RWE Power International ENGINEERING & CONSULTING SERVICES DRIVEN BY RWE’S OPERATIONAL AND NEW BUILD EXPERIENCE
RWE Power International
ENGINEERING & CONSULTING SERVICESDRIVEN BY RWE’S OPERATIONAL AND NEW BUILD EXPERIENCE
ABOUT US 32 RWE POWER INTERNATIONAL – RE GMBH
• is RWE’s engineering consulting company. Our
highly specialised expertise and outstanding per-
formance stem from our employees’ experience
as part of one of the world’s largest energy and
mining groups.
• offers external clients tried and trusted procedures
and innovative solutions that have proven to be
effective within RWE for widely diversified projects
employing the latest construction methods. As an
owner and operator, we are independent of suppli-
ers and equipment manufacturers.
• represents the skill set of the RWE Group.
• RE GmbH, formerly RHEINBRAUN ENGINEERING,
was founded in 1965.
Mining
Power Generation
Our services
• Our services cover all aspects of the power genera-
tion business. This includes everything from feasi-
bility through to planning, construction as well as
commissioning, operation, maintenance and – if
needed – decommissioning.
• Our in-depth knowledge of mining incorporates
diverse types of ore and coal, and ranges from
feasibility and mine development to operation,
maintenance and recultivation.
• With over 50 years of experience in large-scale
mining projects, we are in the ideal position to
provide unrivalled support to our clients for the
construction and optimisation of conveyor systems.
Our team
• RWE Power International’s success is built on the
capabilities of our talented specialists in a variety
of disciplines: project managers, quality managers,
engineers, procurement and claim experts, design-
ers, planners, geologists, environmental scientists
and economists. Numerous other specialists from
associated disciplines contribute to our team’s
strength.
• Our clients around the world benefit from our inde-
pendent engineering expertise. Our experts have
many years of invaluable practical insights acquired
through the operation of our own power plant and
mining sites.
Our worldwide project locations
RWE POWER INTERNATIONAL – RE GMBH
GENERATION BACKGROUND 54 RWE – POWER GENERATION
50 GW INSTALLED CAPACITY. 18,000 EMPLOYEES. 70+ LOCATIONS. OUR POWER GENERATION KNOWLEDGE BASE
RWE operates
• the most diversified generation mix in Europe:lignite, hard coal, biomass, gas, hydro and nuclear.
• one of Europe’s largest and most efficient gas fired powerplants (CCGT): Pembroke Power Station produces over 2,000 MWat 58% efficiency.
• the world’s most efficient super critical lignite fired power plants:BoA 2&3. Each unit has a capacity of 1,100 MW and 42% efficiency rating.
• the first industrial size continuous lignite drying plant:fluidised-bed drying with internal waste heat utilisation,wet coal ~210 t/h, dry coal ~110 t/h.
• the most modern hard coal power plant which can be partially fuelled by biomass: Eemshaven Power Station will produce1,600 MW at 46% efficiency.
Eemshaven
Start-up: 2014Fuel: hard coal/biomassCapacity: 1,560 MW
Denizli
Start-up: 2013Fuel: natural gasCapacity: 775 MW
WestfalenUnit D/E
Start-up: 2013Fuel: hard coalCapacity: 1,528 MW
Pembroke
Start-up: 2012Fuel: natural gasCapacity: 2,188 MW
Staythorpe
Start-up: 2011Fuel: natural gasCapacity: 1,700 MW
EeEeEeEe
StaStaStStFuFuFuFuCa
Moerdijk 2
Start-up: 2012Fuel: natural gasCapacity: 426 MW
Mo
StaStaStaFueCaCa
Claus C
Start-up: 2012Fuel: natural gasCapacity: 1,304 MW
WWeUUn
StaaaStarStaFFFueFueCap
BoA 2&3Neurath
Start-up: 2012Fuel: ligniteCapacity: 2,200 MW Lingen
Start-up: 2010Fuel: natural gasCapacity: 887 MW
By 2014 RWE will have renewed 25% of its generation fleet.
