatively cheap – but look at the current price of an oil barrel. At the start of the crisis it was down to 33$; what I’m saying is that there is serious fluctuation there. I think this instability will potentially help in the development of the smart grid. One thing we also have to remember is that the concept of the smart grid developed two, three years ago when an oil barrel was $150. Smart grid development has slowed down with the decrease in the oil price; however with sharp increases in the price of a barrel, smart grid development could increase massively because energy efficiency is something that will yield better returns.

Steam turbines do not only take the primary position in the orders portfolio for OJSC “Power Machines”, but they also are the most widespread pieces of equipment installed for use in thermal and nuclear power stations worldwide – they account for about 80% of all produced energy.

Russian turbine manufacturers have been amongst the world’s leaders for decades, creating reliable and efficient equipment. A lot of this is down to a key subdivision of Power Machines – SCB (Special Construction Bureau) “Turbina” at the Leningradsky Metallichesky Zavod (LMZ), which celebrates its 105th anniversary this year.

Today, SCB operates in three basic fields: NPP turbines, TPP turbines and the modernization and upgrading of steam turbine equipment for existing power plants. The development of 1200 MW high-speed and low-speed turbines for nuclear power plants is a current focus, and the related operations are underway and on schedule.

The detailed design for the high-speed turbines has been completed, with the prototype being manufactured for the Novovoronezh NPP-2. Turbines such as these have not been manufactured at the LMZ before. The K-1200 steam turbine used in thermal power stations was manufactured for the Kostroma SDPP in November 1977; since then, new technological advancements have been developed as well as new and improved materials which were used for the Novovoronezh turbine, which was contracted even before the detailed design had been completed.

Next on the production line are  the1200 MW high-speed turbines for the Leningrad NPP-2. The detailed design for the low-speed turbines is scheduled for completion in 2013. Production of the low-speed turbine prototypes will take place at “Metallostroy”, our new production facility. The design of the entire turbine plant will be coordinated for a specific power station, with the general design contractor.

Designers at SCB work with the aim of  increasing the capacity of high and low speed turbines from 1200 to 1600 MW, and there is no doubt these machines will be in demand, with power units with this capacity are currently being made in Finland and France. It should be noted that the Power Machines high-speed turbines have a number of very important competitive benefits when compared with other NPP turbine producers, namely lighter weight, smaller dimensions and correspondingly, lower construction costs.

Looking at turbines for ultra critical steam parameters, this project has a complicated history. The idea itself is not new and Russia was at the forefront of its development. At some point in the past, a 100 MW capacity SKR-100 turbine was produced by Kharkov plant and installed at Kashira SDPP. Its operating temperature reached 650°C with a steam pressure of 300 atm. Similar designs for 200-500 MW turbines have been in development at the LMZ since the early 1960s. Due to perestroika however, works in this area were suspended – it was no time for science or new designs during this period. The Company’s order books were not looking great and in order to survive companies were following other avenues. We are now making up for lost time however.

There are a number of options as to how this area can be developed. The best option would be to create a turbine for 700-720°С, which would help gain an immediate competitive advantage by making an unparalleled technical advance. The difficulties faced however include the expense of developing not only the turbine, but the related boiler and ancillary equipment, mastering new metals, higher operating costs. Other European manufacturers have worked closely with Governments on the financing and development of such projects, and therefore creating such a prototype should be seen as a challenge to be undertaken on the national level. As for being in demand, creating such turbine is a goal for the future.

The second option is to create a machine for 570-580 degrees bracket. In this case any large R&D costs could be avoided, because there are already existing developments available. Today however, it is more practical to develop a turbine with industry leading operating parameters and that is what the 660 MW turbine project (to be completed in 2012) is meant to achieve.

Two more new products should also be mentioned among thermal plant turbines – the K-280 and the K-130, which are designed for combined cycle gas plants with 800 and 450 MW capacity, respectively. The detailed design for K-280 will be completed next year, and K-130 design is due to be finished this year. Apart from this, the SCB is carrying out some large-scale works related to design of equipment for the construction of a new thermal plant, as well as full or partial modernization of turbines for existing power plants.

To mention a few projects completed over the last few years, we should note the K-225 steam turbines built for the Cherepets SDPP and the 3rd generating unit at Kharanor SDPP (operated by OGK-3)

The unique point about K-225 steam turbine is that this prototype was made using brand new technology. The K-225 will replace existing machines of average capacity which are currently used at many thermal stations both in Russia and abroad.

A particular aspect of K-225 project was the implementation of new technical solutions from the construction bureau at Power Machines for the power units under construction. During the design of the 225 MW steam turbine, a new type of high pressure cylinder blading was used for the first time in Russian power plant engineering. This new technology will vastly increaset the  efficiciency of the turbine. In the past this type of blading was only used for more powerful turbines (e.g 300MW) at the Konakovo SDPP, the Konasima thermal plant in India and the Wong Bi thermal station in Vietnam.

To improve operational efficiency, the rotors of K-225 turbine were made of heatproof high-chromium steel and the rotor journals were protected with a surface coating made of from special alloy. These operations were carried out using technology developed by the NPP institute, at Power Machines’s automated welding center, which was commissioned in April 2010. Its creation involved the participation of specialists from LMZ and leading European companies including Fronius (Austria), Kistler (Germany) and Heatmasters (Finland).

The company management also made the decision to restore the full-scale testing unit at the TPP-17,Vyborgskaya. There are a number of processes that can’t be reproduced in laboratory conditions or when operating on scaled equipment such as the self-oscillation of blades, heating of the air-gas channels at low-feed operation, influence of steam humidity on the performance efficiency etc. All these occurrences, as well as aerodynamic properties and performance efficiency of the channel section, must be studied in a full-scale testing unit.

Because of this full-scale testing, unique results were obtained during the trials of 960mm x 1000 mm steel exhaust blades and 1200 mm long titanium blades, which were tested on turbines with a capacity from 200 to 1200 MW. Unfortunately, in the 1990s the testing unit was suspended, thus the recent decision to restore the testing unit is a very important step which includes us in the higher echelons of worldwide manufacturers. The design engineers will be able to test the channeling parts and blades for prospective high-speed and low-speed turbines with a capacity from 1500-1800 MW. Right now the TPP is undergoing some disassembling works, while the LMZ workshops are already producing assembling parts and components for the testing unit. Its launch is expected at the end of this year.

As is already known, the Power Machines management made the important decision to reinforce all engineering divisions of the company, which was later supported by a range of related activities. As a result of this, two more departments were created at SCB Turbina, the modernization and NPP departments. Expanding the modernization works has to do with the fact that over 60% of the TP turbines have already passed their recommended operational life, and an increase in implementation of NP units through to 2030 has been proposed by a Resolution of the Russian Government.

Today, the personnel of SCB Turbina, the largest of all engineering divisions of the company is much younger: almost a third of all employees are young graduates below 30. On one hand, this proves that the construction bureau has a bright future, on the other – that the workload for more experienced employees is increasing: there is a lot of mentoring work to be done to save and develop the Russian power plant engineering base.

Today SCB Turbina has the potential necessary to meet the challenges it is facing and there is no doubt that its highly qualified specialists are capable of reaching the goals that have been set.

