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Coal supply: why buy water?

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Contents

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Demand for mobile unloaders is no surprise”

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Editorial

Per KarlssonPresident, Siwertell

Since our Spring issue of Siwertell News we have had a very busy period including our biennial representative meeting with its excellent networking opportunities (page 24). This issue contains several articles from our service organisation that showcase its competence and flexibility. Personally, I think the news item relating to the five-year Siwertell service contract with Masinloc Power Partners in the Philippines (page 27) is extremely interesting. It is a great example of how we can bring additional benefits to our customers even when their machines have been in operation for a long time.

There is a growing demand for quiet operation and the sound test carried out at Dong Energy’s high-efficiency power station in Denmark demonstrates the low noise levels of its Siwertell multi-fuel unloader (page 13).

The mobile unloaders article (page 8) highlights the versatility and importance of this type of product and the

benefits that mobile unloaders can provide for our customers. I hope those of you in the coal business will be interested in our analysis of coal purchasing policy and the factors to consider to get the full picture (page 18).

And lastly, please remember that our offer of a full-scale alumina unloading test, at no cost to you, still stands.

Meanwhile I wish you all a pleasant read and success in your business.

Meeting market needs

Multi-fuel handling: the perfect solution for coal-firing plants Demand for mobile unloaders is no surprise Quiet equipment makes a good neighbour Tailor-made ship loaders demonstrate their capabilities worldwide Coal supply: why buy water? An analysis of coal types Global get-together builds better business Latest news Dismantling a ship unloader in Egypt: it is now ready for resale, relocation and reassembly Overhaul of installation in Turkey: expert attention minimises downtime Training: the key to safe, smooth operations

Siwertell ship unloaders and loaders are based on unique screw conveyor technology, in combination with belt conveyors and aeroslides, and provide a totally enclosed dry bulk handling operation. Virtually any dry bulk cargo can be handled. The Siwertell portfolio includes ship unloaders, mobile ship unloaders, ship loaders, horizontal and vertical screw conveyors as well as complete dry bulk terminal solutions. All Siwertell solutions are designed to ensure sustainable and efficient cargo operations. Siwertell is part of Cargotec Corporation. www.siwertell.com

Siwertell News is Siwertell’s customer magazine Publisher: Siwertell, part of Cargotec, P.O. Box 566 Gunnarstorp, SE-26725 Bjuv, Sweden Editors: Emily Braekhus Cueva, Malin Pekberg ([email protected], [email protected]) Layout and production: Emily Braekhus Cueva Cover: Siwertell Printed by: Tryckaren Engelholm The opinions expressed by the authors or individuals interviewed do not necessarily represent the views of Siwertell.

Ship unloading

handlingMulti-fuel

High efficiency Siwertell ship unloaders with their low environmental impact are perfect for dual-fuel power plants; when you add in Siwertell belt conveyors, the efficiency of a plant’s entire conveying line can be further

enhanced. Global demand for biomass continues to rise. This is predominately driven by the needs of power plants seeking to improve their environmental credentials, often by co-firing – burning coal and biomass – which can reduce the carbon footprint. Biomass is typically about half the density of coal with only two-thirds of its caloric value. “Therefore, a much greater volume is required to deliver the same energy output,” explains Bengt Svensson, Senior Contract Manager for Siwertell. “This in turn requires optimised transport solutions supported by effective, efficient port infrastructures. “Our leading position in this field is, in part, due to the fact that Siwertell screw-type unloaders can handle all types of coal and biomass without the need for any adjustment between cargoes,” continues Mr Svensson. “This makes them ideal for co-firing power stations.”

is the perfect solution for co-firing plants

“This success is reinforced by our relatively recent introduction of fully-enclosed belt conveyors to our range of conveying options,” he says. “We worked hard to develop a belt conveyor with the same market-leading qualities as our screw-type unloaders in terms of reliability, efficiency and cleanliness. Our belt conveyors are extremely efficient and offer significant operational cost savings when applied to multi-fuel power generation intakes.” High efficiency from ship to storage A good example of a high-efficiency, environmentally-friendly Siwertell multi-fuel handling system can be found on Jurong Island in Singapore. The clean, fully redundant system already has two years of successful operations to its credit. In 2010, Siwertell was approached by TP Utilities, a subsidiary of Tuas Power, to deliver a multi-fuel receiving system for its Tembusu Multi-Utilities Complex (TMUC) on the island. Central to the complex, which is managed by TP Utilities, is a biomass clean coal (BMCC) cogeneration plant.

photos SIWERTELLtext BENGT SVENSSON

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handling

5SIWERTELL NEWS

Big Wheel keeps on turningThe plant houses three circulating fluidised bed (CFB) boilers that are capable of firing coal and biomass. Each boiler produces up to 450 tonnes of steam per hour. Tuas Power says that all equipment and systems within TMUC are configured to optimise efficiency. This results in a total system efficiency of around 70 percent. For its part, Siwertell was responsible for the design, manufacture, delivery and installation of two screw-type ST 640 M unloaders, three bucket elevators and 13 covered belt conveyors for conveying the fuel from the unloaders to three coal storage silos and the biomass flat storage. “We were also responsible for the supporting steel structures, the HMI and the PLC control system,” notes Mr Svensson, who was responsible for the TP Utilities project. “To ensure extremely clean, dust free operations, we designed the system with all transfer points fully-enclosed and equipped with dust collectors.” Commenting on the development of the Siwertell solution, Mr Svensson says that local people were resistant to the proposed power plant because they were very worried that it would look like a typical, dirty, coal-fired power plant. “Our client was very concerned about the risk of coal dust emissions, so we paid a lot of attention to this. Siwertell’s enclosed screw-type unloaders were the natural

solution for the unloading processes. For the belt conveyors, we designed a complete enclosure including a bottom plate.” He says belt conveyors are a relatively new addition to Siwertell’s product portfolio and offer particular benefits when ordered as part of a complete ship-to-storage system. “The advantages of our renowned Siwertell ship unloaders are well known and accepted. However, it makes a great deal of sense to turn to Siwertell for the entire unloading/conveying system. “Combining our screw-type unloaders with our fully-enclosed belt conveyors provides a very efficient and economical overall fuel supply solution. The customer

can be sure that all the equipment is well matched and fully compatible. “Furthermore, having Siwertell as the single supplier for the complete fuel-handling system, the client knows exactly who is responsible for the system’s performance,” adds Mr Svensson.

