ESTABLISHMENT HISTORY Urals Power Engineering Company was established in 2002 in accordance with RAO UES of Russia restructuring plan. In August of 2004 the Company was restructured by a merger of the following organizations: • URALTEPLOELEKTROPROEKT, established in 1940 • URALORGRES, established in 1940 • URALSELENERGOPROEKT, established in 1951 • Ural. VTI, established in 1956 • URALVNIPIENERGOPROM, established in 1960 • URALENERGOSETPROEKT, established in 1962 • CHELYABENERGOSETPROEKT, established in 1969 2
ENERGOSTROYINVEST HOLDING Urals Power Engineering Company, JSC has been a part of Energostroyinvest Holding since 2008. Main activities: • • construction of thermal power plant with unit power up to 800 MW construction of HV and ultra-HV power lines and substations (110 -750 k. V) construction of fiber optic communication lines design of power plants and power grids ORGANIZATION 3
Surveys Feasibility Study EPC Services INTEGRATED ENGINEERING SERVICE Scientific Research; Inspection of Power Equipment Designer’s Supervision, Construction Supervision Design of Power Generation and Grid Facilities Integrated Adjustment and Startup 4
INTEGRATED ENGINEERING SERVICES Customer may be offered either a full set of services – “turn-key” construction of power facility from survey to putting the facility in operation, or individual services: ü Technical agent functions; ü Surveys ü Full set of design activities including feasibility study, and development of basic and detailed design; ü Functions of principal commissioning contractor. Being an EPC Contractor Urals Power Engineering Company is able to make the most effective and technically sound decisions due to joint work of specialists at each stage of project implementation. 5
MANAGEMENT SYSTEM ü Project management is performed on basis of Primavera software product with accounting of utilized resources and accurate follow-up on work schedule per Contract and design. ü Quality management is performed both at the Company level (works carried out in accordance with the Company’s Standards which is provided by internal checks and external audit; Quality Committee reviews Customer comments weekly), and at business unit level (Quality control of chief specialists and document quality control) ü Financial and budget management system is based on software product 1 С: ENTERPRISE v. 8 which provides the Company’s performance evaluation in general, for each business unit, and each Contract of the Company ü Human resource management system allows to maintain high level of offered services quality by means of constant upgrading of specialists’ technical proficiency and management skills, personal approach to key personnel of the Company. 6
DIVISIONS Division of Power Generation Facility Design (416 people) • Integrated design of thermal power plants and district heating mains EPC Division and Corporate Center (278 people) Division of Power Grid Facility Design (247 people) • Integrated design of power facilities Division of Engineering Surveys (134 people) • Integrated surveys • Unconventional types of work • Survey and analysis of soil civil materials Ural. VTI Branch (57 people) Ural OGRES (213 people) • Ensuring reliable operation of power equipment 7 • Integrated services on startup, precommissioning, testing and optimization of operation modes of main and auxiliary power plant equipment • Development and adjustment of distributed control systems
OPERATING PERSONAL STRUCTURE 96 18 Survey specialist engineers: (Geologists: 34; land-surveyors, topographers: 35; other specialists: 27) 217 Hydro power engineers 337 Electrical engineers Total number of staff (operating staff): Mechanical engineers 19 Project engineering managers Deputy/Assistant PEM’s Project managers 166 Civil/Structural/ Architectural engineers 8 1159 47 Constructions economics and cost estimation specialists 83 C&I engineers 176 Other disciplines and workers
