engineering & consulting services driven by · pdf file ·...

RWE Power International

ENGINEERING & CONSULTING SERVICESDRIVEN BY RWE’S OPERATIONAL AND NEW BUILD EXPERIENCE

ABOUT US 32 RWE POWER INTERNATIONAL – RE GMBH

• is RWE’s engineering consulting company. Our

highly specialised expertise and outstanding per-

formance stem from our employees’ experience

as part of one of the world’s largest energy and

mining groups.

• offers external clients tried and trusted procedures

and innovative solutions that have proven to be

effective within RWE for widely diversified projects

employing the latest construction methods. As an

owner and operator, we are independent of suppli-

ers and equipment manufacturers.

• represents the skill set of the RWE Group.

• RE GmbH, formerly RHEINBRAUN ENGINEERING,

was founded in 1965.

Mining

Power Generation

Our services

• Our services cover all aspects of the power genera-

tion business. This includes everything from feasi-

bility through to planning, construction as well as

commissioning, operation, maintenance and – if

needed – decommissioning.

• Our in-depth knowledge of mining incorporates

diverse types of ore and coal, and ranges from

feasibility and mine development to operation,

maintenance and recultivation.

• With over 50 years of experience in large-scale

mining projects, we are in the ideal position to

provide unrivalled support to our clients for the

construction and optimisation of conveyor systems.

Our team

• RWE Power International’s success is built on the

capabilities of our talented specialists in a variety

of disciplines: project managers, quality managers,

engineers, procurement and claim experts, design-

ers, planners, geologists, environmental scientists

and economists. Numerous other specialists from

associated disciplines contribute to our team’s

strength.

• Our clients around the world benefit from our inde-

pendent engineering expertise. Our experts have

many years of invaluable practical insights acquired

through the operation of our own power plant and

mining sites.

Our worldwide project locations

RWE POWER INTERNATIONAL – RE GMBH

GENERATION BACKGROUND 54 RWE – POWER GENERATION

50 GW INSTALLED CAPACITY. 18,000 EMPLOYEES. 70+ LOCATIONS. OUR POWER GENERATION KNOWLEDGE BASE

RWE operates

• the most diversified generation mix in Europe:lignite, hard coal, biomass, gas, hydro and nuclear.

• one of Europe’s largest and most efficient gas fired powerplants (CCGT): Pembroke Power Station produces over 2,000 MWat 58% efficiency.

• the world’s most efficient super critical lignite fired power plants:BoA 2&3. Each unit has a capacity of 1,100 MW and 42% efficiency rating.

• the first industrial size continuous lignite drying plant:fluidised-bed drying with internal waste heat utilisation,wet coal ~210 t/h, dry coal ~110 t/h.

• the most modern hard coal power plant which can be partially fuelled by biomass: Eemshaven Power Station will produce1,600 MW at 46% efficiency.

Eemshaven

Start-up: 2014Fuel: hard coal/biomassCapacity: 1,560 MW

Denizli

Start-up: 2013Fuel: natural gasCapacity: 775 MW

WestfalenUnit D/E

Start-up: 2013Fuel: hard coalCapacity: 1,528 MW

Pembroke

Start-up: 2012Fuel: natural gasCapacity: 2,188 MW

Staythorpe


EeEeEeEe

StaStaStStFuFuFuFuCa

Moerdijk 2


Mo

StaStaStaFueCaCa

Claus C


WWeUUn

StaaaStarStaFFFueFueCap

BoA 2&3Neurath

Start-up: 2012Fuel: ligniteCapacity: 2,200 MW Lingen


By 2014 RWE will have renewed 25% of its generation fleet.