“I believe the Siwertell installation has completely fulfilled its environmental requirements. Dust emission is close to zero and the area around the conveying system is very clean.” A reputable manufacturer with a good track record Siwertell is well known in the port of Singapore for environmentally-friendly bulk handling. It has supplied local businesses with a limestone unloader and several cement unloaders equipped with belt conveying systems. TP Utilities chose unloaders and conveyors from Siwertell because it is a reputable manufacturer with a good track record, says Neo Poh Hua, Electrical Maintenance Manager for TP Utilities. “Our requirements were for a highly reliable coal handling rate of 1,000t/h without fugitive coal/biomass emissions during unloading and transfer operations. Singapore has strict environmental regulations and there is a regulatory requirement to minimise any fugitive dust from industrial operations. We needed a dust-free unloading operation with reliable equipment and good after sales support,” he says. The amount of fuel required for the plant means that the island’s jetties are frequently occupied by bulk carriers delivering coal and biomass. The double

We needed a dust-free unloading operation with reliable equipment and good aftersales support”

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conveyor system with two unloaders provides TP Utilities with full fuel supply redundancy all the way from the loaded vessels to the storage facilities. Mr Neo explains that this redundancy is an important factor because a secure fuel supply is critical for the continuous operation of CFB boilers. It is also an advantage during maintenance as it ensures that one unit remains operational. Mr Svensson says that, up to now, the concept of fully redundant fuel delivery systems has been uncommon. “However, it has a number of advantages, and the additional cost is not that great. Normally we are only asked to supply a single-line unloading system, but often with a higher capacity than just one of the lines specified by TP Utilities. However, in this plant it is possible to unload with both lines at the same time, giving double the single line capacity. In addition the power plant remains operational if only one line is in use.” Speaking about the 2012/2013 installation process, Mr Neo says that the Siwertell surveyors worked well with TP Utilities’ staff to ensure the effective operation of the equipment. TP Utilities has a maintenance contract with Siwertell and seeks specialist support when it is required.

TP Utilities Jurong Island, Singapore Fuel-receiving system MATERIALS HANDLED Coal and biomass SHIP UNLOADER TYPES 2 x Siwertell ST 640-M RATED CAPACITY Coal 1,000t/h / 1,300 m³/h

Biomass 300t/h / 750 m³/h

MAXIMUM SHIP SIZE 12,000 dwt OPERATED FROM Operator’s cabin or portable radio control unit TOTAL WEIGHT 287 tonnes (excluding counter weight) CONVEYING SYSTEM 2 x 1,600mm Siwertell jetty belt conveyors,

with cover belts

10 x 1,600mm Siwertell belt conveyors for coal

1 x 1,600mm Siwertell belt conveyor

for biomass, with tripper

2 x bucket elevators for coal (1,000t/h)

1 x bucket elevator for biomass (300t/h)

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text JÖRGEN OJEDA photos SIWERTELL

Demand for mobile unloaders

is no surprise

Ship unloading

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Siwertell is experiencing a great deal of interest in its mobile unloaders, with a number of recent deliveries and a healthy orderbook.

Jörgen Ojeda, Sales Director, Siwertell mobile unloaders, says this is not surprising, because these versatile machines offer the ideal solution for operators looking for flexible, reliable and efficient unloading machinery for smaller vessels and barges. “We offer three sizes of road-mobile unloader – the largest can handle ships of up to 15,000 dwt. Road-mobile systems offer the highest level of flexibility; the unloader is mounted on a road trailer, allowing it to be used at multiple locations.

“For operators that only need mobility within a single port, we offer gantry mounted versions. These can be equipped with self-propelled rubber wheels or steel wheels designed to run on rails.” Gantry mounting raises the unloader well above the jetty and can improve access to vessels’ holds. Some operators want to take advantage of the unloader technology, but do not need the mobility provided by the trailer and gantry-mounted versions. For these situations, Siwertell offers stationary versions mounted on foundation turrets. As with the gantry mounted units, the increased height is an advantage. The largest stationary 15 000 S model can handle vessels of up to 20,000 dwt.

Market leading mobility along with minimal environmental impact provides operators with the flexibility they need to meet both planned and forced operational re-arrangements Demand

for mobile unloaders

is no surprise

9SIWERTELL NEWS 9SIWERTELL NEWS

Clean, quiet, unloading meets strict local regulations Faxe Kalk, part of the Lhoist Group, is a Danish producer and supplier of calcium oxide. The company uses a Siwertell 5 000 S road-mobile ship unloader for environmentally-sensitive unloading operations in Faxe Ladeplads on the Eastern Sjaelland coast, 80km south of Copenhagen. With the import jetty close to the yacht club and town centre, clean, quiet operations are vital. The terminal imposes the toughest possible emissions requirements and these must be met for the company to carry out its import operations. Thomas Koudal Maul, Process Specialist, Faxe Kalk, explains why the company chose a road mobile Siwertell ship unloader. “There were alternative products, road mobile and also fixed solutions which would have met the terminal’s requirements. The choice of Siwertell was taken based on the results of a trial in Landskrona, the distance to the supplier – which is important for convenient spare parts supply and service; and flexibility – the unit is easy to prepare for unloading and road transportation. We also listened to feedback from other Siwertell users.”

A ‘close to dust-

free’ operation was one of the critical factors in this project, and the noise level was another important issue, given the proximity to

residential areas. Siwertell’s totally enclosed screw type technology and dust suppression measures ensure that dust creation is absolutely minimal.

With regard to noise levels, Mr Maul says that the optimal solution would have been to go for an electrically-driven version of the unloader. However, the company’s anticipated deployment plans for the unloader called for maximum flexibility, so a diesel-driven version was chosen, even though the noise level is slightly higher. To meet the local noise level limits, the unloader was supplied with an optional extra noise absorption hood, which reduces the noise produced by 50 percent.

Siwertell mobile unloader specifications MODEL INSTALLATION MAX SHIP SIZE CAPACITY (CEMENT/GRAIN)

5 000 S Road-mobile trailer 5,000 dwt 300t/h / 240t/h

5 000 S Stationary foundation * 300t/h / 240t/h

turret or gantry



turret or gantry



turret or gantry

*Depends on local conditions and ship design

We’ve used the Siwertell mobile unloader at different positions within the port”

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The real value of flexibility When Faxe Kalk ordered its Siwertell unloader, it also planned to use it in Vejle, a port 235km from Faxe Ladeplads. Mr Maul notes that although the unloader has not been used at Vejle, its inherent flexibility has proved extremely valuable. “It is true that the unloader was also intended to be used at our plant in Vejle. But since we purchased our Siwertell unloader only a few ships have docked at the Vejle plant, so for the time-being we have decided not to take it there. “On the other hand, we have used the Siwertell mobile unloader at different positions within the port at Faxe Ladeplads. On a couple of occasions we have been forced to move our ship unloading operation to the port in Køge, due to ice conditions at Faxe Ladeplads. So the road-mobile solution has proved to be the right choice.” The compact nature of the folded unloader offers important additional advantages when compared to a fixed installation. “The weather conditions on the coast can be hard on all technical installations. When we are not using our Siwertell unloader, we store it inside to protect it from the elements. With a road-mobile machine we can carry out regular maintenance at the workshop. We can also drive it to

Siwertell’s workshops at Bjuv, in Sweden, for inspection and repair, as we did this summer.” Mr Maul has no doubts that folding out the unit into operational mode can be carried out by one person in about 30-45 minutes. However, Faxe Kalk prefers to take its time, using the process to carry out greasing, inspection and any necessary adjustments. During fold down, it carries out additional cleaning. Generally speaking, the transitional processes are carried out by the machine’s operator and one person from the maintenance department. He would be happy to recommend Siwertell road mobile unloaders to other operators. “The wear of the machine is lower than we expected; and service and support from Siwertell is good.” Road-mobile unloaders for Libyan reconstruction projects Turkish construction services company Mussa Insaat Dis Ticaret Ltd of Istanbul has recently taken delivery of a Siwertell 10 000 S road-mobile unloader, with another two similar units on order.

