raffinerie
Feyzin refinery ©Olivier Dupont

Strong industrial business activities with controlled impact

 

The industrial sector has, for some years, been focusing on the risks associated with its overdependence on fossil fuels and its greenhouse gas emissions.

Increasingly, risk management strategies go hand in hand with a search for product and service offerings that deliver greater added value from a social and environmental perspective. This is an area in which French industrial expertise stands out from the competition.

Carriere
Stinkal quarry ©Karine Warny – Tandem

All Eiffage divisions except Concessions have long-standing industrial activities. The Group’s strategy targets specialised, increasingly sophisticated high-tech industrial market segments characterised by:

  • Investment to enable innovative, standardised and customisable end products to be mass-produced at controlled cost using well-mastered techniques, accompanied by cost optimisation processes and zero-defect quality standards; employee safety and less labour-intensive production;
  • Decreased environmental impacts of all kinds, including greenhouse gas emissions, noise and odour pollution, material consumption and environmental impacts.
Usine 
Collonges binder plant ©Eiffage Route

 

Industrial offering

The Group’s industrial offering is focused on managing energy reducing greenhouse gas emissions.

Optimising production processes and limiting greenhouse gas emissions from industrial facilities

The Eiffage approach – which covers the complete industrial value chain, from project design to integrated maintenance – actively contributes to decreasing consumption and emissions at industrial facilities. Eiffel Industrie (Eiffage Energie) is well positioned to respond to these crucial challenges, ranging from the straightforward management of comprehensive or specific equipment reliability to ensuring the continuous improvement of the availability of manufacturing processes and production quality.

Replacing fossil energies in the industrial heating sector

The Grenelle environmental summit and the projects selected by the energy control commission (CRE) have been instrumental in creating new opportunities in the industrial heating sector: biomass applications, domestic waste incineration, cogeneration plants, etc. Eiffage harnesses its all-round approach to projects and its experience in this business in order to enhance its offering with superior technical solutions that increase the installation's efficiency. Eiffage's offering also includes installation maintenance services

Usine

 

Clemessy is playing its part in extensive works being carried out by Société de Chauffage de Bagnolet, a Cofely subsidiary, which is renovating the Bagnolet district heating network system. Between 2013 and 2015, fuel oil and coal boilers were replaced with gas and biomass boilers. Clemessy MNO was entrusted with the installation of high and low voltage electricity, fire safety system and automatic control devices, and with supervising the two 11 MW boilers.

 

Rennes cogeneration plant (Eiffage Energie) ©Bertrand Béchard  

 

Focus

Software to optimise waste recycling in the Paris urban area

Syctom processes and recycles the household waste produced by 5.7 million people in 84 districts of the Paris urban area. As part of plan to redesign its weighing management software, Clemessy is developing a web application linked to a decision aid environment. The aim of this application is to make allowance for all the business aspects of household waste tonnage measurement.

The software will enable about 100 users to monitor the tonnages collected for each district authority and the invoices of the main parties involved (collector and transporters).

Other examples are provided in the chapter on renewable energy.

 

Clemessy’s emissions analyser

To help its customers comply with environmental protection standards, Secauto, a Clemessy subsidiary, developed a turnkey emissions analyser offering for the measurement of CO, CO2, NO2, SO2, HCl, HF, H2O, O3, COV, NH4, dust, mercury and dioxin emissions in the air. These analysers also display flow rates, pressures and temperatures. A special data acquisition and processing system displays measurements in real time to optimise the utilisation of data and the output of automated environmental reports.

General Electric Belfort entrusted Secauto with the construction of emission measuring cabinets for four oil and gas turbines fuel to be installed in Angola. The analysers, measuring oxygen, sulphur dioxide, and carbon and nitrogen oxides will be fitted in four shelters. The subsidiary will also supply four dust analysers and a data acquisition system. Secauto has already carried out several similar projects for General Electric in France and other countries, including Algeria, Romania, Belgium and Spain.