Veronica Rostova

The activities of Italian energy giant Enel in Russia is one of the most successful examples of entry of foreign capital into the Russian energy industry. The company was the first among international corporations, even before the start of liberalization of the industry, to begin working in the Russian power sector, taking under control the North-West TPP in Saint Petersburg. Enel was the first to purchase the stake in a generation facility spinning off from RAO UES during the energy sector reform. In July 2011 with the launch of two new, modern CCGTs Enel became the first to complete the investment commitments made during the acquisition of OGK-5. In short, it is the pioneer of the Russian electricity market.

Today, Enel Group is successfully operating in Russia, developing a vertically integrated business in the Russian energy market. The company is active in the gas sector, as well as in the generation and electricity sales. In 2010 the revenue of “Enel OGK-5” reached 52,561 million rubles, net profit stood at 3,695 million rubles, and in the first half of 2011 the net profit totaled 2,275 million rubles.

The promising Russian market has always attracted the largest energy companies in the world, as Russia accounts for almost one seventh of the total primary energy production in the world, in terms of energy consumption the country is ranked fourth.

Enel first entered the Russian market seven years ago, when it took charge of the North-West TPP, together with its partner – a private Russian group called “ESN Energo”. Thus, Enel became the first foreign company to receive access to the management of the Russian power industry facility. Within three years of the supervision contract (2004-2007) the company was in charge of the completion of the second CCGT (combined cycle gas turbine) with a capacity of 450 MW. As the result, the company managed to double the capacity of the power plant and bring it to 900 MW, as well as to significantly improve its technical, economic and environmental performance. The North-West TPP was the first in Russia to become environmentally certified, while Enel had the opportunity to show new standards of business administration in Russia.

Upon the completion of this project, Enel began to expand its activities on the Russian territory further. In 2006 it acquired 49.5% stake in Russia’s largest independent electricity supplier “Rusenergosbyt”. In 2007, together with Eni Enel, we strategically bought shares in the gas development company SeverEnergia. The most important step in the expansion strategy of Enel Group in Russia was the acquisition of OGK-5, and currently OJSC “Enel OGK-5”, is one of the largest producers of electricity in Russia. “Enel OGK-5” is a dynamically developing company, which includes four large power plants located in rapidly developing regions of Russia: Reftinskaya and Sredneuralskaya GRES in the Urals, Nevinnomysskaya GRES in the North Caucasus and Konakovskaya GRES in Central Russia.

The summer of 2011 became a landmark for “Enel OGK-5”, as the company introduced 820 MW of new capacity in Russia, thus becoming the first generation company to completely fulfill its investment obligations in Russia.

On July, 15 the company launched the new combined-cycle gas turbines (CCGT) unit with installed capacity of 410 MW at Nevinnomysskaya GRES in Stavropol region. The inauguration ceremony was attended by Deputy Prime Minister Igor Sechin, Head of the International Division of Enel Carlo Tamburi, Head of Engineering and Innovation Division of Enel Livio Vido and Enel OGK-5 CEO Enrico Viale.

The construction of 410 MW CCGT at Nevinnomysskaya GRES is the only project of this kind and scale implemented in the region. The launch of the new CCGT not only helped increase the installed capacity of the plant, but also the reliability of the North Caucasus power system in general. The project also acquires particular importance in view of the forthcoming XXII Olympic Winter Games in Sochi, since the launch of new generating capacity will contribute to increasing safety and reliability of power supply of the sports and infrastructure facilities.

10 days after, on July 25, 2011, Enel launched the second combined-cycle gas turbines unit with the capacity of 410 MW at Sredneuralskaya GRES in the Urals. The new unit was inaugurated in teleconference by Prime Minister of Russia Vladimir Putin, Deputy Russian Energy Minister Andrei Shishkin and Head of International Division of Enel Carlo Tamburi.

With the commissioning of a second new power unit Enel became the first generating company to fulfill its commitments in Russia in terms of building new capacity. According to Carlo Tamburi, “Enel is proud that with the launch of new power units the company has not only increased the installed capacity and production performance of its power plants in Russia, but also has contributed to the development of the Russian energy system”.

The new generation units are among the most technologically advanced in the whole territory of the Russian Federation. They are constructed on the base of fourth generation technology and equipment, that helps increase electricity production and reduce environmental impact. The efficiency of new CCGTs is about 58%, while the average efficiency rate of conventional gas turbine power units is 35-40%.

CCGTs also help cut fuel consumption, reduce capital investment and maintenance and repairs costs. The combined-cycle power unit consumes one third less cooling water than a conventional plant, owing to this fact the production costs are reduced. In addition to good efficiency CCGTs also meet stringent environmental requirements, as they permit the reduction by twice the level of nitrogen oxide emissions.

Thus, the launch of new units will meet the continuously growing demand for electricity in key industrial regions of Russia – the Urals and the Caucasus, and at the same time will ensure the sustainable use of natural resources and help protect the environment.The total investment in the construction of two new power plants amounts to 800 million euros.
However, having completed the construction of new power units, we do not intend to stop at what has been accomplished.

The modernization of the existing facilities is also one of the priorities for Enel. And it primarily refers to long-term investment programs for the rehabilitation of the existing plants. The need to modernize the energy infrastructure in Russia is very evident. It is no secret that many of the production capacities are quite aged: for example, Sredneuralskaya GRES has recently celebrated its 75th anniversary and Reftinskaya GRES – its 40th anniversary.

In December 2010 “Enel OGK-5” started the modernization of Reftinskaya GRES – the largest coal-fired power plant in Russia. The project on the revamping the plant began with a full-scale reconstruction of 300 MW power unit N5. In a way, this is a unique project: following the modernization, the installed capacity of the unit will increase by 25 MW and its efficiency rate by approximately 3%. But the reconstruction is not limited only to technical performance improvement. An equally important objective is to reduce the environmental impact. In this regard, in July 2011 “Enel OGK-5” and the Government of Sverdlovsk Region signed an Agreement on cooperation in the field of environmental protection, which envisages the implementation of medium- and long-term environmental programs at Reftinskaya GRES. One of the key aspects of the program is the reconstruction of the dry ash removal system and installation of bag filters which will reduce the concentration of ash emissions into the atmosphere by nearly 95%.

Upon the completion of the reconstruction of power unit N5 at Reftinskaya GRES, the company plans to modernize gradually the entire plant. Every two years “Enel OGK-5” is going to carry out the reconstruction of one of the units of the plant. The program provides for the modernization of all 300 MW units of the power plant, including replacement of main and auxiliary equipment with new, more efficient ones that meets modern environmental standards. In particular, it is planned to install bag filters on all power units, which is testifying the company’s commitment to environment.

And last but not least an important aspect for “Enel OGK-5” is investing in strengthening the overall efficiency and optimization processes of its plants. Rich international experience and proven technologies help achieve operational excellence, improve safety and obtain environmental compliance.

