power engineering holding company -...

INTEGRATED SOLUTIONS

FOR MANUFACTURING OF

ENGINEERING EQUIPMENT

POWER ENGINEERING HOLDING COMPANY

01THE HOLDING COMPANY IN FIGURES

o Power-generating equipment manufacturing experience over 15 years

o Production facilities inSaint Petersburg - 30 000 m2

o Workforce - 450 people

o Over 4 000 power-generating equipment items manufactured (DPP, GEPP, MPTS, MBPetc.)

Integrated solutionsfor manufacturing of

engineering equipment

www.ehross.ru POWER ENGINEERING HOLDING COMPANY

02POWER ENGINEERING HOLDING COMPANY ROSS

ELECTRIC POWER GENERATION

ELECTRIC POWER DISTRIBUTION

HEAT POWER ENGINEERING

Dieselpower plants

Modular packagedtransformersubstation 35.10(6) /0.4KV

Mobile modular transformers

substation 110.35/10(6)KV

Modular packaged boiler plants

Standalone,built-in boiler plants

Gas engine power plants

Power centers




03TRANSFORMER SUBSTATION

KTPM -2х63000 (80000)/110/6(10) KV

in reinforced concrete modules with 110 kV power transformers and power rating up to 2х80 mVa with high operational compatibility and compact layout (22x22m) manufactured by Power Engineering Holding Company

ROSS LLC



www.ehross.ru

INNOVATIVE SMART ULTRA-COMPACT SUBSTATION


04KTPM DESCRIPTIONThe basis for performing works is an initiative of Power Holding Company LLC to develop technical solutions in the area of transport and electric power distribution.

The purpose of performing works is to develop main technical solutions for the construction of 110 KV substations (110 kV KPTM) with the following features and advantages:

• Reducing construction time and cost as well as to enhancing construction quality - constructing of 110 KV substations out of ready-to-operate modules

• Facilitating the selection 110 kV substation site in conditions of compact urban development - Minimizing construction site area

• Unifying design solutions to implement various 110 KV substation layouts

• The effective NTD requirements have been considered in the design of 110 KV substations as well as advanced experience in the construction of 110 kV substations within Saint Petersburg.

110 KV KTPM is designed to be deployed in big cities, highly polluted districts (metallurgical works, refineries, highways, chemical production facilities etc) as well as in extreme north conditions

110 kV KTPM is a modular packaged transformer substation utilized to receive, invert and distribute 10 (6.3)-110 kV, 50 Hz three-phase alternating current and intended to supply electric power to housing and public, transport and industrial facilities.

Functionally 110 KV KTPM is a power supply grid unit and a closed step-down distribution substation 110/10(6.3) KV.

Structurally the KTPM is a prefabricated modular-panel frameless reinforced concrete building with bearing walls and consists of the following ready-to-operate modules:

• Basement modules -14 pcs• First floor modules -14 pcs• Second-floor modules - 19 pcs.• Third-floor modules - 19 pcs• Coating elements - 19 pcs

All electric equipment is installed in modules by the manufacturer. 110 kV power transformers and 110 kV Secondary Distribution Switchgear, SF6 insulated are installed on site.




05KTPM TECHNICAL CHARACTERISTICS

Item No Parameter UoM Value

1 Substation type _ Closed

2 Maintenance type _ Without permanent operating personnel.

3 Installed capacity of HV power transformers kVA 2 x 63000 with a possible increase up to 2x80000

4 Design of LV power transformer windings _ Split-up

5 Rated voltage on HV side KV 110

6 Rated voltage on LV side KV 10,5(6,3)

7 High voltage switchgear

7.1 Design _ 110 kV insulated switchgear

7.2 HV switchgear circuitry

7.2.1 Option 1 _No 110-4H "two units with circuit breakers and automatic bridging on lines" (with three circuit breakers)

