PIMA 7 by Pimagazine Asia

PIINSIDER POWER

A S I A’ S L E A D I N G P O W E R R E P O R T

INDONESIA’S ENERGY DECISIONS

NOVEMBER/DECEMBER 2011

PLUS • Malaysia Powergen Showcase • Latest Biomass Technology • Asia Aeroderivative

20/12/2011 21:30

S:7”

S:10”

We can take wind turbines to new heights.

Keep maintenance costs down and send productivity soaring with the complete range of Mobil SHC synthetic lubricants and greases. Each one is formulated to offer outstanding all-around performance, including equipment protection, keepclean characteristics, and oil life. Take Mobilgear SHC XMP. Used in more than 30,000 wind turbine gearboxes worldwide, it’s trusted by builders, proven in the field, and supported by exceptional application expertise. Just a few of the reasons we don’t simply make things run. We make them fly. Visit mobilindustrial.com for more.

1004_EXOD_Wind_Misc2011_AD.indd 1 PI_Mobil_Ad.indd 2

This mechanical prepared by

MRM Worldwide Safety: 7” x 10”

This mechanical should not be modified in any way without prior written direction from MRM Worldwide.

Client: Exxon Mobil

Job Number: EXOD0011 C

12/7/11 12:36 PM 21/12/2011 07:33

welcome PIINSIDER POWER

A S I A’ S L E A D I N G P O W E R R E P O R T

INDONESIA’S ENERGY DECISIONS

At present the topic of every conversation is that of ‘recession’ 27 dip that’! ‘double dip this, double

NOVEMBER/DECEMBER 2011

PLUS • Malaysia Powergen Showcase • Latest Biomass Technology • Asia Aeroderivative

No matter what happens in global markets, certain things will always a necessity, the need for energy and the need for power. without energy, the simple flicking of a bulb would not be possible. In Small villages, children would not have the capacity to learn outside daylight hours, they would not be able to progress, move forward and learn. Quite simply, in Asia without rural electrification programs, small villages would quite literally be left in the dark ages.

20/12/2011 21:30

ContACt us: Editor: Charles Fox Journalist: Robin Samuels Creative Director: Colin Halliday Sales Director: Jacob Gold Business Sales Manager: Sam Thomas Account Manager: Daniel Rogers Accounts & Customer Service Manager: Katherine Stinchcombe Managing Director: Sean Stinchcombe sKs GlobAl limited Kingswood House South Road Kingswood Bristol UK BS15 8JF e: info@sks-global.com w: www.pimagazine-asia.com w: www.sks-global.com t: +44 (0) 1179 606452 F: +44 (0) 1179 608126

SKS Global Power Insider Asia magazine is published bi-monthly and is distributed to senior decision makers throughout Asia and the Pacific. The publishers do not sponsor or otherwise support any substance or service advertised or mentioned in this book; nor is the publisher responsible for the accuracy of any statement in this publication. Copyright: the entire content of this publication is protected by copyright, full details of which are available from the publisher. All rights reserved. No part of this publication may be reproduced, stored in a retrieval system, or transmitted in any form or by any means, electric, mechanical, photocopying, recording or otherwise without the prior permission of the copyright owner.

Regional governments have the best will in the world, they want their citizens to have energy, so they can have a better educated and more productive country, so throughout Asia, governments are doing everything they can to fund and build Re projects. The major problem is now the finance. Due to global market conditions, the issue are now, how do we secure the finance? IPP’s are struggling, banks wont lend without a 25 year guarantee? So what to do! well, Asia, luckily is still growing, governments are not struggling as much as other countries, so moving forward the worlds eyes are looking east and watching every move! This edition covers many pertinent issues and looks at the countries of malaysia and Indonesia, we have some great interviews with David Teng 78 of Ge and regional executives of mobil. our staff and stand were on hand at the Powergen Asia exhibition last month and had great success in signing up many more subscriptions, adding more value to our advertisers.

Big things are expected for 2012 in the power industry, and Pimagazine will be on hand and at the forefront of developments to ensure we do the best job possible for our loyal readership. I would like to take this opportunity to wish you all a very merry christmas and prosperous new year. I hope that you enjoy this edition, if you have news or other information that you feel we should look at, please do not hesitate to drop us a line.

