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The magazine for the international power industry

July-August 2016

Official Media partner for


POWER-GEN Asia 2016

Asia Focus:

SHOW ISSUE

Renewables energy storage

ADVANCES IN FLUE
GAS CLEANING

MANAGING POWER
PLANT CYBERSECURITY

A ROLE FOR COAL IN


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POWER ENGINEERING INTERNATIONAL


JULY-AUGUST 2016/// VOLUME 24/// ISSUE 7

Contents

50

Project & Technology Update

56

Diary

56

Ad Index

Features
2

Energy storage for large-scale renewables


A project in Japan highlights lessons learned in
balancing output from renewable power installations with
battery storage.

A first for South Korea

Energy storage for large-scale renewables, P2


Credit: Q Cells

30

A new chapter in flue gas cleaning has opened in South


Korea with the successful performance test of a plant
using circulating dry scrubber technology.

14

Hydropower monitoring and diagnostics

How the latest surface coating technologies can improve


the expected service life of compressors, turbines and
pumps.

36

How a platform-based approach can improve automatic


fault monitoring and system diagnostics at hydropower
plants.

20

Why a smart energy policy can include coal

42

Why a coal-fired power plant built in the UK in the 1970s


had excellent potential for biomass conversion.

Creating a 21st century valve


How a new kind of valve with a simplified design can
eliminate the main reason for failure in flow regulators.

46
New life for an aging coal power plant

Managing security for power plants


Mitigating the risk of cyberattack requires a rigorous
approach to hardening security controls around IT, ICS
and SCADA.

A pulverized coal power plant in the US demonstrates a


low marginal generating cost with minimal environmental
impact.

26

Extending equipment service life

Rising to the secure power challenge


How customized uninterruptible power supply systems
can meet the environmental and electrical challenges of
difficult environments.

On the cover
An energy storage system in Hokkaido, Japan offers lessons in energy storage for utility-scale renewables. P2

Free Product Info


You can request product and service information from this issue. Simply click on the link below that will provide you access to supplier companies websites,
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If you are considering suppliers or buying products you read about in PEi, please use this service. It gives us an idea of how products are being received to help us continually
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Power Engineering International July-August 2016

8/16/16 10:38 AM

Asia focus: Energy storage

Mount Komekura solar photovoltaic power plant in Japan


Credit: TEPCO

Storage systems
for utility-scale
solar and wind
Experts from Mott
MacDonald offer lessons
learnt in mitigating
real-time power output
fluctuation for solar PV
and wind power plants
using battery storage
systems, and spotlight a
storage project in Japan

n some countries where peak demand

Limited utility-scale experience of ESS in

occurs during the night, an energy

renewable energy applications also raises

storage system can be used to store

uncertainties and risks, such as system failure

energy generation from solar PV plants

causing loss of revenue for power plants.

during the day and inject stored energy to


the distribution system at night.

One challenge for renewable power project

can be used for ancillary services such as

developers relates to the efficient design of

voltage support, frequency control and load

battery capacity to cost-effectively meet the

smoothing, as well as ramp rate control in

grid utilitys requirements. To accurately size

order to maintain grid stability. Controlling

the ESS, it is recommended for the developer

power output fluctuation from renewable

to base battery sizing on high-resolution data

power generation can lower disturbances to

(i.e., one minute or less) of renewable resource

the grid and decrease feeder tripping, which

or power output at the site location.

consequently decreases revenue loss.

1608pei_2 2

Challenges for developers

The energy storage system (ESS) also

For utility-scale projects,it is industry practice

Although the ESS benefits the grid system in

for wind projects to install a meteorological

terms of the intermittency of the power supply,

mast at the site location prior to construction.

plus provides greater control of the network,

With an appropriate setting, high-resolution

integrating the ESS significantly increases

data can be extracted at site and utilized

the total lifetime capital, operation and

for battery sizing. In contrast, it is currently not

maintenance cost of projects. Additionally,

general practice for solar PV plants to have an

an ESS typically has round-trip efficiencies of

on-site weather station before the plant enters

between 70 and 95 per cent, so will discharge

operation. Even for countries with abundant

less energy back into the system than it can

national meteorological stations, irradiation

absorb.

data from such public data sources is mostly

Power Engineering International July-August 2016

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8/16/16 10:38 AM

Asia focus: Energy storage

Financial
Parameters

Units

Capital cost for


Lithium ion battery

m$/MWh

1.0

Capital cost of
supporting
components such as
inverters, transformers,
Energy management
system

m$/MWh

0.5

Battery replacement
rate

% of
installed
battery
capacity/
year

5.0

Discount rate

%/year

8.0

Feed-in tariff for


Japan

JPY/kWh

40.0

Exchange rate

JPY/$

120.0

Operational period of
PV plant

Years

20

Plant power output


degradation

%/year

0.5

Figure 1: Comparison of power output between a solar PV plant with and without ESS

available at only an hourly, daily or monthly

from the system suppliers. As an example,

resolution.

lets consider a detailed analysis of an ESS

Some of the major considerations in the

in Hokkaido, Japan. Hokkaido is an island

design of an ESS are:

with weak electrical interconnection to the

Required through cycle efficiency (this

main Japanese grid and dynamic weather

varies by technology);

conditions that can significantly vary the

Battery cell lifetime (which will vary by

power output from solar photovoltaic (PV)

technology, use and installation condition);

plants.

The design and operation of the battery

management system; and

Values

Given higher geographical differences in


wind resource patterns, the consequent size of

The design and performance requirements

battery storage systems in wind power plants

of the power converter systems.

can be extremely different depending on

The ESS can be integrated into renewable

Table 1. Financial assumptions

specific location, so this case study will focus

fluctuation in power output. The purpose of

configurations

on the analysis of battery sizing for solar PV

battery storage in the system is for smoothing

depending on the type of technology used.

plants. It should be noted, however, that the

power output throughout the day to achieve

Since the concept of this type of battery

battery optimization concepts are applicable

compliance in the rate of change in power

application is in the early stage of deployment,

for both wind and solar power plants.

output stipulated by the grid utility.

power

plants

in

multiple

technical modelling is likely to have high

There were several technical assumptions


for the Hokkaido project:

Battery sizing technical analysis

sensitivity scenarios and return on investment.

If the rate of change of power output from

Based on Mott MacDonalds experience, to

Battery is connected to the AC system of the

the renewable power generation project

generation plant following conversion;

exceeds the regulated level, the plant will be

uncertainty, which

impacts

on

financial

High efficiency lithium-ion battery;

date no energy management system (EMS)


supplier provides any form of guarantee on

annual curtailment loss. Related challenges


include uncertainty in dynamic conditions

required to temporarily shut down or financial

inverter-transformer package;

penalties will be imposed. Such opportunity

and future data forecasting approach, as well


as the limitation of the EMS algorithm to handle

Battery is equipped with an independent


Changes in plant power output limited at 1

loss, referred to as curtailment loss, will occur

per cent of plant AC capacity per minute;

when the battery size both battery capacity

Battery output always reaches battery rated

(MW) and time capacity (h) is insufficient

unpredicted changes. Such circumstances

power regardless of the state of charge and

to absorb high resource fluctuations in some

certainly pose technical risks to project owners

the charging/discharging duration.

circumstances.

and developers.

There

were

financial

also

several

assumptions

and

Challenges for project lenders

these

Efficiency, reliability and lifetime of the current

MacDonalds

battery storage systems over a typical power

international project experience

project life of 20 to 25 years have not yet

on solar PV and wind power

been proven. Therefore, a technology review

plants

or bankability study of the ESS should be

systems.

undertaken to define risks to project investors


and lenders.
regarding

technology

Asian

battery

Mott
and

lifetime

warranty

and

gives a smooth increase and


to the grid. In contrast, the plant

system

package

Maximum
discharge time
of the battery
storage

Percentage of battery rated capacity


compared to rated plant power output
Case 1
(100%)

Case 2
(80%)

Case 3
(60%)

Case 4
(40%)

0.8 h

0-4%

1-5%

7-11%

12-33%

0.6 h

1-5%

1-7%

10-11%

15-34%

0.4 h

1-9%

4-12%

14-15%

18-36%

With the assumptions above,

decrease in energy transmitted

and

Percentage of curtailment loss over total power output

storage

maturity,

performance

1608pei_4 4

on

degradation,

battery

with

based

the power plant with the ESS

Such a study would need to review


evidence

are

Table 2. Percentage of curtailment loss for different battery


capacity options

without the ESS shows high

Power Engineering International July-August 2016

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8/16/16 10:38 AM

Asia focus: Energy storage

cent capacity and 0.4 h maximum discharge


time appears to be the most cost-effective
battery size for the project.
Due

to

differences

in

national

grid

regulations and requirements, as well as a


wide range of project-specific parameters,
Mott

MacDonald

provides

ranges

of

rated capacity, curtailment loss is around

Mott MacDonald strongly recommends this

curtailment loss based on operating power

0 per cent to 9 per cent of the project annual

kind of levelized cost study to be explored

plants. The simulation of the curtailment loss is

output. Curtailment loss increases to between

project-by-project.

based on four different battery rated capacity

12 per cent and 36 per cent when battery

This article provides an example of the

(MW) cases 100 per cent, 80 per cent,

rated capacity is reduced to 40 per cent of

change in levelized ESS cost for a solar PV

60 per cent and 40 per cent of power plant

plant capacity, with maximum discharge time

plant against various ESS cost scenarios as

rated output.

of 0.4h to 0.8h.

illustrated in Figure 2.

power output from different battery capacities

Battery sizing financial analysis

range for a solar PV project decreases

with the maximum discharge time variation

The combination of battery system cost and

consistently along with the reduction in ESS

from 0.4 h to 0.6 h and 0.8 h are shown in

curtailment loss per unit installed battery

package cost.

Table 2.

capacity (MWh) reveal the representative

This article outlines a case study of ESS

It is obvious that high battery rated

expenditures for the battery system over the

use to meet utility requirements, limiting the

capacity and maximum discharge time can

project lifetime. Considering net present value

maximum ramp rate in change of power

have significantly lower curtailment loss under

terms, a levelized ESS cost is used to justify the

output

the scenario considered. For various maximum

most suitable battery capacity option for a

generator, to give an illustration of the

discharge times at 100 per cent battery

project.

parameters, costs and challenges involved.

Percentages of curtailment loss over total

From this exercise, the levelized ESS cost

To

from

ensure

an

intermittent

optimization

of

renewable

the

ESS

wherever such utility requirements apply, Mott


MacDonald recommends a levelized cost
study to be performed project-by-project.
The lack of fine-resolution meteorological
and operating data limits analysis and
simulation, resulting in significant performance
uncertainty.

Additionally,

greater

understanding of the practical ESS control


algorithm performance when equipped with
utility-scale renewable energy generation is
still required.
Since

application

of

utility-scale

ESS

occurs within a multidisciplinary framework,


strong collaboration between the grid utility,
developers, ESS manufacturers and all relevant
Figure 2. Levelized ESS cost for a solar PV plant against various ESS package cost scenarios

parties is necessary for efficient infrastructure


spending. For example, the requirement for
ESS storage and ramp rate regulation can be

Levelized ESS cost for battery storage system net of


curtailment loss (m$/MWh) for a standard ESS package
capital cost of $1.5m/MWh
Maximum
discharge time
of the battery
storage

Percentage of battery rated capacity


over plant power output
Case 1
(100%)

Case 2
(80%)

Case 3
(60%)

Case 4
(40%)

0.8 h

1.79-1.98

1.48-1.66

1.40-1.58

1.27-2.22

0.6 h

1.39-1.57

1.12-1.40

1.26-1.31

1.22-2.09

0.4 h

0.94-1.31

0.9-1.27

1.18-1.22

1.18-2.00

Table 3. Levelized ESS cost for different battery capacity options

The levelized ESS cost for

reduced in cases where the grid utility benefits

the purpose of this article is

from accurate weather forecasting, either from

expressed as the above. The

the specific plant or for the broader renewable

example of levelized cost of

portfolio on the grid system. It could therefore

each battery size for a solar PV

predict production to adjust generation

plant is summarized in Table 3.

dispatch accordingly.

Even though the larger


battery
lower

size

results

curtailment

in

1608pei_6 6

Power Engineering International July-August 2016

Jongsuwanwattana,

Nonthi

Cherdsanguan and Vipant Chayavichitsilp

investment and maintenance

are all graduate renewable energy engineers

cost portions can outweigh

at Mott MacDonald.

the saving opportunity from


curtailment loss. For this article,
the battery with 80 to 100 per

Natthida

loss, the

Visit www.PowerEngineeringInt.com
for more information

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8/16/16 10:39 AM

Gunjang Energys Gunsan city plant


Credit: Hamon

Asia focus: Flue gas technology

A first for
South Korea
A new chapter in flue
gas cleaning technology
has opened in South
Korea with the successful
performance test of a
flue gas desulphurization
plant based on
circulating dry scrubber
technology, write Sung
Yurl Kim, Yonghee Kang,
Claudia Bautsch and
Christian Moser

wo

years

Korean

a metered quantity of hydrated lime as the

Gunjang

absorbent, and over 90 per cent of FGD

Energy decided to install a new

product, recirculated from the downstream

unit, called Seagull, at its existing

arranged filter. Figure 1 shows the arrangement

power plant at Gunsan city.

of the whole CDS system.

electricity

fluidized

ago, South
company

The

bed

(CFB)

circulating
boiler

size

The FGD is located downstream of the air

was

preheater in the power plant arrangement.The

275 MW and it needed to fulfil strict emission

CDS system itself consists of a CDS absorber, a

requirements which came into force in

low pressure fabric filter with eight chambers

January 2015. Therefore, a suitable flue gas

for

desulphurization (FGD) technology to meet

absorber, the connecting ductwork including

this limit became mandatory. Gunjang Energy

the recirculation duct, the ID fans downstream

wanted to install the most economical FGD

of the fabric filter and the connection to the

technology for these demands, and therefore

stack. All equipment has been installed in a

selected circulating dry scrubber (CDS)

compact and space-saving way.

dedusting

downstream

of

the

CDS

technology. The contract was awarded to


Hamon Korea in June 2014 and commercial
operation started on 18 May 2016.
The basic principle underlying a CDS is
the removal of gaseous components and a
downstream filter for dust removal.The flue gas
from the upstream boiler flows through the
CDS and then a filter, and is released into the
atmosphere via induced draft fans and stack.
The main component for the removal of
waste gases is the CDS with the high solid
concentration situated inside it. These solids
contain the dust brought in by the raw gas,

1608pei_8 8

Power Engineering International July-August 2016

The Seagull plant with absorber, filter, solid


handling system, ID fans and ductwork
Credit: Hamon

www.PowerEngineeringInt.com

8/16/16 10:39 AM

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8/16/16 10:39 AM

Asia focus: Flue gas technology

Design features
The CDS system is designed for boiler operation
from 35 to 100 per cent. This wide variation of
load cases is a challenge for every kind of
FGD technology. The CDS system provides
stable operation conditions for all load cases
due to the opportunity of gas recirculation.
The most important thing for proper
operation of the CDS plant is a uniform flue gas
distribution to the CDS absorber. Downstream
of the venturi section, the recirculated solids
are inserted in the gas stream. Both solids and
water, which is injected upstream of the venturi
section, influence the flue gas flow through the
whole CDS absorber.
The interaction of three phases (gas, solids,
water) and the thermodynamic behaviour
can only be simulated using specific software
with in-house developed add-ons. During
Figure 1. Arrangement of Seagull CDS plant

the design and engineering phase of the


CDS system, three main parts of the CDS
technology were investigated in detail: gas

help of high sophisticated computational

very detailed way in one single model. This is

flow and absorber design; solid handling

fluid dynamics (CFD), performed on a high

mandatory to determine all relevant physical

system; and water humidification system.

performance computing (HPC) cluster with 260

effects and their interdependencies.