Ian Hore-Lacy
Director of Public Communications
World Nuclear Association

“Nuclear Safety” comprises the various provisions made at all stages in the design, construction, operation and decommissioning of nuclear facilities to protect people and the environment against exposure to radiation and the dispersal of radioactive substances under all circumstances. Since the first nuclear power plants were built, based on those propelling nuclear submarines, there has been a steady increase in understanding of the technology and a concurrent evolution in design and operation of reactors, which has greatly improved the safety of today’s plants. Only three first-generation reactors remain in operation (in UK), most of the 432 operational reactors are second-generation (Gen II), and a few (in Japan) are third-generation.

The main nuclear reactor designs operating over the last 50 years have been pressurized-water and boiling-water reactors (PWR and BWR), with these designs being strongly represented among those considered Generation III – the most up to date models available today. Hence this article will focus largely on those two broad technologies.

Another key aspect of nuclear safety is the way plants are operated, and the evolution there with the development of safety culture and international benchmarking and peer review is more remarkable and probably more significant than the engineering, which is the focus of this article.

Defence-in-depth
To achieve optimum safety, nuclear plants use a ‘defence-in-depth’ approach, with multiple safety systems supplementing the natural features of the reactor core. Safety could be said to have evolved to Generation III types, giving neighbours greater assurance that there is an extremely small likelihood of significant radioactive release, and even that would not be sudden. For owner/ operators the change is more marked, in that there is much reduced likelihood of equipment damage in any circumstance. (Three Mile Island & Fukushima plants were write-offs, in a Gen III reactor a serious problem is likely just to take the reactor offline for a while.)

The design stage for a reactor usually starts with an essentially “deterministic” approach, listing events that could lead to the dispersion of radioactive material in the environment, and defining the parameters within which the reactor will be designed to avoid this. This is known as the Design Basis, and anything further is ‘Beyond Design Basis’. The designers then devise ways and design systems that to counter incipient incidents or accidents within the Design Basis, and should they occur, to mitigate their consequences. Increasingly, attention is paid to Beyond Design Basis contingencies.

This deterministic approach is then supplemented with a “probabilistic” approach, a verification stage. In this, the robustness of the plant to initiating events is tested, taking into account the various probabilities for engineered systems as well as human operators to succeed or fail in the prevention or mitigation of incidents. These probabilities are either well-established by real observations and actual operating experience, or they are estimated based on the best available comparisons.

Both aspects have moved a long way since the first Gen II plants were designed fifty years ago, which is hardly surprising in the light of 14,500 reactor-years of operational experience since then. The Three Mile Island accident in 1979 was of enormous benefit in developing effective defence-in-depth, and in 1996 additional levels were formally added to the approach. First, ‘beyond design basis’ situations were addressed with the objective of controlling severe plant conditions that were not taken into account in the plant design, and secondly, the mitigation of radiological consequences of significant radioactive releases was addressed.

Several scenarios that were considered ‘beyond design basis’ for Gen II reactors are now included in the design basis for new reactors (notably multiple failures accidents, and core melt accidents). Furthermore, for the existing plants, the defence-in-depth mainly considered the nuclear fuel when loaded in the reactor vessel. For new reactors, the scope of defence-in-depth has to cover all risks involved with the nuclear fuel, even when stored in the fuel pool. Both these have obvious relevance to the Fukushima accident.

Key aspects of the defence-in-depth approach are:
»    high-quality design & construction, using special ‘nuclear grade’ materials and components, complying with international standards such as ASME N-stamp;

»    equipment which prevents operational disturbances or human failures and errors developing into problems;

»    comprehensive monitoring and regular testing to detect equipment or operator failures;

»    redundant and diverse systems to control damage to  the fuel and prevent significant radioactive releases;

»   provision to confine the effects of severe fuel damage (or any other problem) to the plant itself.

These can be summed up as: Prevention, Monitoring, and Action (to mitigate consequences of failures) applied at every stage of the life-cycle: design, construction, operation and decommissioning.

Physical barriers
The safety provisions include a series of physical barriers between the hot radioactive reactor core and the environment, and the provision of multiple safety systems, each with back-up, and designed to accommodate human error. Safety systems in the sense of back-ups and containment account for a substantial part of the capital cost of nuclear power reactors.

The barriers in a typical plant are:
» The fuel is in the form of solid ceramic (UO2) pellets, and radioactive fission products remain largely bound inside these pellets as the fuel is burned;

» The pellets are packed inside sealed zirconium alloy tubes to form fuel rods;

» These fuel rods (as part of fuel assemblies) are confined inside a large steel pressure vessel with walls up to 30 cm thick – the associated primary water cooling pipework is also substantial;

» All this, in turn, is enclosed inside a robust pre-stressed reinforced concrete containment structure with walls at least one metre thick.

There are thus three significant barriers around the fuel, which itself is stable up to very high temperatures. The quality of both the fuel and the barriers has steadily improved over half a century of operating experience.

Each element relating to these barriers is monitored continuously:
»    The fuel cladding, by tracing some specific radioisotopes in the primary coolant water;

»   The primary circuit (high pressure cooling circuit),  by monitoring its leak rate. In the case of PWR plants, primary to secondary system leakage through steam generator tubes is closely monitored in order to anticipate anything that could lead to a tube rupture;

»   The containment structure, by closely monitoring its possible minor leakage rate by computing inside pressure, temperature, and often air input that enters it to power the various apparatus inside.

For all of these barriers, different thresholds are established, allowing either further operation with additional monitoring, or limiting conditions of operations, or curtailing them in order to re-establish sufficient safety margins, or in some cases the plant must be shut down for repair.

Periodical tests during major maintenance outage supplement this online surveillance by additional pressure tests, their severity and frequency usually being defined by national laws or applicable codes: 10-yearly hydro tests for major components including the primary circuit at a higher pressure than those during normal operations, and 10-yearly pressure tests for the containment at a pressure simulating an accident scenario.

Back-up power supply is absolutely basic if the reactors are shut down for any reason. This is normally provided by large diesel generators, two or three per reactor unit, and they are run periodically to ensure readiness. Newer ones are air-cooled, so that they do not have to rely on heat exchangers which may become damaged as at Fukushima (where all but one of the diesels themselves were also swamped).

Inherent and passive safety
Traditional reactor safety systems are ‘active’ in the sense that they involve electrical or mechanical operation on command. Some engineered systems operate passively, e.g. pressure relief valves. Both require parallel redundant systems. Inherent or full passive safety design depends only on physical phenomena such as convection, gravity or resistance to high temperatures, not on the functioning of engineered components. All reactors have some elements of inherent safety, but in some recent designs the passive or inherent features substitute for active systems in decay heat cooling etc.

The main safety features of most reactors are inherent – negative temperature coefficient and negative void coefficient. The first means that as the temperature increases the reactivity decreases (this in fact is used to control power levels in some new designs). The second means that if any steam has formed in the cooling water there is a decrease in moderating effect so that fewer neutrons are able to cause fission and the reaction slows down automatically. These physics features have not changed in the main reactor designs, but their application is improved.