ChArles Fox editor

power insider NoVemBeR/DecemBeR 2011 3

PI_NovDec_Eds_Letter.indd 3

20/12/2011 21:34

Proven. hanging The Energy World. Independence That’s Changing The World. Proven. Energy Proven.Independence That’s Changing The World. Proven. Energy Independence That’s Changing The World. Energy Independence That’s Changing The World.

ng a more efficient Clean fuel planet. cell technology - powering a more efficient planet. Clean fuel cell technology - powering a more efficient planet.

Clean fuel cell technology - powering a more efficient planet. Clean fuel cell V]LYHSS Z`Z[LT LMÄJPLUJ` HUK NLULYH[PVU VM technology - powering a more efficient planet. HUK NLULYH[PVU VM WYV]LU K\YHIPSP[`

owing capability, With its small footprint, quiet operation, load-following capability,

With its small footprint, quiet operation, load-following capability, m is delivering gamepower, heating and cooling, the PureCell® system is delivering gameWYV]LU K\YHIPSP[` V]LYHSS Z`Z[LT LMÄJPLUJ` HUK NLULYH[PVU VM With its small footprint, quietintensive operation, load-following capability, ound the world. changing results for energy buildings around the world. power, heating and cooling, the PureCell® system is delivering gameWYV]LU K\YHIPSP[` V]LYHSS Z`Z[LT LMÄJPLUJ` HUK NLULYH[PVU VM With its small footprint, quietintensive operation, load-following capability, changing results for energy buildings around the world. ® system is delivering gamepower, heating and cooling, the PureCell LJ[Z JOVVZL -VY UL^ JVUZ[Y\J[PVU L_WHUZPVU HUK YL[YVÄ[ WYVQLJ[Z JOVVZL WYV]LU K\YHIPSP[` V]LYHSS Z`Z[LT LMÄJPLUJ` HUK NLULYH[PVU VM results for energy intensive buildings around ®the world. ® system YL*LSS® system changing <;* 7V^LY»Z JSLHU LMÄJPLU[ HUK KLWLUKHISL 7\YL*LSS system is delivering gamepower, heating and cooling, the PureCell -VY UL^ JVUZ[Y\J[PVU L_WHUZPVU HUK YL[YVÄ[ WYVQLJ[Z JOVVZL VYTHUJL ILULÄ[Z MVY \UTH[JOLK ÄUHUJPHS LU]PYVUTLU[HS HUK WLYMVYTHUJL ILULÄ[Z changing results for energy intensive buildings around ®the world. system <;* 7V^LY»Z JSLHU LMÄJPLU[ HUK KLWLUKHISL 7\YL*LSS -VY UL^ JVUZ[Y\J[PVU L_WHUZPVU HUK YL[YVÄ[ WYVQLJ[Z JOVVZL MVY \UTH[JOLK ÄUHUJPHS LU]PYVUTLU[HS HUK WLYMVYTHUJL ILULÄ[Z <;* 7V^LY»Z JSLHU LMÄJPLU[ HUK KLWLUKHISL 7\YL*LSS® system -VY UL^ JVUZ[Y\J[PVU L_WHUZPVU HUK YL[YVÄ[ WYVQLJ[Z JOVVZL MVY \UTH[JOLK ÄUHUJPHS LU]PYVUTLU[HS HUK WLYMVYTHUJL ILULÄ[Z ® system an, efficient and<;* 7V^LY»Z JSLHU LMÄJPLU[ HUK KLWLUKHISL 7\YL*LSS To learn more about how UTC Power provides clean, efficient and

anging the worldMVY \UTH[JOLK ÄUHUJPHS LU]PYVUTLU[HS HUK WLYMVYTHUJL ILULÄ[Z economical fuel cell technology that has been changing the world To learn more about how UTC Power provides clean, efficient and for more than 50 years, visit UTCPower.com. economical fuel cell technology that has been changing the world To learn more about how UTC Power provides clean, efficient and for more than 50 years, visit UTCPower.com. economical fuel cell technology that has been changing the world To learn more about how UTC Power provides clean, efficient and for more than 50 years, visit UTCPower.com. economical fuel cell technology that has been changing the world

UTCPower.com for more than 50 years, visit UTCPower.com.

