hitachi power europe service 7th german-african energy · pdf file ·...

Hitachi Power Europe Service

7th German-African Energy ForumApril 7th – 10th, 2013Hamburg, 9th April 2013

“Value addition through lifetime service“

Hitachi Power Europe Service, a new player in HPE-Group and its abilities for providing rehabilitation and refurbishment services to the energy market

7th German-African Energy ForumHamburg, 9th April 2013

Value addition through lifetime serviceHans-Josef SandkaulManaging Director

Hitachi Power Europe Service GmbH / Company presentation 2013 3

Hitachi Power EuropeGroup of companies

Various businessdivisions around

the world

Babcock FertigungszentrumOberhausen GmbH

BGR Boilers Private Ltd.India

HITACHI Ltd., JapanTurnover: 90 Bn € / 330,000 Employees

Meeraner DampfkesselbauGmbH

Hitachi Power Africa (Pty) Ltd.

Donges SteelTecGmbH

Hitachi Power Europe GmbH

Duisburg / Germany

Hitachi Power Europe Service GmbH


Hitachi Power SystemsCompetence in fossil-fired power plants

FGD

ESP

DeNOx

Boiler

Turbine/Generator

More than 65% of a high efficient power station can be supplied by group members

BoilerTurbine/GeneratorDeNOxFGDEngineeringBOPI & C System

Civil worksInfrastructureBOP others


Hitachi Power EuropeNeurath F&G (BoA II), Germany

2 x 1,100 MWel / 2 x 2,959 t/h

Once-through steam generator, Benson®

Lignite

Design parameters:SH: 600 °C / 292 barRH: 605 °C / 80 bar

Plant in operation: 2012


Global primary energy supplyfrom fossil fuels

Source: International Energy Agency

Hitachi Power Europe Selection of projects / products (as of June 2012)

Project Customer Product Fuel CapacityKusileSouth Africa ESKOM Utility steam generator Bituminous coal 6 x 800 MW

MedupiSouth Africa ESKOM Utility steam generator Bituminous coal 6 x 800 MW

EemshavenNetherlands RWE Flue gas cleaning Bituminous coal 2 x 800 MW

RotterdamNetherlands Electrabel / GDF Suez Power Train ** Bituminous coal 1 x 790 MW

WilhelmshavenGermany Electrabel / GDF Suez Power Train ** Bituminous coal 1 x 790 MW

MaasvlakteNetherlands E.ON Utility steam generator Bituminous coal 1 x 1.100 MW

MoorburgGermany Vattenfall Utility steam generator Bituminous coal 2 x 820 MW

WestfalenGermany RWE Flue gas cleaning Bituminous coal 2 x 800 MW

DattelnGermany E.ON Utility steam generator Bituminous coal 1 x 1,100 MW

Neurath F & GGermany RWE Utility steam generator Lignite 2 x 1,100 MW

BoxbergGermany Vattenfall Utility steam generator Lignite 1 x 670 MW

WalsumGermany Evonik / EVN Turnkey power plant * Bituminous coal 1 x 750 MW

GentBelgium Electrabel Utility steam generator Blast furnace gas 1 x 305 MWel

MalmöSweden E.ON Sverige Combined-cycle power plant Gas 440 Mwel + 250 MWth

* Supply of utility steam generator, flue gas cleaning equipment, steam turbine/ generator, civil engineering including cooling tower; overall plant layout

** Power Train = utility steam generator, flue gas cleaning equipment, steam turbine/ generator including balance-of-plant equipment (excluding construction work, electrical engineering, instrumentation & control, external coal feeding etc.)


Hitachi Power Europe ServiceProducts / Services

Engineering / Technologies Construction / Commissioning

■Engineering (N,S)

■Utility Boiler (S)■ Industrial Boiler

(N,S)■HRSG (N,S)■Special Boiler

(N,S)■Modernisation

(S)■Efficiency Im-

provement (S)■Flue Gas Dust

Precipitator (N,S)

■Catalyst (T)

BoilerTechnology/

Flue GasCleaning

■Engineering (N,S)

■Burner Systems (N,S)

■Combustion chamber (N,S)

■Grates Systems for Waste, RDF and Biomass (N,S)

■Enviromental Protection Measures (N,S)

■Hard Coal (S)■Lignite (S)

FiringTechnology

■Warranty Service for HPE (S)

Warranty Service

■Planning (N,S)■Boiler and Firing

Systems (N,S)■Plant Optimisation

(N,S)■Emission

Measurements (N,S)

■Efficiency and Operational Measurements (N,S)

■Acceptance Tests (N,S)

■Plant Management (N,S)

■Personnel Training (N,S)

Commissioning

■Gas Turbine (T,S)

■Steam Turbine (S)

TurbineService

■Grinding Systems (N,S)

■De-AshingSystems (N,S)

■Coal Feeder (N,S)

Mills & Components

■Planning of Construction (N,S)

■Construction of Boiler (N,S)

■Construction of Firing Systems (N,S)

■Modification, Retrofit, Repair (S)

■Contract work (N,S)

■Supervision (N,S)

■24 h Service (S)

Construction

Spare PartsExplanations: N = New build (activities before PAC)

S = Service (activities after PAC)T = Trading (activities for affiliated companies)


Hitachi Power Europe ServiceService Organisation of Hitachi Power Europe

Intelligent Service

HPE Service offers all kinds of service activities concerning fossil fueled power plants

Services and supplies based on the individual requirements

A clear focus on engineering driven solutions

A large availability of own staff and partner companies with trustful relationships

Tailor made scope


Responsibility and interfaces between the service company and the design units is clearly defined.