11SIWERTELL NEWS

They will be used at a number of Libyan ports to unload cement needed for the country’s reconstruction programmes. The company says it always carefully reviews the market to make sure that it is buying the best machine possible. It trusts Siwertell’s 40 years of experience and appreciated the understanding and flexibility that Siwertell displayed with its orders. Mussa says it expects to return to Siwertell next time it needs a new machine and would recommend Siwertell to other organisations engaged in similar business. Continuous through-the-ship unloading performance In common with many other Siwertell road mobile deliveries, Mussa’s unloaders are all equipped with a double bellows system and dust filter, ensuring that they deliver consistently high levels of efficiency and environmental protection. Road mobile unloaders normally discharge directly into rail wagons or trucks. The double bellows system means that there is no need to halt the unloading process when a truck or wagon is full. Unloading continues at full speed and the stream of cargo is seamlessly transferred to an empty wagon or truck. The sequence of transfer between trucks or wagons continues throughout the discharge; an automatic shifting option is available. In combination with the well known continuous operation of the Siwertell screw-type unloader, this ensures impressive through-the-ship discharge rates. Hazardous cargoes Siwertell road mobile unloaders are often specified for handling sulphur; their dust and spillage free properties make them ideal for this application says Mr Ojeda. “When handling sulphur a dangerous environment can develop,” he explains. “A critical mixture of dust and air could lead to an explosion or fire. Therefore we equip the unloaders with our

4S features – Siwertell Sulphur Safety System, along with ATEX-classified electrical and hydraulic components. “Our road mobile unloaders are also popular for biomass handling. Biomass can be very dusty, consequently it can also present the risk of explosion or fire, so we equip the unloaders with appropriate safety features adapted from 4S.” Mobile unloader boosts unloading efficiency in Trinidad The majority of Siwertell mobile unloaders are used for the complete discharge of a vessel’s cargo. In contrast, Nutrimix Feeds Ltd employs its 2014-delivered ATEX-classified 15 000 S trailer based road-mobile unit to enhance the unloading operations of self-unloading bulk carriers in Point Lisas, Trinidad. Nutrimix says that wheat, corn and soya meal is delivered in vessels up to about 14,000 dwt equipped with their own grab cranes. Its mobile unloader complements the grab cranes, increasing overall unloading efficiency. The Siwertell unloader is used approximately every six weeks. Nutrimix chose a Siwertell machine because its design is more appealing than alternative products and it is more durable. Most competitors offered pneumatic solutions. Mr Ojeda says this is an interesting application for a road mobile unloader. “Grab cranes do not have the manoeuvrability of a Siwertell machine. By incorporating a road mobile unloader in its discharge process, Nutrimix can significantly improve its through-ship unloading efficiency. In particular, the time and effort needed for final clean up will be considerably reduced.”

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Sound levels

Outdoor noise on the walkway between quay and operator cabin: Lp 78 dBA (max level) Indoor noise operator cabin: Lp 50 dBA Total sound power level ship unloader: Lw 104 dBA

Siwertell’s reputation for environmentally-friendly solutions extends beyond clean, dust-free operations, says Ola Johansson, Technical Project Manager for Siwertell. “Our loaders, unloaders and conveyors can be designed to be quiet machines, and this provides a good working environment for the crew and dock workers.” Local, regional and national rules and regulations regarding acceptable noise levels mirror those relating to atmospheric pollution from dry bulk handling; they are becoming more widespread and the limits are generally becoming tighter.

“Our customers’ specifications for ship loaders and unloaders often include noise restrictions that the machines must comply with. These requirements vary in terms of indoor and outdoor locations and distance from the machine.

“The growth of ports and the increasing populations of port towns and cities means that cargo handling machinery is often used very close to residential and business areas. These situations naturally set the highest environmental standards,” notes Mr Johansson . ”We take these requirements into consideration early in the design stage of a Siwertell machine and we have already made a number of deliveries that comply with customers’ special audio requirements.” Siwertell recently commissioned a Swedish urban planning consultancy and acoustics specialist to carry out noise mapping tests at a number of points around the Siwertell screw-type unloader at Dong Energy’s discharge berth in Copenhagen, Denmark. The noise level inside the operator’s cabin was also measured.

Quiet unloaders

Noise mapping confirms that Siwertell screw-type unloaders can meet strict environmental regulations

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L Dong Energy is majority owned by the Danish Government and its 2013-delivered Siwertell unloader handles coal and biomass for the company’s Avedøre multi-fuel power station. Mr Johansson says that the test results were very satisfactory and showed that ship and shore personnel benefit from a pleasant working environment.

“Environmental regulations will inevitably have an increasing impact on dry bulk handling operations. They vary from port to port and from one part of the world to another. The strictest rules we have encountered so far are in California, but there are many other places in the world where rules are very strict; generally relating to ports close to major cities and residential areas. Rules tend to be more relaxed for ports located well away from cities and residential areas. However, it is not a static situation. New and stronger rules are appearing in many places around the world.