ENGINEERING SURVEYS
Division of Engineering Surveys Key services : ü Geodetic survey ü Geologic survey ü Hydrometeorological survey ü Environmental survey ü Geophysical survey ü Geotechnical survey ü Laser scanning ü Laboratory research Major projects (surveys): • Urengoyskaya GRES (CCPP-450 MW); Novogorkovskaya CHP; Surgutskaya GRES (CCPP-800 MW); Nizhnevartovskaya GRES; Novobereznikovskaya CHP, Bereznikovskaya CHP -2; Tyumenskaya CHP -2; Reftinskaya GRES; Troitskaya GRES; Yuzhno-Uralskaya GRES; Sredneuralskaya GRES; Serovskaya GRES; Tom-Usinskaya GRES • 750 k. V power line Kalininskaya NPP – Gribovo; 500 k. V power line Severnaya-BAZ; 220 k. V power line Prizeiskaya-Elgaugol; 500 k. V power line Pomary-Udmurtskaya; 500 k. V power line Troitskaya GRES-Privalovskaya; Revamp of 500 k. V SS Kalino; 500 k. V power line to substation Shagol • Construction of residential houses in Akademicheskiy district of Ekaterinburg 10
Division of Engineering Surveys Equipment: • • • Own off-road vehicles for personnel, equipment and special machinery delivery to survey site Full set of ground-based equipment for geodetic survey and laser scanning Drilling equipment including machinery for off-road operation Equipment for field investigation of soils Equipment for geophysical survey Equipment for environmental survey Equipment and machinery for hydrometeorological survey Set of up-to-date laboratory equipment for soil and chemical research Full complex of IT-infrastructure, hardware and software for field and office treatment of survey materials and for print-and-copy reproduction of materials during development and replicating of technical reports Software: ü ü ü ü Autodesk Civil 3 D 2007 / Auto. CAD 2007 Raster. Desk; Geoni. CS / CREDO Map. Info Geo. Explorer Lakkolit Cyclone Geo. Scan 11
Division of Engineering Surveys Innovative methods for complex geodetic tasks based on groundmounted laser scanner Leica Scan Station and software complex Leica Cyclone. Such survey method combined with topographic survey will provide exhaustive geodetic and engineering information on the survey subject and surrounding situation. Aerial laser scanning has a number of advantages: ü scanning accuracy and speed (distance between points during scanning may reach up to 4 mm at a distance up to 50 m, during 90% shorter time); ü high degree of process automation; ü remote sounding if survey subject is difficult to reach, or if work is impossible in direct vicinity of the object; scanner is able to receive a point cloud remotely; ü integrity of the survey. During scanning, a laser scanner obtains a full 3 D model, an exact copy of actual object. This allows revisiting the model without additional site visit, if required, and receiving of any additional information not being the original purpose of the survey; ü simulated model provides information on types of equipment used on site without personal presence; ü the model provides for inspection of object technical condition.
Division of Engineering Surveys 34 38 Geologists Other specialist and workers Total number of staff (operating staff): 134 35 Geodesist, surveyors 13 27 Other
POWER GENERATION FACILITY AND POWER GRIDS DESIGN
DIVISION OF POWER GENERATION FACILITY DESIGN Key services: ü ü ü Integrated design of thermal power plants of various capacities; Central heating systems for cities and large industrial complexes; Feasibility review for investment projects and business planning in power engineering; District heating systems; Distributed control systems Major projects (design): ü ü ü Sredneuralskaya GRES (extension), 1 х CCPP 410 MW (put in operation in 2011); Surgutskaya GRES-2 (extension), 2 х CCPP 400 MW (put in operation in 2011); Reftinskaya GRES (ash-handling system revamp) (to be put in operation in 2013); Tyumenskaya CHP-1 (2 nd stage rebuild), 1 х CCPP 220 MW (put in operation in 2010); Tobolskaya CHP (revamp, including installation of 110 MW add-on turbine) (put in operation in 2011) Permskaya CHP-6 (110 k. V Switchyard revamp) (put in operation in 2010); Yuzhno-Priobskaya PP, 96 MW (put in operation in 2010) Akademicheskaya CHP CCPP 230 MW (to be put in operation in 2015) Tom-Usinskaya GRES (revamp of main equipment of Units 4 and 5) (to be put in operation in 2013) Nizhnekamskaya CHP (installation of low grade steam turbines) (commenced in September 2012) Kachkanarskaya CHP (extension and revamp) (commenced in October 2012) 15