Development and final check of the design

cores. Due to this high calculating capacity, it

The description and modelling of a three-

for the six venturi CDS system were done with

is possible to describe the CDS process in a

phase simulation consisting of two continuous

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1608pei_10 10

Power Engineering International July-August 2016

O&G Industries (Up/Mid/


Down) stream
Biogas application
Power generation
Petrolchemical
Refrigeration
Refinery
Part of

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8/16/16 10:39 AM

Asia focus: Flue gas technology

Volume flow
boilers

actual

m3/hact

Min Load

Max Load

580,000

1,520,000

m3/hSTP,wet

390,000

995,000

actual

m3/h

1,035,000

1,525,000

norm

m3/
hSTP,wet

745,000

998,000

m3/hact

450,000

1,000

from boiler

118

127

to CDS

101

127

from CDS

71

71

Inlet SO2

mg/
m3STP,dry

146

234

Inlet HCI

mg/
m3STP,dry

47

54

Hydrated lime feed

kg/h

125

410

Humidification water

m3/h

10

35

norm

Volume flow to
CDS

recycle

Gas
temperature

Table 1: The main initial design data

phases (gas and solids) and one particle phase (water droplets)
needs a complex simulation approach with two Eulerian and one
Lagrangian phase.
The specifications of all material properties are temperaturedependent and the system is fully coupled between all phases.
In addition, it allows the engineer to evaluate the performance

Plug in
and relax.

(temperature profile, velocity distribution, solid distribution, water


evaporation, etc) at any point in the process and how the performance
changes with alterations such as turning vanes, water lance insertion
depth, number of solid injection points, number of venturi, etc).With this
approach, the ducting, all installed guiding vanes and other processrelevant internals of the absorber are optimized and finally defined via
CFD simulation considering all relevant load cases.
To achieve a homogeneous gas velocity distribution downstream
of the venturi section, the miter bow is equipped with two optimized
ladder-grid guide vanes. These guiding vanes are a Hamon design
that is validated in several CFD simulations as well as in physical flow

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model tests.
The wide range of flows/loads also influences the solid handling
system. The solid handling system covers the total transport of solids
in the CDS plant. It includes the silos for the absorbent and for the dry

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product as well as the through hopper underneath the fabric filter


which stores the solids to be recirculated.
The air slides, which connect the through hopper and the CDS
absorber, also belong to the solid handling system.
Additionally, the range of volume flow influences the absorbent
feeding system. Due to the range in loads the absorbent feeding
system has to operate in a range of 40 kg/h up to 2000 kg/h.
A further design challenge is the wide range in water volume flow
for humidification nozzles. Here, the right nozzle type, nozzle position
and number of nozzles have to be chosen.
The water humidification system is used to inject water into the CDS
absorber. It is located in the round section of the CDS. The water itself
is necessary for different reasons. It is used to cool the flue gas flow

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8/16/16 10:39 AM

Asia focus: Flue gas technology

commissioning from November to December


2015 and was followed by hot commissioning
from

January

to

April

2016. The

CDS

desulphurization system has successfully been


in operation since May. During commissioning
and performance testing of the new unit it
became clear that the CDS system is able
to operate safely at higher than full load with
lower absorbent consumption and higher SO2
removal than guarantee values.
The performance test was successfully
passed on 1 June, with a flue gas flow of
1,530,000 Am/h.The SO2 absorption efficiency
was almost 99 per cent and the dust removal
efficiency was over 99 per cent.
Sung Yurl Kim is Executive Director of Air
Quality Systems and Yonghee Kang is Senior
Process Manager of Air Quality Systems at
Figure 2. Gas flow through ducts, absorber and filter

Hamon Korea. Claudia Bautsch is Specialist


for CFD and Plant Optimization and Christian
Moser

down to 1015 K above water dew point. This

The most important reason for injecting

increases the absorption and leads to less

water is to start and enhance the absorption

lime consumption because the stoichiometric

of the sulphur dioxide (SO2) from the flue gas.

ratio is decreased.

The commissioning started with cold

is Managing Director at Hamon

Enviroserv, Germany. www.hamon.com

Visit www.PowerEngineeringInt.com
for more information

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Power Engineering International July-August 2016

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8/16/16 3:05 PM

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1608pei_13 13

8/16/16 10:39 AM

Hydropower

Maintaining
engineering expertise
in hydro plants
Efficient automatic
fault monitoring and
system diagnostics for
hydropower plants can
be achieved through a
platform-based approach
that integrates knowledge
management with
predictive maintenance,
writes Roberto Piacentini

n recent years, the importance of asset

and real-time calculations to determine the

monitoring systems for power utilities has

actual state of the asset being monitored.

increased significantly due to the pressing

So how do executives and operations &

challenges of an aging workforce and,

maintenance management staff at power

with the advent of the Internet of Things

utilities handle the transfer of knowledge?

megatrend, an exponential growth of

Ultimately, how

devices connected to the grid.


These two factors have driven power utilities

not

lose

the

workforce?
An asset monitoring system can provide

reliability and availability through enhanced

the necessary insight into production system

equipment performance and productivity

health to help increase production, reduce

using predictive maintenance methodologies

downtime and achieve higher production

and the effective projection of asset failures.

output.

medium-to-large

Development

of

advanced

power

maintenance strategies such as predictive

utility has more than 100 large machines

maintenance involves efficient information

that require monitoring systems in multiple,

and data management methodologies.

geographically dispersed sites covering over

Predictive

maintenance

requires

the

15,000 measurement points. These systems

ability to process a lot of information about

continuously stream data using specialized

sensor

algorithms

measurement

that

convert

the

data

into

types,

measurement
points,

equipment,
measurement

information that ultimately results in corrective

frequency, real-time calculations for health

action.

state estimation, and so on. Additionally,

This represents over 2 GB of acquired

implicit operator/technician knowledge is

and analyzed data per second. Acquiring,

often necessary to diagnose the operational

analyzing, and managing these massive

condition of the equipment, conduct fault

amounts of data efficiently and in a timely

monitoring, and predict failure criticality.

manner is a complex task as machines evolve


and require additional measurement points

1608pei_14 14

they

to strive for higher levels of power system

Typically,

14

do

engineering expertise they face with a retiring

Power Engineering International July-August 2016

With

deployments

throughout

Latin

America, M&D Monitoring and Diagnostics

www.PowerEngineeringInt.com

8/16/16 10:31 AM

Hydropower

The control room at Itaipu Dam in Brazil


Credit: GE

in Rio de Janeiro, Brazil has successfully

(radial and axial); pressure pulsation and

them into machine-learning algorithms that

addressed these challenges by developing

level; flow; air gap and position; temperature

automatically diagnose and recommend

an advanced asset monitoring solution for

(direct measurement and thermographic

maintenance actions to the operations team.

hydropower

substations.

analysis); pump intermittence times; electrical

This approach greatly helps mitigate power

The company created it to considerably

(voltage, current, power), and the amount of

utilities growing concern that, without an

reduce the need for human intervention

physical and chemical lubricant.

intelligent monitoring solution to capture their

generators

and

and to offer intelligent decision support with

The M&D solution uses existing SCADA/

fault monitoring, diagnosis and prognosis

historian systems to extract recent data from

workers would have no time to train new

capabilities.

multiple sources and operational parameters

personnel entering the workforce.

and

As these workers use the M&D asset

Open and flexible platforms

analyzes the data. The solution transforms

monitoring solution, they can review, add or

To meet stringent power utility requirements for

this analysis into graphs, reports and other

update the machine-learning rules (in other

easy integration, interoperability with existing/

real-time analysis tools to provide accurate

words, the digital representation of actual

legacy systems, and high reliability, the M&D

information. These tools can be accessed by

domain experts knowledge) for each asset

approach uses open and flexible commercial

email or web from tablets and mobile phones

or piece of equipment using a graphical

off-the-shelf

to conduct faster and more convenient

and intuitive interface that they can access

decision-making in the field.

with any web browser. Additionally, the M&D

hardware

platforms

and graphical software tools to alleviate the

automatically

correlates

knowledge, retiring, experienced

and

(COTS)

then

domain

complexity of developing, deploying and

solution facilitates knowledge sharing by

Knowledge management

creating a formal and digital organization/

M&D automatic monitoring systems rely

Additionally, this intelligent decision support

domain memory backed by a database

on graphical system design with NI LabVIEW

solution works as the organizational memory

system that senior domain experts can use

software

FPGA-based

of the company by formalizing the experts

as a training tool for novice workers and

hardware to automatically acquire and

knowledge of maintaining equipment over

technicians.

compute math calculations and analyze

the years through database storage and

data in real time using various predictive

management.

managing monitoring systems.

and

CompactRIO

Analysis techniques

techniques.These systems work online or offline

M&Ds

knowledge

and take measurements such as vibration

methodology

digitally

(acceleration and velocity); displacement

experts day-to-day decisions and feeds

www.PowerEngineeringInt.com

1608pei_15 15

management
captures

domain

At the core of the M&D advanced asset


monitoring solution, automated diagnostic
functions

use

fuzzy

logic

algorithms

Power Engineering International July-August 2016

to

15

8/16/16 10:31 AM

Hydropower

determine in real time the equipments current


state. Based on the knowledge previously
captured and digitized from domain experts,
these algorithms identify faulty equipment.
For analysis and reporting, the solution
transforms hundreds of gigabytes of data into
a single-page report that may be generated
automatically or by user request. The solution
uses the following traditional and custom
signal processing and analysis techniques:
l

Trend analysis (parameters and faults);

Orbit analysis with 3D animation;

Comparison analysis in the time and

A medium-to-large utility has over 100 large machines that require monitoring systems
Credit: Alstom

spectral domains;
l

Cascade diagrams;

diagnosis

DAQ

operating characteristics and features for the

strategy avoids storing irrelevant or repeated

DAQ process, equipment health condition

information, which eliminates uncontrolled

assessment, and their respective warnings

growth of data over time. Furthermore, using

and alarms associated with the parameters

Bearing fault analysis (envelope: more than

spectral signature comparison of online

monitored.

8000 pre-recorded bearings).

data and decision algorithms based on

3D graphics;
Temperature profiles;
Correlation analysis;
Intelligent assistant for balancing;

capabilities. The

online

The M&D solution stores online and offline

characteristics of the equipment operating

Deployment and benefits

data in a single database for primary (critical)

point reduces the risk of false alarms and

M&D advanced asset monitoring systems

as well as secondary (balance of plant)

nondetection

for

for the predictive maintenance of plant

equipment. This integrates multiple sources of

noncritical equipment, offline DAQ uses mobile

equipment have been adopted by power

data and increases the systems automatic

data collectors (route-based) with simplified

utilities due to their modularity, performance

events. Recommended

INFORMAL TENDER INVITATION

Disposal of Used Plants & Excess Inventory


Sable Chemical Industries Limited, an ammonium nitrate fertiliser manufacturing company located in
Zimbabwe, would like to dispose of two complete used plants as well as excess inventory associated with
the plants. Tenders are therefore invited from companies and/or individuals interested in the purchase
and safe removal of the following items:
TENDER
NO.
ASP/1/16

DESCRIPTION

OTHER INFORMATION

Air Separation Plant

Plant Designer
LAir Liquide
Installation Date
1972
Technology
Cryogenic Air Separation
Design Output
Nitrogen: 7 300 NM3/hr; Oxygen: 3 970 NM3/hr
Plant Designer
La Grande Paroisse
Installation Date
1972
Technology
High Pressure Process
Design Output
220 tons per day Ammonia
Item Categories include:
Electrical, Instrumentation, Valves and Valve Spares, Chemicals and Catalysts,
Resins, Compressor Spares, Fasteners, Gaskets, Pumps and Pump Spares, Pipes
and Fittings, etc.

ASP/3/16

Ammonia Synthesis
Plant

REI/4/16

Excess Inventory

Tender documents and further information may be obtained from the Sable Materials Manager who is
contactable as follows:
Address:

Sable Chemical Industries Limited, 7 Anne Newton Boulevard, Sherwood Block, P.O. Box
561, Kwekwe, Zimbabwe

Telephone:

+263 55 23601/9; +263 55 23652

Email:

knowledge.samhungu@sablechemicals.co.zw

Tenders close on 31st August 2016 at 1700hrs CAT.


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Power Engineering International July-August 2016

www.PowerEngineeringInt.com

8/16/16 10:31 AM

BIG
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POWER

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8/16/16 10:31 AM

Hydropower

and easy integration with monitoring or


supervisory software. The M&D solution based
on NI hardware and software platforms
monitors 38 per cent of Brazils installed
hydropower: more than 50 plants; more than
230 hydro generators (over 33 GW of power);
more than 34,000 measurement points every
minute all over the country; and more than
2 TB of data automatically analyzed daily.
An advanced asset monitoring system significantly reduces the need for human intervention
Credit: GE

The adoption of a graphical programming


language and an FPGA-based hardware
architecture has resulted in a complete,
sensors-to-enterprise

asset

monitoring

More accurate diagnostics (self-adapting

solution with greater reliability, flexibility, and


performance as well as simpler maintenance.

monitoring, high-fidelity hardware);


l

Decision-making

continual

use

of

advanced

(automatic

maintenance challenges allows organizations

The key benefits of the M&D asset monitoring

diagnostics based on the previous inputs

to collect more accurate and detailed

system include:

of

performance data while applying advanced

management techniques);

Reduced operational costs (automatic

Improved equipment safety (early fault

Easier

of

multiple

maintenance,

expansion

analytics

to

improve

decision-making,

Easy access (web and mobile phone,

generate competitive leverage, and increase

reports by email and SMS);

productivity growth for their operations.

