Design

ROTEC JSC provides a wide range of services in the design and development of network and heat and power facilities, including the General Designer functions.

Basic design services:

  • Feasibility study, development of concepts, system solutions and main equipment solutions for the facility as a whole, based on the technical requirements of the Customer;
  • Development of design documentation (stage “P”);
  • Development of detailed documentation (stage “R”), 3D shooting of reconstruction and retrofitting facilities before the start of design work, development of 3D models of facilities;
  • Facilities construction supervision;
  • Development of standard design projects that reduce the design cost and project execution time, increase economic performance and minimize costs at the pre-investment stage;
  • Technical audit of design work (Customer’s Engineer) that includes participation in coordination of technical solutions, analysis and monitoring of compliance with design schedules, acceptance of design and detailed documentation developed by third-party design organizations.

Team

ROTEC has its own Design Solutions Center
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Vladislav Vladimirovich Malyshkin
Director of the Design Solutions Center
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Dmitry Vladimirovich Kirichenko
Deputy Project Management Director
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Elena Anatolyevna Volkova
Chief Project Engineer
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Konstantin Mikhaylovich Kanashevsky
Chief Project Engineer
42 experienced certified specialists in the field of design, who were directly involved in the design work at power facilities:
Generation Electric Network Activities
Nyaganskaya SDPP (State District Power Plant – SDPP) SS-110/10 kV (substation) for Maloderbetovskaya SPP (Solar Power Plant) 60 MW
Chelyabinsk CHPP-1,2,3 (Combined Heat and Power Plant) SS-110/10 kV for Yashkulskaya SPP 58.5 MW
Chelyabinsk SDPP Sibirskaya SS-110/35/10/6 kV
Ulaanbaatar CHPP-4 Arsenal SS-220 kV
Argayashskaya CHPP SWYD-500/200 kV (outdoor switchyard) at Nyaganskaya SDPP
Tyumenskaya CHPP-2 Prirechnaya SS-110/6 kV
Noyabrskaya CCPP (Combined Cycle Power Plant) Talitskaya 1 SS-110/6 kV
Pervomayskaya CHPP (CHPP-14) Power supply of the RN-Uvatneftegaz LLC facilities
Minsk CHPP-3 et al.
Perm SDPP
Our specialists:
  • Honored Workers of Industry and Energy of the Russian Federation
  • Graduates of Ural State Technical University, Ural Federal University, MPEI, Ivanovo State Power University, Moscow State University of Civil Engineering, Ural State University of Architecture and Art, Ural State University of Railway Transport, Tyumen Industrial University, Siberian State University of Telecommunications and Information, Plekhanov Russian University of Economics
Structure of the Design Solutions Center
Structure of the Design Solutions Center
Design Solutions Center Performance List
No. Project Name Customer Project features
1 Retrofitting and overhaul of the energy utility buildings of the Religious Organization of Orthodox Judaism – Moscow Marinoroshchinsky Jewish Community Moscow Marinoroshchinsky Jewish Community Energy utilities design in urban conditions and existing infrastructure. Development of unique spatial arrangements in the context of a tight job site. Development, coordination and approval of Special Technical Regulations.

A positive Industry Safety Expert opinion was obtained.
2 Retrofitting of the boiler-turbine hall at TPP-1 of Arkhangelsk PPM JSC Arkhangelsk PPM JSC Adaptation of the steam turbine design arrangement for the existing cell of the main building.

A positive Industry Safety Expert opinion was obtained.
3 Comprehensive expert evaluation of the stage FEL 2 readiness under the CHPP Reconstruction Project of SSGPO JSC SSGPO JSC Development of documentation in two languages (Russian and English)
4 Feasibility study for the expansion of Ulan Bator CHP-4 with the installation of a new 150 MW power unit UTW JSC Work was completed within 60 calendar days

Upgrade of the energy source capacity to meet the increasing customer needs for electrical and thermal load.