“I am confident that our development programmes will ensure that we stay ahead of regulatory revisions,” he adds. “This is also good news for companies operating existing Siwertell equipment because any measures developed to meet stricter rules will be offered to them as upgrades if they need them.” If you are faced with strict environmental regulations, please contact us and we will be happy to develop an efficient, economic and reliable solution.

make good neighbours

13SIWERTELL NEWS

There can be no one-size-fits-all for very large machinery; Lars-Eric Lundgren, regional sales manager for Siwertell, explains how close cooperation with customers during the design process delivers the best value from their tailor-made Siwertell loaders

While we are probably best known for our screw-type unloaders, Siwertell ship loaders are in use across the globe, demonstrating the same market leading

standards of performance, reliability, efficiency and cleanliness. This is only natural, as Siwertell ship loaders exploit many of the technologies we have developed for our unloaders over the past 40 years. Clean, environmentally-friendly operations have always been a major goal in our development of dry bulk handling equipment. Many of our competitors design loaders with open belt conveyors to transport

Tailor-made

quality

Ship loading

solutions deliver

text LARS-ERIC LUNDGREN photos SIWERTELL

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quality

the bulk material from its storage area or the truck/wagon station. Our goal when using belt conveyors is to design enclosed systems wherever possible. Our screw conveyors are always totally enclosed; as are many of our other products. For some types of inherently dusty dry bulk material, it is appropriate to equip a loader with a suitable loading spout from our specially-designed range. The cargo is then totally enclosed from the transfer point at the jetty conveyor, all the way out and into the ship’s holds, keeping dust creation to an absolute minimum. For some damper materials a loading spout is not necessarily required. The well-balanced design of our loaders can save customers a great deal of money in preparatory civil engineering works on new and existing jetties. Tailor-made design All our loaders are tailor-made; there can be no one-size-fits-all for machinery on this scale. In close cooperation with a customer, we build a comprehensive picture of their operational requirements, now and in the future. We consider all relevant local aspects, which may be regulatory or related to space limitations. With all this information to hand, supported by our extensive experience, we propose an optimal installation, taking advantage of the range of proven conveying technologies available to us.

There can be no one-size-fits-all for large-scale machinery”

A rail-travelling loader offers the most efficient loading; if the travelling length is adequate it can reach all of a ship’s holds with no need to shift the vessel. To achieve maximum efficiency, a travelling loader should be fed by a jetty conveyor, either through a tripper car

or through shuttling jetty conveyors. However, we can supply loaders with varying degrees of manoeuvrability to reflect a customer’s requirements and budget. Stationary loaders require a ship to shift along the jetty during loading operations. This naturally reduces efficiency, but the operator benefits from lower investment costs for the loader and significantly reduced civil engineering costs. With a slewing loader, the horizontal arm can

move over a range of typically ±110°, allowing it to reach into the hold to spread the cargo reasonably well. A scissor-arm conveyor has the added benefit of a second arm which also has the ability to slew through ±110°, independently of the first arm. This configuration provides a significantly better reach into all parts of the hold and enables loading to take place with closed hatches via a few dedicated loading openings. It also reduces the need for shifting the vessel along the jetty. A telescoping arm allows the loading spout to be directed to a number of positions across the width of the hatch opening. Telescoping can be combined with slewing and gantry-travelling systems to provide even greater positional flexibility for the spout.

Conveying technologies with Siwertell ship loaders Siwertell ship loaders are offered with three different types of conveying technologies, depending on the material to be handled. For example the screw-type is primarily for powdery materials such as cement, sulphur and minerals. The aeroslide conveyor is for fluidised materials such as fly ash and alumina. The belt conveyor is ideal for lumpy, granular and sticky materials, such as fertilisers, coal and iron ore.

Screw-type and aeroslide conveyors are totally enclosed, while belt conveyors can be provided as enclosed systems to minimise dust creation.

As far as we are aware, Siwertell is the only company able to offer all three technologies.

15SIWERTELL NEWS

In 2012 the international mining and materials company Arrium (formerly OneSteel) undertook a major port expansion project with the primary aim of doubling its iron ore export sales to 12 million

tonnes per annum. Among other things, the project called for a new storage facility and berth equipped with a new high capacity Siwertell ship loader. “The shiploader has been in operation since July 2013 and is meeting all of Arrium’s performance specifications,” reports Paul Saliba, Strategic Sourcing Manager for Arrium Mining and Materials. “The project was successfully completed on time and on budget, despite a short lead-time, which was critical to meeting Arrium’s business objectives.” Arrium’s 4,200t/h capacity loader is designed to load directly into bulk vessels of up to 45,000 dwt, the largest that can use the Whyalla terminal. It is also used to load iron ore into two self-unloading transfer barges that take the ore out to a transhipment vessel located in deeper water. From here the cargo is loaded onto Cape-size vessels, primarily for export to China. The floating transfer terminal and the self-unloading transfer barges entered into service in 2007. The loader has one shuttle belt conveyor without any transfer point; its shuttling motion combined with the loader’s travelling capability means it can reach all corners of a vessel’s holds so there is no need to move a vessel during loading. This technology achieves the cleanest possible type of cargo transport from the shore all the way out and into the ship’s hold. Mr Saliba says Arrium was influenced by Siwertell’s proven design expertise for dry bulk material handling equipment, particularly for higher capacities, supported by extensive references. “We were impressed by the proven technical and customer support, including the extensive fault diagnostic system. The measures to limit dust and spillage were very important in complying with our environmental operating licence and protecting the local community.”

Siwertell ship loadersCustomer case studies:

AUSTRALIA

16 SIWERTELL NEWS

Also in 2012, a high-efficiency Siwertell loader entered operations for leading Lithuanian stevedoring company Bega as part of its major agri-bulk hub terminal development at

the Baltic port of Klaipéda. Laimonas Rimkus, Bega’s Technical Director, explained the reasons for making that choice, noting that the advantages and efficiency of a Siwertell ship loader had been well demonstrated by an existing Siwertell loader which Bega had been operating since 2002. “Before the acquisition of a new Siwertell ship loader for the Universal agri-bulk export-import terminal, Bega had already operated a similar Siwertell ship loader at the fertiliser terminal. So the decision was made in the light of good experience gained and the results achieved.”

He says that any initial problems with the new loader were resolved by qualified Siwertell personnel during the testing period

and the company is satisfied with the performance of its loader. “This year we’ve reached full loading capacity, loading Panamax and post-Panamax-type vessels with grain and other agricultural products. This September the

post-Panamax-type vessel Piera was loaded with a record amount of Lithuanian export grain, 74,000 tonnes; the biggest in the history of the Port of Klaipéda. It took a little more than four days, at a rate of 17,000 tonnes/day. During the grain export season, Bega accepts large-tonnage vessels for loading grain every week. “So far we have not had any

problems with loading vessels or the fulfilment of cargo plans,” notes Mr Rimkus.

This year we’ve reached full loading capacity”

T he Siwertell ship loader operated by port logistics specialist, Luka Koper, meets the loading needs of Koper, Slovenia’s largest coal-importing port and recent winner of the

2014 European Sea Ports Organisation’s award. This year the award focused on innovative environmental projects and recognises Koper’s work in creating a sustainable future for the port and its surroundings. The port receives about four million tonnes of coal a year. Luka Koper stores the coal and arranges its export to neighbouring countries in Europe. The 2010-delivered ship loader has a peak maximum capacity of 2,300t/h. Luka Koper made several design specifications to meet its specific needs. The loader had to have as small a footprint as possible when stationary;

the loading chute needed to be able to move towards the jetty, between the two rails, for easy maintenance; a single belt had to run from the shoreside loading point all the way out to the loading bellows, and the conveyor had to be fully retractable. All transfer points had to be equipped with a water spray system to lower dust emissions. Ivo Krnel, Investment Manager at Luka Koper, says that the loader has had no problems meeting its performance criteria. The company did experience some issues with wear on the chain for the telescoping boom, and an order has been placed for a replacement. “In the warranty period we had good cooperation with service personnel,” adds Mr Krnel.