Full configuration, from the sensors to the

data

sources

(multiple parameter monitoring);


l

knowledge

detection);
Correlation

specialists/technicians,

predictive maintenance analysis);

support

The

technologies to address common asset

(future-ready

updates,

and

modular

and

existing knowledge about fault modes,

Roberto Piacentini is Principal Manager at

allowing its adaptation to any type of

National Instruments. www.ni.com

industrial equipment;
l

distributed architecture);

Support for various languages (English,

Spanish and Portuguese).

Visit www.PowerEngineeringInt.com
for more information

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Power Engineering International July-August 2016

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8/16/16 2:15 PM

Longview Powers 770 MWe coal power plant in West Virginia


Credit: Longview Power

Coal-fired power

Why a smart
energy policy can
include coal
A pulverized coal plant in the US is an example of how combining the right
operational model with best-in-class technologies can produce affordable, reliable
and secure power with the lowest possible environmental impact,
write Robert Giglio and Steve Nelson

hile

energy

closer look at recent new pulverized coal

indirect employment and material supply. Due

and

plants coming online, like Longview Powers

to its mine-mouth project structure and its high

power industry leaders

770 MW plant in West Virginia, the reality is not

power plant efficiency, the plant is among the

have differing views on

matching the headlines we see in the media.

lowest cost generator in the US, and the world

policymakers

how to move toward

for that matter. Its marginal generating cost is

The Longview project

lower than all the natural gas combined-cycle

affordable power delivery system, they all

The Longview project is a good example of

and nuclear power plants on the PJM grid

agree on one thing: that a portfolio of fuel

combining the right operational model with

that it serves. As shown in Figure 1, its marginal

and technology options is the best strategy to

best-in-class technologies to produce very

cost is even below most of the hydropower

meet our future energy needs while enduring

affordable, reliable and secure power

the continued uncertainty inherent in the

with the lowest environmental impact.

energy sector.

Longview Power teamed with affiliated

a clean, reliable and

STEAM CONDITIONS

Metric
units

English
Units

Main steam flow rate

2362 t/hr

4876 kpph

The corollary is even more important that

mining company Mepco to build an

over-reliance on a single technology or fuel

integrated coal-mine-to-power energy

Main steam temperature

569C

1056F

can have devastating impact. This can be

complex in Maidsville, West Virginia, in

Main steam pressure

258 bar

3735 psia

seen today in Japans power industry after the

the US.

Reheat steam flow rate

1871 t/hr

4012 kpph

Fukushisma nuclear accident, in oil exporting

The power plant is located within

countries with oil prices more than half the

8 km of the coal mine which produces

Reheat steam temperature

557C

1052F

55.3 bar

788 psia

value they were a year ago, and in the US

high sulphur bituminous coal primarily

Reheat steam pressure

when heavy frame gas turbines were being

for the Longview power plant. The power

POWER GENERATION

sold on eBay at rock bottom prices after the

plant

Gross output

770 MWe

collapse of the combined-cycle build boom

in December 2011 and has a rated

Net output

700 MWe

in 2006.

net capacity of 700 MW and a gross

POWER PERFORMANCE

All technologies and fuels have their

began

commercial

operation

capacity of 770 MW.

advantages, disadvantages and carry risk. For

The plant is owned by major private

pulverized coal, its advantages are low cost,

investment companies and employs

large scale, reliable power. Its disadvantage

over 600 skilled local workers annually,

has been and continues to be its

and adds approximately $43 million per

environmental footprint. However, taking a

year to the local economy in terms of

20

1608pei_20 20

Power Engineering International July-August 2016

Net plant efficiency %


Net plant heat rate

41.3 LHV

39.5 HHV

8726
kJ/kWh

8640
Btu/kWh

Table 1 . Longviews steam and plant performance


values at full load design conditions

www.PowerEngineeringInt.com

8/16/16 10:40 AM

Coal-fired power

plants on the PJM grid, with only wind and solar dispatched in front of
Longview.
With this cost profile, it is no wonder why Longview produced
98.5 per cent of its total rated power production since completion of
recent repairs, and why Longview Power is aiming to achieve a 92 per
cent capacity factor for 2016.
One key factor in achieving this low level of electricity production
cost is due to a very low fuel cost. Since Mepco is an affiliated company,
the coal price is negotiated for the benefit of both companies and
operational enhancements are developed continuously. Further, the
coal travels from the mine to the power plant on a 7.2 km conveyor,
avoiding the higher staff, equipment, fuel and maintenance cost of
trucks, trains, roads and tracks that most other coal plants carry.
Another key factor is related to Longviews recent efforts to optimize
plant efficiency and achieving a very high net plant efficiency of
39.5 per cent (fuel HHV basis), which allows the plant to produce full
power while consuming 17.5 per cent less fuel than the average coal
plant in the US. This, in itself, saves Longview over $10 million per year in
the plants operating cost.

Clean and efficient power


The Longview plant is subject to very strict environmental standards. In
fact, the state of West Virginia imposed on Longview the lowest NOx,
SOx, PM, CO and mercury emissions limits ever imposed on a coal plant
in the entire US.
The plant consistently meets all permitted emissions and is now the
cleanest operating coal power plant in the PJM power market and one

HIGH PERFORMANCE

of the cleanest in the US. As Figure 2 shows, Longviews permitted stack


emissions are many times lower than other coal plants in state of West
Virginia. Further, as Figure 3 shows, the plants actual stack emissions are
also well below the limits of the EPAs strict Mercury Air Toxins Standard
(MATS).
Due to Longviews high net plant efficiency, the plants actual
emissions on a tonne/year or mg/MWh basis are reduced by another
17.5 per cent as compared to the average coal plant in the US. This not
only applies to SOx, NOx, PM, CO, and mercury air emissions, but also to
CO2, as well as all solid and liquid waste streams from the plant, the coal
mine and the fuel delivery system.
The mine-mouth project structure itself provides other environmental
benefits.The power plant is designed to burn run-of-mine coal, avoiding
the waste water streams and coal tailings associated with coal washing,
which is a common practice in many coal mines and plants around
the world. In fact, at Longview, no waste water from any part of the plant
or mine is discharged to surface waters.
Since a conveyor transports Longviews coal to the plant, truck

Electric actuators for the


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gearbox type ranges.
Automating all types of
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Standardised interface for
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Plant Asset Management functions
Service worldwide

and train emissions, road dust, and noise are completely avoided. A
significant portion of boiler fly ash is sold for beneficial use and the
remaining portion is dry landfilled on site, again minimizing truck and
train traffic through local communities where people enjoy the peace
and quiet of the country while utilizing Longviews power for their homes,
schools, farms and businesses.

Discover our

Technology matters
Technology is a big part of Longviews best-in-class performance. To
achieve its high plant efficiency and reliability, the power plant utilizes

solutions for the


power plant industry

www.auma.com

a unique low mass flux, vertical-tube, supercritical pulverized boiler


For more information, enter 15 at pei.hotims.com

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1608pei_21 21

Power Engineering International July-August 2016

21

8/16/16 10:40 AM

Coal-fired power

pressures above 221 bar or 3206 psia) which


allows the steam to absorb more heat from
the burning fuel, resulting in higher plant
efficiency.
It is the supercritical steam condition that
allows Longview to achieve its very high plant
efficiency of 41.3 per cent/39.5 per cent based
on the coals lower/higher heating value.
Longview is the most efficient operating coal
plant in the US, giving the plant its best-in-class
emissions levels and cost competitiveness.
Table 1 shows Longviews steam and plant
performance values at its full load design
operating conditions.
Nearly

all

supercritical

sliding-pressure

boilers angle and wrap the tubes containing


water and steam in a spiral or helix pattern
to form the lower section of furnace walls, as
illustrated in Figure 4. This is done to even out
tube-to-tube temperature differences and
mechanical stresses that occur between
Figure 1. Dispatch merit curve for PJM grid served by Longview

the tubes near the burners, which receive


an intense level of heat, and those much

supplied by Amec Foster Wheeler. This is the

use this advanced coal boiler technology.

further from the burners receiving much less

only supercritical pulverized coal plant in the

The Amec Foster Wheeler PC boiler utilizes

heat. Under supercritical steam pressures,

US and among only a few in the world that

supercritical

the temperature difference and associated

steam

conditions

(steam

Customized special control valves


For the energy producing and consuming industry

HP-, IP- and LPturbinebypasssystems


turbine emergency stop valves
turbine control valves
steam conditioning valves
feedwater control valves

minimum flow control valves


cooling water injection valves
boiler start up valves
boiler blow down valves
desuperheater valves
hydraulic actuating systems

THE AMERICAN SOCIETY


OF MECHANICAL ENGINEERS

WE LLAN D & TUXHOR N AG


A R M AT U R E N -

U N D

M A S C H I N E N FA B R I K

Gtersloher Strae 257 | D-33649 Bielefeld | Tel. +49 (0)521 9418-0 | Fax. +49 (0)521 9418-170, -156 | www.welland-tuxhorn.de | info@welland-tuxhorn.de

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Power Engineering International July-August 2016

www.PowerEngineeringInt.com

8/16/16 10:40 AM

Coal-fired power

stresses can be significant and overtime can virtually tear the tubes
apart and cause them to fail.
But what makes Longviews boiler so different than all the other
supercritical sliding-pressure boilers is that its entire furnace is formed
with only vertical tubes which carrying a very low mass flux of steam
and water (under 1000 kg/m2-s). This is a much simpler design that
costs less to build and is easier to repair and maintain.
The boiler is simply hung from top supports with the vertical boiler
tubes playing a dual role of supporting the boiler and producing steam.
For spiral designs, since the tubes wind around the furnace in a helix
pattern, they want to untwist if supported only vertically and require a
more complex furnace support system which is more costly, heavier,
and requires special bracing when repairing furnace tubes.
Further, the steam has a much shorter distance to travel in the
vertical tube design to reach the top of the furnace, as compared to
the longer path of the spiral tube design. The shorter tubes and the
low mass flux allow the vertical design to have a much lower steam
pressure drop, which translates into lower boiler feedwater pumping
power and higher net plant efficiency.
Spiral designs typically incur an additional 10 bar or 145 psia
steam pressure loss across the furnace, which translates into about
1 MW of additional boiler feed water pump power consumption.
At $50/MWh this loss can translate into annual lost power
sales revenues of about $432,000, and can add up to a
$6.6 million NPV over the life of the plant.
To overcome the tube-to-tube temperature and stress problem, the
Amec Foster Wheeler vertical tube boiler design uses a much smaller
tube diameter which carries much less water and steam. This allows
buoyancy forces within the water and steam in the tube to become
stronger, causing the water and steam flow to increase and provide
additional cooling to the tubes receiving more heat.
This provides a passive self-cooling protection mechanism limiting
the temperature and stress between tubes and across the furnace
walls. As an added protection, the inside of the tubes receiving high
heat are grooved or rifled with a spiral pattern to enhance tube cooling.
These design enhancements add up to a safe, low maintenance,
highly reliable, long life boiler.

Smart emission control


Using the simple principle that it is much less costly to prevent NOx
from forming in the first place than it is to reduce it afterwards, the firing
system of the Amec Foster Wheeler boiler has many advanced and
innovative design features. Mill fineness control, combustion air control
to each windbox and each burner, staged low-NOx combustion and
over-fire air technologies are utilized to achieve very low NOx levels
leaving Longviews furnace.
In addition to ultra-low CO emissions, this minimizes the reduction

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needed by the SCR system, which has a large long-term cost benefit
over the life of the plant when considering ammonia consumption and
catalyst replacement cost.
For example, the burner wind-boxes are compartmentalized
between each of the sic burner rows (three rows on each side of the
opposed wall-fired boiler). A system of air dampers, flow measurements
and control logic is designed so that air flow can be controlled to

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each burner row as well as biased from side to side within each row.
This degree of measurement and controls dedicated to reliably and
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Power Engineering International July-August 2016

23

8/16/16 10:40 AM

Coal-fired power

effectively

controlling

air/fuel

ratio,

CO,

and NOx is truly unique and not reliably


accomplished in many other coal plants.
Instead

of

using

the

typical

ESP

Wet FGD scrubber configuration behind


the

boiler,

Fabric
two

Filter

dual

Longview
+ Wet
flow

utilizes
FGD

trays. This

DSI

scrubber

with

configuration

provides best in class removal rates (e.g.,


99.5 per cent SO2 removal), fuel flexibility
and redundant systems (facilitating on-line
maintenance) to control multiple pollutants
most cost-effectively.
The dry sorbent injection system (DSI)
can utilize a range of sorbents to control
metals and acid gases in the vapour phase
by adsorption onto solid ash particles. The
Figure 2. Permitted title V operating and acid rain emission limits for coal plants in West Viginia

fabric filter captures these particles as well


as the boilers fly ash to levels well beyond
an electrostatic precipitator (ESP). The dual
flow trays in the wet FGD expand the FGDs
capacity to capture all acid gases.
All of these systems are designed with
flexibility

in

mind

to

endure

continued

tightening US environmental regulations and


changes in fuel quality over the long life of the
Longview energy complex.
The Longview energy complex sets a new
level of best-class performance for todays
modern coal power solutions. It demonstrates
a solution for safe, secure, reliable and
affordable
Figure 3. Longviews actual stack emissions are well below MATS limits

coal

power

with

minimal

environmental impact.
Today, coal produces about 40 per cent
of the worlds electricity, the largest share
from any source. In 30 years from now, nearly
all long-term forecasts show that coal will
still produce about one-third of the worlds
electricity. At the global level, this supports the
smart strategy of keeping a diverse portfolio of
generating options.
In order to maintain this level of coal,
forecasters estimate that between 1500 GW
and 2000 GW of new coal plants will be
built over the next 30 years to meet growing
electricity demand and to replace aging coal
plants.
Robert Giglio is Vice-President of Strategic
Planning and Business Development at Amec
Foster Wheeler and Steve Nelson is Chief
Operating Officer at Longview Power.

Figure 4. Conventional sprial vs vertical tube furnace design

24

1608pei_24 24

Power Engineering International July-August 2016

Visit www.PowerEngineeringInt.com
for more information

www.PowerEngineeringInt.com

8/16/16 10:40 AM

Proven, reliable,
and efficient
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1608pei_25 25

8/16/16 10:40 AM

Coal-to-biomass conversion

A new biomass
chapter in a coal
plants life
A coal-fired power plant built in the UK in the 1970s had excellent potential
for a biomass conversion, writes Graham Welford

witching from coal to renewable

The Lynemouth project

and modest steam conditions of 533/543C,

woody biomass is a low cost way

Lynemouth is a 3x140 MW coal-fired power

134 bar.

for old coal-fired power stations

station dating from the 1970s. With no SOx

The high-cycle efficiency made this an

to

or NOx controls and with the rising price of

excellent choice for a biomass conversion

carbon, it faced closure at the end of 2015.

and continued operation of the power station

meet

new

environmental

legislation with a low carbon


solution, whilst extending the life

for

on this site. The project benefited from a UK

conversion to biomass to solve these life-

government subsidy in the form of a Contract

In the conversion of an existing coal fired

threatening problems and extend operations

for Difference (CfD), which has been ratified by

power station to woody biomass pellets, the

at the station. Given its good core attributes

the European Commission.

majority of the power station systems can

of upgraded turbines and cold North Sea

be reused. However, this depends on the

cooling for an excellent underlying efficiency,

compliance,

existing system capacities and conditions

it is probably the most efficient plant of its kind

generator output and 40 per cent gross cycle

since, generally, the power stations proposed

in the UK despite its relatively small unit size

efficiency. It is now designed for virgin white

of these valuable assets by 10 or more years.