7.2.2 Option 2 _No 110-5H "bridge in circuits of lines and transformers" (with five circuit breakers)

7.2.3 Option 3 _ No 110-8 "hexagon"

7.2.4 Option 4 _ No 110-7 "quadrangle"

7.2.5 Option 5 _No 110-9 "one bus-bar system sectioned by circuit breaker with circuit breakers in line circuits" designed for four linear cells and two transformers (with seven circuit breakers)

7.3 Rated current of HV lines A up to 3150

7.4Design of 110 kV power transmission lines to be connected to substation

_ cable lines with cross-linked polyethylene insulation (XLPE – insulation)




06KTPM TECHNICAL CHARACTERISTICS

Item No Parameter UoM Value

8 Intermediate voltage switchgear

8.1 Design _ SWG cabinets with vacuum pressure circuit breakers

8.2 IV switchgear circuitry _ No 10(6)-1 "one operating bus-bar system sectioned by circuit breaker"

8.3 Number of sections _ 4 sections with 2 sections in separate rooms

8.4 Number of outgoing IV lines pcs. 38

8.5 Current limiting reactors pcs. Single, horizontal units

9 Balance-of-plant needs:

9.1Number and power rating of axillary transformers 10 (6)/0.4 kV

kVA 2x400

10 Fireproof characteristics of KTPM building:

10.1 Fire resistance rating _ II

10.2 Structural fire hazard rating _ CO

10.3 Functional fire hazard rating _ F5.1

11 Overall dimensions in operating position:

11.1 Length m 22

11.2 Width m 22

11.3 Height m 11.22

12 Full weight t 3500




07HISTORICAL BACKGROUND OF PREFABRICATED UNIT CONSTRUCTIONThe idea of prefabricated unit construction was originated at the beginning of the 20thcentury in the sphere of housing construction and the prefabricated unit houseconstruction embarked on a solid industrial course in the 60th.

The factor allowing a wide application of building block modules is first of all theirindustrial applicability. According to an economic analysis conducted at that time, theadvantages of prefabricated unit construction in comparison with large panels are asfollows:

• 80% of labor costs are transferred to the factory,

• construction time is cut down by 4-5 times,

• labor intensity is cut down by 2.6-2.8 times on construction site,

• concrete consumption by 25-28%

Specialized workshops were set up in a number of the country's cities in a period of1961-1968. An experimental construction of residential houses and other facilitiesstarted. February 3, 1969. The Council of Ministers of the USSR adopted the resolution"On the development of prefabricated house construction, which allowed constructionof large prefabricated building factories in the RSFSR, Belorussia, Ukraine.

Residential houses with a total area of 150 thous.m² were already built in the USSR in1972 as a result of this resolution. The construction of 9-storied residential houseswas started.

An experimental factory of prefabricated modular engineering structures was set inMoscow in the 70th following the rapid development of industrial prefabricatedconstruction.

Unfortunately, in connection with the economic regress faced by the country in the90th the development of prefabricated unit construction came to a halt both in theindustrial and housing sector.

SINGLE-BLOCK STRUCTURAL LAYOUT OF A BUILDING

MODULAR-PANEL STRUCTURAL LAYOUT OF A BUILDING

BUILDING A RESIDENTIAL HOUSE WITH BLOCK MODULES




08ELEMENTS OF KTPM BUILDING STRUCTURES

6 modules sized 5000x2900 with stair flights and APT

7 modules with auxiliary rooms up to 8580 mm long and 2230; 2750; 2880 and 3260 mm wide

10 modules with double flooring up to 6220 mm long and 1690; 1880; 1930; 2160 and 2340 mm wide

8 modules sized 10800х3100 for current limiting reactors and under-reactor space

10 modules sized 5980х1360; 5660х1840 and 5660х3140 for axillary rooms, walkways and escape routes

8 modules sized 7160х3000 and 6220х1800 to provide the KTPM building stiffening cores

8 modules sized 5410х2250 and 4650х2250 10kV switchgear

8 modules sized 5000х2820 and 5660х2465 for 10 kV capacitance current compensation reactors and under-reactor space