A passive system should not rely on external mechanical or electrical power, signals or forces. It does rely on natural laws of physics, properties of materials, and internally stored energy. Thus decay heat removal from a reactor by thermosyphoning to an elevated tank of water once a valve opens is passive. In practice most designs do allow active signals since there would usually be a need to switch from active heat removal systems for full power operation, to passive decay heat removal systems after an accident, and engineered components may be involved in activating the system. Fully passive designs such as AP1000 and ESBWR do not require any inputs at all for a 72 hours “grace period” to achieve safety.

Main reactor functions
There are three functions, with obvious safety implications, required in a nuclear reactor:
»    to control reactivity, including being able to shut down the reactor

»    to cool the fuel, including removal of decay heat

»    to contain all radioactive substances.

These need to be constantly monitored, and operators must be able to make necessary corrections, if trends show degradation. The monitoring needs to be very reliable, and newer digital control systems present the results to operators more helpfully than in the past.

Control of reactivity is primarily by using the neutron-absorbing control rods which are inserted down into the core in PWRs, and up into it in BWRs (since steam separators etc are above the core). Control rods must be able to be inserted very quickly and reliably to shut down the reaction completely if required. A secondary way to shut down the reactor is to poison the moderator/ coolant water with a neutron absorber such as boron.

While control rod concept and function has not changed greatly in new designs, the quality and robustness of the fuel has improved substantially, allowing increased fuel burn-up with increased enrichment. In line with increasing quality and robustness of fuel rods, some fuels now make greater use of burnable poisons such as gadolinium or erbium, which enable much longer fuel life.

Cooling requires both normal operational systems to transfer the heat from the very energy-dense core to steam in the turbine, and also secondary circuits for prolonged cooling to remove decay heat from the fuel after shutdown – these are sized at about 5% of the main circuit capacity, and in some new designs may be passive.

Then there must be back-up supplies of power and water to enable all this under all circumstances, plus the means of getting this water into the core, and it is these areas that much change has occurred. Emergency core cooling systems are a basic insurance, and modern plants have more of them and more diverse provision here than older ones. Newer plants are more likely to incorporate substantial water storage high in the reactor building.

Emergency core cooling systems (ECCS), though in themselves an insurance and back-up provision, need duplication and back-up, including both high- and low-pressure systems. The number and sophistication of these has grown over the years. For instance in the GE-Hitachi ESBWR design, even the emergency core cooling system has eliminated the need for pumps, using passive systems and stored energy.

In relation to a loss of coolant accident (LOCA), the Westinghouse AP1000 uses a (passive) gravity-driven makeup from the refueling water storage, after the primary cooling system is automatically depressurized. Emergency core cooling water is then added by gravity from the tank at the top of the building.

Mitsubishi’s new APWR has some similar features combining active and passive cooling systems in double containment. It is the basis of Japan’s new PWR construction plans. The ECCS of the US version has four independent trains, and its outer walls and roof are 1.8 m thick.

Rosatom’s new VVER-1200 design building on Russian experience have enhanced active and passive safety features, double containment, and a core-catcher. It is the basis of Russia’s future plans.

In designs such as the new AP1000, decay heat removal from both the primary cooling system and also the containment is passive, by convection. No safety-related pumps or ventilation systems are needed for the first 72 hours. All PWRs have a large tank of cold water, the Refueling Water Storage Tank, used to flood the core when it is shut down for refueling. But the AP1000 design locates this tank inside containment and uses it for emergency decay heat removal. Inside the tank is a passive heat exchanger which is part of a full-pressure, closed, natural circulation loop connected to the reactor coolant system. The heat exchanger is activated by failsafe air-driven valves that open upon loss of power. Thus decay heat can be removed passively by thermosyphoning convection in the event of total power loss.

Not all decay heat removal cooling systems are passive – the new Areva EPR has four separate, redundant active safety systems, as well as passive safety features. The safety systems are physically separated through four ancillary buildings on the same concrete raft, and two of them are aircraft crash protected. Back-up diesel generators are similarly dispersed.

In its broadest sense, passive safety emphasizes the use of natural forces (gravity, self-correcting neutronic feedback) and de-emphasizes systems which require large amounts of electricity (eg for pumps), complex logic, or high energy. This is innately attractive, but active systems enable operators to address precisely what is going on, not relying on a designer having earlier anticipated everything.

Containment is more straightforward. The AP1000 containment consists of an inner steel pressure shell surrounded by a concrete outer shell. If necessary, water from an elevated reservoir at the top of the building flows by gravity over the inner shell to provide passive heat removal via heat conduction through the shell, aided by natural convection of air between the two shells. Following shutdown it too requires no active intervention for 72 hours.

Core melting probability
Originally core melting was ‘beyond design basis’, but today reactors are designed for grappling with the contingency of a core melting and producing a very hot eutectic of fuel, zirconium and debris, known as corium. Provision for this may be with a large ceramic core catcher like a giant water-cooled ashtray under the pressure vessel (as in the EPR), assuming that the corium might melt through the steel, or it may be with in-vessel retention of corium enabled by water cooling around the pressure vessel (AP1000).

Regulatory requirements today for new plants are that the effects of any core-melt accident must be confined to the plant itself, without the need to evacuate nearby residents. Originally, wide evacuation would have been assumed, as at Fukushima.

Calculated core damage frequency has been one of the main metrics to assess reactor safety. European safety authorities prefer a deterministic approach, focusing on actual provision of back-up hardware, though they also undertake probabilistic safety analysis for core damage frequency.

Control systems
In the last fifteen years digital instrument and control (I&C) systems have replaced analogue ones, providing operators with much more data about plant operations and a level of detail and analysis better than available from analogue ones, as well as remote access to diagnostics and data. All US operating reactors, all but four French ones, and most others in the world use analogue I&C systems. All Generation III reactors and most, if not all, new reactors of any type use digital ones.

Related to this is the hardening of control rooms so that power and filtered clean air are guaranteed, even if the main plant systems are down and portable generator trucks are being used. They should also have emergency communications such as satellite phones. With newer plants, such features are standard, and they are retrofitted to some older ones.

Siting and plant layout
Perhaps the most obvious safety provision is in siting a nuclear power plant, and the Fukushima accident has reminded us of that. While nuclear plants are, where possible located close to the sea or other major water bodies to provide for cooling, they must not be vulnerable to flooding. In any case basic equipment such as switchgear and back-up provisions such as generators are today located very conservatively to allow for any major natural disaster that might affect the plant itself.

Conclusion
Just as in comparing a 1960s motor car to a 2010 model the differences add up to quite a lot, though individually the component functions haven’t changed remarkably, so with nuclear reactors. To the engineer and technician the detail changes are more evident, to the lay observer or even driver, they are incremental, and the main change is simply in reliability. But considerable evolution in many aspects of design has occurred, and is reflected in much greater safety today.

Acknowledgment: This article draws on lecture notes of Dr V.Snell for the Reactor Safety Course at McMaster University, advice from Francois Perchet at WNU with his extensive nuclear operating experience, comments from Adrian Bull at Westinghouse, as well as many WNA information papers.

What is new on the Russian utility scene? What are the newest projects and investments and which technologies are leading the way?
 
Federal Grid Company, the world’s largest power transmission company and Host Utility of Smart Utilities Russia, is in the process of creating a modern communication infrastructure on its vast networks. This will lead to a better capacity, peak load management and blackout prevention.
 