UTCPower.com UTCPower.com UTCPower.com UTCPower.com

PI_UTC_Ad.indd 4

21/12/2011 07:45

CONTENTS 6

News Powergen Asia 2011 27

Indonesia - Asia’s Rising Economy

Asia’s Aeroderivative

Biomass Technology

Beijing Wind Power Tour

Inshore ROV Case Study

Direct Drive Permanent Magnet Generator 46 Diagnostic Monitoring

Malaysia Solar PV

Low Impact Hydro

Power Plant Maintenance

POWER INSIDER NOVEMBER/DECEMBER 2011 5

PI_NovDec_Contents.indd 5

21/12/2011 14:54

NEWS DESK HONEYWELL AWARDED MULTI-MILLION USD CONTRACT TO SUPPLY INTEGRATED SYSTEM FOR VIETNAM OFFSHORE OIL PLATFORMS Company Named Main Contractor and Recognized for Outstanding Performance HONEYWELL HAS BEEN NAMED main electrical and instrumentation building contractor by the Hoang Long Joint Operating Company (HLJOC) for its H-04 wellhead platform in the Te Giac Trang (TGT) Field. This announcement follows the successful completion of an earlier phase (H-01 wellhead platform) of the TGT field, which was completed earlier this year on schedule and within budget for HLJOC. As recognition for the company’s exemplary performance on the first phase of the project, HLJOC presented Honeywell with a customer award recognizing their outstanding performance. Honeywell Process Solutions (HPS) was selected as main contractor for this project based on its strong engineering expertise and proven track record in meeting fast-track delivery schedules. In

addition, HLJOC would gain value from an integrated Honeywell solution, managed by Honeywell’s integrated control and safety system, which consists of the Experion® Process Knowledge System (PKS) and Safety Manager. This new project will require Honeywell to execute the design, procurement, construction, integration, testing and commissioning for the electrical and instrumentation building of the oil platform. HPS will also supply the main and backup power generators, wellhead control panel and chemical injection skid. “When we reach full production, the Te Giac Trang oil field will be a significant generator of resources for Vietnam and its business partners,” said Dr. Ngo Huu Hai, General Manager, HLJOC. “As a recent discovery, initiating operations quickly and safely in the oil field was of the utmost

importance. Honeywell was able to provide a high level of project management, integration capability and reduced schedule risk that we couldn’t find anywhere else.” “When these wellhead platforms are optimized, the Te Giac Trang oil field will play a crucial role in Vietnam’s energy production and lessen reliance on foreign sources of oil,” said Tony Cosgrove, Vice President for Asia Pacific, Honeywell Process Solutions. “The Hoang Long Joint Operating Company’s decision to award both projects to Honeywell reflects the growing acceptance of turnkey solutions and their importance in helping our customers in the oil and gas industry exceed their business objectives.” One of the largest joint operating companies in Vietnam, HLJOC is a state-owned partnership comprising PetroVietnam, PTTEP, SOCO

COMPANY NEWS FROM AROUND THE WORLD

Caterpillar and Dealer Ring Power Sign Agreement with APR Energy

Cat dealer Ring Power and APR Energy plc (“APR” – LSE: APR), today announced they have signed an agreement to develop temporary power solutions globally to meet the needs of the growing international power projects (IPP) market, especially in the

emerging markets. The five-year agreement centers on APR working with Caterpillar, Ring Power and the Cat dealer network to originate and respond to temporary power plant opportunities. As part of the agreement, Caterpillar will supply mobile generator sets through Ring Power to APR Energy, including the new

XQ2000 and XQ1475G power modules, designed specifically for the international power projects market. APR will benefit from an increased flow of temporary power plant opportunities and from clear visibility of an integrated supply line to fulfill on its diesel and gas engine requirements, and Caterpillar will benefit from an increased presence,

on a global basis, in the IPP market. “We are pleased to be working with Ring Power and APR Energy as we expand our growth in the international power projects business,” said Bill Rohner, Caterpillar vice president with responsibility for electric power. “APR’s experience in temporary power solutions, Caterpil-

lar’s engineering and product expertise and Ring Power’s rental experience will enable us to better serve our customers,” continued Rohner. By working with Caterpillar and Ring Power, APR continues to strengthen its position as one of the fastest growing providers in the IPP market. The extensive Cat dealer network will allow

6 NOVEMBER/DECEMBER 2011 POWER INSIDER

PI_NovDec_News.indd 6

20/12/2011 21:49

International and OPECO. When completed and at full production the facility, located in the Cuu Long Basin off the Southern Vietnam coast, will be capable of producing more than 55,000 barrels of oil per day. Honeywell International (www.honeywell. com) is a Fortune 100 diversified technology and manufacturing leader, serving customers worldwide with aerospace products and services; control technologies for buildings, homes and industry; automotive products; turbochargers; and specialty materials. Based in Morris Township, N.J., Honeywell’s shares are traded on the New York, London, and Chicago Stock Exchanges. For more news and information on Honeywell, please visit www.honeywellnow. com. Honeywell Process Solutions is part of Honeywell’s Automation and Control Solutions group, a global leader in providing product and service solutions that improve efficiency and profitability, support regulatory compliance, and maintain safe, comfortable environments in homes, buildings and industry. For more information about Process Solutions, access https://www.honeywellprocess.com.