 

 

  
Usine
The Lauterbourg plant ©Eiffage Métal
Focus

Secan-RSH, an alternative to laboratory testing for kerosene

International standards impose a maximum limit for the concentration of mercaptans (RSH) in kerosene: this requirement is both restrictive and costly for refiners as the kerosene they produce has to undergo systematic laboratory tests. Secauto (Clemessy), which specialises in industrial analyses, offers its customers an alternative solution. After more than 1,000 hours of studies and the installation of a dedicated platform Secanat the Feyzin refinery, its teams have developed the Secan-RSH apparatus enabling analyses to be performed on-line, on the production site, with the same level of measuring quality as laboratory tests. The solution offers numerous benefits, including: repeatable, real-time measurements – reliable and readily available equipment which is easy to use and maintain – and optimal costs. The Secan-RSH system has already been approved by Total and SK Corporation.

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In the context of a project launched in 2013 to build and renovate power plants in Mayotte, Clemessy in partnership with Steuler fulfilled a turnkey contract for the design and construction of an emissions decontamination system for five diesel engines (denitrification) at the existing power plant (Longoni 1). This SCR system significantly reduces toxic discharges of nitric oxide and nitrogen dioxide (Nox) contained in exhaust fumes by converting them to water and nitrogen.

 

Solutions for aviation 

Clemessy is also working on the Greentaxing R&D project aimed at cutting emissions produced by aircraft using runways and taxiways by equipping landing gear with electric motors, dispensing with the need to use their main engines. The part Clemessy played in this project consists in supplying two highly adaptable test benches (mechanical support structure, control system, data acquisition and analysis system, motors, etc.), enabling the customer to qualify the various specimen versions, from the prototype phase through to the industrial production phase.

Clemessy is working alongside a number of major aerospace manufacturers (including Messier Bugatti, Sagem and Hispano-Suiza) on the Recupener project. Under the aegis of the ASTech centre of excellence, the project addresses two major obstacles faced by fly-by-wire aircraft, namely reducing the weight of the electrical system and smoothing power fluctuations. This is achieved by placing power storage and distribution subsystems near flight controls. The goal is to develop an end product suitable for use in various aircraft applications (business jets, regional flights and aircraft carrying more than 100 passengers) in the short to medium term. Also in the area of fly-by-wire aviation, this project incorporated two other European projects (Actuation 2015 and High PMAAC) part-funded by the European Commission via FP7 and Cleansky.

Soudeurs

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Safety of nuclear installations – a core business line

Eiffage divisions are involved in most fields of the nuclear industry. Their complementary areas of expertise are playing a part in responding to calls for greater safety following the major Fukushima accident.

Long-standing design-and-build expertise

These activities draw on expertise from all Eiffage divisions (except Concessions). Eiffage Métal has been operating in this sector ever since the French nuclear power plant construction programme was first launched. The division designs and produces fabricated, sheet metal and electromechanical structures intended for next-generation EPR nuclear plants and for planned decommissioning programmes. Recognised for its expertise in the manufacture of polar cranes and equipment hatches for the reactor buildings at EPR power plants, the division supplies equipment suitable for heavy-duty operating conditions and that is designed to withstand exceptional seismic events.

Focus

Vercors

Maquette
© Léonard de Serres

The Eiffage consortium – led by Eiffage Infrastructures division’s GCN (major nuclear overhaul) department and including Eiffage Construction Métallique, Eiffage Energie and Eiffage Route – has been entrusted with the task of building a model of a double-wall nuclear reactor containment for EDF at its Les Renardières R&D site. This model – named Vercors – is intended to demonstrate the design's robustness in the event of a severe accident and improve the understanding of the phenomena of ageing and transfers through the concrete. All the models dimensions are represented at a scale of 1:3 with the aim of obtaining stress levels similar to those exerted on French nuclear power plants. After six years in operation, this model will enable EDF researchers to assess the behaviour of the concrete used on actual containments at an age of 54 years, as the model’s rate of ageing is multiplied by a factor of 9 owing to the effect of scale.

This project called for extremely careful construction in accordance with very specific building requirements, such as: formwork with no through rods, concrete with no attachment hardware, and 700 sensors installed in the concrete. Upstream, modules were also constructed with the aim of industrialising and optimising the process.