This

site

has

excellent

potential

The

project

targeted

IED

emissions

maintaining

the

140

MW

for conversion of this type are old and


have reached the end of their life on coal,
threatened by tightening emissions or the
rising carbon floor price. However, the worn
out components are easily replaced or
upgraded.
Conversions are bespoke designs to suit
the particular host coal-fired power station
and the project drivers.
Biomass conversions of old coal units
are not only a green technology in terms of
sustainable generation with low CO2, but also
recycle power stations which would otherwise
be demolished, a wasteful and socially
damaging process with loss of local jobs and
infrastructure which have been supported for
40 years in many cases.

26

1608pei_26 26

Power Engineering International July-August 2016

Full-scale burner test facility schematic


Credit: Doosan Babcock

www.PowerEngineeringInt.com

8/16/16 10:40 AM

Coal-to-biomass conversion

Lynemouth power station


Credit: Lynemouth Power Ltd

wood pellets, although a design variant also


considered a steam exploded black pellet.

The model was validated using trial data

sufficient capacity to satisfy the 140 MW full

for operation on coal and biomass, and it was

load on biomass.

end

thus calibrated.The model could then be used

modifications to grind biomass, upgraded

engineering design (FEED) study and tender

to predict with confidence the full conversion

safety systems, and to ensure consistency of

process starting in 2013, Doosan Babcock was

performance on the selected biomass fuels for

the particle size dynamic classifiers will be

engaged for the combustion and emissions

the project, and importantly to test sensitivities

added.

work because of its extensive experience in

to variations in fuel properties, operating

biomass conversions over a 25-year period,

regimes and loads.

Following

competitive

front

The mills require some

The furnace at Lynemouth predates NOx


requirements and so is small by modern

including the UK plants at Tilbury, Ironbridge

The model was used to incorporate

standards. To achieve the NOx emissions now

and Drax and the Atikokan power station in

the revised low NOx biomass combustion

demanded requires a staged combustion

Canada.

system essential for meeting emissions and

system and a new over-fire air stream to be

Firstly, Doosan Babcock considered the

techniques to maximize the boiler and cycle

added in addition to low NOx burners. To

safety requirements for the use of wood fuel

efficiency. The resulting optimized process

maximize the combustion efficiency in the

and incorporated the necessary design

flow diagram (PFD) was used to assess the

small furnace, the over-fire air system uses

changes. Then it conducted an overall

suitability of all existing plant components,

a booster fan to provide a higher injection

evaluation of the existing boilers and modelled

identify bottlenecks, system by system, and

velocity and greater turbulence.

them with the pre-requisites of meeting full

find cost-effective solutions to upgrade or

Doosan Babcock has been supplying low

load on the biomass fuel, satisfying the

replace components and to make the system

NOx burners since the 1980s for all types of

pending emissions legislation and operating

operate safely on biomass. This resulted in

coals

at maximum efficiency. The model was used

the replacement of fans, a new low NOx

younger fuels akin to

to identify and resolve any bottlenecks limiting

combustion system with over-fire air and

w o o d

full load operation on biomass and to meet

dynamic classifiers, a primary air cooler for

the other pre-requisites with a safe system.

efficiency, and an ESP upgrade. The changes

and test work was extended to

necessary for the key combustion and boiler

Combustion and emissions system

systems are described below.

The physical design of the existing boilers

The existing boilers each had four coal mills,

and the heating surface at Lynemouth was

allowing full load on three mills with one spare

modelled from drawings and operating data

mill, a generous 33 per cent spare capacity.

using

Thus, by using all four mills for biomass with

well-established

Doosan

design programs.

www.PowerEngineeringInt.com

1608pei_27 27

Babcock

its much lower energy density, the mills had

Doosan
Babcock
low NOx
biomass
burner
Credit: Doosan Babcock

Power Engineering International July-August 2016

27

8/16/16 10:40 AM

Coal-to-biomass conversion

NOx burner, shown on page 27, specifically


optimized for wood pellet pulverized fuel, and
this is being applied to the Lynemouth project.
The most obvious design consideration
for the burner is to be able to slow down
the higher velocity fuel and air stream whilst
preventing drop-out of particles within the
burner and at the same time reducing the
burner exit velocity to ensure a fully rooted
flame for good NOx control.
The burner has been proven at full
commercial scale on both steam exploded
black and virgin white wood pellets on the
Doosan Babcock full scale test facility, and
also on one mill group within a utility boiler.
Full-scale burner test facility
Credit: Doosan Babcock

The performance in these circumstances has


allowed Doosan Babcock to be confident
about meeting the required emissions limits

during the late 2000s. With a higher reactivity

to get a stable and rooted flame. The test

within the Lynemouth boiler when the burners

than coal, wood can be burnt at larger particle

work gave the basis of modifications required

are used in a staged configuration using over-

sizes. However, the larger particles take longer

to the burners which Doosan Babcock has

fire air.

to heat up in the furnace and biomass flames

applied at previous biomass conversions

Over-fire air is a standard technology

tend to stand-off the burner front. This would

such as Atikokan, Tilbury and Ironbridge. The

applied to pulverized fuel boilers to reduce

not allow the burner to control the access of

projects have given Doosan Babcock real-life

NOx further than is possible by low NOx

air to the fuel, essential for low NOx operation,

experience which has been integrated into a

burners alone.

and so lower burner exit velocities are required

variant of the standard Doosan Babcock low

normal combustion air is taken away from

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28

1608pei_28 28

Power Engineering International July-August 2016

www.PowerEngineeringInt.com

8/16/16 10:40 AM

Coal-to-biomass conversion

INDUSTRIAL ELEVATORS
the low NOx burners and instead injected higher up the furnace, giving
a larger residence time under reducing conditions for NOx reduction
reactions to occur. The over-fire air then burns off the resulting flue gas
high in reducing species such as CO.
This delay in combustion takes more space, which is why modern
furnaces are much larger than those in the 1970s. By accelerating
the over-fire air, the burn-out can be maximized in the space and
time available within the existing Lynemouth furnace dimensions. Hot
secondary air is taken off the supply ducts to the burner windbox and
routed to a booster fan before ducting back to the injection nozzles
above the top row of burners. Compared to unboosted over-fire air, the
combustion efficiency is improved and, as a result, unburned carbon in
ash is reduced.

Boiler heating surface


The boiler modelling described above was used to study the impact
of the fuel switch from coal to biomass on all aspects of the heating
surface and its ability to pick up heat from the flue gas and convert
it into steam without overheating the boiler pressure part tubing and
maintaining critical steam temperatures to the turbine at the required
maximum duty.
In moving to biomass firing from coal, there are differences that are of
importance to the boiler heating surface:
1) Biomass fuels have lower ash fusion temperatures than coals; and
2) Biomass fuels have high calcium contents in the ash, and this tends
to coat the inside of the furnace with a white reflective material.
These effects tend to increase the furnace exit gas temperature
and increase the chances of slagging in the first heating surface at
the furnace exit. They may also upset the balance between furnace
evaporation and that of the convective surface. The boiler becomes
much more sensitive to the furnace exit gas temperature. This has
been studied in great detail to ensure it will not impact the boilers
performance.

Efciency.
Made in Germany

The project builds on the experience and previous success in


biomass conversions and co-firing by Doosan Babcock.

Biomass

conversions are bespoke, drawing on a toolkit of products and


technologies. The combustion and emissions system for Lynemouth is a
comprehensive approach designed for maximum power and efficiency
and to maximize availability throughout the 10 years of the CFD subsidy
contract, whilst complying with emissions standards.
Contracts were let by Lynemouth Power Limited for all parts of the
project at the end of January 2016, with final notice to proceed at the
end of April 2016. The final unit is planned to be operational in early
2018. At July 2016, all major subcontracts have been placed for the
boiler works and demolition and refurbishment activities within the boiler
house are well underway.
After the conversion the resulting power station will have been
recycled and fit for the next 10 years of profitable operation using a

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GEDA can offer several elevator options
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and precipitators.

green, low CO2, renewable and sustainable fuel meeting all emissions
legislation.
Graham Welford is Sales Director at Doosan Babcock.
www.doosanbabcock.com

Visit www.PowerEngineeringInt.com
for more information

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1608pei_29 29

Power Engineering International July-August 2016

29

8/16/16 10:40 AM

Protective coatings help to increase the efficiency and extend the service life of the gas turbine
Credit: Sulzer

Protective coatings

Extending service
life for rotating
equipment
Thanks to the latest
surface coating
technologies, it is
possible to offer massive
improvements to the
expected service life of
compressors, turbines
and pumps, writes Travis
Cockrell

ong-term reliability is a common goal

slowly degrades, the efficiency of both the

for all plant operators. Achieving it

compressor and turbine is reduced.

requires a considered approach


that takes into account a range of

Compressor section

contributory factors and makes use

This process can be arrested in the compressor

of the most appropriate technology

section of the gas turbine, and the surface

and manpower available to them.

finish restored, by the application of suitable

Rotating equipment that is in direct

There is a range of options open to suit the

constant attack presents a major challenge.

specific duty of the turbine in question, but

It is possible, however, to reduce degradation

all include a type of metal deposition where

to a minimum by selecting the correct coating

a tough corrosion-resistant surface is created.

system.

An aluminium base layer is typically used

Generally,

turbines,

compressors

and

protection

environmental

contribute

components in moist conditions. It provides

to corrosion, erosion, fouling and various

galvanic protection, which means that small

temperature-related issues.

scratches to the surface layer are less likely to

conditions

that

of

ferritic/martensitic

steel

The first step is to understand the operating

cause corrosion. It is produced by spraying a

environment of the machinery. From there,

slurry of aluminium and an inorganic binder,

the sources of degradation can be classified

rendered insoluble by a medium-temperature

and specific coating systems can be used

baking process. This layer can then be

to increase efficiencies, lengthen the interval

covered by a harder layer that might include

between

metals such as chromium.

scheduled

maintenance

and

maintenance events.

The harder layer is usually applied using


a spray coating method such as Chemical

The flow path of air and fuel through a

Vapour Deposition (CVD), Air Plasma Spraying

gas turbine presents a number of different

(APS), Low Pressure Plasma Spraying (LPPS) or

conditions that can have an adverse effect

High Velocity Oxygen Fuel (HVOF). Which one

on the performance of the turbine.

will depend on the coating thickness required

The combination of heat, microscopic


abrasives

and

gradually

increasing

concentration of corrosive elements can


cause

1608pei_30 30

in gas turbine compressors for corrosion

pumps are all subject to a variety of

reduce the occurrence of unscheduled

30

metallic coatings.

contact with the process media and under

damage

to

processes are hotter than others.


By

applying

corrosion-inhibiting

and

once

surface finish-enhancing coatings to the

smooth airfoil surface. As the surface finish

compressor section it is possible to increase

Power Engineering International July-August 2016

significant

and the sensitivity of the part to heat, as some

www.PowerEngineeringInt.com

8/16/16 10:40 AM

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1608pei_31 31

8/16/16 10:40 AM

Protective coatings

the efficiency and extend the service life of the


gas turbine.

Hot section
Modern gas turbine hot section components
are made using nickel- or cobalt-based
superalloys, which are designed to operate in
high temperatures.
However, these alloy compositions are less
well suited to providing corrosion and oxidation
protection and need to be supplemented
with custom coatings that can deliver the hot
corrosion and oxidation protection required
for extended service lives.
The process of oxidation causes a layer
Modern coating technology can now be applied to legacy equipment
Credit: Sulzer

of metal-oxide to form on the surface, which,


in general, protects the underlying material.
Therefore the oxidation process slows down as
the thickness of the oxide layer increases. This

compressors are used to increase the energy

substrate is more easily eroded being the

process can be replicated with the intentional

of gases. As such, the main issues with these

secondary source of degradation.

formation of oxides that provide a protective

components

layer preventing further atmospheric attack.

fouling.

are

corrosion, erosion

and

Modern coating technology can now


be applied to legacy equipment that was

Corrosion of a gas turbine component

Corrosion is defined as a chemical

not designed to take account of particulate-

usually occurs in one of two ways. Hot

reaction between the component surface

laden gas streams. In this way the original

corrosion may take place between 788C and

and the reacting fluid passing through a

surfaces can be restored and upgraded with

899C and it attacks the entire surface of the

turbomachine, for example.

greatly improved anti-fouling and corrosion

component.

Many metals form oxide layers that adhere

resistance. Implementing a new coating

cooler

to and passivate the surface to prevent

as part of a refurbishment project can

temperatures is more localized and therefore

further corrosion, but the change in the

significantly improve the performance and

tends to create distinct layers of oxide and

physical properties of the surface significantly

reliability of existing equipment.

exposed metal. Further damage can be

increases the frictional properties and thus

caused by erosion which involves repetitive

decreases aerodynamic efficiencies, so there

Coating processes

mechanical abrasion by particles in the air

is a balance to be struck between protection

Oxidation and corrosion resistant coatings, as

stream.

and efficiency, which is where advanced

mentioned previously, are usually aluminides

coatings can help.

applied by a variety of thermal spray or surface

Alternatively,

corrosion

at

Standalone High Velocity Oxygen Fuel


applied
to

MCrAlY

combat

coatings

are

corrosion/oxidation

sufficient
at

Particulate fouling results from the presence

deposition

techniques.

Corrosion-resistant

lower

of small particles in the ingested air streams

coatings will also use an aluminium base coat

firing temperature gas turbines. For newer

that can cause a distortion to the oncoming

that is designed to be conductive, allowing for

technology, higher firing temperature gas

laminar flow. This degrades flow capacity and

cathodic protection. The aluminium becomes

turbines, the combination of a MCrAlY bond

can reduce the efficiency of the equipment

the sacrificial element, and therefore protects

coat coupled with a ceramic thermal barrier

in a short period of time. This is a particularly

the less active base metal component. The

coating will reduce the surface temperature

serious issue in the oil and gas industry where

electrons flow from the aluminium to the

of the substrate and reduce the degenerative

sticky hydrocarbon aerosols are constantly

base substrate, which becomes negatively

effects of oxidation and corrosion.

present.

polarized and therefore protected against

In the harshest of operating conditions,

corrosion.

