Risks of an Inadequate Electrical Trace Heating Solution

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  • 1. AKOTRACEthe integral solution forheat tracingAKOTRACE the leading heat tracing solution for CSP technology
  • 2. ELECTRICAL HEAT TRACINGMANAGEMENT: CRITICAL POINTFOR CSP PLANTS 5
  • 3. 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.... 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 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 BINOMIAL6 7
  • 4. OTRACEintregral de traceado eléctrico AKOTRACE the integral heat tracing solution RED DE ELECTRICAL ENERGÍA abast POWER ELÉCTRICA TO GRID TANQUE SAL CALOR HOT SALT TANK TURBINA STEAM HTF CALOR GENERADOR HTF HOT TURBINE VAPOR GENERATOROLAR SOLAR FIELD OIL / STEAM ELECTRICAL HEAT TRACING IS HEAT INTERCAMBIADOR EXCHANGER ACEITE/VAPOR CALOR INTERCAMBIADOR OIL / SALT ACEITE/SAL HEAT CRITICAL FOR ENERGY HTF FRÍO CALOR HTF COLD EXCHANGER TANQUE SAL FRÍO CONDENSADOR COLD SALT TANK CONDENSER PRODUCTION PROCESSES IN CSP THERMO-SOLAR PLANTS TORRE REFRIGERACIÓN COOLING TOWER 9
  • 5. AKOTRACE solución líder en traceado eléctrico AKO IS THE WORLD LEADER IN ELECTRICAL HEAT TRACING SOLUTIONS IN THERMO-SOLAR PLANTS WITH OVER 80% PLANTS UNDERTAKEN SINCE 2008, THE ONLY COMPANY THAT HAS CARRIED OUT TRACING PROJECTS IN CONCENTRATION TOWERS WITH MOLTEN SALTS 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 PLANT10 11
  • 6. ASSOCIATED TECHNICAL RISKS 13
  • 7. CSP PLANT PERFORMANCE INVESTMENT DAYS OF PRODUCTION OF PRODUCTION EFFICIENCY (CAPEX) THE THERMO-SOLAR PLANT (PERFORMANCE-COSTS) MAIN RISK SOURCE OF THE RISK IMPACT Non-desired stoppages due to the freezing of heat Lack of thermodynamic engineering expertise: 1 day of no production in the plant at €195.000 of loss of carrying fluids or water Under-sized system earnings (€120.000 in plants without accumulation) Weak Control solution: Lack of information in real time para for corrective detection of faults: BREAKDOWNS Intervention costs in repair of the tracing and/or Bad Installation practice associated damaged equipment up to 6 million Euros Non-foreseen investments or interventions in the plant Lack of tracing engineering expertise: CAPEX Budget Variance from €150.000 to €225.000 operation phase Under-sized system (10-15% budget variation) Delays in Start-up in a Project Phase without time for Weak Control & Supervision solution 1 day of no production in the plant at €195.000 of loss reaction as tracing is one of the last supplies Bad Project Management / Lack of Experience of earnings (€120.000 in plants without accumulation) (Project Management) Bad Installation practice Loss of performance efficiency due to incorrect tempe- Lack of thermodynamic and control engineering expertise: Increases in energy expenditure from €38.000 a year rature regulations of the processes (HTF, Salts, BOP) Under sized system (5% increase in electrical consumption of the tracing Weak regulation solution: system) Lack of historic information to improve the performan- Weak control & supervision solution Non-implementation of operating improvements in the ce of the plant plant (in study phase) Increased investment costs Lack of engineering expertise: Over-sized system Variation CAPEX Budget up to €300.000 (20% budget variation) Inadequate requirements Lack of engineering expertise Costs due to accidents / Sick leaves Bad Installation practice Weak Operator Training in Plant *Estimated a 50 MW CSP Plant (molten salts) 1514
  • 8. AKOTRACE® IS THE PERFECT SOLUTION FOR THE OPTIMUM PER-FORMANCE OF THE THERMO-SOLAR PLANTAKOTRACE® is the WORLD LEADER given its complete solution that co-vers all of the essential aspects of the Thermo-Solar Plant and guaranteesthe 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 17
  • 9. INITIAL INVESTMENT PLANT PRODUCTION DAYS PRODUCTION EFFICIENCY (CAPEX) (PERFORMANCE-COSTS) AKO GLOBAL SOLUTION SCOPE BENEFITS Area of professionals in the Tracing application field Development of Solutions that reduce investment and Development of tools and solutions to manage Development of solutions to lengthen the working guarantee requirements operating risks and critical points in the Plant life of the facility, optimise heat tracing’s energy R&D Experimentation Room where we analyse the efficiency and its maintainability. behaviour of our global AKOTRACE solution, stress test, critical points analysis, performance & availability test of the system Team of graduate engineers with high level of OPTIMUM Technical-Financial calculation and sizing Engineering with successful results in over 20 Calculations and sizing to make the energy of the BASIC experience in electrical tracing and thermo-solar project for current and future Process requirements