OTHER ELEMENTS

R/C plinths for transformers

Standard foundation

blocks

R/c cable traysLift slabs and enclosing panels

Steel stairways and platforms

Basement areaways




09KTPM LAYOUT. GROUND FLOOR




10KTPM LAYOUT. FIRST FLOOR




11KTPM LAYOUT. SECOND FLOOR




12KTPM LAYOUT. THIRD FLOOR




13KTPM LAYOUT. SECTION



www.ehross.ru

№ Designation Name Qty

Power equipment

1 EXK-0110 kV insulated switchgear, ABB

1

2 LEADER10kV; 4000А; 31,5kA Leader switchgear

1

3TRDTsN-80000/110-U1

Power transformer 80MVA 110 kV

2

4RBDG 10-4000-0,18UZ

Current liming reactor 4

5 TS-400/10Power transformer 400kVA 10/0.4kV

2

6 ZON-110М-UkhL1Grounding disconnect switch 110 kV

2

7OPN-P-110/56/10/550 UKhL1

Voltage surge arrestors 110 kV 6

8OPN-P-10/12/10/400 UKhL1

Voltage surge arrestors 10 kV 6

9 TLO-10 Current transformers 10 kV 12

10 FMZO-500/11 Zero-sequence coupling filter 2

11 RDZ-10-400Grounding disconnect switch 10 kV

2

12 RZDPOMA-480/10Grounding arc suppressor reactor

2


14KTPM LAYOUT




TOTAL 8 MONTHS SINCE THE BEGINNING OF PRODUCNION TILL START-UP

15MAIN ADVANTAGES

Special construction perculiarities of classic closed 110 kV substations Advantages of 110 kV KTPM

Substantial construction area (similar substation sized 30.4x35m, in other words,

1064 sq.m)Small size construction site (110 kV KTPM 22х22 m, in other words, 484 sq.m)

Individual solutions for each type Unification of structural solutions for various 110 kV schemes

There are no typical solutions, individual project design for each siteThe KTPM design consists in adapting standard design projects excluding long-term

approvals of technical solutions

Land allotment, long-term lease registrationA simplified registration of land allotment for a modular KTPM as per established

procedures similar to those for 6(10) kV transformer substations.

Works to be carried out in the open air in construction site conditions including in

winter time.

Improvement in quality due to well-adjusted production technologies with stepwise

quality control in factory conditions.

Long construction time - 1.5 years. Reduced construction time due to modular solutions - up to 8 months

Construction of a capital building with the installation of all engineering systems,

equipment and materials on site.

Reduced facility cost due to erecting a building from reinforced concrete modules

equipped with all necessary equipment and systems on a ready-to-operate basis




16MAIN ADVANTAGES 1

CLASSIC SUBSTATION 110 kV: 30.4x35m, in the words, 1064 sq.m

110 kV KTPM: 22x22m, in other words. 484 sq.m.

SMALL CONSTRUCTION AREA




17MAIN ADVANTAGES 2

No 110-4H "two units witch circuit breakers and automatic bridging on the side of power lines"

No 110-5H "bridge with circuit breakers in circuits of power lines and transformers" (with five circuit breakers)

No 110-9 "one bus-bar system sectioned by circuit breaker with circuit breakers in line circuits" designed for four linear cells and two transformers (with seven circuit breakers)

The 110 kV KTPM design makes it possible to implement various 110 kV options without changes to the construction part.

UNIFICATION OF DESIGN SOLUTIONS FOR VARIOUS 110 KV OPTIONS




18MAIN ADVANTAGES 3

THE KTPM DESIGN CONSISTS IN ADAPTING STANDARD DESIGNPROJECTS, EXCLUDING LONG-TERM APPROVALS OF TECHNICALSOLUTIONS.

ALL THE KTPM ELEMENTS ARE DEVELOPED IN 3D ANDDESIGNED TO WITHSTAND HIGH LOADS.