LITHUANIA SLOVENIA

17SIWERTELL NEWS

Analysis

18 SIWERTELL NEWS

About 900 million tonnes of coal is transported by sea every year for electrical power generation.

But what do we mean by a tonne of coal? Coal comes in a range of grades that are determined by its properties, including calorific value, along with sulphur, ash and moisture content. Naturally, these variations are reflected in price differentials and these can be dramatic. Optimisation of the buying process can create huge cost savings. However, there are a number of factors related to the total price you pay to have the coal in your stockyard and these should take into account the energy value you have received for the money you have spent. Is it possible to justify the higher price you must pay for higher kcal coal, or is the trend to buy lower kcal coal for a much lower price the right decision for the profitability of your power station?

This article is an attempt to identify the best coal purchasing policy for a power station owner seeking to maximise profitability, while minimising environmental impact. There is much more to consider than just the price and calorific value of the different grades of coal. The basis for this article and my calculations is the Indonesian Coal Index Report (issue 033), released on August 15th this year. Although it relates to Indonesian coal, it can easily be applied to all other types of coal from producers around the world. Looking at table 1 (next page) it is not difficult to understand why ICI 5 coal looks commercially attractive. You can buy more than three tonnes of ICI 5 coal, which together gives you 10,200 kcal, for 2.94 USD less than you would pay for one tonne of ICI 1 coal that gives you 6,500 kcal. However, ICI 5 coal needs a power plant with a process capable of handling the high moisture content, and this means it is more expensive to build compared with a power station

If you need coal for your power plant, why buy water and then pay to transport it across an ocean? Per Karlsson, President of Cargotec Sweden Bulk Handling AB (Siwertell), examines data from the latest issue of the Indonesian Coal Index Report to highlight factors that should influence an optimum coal supply policy

Coal supply: why buy

water?text PER KARLSSON photos SIWERTELL

19SIWERTELL NEWS

intended for higher kcal coal. Even so, on paper this seems easy to justify, since you pay less for the coal and get more kcal; and kcal is what in the end generates the kWh. But there are more factors to be considered, including freight costs, operational costs and maintenance costs; these all reflect the much greater volumes of coal you will need to handle. Determining the real cost If we consider a power station importing two million tonnes of coal per year, the value of ICI 1 coal is 146,750,000 USD, compared to 46,960,000 USD for ICI 5 coal. This gives a saving of almost 100,000,000 USD, which makes ICI 5 look like the best deal. But everything will be drastically changed in our calculations of the operation and its net profitability if we start to consider and compare the actual kcal purchased in relation to the volume handled. Let us say the coal has a sea-transportation time of seven days, including loading and unloading time, via Panamax vessels. The 2,000,000 tonnes of coal is related to the maximum kcal (ICI 1) that can be bought from an Indonesian coal supplier; that is 2,000,000 x 6,500 = 13,000,000 kcal. From table 1 you can see that low kcal coal always has a greater moisture content than higher kcal coal. This applies for all

types of coal from anywhere in the world. Table 2 shows, in simple terms, the effect of moisture content on the price per kcal. It makes ICI 1 coal look the most attractive, but this is not the end of the story. Transportation, operation and maintenance costs must also be considered to come to a valid final result.

The ICI 5 coal has a moisture content of up to 50 percent. Even though the value is only about a third of the high grade coal, the moisture content creates a volume problem because you have to pay for the transportation of the water content. In addition to this you have to pay for the drying process necessary to get the coal into a suitable condition for burning. It is also worth noting that high moisture content coal presents unloading and handling problems. Grab, bucket chain and screw type unloaders all experience clogging problems since this type of mud has the consistency of a snowball.

The problems continue all the way up to the furnace and in the furnace itself. However, when the coal starts to look like a slurry the Siwertell unloader works without any problems. It’s like handling water. Table 3 shows the effect on calculations when all these different factors are taken into consideration. It indicates the best type of coal to buy when targeting the outcome in terms of the price per kcal at the point of burning in your power plant instead of the price per tonne at the loading port. With a targeted kcal per year figure adjusted for the total moisture content of the coal, table 3 shows that the ICI 1 coal will have a cost benefit varying from 7,200,000 USD to 31,500,000 USD per year.

The ICI 5 coal could not even be considered, because the number of unloading days required exceeds the number of days in the year. Considering the moisture content impact of the coal handled you can see that buying coal with a high moisture content is certainly not so good for business if you take into account the actual

kcal you get from the coal.

Table 1 - The Indonesian Coal Index Report (issue 033) highlights the significant differences between the top and bottom grades of coal Grade (kcal) CV Price (USD) Sulphur content Ash content Moisture content

ICI 1 6,500 73.38 up to 1 % up to 12 % up to 12 %

ICI 2 5,800 63.41 up to 0.8 % up to 10 % up to 18 %




Table 2 - Simple comparison table showing the cost per kcal after taking moisture content into consideration ICI 1: USD 73.38/MT*1,000 kg / 5,720 kcal/kg = USD 12.83/kcal ((low moisture content)ICI 2: USD 63.41/MT*1,000 kg / 4,756 kcal/kg = USD 13.33/kcal ICI 3: USD 51.12/MT*1,000 kg / 3,500 kcal/kg = USD 14.61/kcalICI 4: USD 37.20/MT*1,000 kg / 2,520 kcal/kg = USD 14.72/kcal

ICI 5: USD 23.48/MT*1,000 kg / 1,700 kcal/kg = USD 13.81/kcal (high moisture content)

20 SIWERTELL NEWS

Table 3 - Cost calculation for buying coal in relation to kcal

Download this chart, type in your own numbers and calculate how much you can save. Find it at siwertell.com

*Gross as received

*

*

*

21SIWERTELL NEWS 21SIWERTELL NEWS

Calculations are also carried out, taking the ash content of the coal into consideration, bearing in mind that the ash is not worth anything in the handling process. The outcome of the calculations is then changed as you can see from table 3. Even in this case, it still makes good business sense to target the high kcal coal. It should be noted that there is high kcal coal on the market with a low ash content, so this particular comparison then produces a different result. A low ash content value would further support the case for high kcal coal. A new dimension for coal purchasing In summary, there are a number of factors to be considered if you want to improve the profitability of a power station. One of them is the process of buying the right coal. The calculations here show that it is not always as easy as you might think to make the correct

decisions. Perhaps this article will create a new dimension for this process, where factors other than just the price of the coal itself will be considered to show that there are huge cost savings to be made by understanding all the interlinked factors. Ultimately, you get what you pay for. It would be very interesting to have your comments on this article; perhaps you can confirm our assumptions, or point out that we have missed some element of the coal handling/power generation business that makes it more complex than it seems? We would be very happy to provide you with a memory stick containing our calculations so that you can enter the relevant figures to see the full impact on your own operation.