Real-time communication remains the backbone of the smart grid, and is of a particular importance to Russia, due to its geographical reach – spanning 11 time zones and a variety of climates.
 
At Smart Utilities Russia 2011, Roman Nikolayevich Berdnikov, Deputy Chairman of the Management Board from Federal Grid Company will discuss Russia’s very own challenges and drivers for power system modernisation, such as the combination of old and modern technologies to improve communication on the network to reduce energy losses and improve reliability.
 
How can you turn this market intelligence into long-term financial gains?
• Global technology providers and telecoms giants have made a significant contribution to the development of smart grid, with numerous technology-enabled projects throughout the US and Europe – Position yourself as the leading solution provider for the Russian power sector!

• For nearly 2 decades, Russia’s electricity sector remained on the fringes of Western Europe, mainly due to the organisational sluggishness of state-owned utilities. We are now seeing a rapid change in the efforts to revive the sector. This opens up an unparalleled potential for you to share your technical expertise, partner with local utilities and accelerate change

• Learn from the best! Get the latest updates on these exciting projects

o    A new telecommunication project between Lenenergo and Megafon

o    How to unlock the huge potential of raw data through data analytics by Teradata

o    Updates on PermEnergo –  the Russian most comprehensive smart metering project

o    New ways to improve energy efficiency by Saint-Petersburg Electricity Company
 
…to name just a few.
 
To view the full programme with many more of domestic and international experiences, click here.

Join over 200 utility professionals for your chance to debate, connect and explore a huge business potential opening up after decades of underinvestment and deferred innovations.

Register online today to be part of this debate and meet the people that matter in the Russian utility world.

PowerTec Russia invites you to attend Smart Utilities Russia with a 20% discount!

To receive 20% discount, please register via following link: http://www.smartutilitiesrussia.com//default.aspx?page=11475

Volatile prices of raw materials and equipment, fluctuating demand and intense cost pressures in the global markets make it necessary for companies to be highly adaptable in their production in order to respond to market pressures, meet market requirements and to continually improve efficiency and effectiveness.

“As a leadThe international automation company COPA-DATA will present its new product for dynamic reporting, the zenon Analyzer, for the first time at the SPS/IPC/DRIVES 2011 trade fair. The software is designed to display all the vital information from manufacturing processes or energy management with a clear overview and in graphical form, so that comprehensive evaluations of operating efficiency can be carried out. The zenon Analyzer is useful for production and factory managers, as well as financial controllers and company management. …

ing provider of HMI/SCADA solutions, COPA-DATA has many years of experience in industrial automation and is familiar with the requirements of different sectors and industries. With the zenon Analyzer, we are offering an innovative solution for Dynamic Production Reporting, which supports our customers optimally when monitoring their manufacturing processes. It also reveals any potential for optimizing consumption and production”, explains COPA-DATA CEO, Thomas Punzenberger.

Dynamic Production Reporting analyzes all relevant data obtained from production. The reports generated provide those responsible for production and management with a comprehensive and transparent overview of previous activity as well as the current manufacturing situation. These reports use both real-time data and historical data for evaluations. Users can apply standardized, pre-defined templates to deploy the tool quickly and efficiently. There is also the capability to adapt the pre-defined reports or to define individual reports to precisely portray the company-specific requirements. The reports can also be used as a basis for quality control as well as adherence to compliance requirements.

Companies can deploy the zenon Analyzer as either an independent and freely-configurable application or in conjunction with zenon as the HMI/SCADA solution. The software can be easily integrated into existing automation solutions or IT infrastructures – without adaptations or changes needing to be carried out on existing machines or equipment. The zenon Analyzer compiles the data from various machines, production stages and equipment consistently and provides all relevant information quickly and with a clear overview. As a result, users can view OEE and KPI figures, such as material use, downtimes, or energy consumption. Thanks to the management of user roles, it is also possible for different users or user groups to only receive the analyses and evaluations that are relevant to them.

• Web-based solution for dynamic evaluation of production data
• Compilation and preparation of data from different sources of data (machines, production lines, etc.)
• Evaluation of real-time data and historical data
• Use of standardized or user-defined reports
• Creation of reports at pre-defined times (such as at the end of a shift)
• Use as a stand-alone solution or in conjunction with zenon HMI/SCADA software
• Simple integration into existing infrastructure
• Flexible access from any workspace
• Comprehensive filter functions (machine, equipment, time, article, order, batch, etc.) and drill-down reports
• Integrated Microsoft SQL Server 2008 R2

The zenon Analyzer is officially available at SPS/IPC/DRIVES 2011

Source

State-of-the-art technologies will help manage mechanical equipment, improve efficiency, and enhance operational reliability of Surgut-2 unit

Russian power-generation company E.ON Russia has chosen Emerson Process Management as main automation contractor for Unit 3 of its Surgut-2 power station. Emerson’s technology and services will help the 800MW plant block’s operators maintain effective control of mechanical equipment, improve efficiency, and enhance operational reliability.

With a total generating capacity of 5600 MW, Surgut-2 is one of the largest natural gas thermal power plants in Europe. It is also the largest Russian power station operated by energy supplier E.ON Russia, which is majority-owned by E.ON.

Emerson will provide its PlantWeb™ architecture with Ovation™ expert control system to provide comprehensive process control for the plant’s 800-MW, gas-fired Unit 3. AMS Suite predictive maintenance software will help optimize plant performance by using diagnostics to ensure measurement devices are operating correctly. And a CSI 6500 Machinery Health Monitor will provide protection and prediction monitoring of turbo generating set equipment, turbo feed pumps, and forced-draft mechanisms.

Emerson’s innovative technology meets the requirements for an integrated solution and will improve unit controllability. The operator interface will be compatible with those in neighboring units, which will help the operating personnel adapt easily to the new controls and take full advantage of the Ovation control system.

Emerson will commission the Unit 3 automation including the control system, instrumentation, control valves, and other related equipment. Emerson will also modernize controls for the fluid end of the turbine set, reconstruct and equip the Unit 3 control room, provide engineering and installation services, certify compliance with requirements of Russia’s Unified Energy System, and assist with unit startup.

“This joint project with E.ON Russia will benefit from Emerson’s global experience, advanced technologies and expertise for automation of thermal stations,” said Bob Sharp, president of Emerson Process Management in Europe. “Relying on these strengths and the coordinated work of specialists from both companies, we look forward to the successful and on-time completion of this important project.”

Startup of Unit 3 is planned for October 2012. The Surgut-2 station continuously provides Western Siberia and Ural with power and heat. It uses natural gas coming from Tyumen Region`s oil fields. Based on its annual output, this plant is one of the biggest thermal power stations in the world, producing more than 35 billion kWh per year.

Doosan Heavy Industries & Construction has awarded Siemens Water Technologies with a contract to provide a condensate polisher package with external regeneration facility to GMR Chhattisgarh Energy Private Limited. The polishers will be used at the 1,370-megawatt Raipur Super Thermal Power Plant in the state of Chhattisgarh, India, which is being built to increase power generation capacity in the district. Siemens will design, engineer and
fabricate the condensate polisher system, which is currently scheduled for start-up in June 2014.