DIVISION OF POWER GENERATION FACILITY DESIGN Software: ü General Layout (Autodesk Civil 3 D; Auto. CAD 2007; Raster. Desk; Geoni. CS) ü Civil/Structural (Autodesk Architectural Desktop; Project Studio. CS; SCAD Office) ü Architecture (Autodesk 3 D Max) ü Mechanical (Autodesk Auto. CAD 2007; PLANT-4 D; AVEVA PDMS; Piping Systems Fluid Flow) ü Electrical (Autodesk Auto. CAD 2007; Electri. CS 3 D; Electri. CS Storm; Electri. CS Light; Energy. CS; Project Studio. CS) ü Hydraulic Engineering (Autodesk Civil 3 D 2007; PLATEIA; PLAXIS Professional; PLAXIS Flow; Piping Systems Fluid Flow) ü Water Supply and Sewage (Autodesk Auto. CAD 2007; Project Studio. CS ) ü HVAC (Autodesk Auto. CAD 2007; АРС-ПС; Potok – 1 F; TEPLOOV) ü Cost Estimates (АВС-4 PC; ESTIMATE, Grand-Smeta) 16
DIVISION OF POWER GENERATION FACILITY DESIGN Design Environment AVEVA PDMS is a software for complex 3 D design by several disciplines within a single information environment. Main functions of 3 D modeling system – (1) layout of equipment and civil structures using equipment and material database and (2) issue of basic and detailed design documentation (drawings and bills of quantities). Since 3 D model contains information from all disciplines it enables detection of all possible interferences between equipment and civil structures and simplifies interface between different disciplines within a single information environment. AVEVA PDMS is a multiuser design environment with centralized data storage for all design disciplines involved in 3 D modeling of power industry facilities. The system includes modules for design of equipment, piping, cable trays, HVAC and civil design. 17
DIVISION OF POWER GENERATION FACILITY DESIGN 22 89 Electrical engineers Constructions economics and cost estimation specialists 56 C&I engineers 18 11 Hydro power engineers Total number of staff (operating staff): 119 Civil/structural/ architectural engineers 416 Project engineering managers Deputy/Assistant PEM’s Project managers 21 Other disciplines and workers 80 Mechanical engineers 18
ENERGOSETPROEKT Key services: • • • Forecasting and proactive planning in the field of energy system development; Development of power grid schemes for large consumers – 110, 220, 500 k. V – and smaller users, i. e. towns and cities with 0. 38 – 10. 35 k. V grids; Feasibility study for construction of new power grid and power generation facilities; Comprehensive design for power grids, including green field construction, expansion, revamp, upgrade of main and distribution grids; Power evacuation studies Software : • • • Power Systems (Autodesk Auto. CAD 2007; MUSTANG; Rastr. Win; HMI СРЗА; Map. Info) Transmission Facilities (Autodesk Auto. CAD 2007; Energy. CS Line; Real Steel) Electrical (Autodesk Auto. CAD 2007; Electri. CS 3 D; Electri. CS Storm; Electri. CS Light; Energy. CS; Project Studio. CS) Water Supply and Sewage (Autodesk Auto. CAD 2007; Project Studio. CS) HVAC (Autodesk Auto. CAD 2007; TEPLOOV) Cost Estimates (АВС-4 PC) 19