Compressors

solid and/or liquid particles can pass through

Pumps and compressors account for more

the

than 20 per cent of the worlds electricity

that results in moderate to severe material

CVD) techniques allow for different coating

demand and the energy costs to run them

loss can change aerodynamic efficiencies

thicknesses,

represent 95 per cent of the running costs. It is

significantly.

restrictions; the spray techniques can be

equipment

causing

erosion. Erosion

The basic thermal spraying and physical/


chemical

vapour
but

deposition
also

have

(PVD

and

application

therefore essential to minimize these costs by

It can also lead to premature blade/

used to apply a thicker layer but need a

improving performance and efficiency; these

vane replacement and failure. In operating

relatively flat surface and direct line-of-sight in

efforts will also have the beneficial effect of

conditions where both erosion and corrosion

order to accurately apply consistent coating

improving reliability and service life.

are present, corrosion can be the primary

thicknesses.

source of attack by weakening the substrate

typically produce a thinner layer but can coat

surface. Once corrosion has initiated, the

more complex shapes easily.

While turbines extract energy from a


gas

expansion

32

Power Engineering International July-August 2016

1608pei_32 32

process,

turbofans

and

The

deposition

techniques

www.PowerEngineeringInt.com

8/16/16 10:40 AM

Fast and cost effective solutions


to increase efficiency, reliability
and lower capital expenditure
+ Visual inspection by a well trained and
experienced diagnostic engineer is key
for a reliable assessment
+ We offer a comprehensive diagnostic
program with the visual inspection
supported by electrical and mechanical
testing
+ Comprehensive report with recommendation for future
maintenance requirements and operating scheme
+ Critical findings will be highlighted instantly, so mitigation
actions can be implemented during the outage
+ Test instruments can sometimes not replace human senses
+ Fast and cost efficient solution thanks to personnel and
equipment located in Asia.
To find out more:
Visit us at booth B60
Or email enquiries@ethosenergygroup.com
www.ethosenergygroup.com

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1608pei_33 33

8/16/16 10:40 AM

Protective coatings

chemical attack from substances with a pH

Zirconia-ceramic materials can be used to

between 3 and 9, as well as resistance to many

minimize this clearance in high temperature

solvents and fuels. For specific applications

applications.

that

require

protection

beyond

these

Clearance-control coatings or abradable

characteristics, more specialized coatings can

coatings function by allowing a rotating part,

be tailor-made to suit a particular application.

such as a blade, to cut a path in a sealing


abradable layer with minimum clearance.

Keeping in balance

Many advanced gas turbines use a thick

In all turbomachinery applications, dynamic

ceramic coating to impart both thermal-

balance is a crucial requirement, so the

barrier and abradability properties.

application of any coating system has the

Coatings can be tailored to specific


applications
Credit: Sulzer

potential to upset the balance of a turbine

Future-proofing

or compressor, even if it is only a few microns

As design technology and materials science

in thickness. It is therefore essential that the

advance, the newest generation of turbine

component being coated is checked for

components can present a considerable

balance both before and after the protection

challenge to repair specialists. Finding the

layer is applied.

most suitable coating depends on a number

The techniques and equipment used to

of factors including adhesion qualities, heat

The thermal spraying process involves

apply the latest coatings depend largely on

and erosion resistance as well as compatibility

heating a material, in powder or wire

the type of coating being applied and the

with the design of the component.

form, to a molten or semi-molten state. The

function of the component. Coatings that

For example, the challenges of protecting

material is propelled using a stream of gas

are designed to provide high temperature

components, especially those within the hot

or compressed air toward the material to be

corrosion resistance are often applied using a

section of a gas turbine, are considerable,

coated, or substrate, creating a new surface

HVOF gun, which produces a dense coating

especially when the temperature of the

structure as it impacts.

with a high bond strength.

combustion gas is higher than the melting

The coating materials can be melted

Due

to

the

precision
and

required

maintaining

in

point of the base materials.

using several different processes, including

manufacturing

high

The combination of internal cooling ducts

HVOF, plasma spray, and electric-arc delivery

temperature turbine blades, these coatings

and a thermal barrier coating (TBC) work

systems. The process can take place under

should be applied using a robotic manipulator

together to maintain the desired component

standard atmospheric conditions or in a

with automated thermal spray equipment. In

temperature. The latest turbine blades are

special, highly controlled atmosphere.

this way, the coating is applied uniformly on

designed with a large number of tiny cooling

Applications include protection from wear,

each blade by removing the human error that

holes, often in excess of 500 in a single part,

high temperatures or chemical attack, as well

is associated with hand spraying. Balancing

which must remain unaffected by the coating

as providing a substitute for chromium which

should then be carried out to ensure each

process.

can be hazardous in some states. Coatings

machine will operate perfectly after being

can be metallic, ceramic or any combination

protected.

required to meet a broad range of physical

Conventional thermal spraying processes


would block off many of the holes, rendering
the cooling system almost useless. However,

Improving efficiency

new coating techniques are required to

With such high energy requirements, the

ensure that none of the cooling ducts are

Anti-fouling

hydrocarbon processing industry often uses

closed off by using conventional plasma

For applications that require improved anti-

on-site generation plants and the growing

spraying processes.

fouling protection, coatings can be applied to

demand for power has led to significant

both stationary and rotating blades as well as

research into improving production efficiency.

continue to develop new coatings and new

diaphragms, guide vanes, rotors and impellers.

Essentially this can be divided into combustion

application methods that can keep pace

efficiency and mechanical efficiency.

with the advances in the turbomachinery

criteria.

Coatings can be tailored to specific

It

is

essential

that

repair

specialists

applications and include an aluminium base

Combustion efficiency looks at increased

sector. In this way, plant operators will have

coat for corrosion protection as well as an

combustion temperatures which require the

the confidence to invest in repairs that have

inorganic sealer and a specialist non-stick

latest coating technologies to prevent heat

the ability to provide many years of continued

final layer.

damage to the components in the hot gas

service.

These

anti-fouling

coatings

flow. Mechanical efficiency looks at reducing

thickness between 75 and 125 microns and

losses in the power train, including the

Travis Cockrell is Component Superintendent

use

clearance between the rotor blades and the

of the Coating Department at Sulzers Houston,

stator casing.

Texas Service Centre. www.sulzer.com

polytetrafluoroethylene

have

(PTFE), which

gives excellent chemical resistance in low


to medium temperatures with a maximum
operating temperature of 288C.
PTFE

34

1608pei_34 34

offers

excellent

protection

The clearance is crucial in determining


the efficiency of the turbine, and therefore

from

a large part of its costs and productivity.

Power Engineering International July-August 2016

Visit www.PowerEngineeringInt.com
for more information

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8/16/16 10:40 AM

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1608pei_35 35

8/16/16 10:40 AM

More data is available than ever before


Credit: Steag-VGB Power Tech GmbH

Cybersecurity

Security
management for power
installations
Todays higher levels of connectivity also increase demands on security
management for operational technologies. Preventing a cyberattack requires a
rigorous approach and is a continuous and ongoing process, writes Eli Mahal

hese

are

exciting

for

isolation. The new emphasis on connectivity

with a hardened perimeter is no longer

The

provides exposure to the corporate network

adequate.

Industrial Internet of Things (IIOT),

and potentially to the public internet, which

Mitigating the risk of a cyberattack requires

Industrial Internet, Industry 4.0,

increases the attack surface. Control of

a rigorous approach to hardening the security

Integrated Operation or maybe

industrial assets no longer requires physical

controls around both the IT and the ICS and

IT-OT convergence whatever

access to the equipment, or even to the plant,

SCADA platforms. It is important to emphasize

you prefer to call it promises to revolutionize

as remote access is enabled by network

that this is a continuous and ongoing process

the use of information in everything from

connections. While remote control is intended

requiring the close collaboration of IT and OT

manufacturing plants to generating facilities,

only for authorized operators and third party

as well as of the plants and the headquarters.

pipelines and transmission systems, refineries

suppliers, it can just as easily be accessed

There are three important pillars to the

and more.The connected operation is already

and exploited by unauthorized users with

process of hardening the security controls:

enabling more sensors and more connected

malicious intentions unless safeguards are

Discover, Connect and Protect. Discover

devices in more places and is creating more

imposed.

entails obtaining and maintaining full visibility

industrial

times

operations.

data than has ever been available before.


The benefits of having integrated and

Security experts warn of the consequences


of

industrial

control

systems

(ICS)

and

of all distributed assets and a complete and


thorough inventory of what devices and

connected operations are too good to ignore.

Supervisory Control and Data Acquisition

equipment are on the network.

Plant owners and operators can measure

(SCADA)

to

means having the ability to securely connect

everything that is worth measuring in order

cyberattacks and other security issues. Just

to every asset with strict authentication to

to make important data-driven decisions,

recently, the National Cybersecurity and

keep out unauthorized users and others

such as to predict operational failures and

Communications Integration Center (NCCIC)

with malicious intentions. Protect involves

provide preventive maintenance to improve

and the Industrial Control Systems Cyber

protecting every asset by patching systems,

safety and asset reliability as well as to

Emergency Response Team (ICS-CERT), part

addressing vulnerabilities, keeping anti-virus

utilize analytics to manage processes more

of the US Department of Homeland Security,

(AV) signatures current, alerting on policy

effectively and reduce costs. This all translates

stated, Cyber intrusions into US Critical

violations and similar activates.

to higher levels of safety, improved productivity

Infrastructure systems are happening with

and better profit margins.


But
also

higher

increase

levels

of

vulnerable

Connect

increased frequency. For many industrial

Why is security still a challenge?

connectivity

control systems, its not a matter of if an intrusion

Many energy companies and utilities service

operational

will take place, but when. The capabilities of

providers have already invested significant

our adversaries have been demonstrated and

resources and budgets into plant security

Industrial systems have traditionally benefitted

cyber incidents are increasing in frequency

measures, but gaps in protection still persist.

from security through obscurity and physical

and complexity. Simply building a network

Complexity can cause quite a few challenges,

36

1608pei_36 36

(OT)

security

on

being

management.

technology

demands

systems

Power Engineering International July-August 2016

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8/16/16 10:41 AM

HRSGs for the


Worlds Most Ecient
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8/16/16 10:41 AM

Cybersecurity

and, thus, it is preferable that discovery


be done in an unobtrusive way to avoid
disrupting availability. As such, a combination
of passive and active approaches should
be implemented to map the devices and
equipment and to understand what they
communicate with, and how.
It is also important to understand that every
network environment is dynamic. Thus there is
a need for automated asset discovery and
mapping. All changes to the baseline should
be documented and incorporated into a
continuously updated inventory. Once the
organization has a clear picture of its cyberassets, it then can consider itself in the position
Bulgarias Kozloduy nuclear power plant
Credit: Yovko Lambrev/Wikimedia Commons

to establish an in-depth defense strategy and


plan and to start putting proper hardening
processes in place.

especially for companies with multiple plant

for energy companies and utilities service

sites, multiple vendors requiring access to

providers:

assets, multiple lines of business, and legacy

1. A

with

A variety of first- and third-party professionals

and proprietary equipment, much of which

centrally-defined plant-wide policies that are

need access to ICS systems used by energy

is old and may have been designed without

automated to ensure consistent shielding of

companies and utilities service providers. Their

considerations for the need for security.

all field assets;

jobs require them to maintain and monitor

Manual processes are also still prevalent and

2. Organizations should focus on the security

equipment, perform security processes such

they cannot scale because there are too

essentials, securing what matters and doing

as patching and log collection, and improve

many assets across too many locations. At

the basic things right on an ongoing basis in

asset uptime. In some cases, fast access is

the same time, there simply are not enough

order to shield industrial assets from risk;

required for incident response. Performing

security experts available to provide sufficient

3. Prioritize protecting the field assets which are

these tasks in person may not be practical

coverage.

key for production safety and integrity.

or even physically possible, making remote

top-down

Remote access control


security

approach

Energy companies and utilities service

This security hardening is a continuous

access an absolute necessity. In addition,

providers have been accustomed to applying

process with each iterative step closing the

some of these activities are based on

security piecemeal, asset by asset and plant

security gap bit by bit.

machine-to-machine (M2M) devices, which


can be completely automated without any

not be fully utilized and they certainly are

Gaining end-to-end visibility

not integrated. The result is partial coverage

Both the NIST framework and NERC-CIP v5

While these remotely performed activities

of the security essentials. Now that there is

state that asset identification is foundational

are often critical to plant safety and reliability,

an IT-OT interface, it is critically important

for knowing what must be protected. A

having connectivity from the outside and

to

across

comprehensive and up-to-date asset inventory

allowing various remote access processes,

the entire organization using a centralized

is vital to developing and maintaining an

especially by third parties, increases the

approach. Moreover, automation is absolutely

appropriate defense strategy and plan of an

ICS attack surface. It is imperative to protect

necessary to ensure that every asset has the

industrial network and infrastructure. Clear

against unauthorized users and malicious

proper controls and is monitored for ongoing

visibility into what devices and equipment

attackers who aim to exploit the vulnerabilities

compliance with security policies.

are on the network, what they communicate

of remote access.

implement

The

NIST

security

SP

practices

for

with and how, and their characteristics as well

cybersecurity of ICS systems is a good

as any known vulnerabilities is an essential

proprietary remote access tools are commonly

reference model for OT security management.

starting point. According to the analysis firm

used, but these practices pose risks to the

The

consideration

Gartner in its Strategic Planning Assumption

organization from multiple communication

the unique nature of ICS and SCADA

No. 2, By 2020, a third of successful attacks

lines across the enterprise and shared access

environments, where logical controls have

experienced by enterprises will be on their

credentials. A much better means of secure

physical impacts and the goals of safety and

shadow IT resources. Gartner recommends

communications is to funnel all remote

efficiency sometimes conflict with security in

that security organizations must invest in

access through a single location that is fully

the design and operation of control systems.

capabilities to discover and track shadow IT.

controlled by the organizations IT security

framework

800-82

takes

into

framework

human intervention.

Virtual

private

networks

(VPNs)

and

The following three principals for OT security

Conducting this asset discovery in an OT

professionals. This eliminates proprietary end-

management are strongly recommended

environment has its challenges. For example,

runs around security controls that go straight

and can be considered best practices

decades-old equipment might be sensitive

into the industrial assets.

38

1608pei_38 38

Power Engineering International July-August 2016

www.PowerEngineeringInt.com

8/16/16 10:41 AM

02/2016 - Petergraf

by plant. Even at that, security solutions may

A new generation is born

02/2016 - Petergraf

New products.
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Cybersecurity

NEM IS A GLOBAL
LEADER IN
HEAT TRANSFER
TECHNOLOGY

Best practices also call for remote user authentication without


sharing assets credentials, ideally through a password vault that
enables access without sharing the actual password. All user access
should be set to least privilege mode with exceptions to the policy
on an individual basis. Finally, all users activities should be monitored
and audited with IT and OT being able to approve, deny or terminate
a session as necessary.