For the Raipur power plant, Siemens Water Technologies will provide six condensate polishers that will treat over 3,100m 3/hr of return condensate. Condensate is formed when the steam from the boiler cools. To reuse it, impurities such as metal oxides, trace ionic impurities and silica have to be removed by condensate polishers. They help to improve and maintain the boiler feed water chemistry. The system will increase the likelihood that the power plant will stay online during small to moderate condenser leaks. The exhausted resins will be transferred and regenerated in a Fullsep external regeneration system that allows separation of the resins with minimum crosscontamination, thus assisting the customer in maintaining consistent high-quality water.

Doosan Heavy Industries & Construction is a multi-billion-dollar Engineering Procurement and Construction (EPC) company and a global leader in the power and water business. GMR Chhattisgarh Energy Private Limited is a subsidiary of the GMR Group, and has been developing power plants of over 8,000 megawatt capacity.

How long has your Company been doing business in the region?
In 2010, Landis+Gyr opened a representative office in Russia. In this respect we are quite new on the market, but, as a world leader in the metering industry, we were supplying our products and systems to Russian customers years prior  We were shipping to major Russian utilities since the 1990s and 2000s, so the brand is well established and recognized among specialists in the country’s energy sector.

Do you have a specific target markets in the region?
Our wide product offering covers metering demands across the full energy value chain, starting from power generation companies and ending at the point of delivery to residential consumers. We specifically target high-end metering products and systems needed at power generation, T&D and wholesale applications, as well as modern smart metering systems demanded at the retail market.

What are your key products for the region and what are their benefits?
We offer ZQ meters that feature high precision, exceptional build quality, flexibility and multi-functionality. This product, designed and manufactured in Switzerland, is built on the experience of Landis+Gyr in grid applications. It tops the list of ICG devices that we offer in Russia, the most popular of which are ZD meters that combine exceptional quality and functionality with competitive price. For residential applications, we offer a wide range of modern smart metering technologies based on our global experience. All of our products are united under the Gridstream™ solution which is our platform that offers seamless integration into the Customer’s IT environment.

What potential is there for your products in the market?
The reform of the Russian energy sector that started in 2003 is an ongoing process and we see many positive changes underway. Still, the reform would neither be accomplished nor successful without modern metering in place. Together with recent legislation promoting energy efficiency and, more specifically, development of smart metering technologies in Russia, we see a huge demand for modern, intellectual metering technologies that will drive fast development of the metering market. There will certainly be a place for products that have brand, reputation and quality on the market, and therefore we see a good potential for our company within it.

How do you compare and compete with existing Russian Technology?
Until very recently, the Russian metering market was quite isolated from the international markets and was largely dominated by the local manufacturers. Partly because of that, metering equipment and technologies have not been developing in Russia as fast as in extremely competitive global markets. Therefore, most of the existing metering technologies deployed in Russia are lagging behind. Nevertheless, we see some good examples of Russian technologies being quite innovative and aggressive and it is a privilege for us to compete with them, both locally and globally. But today, it is most important for all of us to realize that the demand for energy efficiency and modernization requires a very fast change of metering practices in Russia. Those suppliers who will be unable to adapt to such a fast changing environment will not be able to survive on this market.


How do you see the market developing over the next 5 years in your industry sector?
As I explained above, there is much to be done within the Russian metering market and I believe that the next five years will bring a quality change to the market environment with a focus on functionality, modernization and value.

Do you have any new products being launched?
Indeed, this is a permanent process. We spend over $100 million a year on R&D, and as a result there is a range of new products every year. Not only are the products becoming more functional, precise and reliable, but they are also becoming more environmentally friendly and efficient. This year we will launch a product that has a focus on smart grid applications and is being designed primarily with the Russian market in mind.   It is a new generation of high precision ZQ meters with IEC 61850 interface that we shall supply to the digital substation pilot project of the Federal Grid of Russia.



Do you have any recent regional success stories?
This year we shall participate in one of the first smart metering pilot projects in Russia. It is a big honor for us to offer the best of our knowledge, know-how and practical experience in a massive rollout to our Russian customer.

Any further comments?
Yes! Please visit the Landis+Gyr exhibit at the Smart Utilities Russia conference and exhibition – November 16-17, 2011– in Moscow.

Virtualization Reduces Total Cost of Ownership and Improves Availability of DCS Systems and SCADA Infrastructure

Honeywell  today announced the availability of virtualization support for its core product line, Experion® Process Knowledge System (PKS) for both Distributed Control System (DCS) and SCADA applications. The latest additions to the company’s virtualization portfolio establish Honeywell Process Solutions (HPS) as the only process industry vendor to offer a comprehensive virtualization solution.

For many of today’s manufacturers, the process control environment requires separate servers to support different applications. Virtualization resolves this issue by allowing a single server to simultaneously run multiple operating systems and applications. It also improves reliability by insulating these operating systems from hardware changes and the net benefit to users results in lower operational costs.

HPS’ virtualization offerings are developed with VMware®, the world’s largest supplier of virtualization products and solutions. These solutions help industrial plants reduce PC hardware requirements and minimize the frequency and impact of operating system and hardware changes while simplifying overall system management and improving availability, reliability and disaster recovery.

The popularity of virtualization is growing rapidly throughout the IT industry as a whole, with a recent study by Gartner showing that over 40% of servers are virtualized today and that figure will rise to 75% by 2015. HPS’ holistic approach to industrial virtualization encompasses the delivery and support of  virtualization infrastructure uniquely tailored to the needs of the process control industry. Additionally, Honeywell provides a full range of applications that can be supported through virtualization, providing end users with a complete solution right out of the box.

“As the broad shift in the IT industry towards virtualization extends to the industrial marketplace, it’s becoming more and more common to see applications and infrastructure deployed virtually rather than physically,” said Paul Hodge, Experion Infrastructure & HMI Product Manager, Honeywell Process Solutions. “Honeywell is the only company able to deliver total virtualization support for process automation environments. We see virtualization as game- changing, and our offerings have been developed as strategic, long-term automation tools.”

The international automation expert COPA-DATA received another accreditation for its zenon software: the zenon Client Driver, developed in-house to meet the IEC 61850 energy technology standard, has been certified by the international testing body, KEMA.

In order for an automation system such as zenon to be able to communicate with different protocols and standards when being used in substation systems, users need a corresponding driver. For this reason, the COPA-DATA development team developed the zenon IEC 61850 Client Driver in 2006 to enable the exchange of data using the international standard IEC 61850. After comprehensive tests, the zenon Client Driver has now been certified by the international testing and certification company KEMA. This certification confirms smooth communication with the IEC 61850 standard and seamless interoperability with all available servers within a zenon substation project.

Jürgen Resch, Energy Industry Manager at COPA-DATA, stresses the importance of this certification: “The zenon IEC 61850 Client Driver has already been successfully integrated into energy projects. However, the certification of the driver is now often required in tenders in the field of substation automation. Only a few companies in the world are currently able to offer this certification. This makes it all the better for us; the fact that we can also meet this criterion now. Confirmation from an independent testing body such as KEMA guarantees us significant competitive advantage and underscores our role as a pioneer in substation automation.”

