risks of an inadequate electrical trace heating solution
DESCRIPTION
TRANSCRIPT
AKOTRACEthe integral solution forheat tracing
AKOTRACEthe leading heat tracing solution
AKOTRACEthe integral solution forheat tracing
AKOTRACEsolución líder en traceado eléctrico
for CSP technology
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ELECTRICAL HEAT TRACING MANAGEMENT: CRITICAL POINT FOR CSP PLANTS
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In recent years, thermo-solar plants have been involved in a spectacular growth in the renewable energy market. Spain has been a pioneer in this phenomenon which is now extending to other markets / countries in the “SO-LAR BELT”: USA, Northern Africa, Australia....
One of the main keys to consolidating and increasing the development of the solar thermal plant market is the OPTIMISATION OF THE PERFORMANCE of these plants. We understand Performance as the expected net production that is directly related to:
PLANT INVESTMENT (CAPEX)
DAYS OF PRODUCTION
EFFICIENCY IN PRODUCTION: PERFORMANCE-PRODUCTION AND OPERATING COSTS BINOMIAL
WITH AN INVESTMENT OF LESS THAN 0.5% OF THE TOTAL PLANT INVESTMENT, ELECTRICAL HEAT TRACING IS A CRITICAL SYSTEM AS IT
GUARANTEES THE EFFICIENT PERFORMANCE OF THERMO-SOLAR PLANTS
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HOT SALT TANK
SOLAR FIELD
HTF HOT
HTF COLD
COOLING TOWER
CONDENSER
OIL / SALTHEAT
EXCHANGER
OIL / STEAMHEAT
EXCHANGER
STEAMTURBINE
GENERATOR
ELECTRICALPOWERTO GRID
AKOTRACEthe integral heat tracing solution
COLD SALT TANK
abast
TANQUE SAL CALOR
CAMPO SOLAR
HTF CALOR
HTF FRÍO
TORRE REFRIGERACIÓN
CONDENSADOR
INTERCAMBIADOR ACEITE/SAL
CALOR
TURBINAGENERADOR
VAPOR
RED DE ENERGÍA
ELÉCTRICA
AKOTRACEla solución intregral de traceado eléctrico
TANQUE SAL FRÍO
alcance
INTERCAMBIADOR ACEITE/VAPOR
CALORELECTRICAL HEAT TRACING IS CRITICAL FOR ENERGY PRODUCTION PROCESSES IN CSP THERMO-SOLAR PLANTS
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In both Parabolic trough plants and Concentration tower plants, the ther-moelectrical solar energy concept consists of exploiting the energy from the sun to obtain electrical energy, by means of heating and thermal transfer between heat carrying fluids: water steam, thermal oil and salts... to generate STEAM.
THE ELECTRICAL HEAT TRACING SYSTEM IS CRITICAL in the management of these ESSENTIAL PROCESSES FOR THE OPERATION OF THE PLANT either to maintain the temperature of these fluids or to prevent them from solidifying / freezing.
A NON OPTIMUM Electrical Heat Tracing solution might:
INCREASE THE PLANT’S COSTS
GENERATE NON-DESIRED PLANT STOPPAGES, THAT RESULT IN LESS DAYS OF PRODUCTION AND/OR HIGHER REPAIR COSTS
REDUCE THE PERFORMANCE OF THE ESSENTIAL SYSTEMS FOR ELECTRICAL PRODUCTION
INCREASE THE COSTS OF ELECTRICAL SELF-CONSUMPTION AND MANAGEABILITY OF THE PLANT
AKO IS THE WORLD LEADER IN ELECTRICAL HEAT TRACING SOLUTIONS IN THERMO-SOLAR PLANTS WITH OVER 80% PLANTS UNDERTAKENSINCE 2008, THE ONLY COMPANY THAT HAS CARRIED OUT TRACING PROJECTS IN CONCENTRATION TOWERS WITH MOLTEN SALTS
AKOTRACEthe integral solution forheat tracing
AKOTRACEthe leading heat tracing solution
AKOTRACEthe integral solution forheat tracing
AKOTRACEsolución líder en traceado eléctrico
!