POWER GENERATION SERVICES 76 POWER GENERATION SERVICES

Health and Safety, Quality, Environment

Project and technical services:

• Expediting and on-site surveillance

• Quality control and inspections

• Expert witness, materials testing and damage

analysis

• Consulting on materials and technical components

Management system services:

• Quality management system development

• Environmental management system development

• Supplier quality evaluation and auditing

Documentation services:

• Document management

• Technical data management

Nuclear Industry

• Technical analysis of nuclear new build projects

• Operational safety assessment of Nuclear Power

Plants (NPP’s)

• Efficiency enhancement of NPP’s

• Maintenance measures and outage performance

management

• Transfer of management know-how and safety

culture

• Training tailored to local requirements

Maintenance Services and Ash Products

TSG Ferrybridge

• Maintenance, overhaul and modification

• Outage management

• Support for plant refurbishment, repair and

upgrade

• Inspections

• Manufacturing of spare parts

• Steam and gas turbine specialist services

Generation Aggregates

• Provision of cost effective, readily available

ash products for construction and engineering

applications

• Monitoring of ash quality in accordance with the

Quality Protocol to ensure its suitability

• Advice on the standards relevant to the use of ash

• Provision of technical data to enable you to assess

the suitability of ash in your particular application

• Advice on best practices for use in your application

Project Development and Management

From preliminary study to investment decision

• Site evaluation

• Estimation of capital expenditure (Capex)

• Concept, pre-feasibility and feasibility studies

• Project scheduling and cost estimations

• Technical due diligence

• Support of studies for licensing and permits

• Development of contract/procurement strategy

• Supplier evaluations

• Project planning, controlling and monitoring

Engineering Support

• Technical contract management

• Design management

• Technical specifications and definition of

requirements

• Review of basic/detailed engineering

• Interface management for technical lots

• Technical consultancy in specialist areas

• Plant operation optimisation and operational

support

• Retrofit and lifetime extensions

Achieve sustainable improvement in plant performance with the support of RWE Power International’s cutting-edge services.

Project planning, controlling and monitoring Retrofit and lifetime extensions

EXPERIENCED. FOCUSSED. FLEXIBLE.

4QUALITY

2 PROJECT ENGINEERING

INITIAL IDEA1

3 CONSTRUCTION

5HANDOVER

!PLANNING, CONTROLLING AND DELIVERING

POWER GENERATION PROJECT EXPERIENCE 98 POWER GENERATION PROJECT EXPERIENCE

NEW BUILD

REPLANTING

RWE Power International possesses worldwide experience in the modernisationand replanting of all types of power stations.

We make use of our in-depth knowledge to secure

the long-term value of our clients’ assets. Our engi-

neers help our clients to extend the life of their

power plants and make lasting improvements to

plant performance.

Numerous power plants around the world serve as

examples of how successful we are at modernising

and refurbishing existing plants. For example, in

Hungary and

South Africa,

we succeeded

in increasing

the output of

several power plants whilst also significantly extend-

ing their operational life and ensuring full compli-

ance with environmental requirements.

In south eastern Europe, we supported several boiler

system modernisation projects. In the first stage of

these projects, we provided the technical specifica-

tions with particular focus on increasing efficiency

and reducing NOx emissions. Subsequently we

assisted with the evaluation of bids for tender.

During the refurbishment stage we advised the

owner regarding the ongoing works on-site and in

technical discussions with suppliers.New turbines for CCGT Little Barford, UK

When it comes to the construction of modern power plants, there are few energy businesses that have as much international experience as RWE Power International.

From conventional electricity generation to regener-

ative technologies, from large-scale power plants to

smaller, decentralised systems: our engineers have a

wealth of experience as owners and operators of the

most diverse types of power plants.

A good example of RWE Power International’s new-

build projects is the BoA 2&3 project in Neurath,

Germany. There, we have constructed the world’s

most modern and most efficient lignite-fired power

plant to replace older, less efficient plants. We like

to think big. Take our com-

bined cycle power plant at

Pembroke in the UK which

is the largest of its type in

Europe.

In addition to Pembroke and Staythorpe in the UK

we have also just completed some of the most

technically advanced new combined cycle power

plants in Germany, the Netherlands and Turkey.

Our experts have also just built dedicated biomass

projects in Scotland, Germany and Italy.

Always on the cutting edge of technology, we are

nearing completion of a 1,600 MW hard coal power

plant in Hamm, Germany and Eemshaven in the

Netherlands. Through targeted process optimisa-

tion, the power plant is to achieve an efficiency of

up to 46%.