Source www.copadata.com

Alexey Miller, Chairman of the Gazprom Management Committee and Dr. Jürgen Grossmann, CEO of RWE signed a Memorandum of Understanding on strategic partnership in power generation in Europe. It also affirms the companies’ intentions to conclude the ongoing commercial negotiations to a mutually satisfactory result.

In order to implement these considerations RWE and Gazprom will enter into negotiations. The subject of these negotiations is the possible formation of a Joint Venture which shall consist of existing or newly built gas and coal power plants in Germany, United Kingdom and the Benelux.

“The power industry is one of the priorities of Gazprom in Europe. In light of recent decisions by the German government to reduce their nuclear power programs, we see good prospects for the construction of new modern gas fired power plants in Germany. The signed Memorandum provides RWE with exclusive rights for negotiations with Gazprom on the implementation of energy projects in Germany, UK and the Benelux countries for a period of three months,” said Alexey Miller.

“This MoU, when put into commercial reality, could secure safe and competitive natural gas supply to RWE. It can furthermore provide for potential partnerships in coal and gas fired power plants inside and outside Germany and thus lead to mutually fruitful common growth opportunities,” said Jürgen Grossmann.

Source www.gazprom.com

Industry report confirms potential for cogeneration in low carbon energy policy

In a just published report highlighting the likely future role of cogeneration COGEN Europe outlines a high efficiency scenario for 2050 in which at least two thirds of cogeneration will be renewable based. However, the poor current performance of the sector must be radically improved if this is to be achieved.

In its scenario ‘Cogeneration 2050’ COGEN Europe has taken the various existing projections for fuel mix changes achieving 85% CO2 reduction and prepared a “high efficiency low carbon” vision of 2050. Building on the previous report ‘Cogeneration as the foundation of Europe’s 2050 low carbon energy policy’ released in December 2010, the new report shows the significant role which cogeneration can play in the sustainability of renewables lifting the overall efficiency of bio–energy use. In a 2050 world of highly electrified transport and better insulated buildings cogeneration emerges as the logical mode of supplying low carbon process heat to industry. The report includes new fuel flow diagrams for the European economy, visualising the intricate pathways of energy through the economy and highlighting the key transformation and distribution points.

The cogeneration sector supplies both heat and electricity simultaneously, cutting across traditional economic and commercial boundaries. However, the poor current performance of the sector remains a major disappointment. The European Commission has indicated that cogeneration basically stood still from 2004-2008 with only 0.5% growth per annum. Neither the 2004 Cogeneration Directive nor the European Emission Trading Scheme regimes have stimulated investors to move into this sector. “Member States themselves have identified the potential for an additional minimum 20 Mtoe cogeneration annual energy savings by 2020.” said Dr Fiona Riddoch, Managing Director of COGEN Europe. ”It is hard to argue that Europe should continue to waste energy. All the European Institutions must now get real about energy efficiency policy and cogeneration and deliver a strong Energy Efficiency Directive”.

Source: www.cogeneurope.eu/

Siemens Water Technologies in India has secured a contract to provide a water treatment system for Torrent Power Limited’s 382.5 megawatt UNOSUGEN gas-based combined cycle power plant in Surat, district Gujarat, India. Siemens will supply two Contrafast Concentric systems, which will treat water from the Tapi River and produce up to 4 million gallons per day (15,142 m3/day) of cooling tower make-up water. The system, which is part of a capacity expansion at the power plant, is scheduled to be commissioned in September 2012.

Power plants need a consistent, reliable source of water for cooling tower make-up that is also cost effective and sustainable. In many cases, cooling tower make-up water must be treated for suspended solids reduction and/or hardness reduction. With properly treated water, the potential for scaling in the cooling tower is significantly reduced. This reduces cooling circuit cleaning requirements, extends the life of the cooling equipment, and reduces the cooling tower blowdown
flow to the environment.

The Siemens Contrafast Concentric system supplied for the UNOSUGEN power plant is a highrate clarification and thickening process that consists of a solids contact reaction chamber, clarifier with tube settler and gravity thickener in a single tank. The entire process is contained in a single, unitized steel basin, and is designed to simplify installation time and reduce cost. The design allows up to an 80% reduction in footprint compared to conventional clarification systems, and the process enhances suspended solids’ removal, lime softening and heavy metals removal. Torrent Power chose the Contrafast Concentric system for the UNOSUGEN plant mainly because of the system’s integral solids thickener and minimal footprint.

Siemens Water Technologies in India will engineer and source the system hardware, with design review and on-site technical services provided by Siemens Water Technologies in Ames, Iowa, U.S.A.

Torrent Power is one of the largest private players in India with integrated operations in the power sector. It generates 1,647.5 megawatts of power and distributes to nearly 3 million customers in the cities of Ahmedabad, Gandhinagar and Surat in Gujarat, Bhiwandi in Maharashtra, and Agra in Uttar Pradesh.

For more information, please visit www.siemens.com/siww

Solutions for the power generation market: Siemens helps provide high-quality water for power producers in Asia

The Asian power industry is currently experiencing a significant increase in power plant construction. India, for example, has planned to add more than 100,000 megawatts of capacity in the next five years. The single largest industrial use of water in India is for power plants, as these plants consume around 90% of the water used by all industries combined. A reliable water supply, therefore, is vital for the region’s power generation.

Among the critical areas for water treatment and use in power plants are intake screening, the steam turbines cycle (boiler feed and condensate treatment) and the cooling water system. Providing these and other solutions, Siemens recently secured several power projects in Asia.

Water treatment systems for the power generation market have to fulfill specific requirements depending on their application within the power plant. Intake systems help protect the power plant’s condenser cooling system from damage, by removing debris from the incoming cooling water. Bar racks first capture rough and larger debris to prevent it from reaching the finer mesh of the traveling water screen. The bar racks are cleaned by trash rakes. Siemens’ dual-flow traveling water screens are positioned parallel to the direction of the flow, and present nearly twice the screening area and debris carrying capacity of other designs. These screens help to eliminate debris carryover downstream of the system, making them ideal for intakes that require high volumes of water or heavy duty debris handling. Siemens is supplying a comprehensive intake system for a Vietnamese power plant. The system will include dual-flow traveling water screens, bar racks, grab-style trash rake, interconnecting piping and associated controls for the plant’s once-through condenser cooling system.

Water treatment solutions for the steam turbines cycle

Siemens’ triple membrane (3Mi) integrated solution is an innovative membrane treatment approach to achieving consistent, cost-effective boiler feed water. It consists of a Memcor ultrafiltration system, a Vantage reverse osmosis system and an Ionpure continuous electrodeionization system, for removing suspended solids, dissolved inorganic impurities and dissolved and suspended organics. Historically, boiler feed water treatment systems have been based on chemically regenerated ion exchange resins. In the 3Mi process, the bulk consumption of chemicals, such as acid and caustic, is eliminated, together with the hazards associated with chemical handling. It also reduces the production of solid wastes that typically require dewatering and disposal.

