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AKOTRACE the integral solution forheat tracing

AKOTRACE the leading heat tracing solution

for CSP technology


ELECTRICAL HEAT TRACING MANAGEMENT: CRITICAL POINT FOR CSP PLANTS 5


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 “SOLAR 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:

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PLANT INVESTMENT (CAPEX)

DAYS OF PRODUCTION

EFFICIENCY IN PRODUCTION: PERFORMANCE-PRODUCTION AND OPERATING COSTS BINOMIAL

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OTRACE

AKOTRACE

intregral de traceado eléctrico

RED DE ENERGÍA ELÉCTRICA

the integral heat tracing solution

ELECTRICAL POWER TO GRID

abast

TANQUE SAL CALOR

HOT SALT TANK TURBINA GENERADOR VAPOR

HTF CALOR

STEAM TURBINE GENERATOR

HTF HOT

OLAR

SOLAR FIELD

ELECTRICAL HEAT TRACING IS CRITICAL FOR ENERGY PRODUCTION PROCESSES IN CSP THERMO-SOLAR PLANTS HTF FRÍO

OIL / STEAM HEAT EXCHANGER

INTERCAMBIADOR ACEITE/VAPOR CALOR

INTERCAMBIADOR ACEITE/SAL CALOR

TANQUE SAL FRÍO

CONDENSADOR

TORRE REFRIGERACIÓN

HTF COLD

OIL / SALT HEAT EXCHANGER

COLD SALT TANK

CONDENSER

COOLING TOWER

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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 thermoelectrical 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

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INCREASE THE COSTS OF ELECTRICAL SELF-CONSUMPTION AND MANAGEABILITY OF THE PLANT

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ASSOCIATED TECHNICAL RISKS 13


CSP PLANT PERFORMANCE INVESTMENT (CAPEX)

DAYS OF PRODUCTION OF THE THERMO-SOLAR PLANT

PRODUCTION EFFICIENCY (PERFORMANCE-COSTS)

IMPACT

MAIN RISK

SOURCE OF THE RISK

Non-desired stoppages due to the freezing of heat carrying fluids or water

Lack of thermodynamic engineering expertise: Under-sized system Weak Control solution: Lack of information in real time para for corrective detection of faults: BREAKDOWNS Bad Installation practice

1 day of no production in the plant at €195.000 of loss of earnings (€120.000 in plants without accumulation)

Non-foreseen investments or interventions in the plant operation phase

Lack of tracing engineering expertise: Under-sized system

CAPEX Budget Variance from €150.000 to €225.000 (10-15% budget variation)

Delays in Start-up in a Project Phase without time for reaction as tracing is one of the last supplies

Weak Control & Supervision solution Bad Project Management / Lack of Experience (Project Management) Bad Installation practice

1 day of no production in the plant at €195.000 of loss of earnings (€120.000 in plants without accumulation)

Loss of performance efficiency due to incorrect temperature regulations of the processes (HTF, Salts, BOP)

Lack of thermodynamic and control engineering expertise: Under sized system Weak regulation solution:

Increases in energy expenditure from €38.000 a year (5% increase in electrical consumption of the tracing system)

Lack of historic information to improve the performance of the plant

Weak control & supervision solution

Non-implementation of operating improvements in the 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 Bad Installation practice Weak Operator Training in Plant

Costs due to accidents / Sick leaves

Intervention costs in repair of the tracing and/or associated damaged equipment up to 6 million Euros

*Estimated a 50 MW CSP Plant (molten salts) 15

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AKOTRACE速 IS THE PERFECT SOLUTION FOR THE OPTIMUM PERFORMANCE OF THE THERMO-SOLAR PLANT AKOTRACE速 is the WORLD LEADER given its complete solution that covers 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

WARRANTY AND QUALITY

INSTALLATION AND START-UP

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INITIAL INVESTMENT (CAPEX) AKO GLOBAL SOLUTION

SCOPE Area of professionals in the Tracing application field

PRODUCTION EFFICIENCY (PERFORMANCE-COSTS)

BENEFITS Development of Solutions that reduce investment and guarantee requirements

Development of tools and solutions to manage operating risks and critical points in the Plant

Development of solutions to lengthen the working life of the facility, optimise heat tracing’s energy efficiency and its maintainability.