POWER GENERATION SERVICES 76 POWER GENERATION SERVICES
Health and Safety, Quality, Environment
Project and technical services:
• Expediting and on-site surveillance
• Quality control and inspections
• Expert witness, materials testing and damage
analysis
• Consulting on materials and technical components
Management system services:
• Quality management system development
• Environmental management system development
• Supplier quality evaluation and auditing
Documentation services:
• Document management
• Technical data management
Nuclear Industry
• Technical analysis of nuclear new build projects
• Operational safety assessment of Nuclear Power
Plants (NPP’s)
• Efficiency enhancement of NPP’s
• Maintenance measures and outage performance
management
• Transfer of management know-how and safety
culture
• Training tailored to local requirements
Maintenance Services and Ash Products
TSG Ferrybridge
• Maintenance, overhaul and modification
• Outage management
• Support for plant refurbishment, repair and
upgrade
• Inspections
• Manufacturing of spare parts
• Steam and gas turbine specialist services
Generation Aggregates
• Provision of cost effective, readily available
ash products for construction and engineering
applications
• Monitoring of ash quality in accordance with the
Quality Protocol to ensure its suitability
• Advice on the standards relevant to the use of ash
• Provision of technical data to enable you to assess
the suitability of ash in your particular application
• Advice on best practices for use in your application
Project Development and Management
From preliminary study to investment decision
• Site evaluation
• Estimation of capital expenditure (Capex)
• Concept, pre-feasibility and feasibility studies
• Project scheduling and cost estimations
• Technical due diligence
• Support of studies for licensing and permits
• Development of contract/procurement strategy
• Supplier evaluations
• Project planning, controlling and monitoring
Engineering Support
• Technical contract management
• Design management
• Technical specifications and definition of
requirements
• Review of basic/detailed engineering
• Interface management for technical lots
• Technical consultancy in specialist areas
• Plant operation optimisation and operational
support
• Retrofit and lifetime extensions
Achieve sustainable improvement in plant performance with the support of RWE Power International’s cutting-edge services.
Project planning, controlling and monitoring Retrofit and lifetime extensions
EXPERIENCED. FOCUSSED. FLEXIBLE.
4QUALITY
2 PROJECT ENGINEERING
INITIAL IDEA1
3 CONSTRUCTION
5HANDOVER
!PLANNING, CONTROLLING AND DELIVERING
POWER GENERATION PROJECT EXPERIENCE 98 POWER GENERATION PROJECT EXPERIENCE
NEW BUILD
REPLANTING
RWE Power International possesses worldwide experience in the modernisationand replanting of all types of power stations.
We make use of our in-depth knowledge to secure
the long-term value of our clients’ assets. Our engi-
neers help our clients to extend the life of their
power plants and make lasting improvements to
plant performance.
Numerous power plants around the world serve as
examples of how successful we are at modernising
and refurbishing existing plants. For example, in
Hungary and
South Africa,
we succeeded
in increasing
the output of
several power plants whilst also significantly extend-
ing their operational life and ensuring full compli-
ance with environmental requirements.
In south eastern Europe, we supported several boiler
system modernisation projects. In the first stage of
these projects, we provided the technical specifica-
tions with particular focus on increasing efficiency
and reducing NOx emissions. Subsequently we
assisted with the evaluation of bids for tender.
During the refurbishment stage we advised the
owner regarding the ongoing works on-site and in
technical discussions with suppliers.New turbines for CCGT Little Barford, UK
When it comes to the construction of modern power plants, there are few energy businesses that have as much international experience as RWE Power International.
From conventional electricity generation to regener-
ative technologies, from large-scale power plants to
smaller, decentralised systems: our engineers have a
wealth of experience as owners and operators of the
most diverse types of power plants.
A good example of RWE Power International’s new-
build projects is the BoA 2&3 project in Neurath,
Germany. There, we have constructed the world’s
most modern and most efficient lignite-fired power
plant to replace older, less efficient plants. We like
to think big. Take our com-
bined cycle power plant at
Pembroke in the UK which
is the largest of its type in
Europe.
In addition to Pembroke and Staythorpe in the UK
we have also just completed some of the most
technically advanced new combined cycle power
plants in Germany, the Netherlands and Turkey.