Condensate is formed when the steam from the boiler cools. It can be collected and reused as boiler feed. Prior to reuse, impurities, such as metal oxides, trace ionic impurities and silica from the power plant’s condensate, have to be removed. Siemens’ spherical condensate polishers help to improve and maintain the boiler feed water chemistry and increase the likelihood that the power plant will stay online during small to moderate condenser leaks. To remove impurities from the condensate, exchange resins can be used. The exhausted resins can be transferred and regenerated in a Fullsep external regeneration system that allows separation of the resins with minimum cross-contamination, thus assisting the customer in maintaining consistent high-quality water.

In India, Larsen & Toubro Limited selected Siemens to provide a condensate polisher package with external regeneration facility to treat condensate for two 660-megawatt super-critical boilers for a new power plant. The project involves design, engineering, fabrication, installation, testing and commissioning of the condensate polisher system, scheduled for start-up in April 2013. Siemens India and Siemens Singapore will work together to execute the project, including design and project management.

Chlorination and clarification systems support power plants in India In the cooling water circuit, micro and macro fouling can occur, which in turn affects the heat transfer efficiency in the power plant condenser tubes; this can affect the overall power plant efficiency. This fouling can be controlled by chlorinating the cooling water. The Chloropac seawater electrochlorination system from Siemens is designed for this purpose. During electrochlorination, special transformer rectifiers provide DC power with high amperage for electrolysis of the seawater. The electrolysis produces sodium hypochlorite, which acts as an effective disinfectant to control biofouling.

One of the largest Greenfield ultra mega power plants in India selected the Chloropac system to control biofouling in the cooling water. The power plant owner evaluated possible options for biofouling control including gas chlorination, chlorine dioxide treatment, non-oxidizing biocide treatment and electrochlorination. Gas chlorination would have required a large number of chlorine gas storage containers. Safety requirements during handling, storage and use at the site, and during transport to the site, as well as space requirements, were major considerations. The Chloropac system not only provided a safer alternative to gas chlorination, but also provided the lowest lifecycle cost for the application.

Power plants need a consistent, reliable source of water for cooling tower make-up that is also cost effective and sustainable. In many cases, cooling tower make-up water must be treated for suspended solids reduction and/or hardness reduction. With properly treated water, the potential for scaling in the cooling tower is significantly reduced. This reduces cooling circuit cleaning requirements, extends the life of the cooling equipment, and reduces the cooling tower blowdown flow to the environment. The Siemens Contrafast Concentric system is a high-rate clarification and thickening process that consists of a solids contact reaction chamber, clarifier with tube settler and gravity thickener in a single tank. The entire process is contained in a single, unitized steel basin, and is designed to simplify installation time and reduce cost. The design allows up to an 80% reduction in footprint compared to conventional clarification systems, and the process enhances suspended solids’ removal, lime softening and heavy metals removal.

Siemens received a recent order from Torrent Power Limited for two Contrafast Concentric systems, which will treat water for the 382.5 megawatt UNOSUGEN gas-based combined cycle power plant in Surat, district Gujarat, India. The Contrafast Concentric systems will treat water from the Tapi River and are designed to produce up to 4 million gallons per day (15,142 m3/day) of cooling tower make-up water.

Chloropac, Contrafast, Fullsep, Memcor, Vantage and Ionpure are trademarks of Siemens and/or its affiliates in some countries.

For more information, please visit www.siemens.com/siww

Further information about solutions for water treatment is available at: www.siemens.com/water

www.siemens.com/industry-solutions

Alstom is continuing with its long-term strategy to establish a presence in Russia and signed during the St. Petersburg International Economic Forum two agreements to produce and engineer equipment for high-voltage electricity transmission.

“Alstom is keen – alongside its main economic and institutional stakeholders – to support Russia’s infrastructure development. We are extremely proud that our knowledge and expertise in generating and transmitting electricity are acknowledged by leading companies in Russia’s industrial sector which was proved by the two signed agreements”, said Patrick Kron, chairman and CEO of Alstom.

Alstom Grid and Soyuz Holding S.A. signed a Memorandum of Understanding (MoU) in the presence of Federal Grid Company (FSK), who welcomes the notifying advancement of joint venture negotiations to begin local manufacture and commercialisation of Alstom Grid high voltage switchgear products by the end of this year.

The MoU builds on an agreement signed between Alstom Grid and FSK in October 2010, which established the framework for an ongoing industrial and technology collaboration, specifically, to implement Smart Grid technologies in the modernisation of the Russian electrical grid. Manufacturing for the new joint venture is set to take place in the existing high voltage switchgear facilities of Soyuz in Mozhaisk.

Alstom Grid has joined forces with KER Ltd. to study the creation of a joint venture for engineering and project execution in the High Voltage Direct Current (HVDC) sector. The objective of the joint venture is the localisation of expertise in Russia, as well as the realisation of a direct current Engineering Centre in Saint Petersburg by the end of 2011. Alstom Grid is a recognised leader in HVDC technology, essential to carrying greater electrical loads over extremely long distances, reliably and efficiently. This new joint venture would enable locally based interests to play a major role in the supply and development of HVDC projects such as Vyborg – LAES, linking Russia to Finland.

Alstom Grid has been supplying electrical equipment and engineered projects in Russia for over 50 years, and already has manufacturing, engineering and service activities in Krasnoyarsk, Yekaterinburg and Moscow.

Source http://www.alstom.com/grid/news-and-events/press-releases/Alstom-enters-into-two-electricity-transmission-agreements-in-Russia/

License agreement represents a milestone for the two companies

Dow Wire & Cable, an international leader in technology and material science solutions for the power and telecommunications industries, announced today at the 2011 Wire Russia show in Moscow an agreement with Sevkabel Holding to become one of the first Dow Inside licensees worldwide. Sevkabel is a leading cable manufacturer in the Russian Federation. Under the terms of the agreement, Sevkabel will use DOW ENDURANCE™ insulation, semiconductive and jacketing materials to manufacture medium and high voltage power cables. In exchange, Dow Wire & Cable will provide Sevkabel with forward-thinking technology, proven products and enhanced service that will help give both companies a competitive edge in a demanding market.

“We are delighted to be working with Sevkabel as a Dow Inside licensee,” said Filip Tauson, Commercial Director Europe/Middle East/Africa, Dow Wire & Cable. “The Russian Federation is a very important region for growth and innovation in the power industry. This next step with our valued customer, Sevkabel, will certainly benefit both organizations as well as utilities and consumers that will realize more reliable power supply from the manufacture of long-life cables that meet strict international quality standards.”

Vladimir Bukhin, Director General, Sevkabel Holding, added, “For Sevkabel this partnership demonstrates our commitment to innovation and strategic relationships with our suppliers and customers. This partnership with Dow will help us deliver more reliable and modern cables to the Russian market, further reinforcing our strong market position.”

Dow Inside is a recent initiative from Dow Wire & Cable that benefits cable manufacturers and utilities alike. It further reinforces the organization’s commitment to the power industry by helping to provide better cable reliability and long service life based on exceptional materials, dedicated R&D, deep industry knowledge and close working relationships with cable manufacturers, utilities and other power industry influencers.

Source www.dowwireandcable.com