A top-down, integrated approach

FROM DESIGN TO AFTERMARKET SERVICES

Once an energy company or utilities service provider obtains and


maintains its complete asset inventory and it can reach all of those
assets remotely through secure connections, only then is it in the
position to begin applying continuous protection using a top-down,
integrated approach.
By top-down, we mean that the head operation and control
office should be driving the policies, procedures and technology
solutions that secure the entire environment. By integrated, we mean
that the intersection points among IT and OT, remote plants and head
office, and third parties such as equipment vendors are all considered
when choosing the means to enforce the policies and execute the
procedures so that everything works together properly.
ICS security policy creation, deployment and monitoring should be
top-down with an integrated operation in mind, and the primary focus
of this policy should be shielding the field assets. These are assets that,
if compromised, pose the biggest risk to operational safety, integrity
and efficiency. Security policies enforcement must be automated.
Energy companies and utilities service providers should address
the security essentials, focusing on doing the basic things right.
Examples include applying qualified operating system patches and

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anti-virus signatures, collecting and analyzing devices logs, scanning


IP address ranges to look for unexpected changes, and so on.

Security is a process, not a project


Securing a large-scale industrial complex is a big task, but owners
and operators do not have to do everything at once. Hardening
the environment with good security controls is an ongoing process
and not a one-off project. By taking incremental steps through a topdown, integrated approach and doing the right things first, energy
companies and utilities service providers can significantly improve
their security postures and compliance efforts.
Only when the OT environment is reasonably secure can an
organization enjoy the benefits of having more data available from an
integrated and connected operational platform.
This article is the first in a series of articles on recommendations for
OT security management for energy companies and utilities service
providers. The following articles will provide an in-depth analysis
of each of the three recommended best practices for OT security
management.The next article will take a detailed look at the discovery
considerations for maintaining full network visibility and asset inventory.

VISIT US AT
WWW.NEM-GROUP.COM

Eli Mahal is vice-president of NextNine, a provider of security


management solutions for connected industrial control system
environments. www.nextnine.com

P.O. BOX 22, 2380 AA ZOETERWOUDE, THE NETHERLANDS


TELEPHONE +31 71 5792444 FAX +31 71 5792792 EMAIL INFO@NEM.NL

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Tom Povey, Oxford Flow Technical Director


Credit: Oxford Flow

Valve technology

Creating a 21st
century valve
When a leading academic at one of the worlds best universities needed a valve
that would enable very tightly controlled flow of gas for his research, he couldnt
find one so he created it himself, writes Chris Leonard

n the power industry, downtime can be the

only have dreamed of, pressure regulation

on elastomers to enable all sorts of things is

difference between profit and loss. High

has witnessed very little innovation since the

also, unfortunately, the fatal flaw that leads to

reliability and availability of equipment

Victorian age, when, in 1886, the venerable

their eventual downfall. And in the valves that

are key ingredients to success.

Bryan Donkin submitted his patent declaring

are used in the power generation field, the very

Be it known that I, Edwin Bryan Donkin, a

thing that makes elastomers such a useful

including

subject of the Queen of Great Britain, residing

tool is also the thing that makes them so very

natural gas, hydropower and nuclear, the

at Bermondsey, in the county of Surrey,

capricious. They cannot cope with steam or

humble pressure regulator or control valve

England, mechanical engineer, have invented

gas at very high pressures, or at least not for a

has provided sterling service for many years.

certain new and useful Improvements in

period of time that makes their use viable. This

However, the reliability of these pressure

Valves for Regulating the Flow of Gas in Mains

has meant that until now, the power industry

regulators is not necessarily inherent and

and other Passages.

has needed to fall back on actuated valves.

A core component of many power

generation

applications

is achieved, in many instances, by frequent

A great leap forward for flow regulation.


Unfortunately,

has

many of the pressures of the industry, this

diaphragms.

fundamentally changed and pressure and

comes, quite literally, at a price. Powered as

flow regulators still need their Achilles heel in

they are by electricity, these actuators require

order to function an elastomer diaphragm.

generators and backup generators in order to

Maintenance means downtime, and with


increasing demands on plant productivity
and availability this sometimes unavoidable
activity has set the limits of performance.

since

then

little

However, while these are able to withstand

maintenance to replace worn elastomer

A typical flow regulator uses a diaphragm

function.

that constantly modulates in order to manage

Oil and gas isnt the only industry to find

flow

pressure, enabled by a limited range of

itself thwarted by the limitations of the valves

regulation is in not just the power generation

elastomers, which flex as required in order

currently on the market. It was the limitations

industry, but for virtually every industry that

to provide accurate control. The flexibility

of the conventional pressure regulation valve

involves manipulating and distributing matter,

required is enabled by the elastomers, but

that Oxford Universitys Professor Thomas

the lack of innovation in this sector has been

unfortunately it is this very flexibility that leads

Povey found his own endeavours limited by

startling.

to the potential for erosion, embrittlement,

as he carried out research into jet engine

bursts and other risks to reliability.

performance for a household name industrial

Given

just

how

crucial

While

proper

the

20th

century and, indeed,


the

beginning

1608pei_42 42

is

caused

mundane, and

by

something

something

that

rather
anyone

partner at the world-famous Osney ThermoFluids laboratory.

of this one have

familiar with any elasticated or rubber product

Here, when trying to undertake very precise

seen

innovations

will be too familiar. Stretch the elastomers too

measurement of heat transfer in turbine

our forebears could

far, or just use them for too long, and this

blades in order to enable the development

will lead to fatigue, erosion and eventually

of more efficient jet engines and gas turbines,

breakage.

he needed a valve that would enable a very

Oxford Flow Regulator


Credit: Oxford Flow

42

This

Power Engineering International July-August 2016

The very quality that makes engineers seize

tightly controlled flow of gas if he and his team

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Valve technology

replaced by a direct sensing piston actuator,


which greatly simplifies the design of the
regulator as well as eliminating the main
reason for failure in these devices.
One side of the piston is exposed to
downstream pipeline pressure while the
other side is balanced against a pressure
cavity controlled by a pilot regulator. This
piston actuator operates over an optimized
feed-hole configuration to provide precise,
stable control across the entire operating
range. During operation, the piston moves
inward, reducing the size of the cavity when
the downstream pipeline pressure exceeds
that within the pressure cavity set by the pilot
Fitting an Oxford Flow Regulator
Credit: Oxford Flow

regulator.
The movement of the piston actuator in
closing reduces the flow rate to maintain a

were to be able to effectively capture the data

academic

best

stable downstream pressure. When demand

they needed.

universities, Professor Povey was undeterred. If

at

one

of

the

worlds

increases, the downstream pressure falls below

Unfortunately for Professor Povey, no such

he required a higher performance valve, he

that set by the pilot and the reverse operation

valve was forthcoming. Even the current

would just have to create one himself. And

occurs: the cavity contracts as the pilot feeds

market-leading regulators were not accurate

that is precisely what he did.

it, opening the flow path, which increases flow

or efficient enough to meet the standards


required as part of these experiments.
As you might expect from a leading

and maintains a stable downstream pressure.

Swapping elastomers for pistons

Meticulous testing revealed that, as well as

In the Oxford Flow model, the diaphragm is

being a much more efficient, durable way of

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Power Engineering International July-August 2016

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8/16/16 10:45 AM

Valve technology

regulating pressure, these designs also bring

Regulator for Gas or Liquid, and the IHP Series

both installation and maintenance costs.

with them a host of other benefits, including

Wafer Type High-Pressure Regulator.

And while not the primary aim, an attendant

reduced

hunting, lower

noise

emissions,

benefit of the more hands off approach

minimized flow turbulence and reduced

Lowering costs

enabled by the new style valve also includes

minimum pressure head-drop. What Professor

The Oxford Flow model is an elegantly simple

a significantly lowered carbon footprint.

Povey had invented was something which,

solution which enables companies working

This new technology has the potential

in short, maximized the positive aspects of

in a wide range of market sectors to hit the

to be truly transformative. It is self-powered,

flow regulation technology while significantly

holy trinity of production: doing more, for less,

self-regulating, self-controlling and simpler

mitigating the downsides.

sustainably.

in its construction than any other valve on

The possibilities if this device were to be

Pressure

the market. It can greatly reduce costs and

commercialized were readily apparent, and

Regulators light weight (typically, an Oxford

its simple design, with just one moving part,

it attracted the attention of Oxford Sciences

Pressure Regulator will weigh less than a

means that the risk of failure in service and the

Innovation

million

quarter of the weight of traditional regulators)

requirement for frequent replacement and

company created to support ambitious

reduces installation costs by removing the

maintenance are removed.

Oxford technology companies. Backed by

need for lifting equipment for either installation

Indeed, it offers tangible improvements in

innovation stalwarts such as Google and the

or maintenance. Indeed, many models can

running costs and reliability while making no

Wellcome Trust, the fund aims to ensure that

be held in the palm of the hand.

sacrifices in terms of performance. In an age

(OSI), the

new

$420

the breakthroughs made in the laboratories of

For

example,

the

Oxford

The devices can also be retrofitted into

when operators are under constant pressure

existing infrastructure, easily fitting into the

to do more for less, innovations like this can be

With the support of OSI, what is now Oxford

current strainers and filters used in the industry.

genuinely game-changing.

Flow, which is still based at the Osney Mead

For example, the IM Series wafer-type and

Thermo-Fluids laboratory, has developed a

IHF Series can both be installed between

Chris

range of pressure regulation valves aimed at

PN or ANSI flanges to minimize installation

Director at Oxford Flow. www.oxford-flow.com

the energy and water industries: the IHF Series

footprint. Similarly, both designs have just one

Oxford Regulator for Gas, IP Series Oxford PRV

moving part, which simultaneously maximizes

for Water, IM Series High Pressure Wafer Type

reliability while, again, significantly lowering

the university filter out into industry.

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Leonard is Business Development

Visit www.PowerEngineeringInt.com
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Credit: Shutterstock

Uninterruptible power supplies

Rising to the secure


power challenge
Extremely high power availability is a critical requirement for any power plant.
However, this poses environmental and electrical challenges which can preclude
the use of commercial uninterruptible power supplies. David Bond describes how
these challenges can be overcome
ower plants not only generate

Apart from the sites extremely challenging

electricity they also need to

environmental protection requirement, the

INTEGRA
AND ELEC
into a rack. Load sizes can be accurately

consume it to function safely.

number of small, self-contained UPS modules

system had to deliver electrically protected

matched without wasted capacity, and the

Control, monitoring, IT, security

high power AC and DC supplies of various

system is scalable by increments as the load

and communications functions

voltages and power ratings using a 1750 A

grows. N+1 redundancy can also be achieved

all

equipment

rectifier, 60 kVA inverter blocks and multiple DC-

economically. While Benning UPS extend this

that requires secure, clean power, as do less

DC converters. Such a complex requirement

approach to heavy industrial applications,

obvious areas like warehouses and workshops.

eliminates nearly all commercial UPS suppliers,

the companys power protection strategy is

even those offering customized systems.

modular in another sense, too.

The

normal

use

sensitive

approach

to

providing

secure power is to install uninterruptible

So how is it possible for power plant

power supplies (UPS) of sufficient capacity

operators to achieve the reliable, clean,

does not have to be an indivisible

to satisfy current demand, with scalability to

tightly conditioned power they want, while

function.

accommodate future growth. UPS of all sizes

accommodating a suitable range of AC and

can be, but it

are available from a huge number of suppliers

DC inputs, outputs and power capacities?

can also be

throughout the world.

And can all this be delivered from equipment

considered as

suitably

an assembly

However, most of these UPS will not be

ruggedized

for

environmental

An innovative approach is that the UPS


It

suitable for power station environments, due

conditions prevailing within the plant and

of

to a number of limitations. A perhaps extreme

supplied as a package thats economical in

components

but nevertheless illustrative example of this is a

terms of both price and space?

the rectifier

DC power supply system recently developed

for converting

by Benning for a gas power plant operated

Industrial solutions

by SPE (Socit de Production de lElectricit

Benning is one company that has developed

Algerinne) at their Boufarik site in Algeria.

viable answers to these requirements, based

As this is an earthquake-prone area, the

on over 50 years experience with both

power protection system had to be contained

conventional

within

that

operators around the globe. Its approach

are approved to be earthquake-proof. The

is broadly defined by three key areas

system is also built to operate at high ambient

modularity, ruggedization and support.

specially

designed

housings

and

nuclear

power

plant

temperatures and is protected from dust and

In the commercial UPS industry,modularity

dripping water to an international standard

usually refers to the concept of achieving

EN 60529 ingress protection rating of IP41.

a required UPS capacity by assembling a

46

1608pei_46 46

key

Power Engineering International July-August 2016

Invertronic
modular
20-120 kVA
inverter system
with manual
bypass switch,
static bypass
switch and
door mounted
MCU 2500
monitoring &
control unit
Credit: Benning

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8/16/16 10:45 AM

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Uninterruptible power supplies

incoming AC into DC for battery charging,


the inverter for converting DC back into AC for
the client load, DC-DC converters to provide
multiple DC outputs and the battery systems.
By working at this component level, flexibility
can be achieved, offering any combination
of AC or DC input and AC or DC output. For
example, the Tebechop rectifier could be used
Tebechop 3000 DC 12 kW DC-DC converter with MCU 2500 monitoring & control unit
Credit: Benning

to operate from a single- or three-phase AC


input to provide a DC output. These rectifiers

plant of its kind, with an output of 1600 MW.

itself and in demanding power station

allowing DC UPS functionality.

During construction, RWE chose Benning,

environments, this must include adequate

Many applications will require a protected

as their long mutual history and the power

ruggedization.

AC as well as DC supply if so, inverter

protection suppliers capability to develop

Bennings approach is to invest in high

modules such as the Invertronic Modular can

bespoke solutions convinced them that they

reliability hardware at both component and

be added to provide this capability, drawing

would receive a power system with the security

system level. Over-specified components are

their power either from the rectifier or, if the

they needed, complying with the availability

carefully laid out on PCBs to help prevent

mains fails, the battery.

levels critical to power plants of all types.

ambient contamination (such as dust and

these

modules

moisture) from, for example, creating short

mounted in the same rack as the rectifiers

supplies based on modern IGBT rectifiers

circuits across tracks. In more hostile ambient

in an application-specific mix and match

in mono block design, modular DC-DC

environments, these PCBs can also be

configuration.

for

converters and modular inverters. These

coated to provide additional contamination

separate inverter and rectifier racks allows

were configured as two systems that operate

protection.

great space and cost savings.

entirely independently of one another, to

the

need

be

These savings are enhanced because

Accordingly, Benning

delivered

ensure high availability.