Our experts have also just built dedicated biomass
projects in Scotland, Germany and Italy.
Always on the cutting edge of technology, we are
nearing completion of a 1,600 MW hard coal power
plant in Hamm, Germany and Eemshaven in the
Netherlands. Through targeted process optimisa-
tion, the power plant is to achieve an efficiency of
up to 46%.
Boiler structural steelwork for the hard coal power plant Hamm, Germany
KNOWLEDGEABLE. WELL-ROUNDED. PROVEN.
QUALITY AND VENDOR CERTIFICATIONS 1110 POWER GENERATION PROJECT EXPERIENCE
No apu sms: 006184No RePro: 342106No regic: 504017
Registrado
regic RePro
Registrado Accredited
apu sms
NUCLEAR
Our services are quality approved:
We are an Achilles recognised company.
With experience in a variety of modernisation measures and safety upgrades, our engineers can be relied on for professional consulting and proven project management for nuclear power plants.
For more than ten years, our nuclear experts have
been helping to improve the safety of nuclear power
plant projects around the world. Whether they are
shift leaders, trainers or project managers, the mem-
bers of our nuclear
team all have specific
expertise in certain
aspects of nuclear
power plant construc-
tion and operation. Equipped with this in-depth
knowledge, we support several international mis-
sions as well as several EU expert committees on
nuclear safety. Our nuclear fleet comprises four
units in operation, with a total capacity of 4,400
MW and five units in the decommissioning phase.
We provide consultancy services in the nuclear field
to public institutions as well as to private compa-
nies. We possess in-depth knowledge regarding
Generation I to Generation III reactors as well as the
commissioning and decommissioning of all types of
nuclear power plants. We have contributed our
expertise to nuclear development programmes in
Belene, Bulgaria; Cernavoda, Romania and the Hori-
zon project in the United Kingdom.
We offer detailed knowledge of technical design
standards and international licensing standards. In
the field of nuclear power, our tasks typically include
the assessment of technical requirements, prepara-
tion of technical specifications, contracting and on-
site management during every stage of a project.
We are also ideally placed to assist you with meas-
ures for radiation protection and radioactive waste
management.
View from the technical training center of NPP Zaporozhye, Ukraine
View into cooling basin of Biblis Power Plant, Germany
QUALITY. HEALTH AND SAFETY. ENVIRONMENT.
IS0 9001 accredited
IS0 14001 accredited
OSHAS 18001 accredited
MINING BACKGROUND 1312 RWE – LIGNITE MINING
HAMBACH MINE. GARZWEILER MINE. INDEN MINE.OUR MINING KNOWLEDGE BASE
RWE operates
• three totally continuous open pit mines, producing 100 Mt/a lignite.
• 20 of the world’s largest bucket wheel excavators (up to 240,000 m³/d).
• 18 inpit overburden spreaders, to dump more than 480 M bcm/a.
• 240 km of up to 2.8 m wide belt conveyors, running at 7.5 m/s.
• the largest private European heavy duty rail networkwith a length of 565 km for coal transport.
• 19 km/a exploration and 45 km/a dewatering drilling.
�
Cologne
Dürwiß
B 477 n
Tagebau Garzweiler
L 23
8n
Tagebau Hambach
Rhine
Frechen
BerrenrathKW Knapsacker Hügel
Tagebau Inden
as of 01/2013
Munich
Stuttgart
Saarbrücken
Mainz
Frankfurt
AachenCologne
Dortmund
Bremen
Hard coal
Lignite with integratedopencast mines
Natural gas
Nuclear power stations
Other conventionalpower plants
Hydropower stations** * in deconstruction** RWE Power including holdings as well as plants operated on behalf of RWE Innogy
*
Garzweiler Mine35 – 40 Mt/a
Hambach Mine35 – 40 Mt/a
Inden Mine20 – 25 Mt/a
Production capacity: ~100 Mt/a
Reserves, legallysecured: 3.3 billion t
MINING SERVICES 1514 MINING SERVICES
Our Specialists
• plan and develop your mines towards truly
continuous mining operations.
• assist with the establishment of state-of-the-art
mining technology and techniques, e.g. IPCC.