APR to benefit from a truly global network of parts availability and services provided by the 188 Cat dealers and 126,700 Cat dealer employees around the world. Along with parts and services support, APR’s cooperation with Caterpillar and its dealers will present new sales opportunities previously unfulfilled by either party.

URBAN SOLID WASTE COLLECTION TURNS ‘SMART’

THE SWISS COMPANY PARADOX ENGINEERING and Rete di Imprese STEP, the clustering that comprises Italian firms Tecnotel, Sortron and PZ, announced today the launch of the pilot project ‘Solid Waste Integrated Network Gathering System’ (SWINGS) for the advanced monitoring of urban solid waste. Backed by the entrepreneurial association CNA Industria ForlìCesena, the project consists in the implementation of an innovative electric-mechanical system on traditional dump bins in order to monitor the input of waste and therefore optimize its collection. Thanks to this solution, data regarding environmental services usage and the status of every bin located in the area can be tracked and collected. The technology can even be installed on existing bins, avoiding further investments. Within April 2012, about 900 bins in the province of Forlì-Cesena (Emilia-Romagna region, in the Center of Italy) will be automated, serving a basin of about 11.000 users. The system will be gradually offered to all interested local administrations, through the respective multi-utilities. SWINGS stems from an important multi-utility based in Emilia-Romagna, willing to increase efficiency of urban solid waste collection thanks to an accurate evaluation of the input of waste and service costs, as well as the creation of a statistical base concerning environmental services usage. Compared to door-to-door collection, SWINGS can originate significant savings, along with important benefits in terms of environmental impact reduction, making the separate collection of rubbish easier and improving service levels. The system is applicable to every type of dump bins, even the existing ones. The project was developed by Rete di Imprese STEP, a consortium made by the Italian companies Tecnotel, specialized in telecommunication systems, PZ, which deals with mechanical

“I have been doing business with Caterpillar for more than 20 years, and APR has used their power modules for its entire history. We know Caterpillar well and have great respect for them. This is an exciting win-win for all of us,” said John Campion, CEO of APR. “With this agreement, we can work together to fulfill a far greater number of global

power opportunities.” As part of the agreement, Cat dealer Ring Power will provide application, engineering, sales and product support to APR Energy. “Our market leading product support and rental service capabilities enable us to deliver world-class energy solutions to our customers, and we look forward to

manufacturing, and SORTRON, which designs electronic systems for industrial applications. Paradox Engineering, Swiss company specialized in smart metering, smart grid, virtual network and wireless sensor network technologies, actively contributed to the project. “SWINGS aims at improving the collection of urban solid waste and, in a broader sense, increasing environmental and health protection. The constitution of Rete di Imprese allowed us to gather the necessary resources to develop the initial idea, leveraging the local industrial network competences enriched by our partner Paradox Engineering”, stated Giuliano Sartini, Rete di Imprese. “We wish the implementation of SWINGS could boost the local economy, originating positive spillovers on employment”. “SWINGS represents an excellent example of how it is possible to aggregate competences and resources to promote innovation and develop concrete projects. We invested a lot in this project and we offered our experience and technological solutions, designed and produced in Switzerland where we have our headquarters and laboratories”, explained Gianni Minetti, CEO, Paradox Engineering. “The system we are implementing has truly unique and innovative features, and it is prearranged to support smart metering, public lighting management, and other applications for Smart Cities. As an additional contribution to the collaboration with Rete di Imprese, it is our intention to promote SWINGS at international level, spreading the solution within the ensemble of partners and clients we usually work with at a global level”. “We have been supporting the SWINGS project from the very beginning, and it is a pleasure to learn that the pilot phase is now at start. This kind of announcements shows that also in Italy it is possible to kick-off interesting and innovative projects, despite the general mood of mistrust and pessimism. Certainly, far-sighted administrators and entrepreneurs caring about the valorization and growth of the local territory are essential”, added Maurizio Garavini, CNA Industria Forlì-Cesena. “No surprise that such an initiative obtained the interest of a foreign firm from Switzerland, which accepted the challenge to invest in Italy and share its know-how”.

