ZTC: serving the city reliably and responsibly

The implementation of the investment program aimed at modernizing the Western Thermal Complex (ZTC) was inspected by DCREM specialists, representatives of the public and the media at the end of last week. Airi ZHAN

The group included: Mukhamedali Zhambyluly, chief specialist of the Department for Regulation of Natural Monopolies and Prices of the DKREM of the Ministry of National Economy of the Republic of Kazakhstan for the city of Almaty, as well as members of the regional council: Bibigul Samigulovna Zhunuspaeva, Svetlana Vladimirovna Druzhinina, Vladimir Vitalievich Malishevsky, Natalya Pavlovna Kazakova, Zhanova on Vasilievna Slavko, Shamil Mukhametzhanovich Gizatullin.

The Western thermal complex (ZTC) plays a huge role in providing Almaty with heat and supporting the hydraulic balance of the entire heat supply system of the city, and in fulfilling the heat load dispatch schedules. The ZTC currently includes: Western District Boiler House (SAM), Novo-Zapadnaya Boiler House (NZK), South-Western District Boiler House (YuZRK), two Central Thermal Distribution Points (CTDP) and a pumping station. Their total installed thermal capacity is 1100 Gcal/h, for the steam part – 20 Gcal/h.

But, like most structures of the city’s energy complex, ZTC, which recently celebrated its 55th anniversary of foundation, needed reconstruction and overhaul. More precisely, in modernization, ahead of the potential needs of the city, since Almaty and its needs are growing rapidly. For example, if four years ago the consumption of hot water in the city was 24 thousand cubic meters/hour, now it is 28 thousand cubic meters/hour. And such dynamics of demand growth remains.

Therefore, it was so important in a timely manner, in accordance with the schedule, to carry out all the work provided for by the investment program. One of the most important objects of reconstruction is the overhaul of the convective packages of the boiler unit KVGM-100-150 st. №4 of the Western Thermal Complex. It provided for the complete replacement of packages of coils (half sections), with a total of 104 pieces. The work also included the dismantling of worn packages, the installation of new convective packages, hydraulic, quality control of welded joints and seams and the restoration of thermal insulation. The total cost of overhaul of the boiler unit: amounted to 717.6 million tenge excluding VAT. The customer of the project is Almaty Electric Stations JSC, the contractor is Asia Spets Energo Montazh LLP.

The relevance of the project is emphasized by the fact that the reconstruction of this facility, which is being completed at the ZTC, was included by the joint order of the DKREM of the Ministry of National Economy of the Republic of Kazakhstan for the city of Almaty and the Almaty region and the Ministry of Energy of the Republic of Kazakhstan in the framework of changes in the investment program of AlES JSC for heat energy production services for 2022-2026.

In accordance with the investment program, work is planned on the reconstruction of the combined ash and slag removal system CHPP-2 the 7 th stage, overhaul of hot water boilers of KVGM-100 №4 and PTVM-100 st. №3 at the ZTC, work is underway to create a centralized monitoring point for monitoring and analyzing compliance with occupational safety and health for the ZTC, repair of 6-10 kV switches has been completed and fixed assets have been purchased for ZTC. At the moment, the implementation of the investment program is estimated at 95%.

“Given the large volume of work and high capital intensity, the work was carried out in stages. In particular, the work front for 2024 provided for investments in the amount of 2882 million tenge. At the end of last year, work was carried out on the reconstruction and overhaul of energy sources at 15 complexes,” – quotes the Deputy Chairman of the Management Board of AlES JSC – Chief Engineer Bauyrzhan Kaliev. “For the current year, the investment program approved the amount of 1,623 million tenge and planned overhaul of energy sources of 4 complexes. According to the work of 2025, station №4 (gas-oil hot-water boiler) on the KVGM-100-150 water boiler, 100% replacement of the convective part in the amount of 104 packages was completed. Currently, work is underway to restore service sites and arrange thermal insulation. The total volume of completed repairs is 95%, respectively, 5% of the work remains to be completed in accordance with the schedule before the scheduled date.

The specialists and social activists who visited the ZTC were able to see with their own eyes both the completed work and the remaining insignificant front of work. As Zhanna Vasilievna Slavko noted following her visit to the ZTC, it is very important that all work is carried out strictly according to plan, without getting out of schedule, and most importantly, all work on the investment program will be completed on time. After inspecting the objects, such confidence remained.

For citizens, this means that the coming heating season promises to be stable. For the power engineers themselves, the large-scale reconstruction and repair work means the reliability of the equipment, the reduction of emergency situations.

“Our economists have estimated the expected effect of implementing only the boiler unit repair project: for example, the reduction in boiler wear will be 33.7%, that is, a decrease from 51.9% to 18.2%,” – comments on the project results Roman Krainov, chief engineer of ZTC. – The reconstruction will significantly improve the reliability and operational safety of the boiler unit. In particular, a significant reduction in the risk of leaks and emergency downtime will be achieved. We also forecast a decrease in operating and repair costs in the medium term due to the extension of equipment life and a decrease in the frequency of unscheduled repairs.

I must say that ZTC not only completes a large-scale reconstruction and repair company with equipment updates, but also successfully implements an environmental program. In particular, at the ZTC in 2024, the equipment of the German Automated Monitoring System (AFM) “SICK” was installed, passed the test mode and put into operation. Currently, at the Western Thermal Complex, an automatic monitoring system is installed on three chimneys. Monitoring is carried out continuously, and information from sensors every 20 minutes enters the National Environmental Protection Data Bank of the Republic of Kazakhstan.

This complex and accurate equipment provides continuous emission monitoring. In particular, measurement of the concentration of CO, NO2 , NO, SO2 and O2 gases in the exhaust flue gases. The principle of operation is based on ultrasonic flow meters FLOWSIC100, dust measurement system DUSTHUNTER and gas analysis system MCS. All indicators of emissions into the atmosphere are recorded. The current analysis of the data confirms that the ZTC complies with the established environmental standards.

ZTC plans to install electric generating equipment. This will allow you to provide your own need for electricity, and transfer the surplus to the city. It is also planned to develop a project for the reconstruction of boiler burners – from an environmental point of view, as a result, there will be less harmful emissions.

In the future, it is planned to install Fitch catalysts on gas pipelines. This will save gas consumption up to 360 thousand m3 per year on the boiler. It is also planned to introduce a frequency control system for a group of pumps, saving more than 1 million kW per year.

Summing up the results of the repair work and assessing plans for the future, Bauyrzhan Kaliyev expressed confidence that such an important energy facility of the city as ZTC will continue to serve the city and its people responsibly and reliably for many decades to come.