22 SIWERTELL NEWS

Say goodbye to crushing, dust, spills,

and additional fines in

alumina unloading

Take advantage of a free demonstration at your facility and let us show you what

advanced alumina handling really looks like.

Contact us for more [email protected]

1974 201440YEARS

23SIWERTELL NEWS

Siwertell solutions are marketed across the world, supported by the efforts of a network of dedicated local and regional representatives. Although united by a common purpose, these people

rarely, if ever, meet in the normal course of their work. “At Siwertell, we benefit from a wonderful sense of loyalty and collective endeavour and this is part of the reason that we hold a meeting for all our representatives every two years,” says Per Karlsson, President, Siwertell. “While there are sound business reasons for these events, we also see them very much as ‘Siwertell family gatherings’, where friendships can be made and renewed and we can all gain a greater sense of our global activities and the cultures in which we operate.” The most recent meeting was held in Copenhagen, Denmark in

May this year. The event included a one-day conference, a site visit to the Siwertell ship unloader at Dong Energy in Avedøreverket and a number of workshops. In response to requests from some

Siwertell representatives at the 2012 event in Croatia, plenty of time was allocated for networking. “As this is Siwertell’s 40th anniversary, there was naturally a celebratory atmosphere, with a seminar highlighting important events and milestones in the brand’s 40 successful years,” says Mr Karlsson. It is always good for company morale to hear from an appreciative customer, so an extremely positive presentation from Jim Gatens, President of the Houston Cement Company, made a powerful impression. Mr Gatens is in no doubt about the

operational, environmental and economic benefits of owning and operating a Siwertell unloader. His company’s Siwertell unloader was commissioned in August 2006; as expected, all guarantees were met including an impressive 1,050t/h through-ship figure,

Biennial meetings of Siwertell representatives not only serve as a platform to gain a greater sense of global activities, they also have the feel of a happy, productive family gathering

There was definitely a

celebratory atmospere as Siwertell turns

40 this year”

Networks

text PER KARLSSON photos SIWERTELL

Global get-together

builds better business

24 SIWERTELL NEWS

Dominique Faath (France)

Team activity at the conference

Fredrik Gustavsson, Siwertell Surveyor

1

2

3

1 2 3 4

Valentin Bulkin (Ukraine) Jong Sung Kim (S. Korea)

4

excluding final clean-up. “Since then we’ve unloaded a total of 6.2 million metric tonnes from 152 ships of all sizes,” he said. “The unit averages approximately one hour of mechanical delay per vessel.” Total cost savings resulting from employing the Siwertell unloader – freight, electricity and manpower – are in the $4.00 per tonne range. Over time, he says, these cost savings are quite substantial. Biomass handling is set to be a growth sector, so the presentation about Dong Energy’s Siwertell unloader at Avedøre power station – handling both coal and biomass – was particularly relevant. Dong Energy says the reasons for choosing a Siwertell unloader included low noise, the ability to unload in the rain as a result of the enclosed system, lower operational expenditure

than alternative solutions and the ability to contain high levels of dust. That final quality must be particularly appreciated; Dong Energy says two out of three loads of wood pellets have exceeded the dust specification. In summary, Mr Karlsson says the event was a great success, offering a good balance of informative presentations, pleasant social events and rich networking opportunities. “It is always a pleasure when we can all get together like this. I look forward to the next meeting, when I expect that we will have plenty to discuss, including feedback on new products such as our very high capacity unloaders and loaders.

Site visit to Dong Energy, Avedøreverket, Denmark

Nga Hoang (Vietnam) and Stephanie Dong (China)

25SIWERTELL NEWS

Latest news

From the left: Jörgen Ojeda, Director, Siwertell mobile unloaders, Ufuk Erden, Technical Consultant, Tracim Cimento San. A.S and A. Zeki Cicim, General Director, Mussa Insaat Dis Ticaret Ltd Sti

The Turkish construction services company Mussa Insaat Dis Ticaret Ltd of Istanbul has ordered a further road-mobile Siwertell 10 000 S cement unloader. The trailer based, diesel powered unit will have a rated discharge capacity of 300t/h and will be equipped with a dual bellows system and dust filter. “This is the third road mobile cement unloader order for the same customer within a very short period,” says Jörgen Ojeda, Director for Siwertell mobile unloaders. “It will take its place in our customer’s cement unloading operations at several sites along the Libyan coast, helping to meet the demand for cement needed for the country’s extensive rebuilding programmes. The customer ordered this third unloader to further strengthen its position on the Libyan market. “This repeat order indicates a very satisfied customer that appreciates the well known reliability of Siwertell mobile unloaders, along with their high unloading capacity and low operational and maintenance costs,” adds Mr Ojeda.

Autumn 2014

Three orders in a row

Power station expansion projectSiwertell has secured an order for a rail-travelling unloader from South Korean company Daelim Industrial Co Ltd. The unloader has been ordered as part of an expansion programme at Pagbilao coal-fired power-generation plant in the Philippines, and is scheduled for delivery in October 2016.

“To meet growing power demands, the Pagbilao plant is expanding and requires a high-efficiency, environmentally-friendly coal unloader; these are some of the main attributes of a screw type Siwertell unloader,” says Ola Jeppsson, Siwertell Sales Manager. “In addition, Siwertell unloaders offer very high levels of reliability, by virtue of their well proven technology.”

Pagbilao Energy awarded the contract for the site’s third coal-fired unit to a consortium comprising Mitsubishi Hitachi Power Systems Ltd, Japan and Daelim, responsible for the project’s coal handling system.

“The ST 790-D unloader is designed to discharge coal from vessels of up to 92,500 dwt at a rated capacity of 1,400t/h. With its continuous operation, it will offer an unbeatable through-the-ship capacity while delivering environmentally-friendly operations with minimal dust and no spillage,” says Mr Jeppsson.

The Pagbilao site currently has two non-continuous unloaders. “For this latest expansion, the owner wanted a more efficient type of unloader, and decided that a screw type unloader would meet all its needs,” he explains. “We are the number one supplier of screw-type unloaders. Furthermore, Siwertell is a very well-known brand in the Philippines because of

26 SIWERTELL NEWS

Latest news

New cement facilitySiwertell has received an order from CITIC Heavy Industries Co Ltd (CITIC) for a rail-travelling ship unloader. CITIC is one of China’s largest conglomerates, headquartered in Luoyang, Henan province.