solar thermal Project that guarantee the correct Heat Tracing System efficient ENGINEERING plants in particular management of the criticality of the heat-tracing Team of Project Directors to guarantee compliance in system. time and quality. Advice to optimise the electrical tracing system in Integration of specialised and optimum components Wide range of our own highly reliable and dura- Technical solutions that guarantee the efficient per- TECHNICAL specifications phase. Electrical heat tracing system, in the electrical heat tracing field / thermo-solar ble Solutions to ensure the robustness and availa- formance of the System with a high manageability SOLUTION power and control panels & supervision system plants, the result of AKO’s over 30 bility of the System level Detailed engineering team and documentation for Standardisation of resources and processes for maxi- Avoid delays in the Commissioning of the Plant, a As built documentation with the maximum details PROJECT industrialisation in Project time mum Project efficiency, the result of our experience in crucial building phase: without time for manoeu- including photographic books) that allow the maxi- MANAGEMENT Team of Project Directors to guarantee compliance in thermo-solar plants. vre and with critical process (eg. Salt Melting) mum maintainability of the Plant time and quality. Own methodology, PROJECT MANAGEMENT Development of Own Know How and Installation Installation management and execution deadlines per- Management of the Start-up to guarantee the Training Plans for operating staff and maintenance protocols in thermo-solar plants fectly standardised based on our extensive experience. perfect start up of the Project and execution of staff that allow knowing and managing the electrical INSTALLATION Installation system inspection and safety protocols electrical heat tracing inspection Protocols. heat tracing system AND PEM Advice in the Start-up Training sessions for the plant’s operators Management and Environmental Quality Systems Global Quality System guarantees the compliance of Assurance of the Project’s quality and the com- Preventive Maintenance Programme to guarantee (ISO9001, ISO14001) the Project in form, time, costs and financial solvency ponents of the Heat Tracing System, by means of the efficiency and working life of the Heat Tracing GUARANTEE AND Internal quality protocols for materials and Project Field audits System QUALITY (Field Audits) Materials and installation Guarantee Plan Certifications18 19
  • 10. 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 tanks20 21
  • 11. 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 tanks22 23
  • 12. we make it easy we make it ecus earnings energy efficiency Joint Venture AKO Solutions optimize energy savings and the overal AKO solutions optimise energy savings and the global cost of the ins- cost of installation, offering the best technical-econo- tallations, offering the best Technical-Financial solution. mic solution. assessment connectivity Advice Continuously monitors real-time and the proper Our customers’ needs are our main worry, and knowing them allows functioning of the facility, locally or remotely. AKO to research and develop solutions with high added-value and re- liability. usability support Easy to install modular and scalable allowing correcti- ve action, without stops production processes.. Tools 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 safety & security Our Know-How do we know the points in the system, you avoiding the risk that a stop unwanted behavior. Passion 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.24 25
  • 13. HEADQUARTERS Spain Av. Roquetes, 30/ 38 08812 St. Pere de RibesFORWARD LOOKING APPROACH (Barcelona) España Tel. SAT (34) 902 333 145Our future is centred in the International Market Tel. (34) 938 142 700In AKO, we know our customers and their market Fax (34) 938 934 054needs with the aim of offering the best solution. ako@ako.comAKOTRACE® The Global Solution with over 30 yearsexperience and present in over 80 countries, we are SUBSIDIARIESconstantly growing, and 14% of our research is ear- Mexicomarked to R&D to develop the best solutions thanks AKO Electromecánica México, S.A. de C.V.to a qualified team with a high level of know-how Av. Lomas Verdes, 750, OF. 201 CP 53120 Naucalpan (Estado de México) Tel. (52) 5553 635 780...and always easy mexico@ako.com Portugal Rua Eucaliptos, 82-Ba. Encarnaçao 1800-202 Lisboa (Portugal) Tel. (+351) 218 522 405 Tel. SAT (+34) 902 333 145 Fax (+351) 218 514 621 portugal@ako.com EMEA (Europe, Middle East, Africa) emea@ako.comwe make it easy A&P (Asia & Pacific) a&p@ako.com N&LA (North & Latin America) n&la@ako.com
  • 14. www.ako.com