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ASSOCIATED TECHNICAL RISKS
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CSP PLANT PERFORMANCE
MAIN RISK SOURCE OF THE RISK IMPACT
DAYS OF PRODUCTION OF THE THERMO-SOLAR PLANT
Non-desired stoppages due to the freezing of heat carrying fluids or water
Lack of thermodynamic engineering expertise:Under-sized systemWeak Control solution: Lack of information in real time para for corrective detection of faults: BREAKDOWNSBad Installation practice
1 day of no production in the plant at €195.000 of loss of earnings (€120.000 in plants without accumulation)
Intervention costs in repair of the tracing and/or associated damaged equipment up to 6 million Euros
CAPEX Budget Variance from €150.000 to €225.000 (10-15% budget variation)
Increases in energy expenditure from €38.000 a year (5% increase in electrical consumption of the tracing system)
1 day of no production in the plant at €195.000 of loss of earnings (€120.000 in plants without accumulation)
Non-implementation of operating improvements in the plant (in study phase)
Variation CAPEX Budget up to €300.000 (20% budget variation)
Costs due to accidents / Sick leaves
Lack of tracing engineering expertise: Under-sized system
Lack of thermodynamic and control engineering expertise: Under sized systemWeak regulation solution:
Lack of engineering expertise: Over-sized system
Lack of engineering expertiseBad Installation practiceWeak Operator Training in Plant
Weak control & supervision solution
Weak Control & Supervision solution Bad Project Management / Lack of Experience(Project Management)Bad Installation practice
Non-foreseen investments or interventions in the plant operation phase
Delays in Start-up in a Project Phase without time for reaction as tracing is one of the last supplies
Loss of performance efficiency due to incorrect tempe-rature regulations of the processes (HTF, Salts, BOP)
Lack of historic information to improve the performan-ce of the plant
Increased investment costs
Inadequate requirements
PRODUCTION EFFICIENCY(PERFORMANCE-COSTS)
INVESTMENT(CAPEX)
*Estimated a 50 MW CSP Plant (molten salts)
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AKOTRACE® is the WORLD LEADER given its complete solution that co-vers all of the essential aspects of the Thermo-Solar Plant and guarantees the maximum efficiency in the critical electrical heat tracing aspect.
R & D
ENGINEERING PROJECT
HEATING CABLE PROJECT
ELECTRICAL PANEL PROJECT
MONITORING SYSTEM INSTALLATION AND START-UP
WARRANTY AND QUALITY
AKOTRACE® IS THE PERFECT SOLUTION FOR THE OPTIMUM PER-FORMANCE OF THE THERMO-SOLAR PLANT
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R&D
PROJECT MANAGEMENT
INSTALLATION AND PEM
GUARANTEE AND QUALITY
BASIC ENGINEERING
TECHNICALSOLUTION
Area of professionals in the Tracing application field
Experimentation Room where we analyse the behaviour of our global AKOTRACE solution, stress test, critical points analysis, performance & availability test of the system
Detailed engineering team and documentation for industrialisation in Project time Team of Project Directors to guarantee compliance in time and quality.Own methodology, PROJECT MANAGEMENT
Development of Own Know How and Installation protocols in thermo-solar plantsInstallation system inspection and safety protocolsAdvice in the Start-upTraining sessions for the plant’s operators
Management and Environmental Quality Systems (ISO9001, ISO14001) Internal quality protocols for materials and Project (Field Audits)Materials and installation Guarantee Plan Certifications
Team of graduate engineers with high level of experience in electrical tracing and thermo-solar plants in particularTeam of Project Directors to guarantee compliance in time and quality.
Advice to optimise the electrical tracing system in specifications phase. Electrical heat tracing system, power and control panels & supervision system
Development of Solutions that reduce investment and guarantee requirements
Standardisation of resources and processes for maxi-mum Project efficiency, the result of our experience in thermo-solar plants.
Integration of specialised and optimum components in the electrical heat tracing field / thermo-solar plants, the result of AKO’s over 30
Installation management and execution deadlines per-fectly standardised based on our extensive experience.
Global Quality System guarantees the compliance of the Project in form, time, costs and financial solvency
OPTIMUM Technical-Financial calculation and sizing project for current and future Process requirements
Development of tools and solutions to manage operating risks and critical points in the Plant
Avoid delays in the Commissioning of the Plant, a crucial building phase: without time for manoeu-vre and with critical process (eg. Salt Melting)
Management of the Start-up to guarantee theperfect start up of the Project and execution of electrical heat tracing inspection Protocols.
Assurance of the Project’s quality and the com-ponents of the Heat Tracing System, by means of Field audits
Engineering with successful results in over 20solar thermal Project that guarantee the correct management of the criticality of the heat-tracing system.
Wide range of our own highly reliable and dura-ble Solutions to ensure the robustness and availa-bility of the System
Technical solutions that guarantee the efficient per-formance of the System with a high manageability level
Development of solutions to lengthen the working life of the facility, optimise heat tracing’s energy efficiency and its maintainability.