19MAIN ADVANTAGES 4

1. Simple and proportional architectural forms of 110 kVKTPM make it possible to fit it into in any cityscape.2. The design of KTPM units allows any exterior finishcompatible with the adjacent and surrounding developmentincluding facade artificial rock coating.3. The KTPM placement on a concrete slab with lowspecific stress on the ground allows the KTPM to beerected practically in any district of Saint Petersburgwithout pile foundation.4. With construction and installation works arrangedproperly, there is no need for additional space to be usedfor a site warehouse, areas for final assembly of equipmentetc.

SIMPLIFIED REGISTRATION OF LAND ALLOTMENT FOR A MODULAR KTPM.




IMPROVEMENT IN QUALITY DUE TO WELL-ADJUSTED PRODUCTION TECHNOLOGIES WITH STEPWISE QUALITY CONTROL IN FACTORY CONDITIONS

20MAIN ADVANTAGES 5

A new innovative method for constructing buildings is the application of modular-spatial (in short modular) blocks. Constructing with modular blocks makes it possible to significantly enlarge prefabricated elements and increase their operational compatibility. Modular blocks are large reinforced concrete boxes being separate rooms or sections manufactured in factory conditions While modular blocks are being manufactured in factory conditions all finish works are carried and are internal equipment is installed at the same time.

Power Engineering Holding Company LLC has implemented quality management systems allowing products to be quality controlled at all stages of production

Consignment note

Documenton concrete quality

Test samplesof concrete (4 pcs)

Heatingdocument

An entry in the concrete works log-book.

A conclusion on concrete testing by independent

examination

REPORT No.1

Construction part,

grouting of lower modules +photograph

REPORT No 2Construction part,

grouting of upper modules

+photograph

REPORT No 3.1Lower modules Ready to hand over a module for

auxiliary needs and finish works

REPORT No 3.2Upper modules Ready to hand over a module for

auxiliary needs and finish works

Finish works Auxiliaryneeds

Input and distribution gear

Single-end service chambers or metal-clad switchgear

Switchgear panel equipment Complete set

INTERMEDIATE ACCEPTANCE

REPORT No.4 for Lower modules

+photograph

INTERMDIATE ACCEPTANCE

REPORT No.5 for upper modules+photograph


REPORT No. 6, 7 for lower and upper

modules +Photograph

INTERMEDIATE ACCEPTANCE REPORT No.8

+photograph


REPORT No 8.1

+photograph

Installation in modules

REPORT No.12On handover З/Зto factory testing

REPORT No.13Laboratory

REPORT No.14working commission

REPORT No.15on technical readiness of

module, finish works

REPORT No.16 of concluding commission REPORT No.17

independent examination

REPORT No.18Acceptance-handover with Customer's

signature + Complete set list of construction and electrical parts


+photograph






REDUCED CONSTRUCTION TIME DUE TO MODULAR SOLUTIONS - UP TO 8 MONTHS

21MAIN ADVANTAGES 6

Modules are delivered to construction site with complete interior and exterior finish, completely equipped with electrical equipment. On construction site, these modules are just mounted on preliminarily arranged foundations, jointed and connected to utility lines and roof is constructed. To carry out all construction works it is sufficient to have a 160-ton truck-mounted crane, lifting tower of AGP type and a team of 10 persons. Total KTPM construction period does not exceed 8 months.

LABOR COSTS:

Total: 2783 man*h

A team of 10 persons for 1, 7 months

BASIC EQUIPMENT AND MECHANISMS:

- Truck-mounted trawl: 35 shifts

- High sided truck up to 8 t: 10 shifts

- 160 ton truck-mounted crane: 10 shifts

AUXILIARY EQUIPMENT AND MECHANISMS:

-welding machine.