The ST-640 M-type unloader has been ordered to support the energy production requirements for a new cement production facility in Burma/Myanmar and will unload coal from barges at a rate of 800t/h. The facility is being built as part of a collaboration between CITIC and the Thailand-based Siam Cement Group subsidiary, Mawlamyine Cement Ltd (MCL). CITIC states that the new production plant will have a cement capacity of 5,000 tonnes per day.

“This order has special commercial significance for Siwertell as it will be the first delivery to Burma/Myanmar,” says Ola Jeppsson, Siwertell Sales Manager. “MLC will benefit from all the excellent attributes of our Siwertell unloaders including efficiency and quiet, safe, environmentally-friendly operations without dust or spillage.”

The delivery is scheduled for mid-2015, and will include an enclosed discharge arrangement for transferring

coal to the jetty conveyor. The unloader will be delivered in pre-assembled parts, with final assembly, testing and commissioning taking place on site at Mawlamyine.

Five-year service contract signed Siwertell has commenced a five-year service contract with Masinloc Power Partners Co Ltd in the Philippines. The Level 1 Siwertell Support Care Agreement relates to two Siwertell ST-790D ship unloaders, installed in 1997 and used to discharge coal, initially at a rate of 800 t/h each. Masinloc Power Partners is part of the AES Corporation, a global power company providing energy to customers in 20 countries. Previously, Siwertell had a reactive service arrangement with Masinloc Power Partners, supported by pro-active sales and recommended actions.

Operations and Sales Manager for Siwertell services, Daniel Frostberg, says: “I am confident that this new service agreement will improve the unloaders’ reliability and provide a cost-effective way to ensure that the owners benefit from years of continued efficient coal discharge. “Siwertell unloaders and loaders are designed to deliver reliable operations over a long service life,” he continues. “However, they work in exposed environments and naturally require an appropriate degree of care and maintenance. Regular inspections by our surveyors – ideally as part of a Siwertell Care agreement – ensure that unloader settings are optimal and the highest possible operating capacity is maintained.” Siwertell carried out major overhaul work on the unloaders

Learn more about Siwertell Care,

its modules and levels at

siwertell.com

the many deliveries and references we have in the country. Consequently, we have a very good local reputation.”

The unloader will be completely assembled before delivery at the premises of a Siwertell subcontractor in Nantong, China. It will then be shipped in one piece to the Philippines. Final testing, commissioning and training will be carried out by Siwertell engineers on site.

“There are plans for several new coal-fired power plants in the Philippines, along with more expansion projects for existing plants. Therefore, this market is very important for us now and over the coming years,” Mr Jeppsson adds.

in 2008 and 2009, resulting in reduced turnaround times for ships. “However, last summer, in the light of normal, progressive deterioration, we began discussions about an optimisation plan through a service agreement, with a planned schedule of maintenance, supply of parts, upgrade of the PLC/HMI system, along with a capacity increase to 1,200t/h per unloader,” Mr Frostberg notes. Machine owners and operators differ widely in the levels of in house technical expertise and resources available to them; so there can be no standard fit when it comes to service agreements. Siwertell provides its customers with all the advice necessary to put together the ideal package, incorporating elements from five modules.

27SIWERTELL NEWS

For sale

The machine is still for sale, and interested parties can contact Mr Dahrough, Terminal Manager, for

further information [email protected]

text KARI LEPPÄNEN photos SIWERTELL

AND relocation

the business, the ship unloader was no longer required on site, says Ossama Youssef Dahrough, Terminal Manager at Damietta port. “With its terminal in Damietta closing, our customer contacted us for help regarding dismantling its ship unloader in the most effective way,” explains Kari Leppänen, Senior Surveyor for Siwertell. “The customer’s intention for the unloader was to dismantle it into sections that could be removed from the site in trucks. Then it would be prepared either for long-term storage or for resale. “We developed a suitable plan in consultation with our customer. It went very much according to schedule and by June this year the dismantling process had been completed in just sixteen days, including pre-inspection. We didn’t encounter any major issues.” Initial visual inspection of the unloader showed that the equipment was in generally good working condition, even though it is sixteen years old. “When it comes to dismantling a Siwertell unloader and getting it ready for re-assembly and work at another site, we are the best people to consult,” said Mr Leppänen. “We are the only company with access to all the original documentation, design calculations, drawings and specifications, for example. We know our machines better than anyone else, and we can provide definitive information about any necessary repair work. We are also able to inform the new owners about the upgrades needed to bring it up to the latest Siwertell standards before re-installation in a new location.”

Ready for resale,

When a Siwertell unloader becomes redundant at its installed site, Siwertell’s versatile service surveyors can advise on dismantling, storage and any repairs and upgrades necessary to prepare it for resale or eventual re-commissioning

In an ideal world, a major piece of machinery such as a Siwertell unloader would see out its long service life doing the job for which it was purchased, at

its original construction site. But things do not always work out quite as planned. Over time, operational requirements may change, requiring equipment upgrades. In some cases, the machinery may become redundant at its original operational site, even though it may still be good for years or even decades of efficient operation. This was the case with the stationary Siwertell F-type ship unloader which was installed at Cemex’s El Fahd terminal in the port of Damietta in Egypt in 1998. The unloader had been used to discharge cement at a rate of 800t/h, but with the closure of

reassembly

Service

28 SIWERTELL NEWS

“If the machine is to go into long-term storage, we can advise on measures necessary to minimise deterioration during this period,” notes Mr Leppänen. “We strongly recommended that if and when the unloader is reassembled, the owner – or new owner – should again contact Siwertell to find out what needs to be installed, adjusted and checked before the machine is taken back into operation. This will ensure safe, efficient operations and should deliver a long, trouble free second phase to its service life. “To assist Cemex in selling the ship unloader for further use, Siwertell Service department can advise and answer technical questions about the machine. Siwertell can, on request and with a suitable contract in place, send a surveyor for inspection work and to help with reassembly of the unloader.”

29SIWERTELL NEWS

When a major piece of machinery is in almost constant use, reliability is essential and any downtime for maintenance must be carefully planned and effectively handled.

Akçansa is a leading Turkish cement company; its terminal at Çanakkale employs a Siwertell shiploader. “Our ship-loading traffic is very high; we exported 862,000 tonnes of clinker and 877,000 tonnes of cement last year. Consequently there is no free time for the ship loader,” says Ozan Kırkgöz, Akçansa Mechanical Maintenance Supervisor. “Because of this, the reliability and speed of the shiploader is vital for us.”

When Akçansa detected signs of wear in the ship loader’s slewing bearing earlier this year, it immediately contacted Siwertell, who recommended some initial checks and precautions. This was quickly followed by a visit from Siwertell surveyors who confirmed that the slewing bearing needed to be replaced. The ship loader continued in use while a plan was formulated for bearing replacement and other overhaul elements. The plan recognised the terminal’s busy schedule and the need to manage downtime very carefully.

