2.4.

Modernization, technical upgrade and reconstruction

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Maintenance of a proper technical condition of the equipment is one of the essential tasks of the Group’s activity. Quality and reliability of production and technological processes depend on timely maintenance, planned repair works and modernization of equipment, buildings, facilities and power plants communications.

Condition index18 for PJSC RusHydro primary equipment groups as of 31.12.2016, %

Type of equipmentCondition index, %
Turbines70.88 %
Generators77.38 %
Transformers81.64 %

To maintain equipment in a proper technical condition, JSC RusHydro and RAO ES of the East implement the special programs:

COMPREHENSIVE MODERNIZATION PROGRAM OF PJSC RUSHYDRO GENERATING FACILITIES (CMP)

Large-scale program aimed at replacing the obsolete and worn-out equipment
Modernization of generating facilities as integral technological complexes

TECHNICAL UPGRADE AND MODERNIZATION PROGRAM OF PJSC RUSHYDRO

Program duration – 2011-2025
Based on Comprehensive modernization program
Pinpoint replacement of obsolete equipment for modern

TECHNICAL UPGRADE AND MODERNIZATION PROGRAM OF RAO ES EAST HOLDING

Program duration – 2014-2025
Part of the investment program of the Holding
Pinpoint replacement of obsolete equipment for modern

REPAIR OPERATION PROGRAM OF PJSC RUSHYDRO

Planned repair of equipment
The program is formed annually

REPAIR OPERATION PROGRAM OF RAO ES EAST HOLDING

Planned repair of equipment
The program is formed annually

2.4.1. Comprehensive Modernisation Program

A significant part of HPPs was commissioned in 1950-1960-s. By early 2000-s, there was a need for upgrade and replacement of the operating equipment. Due to the economic difficulties of those years, it wasn’t possible to replace obsolete and worn out equipment, and PJSC RusHydro could only execute periodic repairs and replacement of some components.

Since the mid 2000-s, PJSC RusHydro has conducted a selective replacement at several HPPs, but the rate of asset renewal did not allow to reverse the trend of HPPs’ ageing.
In December 2011, the RusHydro’s Board of Directors approved the Comprehensive Modernisation Program of generating facilities of PJSC RusHydro (CMP), for the period until 2025.

CMP is the unique project (in terms of its massive scale) of renewing operational assets in the energy sector. Within CMP, before 2025, RusHydro plans to will have replaced more than half of general equipment of the HPPs:

  • 154 turbines (55 % of the total turbine fleet),
  • 119 generators (42 % of the total generator fleet),
  • 176 transformers (61 % of the total transformer fleet),
  • 396 power circuit-breakers,
  • around 8 thousand secondary control equipment items,
  • more than 4 thousand auxiliary equipment,
  • and to reconstruct hydraulic structures.
Комплексная модернизация

The CMP key goal is removal of all generating equipment with an expired safe operation life by 2025.

Apart from operational performance, modernization of the equipment improves its environmental performance and helps to reduce anthropogenic impact.

The program is delivered using innovative and energy efficient solutions (fibre optics, optical transformers, deposition of nanostructured materials, control systems based on microprocessors, systems of vibration monitoring, etc.).

MAIN RESULTS OF COMPREHENSIVE MODERNISATION PROGRAM IN 2016

For five years of the CMP implementation, 39 hydraulic turbines, 23 hydro generators, 41 transformers and more than 4,000 units and auxiliary electrical equipment were replaced. In addition, single components were replaced in a large amount of equipment.

Комплексная модернизация

In 2011-2016, the total capacity of the RusHydro’s HPPs increased by 267 MW.

It can be compared with the commissioning of a new HPP of medium size.

In 2016, the capacity of HPPs increased by 66.5 MW, seven hydraulic turbines, six hydro generators and eight transformers were replaced.

Results of Comprehensive Modernisation Program in 2016

HPPWorks performedIncrease of installed capacity, MW
2016, actual2017, planned
Zhigulevskaya HPPCompletion of reconstruction of three hydrounits with replacement of hydraulic turbines and modernisation of hydro generators4221
Volzhskaya HPPReplacement of a hydraulic turbine and two hydro generators10,510,5
Saratovskaya HPPCompletion of reconstruction of all vertical hydro generators, replacement of turbine on hydrounit No.4, completion of concrete restoration in the zone of variable level66
Novosibirskaya HPPReplacement of a hydraulic turbine, equipment remarking55
Kamskaya HPPCompletion of replacement of all hydro turbines and reconstruction of generators (completed in 2015)30
Rybinskaya HPPCompletion of replacement of transformers and reconstruction of outdoor-switchgear-220 kV, beginning of the replacement of the hydraulic unit No.1 (commissioning is scheduled for 2017)

2.4.2. Technical upgrade and modernisation program

Technical upgrade and modernisation program (TUMP) is based on Comprehensive Modernisation Program. Its goal is to maintain a proper operational condition of the equipment and introduce new production facilities. Unlike CMP, this program involves a selective replacement of the equipment by its analogues with an improved performance. TUMP also involves extension of the statutory period of the main generating equipment, reduction of production costs, increase in the efficiency of HPPs.

Within TUMP (including implementation of CMP at PJSC RusHydro HPPs), in 2017-

  • 2020, it’s planned to put into service:
  • 231.5 МW of capacity,
  • 1,166.8 km of power lines,
  • 46.73 of heat transmission pipelines.