• provide the necessary transfer of skills to your
own operators.
• ensure minimal impact on the surrounding environ-
ment throughout the mine’s life.
• support you throughout your total mining process.
INNOVATIVE. SUCCESSFUL. SOPHISTICATED.
We are committed to maximising value from your mining assets by tailoring our Services to your needs.
Mine Design, Planning and Optimisation
• Conceptual and detailed mine design studies
• Individual opencast mine planning such as IPCC
• Net-present-value pit optimisation
• Choice of mining method and haulage method
• Life-of-mine stockpile, waste dump and tailings
dam design
• Production and equipment schedule optimisation
• Run-of-mine tonnage and grade scheduling
• Equipment, staff and material requirements
determination
Geological Services
• Exploration management
• Hydrological assessment
• Acid mine drainage studies
• Geotechnical assessment
Equipment Maintenance and Optimisation
• Development of a suitable maintenance strategy
• Maintenance planning and organisation
• Mine maintenance and warehouse management
• Maintenance training, audits and benchmarking
• Mine maintenance development
• Check and verification of the mine equipment’s
rehabilitation needs
In-pit Crushing and Conveying (IPCC)
• Conceptual and detailed IPCC mine design
• Brownfield integration planning
• Equipment selection advice
Conveyor Belt Inspection
• Direct feedback of recommended improvements at
plant inspection
• Analysis of plant breakdown
• Proposals for plant improvement through detailed
analysis
Conveying Engineering
• Design of the whole conveyor chain-systems
• Independent checking and verification of an
equipment manufacturer’s design
• Preparation of tender documents
• Evaluation of bids and recommendation of the
most suitable bidder
• Assistance during contract negotiations
• Mine equipment erection supervision
Conveyor Belt Testing (laboratory)
• Conveyor belt testing according to DIN, ISO and
other international standards (all testing equip-
ment available)
• Belt testing according to RWE standards for heavy
duty mining demand (large scale testing)
• Expertise in belt failure analysis and lifetime
prediction
16 MINING PROJECT EXPERIENCE MINING PROJECT EXPERIENCE 17
IPCC
EQUIPMENT ENGINEERING
Our experience in this area is wide-ranging, both
geographically and technically. Whatever your pro-
ject – coal, copper, ore or overburden – RWE Power
International is your best choice for the task. For
example, we built the world’s largest compact
bucket wheel excavator for the Bükkábrány opencast
mine in Hungary. Our engineers were responsible
for drafting the plans, constructing the coal storage
and selecting and qualifying the suppliers.
The parts for the excavator were manufactured in
several European countries including Bulgaria and
Poland. Before the first elements were manufac-
tured, we conducted construction audits and during
the production stage we held factory acceptance
tests for key components. Our
experts guided and supervised the
project from the start through to completion, there-
fore ensuring that the production quality remained
consistently high throughout and maintaining the
same high standard for which our mining projects
are known.
In Serbia, we conducted similar projects for the state
electricity company, EPS including supporting the
completion of complex overburden removal
systems.
We also analysed existing bulk ore conveyor and
transport systems for several copper mines in Chile
to identify weak points. We then developed a num-
ber of solutions for improving performance and
increasing throughput.
Our customers can be confident of maximum safety
and reliability when they purchase conveyor belts
which are “RWE tested”. We want you to feel confi-
dent that you integrate reliable components into
your production system. For this reason, we refuse
to buy any products that have not successfully with-
stood rigorous testing in our own
laboratories.
There are good reasons for this. As far as fuel con-
sumption, carbon dioxide emissions and time are
concerned, modern IPCC systems have clearly
proven to be more efficient than traditional “shovel-
and-truck” methods. With mounting international
pressure on mining companies to increase their
environmental responsibility, the new technology
is becoming more and more attractive – not to men-
tion the potential savings on fuel and operating
costs.
The overall expenses for haulage systems that still
rely on shovel-and-truck can easily add up to 50%
of the total mining costs. Although the initial
expenditure that is generally needed for an IPCC
system can be significant, it soon pays back due to
a high return on investment.