Calculations and sizing to make the energy of the Heat Tracing System efficient
As built documentation with the maximum details including photographic books) that allow the maxi-mum maintainability of the Plant
Training Plans for operating staff and maintenance staff that allow knowing and managing the electrical heat tracing system
Preventive Maintenance Programme to guarantee the efficiency and working life of the Heat Tracing System
INITIAL INVESTMENT(CAPEX)
SCOPE BENEFITSAKO GLOBAL SOLUTION
PLANT PRODUCTION DAYS PRODUCTION EFFICIENCY (PERFORMANCE-COSTS)
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THERMO-SOLAR REFERRAL PROJECTS
• ANDASOL I & II (Granada) - TJV COBRA+ SENER HTF – BOP pipes and tanks
• ANDASOL III (Granada) - TJV FLAGSOL+ DURO FELGUERA salt pipes, exchanger tanks, HTF - BOP pipes and tanks
• IBERSOL (Puertollano) - IBERDROLA HTF pipes and tanks
• EXTRESOL I & II (Badajoz) - TJV COBRA +SENER salt pipes and exchangr tanks
• PALMA DEL RIO I & II (Córdoba) - INGETEAM POWER PLANTS HTF pipes and tanks
• EXTRESOL III (Badajoz) - TJV COBRA+ SENER salt pipes, exchanger tanks, HTF - BOP pipes and tanks
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THERMO-SOLAR REFERRAL PROJECTS
• LEBRIJA I (Sevilla) - IBERESE HTF pipes and tanks
• MANCHASOL I & II (Ciudad Real) - TJV COBRA+INITEC salt pipes and exchanger tanks
• MAJADAS DE TIETAR (Caceres) - SERIDOM HTF pipes and tanks
• VALLE I & II (San José del Valle) - TJV COBRA+SENER salt pipes, exchanger tanks, HTF - BOP pipes and tanks
• ASTEXOL II, ASTE 1A, ASTE 1B (Badajoz) - ELECNOR HTF – BOP pipes and tanks
• SAMCASOL I & II (Badajoz) - TSK PLANTAS INDUSTRIALES salt pipes, exchanger tanks, HTF - BOP pipes and tanks
• GEMASOLAR (Sevilla) - TJV COBRA+SENER salt pipes, tanks and exchanger tanks
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earningsJoint VentureAKO solutions optimise energy savings and the global cost of the ins-tallations, offering the best Technical-Financial solution.
assessmentAdviceOur customers’ needs are our main worry, and knowing them allows AKO to research and develop solutions with high added-value and re-liability.
supportTools
Our experience has allowed us to form an internal team of professio-
nals to offer integral support: from Project Design to the Start-up of
the System
youPassion for the Customer
As the customer is our passion, it is also the driving force behind AKO’s
development to continue to innovate for the regulation and integral
control of the facilities.
energy efficiencyAKO Solutions optimize energy savings and the overal cost of installation, offering the best technical-econo-mic solution.
connectivityContinuously monitors real-time and the proper functioning of the facility, locally or remotely.
usabilityEasy to install modular and scalable allowing correcti-ve action, without stops production processes..
safety & securityOur Know-How do we know the points in the system, avoiding the risk that a stop unwanted behavior.
we make it easy we make it ecus
we make it easy
HEADQUARTERSSpain
Av. Roquetes, 30/ 3808812 St. Pere de Ribes
(Barcelona) EspañaTel. SAT (34) 902 333 145
Tel. (34) 938 142 700Fax (34) 938 934 054
SUBSIDIARIESMexico
AKO Electromecánica México, S.A. de C.V.Av. Lomas Verdes, 750, OF. 201
CP 53120 Naucalpan (Estado de México)Tel. (52) 5553 635 780
PortugalRua Eucaliptos, 82-Ba. Encarnaçao
1800-202 Lisboa (Portugal)Tel. (+351) 218 522 405
Tel. SAT (+34) 902 333 145Fax (+351) 218 514 621
EMEA (Europe, Middle East, Africa)[email protected]
A&P (Asia & Pacific)a&[email protected]
N&LA (North & Latin America)n&[email protected]
FORWARD LOOKING APPROACH
Our future is centred in the International Market In AKO, we know our customers and their market needs with the aim of offering the best solution. AKOTRACE® The Global Solution with over 30 years experience and present in over 80 countries, we are constantly growing, and 14% of our research is ear-marked to R&D to develop the best solutions thanks to a qualified team with a high level of know-how
...and always easy