Improving the reliability of customers power supply and the power system reliability
5 Feasibility study for the reconstruction of Chelyabinsk CHP-1 Fortum PJSC Work was completed within 45 calendar days

Construction of the CCGT unit #1 on the basis of gas turbines and HRSGs installed at ChCHP-1
6 Market research and benchmarking for the construction of a CCGT unit under the project of a CCGT construction on the Shymkent CHP-3 site Joint Stock Company 3-Energoortalyk Development of documentation in two languages (Russian and English)
7 Calculation of the standard number of Chelyabinsk CHP-2 productive workforce in 2019 Fortum PJSC Analysis of the CHP staffing schedule and providing recommendations for optimizing the productive workforce number, taking into account the requirements of regulatory documents and CHP performance indicators
8 Design of the EP-3-700-1m ejectors piping for the modernization of turbine generators #1, 4 at Ulan Bator CHP-4. Stage 2 UTW JSC Replacement of the existing equipment while maintaining mounting dimensions and engineering piping
9 Specifications analysis for compliance with the technical requirements for the UTW JSC equipment supply under the project of the Minsk CHP-3 reconstruction UTW JSC Customer’s Engineer functions
10 An adjustment to the project of liquidation of a hazardous production facility (HPF) “Fuel oil storage area” at Chelyabinsk CHP-1 and issuing industry safety expert opinion for changes in the design documentation for the liquidation of HFP Fortum PJSC Necessary sections were developed to eliminate signs of a hazardous production facility without dismantling the equipment, in order to cancel registration in the Federal Service for Environmental, Technological, and Nuclear Supervision as a hazardous production facility, with a relevant record on the State register of hazardous production facilities.

A positive safety expert opinion was obtained
11 Development of design and detailed documentation and providing a field supervision for the following facilities:
- SS-110/10 kV for Maloderbetovskaya SPP 60 MW

- SS-110/10 kV for Yashkulskaya SPP 58.5 MW
Avelar Solar Technology LLC Design and survey work for solar power plants output to the 110 kV network

Positive safety expert opinions were obtained
12 Justification of investments in the modernization of Severodvinskaya CHP-2 and Arkhangelsk CHP within the framework of CSA-2 program (capacity supply agreement) TGC-2 PJSC Work was completed within 45 calendar days

Justification for the CSA-2 price bid was prepared

Analysis of modernization options to convert the existing generating equipment to CCGT using combined cycle technologies
13 Banking feasibility study of the 150 MW TPP for Transalloys SiMn smelter complex Transalloys PTY Limited Development of documentation in two languages (Russian and English)

Marketing research in South Africa

Performing economic analysis and technical analysis of all available technologies most optimal for the facility

Development of closed water balance for the facility
14 Reconstruction of gas facilities for the needs of Nyaganskaya SDPP Fortum PJSC Customer’s Engineer functions
15 Development of design documents for the renovation of the turbine units #2 and #3 at Ulan Bator CHP-4 (Mongolia) UTW JSC Expert reviews of the project undergone in Russia and Mongolia.

Documentation developed in two languages (Russian and Mongolian)
See the whole table

General Contracting

General contracting and provision of technical customer/customer engineer’s services is one of the main areas of activity.

Basic general contracting services:

  • Selecting suppliers and entering into contracts with subcontractors for work, supply of construction materials and equipment;
  • Providing the construction process with all necessary materials;
  • Monitoring compliance with the requirements of the state supervisory authorities;
  • Technical supervision of construction, compliance with cost and quality requirements;
  • Providing the customer with complete information on the construction progress at any work stage;
  • Compliance with deadlines in accordance with the construction time-schedule;
  • Ensuring compliance with industrial and occupational safety requirements;
  • “Turnkey” commissioning of a completed facility to the customer.