-hydraulic hoist: 10 shifts

MODULAR KTPM CONSTRUCTION COSTS (GESNM 08-01-025-15)

CLASSIC SUBSTATION CONSTRUCTION COSTS(USN 19-1)

LABOR COSTS:

Total: 35 000 man*h

A team of 30 man for 7 month

BASIC EQUIPMENT AND MECHANISMS:

Concrete mixers< truck-mounted crane, dump truck, concrete pumps etc, for at least 3 months.

AUXILIARY EQUIPMENT AND MECHANISMS:

A lot of tools and mechanical gear is required including inventory form work, solution mixers, polishing and grinding machines etc.




REDUCED FACILITY COST DUE TO CONSTRUCTION OF A BUILDING FROM REINFORCED CONCRETE MODULES EQUIPPED WITH ALL NECESSARY GEAR AND SYSTEMS ON A READY-TO-OPERATE BASIS.

22MAIN ADVANTAGES 7

Cost calculation for 110|10 KV substation as per 110-9 option (2 transformers per 63MVA; 8 cells 110 kV, 50 cells 10 kV)

Calculations are made as per STO 56947007-29.240.124-2012

Price variation indexes are accepted as of the 1 quarter of 2015:- Construction&

Installation 6.15- Other expenditures: 7.94- Equipment: 4.04

Cost item name

Classic substation cost, thous.rub. 110 kV KTPM cost, thous. rub.

Equip.Relay protection and emergency

controls

Construction&Installation

TOTAL: Equip factory assembledRelay protection and

emergency controls factory assembled

Construction& Installation with block assembly

TOTAL:

110 kV insulated switchgear 200,513 111,920 91 571 404,004 5% 210,539 +60% 179,072 -60% 36 628 426,240

10 kV switchgear 18 180 10 148 8 303 36 630 25% 22 725 +60% 16 236 -70% 2 491 41 452

Power transformer 63MVA 110/10kVA 52 863 29 506 24 141 106,510 5% 55 506 +60% 47 210 -60% 9 657 112,372

Current limiting reactors RB 7 747 4 324 3 538 15 609 25% 9 684 +60% 6 919 -70% 1 061 17 664

Constant cost component 40 467 40 467 -80% 8 093 8 093

TOTAL: 279,303 155,898 168,020 603,221 298,454 249,437 57 931 605,821

Temporary buildings and structures 14 507 -70% 4 352

Other works and costs 82 206 -70% 24 662

Design and survey works 42 225 -65% 14 779

TOTAL: 742,159 649,614

VAT 133,589 116,930

TOTAL: 875,747 766,544




REDUCED FACILITY COST

23MAIN ADVANTAGES 7

USING THE 110 kV KTPM MAKES IT POSSIBLE TO REDUCEDIRECT COSTS BY GREATER THAN 10-15%



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COST COMPARISON

COST STRUCTUREOF CLASSICAL SUBSTATION

COST STRUCTUREOF 110 kV KTPM

Mainequipment

38%

Auxiliary equipment

21%Construction&

Design24%

Other costs11%

Design&survey6% Main

equipment46%

Auxiliary equipment

38% Construction&Design

10%

Other costs4%

Design&survey

2%

0

100000

200000

300000

400000

500000

600000

700000

800000

CLASSIC SS 110 kV KTPM

MAIN EQUIPMENT

AUXILIARY EQUIPMENT

Construction&Design

OTHER COSTS

Design&survey


CO

ST

, M

LN

. RU

B

24ADDITIONAL LAYOUT SOLUTIONS



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110 kV KTPM sized 12.5x44 m





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110 kV KTPM sized 12.5x44 m





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220 kV KTPM sized 23.5x26.5m





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30PARTNERS, CLIENTS, FEEDBACK




31HEAD OFFICE



www.ehross.ru

Saint PetersburgConstitution square, bld.3+7 (812) 313-65-78

www.ehross.ru

Integrated solutions for manufacturing of engineering equipment


www.ehross.ru

2015

www.ehross.ru

2015


power engineering holding company -...

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