Team of graduate engineers with high level of experience in electrical tracing and thermo-solar plants in particular Team of Project Directors to guarantee compliance in time and quality.

OPTIMUM Technical-Financial calculation and sizing project for current and future Process requirements

Engineering with successful results in over 20 solar thermal Project that guarantee the correct management of the criticality of the heat-tracing system.

Calculations and sizing to make the energy of the Heat Tracing System efficient

Advice to optimise the electrical tracing system in specifications phase. Electrical heat tracing system, power and control panels & supervision system

Integration of specialised and optimum components in the electrical heat tracing field / thermo-solar plants, the result of AKO’s over 30

Wide range of our own highly reliable and durable Solutions to ensure the robustness and availability of the System

Technical solutions that guarantee the efficient performance of the System with a high manageability level

PROJECT MANAGEMENT

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

Standardisation of resources and processes for maximum Project efficiency, the result of our experience in thermo-solar plants.

Avoid delays in the Commissioning of the Plant, a crucial building phase: without time for manoeuvre and with critical process (eg. Salt Melting)

As built documentation with the maximum details including photographic books) that allow the maximum maintainability of the Plant

INSTALLATION AND PEM

Development of Own Know How and Installation protocols in thermo-solar plants Installation system inspection and safety protocols Advice in the Start-up Training sessions for the plant’s operators

Installation management and execution deadlines perfectly standardised based on our extensive experience.

Management of the Start-up to guarantee the perfect start up of the Project and execution of electrical heat tracing inspection Protocols.

Training Plans for operating staff and maintenance staff that allow knowing and managing the electrical heat tracing system

Management and Environmental Quality Systems (ISO9001, ISO14001) Internal quality protocols for materials and Project (Field Audits) Materials and installation Guarantee Plan Certifications

Global Quality System guarantees the compliance of the Project in form, time, costs and financial solvency

Assurance of the Project’s quality and the components of the Heat Tracing System, by means of Field audits

Preventive Maintenance Programme to guarantee the efficiency and working life of the Heat Tracing System

R&D

BASIC ENGINEERING

TECHNICAL SOLUTION

GUARANTEE AND QUALITY

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PLANT PRODUCTION DAYS

Experimentation Room where we analyse the behaviour of our global AKOTRACE solution, stress test, critical points analysis, performance & availability test of the system

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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 22

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we make it easy earnings

we make it ecus energy efficiency

AKO solutions optimise energy savings and the global cost of the installations, offering the best Technical-Financial solution.

AKO Solutions optimize energy savings and the overal cost of installation, offering the best technical-economic solution.

assessment

connectivity

Joint Venture

Advice

Our customers’ needs are our main worry, and knowing them allows AKO to research and develop solutions with high added-value and reliability.

Continuously monitors real-time and the proper functioning of the facility, locally or remotely.

usability support Tools

Our experience has allowed us to form an internal team of professionals to offer integral support: from Project Design to the Start-up of the System

you

Easy to install modular and scalable allowing corrective action, without stops production processes..

safety & security

Our Know-How do we know the points in the system, 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

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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 earmarked to R&D to develop the best solutions thanks to a qualified team with a high level of know-how ...and always easy

HEADQUARTERS Spain Av. Roquetes, 30/ 38 08812 St. Pere de Ribes (Barcelona) España Tel. SAT (34) 902 333 145 Tel. (34) 938 142 700 Fax (34) 938 934 054 ako@ako.com SUBSIDIARIES Mexico 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 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

we make it easy

EMEA (Europe, Middle East, Africa) emea@ako.com A&P (Asia & Pacific) a&p@ako.com N&LA (North & Latin America) n&la@ako.com


www.ako.com

Risks of an Inadequate Electrical Trace Heating Solution  

An electrical heat tracing system represents just 0,5% of the total investment in a CSP project, but its failure could lead to major losses...

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