Boiler structural steelwork for the hard coal power plant Hamm, Germany

KNOWLEDGEABLE. WELL-ROUNDED. PROVEN.

QUALITY AND VENDOR CERTIFICATIONS 1110 POWER GENERATION PROJECT EXPERIENCE

No apu sms: 006184No RePro: 342106No regic: 504017

Registrado

regic RePro

Registrado Accredited

apu sms

NUCLEAR

Our services are quality approved:

We are an Achilles recognised company.

With experience in a variety of modernisation measures and safety upgrades, our engineers can be relied on for professional consulting and proven project management for nuclear power plants.

For more than ten years, our nuclear experts have

been helping to improve the safety of nuclear power

plant projects around the world. Whether they are

shift leaders, trainers or project managers, the mem-

bers of our nuclear

team all have specific

expertise in certain

aspects of nuclear

power plant construc-

tion and operation. Equipped with this in-depth

knowledge, we support several international mis-

sions as well as several EU expert committees on

nuclear safety. Our nuclear fleet comprises four

units in operation, with a total capacity of 4,400

MW and five units in the decommissioning phase.

We provide consultancy services in the nuclear field

to public institutions as well as to private compa-

nies. We possess in-depth knowledge regarding

Generation I to Generation III reactors as well as the

commissioning and decommissioning of all types of

nuclear power plants. We have contributed our

expertise to nuclear development programmes in

Belene, Bulgaria; Cernavoda, Romania and the Hori-

zon project in the United Kingdom.

We offer detailed knowledge of technical design

standards and international licensing standards. In

the field of nuclear power, our tasks typically include

the assessment of technical requirements, prepara-

tion of technical specifications, contracting and on-

site management during every stage of a project.

We are also ideally placed to assist you with meas-

ures for radiation protection and radioactive waste

management.

View from the technical training center of NPP Zaporozhye, Ukraine

View into cooling basin of Biblis Power Plant, Germany

QUALITY. HEALTH AND SAFETY. ENVIRONMENT.

IS0 9001 accredited

IS0 14001 accredited

OSHAS 18001 accredited

MINING BACKGROUND 1312 RWE – LIGNITE MINING

HAMBACH MINE. GARZWEILER MINE. INDEN MINE.OUR MINING KNOWLEDGE BASE

RWE operates

• three totally continuous open pit mines, producing 100 Mt/a lignite.

• 20 of the world’s largest bucket wheel excavators (up to 240,000 m³/d).

• 18 inpit overburden spreaders, to dump more than 480 M bcm/a.

• 240 km of up to 2.8 m wide belt conveyors, running at 7.5 m/s.

• the largest private European heavy duty rail networkwith a length of 565 km for coal transport.

• 19 km/a exploration and 45 km/a dewatering drilling.

�

Cologne

Dürwiß

B 477 n

Tagebau Garzweiler

L 23

8n

Tagebau Hambach

Rhine

Frechen

BerrenrathKW Knapsacker Hügel

Tagebau Inden

as of 01/2013

Munich

Stuttgart

Saarbrücken

Mainz

Frankfurt

AachenCologne

Dortmund

Bremen

Hard coal

Lignite with integratedopencast mines

Natural gas

Nuclear power stations

Other conventionalpower plants

Hydropower stations** * in deconstruction** RWE Power including holdings as well as plants operated on behalf of RWE Innogy

*

Garzweiler Mine35 – 40 Mt/a

Hambach Mine35 – 40 Mt/a

Inden Mine20 – 25 Mt/a

Production capacity: ~100 Mt/a

Reserves, legallysecured: 3.3 billion t

MINING SERVICES 1514 MINING SERVICES

Our Specialists

• plan and develop your mines towards truly

continuous mining operations.

• assist with the establishment of state-of-the-art

mining technology and techniques, e.g. IPCC.

• provide the necessary transfer of skills to your

own operators.

• ensure minimal impact on the surrounding environ-

ment throughout the mine’s life.

• support you throughout your total mining process.