Expert attention

text PER ANDERSSON photos SIWERTELL

Limited time for maintenance means that busy operator Akçansa relies on the proven longevity of Siwertell systems, regular maintenance and the carefully-planned replacement of essential components

minimisesdowntime

Service

30 SIWERTELL NEWS

From the left: Per Andersson (Siwertell), Jim Little (Siwertell), Ozan Kirkgöz (Akçansa) and Süreyya Güler (Akçansa)

Per Andersson, Siwertell Services Surveyor, says the work on the unloader was carried out as quickly as possible, employing a shift-work system. “In addition to the slewing bearing exchange, accumulated cement was cleaned from the unloader to reduce stress on the structure. All wire locks were renewed and the pipe for the horizontal arm was exchanged. The dust filter equipment and pipes were cleaned and new filter bags installed.” “Before leaving Turkey, we discussed the work we had carried out with Akçansa personnel and suggested some measures to improve maintenance, including an annual inspection agreement.

We thanked Akçansa for the excellent co-operation of its staff throughout the overhaul.” Mr Kırkgöz says that, in line with the plan, the Siwertell surveyors, assisted by Akçansa personnel, carried out the bearing replacement and other overhaul work in ten days: “I had a chance to work with the Siwertell team during our shiploader’s overhaul,” he says. “They paid attention to even the smallest details and wanted everything to be perfect. When we had some small misfortunes, the Siwertell team supported us as fast as they could.

31SIWERTELL NEWS

We also developed a friendly relationship with the team; I felt that we had been working with them for many years.” Importance of proper maintenance Mr Kırkgöz says that regular and preventive maintenance is the most important factor in maximising the service life of a machine; it prevents big surprises for maintenance teams, along with the associated long stoppages. He sees a clear analogy between earthquakes and maintenance. “I equate small earthquakes to regular maintenance. If a small earthquakes happens, the

accumulated energy in the ground releases slowly and nobody gets hurt. But if these small earthquakes do not happen, a big earthquake hits and causes substantial damage.” Until Siwertell was called in for specialist assistance with the bearing replacement, Akçansa had carried out its own maintenance procedures, but this is about to change. “From now on we want to benefit more from the expertise of Siwertell and we will request a periodic check every year.”

He says that in addition to safety and efficiency benefits, regular maintenance has direct environmental advantages. Akçansa has been identified as an environmentally-friendly company through an award presented by the Istanbul Chamber of Commerce. “Our Siwertell loader meets all relevant current environmental requirements, but we’ve noticed, especially after the last overhaul, that there is no dust during cement loading. Both our loading team and ships’ crews are happy with the result. I also believe that it can meet much stricter requirements in the future.”

32 SIWERTELL NEWS

Akçansa’s Siwertell ship loader at Canakkale was installed in 1993, loading cement at 800t/h. It also operates a ship unloader in Istanbul installed in the same year. Mr Kırkgöz says Siwertell’s excellent reputation for the longevity and reliability of its equipment is well deserved. “We’ve used our Siwertell ship loader for a very long time and during that time we’ve only changed wear parts and now the slewing bearing. After the last overhaul, it looks like a brand new machine.” He goes on to say that as the shiploader is almost constantly in use, the company finds very limited time to undertake maintenance procedures; nevertheless its performance and reliability are very good, with very high efficiency. He expects that it will remain in use for a very long time, undergoing regular maintenance and the periodic replacement of wear parts. Active in the Marmara, Aegean and Black Sea regions, Akçansa is one of Turkey’s leading cement companies, supplying 10 percent of the country’s cement demands and handling 12.5 percent of the country’s total cement and clinker exports. Akçansa says that it maintains its leading position through its outstanding service approach and facilities equipped with the latest technology.

Good experience

with a hard working loader

From the left: Süreyya Güler (Akçansa), Lars Skog (Milenko), Ozan Kirkgöz (Akçansa) and Per Andersson (Siwertell)

33SIWERTELL NEWS

text

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Effective training is very important for any type of industrial plant; Siwertell machines are no exception. Properly trained operators follow safe, efficient

working practices and minimise the risk of damage to the machine. Training for those responsible for maintenance helps to maximise a machine’s service life, while minimising downtime. It also helps to eliminate start up problems for new operations. “Siwertell places great emphasis on training and will make every effort to deliver it in an effective

Training:the key to safe, smooth operationsSiwertell surveyors give 100 percent to ensure local operators are well equipped to get the best from their equipment; training can be included as an element of a Siwertell Care agreement

manner, regardless of the circumstances,” says Örjan Westerberg, Siwertell Surveyor. “Our recent Siwertell training activities in Brazil demonstrate the flexibility we can offer our customers in non-standard situations.” In 2010, Siwertell delivered the component parts of a D-type unloader to the Brazilian power generation and trading company, Eneva. Intended to unload coal for the company’s new 360MW thermoelectric plant at Itaqui, the unloader was not assembled until 2013.

Training

34 SIWERTELL NEWS

Although some training took place in 2013, when the unloader was taken into commercial operation earlier this year, Eneva’s personnel at Itaqui did not have sufficient expertise to operate and maintain the machine effectively. Therefore, Siwertell was asked to undertake the necessary theoretical and practical training. As the unloader was operational during this period, Siwertell experts also took care of the cargo operations through an attended operation arrangement. “These were not the easiest conditions for training, especially as grab cranes were also involved in the discharge,” Mr Westerberg says. “There were also problems with the customer’s conveyor belt used to transfer coal to the power plant. However, we managed to put all this enforced downtime to good purpose by using it to train operators in maintaining the unloader. “When there was no ship on the berth, we continued with a simulated training programme. We taught the operators how to use all the movements available and they were instructed in running the vertical inlet in different patterns and at different levels.”

“The training programme ended in June as, by then, six local operators were competent in all aspects of unloader operation. Eneva had gained valuable insight into the importance of effective maintenance, and its relevant personnel had achieved a good level of competence. “The need for initial operator training is obvious, and it can be very useful to refresh operators’ skills after a few years, and will increase the level of safety on site. Training should also be offered when there is a crew change.” “Sometimes it can be difficult to convince owners that they need to give equal consideration to maintenance,” notes Daniel Frostberg, Operations and Sales Manager for Siwertell Services. “However, we work hard to persuade them that properly maintained machines are in their very best interests, for safety, efficiency and cost effectiveness throughout a long service life.” Training considerations can be included in a Siwertell Care agreement.

Salomão Duarte (Eneva) during operations training

35SIWERTELL NEWS

24 hours a day With the Siwertell CARE

service agreement you can reach us at anytime. Learn more about our customer promises at siwertell.com

Download - Siwertell News - Issue 2 - 2014

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