ENERGOSETPROEKT Major projects (design): ü ü ü ü 500 k. V substation revamp: Zlatoust, Shagol, Kalino, Tagil, Vyatka; External power supply for AVISMA. 200 k. V substation Kosmos with 220 k. V power line; Rebuild of big crossing of Sanina river by power line-500 k. V Surgut GRES-2 – Pyt-Yakh; National Power Grid Development (UES of Urals), voltage 220 k. V and over, for the period of 2003 -2012; Development of 110 -220 k. V power grids of Ekaterinburg and neighborhoods till 2010 -2025 (load 1700 -2100 MW within city limits); External power supply for Surgut for the period of 2005 -2010 with prospective till 2015; Development of power grids 110 k. V and over; Power evacuation study for Unit 4, Beloyarskaya NPP; 500 k. V power line Kurgan – Kozyrevo; 500 k. V power line Severnaya – BAZ, with extension of Substation-500 k. V BAZ; 500 k. V power line Kholmogorskaya – Muravlenkovskaya – Tarko-Sale with Substation-500 k. V Muravlenkovskaya; 220 k. V substation Elgaugol and 220 k. V power line Prizeyskaya – Elgaugol, circuit I, II, 220 k. V substation "А" and 220 k. V substation “B“; 500 k. V substation Kholmogorskaya, 220 k. V substation Yanga-Yaha; 500 k. V Power line Troitskaya GRES – Privalovskaya. 500 k. V Power line Pomary - Udmurtskaya 20
ENERGOSETPROEKT 17 20 Other disciplines and workers Constructions economics and cost estimation specialists 8 Total number of staff (operating staff): Project engineering managers Deputy/Assistant PEM’s Project managers 247 5 C&I engineers 32 Civil/structural/ architectural engineers 21 165 Electrical engineers
INTEGRATED ADJUSTMENT. TESTS.
Ural. ORGRES Key services: ü ü Set-up activities, thermal and balance testing of existing power plant equipment aimed to increase the efficiency, optimize operation modes and reduce environmental impact services of head commissioning contractor, construction and upgrade of power facilities on basis of subcontract Integrated commissioning, adjustment and startup of new and auxiliary thermal power plant equipment, inspection of technical condition and industrial safety examination of hazardous operation facilities (power equipment, buildings and facilities, etc), including approval of results by Rostechnadzor, energy audit Research and development activities aimed at improvement of processes in the field of power engineering, power equipment, buildings and facilities; development of technical, methodological and operational documentation Major projects : • • • • Commissioning of turbine Р-100 -130 (Unit 3) with installation of add-on turbine К-110 -16 at Tobolskaya CHPP as head commissioning organization , and certification tests and primary frequency control tests Commissioning and optimization of Unit 2, CCPP-190/220 at Tyumenskaya CHPP-1 Participation in commissioning of 410 MW CCPP at Sredneuralskaya GRES (Enel OGK-5) Turn-key construction of dry ash removal system at Gacko TPP (Serbia) Commissioning of main turbine К-660 by Power Machines (LMZ) at Units 1, 2, 3 of Sipat TPP (India); Commissioning and optimization of Gas Turbine Power Plant at BKPRU-4 for Ural. Kali. Commissioning works at steam boiler room and chemical water treatment system for CCPP-120 at Permskaya CHP-6 Turn-key construction of automatic power control system at BOP equipment of Yuzhnouralskaya GRES - OGK-3, JSC Guarantee tests of Electrostatic Precipitators manufactured by Alstom, Unit 6, Reftinskaya GRES Development of Environment Impact Assessment (EIA) for Unit 3, CCPP-800 at Nizhnevartovskaya GRES Development of revamp project for Verkhnetagilskaya GRES boiler Complete thermal testing of turbine К-1000 -60/3000 at Unit 3 of Kalininskaya NPP Construction and installation works for “Akademicheskaya CHP Construction” design, construction phase 1 23
Ural. ORGRES 13 C&I engineers 6 Civil/structural/ architectural engineers 15 Commissioning and Testing Department specialists Total number of staff (operating staff) 35 Electrical engineers 11 Construction, installation and general contract works managers 213 113 Mechanical engineers 20 Other disciplines and workers Software: 24 Auto. CAD SPDS Grafi. CS 4. 0 Ecolog 3. 0 Standard SUBGRAPH 3. 0 CREDO NIVELIR GRAND SMETA GRAND STROYINFO Zulu 5. 2. , 6. 0 Visual Fox. Pro 9. 0 Professional Visual Fox. Pro 9. 0 Baseline PROMT Professional 7 Giant Geo. Scan 32 2. 400 Corel. DRAW Grafics Suite X 3