In 2016, PJSC RusHydro and generating subsidiaries allocated 22.6 billion rubles on Technical upgrade and modernisation program.

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TECHNICAL UPGRADE AND MODERNISATION PROGRAM OF RAO ES OF THE EAST

Technical upgrade and modernisation program of RAO ES of the East is a part of the Holding’s investment program and is related to the necessity to maintain reliability of the technological complex in a long-term perspective at large. Development and implementation of the Program are held within Technical policy of PJSC RAO ES of the East.

Technical upgrade and modernisation program of RAO ES of the East in 2016 amounted to 8,481 million rubles, including VAT. Actual implementation of the Program amounted to 8,602 million rubles, including VAT (101 %).

Program priority areas are:

  • Change in the fuel balance by gasification of one unit at Khabarovskaya CHPP-1 (JSC FEGC) plant and gasification of Anadyrskaya CHPP
    (JSC Chukotenergo).
  • Maintenance of operational funds by technical upgrade and modernisation of general equipment of the power plants, heating network and power grid complexes (affiliates of the Far Eastern Federal District).
  • Elevation of the ash dumps dam at Artyomovskaya CHPP and Khabarovskaya
    CHPP-3 (JSC FEGC).
  • Removal of network constraints, increase in reserve electrical power supply centres, development of existing infrastructure for connecting consumers (JSC FEGC and other grid companies of the Far Eastern Federal District).
  • Installation of the energy accounting meters with inclusion in an automated system
    (JSC FEDC, PJSC Magadanenergo).
  • Reconstruction of substation 220 kV «Orotukan», «Palatka», «Tsentralnaya»
    (PJSC Magadanenergo).
  • Modernistion of gas turbines at power units No.4 and No.5 of Yuzhno-Sakhalinskaya CHPP (JSC Sakhalinenergo).
  • Reconstruction of the grid objects to ensure the scheme of power distribution
    (Sakhalinskaya TPP-2).
  • Reconstruction of overhead transmission lines-110 kV «ETPP-Iultin» (JSC Chukotenergo).
  • Reconstruction of heat pipelines from heat chamber -23 kV 114 to thermal unit UT-1 kv 66 in Yakutsk, to ensure the thermal power output of Yakutskaya TPP-2 (PJSC Yakutskenergo).
  • Reconstruction and replacement of generating equipment of diesel power stations
    (JSC Sakhaenergo, JSC SENK).
  • Provision of reliable power supply to consumers.

2.4.3. Repair operation program

Repair program and schedules are formed in RusHydro Group annually and are based on the requirements of regulatory documents to provide reliability and efficiency, analysis of the equipment’s technical condition. The implementation of planned repairs ensures a stable provision of electric and thermal energy to all categories of consumers even during the most intense periods of operation of the power systems.

During the reporting period RAO ES of the East implemented a repair program in the amount of 11,568 million rubles (101 % of planned sum, which amounted to 11,435 million rubles).

Implementation of Repair Operation Program of PJSC RusHydro in 2016 by costs, million rubles

PJSC RusHydro branch/subsidiaryPlanActualPerformance, %
PJSC RusHydro’s branch Volzhskaya HPP429.4372.586.78 %
PJSC RusHydro’s branch Votkinskaya HPP179.5155.386.52 %
PJSC RusHydro’s branch Zhigulevskaya HPP302.9272.790.04 %
PJSC RusHydro’s branch Kamskaya HPP143.2115.480.62 %
PJSC RusHydro’s branch Cascade of Verkhnevolzhskiye HPPs66.864.997.21 %
PJSC RusHydro’s branch Nizhegorodskaya HPP93.187.193.58 %
PJSC RusHydro’s branch Saratovskaya HPP229.9196.885.60 %
PJSC RusHydro’s branch Cheboksarskaya HPP150.89115.876.78 %
PJSC RusHydro’s branch Sayano-Shushenskaya HPP386.4333.886.39 %
PJSC RusHydro’s branch Bureyskaya HPP80.792114.09 %
PJSC RusHydro’s branch Zeyskaya HPP190.3146.576.98 %
PJSC RusHydro’s branch Novosibirskaya HPP55.24683.36 %
PJSC RusHydro’s branch Cascade of Kubanskiye HPP231.5188.681.49 %
PJSC RusHydro’s branch Dagestan branch159.1135.885.36 %
PJSC RusHydro’s branch Karachay-Cherkessia branch33.834.8103.0 %
PJSC RusHydro’s branch Kabardino-Balkarian branch67.154.480.99 %
PJSC RusHydro’s branch North Ossetian branch66.757.486.14 %
PJSC RusHydro’s branch Zagorskaya PSPP302.9277.491.59 %
Total for PJSC RusHydro3,169.42,747.786.69 %

Expenses of the RAO ES of the East for the repair of fixed production assets in 2016, million rubles

CompanyExpenses
JSC FEGC4,636.07
JSC FEDC726.8
PJSC Kamchatskenergo759.78
PJSC Magadanenergo1,050.41
PJSC Mobile energy (Peredvizhnayaenergetika)56.05
PJSC Sakhalinenergo1,333.6
JSC Sakhaenergo328.4
JSC Teploenergoservice129.9
JSC Chukotenergo313.7
JSC KSEN372.3
PJSC Yakutskenergo1,746.3
TOTAL11,453.3

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