STEAG Energy Services O&M for Solar Thermal Power Plants Winfried Ortmanns STEAG Energy Services Solar STEAG Group 780 MW Bergkamen A Bergkamen Herne Lünen 6/7 1,504 MW Bexbach / Weiher 960 MW Herne 2/3/4 Bexbach 1 / Weiher 3 Iskenderun 1/2 1,320 MW Iskenderun 507 MW Lünen Mindanao 1/2 232 MW Mindanao STEAG - Power Plant Sites based on fossil-fuels Voerde 1/2 A/B 2,234 MW Voerde 211 MW Refinery captive Köln-Godorf Refinery 165 MW Termopaipa IV Paipa hard coal coke oven gas Walsum 9/10 1,350 MW Duisburg Refinery captive 162 MW Leuna Refinery MKV, HKV, MHK *) 466 MW Völklingen-Fenne refinery by-products 2 STEAG Energy Services Group Susidiaries: • Brazil • India • Switzerland • South Africa • Spain • Turkey • USA STEAG Energy Services Energy Technologies Design, site supervision and commissioning of power plants Plant Services Nuclear Technologies Operation & Maintenance, catalyst management and –regeneration, personnel services Decommissioning and dismantling of nuclear plants, safety, radiation protection and realization of final disposal sites System Technologies Energy Management Systems, process optimization by sensor-based solutions, user trainings Information Technologies Operation Management Systems, Communication Technologies, Site IT 3 International Operation & Maintenance Rades II 471 MW El Kureimat 1.300 MW 2004 - 2010 Arenales 50 MW CSP 2001 – 2006 2013 - 2030 RAWEC 360 MW 2013 - 2014 Bathinda 165 MW 2011 - 2016 Gandhar 30 MW 2003 - 2007 Afam V/VI 900 MW CSA Sepetiba 480 MW 2005 - 2009 Haldia 116 MW 2007 - 2012 2006 - 2014 Canoas 160 MW Vedanta 2.400 MW 2001 - 2011 2010 - 2017 Santa Maria I, 350 MW 2010 - 2013 Agua del Cajón 680 MW 1999 - 2002 Ikot Abasi 540 MW 2002 - 2004 Hazira 507 MW Morupule B 600 MW 2013 - 2014 2001 - 2016 Goa 30 MW 2006 - 2009 Vishakhapatnam 1040 MW 2012 - 2027 Projects in Execution Finished Projects 4 CSP Technology at a Glance Solar field Oil tank Re-heater Super-heater Condenser Vaporizer Gen Set Pre-heater Feed water heating 5 Technical data CSP Arenales Nominal Capacity 1 x 49,9 MWe Solar Field Nominal Capacity 510.120 m² 290 MWth Storage Nominal Capacity 24.500 tons Molten Salt 943 MWhth Est. electricity generation: 170 GWh p.a. 6 Standard CSP O&M Responsibility COD Construction Years • • • 1 Comm. 2 FAC Acceptance Acceptance Test Test 3 4 Operation 5 CSP mostly project financed CSP still considered as „unproven technology“ Financing institutions require EPC contractors to remain in the plant Challenges for the Owner • EPC tends to optimize plant on CAPEX vs. OPEX • Owner has little insight on the plant for a longer period Mitigation • EPC required to take ownership (but again CAPEX vs. OPEX) 7 Improved CSP O&M Responsibility COD Construction Years • • 1 FAC Comm. Operation Acceptance Test 2 3 4 Operation 5 Eliminate long term acceptance test Include O&M contractor already during construction & commissioning Benefits for the Owner • O&M tends to optimize plant on OPEX vs. CAPEX • Owner has more insight on the plant via O&M Contractor 8 Staffing CSP Project Plant Manager Operation Manager Maintenance Manager Shifts [5x4] Electrical [6] Solar Field [6] Mechanical [7] General [5] Chemical [1] Total: 48 9 CSP O&M Costs Variable O&M Cost << Fixed O&M Cost • Due to absence of fuel / ash / emission cost • Due to low consumable cost • Due to high capital cost (3000 – 6000 EUR/MWe installed) • Due to small capacities (~50 MWe) • High Internal Labor Quota (Internal/External) > 1 Example: Internal Staffing Cost in EUR per MWh Coal 0,5 Combined Cycle CSP 2 11 10 How to lower O&M Cost for CSP? Increase capacity of project • Out of Operater scope Virtually combine projects (synergy effects) • Requires increased management structure • Multi project management (> processes) • Multi resource management (> processes) Increase quality and structure of O&M services • Streamlined O&M processes and procedures • Centralized CMMS • Centralized O&M backoffice management (procurement, reporting, data and document management) October 22nd, 2013 Arab-German Energy Forum 11 Project Challenges • • • Political / contractual setup of the ownership, EPC and O&M contract Availability of both CSP and conventional PP trained personnel Quality of EPC delivery • • Quality of cooling water Quality issues of the delivered CSP plant (civil, I&C automatization, HSE) Operational issues such as high fluctuation of heat input during winter and spring time Load limitations, changes to standby operation Synchronization of optimum solar field operation, optimum storage operation and optimum turbine operation • • • October 22nd, 2013 Arab-German Energy Forum 12 Conclusions SH(ESG1 • Ideal O&M Setup requires 3rd party O&M contractor in order to challenge technology provider for sustainable solutions • Spanish CSP change of FIT results in extreme cost pressure on O&M contractor and thus unlocks cost optimization potential on O&M side • Experience from conventional thermal power plants is essential for the cost optimization aproaches and operational challanges of the solar steam water cycle October 22nd, 2013 Arab-German Energy Forum 13 Folie 13 SH(ESG1 Schierenbeck, Heiko (STEAG Energy Services GmbH); 22.10.2014 Project Impressions CSP Arenales – View from North 15 CSP Arenales – View from South 16 Power Block and Balance of Plant 17 Power Block and Balance of Plant (South View) 18 Molten Salt Storage 19 HTF Steam Generator 20
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