The PCBs are then integrated into inverters,


rectifiers and DC-DC converters, which are

the inverters and rectifiers are also modular

Additionally, each system included N+1

in the more traditional sense, offering flexibility

redundancy, so availability levels actually

and scalability while eliminating the need

exceeded RWEs stated requirements. Efficient

for unnecessary capacity. Overall availability

integration with a minimal footprint was

accordance with EN 60529 to levels of

can easily be improved by adding an

achieved by mixing different module types

moisture, water, dust and vermin ingress

extra module for N+1 redundancy; further

within racks as described above.

protection as specified by the customer. The

The load comprises PLCs, computers,

IP-rated

in

cabinets can also be designed to withstand

that a failed module can be removed and

equipment and emergency lighting. Some

by using diagonal braces or cruciform

replaced with a good unit without interrupting

applications

very

shapes. For more extreme environments,

power to the system, which minimizes mean

low input current distortion (THDi) and unity

cabinet systems with welded designs are

time to repair (MTTR).

power factor; Bennings rectifier modules fully

developed.

rectifiers

control

be

network

required

process

can

modules are hot swappable. This means

Power availability is a very high priority in

components,

cabinets

with

complied with this requirement.

power stations of all types. RWE, one of Europes

heavy

vibration

or

seismic

disturbances

support as well as quality of product.

As discussed, availability is maximized by

Ideally the provider is often involved with

nuclear power and renewable sources for

using N+1 redundancy and by minimizing

the customer from the early stages of a

and

gas

companies,

AND S

OAL ASH

AND STORAGE

CES

Ultimately, success in power protection

Ruggedizing UPS systems

electricity

project and, if appropriate, takes part in


power system design extending well beyond
simply supplying standard components. At
Boufarik, for example, the complex system
development included 2500 A DC switches
and custom-built transformers and chokes.
David Bond is Managing Director at Benning
UK. benninguk.com
125 V/DC power plant system with 1750 A rectifier and 60 kVA inverter blocks
Credit:Benning

48

1608pei_48 48

Power Engineering International July-August 2016

COAL

MANAG

projects depends on high levels of customer

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Project Update
Putting power for the Games on the fast track
There may be a full four years between every

GE said this process saved valuable time

all the components of a comprehensive

Olympic Games, but deploying Olympic

up front, helping to ensure the right technology,

network of power systems across some 32

Games-scale

system configurations and support services

venues and facilities can be daunting. Its

were specified.

a logistical challenge to not only ship all the

power

distribution, backup

power and protection systems typically comes


down to the final months or even weeks

and

equipment and components from various

before the Opening Ceremony of the games.

2954 single-phase UPS units being used in Rio,

locations, but also for the local crew to bring

For this years Rio Olympic Games, GE

GE said that it was important to standardize

together all the components into the right

on core platforms.

solutions.

Energy Connections implemented a series of

Given

the

110

GE

three-phase

fast-track processes based on lessons learned

By standardizing on its SG and TLE series of

Scappini said: Choosing the right solution

from work at five previous games to help scale

UPS backup power units early in the process,

can be similar to deciding between going to

up the power for more than 32 venues and

downstream issues of commissioning and

a lumber yard to collect the wood, nails and

facilities.

deploying power protection systems were

tools needed to build a house or getting a

Having supported the Olympic movement

greatly simplified. In addition, standardizing

pre-packaged house kit of all the supplies

since the Torino 2006 Olympic Winter Games,

on basic units continued to offer flexibility in

and equipment delivered on one truck. For

weve learned some valuable lessons about

terms of power capacity output while also

the Olympic Games, we looked at each of

how to deploy comprehensive power systems

streamlining potential issues such as training,

the 32 venues and facilities and determined

across multiple sports venues and facilities

support and parts inventory depending on

it would be best to deliver ready-to-deploy,

under a highly compressed timetable, says

settings and requirements.

complete equipment and system packages

Rohan Kelkar, general manager for one of GEs


Energy Connections businesses.

In typical power protection and distribution


applications such as a data centres, for

in containerized units for each venue and


application.

For the Rio games, GE provided more

example, design and deployment schedules

Having a full complement of pre-specified

than 3000 three-phase and single-phase

were well defined and managed. GE said:

equipment consolidated in a single container

uninterruptible power supply (UPS) systems,

Provisioning power at a new or upgraded data

helps ensure that all of the right equipment

65 power transformers and a host of electrical

centre typically proceeds along a clear and

and components are in the right place at the

distribution

linear path. When providing power systems to

right time, accelerating GEs schedule and

facilities that are under construction, however,

helping to ensure quality.

equipment

from

low-voltage

panels to switchgear.
All of this equipment needed to be

delivery and installation flexibility is essential.

Developing an extensive training regime for

delivered, installed, tested and connected to

Mauro Scappini, senior service manager

both GEs Energy Connections critical-power

a centralized power monitoring centre in time

for critical power products at GE Energy

services team and its channel partners in

for the Opening Ceremony on 5 August.

Connections, said: Unlike many of our

Brazil was also part of the companys fast-track

commercial

final

strategy to ensure installation and services

Services, says

deadline sometimes varies, the Opening

teams were ready for the quick deployment

that there is no way that this can happen

Ceremony of the Olympic Games is a cant-

strategies put in place years before the

unless there is strong co-ordination. Its about

be-missed deadline.

Games and the companys Rio teams began

Sotiris Salamouris, chief technology officer


at

Olympic

Broadcasting

teamwork there is no other way.


Working

with

fast-track

deployments

when

GE said that figuring out how to assemble

tools

their training in February.

and

methodologies developed as part of the GEs


FastWorks process, the company looked at
every phase of the project from customerfocused

specifications

and

ongoing

interactions to ways of enhancing delivery


and deployments to help ensure every
power system would be up and ready for the
Games.
Before the final specifications were put in
place, GE shared its experience and data
collected from past Olympic Games projects
with the Rio 2016 Organizing Committee to
develop an optimum list of requirements.

50

1608pei_50 50

Power Engineering International July-August 2016

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8/16/16 10:45 AM

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As part of the POWER-GEN Russia conference programme are a series of


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Localization of Power Generating Equipment

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1608pei_51 51

8/16/16 10:45 AM

Project Update
Enerpac SE Asia launches electric torque wrench
Enerpac SE Asia is introducing its new Electric

tool, so that it can be read easily, even in bright

versatile, said Ramit Sharma, bolting manager

Torque Wrench throughout the region to

sunlight.

at Enerpac SE Asia. We have a full range of

improve bolting efficiency and performance

The control box is designed to simplify


complex

of

different applications, and can even supply

high precision.

automatic presets. In addition, fastening

non-standard versions on request to suit

records can be viewed on-screen and

special applications.

Advances incorporated into the design

jobs

of the wrench include a large seven-inch

transferred

touchscreen on the control box as well as a

connection.

bright three-line LED display on the back of the

through

through

the

creation

sockets, extensions and reaction arms to suit

for industries requiring high repetition and

standard

USB

Sharma said the the LED display on the


back of the tool is excellent for minimizing

The new Electric Torque Wrench is highly

downtime.

EthosEnergy wins $8m Myanmar gas turbine deal


EthosEnergy has won a gas turbine overhaul

will overhaul one 701D unit with all new parts

to the original manufacturers performance

and upgrade contract worth over $8m from

and upgrade two MHI 701D units including

specifications of 120 MW. Equally we expected

Myanmar Electric Power Enterprise (MEPE).

controls.

a proven state of the art control system to allow

The deal is for equipment at the Ywama

MEPE said that when awarding the contract

power plant in Yangon, where EthosEnergy

it was looking for the ability to restore the units

us accurate and efficient machine calibration,


monitoring and control.

Toshiba wins Vietnam steam


turbine and generator deal
Toshiba has won an order to supply steam turbines and generators for
the extension of a coal-fired plant in Vietnam.
The extension of the Vinh Tan 4 plant owned by Vietnam
Electricity is currently being carried out by a consortium of Mitsubishi
Corporation and Doosan Heavy Industries & Construction.
The 600 MW steam turbines and generators that Toshiba will
supply generate steam at a pressure of over 240 bar, with a reheat
steam temperature of 593C. Toshiba said they are considerably
more efficient than the steam turbines and generators now in wide
use in Vietnam. The firm will start delivery in January 2018, with
commissioning scheduled for 2019.
In 2014 Toshiba won a contract to provide the same equipment
for Units 1 and 2 of Vinh Tan 4, and started delivery in December
2015.
Takao Konishi of Toshibas Energy Systems & Solutions Company
said: Demand for power is growing fast in Vietnam and Toshiba is
pleased to help increase capacity. Selection of our steam turbines
and generators for Vinh Tan 4 extension is a strong testament to the
countrys confidence in the technologies and services which Toshiba
has developed over the years.
Strong economic growth is putting a strain on Vietnams power
generating capacity, with the south of the country particularly
susceptible to shortages and the government is responding with
expansion plans to boost electricity supply.
For more information, enter 34 at pei.hotims.com

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1608pei_52 52

Power Engineering International July-August 2016

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8/16/16 10:45 AM

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Keynote speakers include the below, PLUS, invited high-level representatives from the Ministry of Trade, Industry and
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Heung-Gweon Park
Executive Vice President & CEO
Turbine/Generator Business Group
Doosan Heavy Industries &
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Willi Meixner
CEO
Power and Gas Division
Siemens AG, Germany

Steve Bolze
President and CEO
GE Power, United States

We invite you to join us in Seoul to meet and network with senior executive and industry leaders for three days of conference sessions
across 7 tracks under the theme of Exchanging Knowledge Generating Solutions, a vast exhibition floor containing the worlds
leading industry players, plus various networking events to enable all attendees to wind down at the end of the day.
For the full conference programme across the 7 Asia Power Week tracks, and the latest exhibition floor plan,
please visit www.asiapowerweek.com.

COVERING CONVENTIONAL POWER, RENEWABLES AND FINANCE ALL UNDER ONE ROOF

24

8Attendees
,000

250
International
Exhibitors

130
Industry Expert
Speakers

50
Conference
Sessions

7
Conference
Tracks

th
24
Annual Event

LEARN HOW TO PARTICIPATE AT THIS PREMIER EVENT: WWW.ASIAPOWERWEEK.COM


Owned and Produced by:

Presented by:

Under the Patronage of:

Host Utility:

Diamond Sponsor:

Gold Sponsors:

Official Supporters:
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8/16/16 10:45 AM

Project Update
Funding for fourth coal unit on Mindanao
Funding has been secured for a fourth unit at

The project is to be funded by 70 per cent

As the Philippines prepares to draft an

a 540 MW coal-fired power plant on the island

debt from domestic and foreign banks plus

energy policy under the new administration

of Mindanao in the Philippines.

30 per cent equity. The first three 135 MW units

of President Rodrigo Duterte, energy secretary

are currently under construction and unit 1 is

Alfonsi Cusi said in July that as a developing

conglomerate

planned to be completed late next year, with

country we cannot afford not to have coal.

Ayala Corporation, said financial close has

the entire plant expected to come online in

He added: We have to find a happy balance.

been achieved on the $1bn project in the

2018. The plant will feature pulverized coal

We cannot afford to rely solely on renewables.

municipality of Kauswagan in Lanao del Norte

combustion technology with Shanghai boilers

Coal is the more dependable, the more

province.

and Siemens turbines and generator.

reliable source for baseload.

Developer
subsidiary

AC

of

Energy

multinational

Holdings,

Covestro makes first polyurethane turbine blade for Asia wind market
German polymer company Covestro has

was fabricated with a special polyurethane

polyurethane resin has very good physical

manufactured the first polyurethane rotor

infusion resin from Covestro and glass fibre

properties, an excellent flowability and it

blade for wind turbines in Asia.

mats from Chongqing Polycomp International,

thoroughly wets the glass fibers. Furthermore,

a Chinese glass fibre manufacturer at the

less thermal energy is released during its

Shanghai FRP Research Institute.

processing than with epoxy resins.

The 37.5 metre-long rotor blade is designed


for a wind turbine with an output of 1.5 MW. It

A vacuum pressure
infusion

system

with

continuous degassing,

Best in class Motor Starting Solutions

manufacturers a major cost advantage.

developed by process

The resin was developed in a collaboration

technology company

between the Covestro Wind Competence

HBERS,

used

Centre in Denmark and the Polymer Research

to produce the rotor

was

Development Center (PRDC) of Covestro in

blade.

Shanghai.

Kim
global

Klausen,
head

Covestros

At the recent China Summit Forum 2016 for

of

International Wind Power Composite Materials

wind

in Zhejiang, Dr. Roland Stoer, general manager

programme,

of WINDnovation, a leading rotor blade design

said the milestone is

company, said about the use of polyurethane:

further proof of the

We would like to optimize rotor blade design

performance

and take full advantage of the benefits of

energy

cost

and

advantages

of

polyurethanes.We are impressed by Covestros

over

research capability and commitment, and

epoxy resins in wind

would like to cooperate with the company to

power generation.

design even more sophisticated rotor blades

polyurethanes

Covestro says the

in the future.