These teams gave a clear demonstration of their expertise and synergy. During acceptance inspections conducted by EDF in November 2015, the containment tightness test confirmed the containment’s effectiveness with results that were well below the specified maximum level (7m3/hour compared with the specified maximum of 50m3/hour). Final handover of all the buildings was scheduled for April.

 

Specialised companies in the Energie division have more than 500 qualified and approved employees working on projects involving high and low voltage electricity, instrumentation and control, site safety and security installations, networks and telecommunications, pipework and welding, auxiliaries and diesel generators, and rotating machinerys.

Focus

Building power plants

Over the past 50 years, Eiffage Génie Civil has helped to build almost half of the nuclear power plants in the French fleet. The division harnesses the knowledge and expertise acquired over that period to develop innovative methods and products that satisfy the highest safety standards.

Centrale de Nogent 
Nogent-sur-Seine power plant ©Alex Béraud
 
Operation and maintenance

More than 800 Group employees hold “DATR” radiation exposure qualifications, certifying their ability to work safely in ionising environments.
The teams working for Clemessy’s nuclear department have more than 40 years' experience and have performed more than 10,000 maintenance operations and projects to reinforce existing structures, alter utility systems and create new structures designed to withstand potential accident scenarios.
Training sessions on best practices to improve personal reliability in nuclear environments was designed in order to foster the right behaviour to ensure compliance with nuclear power plant safety requirements. Fifty-nine employees benefitted from this training in 2015.

Usine de Fos sur Mer
©Eiffage Métal

The Energie division collaborates closely with CEA (French atomic energy commission) on numerous projects. While Clemessy is heavily involved in the process aspect of major projects at Valduc (military operations) and Cadarache (civilian operations) – such as the Jules Horowitz experimental reactor – there is also great potential at other CEA sites. Clemessy’s teams have therefore widened the scope of the expertise. In addition to their usual skills in high and low voltage electricity, they now offer a wide range of services that is practically unmatched on the market. This includes for example their expertise in containments that are indispensable for the purposes of nuclear research programmes. This know-how covers the implementation of leak tests, work on pipes carrying fluids (such as gas and acids) and process instrumentation and control. As regards building infrastructure, Clemessy has expertise in nuclear ventilation and industrial pipework. The company is also the leading expert in radiation protection for CEA.

For its part, Eiffage Energie Vallée du Rhône has been meeting CEA requirements at Marcoule for more than 30 years in the fields of electricity, instrumentation and automatic control systems for both new works and multitechnical maintenance. Other Eiffage Energie entities including its Ile-de-France and Bourgogne subsidiaries are also partners for CEA at its Valduc and Bruyères-le-Châtel military sites.

Focus

Eiffel Industrie at work for Chinon nuclear power plant

The Nuclear department of Eiffel Industrie Ouest is working on the monochloramine water treatment unit at Chinon nuclear power plant, under a contract for preventive and remedial maintenance of the air cooling system (including mechanical components, valves and HDPE and ECTFE composite pipes) from 2015 to 2018.

 
Improving the safety of infrastructure

Since 2011, the Group’s design offices have been taking part in the campaigns of safety improvement works arising out of the tighter safety and security requirements introduced in the light of the Fukushima accident. These improvements mainly relate to flood risk management, enhanced seismic performance, the strengthening of existing infrastructure, safe storage of borated water, temporary autonomous power, and intruder protection measures.

 

Maquette
© Léonard de Serres

As leader of a consortium, Clemessy won a contract for the supply, installation and operational maintenance of ultimate diesel generators for all the 900 and 1,450 MW plant units in the French nuclear fleet, i.e. a total of 38 plant units.

Dismantling services - driving growth

In this field, the divisions are now providing their expertise for a variety of projects relating to special-purpose machinery, automatic control functions to create operational conditions in systems during the decommissioning phase, upkeep maintenance for fire detection, ventilation and site security systems, etc. Eiffage Génie Civil GCN (major nuclear overhaul) department is playing an active part in work on the decommissioning of the G1 UNGG reactor, the very first French nuclear power plant. The teams have developed an extremely safe process for the sampling of the reactor’s graphite, with dry coring operations being performed in a controlled environment, at a moderate temperature and with measures taken to limit the production of dust in order to avoid adversely affecting the material.