Current Projects

Technical supervision of the “Modernization of the GSR CHP JSC heating system” project, Kolpino
Technical supervision of the “Modernization of the GSR CHP JSC heating system” project, Kolpino
Technical and financial monitoring of the investment project activities
  • Supervision is carried out for Sberbank of Russia.
The scope of services, according to the technical specification of the customer, includes:
  1. General design review
    • Title and enabling documentation verification;
    • Design/survey verification;
    • Estimate documentation verification;
    • Construction expertise and monitoring.
  2. Technological expertise / Project monitoring
    • Title and initial permissive documentation analysis;
    • Examination/monitoring of contracting and operating documentation for the Project;
    • Examination/monitoring of contracting and technical documentation for equipment, Project facilities monitoring;
    • Technical supervision and the construction process monitoring.
General Contractor for the Reconstruction of sewage treatment plants
General Contractor for the Reconstruction of sewage treatment plants
Project was implemented on the territory of the existing right-bank sewage treatment plants in Ulan-Ude, Republic of Buryatia
  • Capacity 185,000 m3/day;
  • Total land area is 334,485 m2, the total construction area at stage 1 is 2,297 m2
  • Construction seismicity is 8 points
Project features:
  1. The project was implemented on the territory of the existing right-bank sewage treatment plants in Ulan-Ude, Republic of Buryatia.
    Strategic social municipal object.
  2. To ensure continuous operation of sewage treatment plants, staging of work and commissioning of new equipment is foreseen.
  3. In the first start-up complex, a mechanical treatment unit, air blower station, radial sand-catchers and water and heat supply networks were constructed. Statement of conformity was received for 1 startup complex.
  4. In the second and third start-up complexes the following activities were performed: construction of distribution and dead-end power supply substations, inlet pipelines, inlet and distribution chambers, switching chamber, channel K-6, detailed documentation development.
General Contractor for the power plant construction for Solikamskbumprom
General Contractor for the power plant construction for Solikamskbumprom
Solikamsk CHP reconstruction using gas piston modules in
Solikamsk, Perm Krai
  • The largest power GPU (gas piston units) of the Wartsila company with a unit capacity of 18.3 MW are used.
Project features:
  1. Dismantling works and relocation of engineering lines, supply of auxiliary equipment, construction and commissioning works are being carried out.
  2. A new power plant has been built from February 2017 to December 2018. It includes three gas piston units that supply water-heating HRSGs.
The CHP General Contractor is EUROCHEM, Kingisepp
The CHP General Contractor is EUROCHEM, Kingisepp
Providing new ammonia production of EuroChem-NorthWest JSC with electricity and heat Project features
  • Works are performed on existing production in the city of Kingisepp.
Project features:
  1. Design, equipment supply, construction and commissioning works.
  2. A new power plant has been built from December 2016 to September 2018, it will include a steam turbine P-12-4,7/0,8/0,4 with double automatic extraction.
General Contractor for the construction of 110/6 kV Kekura substation, Chukotka Autonomous Region
General Contractor for the construction of 110/6 kV Kekura substation, Chukotka Autonomous Region
Capital construction within the framework of the “Mining and processing enterprise based on the Kekura gold field” project of “Base metals” JSC
  • The project also developed engineering solutions for the construction of the 110 kV transmission Bilibino-Kekura-Peschanka line.
Project features:
  1. Outdoor switchgear-110 kV is made according to the “Two circuit breaker units with non-automatic jumper on the line side” scheme, using TDN-16000/110/6 transformers, 110 kV gas-insulated switches, a joint station-wide control center and a closed 6 kV switchgear. The first phase of construction involves the construction and commissioning of a single unit.
  2. Equipment delivery to the port of Pevek along the Northern Sea Route, then along the winter road to the field.
  3. In this project, the substation units are specially adapted to work in Arctic conditions
General Contractor for the construction of 110/6 kV substation Arshanovsky Section, Khakassia
General Contractor for the construction of 110/6 kV substation Arshanovsky Section, Khakassia
The project is implemented south of the village of Arshanovo, Altai region of the Khakassia Republic
  • In addition, engineering solutions were developed for the construction of a 110 kV overhead line from the 110/35/10 kV Raikovo substation (SS) to the projected 110/6 kV SS Arshanovsky Section to provide an external power supply to the Beisk coal field.
Project features:
  1. Outdoor switchgear-110 kV is made according to the “Two circuit breaker units with non-automatic jumper on the line side” scheme, using TDTN-16000/110/6 transformers, 110 kV gas-insulated switches, station-wide control buildings and a closed 6 kV switchgear.
  2. Seismicity of the work area – is 7 points. Groundwater shallowness.
General Contractor for retrofitting of the energy facility in the Marina Roscha Jewish Community, Moscow
General Contractor for retrofitting of the energy facility in the Marina Roscha Jewish Community, Moscow
Investment volume amounts to more than 400 million rubles;
Autonomous heat and power supply of the Customer’s facilities is provided.
Project features:
  1. Installation of 2 СUMMINS С1540N5C gas piston units with electric capacity of 1.54 MW each;
  2. Installation of one HYUNDAI HHW-770 chiller absorption-type installation with an installed capacity of 3 MW;
  3. Reconstruction of power facility buildings and structures is foreseen;
  4. Reconstruction of energy facility distribution substation is planned.