An IPCC system consists of a crusher that is con-
nected to several conveyors. The crusher is strategi-
cally positioned in the opencast mine and the con-
veyors remove the crushed material. A major
advantage of this system is that while trucks are
only able to transport overburden, ore or coal on
inclines up to 12%, the conveyors can operate safely
and reliably at gradients of up to 25%. Therefore,
this not only reduces the distance
that the material has to travel from
the pit but it also lowers costs for
fuel, maintenance and personnel.
We have many years of experience using IPCC, par-
ticularly in South America. Our first project was in
Chile in the early 1990s with the design, develop-
ment and supervision of the construction of a
crusher-belt conveyor-spreader system. After suc-
cessfully completing this project, our team was sub-
sequently awarded a contract by the Chilean copper
mining company Codelco. In 1995, we were awarded
a contract to construct a tunnel conveyor to trans-
port ore 1,200 metres downhill from Antofagasta’s
Los Pelambres copper mine. We continue to assist
the company with the operation and maintenance of
the system. In addition, we have conducted numer-
ous IPCC studies for locations around the world,
including Peru, Columbia, Thailand, India, Indonesia
and Australia.
RELIABLE. VISIONARY. DURABLE.
In opencast mining, the use of In-Pit Crushing and Conveying (IPCC) systems is becoming increasingly common.
Of our many support services, none is more in demand than our mining equipment engineering support.
Truck dumping into hopper of semi-mobile crusher plant atMaeh Moh Mine, Thailand
World largest compact bucket wheel excavator in BükkábrányOpencast Mine, Hungary
HOW TO REACH US 1918 MINING PROJECT EXPERIENCE
MINE PLANNING
Building on many years of specialised expertise, we provide our clients with one-stop solutions covering the entire cycle of a mining project.
Our practical experience covers all types of open-
cast mining and construction projects. For instance
as part of a mine feasibility study, we conducted
exploration drilling and hydrological pump tests
in the Thar Desert in Pakistan. The investigations
revealed lignite reserves of around 400 million
tonnes.
For an opencast mining project in the Bushveld
Complex in South Africa, our experts drafted a
precise model of a platinum-palladium deposit
which enabled the client to carry out highly targeted
mining operations.
On a contract for
Neyveli Lignite
Corporation (NLC),
which operates
several opencast lig-
nite mines in southeast India, we con-
ducted a feasibility study including
detailed mine planning. Our
experts needed to overcome
a number of geotechnical, envi-
ronmental and technological
challenges. For the duration
of the project, we supported
NLC on site and also via inter-
net from Cologne.
The Gallilee Coal Basin in Australia is being devel-
oped by several mining companies. Our team of
experts is involved in concept and feasibility stage
studies, especially when it comes to the utilisation
of continuous mining equipment. To develop totally
continuous operating coal and overburden transport
systems our operational knowledge is of extraordi-
nary value in the fields of mine stage
planning and equipment selection.
Mining Power Plant
Meet us at selected fairs, exhibitions and conferences.
Stuettgenweg 2
50935 Cologne
Germany
T +49 221 480 1300
F +49 221 480 1350
Further information may be found on our website: www.rwepi.com
Huyssenallee 2
45128 Essen
Germany
T +49 201 12 22673
F +49 201 12 22671
Maintenance Services and Ash Products
TSG Ferrybridge – Maintenance Services
Old Great North Road / Knottingley
West Yorkshire / WF11 8PR
United Kingdom
T +44 1977 632201
F +44 1977 632311
Generation Aggregates
Electron / Windmill Hill Business Park
Whitehill Way / Swindon
Wiltshire / SN5 6PB
United Kingdom
T +44 800 7312865
F +44 1793 892421
Our mining engineering team in the clients office in Indonesia
HELPFUL. INTERCONTINENTAL. ACCESSIBLE.
RWE Power International
RE GmbHStuettgenweg 250935 Cologne
T +49 221 480 1300F +49 221 480 1350I www.rwepi.comE [email protected]
Huyssenallee 245128 EssenGermany
T +49 201 12 22673F +49 201 12 22671
Registered Office:Registered at CologneLocal Court under no.HRB 2635
© 3/2013 RE GmbH