Controlled start current


Reduction of mechanical stresses
Reduction of maintenance costs
Increase of system uptime

Po

wered

The faster curing significantly improves


productivity, added Klausen, and that gives

by IGE

IGEL Electric GmbH Industrieweg 1315 48324 Sendenhorst Germany


Phone +49 (0)2526 9389-0 Fax +49 (0)2526 9389-22 info@igelelectric.de igelelectric.de

For more information, enter 36 at pei.hotims.com

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1608pei_54 54

Power Engineering International July-August 2016

www.PowerEngineeringInt.com

8/16/16 10:45 AM

11-13

MAY

Renewables | Fossil Fuels | Nuclear

PRAGATI MAIDAN,
NEW DELHI, INDIA
www.power-genindia.com

SAVE THE DATE

FOR INDIAS LEADING CLEAN ENERGY EVENT


India is looking meet rising energy demands and to secure a lower carbon sustainable
future. Against this backdrop, there is no better time to participate at Indias leading
clean energy event

LEARN
about the latest
challenges and
solutions for the Indian
power generation
industry

SHOWCASE
your companys
products and services
to the Indian
power generation
industry

EXPERIENCE
first-hand the latest
technology for the
Indian power
generation
industry

ATTEND AS
A DELEGATE
SIGN UP AS
AN EXHIBITOR
JOIN AS A
VISITOR

5,500+

200+

75+

20+

16

Attendees

Exhibitors

Speakers

Conference Sessions

Annual Event

th

Event Organizers:

For information on how to participate visit www.power-genindia.com


For more information, enter 37 at pei.hotims.com

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8/16/16 10:45 AM

Diary
September
POWER-GEN Asia
2022 September
Seoul, South Korea
www.asiapowerweek.com
Renewable Energy World Asia
2022 September
Seoul, South Korea
www.asiapowerweek.com/en/
renewable.html
Wind Energy Hamburg
30 September
Hamburg Messe, Germany
www.windenergyhamburg.com

October
South Africa Gas Options
35 October
Cape Town, South Africa
www.energynet.co.uk/event/southafrica-gas-options-2016
European Biomass to Power 2016
56 October
Seville, Spain
www.wplgroup.com
China Wind Power
1921 October
Beijing, China
www.chinawind.org.cn

Visit www.PowerEngineeringInt.com
for more information

6th Power Engineering and


Automation Conference
2123 October
Shanghai, China
www.engii.org/cet2016/PEAM.aspx
PowerElec India
2426 October
Mumbai, India
www.powerelec.co.in
POWER-GEN Russia
2527 October
Moscow, Russian Federation
www.powergen-russia.com
Hydrovision Russia
2527 October
Moscow, Russian Federation
www.powergen-russia.com

Ad Index
AARDING THERMAL ACOUSTICS BV
AKSA POWER GENERATION (CHINA) CO. LTD.
ALIMAK HEK AB
ANSALDO ENERGIA
ASIA POWER WEEK
AUMA RIESTER GMBH & CO. KG
BABCOCK & WILCOX CO
BFI AUTOMATION
CATERPILLAR ENERGY SOLUTIONS GMBH
CLARCOR
CMI ENERGY
CRESTCHIC LIMITED
ENERPROJECT SA
ETHOSENERGY
GE OIL & GAS
GE POWER
GEDA DECHENTREITER GMBH & CO KG
HEMPEL A/S
IGEL ELECTRIC GMBH
KBS MEDIA

44
C3
23
39
53
21
C4
18
C2
52
37
10
10
33
17
9
29
45
54
7

KELVION HOLDING GMBH


M&I MATERIALS LTD
MAN DIESEL & TURBO SE
MAPNA INTERNATIONAL FZE
MTU FRIEDRICHSHAFEN GMBH
NEM ENERGY BV
NOOTER ERIKSEN
OVIVO
PENNENERGY EQUIPMENT
PENNWELL CORPORATION
POWER-GEN EUROPE
POWER-GEN INTERNATIONAL
POWER-GEN RUSSIA
POWERGEN NATURAL GAS 2016
SABLE CHEMICAL INDUSTRIES LIMITED
SCANIA CV AB
SIEMENS AG
VALMET AB
WELLAND & TUXHORN AG

13
12
5
35
19
40
31
3
28
55
47
49
51
43
16
11
25
41
22

PennWell Global Energy Group, The Water Tower, Gunpowder Mill, Powdermill Lane, Waltham Abbey, Essex EN9 1BN, United Kingdom.
Phone: +44 1992 656 600 Fax: +44 1992 656 700 Web: www.PowerEngineeringInt.com
Publisher Heather Johnstone peinews@pennwell.com Chief Editor Kelvin Ross peinews@pennwell.com Associate Editor Nigel Blackaby peinews@pennwell.com
Production Editor Richard Gibson Design Samantha Heasmer Production Daniel Greene Group Publisher Rich Baker
Advertisement Sales Manager Tom Marler tomm@pennwell.com
Corporate Headquarters PennWell Corporation, 1421 S. Sheridan Road, Tulsa , OK 74112 USA. Phone: +1 918 835 3161 Fax: +1 918 831 9834
Chairman Robert F. Biolchini Vice Chairman Frank T. Lauinger President and Chief Executive Officer Mark C. Wilmoth Executive Vice President, Corporate Development and
Strategy Jayne A. Gilsinger Senior Vice President, Finance and Chief Financial Officer Brian Conway
Sr. VP Audience Development and Book Publishing June Griffin Magazine Audience Development Manager Jesse Flyer
For Assistance with Marketing Strategy or Ad Creation, Please Contact:
PennWell Marketing Solutions Vice President: Paul Andrews. Phone: +1 240 595 2352. Email: pandrews@pennwell.com
Subscriber Customer Service: PO Box 3264, Northbrook, IL 60065-3264, USA. Customer Service Phone: 1-847-763-9540. Fax: 847-763-9607. E-mail: pei@halldata.com
Power Engineering International, ISSN 1069-4994, is published eleven times a year by PennWell Global Energy Group, Copyright 2016 by PennWell Corporation, 1421 S. Sheridan Rd.,
Tulsa, OK 74112, USA. All rights reserved. Subscriptions/circulation and reader enquiry office: Power Engineering International, PO BOX 3264, Northbrook, IL. 60065-3264, U.S.A. Paid annual
subscription rates: Worldwide $60 Digital Version. E.U. $173, No. America $214. United Kingdom $143. All other countries $214. Single or back copies: $26 for all regions.
Reprints: If you would like to have a recent article reprinted for a conference or for use as marketing tool, please contact Rae Lynn Cooper. Email: raec@pennwell.com.
USA circulation only: Power Engineering International,Periodicals POSTAGE PAID at Rahway NJ. Subscription price is $210 Periodicals Postage Paid at Rahway NJ. Postmaster send
address corrections to: Power Engineering International, C/O Mercury Airfreight International Ltd. 365 Blair Road, Avenel, NJ 07001. Power Engineering International is a registered
trademark of PennWell Corporation. POSTMASTER: Send address changes to Power Engineering International, PO BOX 3264, Northbrook, IL. 60065-3264. U.S.A. Member American
Business Press Business Publications Audit3 Printed in the United Kingdom GST No. 12681315

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Power Engineering International July-August 2016

www.PowerEngineeringInt.com

8/16/16 3:28 PM

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8/16/16 10:45 AM

For more information, enter 39 at pei.hotims.com

1608pei_C4 4

8/16/16 10:45 AM

THE COMPLETE
POWER PORTFOLIO

1607DENAtlas_digital_1 1

7/13/16 8:55 AM

WELCOME!
When it comes to providing power solutions we have two focus areas. The first,
Predictable Power, is a promise of the performance you will receive from our
generators. We understand the need for constant, guaranteed power is critical.
You can be assured that our generators provide predictability and peace of mind,
empowering your work with an uninterrupted power supply.
The second, and what drives us, is Forward-Thinking. This is a promise of the
problems you can expect to avoid as a result of using our products, such as: high fuel
bills, downtime and usability issues. Innovation drives Atlas Copco forward. We put
time, money and resources into delivering a product that is ahead of the curve and,
more importantly, puts you ahead of the curve too ensuring competitive advantage.
We have dedicated representatives in over 180 countries. The depth and knowledge
of this network, coupled with our product expertise, makes us the go-to partner
for thousands of critical power projects across the globe.
Take a look at our portfolio and lets start a conversation!
Ben Van Hove
VP Marketing, Atlas Copco Portable Energy

POWER ON THE MOVE

WITHSTANDING THE ELEMENTS

INDUSTRIAL POWER

iP, P and QEP range

QES range

QIS range

1607DENAtlas_digital_2 2

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PORTABLE GENERATORS

MOBILE GENERATORS

INDUSTRIAL GENERATORS

MOBILE RENTAL GENERATORS

CONTAINERIZED GENERATORS

iP, P and QEP range

QES range

QIS range

QAS range

QAC, QEC

1,6 to 11 kW

9 to 200 kVA

10 to 2250 kVA

14 to 630 kVA

800 to 1250 kVA

THE POWER OF CONNECTIVITY

THE FUEL SAVER

THE TOUGHEST CONTAINER

QAS range

QAC range

QEC range

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BUILT FOR YOU


Rain or shine. Guaranteed power all the time!
The QES range is tested to withstand the elements.

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7/13/16 8:55 AM

MOBILE GENERATORS
WITHSTANDING THE ELEMENTS - QES range
Successfully launched in 2015, the QES range has been expanded. Initially offering five power nodes,
9 to 40 kVA, the range now offers six new models from 60 to 200 kVA.
The QES range is the straightforward, rugged and durable solution for general applications across
construction environments.

11

MODELS

NEW

IN 2016

9-200kVA

THE POWER OF CONNECTIVITY - QAS range


We have bolstered our QAS series of generators with the addition of the QAS 630. By incorporating
the compact frame of the QAS 500, the QAS 630 can generate 20% more power without needing
a larger footprint.
The expanded QAS generator series provides complete, compact and fuel-efficient solutions from
14 to 630 kVA, making this series the preferred choice for a wide range of applications throughout
the world.

15

NEW

MODELS

IN 2016

14-630kVA
SIMPLE
PARALLELING
CAPABILITY

www.atlascopco.com
5

1607DENAtlas_digital_5 5

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MAKE THE PERFECT POWER


When you need power, maybe a single generator is not always the most efficient solution. Does the
application load vary? Do you need prime power for long term projects on a remote site? Do you need a
semi-permanent installation that can be upgraded or downgraded?
A Modular Power Plant (or paralleling multiple generators) is the efficient solution if you answered yes
to any of the above questions. Simply, this is a configuration of generators working together.

We have developed a unique Power Management System (PMS). The PMS system enables the
optimisation of fuel consumption and expands the generators lifetime. PMS manages the quantity
of generators running in parallel with load demand, starting and stopping units in line with increases
or decreases in load. In this way, the load on each generator remains at a level which optimises fuel
consumption. It also eliminates the need for generators to run with low load levels, which can cause
engine damage and shorten the life expectancy of the equipment.
QEC 800
800
QAS 250

700

kW (15min)

600
500

QAS 250

400
300

Power avaliable
QAS 250

200
100

Note: this data is simulated. Its based on a typical industrial daily load diagram.

0
20:
15
21:
00
21:
45
22:
30
2 3:
15

18:
4

19:
3

18:
0

0
5:1
5
6:0
0
6 :4
5
7: 3
0
8:1
5
9:0
0
10:
30
11:1
5
12:
00
12:
45
13:
30
14:
15
15:
00
15:
45
16:
30
17:
15

4: 3

3 :4

2:1
5

3:0

5
1:3
0

0 :4

0:0

hh:mm
Load Profile

PMS Plant Capacity


Big Unit Capacitiy

Just one example:


The deployment of a 1MVA generator as a prime power source, taking the demand patterns
of a typical industrial application as a guide, could mean up to 1,677 litres of fuel being
consumed each day. That compares with approximately 1,558 litres of fuel if three 325kVA
generators were doing the same job. In this case, an estimated annual fuel saving of 30,000
makes for a compelling case, not to mention 85 tons of CO2 saved over the course of a year.

Check out videos on all of our products


Visit www.youtube.com/atlascopcoconstruct
6

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THE POWER OF
CONNECTIVITY
24/7 x 365 in over 180 countries. Power is critical there is no room
for compromise!

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CONTAINERIZED GENERATORS
THE FUEL SAVER - QAC range
The QAC generator is a real fuel saver. The electric VSD (Variable Speed Drive) motor-driven, cooling
fan, adjusts the cooling flow to the specific requirements of the engine. It may sound simple, but
this engineering sets the QAC generator apart.

63 dB(A)
at 7m
500

FUEL CONSUMPTION
AT FULL LOAD

-480

Per day

-175.000

LITERS

-10

LITERS

H
SERVICE
INTERVAL

Per year

THE TOUGHEST CONTAINER - QEC range


The QEC generator packs a punch! Up to 1 megawatt of containerized power that can be easily
transported from one worksite to the next. Extremely reliable, it is the flexible solution for your
prime and critical standby power needs in the rental, mining and oil & gas industries.

ROBUST

1MW

OF RELIABLE
POWER

1607DENAtlas_digital_8 8

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QAC 1100 TwinPower generator


For sites with variable power needs, we have launched the QAC 1100 TwinPower generator.
Comprised of two 500kVA generators inside a single container, the QAC 1100 is a fully-engineered
package with an advanced control system that enables the two generators to work independently or
in parallel with each other.
It enables operators to use up to one megawatt of power at anywhere between full load and low
load, maximizing fuel efficiency and cutting associated running costs.

ENGINES, 1 BOX

100%

LOAD STEP

DOUBLE THE FLEXIBILITY,


TWICE THE POWER

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WHAT IS THE COST


OF NO POWER?

10

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INDUSTRIAL POWER - QIS range


The QIS range is designed to combine maximum choice with exceptional reliability and performance.
From primary to critical backup power needs, open-frame or soundproof, these generators are
designed for optimal performance in the most demanding conditions. The QIS is perfect for multiple
industries including: data centers, healthcare, manufacturing, utilities and retail.

23

MODELS

10-2250kVA

POWER ON THE MOVE - iP, P and QEP range


We have developed a range of portable generators for people who work hard all day, every day! Built to
last, every generator in this range delivers long-term reliability, even in the toughest working conditions.
Easy operation, built-in safety features and an exceptional build quality make these generators the
perfect working partner for construction professionals, no matter the job site or task in-hand. From
simple one-person jobs, all the way to large construction sites, we have the solution for you.

P 3500i

P 6500

QEP

QEP R

QEP S

1,6 to 3 kW

5 to 6,5 kW

2,5 to 6,5 kW

5 to 11 kW

3,5 to 11 kW

21

52

42

69

99

63 dB(A)
at 7m

70dB(A)
at 7m

67dB(A)
at 7m

68dB(A)
at 7m

61dB(A)
at 7m

KG

6hrs

BEFORE REFUELLING

KG

11hrs

BEFORE REFUELLING

KG

9hrs

BEFORE REFUELLING

KG

12hrs

BEFORE REFUELLING

KG

12hrs

BEFORE REFUELLING
11

1607DENAtlas_digital_11 11

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PORTABLE ENERGY SOLUTIONS PORTFOLIO


AIR COMPRESSORS
READY TO GO
1-5 m/min
7-12 bar

VERSATILITY
7-22 m/min
7-20 bar

PRODUCTIVITY
PARTNER
19-64 m/min
10-35 bar

Diesel and electric options available.

GENERATORS
PORTABLE
1,6-13,9 kVA

MOBILE
9-1250* kVA

INDUSTRIAL
10-1250* kVA

*Multiple configurations available to produce power for any size application.

ELECTRIC
SUBMERSIBLE
275-16.500 l/min

DIESEL DRIVEN
CANOPY
833-9833 l/min

DIESEL DRIVEN
OPEN FRAME
3300-7500 l/min

METAL
HALIDE

SOLAR

2016 Atlas Copco Portable Energy All rights reserved. Atlas Copco is a registered trademark of Atlas Copco AB

DEWATERING PUMPS

LIGHT TOWERS
LED

COMMITTED TO SUSTAINABLE PRODUCTIVITY


Atlas Copcos Portable Energy division has a forward-thinking
philosophy. For us, creating customer value is all about anticipating
and exceeding your future needs while never compromising our
environmental principles. Looking ahead and staying ahead is the only
way we can ensure we are your long term partner.

www.atlascopco.com
Photos and illustrations contained herein might depict products with optional and/or extra components which are not included with the standard version of the product and, therefore, are not included in a
purchase of such product unless the customer specifically purchases such optional/extra components. We reserve the right to change the specifications and design of products described in this literature
without notice. Not all products are available in all markets.

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