Hitachi Power Europe ServiceService for New Built Plants

Erection ofnew plants

The Service Company will selectively take care of new plant erection jobs as a key to the aftersales

business

Integration of Service Company

within proposal preparation

Design unitsNew plant business

Service company Operations

Guarantee

After Sales business• Revamp and Retrofit• Spare parts• Operation + Maintenance

Implementation operating units HPE

Implementation Service Company HPES

EngineeringProjectacquisition

Responsibility


Full ServiceMaintenance Contract +

Material/Personnelmanagementincluding O&M

Inspection ContractPlant Status appraisal/Inspections during Shut-down/ Planning and budgeting of checksInstallation

& Revamping of various maintenance

elements

Ext

ende

d S

ervi

ces

Extended Guarantee

Repair ContractInspection contract +

implementation ofchecks

Maintenance ContractRepair contract +

unscheduled repair work

Hitachi Power Europe ServiceFull Service Provider


Measures of Maintenance

harm-basedmaintenance

preventive maintenance

measures for plant life-time

extension

maintenance based on inspection

maintenance based on condition

maintenancebased on intervall

Hitachi Power Europe ServiceDifferent Maintenance Models


Hitachi Power Europe ServiceMeasures of Maintenance

Decision criteria for various maintenance models

Consequently: Operators who are active in the utility business and who are not able to revert on

short-term alternatives or back-up units is recommended:


high availability (cost advantage) execution during planned shutdowns high reliability in plant operation


harm-basedmaintenance

limited availability negative effect on operation costs limited or no security given for staff, plant and

environment.

measures for plant life-time

extension

detailed analyze of the operation method and current condition of the plant

finding and examination of material samples calculation of critical components preparation of "tailor-made" and cost-effective

package of measures for life-time extension


-5

0

5

10

15

20

25

30

1 2 3 4 5 6 7 8 9 10 11 12 13 14 15

Maintenance Grade

Cos

ts &

Fol

low

up

Cos

ts

“Time Based” Costs

Damage causedFollow-Up Costs

“Condition Based” Costs

Total Maintenance Costs

Under maintained Over maintained“Best Practice”

Hitachi Power Europe ServiceTotal Costs vs. Maintenance Grade

Best Practice Maintenance: A clever, component-wise mix of different maintenance strategies


Hitachi Power Europe ServicePreventive Maintenance

Extend the functionality through preventive maintenance

100 %functional

ability

timeextension of the functionality


measures

critical point

significant increase of availability safety for staff, equipment and

environment long life expectancy simultaneous optimization / reduction of

maintenance costs reduced operating costs lead directly to

profit


Flexible and mobile safety equipment for large working spaces

Complete coverage of the cross section area

Hitachi Power Europe ServiceShield for Accelerated Boiler Service SABS®

Increases safety for personnel doing maintenance or inspection work

Canvas is most tearproof and heat-resistant


Hitachi Power Europe ServiceShield for Accelerated Boiler Service SABS®

Assembly Total Duration

SABS® canvasassembly, insert, fixate

SABS® canvas, 76 mlift, pre-assemble, tension

Conventional safety equipmentscaffolding, lagging, safety net, etc.

4 h

6 h

Disassembly Total Duration

SABS® canvas, 76 mclean, release, lower

SABS® canvas, 0 mlay down, joggle, recover

Conventional safety equipmentscaffolding, lagging, safety net, etc.

3 h

3 h

* Data of Vattenfall Europe Generation

Parallel work during the fine cleaning: additional 72 h*

Potential savings at planned outage: 70 h*

48 h*

38 h*


Major Overhaul & RehabilitationTarget: to increase availability from less than 50% to about 90%

Fuel: LigniteUnit capacity: 305 MWelBoiler capacity: 920 t/hSH outlet press: 183 barSH outlet temperature: 543 °C

Hitachi Power Europe Service Lignite fired Power Plant, Obrenovac, Serbia

Contracting party: European Agency for Reconstruction (EAR)

Owner: Electric Power Industry of Serbia (EPS)

Plant: Lignite Fired Power Plant (6 Units)Nicola Tesla A, Unit 3Obrenovac, Serbia

Scope: Pressure partsFiring systems E-C&ITurbine, generatorAir and flue gas ductsWater treatmentFD and ID fansSoot blower, rotary air heater, Ash removal systemElectrostatic precipitator Pumps and fittingsLive steam pipingInsulation and brick liningsAuxiliaries

Start-up: 2003


Emergency Repair of a Steam Generator in Kuwait

Fuel: Heavy fuel oil/natural gasUnit capacity: 300 MWelBoiler capacity: 975 t/hSH outlet press: 146 barSH outlet temperature: 540 °C

Hitachi Power Europe ServiceHeavy fuel oil/natural gas fired Boiler, Kuwait

Owner: MEW (Ministry of Electricity & Water) Kuwait

Plant: Sabiya Power PlantUnit 1

Boiler manufacturer: Mitsubishi Heavy Industry (MHI, Japan)

Scope: Dismantling of damaged pressure partsInstallation of Boiler pressure partsSuperheaterMembrane wallsSteam-water pipes and headerBurner systemSteel structure and platformsInsulation and brick liningsExpansion jointsHangersAuxiliaries

Start-up: 08/2010 (Repair period: 5 month)


Hitachi Power Europe ServiceHeavy fuel oil/natural gas fired Boiler

Heavy fuel oil/natural gas fired Boiler, KuwaitEmergency Repair of a Steam Generator in Kuwait


Repair / Rehabilitation / Modernization of facilities of all sizes and types of fossil fuel power plants

Emergency Repair 24/7

Performance enhancement through optimization

Improvement in efficiency

Modularized plant optimization

Know-how based on OEM

Summary of Hitachi Power Europe Service


Conclusion

Customized, flexible service solutions based on our

expertise are the strength of the Hitachi group!


Thank you for your attention!

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