continuing our long-standing relationship with APR Energy,” said Randy Ringhaver, president of Ring Power. A world-class manufacturer of diesel and natural gas engines and an industry leading provider of complete solutions for the electric power industry, Caterpillar pioneered the development of the mobile power module and

has provided customers with power systems solutions for more than 70 years. To meet the needs of international power projects customers, Caterpillar released a new version of its successful XQ2000 power module utilizing the 3516B engine. This new diesel power module is capable of running both 50 and 60 Hz, which is ideal for

POWER INSIDER NOVEMBER/DECEMBER 2011 7

PI_NovDec_News.indd 7

20/12/2011 21:50

news desk new C3000 series Genset wiLL eXtenD Cummins Power Generation CaPaBiLitY uP to 3.5-mw Cummins Power Generation, a business unit of Cummins Inc. announced recently a major leap forward in power capability with the new C3000 Series generator set offering up to 3.5 megawatts (MW). The C3000 Series incorporates the new Cummins QSK95 engine to set a new industry standard as the most powerful high-speed diesel genset. For multiple-set applications, the exceptionally high-output of the C3000 Series will increase power installation efficiency and realize higher economies of scale. The C3000 Series genset is ideally suited to provide critical power protection for facilities requiring high-output gensets such as data centers, hospitals and utilities. In developing countries, the C3000 Series meets the need for highoutput gensets to support gaps in the power grid infrastructure. For mining, oil and gas projects in remote locations, the need for dependable microgrids generating cleaner, lower-cost power makes the C3000 Series an attractive option. Equally impressive as the high power output of the C3000 Series genset is the ability to meet stringent EPA Tier 4 Final emissions taking effect in 2015. Cummins Selective Catalytic Reduction (SCR) aftertreatment system is intended to replace the exhaust muffler on the genset, offering a proven and highly flexible packaging solution. The C3000 Series genset leverages Cummins “Power Of One” capability, with single-company design and manufacture of all key systems. The new QSK95 engine, alternator, controls and Tier 4 SCR

aftertreatment have been developed simultaneously with the C3000 to deliver a fully integrated and highly optimized generator set. Performance validation work will continue during 2012, followed by a rigorous series of customer field tests during 2013 and 2014. “The new C3000 Series genset with the QSK95 engine will change expectations of what can be achieved by high-speed diesel technology, marrying industry-leading power density with increased durability,” said Tony Satterthwaite, President – Cummins Power Generation Business. New C3000 Series Genset Will Extend Cummins Power Generation Capability Up To 3.5-MW “Designed as a global product platform, the C3000 Series genset can be used anywhere in the world for standby, prime or continuous duty applications – with the ability to meet the toughest emissions requirements. “The C3000 Series will mark the start of a new line of diesel- and gas-powered generator sets. When the larger QSK120 version of the QSK95 engine becomes available, this will extend our product line beyond 4 megawatts. Our natural gaspowered product line will be designed specifically for gas, not just a derivative of the diesel product line,” added Satterthwaite. At 3.5-MW output, the C3000 Series will have the highest power rating available in a high-speed diesel genset. Compared with larger medium-speed gensets, the C3000 Series provides a footprint reduction of 30 percent to 40 percent, and a lower capital cost.

PerformanCe oPtimizeD Flexible customized packaging based on standard configurations will be available with the C3000 Series. Performance can be optimized among fuel consumption, transient response and emissions reduction to suit different application needs. The C3000 Series genset will seamlessly fit within Cummins large-power project expertise, with individual projects designed and commissioned with up to 260 MW installed power. Cummins Power Generation has invested heavily in switchgear and transfer switch capability to support these highly complex power projects. The C3000 Series genset will be tested in the recently opened Acoustical Testing Center (ATC) at the Fridley, Minn., headquarters of Cummins Power Generation. The largest enginetesting facility of its kind in the world, the ATC testing helps eliminate any external noise interference with a state-of-theart hemi-anechoic (no echo) chamber, allowing for the precise measurement of noise output from the fully assembled genset.

company news from around the world a global power provider like aPr. the new XQ1475G power module contains the world leading G3516e natural gas generator set.