Completed projects

ROTEC has considerable experience in engineering and construction of energy and infrastructure facilities. Volume of power capacity created or reconstructed: 2.7 GW

Engineering projects:

Project Period
Reconstruction of Vladimir CHP-2, CCGT - 230 MW 2011-2014
Reconstruction of Novogorkovskaya CHP, CCGT - 330 MW 2011-2014
Perm CHP-9 expansion, CCGT - 165 MW 2011-2013
Novokuibyshevskaya CHP-GTU retrofitting - 240 MW 2011-2013
Reconstruction of buildings and structures of the Ural Turbine Works 2013-2014
Creation of the Gas Turbines Hot Path Repair Center 2015-2016
Reconstruction of Kirov CHP-3, CCGT - 220 MW 2012-2014
Reconstruction of Izhevsk CHP-1, CCGT - 230 MW 2012-2014
Reconstruction of Nizhneturinskaya GRES (State District Power Station), CCGT - 2x230 MW 2013-2015
Construction of Akademicheskaya CHP, CCGT - 200 MW 2013-2015
Ulaan Bator CHP-4 expansion, Mongolia - 123 MW 2013-2015
Reconstruction of Omsk CHP-5 steam turbine PT-80-130 2014-2015
General design of Kazan CHP-3 retrofitting and replacement of the steam turbine PT-60-130/13 2012-2014
Reconstruction of steam turbine PT-60-130/13 at Kazan CHP-3 2013-2015
Construction of the building of the RENOVA R&D Research and Development Center at the Skolkovo IC (Innovation Center) 2014-2016
Energy audit of Aginsky MPP (Mining-Processing Plant) and Zolotoe field, Kamchatka 2015
Energy audit of the Ametistovoe field, Kamchatka 2016
General Contract for the reconstruction of Sulzer Chemtech buildings and structures complex, Serpukhov 2016-2018
Construction of 8 autonomous hybrid mini-power installations based on solar modules for the Amur Tiger Center, Primorsky Krai, Khabarovsky Krai 2017-2018
Functions of a technical customer for the construction of the R&D Renova building in Skolkovo
Functions of a technical customer for the construction of the R&D Renova building in Skolkovo
The project is implemented on the territory of the Skolkovo Innovation Center.
  • Total area of the object is 25,447 m2;
  • Number of floors varies from 3 to 5.
Project features:
  1. R&D Renova was built according to the design project of the Dutch organization EGM Architecten using technological and engineering solutions of leading international corporation Ove Arup & Partners.
  2. R&D Renova building design and construction is carried out while taking into account the environmental and energy efficiency of buildings according to the international standard LEED SILVER.
  3. Association of Professional Organizations in the Field of Energy Survey “Inter-regional Union of Energy Auditors” awarded the building the highest energy security class: A.
  4. A number of research areas requires rooms of a certain purity, regulated by ISO-14644-1 standards. In this project, 7 and 6 levels of purity are used for the microelectronics laboratories, and level 5 is used for chemical and biochemical laboratories.
Creation of the Gas Turbines Hot Path Repair Center, Yekaterinburg
Creation of the Gas Turbines Hot Path Repair Center, Yekaterinburg
The production cycle is unique for Russia. The project is implemented on the territory of the Ural Turbine Works
  • Total area: workshop – 3.1 thousand m2, AAB (administrative and amenity building) – 0.5 thousand m2.
Project features:
  1. Production site includes a laboratory department, a mechanical area, and a welding and machine-tool area.
  2. The workshop equipment allows for the implementation of the entire technological chain for restoring working and guide blades and other parts of the hot path of gas turbines, including product control, cleaning, heat treatment, welding and grinding, soldering, vacuum and atmospheric application of heat-protective and corrosion-resistant coatings, control and measuring operations.
Reconstruction of buildings and construction of test facilities of Ural Turbine Works JSC, Yekaterinburg
Reconstruction of buildings and construction of test facilities of Ural Turbine Works JSC, Yekaterinburg
Building area – more than 1.5 thousand m2. The total area is more than 6.6 thousand m2.
Project features:
  1. The bearing walls of the building were reinforced, the roof was replaced with reinforced truss structures, and the facade insulation system was made.
  2. Alterations to the premises were made, the engineering networks were replaced in accordance with modern fire safety requirements and the requirements for the indoor microclimate. Modern air conditioning systems based on chiller fan coil system were installed.
  3. The world's largest test facility for testing the most powerful cogeneration turbines was built.
Carrying out the functions of a general contractor and supplier of equipment for Ulaan-Bator CHP-4, Mongolia
Carrying out the functions of a general contractor and supplier of equipment for Ulaan-Bator CHP-4, Mongolia
Increase of the power plant capacity by 25% and thermal capacity by 30%.  Works are performed at the operating power plant facility.
Project features:
  1. For the first time in the post-Soviet period, in 2012, Ulaan Bator CHP-4 signed a contract with Ural Turbine Works JSC for the supply of a new T-120/130 steam turbine, which supplemented the three turbines of the previous generation T-110/120 installed at the CHP 30 years ago.
Carrying out the functions of a general contractor for TGC-16 JSC at Kazan CHP-3
Carrying out the functions of a general contractor for TGC-16 JSC at Kazan CHP-3
Retrofitting the thermal circuit and steam turbine PT-60-130/13 st. No.1 with the use of a bottom turbine and with the replacement of electric motors of feed pumps with turbo drives.
During the retrofitting, the following works were performed:
  1. Reconstruction of feed electric pumps st. No. 5,6 PE-500-180 and replacement of electric motor with a steam turbine (turbo drive);
  2. Reconstruction of turbine PT-60-130/13 st. No. 1 for using a steam of 13 ata.
Energy survey of gold fields and mineral processing enterprises, Kamchatka Krai
Energy survey of gold fields and mineral processing enterprises, Kamchatka Krai
Completed work:
  1. Analysis of the power supply system structure at the enterprise;
  2. Assessment of technical condition of the electrical equipment, power supply networks, power consumption accounting and metering system of the enterprise;
  3. Carrying out selective testing in the power supply system of the enterprise for energy efficiency assessment (equipment efficiency, network losses, etc.);
  4. Checking the validity and effectiveness of the operating conditions of main electrical equipment and electrical load distribution between the units;
  5. Drawing up an electrical balance at the enterprise;
  6. Development of a power supply performance improvement program, proposals (technical requirements) to improve technical and commercial accounting of electricity;
  7. Analysis of the possibility to use renewable energy sources with the choice of specific equipment suppliers;
  8. Analysis of options for the location of a source of power supply.
Feasibility study of Energy Complex of the EuroChem-Karatau Chemical Plant
Feasibility study of Energy Complex of the EuroChem-Karatau Chemical Plant
An option of a power unit with two Siemens SGT-600 gas turbines and two SST-400 and 300 steam turbines was adopted.
During the development of feasibility study the following work was performed:
  1. The optimal parameters of the power plant were determined to supply energy supply to the main production;
  2. The analysis and selection of the best technical solution – a combined-cycle power unit with two steam turbines was carried out, ensuring the use of industrial steam at TPP and covering the technological needs for a heat agent;
  3. Equipment providing optimal performance and optimal cost of the life cycle was verified;
  4. Calculations of the investment efficiency of various options for the energy complex construction were carried out.
General Contractor: Sulzer Chemtech, Serpukhov
General Contractor: Sulzer Chemtech, Serpukhov
Repair and reconstruction of a complex of buildings and structures for production of the petrochemical equipment on a turnkey basis
  • Total area is 6,015 m2, building volume = 42,027 m3 (main objects of reconstruction).
Project features:
  1. Land and buildings were purchased by the Developer in different periods without topographic and engineering network surveys. There was a need for a number of approvals, public hearings for construction, relocation of main engineering lines of third owners, and the dismantling of auxiliary buildings;
  2. Reconstruction of the existing buildings was carried out in cramped conditions, including strengthening the ceramic metal framework of existing workshops, interfacing new structural elements and networks with existing ones (due to the developer’s desire to optimize costs);
  3. Change of functionality of one of the buildings for production use;
  4. Hard time limit for design and construction and installation work due to the need to accommodate imported process equipment.
Construction of 8 autonomous hybrid mini-power installations, Far East
Construction of 8 autonomous hybrid mini-power installations, Far East
Construction of diesel-solar power plants for power supply of scientific and environment-oriented stations on a turnkey basis
  • Customer – Amur Tiger Center – an organization created by the Russian Geographical Society on the initiative of the President of the Russian Federation;
  • Objects are located at a considerable distance from residential places and each other. The distance between the most southern and the most northern object is more than 1,000 km.
Features of objects:
  1. Construction was carried out in harsh weather conditions at temperatures below -20 degrees Celsius.
  2. Delivery of machinery and equipment was carried out along bad or impassable roads over long distances (delivery distance of 600 km).
  3. Power installations are based on the use of photovoltaic modules (PVM) of the Hevel company – Russian developer and manufacturer of highly efficient heterostructure-based PVM with the efficiency of more than 22%.

How else can ROTEC help you?

Predictive analytics
Turbine manufacture
Honeycomb seals