SCIENTIFIC RESEARCH; INTEGRATED INSPECTION OF POWER EQUIPMENT
Ural. VTI Branch Key Activities: ü Industrial safety evaluation (boiler inspection), integrated inspection, evaluation of technical condition and remaining service life of power plant equipment, turbine rotor diagnostics ü Inspection and adjustment of piping supports and hangers including those at new power Units ü Research and firing of offspec coals at thermal power plants and boiler upgrade designs for transfer to offspec coal ü Optimization and testing of boiler equipment including that fired by offspec coal ü Design of new fuel handling systems and revamp of fuel supply lines at power plants and individual fuel handling systems ü Manufacturing and supply of equipment for incoming and process control over fuel quality (sample preparation machine MPP-150/3; ü R&D in the field of development of diagnostic equipment and NDT methods ü R&D in the sphere of coal and boilers using firing facility of Ural. VTI 26
Ural. VTI Branch Major projects: ü Metal monitoring, technical diagnostics, industrial safety evaluation and prolongation of service life of power equipment at Yuzhnouralskaya GRES ü Pilot firing of offspec coals (Yuzhnouralskaya GRES and Gusinoozerskaya GRES (OGK-3), Reftinskaya GRES (OGK-5), Verkhnetagilskaya GRES (OGK-1), Mechel-Energo CHP, AES –Ekibastus GRES-1 and AES – Ust-Kamenogoskaya CHP (Kazakhstan)); ü Design of Gusinoozerskaya GRES Unit 2 upgrade for firing of coal from Okino-Klyuchevskoy mine ü Inspection and adjustment of piping supports and hangers at Unit 3, 230 MW CCPP of Chelyabinskaya CHP-3, FORTUM JSC after installation ü Fuel handling design for Unit 9 with hot fluidizing bed boiler at Novocherkasskaya GRES ü Development of automated complex GIB-2 M for NDT of piping and bends at interior side without removal of thermal insulation for Zainskaya GRES, Generating Company JSC (Tatarstan) Customers and facilities: In Russia: OGK-1, OGK-2, OGK-3, OGK-4, OGK-5, TGC-2, TGC-5, TGC-7, TGC-8, TGC-13, TGC-14, FORTUM JSC, Generating Company JSC (Kazan), Power Machines - LMZ In CIS: Ekibastuz GRES-1, Ekibastuz GRES-2, Ust-Kamenogorskaya CHP (Kazakhstan); Moldavskaya GRES (Moldova) In Europe: Agios Dimitrios TPP, Kardia TPP, Amindeon TPP (Greece); Plevle TPP (Montenegro); Bitola TPP (FYROM)
Ural. VTI Branch Total number of staff (operating staff) 33 57 Other disciplines and workers 24 Thermal power engineers Software : • estimates and simulation of aerodynamics, heat exchange processes, burning and slag formation processes in boilers: Sigma Flame, Boiler designer, Math. CAD • strength and flexibility analysis of piping supports and hangers: RAMPA, Math. CAD, Ansys, START • power equipment elements stress analysis: Ansys • design of NDT instruments and equipment: Visual studio, COMPAS-GRAFIK, Auto. CAD 2007 • design of fuel handling units and systems, and design of boilers: COMPAS-3 D, Auto. CAD 2007 • cost estimates: Grand Smeta • project management: Primavera, MS Project 28
EPC Services
EPC Services Key Activities: Expert evaluation of completed basic and detailed design in order to ensure: Optimization of design solutions; Reduction of project implementation timeframes and costs; Arrangement of onsite construction and installation activities : Formation of individual pool of subcontractors; Arrangement and conducting of bidding processes for award of subcontracts addressing Customer’s requirements; Development and monitoring over performance of integrated preparatory works; General arrangement of onsite activities (security, video surveillance, management, procurement, etc. ); Construction supervision; Work planning, approval by Customer, reports; Designer’s supervision; Preparation of as-built documents; Equipment supplies: Arrangement and conducting of bidding processes for award of subcontracts addressing