Honeywell to deliver control and safety system for Australia Pacific lng joint venture project Honeywell announced that it

has been selected by Bechtel international inc. to design and implement automation and safety solutions for a new multi-train liquefied natural gas (LnG) facility under construction as part of the australia Pacific LnG Project in Queensland. the australia Pacific LnG Project -- a joint venture

between origin energy, ConocoPhillips and sinopec - will create a long-term industry utilising australia Pacific LnG’s coal seam gas (CsG) resources in the surat and Bowen basins. Bechtel selected Honeywell Process solutions (HPs) to provide vital integrated Control and safety systems (iCss) at the

new facility, which is designed to convert CsG to LnG. the Project will produce coal steam gas for commercial markets both locally and overseas and already supplies gas to power stations in Qeensland, major industrial customers and homes and businesses in south east Queensland.

the solution consists of components including experion™ PKs, Honeywell’s award-wining process distributed control system that unifies people with process, safety manager, which delivers enhanced safety assurance for operators who oversee industrial processes, and also includes Honeywell’s

8 november/december 2011 Power insiDer

PI_NovDec_News.indd 8

20/12/2011 21:50

BLACK & VEATCH EXPANDS ENERGY TEAM IN INDIA Black & Veatch has hired Kaushik Mukherjee as Regional General Manager, Sales, to work with local clients to improve India’s energy infrastructure. Kaushik brings 18 years of extensive planning and engineering, procurement, and construction (EPC) expertise, having developed and supported the execution of multiple major power generation projects. He is based in Black & Veatch’s Mumbai office. “Energy is central to India’s continued growth, prosperity and quality of life. Talented professionals like Kaushik, combined with our quality local and global staff, ensure the planning and smooth execution of local projects,” said Arthur Close, Energy Sales Director for Black & Veatch’s Middle East, India, Europe and Africa operation. “India is a growth market because of its energy, telecommunications and water needs. Kaushik’s experience will

Safety Instrumented Systems (SIS), their Fire & Gas Systems (FGS), and Enterprise Building Integrator, which serves as a platform for both fire detection systems and security systems, integrating seamlessly with Experion PKS to provide operators with total situational awareness. “Honeywell solutions will

provide Australia Pacific LNG with a safe and reliable system from day one.” said Frank Whitsura, vice president-HPS Projects and Automation Solutions. “We design our systems to integrate seamlessly with other Honeywell and third party products and solutions, which increases efficiency and

further help to improve conditions in many of India’s communities.” Black & Veatch provided project management and conceptual design services for the Sasan and Krishnapatnam power projects, among the largest multi-unit coal plants in the world. The company is currently providing designservices for the Samalkot power plant (2,400 MW). When completed in 2012 it will be the largest natural gas-fueled facility in India. In addition, Black & Veatch provided innovative sulfur processing solutions for the Jamnagar refining complex, the largest refinery in the world. “For more than 40 years Black & Veatch has been working in India, undertaking projects that enhance quality of life: power generation to support economic development, and water and sanitation to improve health. I look forward to working with local clients to meet India’s growing demand,” said Mukherjee.

reduces risk on a project so that it is completed on time and on-budget the best possible outcome for all”.

APR Energy Enters Strategic Partnership with Pratt & Whitney Power Systems Energy plc (APR) and Pratt & Whitney Power Systems (PWPS) announced a strate-

gic partnership to jointly address global temporary power needs and to increase the availability of mobile turbines for temporary power solutions. This partnership has already facilitated APR orders of 100MW on a flexible delivery schedule. Pratt & Whitney is a United Technologies Corp. (NYSE:UTX) company.

Under the terms of the global agreement, APR Energy becomes the exclusive provider of Pratt & Whitney’s FT8® MOBILEPAC® rental power solutions. In addition, APR will benefit from a 12-month warranty, a five-year service agreement and access to dedicated global support from PWPS, including project

