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