Customer’s requirements; Support of equipment delivery to Site; Arrangement of equipment incoming control; Putting the facility in operation: Performance of principal commissioning contractor functions, development of commissioning procedures; Facility handover to Rostechnadzor or other authorities/authorized organizations Arrangement of guarantee maintenance Integrated performance of all above activities and facility handover on “turn-key” basis Our company has a serious experience in interface and established contacts with major foreign EPC contractors. In case of technically or organizationally complex projects (including those based on imported equipment), Customer will be offered best foreign project management practices. 30
EPC SERVICES Completed Projects: 1. EPC Contract: design, manufacturing, testing, delivery, installation, completion and startup of Internal Fly Ash Removal System Replacement Project for Gacko TPP. New internal pneumatic fly ash transportation system from hoppers of two ESP’s of 300 MW Unit with capacity of 100 t/h. Bosnia and Herzegovina / Republic of Srpska. Project status – completed 2. EPC Contract: design, delivery, and turn-key construction of pilot ash removal station of Units 1&2 at Eesti Power Plant with capacity of 240 t/h. Eesti Power Plant Site in Narva (Republic of Estonia) Project status – completed 3. EPC Contract: Akademicheskaya CHP construction phase 1. 4 -a Skaldskoy lane, Ekaterinburg Project status – Final stage 4. EPC activities for 410 MW CCPP at SUGRES (principal commissioning contractor): facility startup for commercial operation with observance of all required parameters. Project status – completed 5. Currently Urals Power Engineering Company has been awarded a contract and is starting activities on second construction phase of Akademicheskaya CHP (230 MW CCPP). 4 -a Skaldskoy lane, Ekaterinburg 31
EPC Services Typical Project Management Organization Customer Ural. ORGRES Project Team Manager from Corporate Center Division of Power Generation Facility Design Project Director Planning and Contract Dept. Comprehensive Commissioning, Technical Examination, Start-up Designer Supervision Team Procurement Dept. Deputy Site Project Manager Corporate Center Industrial Engineering Dept. Preparatory Work Dept. Work Monitoring Team Civil/ Installation Procurement Team Documents Preparation Team Ural. ORGRES Site Project Manager Document Control Technical archive Cost Estimate Dept. Site Operational Support Service Electrical, I&C Team HSE Team Division of Power Generation Facility Design Urals Power Engineering Company Efficiency of EPC services is ensured among other tings by direct interface inside a single company between EPC specialists and “survey” and “integrated commissioning” specialists during Facility construction/revamp. 32
CERTIFICATES
ü ü ü ü ü Certificate in international certification system IQNET No. RU-Q 00982 Certificate in certification system GOST R No. РОСС RU. ИСО 9. К 00982 Certificate in environmental management system No. РОСС RU. ФК 13. К 00023 Certificate of self-regulating organization for design activities (SRO NP Urals Architectural and Civil Design Society) Certificate of self-regulating organization for survey activities (SRO NP Tsentrizyskaniya) Certificate of self-regulating organization for construction activities (SRO NP Stroiteli Sverdlovskoy Oblasti) Certificate on qualification of NDT laboratory. Issued by Independent NDT laboratory certification authority. Certificate on authorization for testing. Issued by voluntary certification system for power engineering En. SERTIKO. Accreditation certificate of test laboratory for fuel inspection and firing issued by Federal Agency for Technical Regulation and Metrology Certificate of membership in non-commercial partnership Soyuz Energoeffektivnost (energy inspections). 34
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