INNOVATIVE. SUCCESSFUL. SOPHISTICATED.

We are committed to maximising value from your mining assets by tailoring our Services to your needs.

Mine Design, Planning and Optimisation

• Conceptual and detailed mine design studies

• Individual opencast mine planning such as IPCC

• Net-present-value pit optimisation

• Choice of mining method and haulage method

• Life-of-mine stockpile, waste dump and tailings

dam design

• Production and equipment schedule optimisation

• Run-of-mine tonnage and grade scheduling

• Equipment, staff and material requirements

determination

Geological Services

• Exploration management

• Hydrological assessment

• Acid mine drainage studies

• Geotechnical assessment

Equipment Maintenance and Optimisation

• Development of a suitable maintenance strategy

• Maintenance planning and organisation

• Mine maintenance and warehouse management

• Maintenance training, audits and benchmarking

• Mine maintenance development

• Check and verification of the mine equipment’s

rehabilitation needs

In-pit Crushing and Conveying (IPCC)

• Conceptual and detailed IPCC mine design

• Brownfield integration planning

• Equipment selection advice

Conveyor Belt Inspection

• Direct feedback of recommended improvements at

plant inspection

• Analysis of plant breakdown

• Proposals for plant improvement through detailed

analysis

Conveying Engineering

• Design of the whole conveyor chain-systems

• Independent checking and verification of an

equipment manufacturer’s design

• Preparation of tender documents

• Evaluation of bids and recommendation of the

most suitable bidder

• Assistance during contract negotiations

• Mine equipment erection supervision

Conveyor Belt Testing (laboratory)

• Conveyor belt testing according to DIN, ISO and

other international standards (all testing equip-

ment available)

• Belt testing according to RWE standards for heavy

duty mining demand (large scale testing)

• Expertise in belt failure analysis and lifetime

prediction

16 MINING PROJECT EXPERIENCE MINING PROJECT EXPERIENCE 17

IPCC

EQUIPMENT ENGINEERING

Our experience in this area is wide-ranging, both

geographically and technically. Whatever your pro-

ject – coal, copper, ore or overburden – RWE Power

International is your best choice for the task. For

example, we built the world’s largest compact

bucket wheel excavator for the Bükkábrány opencast

mine in Hungary. Our engineers were responsible

for drafting the plans, constructing the coal storage

and selecting and qualifying the suppliers.

The parts for the excavator were manufactured in

several European countries including Bulgaria and

Poland. Before the first elements were manufac-

tured, we conducted construction audits and during

the production stage we held factory acceptance

tests for key components. Our

experts guided and supervised the

project from the start through to completion, there-

fore ensuring that the production quality remained

consistently high throughout and maintaining the

same high standard for which our mining projects

are known.

In Serbia, we conducted similar projects for the state

electricity company, EPS including supporting the

completion of complex overburden removal

systems.

We also analysed existing bulk ore conveyor and

transport systems for several copper mines in Chile

to identify weak points. We then developed a num-

ber of solutions for improving performance and

increasing throughput.

Our customers can be confident of maximum safety

and reliability when they purchase conveyor belts

which are “RWE tested”. We want you to feel confi-

dent that you integrate reliable components into

your production system. For this reason, we refuse

to buy any products that have not successfully with-

stood rigorous testing in our own

laboratories.

There are good reasons for this. As far as fuel con-

sumption, carbon dioxide emissions and time are

concerned, modern IPCC systems have clearly

proven to be more efficient than traditional “shovel-

and-truck” methods. With mounting international

pressure on mining companies to increase their

environmental responsibility, the new technology

is becoming more and more attractive – not to men-

tion the potential savings on fuel and operating

costs.

The overall expenses for haulage systems that still

rely on shovel-and-truck can easily add up to 50%

of the total mining costs. Although the initial

expenditure that is generally needed for an IPCC

system can be significant, it soon pays back due to

a high return on investment.