POWER INSIDER NOVEMBER/DECEMBER 2011 9

PI_NovDec_News.indd 9

20/12/2011 21:51

NEWS DESK SIEMENS TO ADD PRODUCTION IN ST. PETERSBURG TO ITS GLOBAL GAS TURBINE MANUFACTURING NETWORK

SIEMENS IS TO FURTHER EXPAND its global gas turbine manufacturing network and launched a new joint venture in Russia named Siemens Gas Turbine Technologies. “The joint venture intends to invest approximately 275 million euros in a new gas turbine site in St. Petersburg and consequently will create 500 jobs. Starting in 2014, advanced, high-efficiency gas turbines are to be produced there for the growth market in the Commonwealth of Independent States (CIS),” said Michael Suess, member of the Managing Board of Siemens AG and CEO of Siemens Energy. Siemens has a 65 percent stake in the joint venture and its Russian partner Power Machines holds the remaining shares. The site will also feature research and development activities in addition to production, service, and sales and marketing. This commitment is part of the plans announced by Siemens to invest one billion euros in Russia and thus create a total of 4000 jobs. Besides the high availability of natural gas, modernization and expansion of the power plant fleet will be the drivers for the gas turbine market in the CIS region. Siemens expects total power generation in the member countries to increase by approximately 2 percent annually during this decade. Here, gasturbine power plants will play a major role: In 2010, power plants operated with gas turbines in the CIS contributed 30 gigawatts (GW) to the combined installed capacity of 370 GW. By 2020, based on Siemens estimates this share

will rise to 100 GW. “As global market leader in advanced gas turbines Siemens will obviously benefit from that,” added Suess. Siemens only recently opened a new turbine production facility in the U.S. in Charlotte, North Carolina as a supplement to its established manufacturing plant in Berlin. Above all high-efficiency combined cycle power plants will be of major importance for power generation in the future in the CIS. Siemens holds the world record with its H-Class turbine with an efficiency of 60.75 percent, testified at the installation site in Irsching. The average efficiency of thermal power plants operated in the CIS is less than 37 percent and half of them are more than 30 years old. Compared to the gas turbine power plants currently in operation, the latest-generation Siemens gas turbines operated in combined cycle duty with a steam turbine reduce both carbon dioxide (CO2) emissions and gas consumption on average by a third. Siemens has been doing business in Russia for almost 160 years. Examples of recent activities include an assembly plant for medium-voltage switchgear in Dubna in the vicinity of Moscow and a joint venture for pipeline compressors headquartered in Perm. Operations were also recently started at a factory for high-voltage products in Voronezh, which is located 500 kilometers south of Moscow. Next year, a transformer factory is to be opened there and a production plant for gas-insulated switchgear is to follow.

COMPANY NEWS FROM AROUND THE WORLD management, engineering and aftermarket resources. PWPS will refer temporary power inquiries to APR and will promote APR across a range of media, including trade fairs, advertising and promotions. Under this exclusive agreement PWPS will not sell or lease FT8 gas turbines

to any other temporary power rental provider. Pratt & Whitney’s FT8 MOBILEPAC unit is an ideal fit for APR’s fleet strategy. Earlier this year, it was used to help APR provide muchneeded temporary power in Japan, and its modularized design allows for rapid de-

ployment and installation as well as dual fuel flexibility and remote starting capabilities. This partnership announcement follows APR Energy’s recent similar global agreement with Caterpillar Inc. and Cat dealer Ring Power. “After the successful provision of FT8 modular units

for our emergency power projects in Japan, APR and Pratt & Whitney felt confident that a partnership would thrive,” said John Campion, CEO of APR. “This partnership complements our recent agreement with Caterpillar and Ring Power for diesel engine units and means we

can greatly increase the immediate availability of turbine resources to APR Energy’s customers globally, as well as jointly promoting new temporary power contracts.”

10 NOVEMBER/DECEMBER 2011 POWER INSIDER

PI_NovDec_News.indd 10

20/12/2011 21:51

The power of innovative turbine control.

HR_TriSen_ADVERT_205x275.indd 3

PI_TriSen_Ad.indd 63

1/12/11 8:54 AM

21/12/2011 15:00

POWERGEN MALAYSIA

POWER GEN ASIA 2011, KUALA LUMPUR & MALAYSIA OUTLOOK THE MONTH OF SEPTEMBER 2011 SAW ASIA’S PREMIERE GATHERING FOR THE POWER INDUSTRY TAKE PLACE, IN THE WELCOMING AND VIBRANT LOCATION OF KUALA LUMPUR. MALAYSIA’S CAPITAL CITY PLAYED A WONDERFUL HOST TO THE REGIONS SHOWCASE EVENT FOR THE ENERGY INDUSTRY.