An IPCC system consists of a crusher that is con-

nected to several conveyors. The crusher is strategi-

cally positioned in the opencast mine and the con-

veyors remove the crushed material. A major

advantage of this system is that while trucks are

only able to transport overburden, ore or coal on

inclines up to 12%, the conveyors can operate safely

and reliably at gradients of up to 25%. Therefore,

this not only reduces the distance

that the material has to travel from

the pit but it also lowers costs for

fuel, maintenance and personnel.

We have many years of experience using IPCC, par-

ticularly in South America. Our first project was in

Chile in the early 1990s with the design, develop-

ment and supervision of the construction of a

crusher-belt conveyor-spreader system. After suc-

cessfully completing this project, our team was sub-

sequently awarded a contract by the Chilean copper

mining company Codelco. In 1995, we were awarded

a contract to construct a tunnel conveyor to trans-

port ore 1,200 metres downhill from Antofagasta’s

Los Pelambres copper mine. We continue to assist

the company with the operation and maintenance of

the system. In addition, we have conducted numer-

ous IPCC studies for locations around the world,

including Peru, Columbia, Thailand, India, Indonesia

and Australia.

RELIABLE. VISIONARY. DURABLE.

In opencast mining, the use of In-Pit Crushing and Conveying (IPCC) systems is becoming increasingly common.

Of our many support services, none is more in demand than our mining equipment engineering support.

Truck dumping into hopper of semi-mobile crusher plant atMaeh Moh Mine, Thailand

World largest compact bucket wheel excavator in BükkábrányOpencast Mine, Hungary

HOW TO REACH US 1918 MINING PROJECT EXPERIENCE

MINE PLANNING

Building on many years of specialised expertise, we provide our clients with one-stop solutions covering the entire cycle of a mining project.

Our practical experience covers all types of open-

cast mining and construction projects. For instance

as part of a mine feasibility study, we conducted

exploration drilling and hydrological pump tests

in the Thar Desert in Pakistan. The investigations

revealed lignite reserves of around 400 million

tonnes.

For an opencast mining project in the Bushveld

Complex in South Africa, our experts drafted a

precise model of a platinum-palladium deposit

which enabled the client to carry out highly targeted

mining operations.

On a contract for

Neyveli Lignite

Corporation (NLC),

which operates

several opencast lig-

nite mines in southeast India, we con-

ducted a feasibility study including

detailed mine planning. Our

experts needed to overcome

a number of geotechnical, envi-

ronmental and technological

challenges. For the duration

of the project, we supported

NLC on site and also via inter-

net from Cologne.

The Gallilee Coal Basin in Australia is being devel-

oped by several mining companies. Our team of

experts is involved in concept and feasibility stage

studies, especially when it comes to the utilisation

of continuous mining equipment. To develop totally

continuous operating coal and overburden transport

systems our operational knowledge is of extraordi-

nary value in the fields of mine stage

planning and equipment selection.

Mining Power Plant

Meet us at selected fairs, exhibitions and conferences.

Stuettgenweg 2

50935 Cologne

Germany

T +49 221 480 1300

F +49 221 480 1350

Further information may be found on our website: www.rwepi.com

Huyssenallee 2

45128 Essen

Germany

T +49 201 12 22673

F +49 201 12 22671

Maintenance Services and Ash Products

TSG Ferrybridge – Maintenance Services

Old Great North Road / Knottingley

West Yorkshire / WF11 8PR

United Kingdom

T +44 1977 632201

F +44 1977 632311

Generation Aggregates

Electron / Windmill Hill Business Park

Whitehill Way / Swindon

Wiltshire / SN5 6PB

United Kingdom

T +44 800 7312865

F +44 1793 892421

Our mining engineering team in the clients office in Indonesia

HELPFUL. INTERCONTINENTAL. ACCESSIBLE.

RWE Power International

RE GmbHStuettgenweg 250935 Cologne

T +49 221 480 1300F +49 221 480 1350I www.rwepi.comE [email protected]

Huyssenallee 245128 EssenGermany

T +49 201 12 22673F +49 201 12 22671

Registered Office:Registered at CologneLocal Court under no.HRB 2635

© 3/2013 RE GmbH

engineering & consulting services driven by · pdf file ·...

Documents