12 NOVEMBER/DECEMBER 2011 POWER INSIDER

PI_NovDec_Malaysia_Powergen.indd 12

20/12/2011 22:18

enwell once again excelled in organization and co-ordination of the colossal occasion, and their efforts were rewarded with a record attendance for the show, accommodating for over 6700 energy professionals. An area for commandment included catering for the growing demand in alternative solutions with the incorporation of Renewable Energy World for the third year running. This notion has real significance and correlation to current issues facing the industry, particularly with utilities and other generators beholding increasingly diverse portfolios requiring more integration and co-operation than ever to ensure a stable supply for the end user. Estimated figures released by the ‘United Nations Population Division’ expect anywhere up to 5.3 billion people to reside in Asia by 2050, a phenomenal figure by any standards. Countries are experiencing unprecedented industrialization and urbanization, but to ensure continued economic and social growth, and also an acceptable standard of living, access to a consistent power source becomes a necessity. After the horrific events that took place in Japan on the 11th of March 2011, and the devastating

aftermath felt globally following the Fukushima Daiichi nuclear disaster, many doubts about the energy source were once again brought to surface. With nuclear plants it is always a going to be a case of easing strong opposition amid concerns of the potential dangers to people and the environment, in case of an accident. In essence you cannot discard the fact that there is no emission of CO2 in the reaction process, and once safety and security is established, there is no doubt that it has a significant role to play in the future energy mix. GOVERNMENT PERSPECTIVE AND INCOMING POLICY The keynote ceremony began with a warm welcome to the country of Malaysia from Datuk Loo Took Gee, the Secretary General from KeTTHA, Malaysia’s Ministry of Energy, Green Technology and Water. She has been with the Ministry for a long time working through a variety of positions before taking on her current role in August 2010. To initiate proceedings, Datuk Loo Took Gee talked about the soaring price of fossil fuels coupled with a global reduction in their availability.

Malaysia has traditionally been a well endowed country when it comes to natural resources, with proven gas reserves estimated at 2350 billion m3 in 2010. Although consistent to the rest of Asia, the country is experiencing an increased standard of living across its 28 million residents and Secretary General spoke of the increased strain that this was subsequently putting on the government and also on natural resources. She spoke of the importance in “managing the energy mix” as volatility in the price for a barrel of oil has seen figures reach the region of $150. Malaysia, at present is heavily dependent on fossil fuels for power generation, with coal and gas representing 94 % of a portfolio that is undergoing much investment and development. The government is taking a comprehensive and systematic approach towards energy efficiency, keen to increase renewable implementation and relinquish the subsequent reliance on fossil fuels. In January 2010 they introduced the Green Technology Financing Scheme (GTFS) with a RM1.5billion fund to provide soft loans with an interest subsidy of 2 per cent, towards companies

POWER INSIDER NOVEMBER/DECEMBER 2011 13

PI_NovDec_Malaysia_Powergen.indd 13

20/12/2011 22:19

powergen malaysia that supply, utilize and promote green technology, including energy efficiency and conservation. Suppliers are able to obtain loans of up to RM50 million and for consumers up to RM10million. Loo Took Gee also mentioned that finally a Renewable Energy Act had been passed for 2011 and after work with the Attorney-General’s Chambers to finalise the legal instruments, the feed in tariff (FiT) would come into effect from the 1st of December, she said that this combined with a investment tax allowance would stimulate the development of renewable energy and represent what is thought to be a real market driver. The most viable resources for renewable energy in Malaysia include biomass and biogas (in particular with the vast palm oil plantations and production facilities across the country) waste to energy, solar power and perhaps most importantly, hydro power. Other areas of energy efficiency promotion are being actively pursued by the government, in relation to their ‘SAVE’ or ‘Sustainability Achieved via Energy Efficiency’ program. Datuk Loo Took Gee said that electricity supply in the rural areas will also be “extended through the national grid” and the mentioned that “alternative systems would form a large part of the push.” She said that continued development of the basic rural infrastructure would represent another key area to improve as targets for rural electricity coverage will be almost 100 per cent in peninsular Malaysia and 99 per cent in Sabah and Sarawak. The plans in place by the Malaysian government all seem to represent positive moves as they finally appear to be taking a more vibrant view of green energy and the role it will inevitably have to play in the countries power generation needs for the future. Consideration of power plant operation in efficient fuel use is critical towards effectively managing natural resources, and power generators have significant responsibility in consciously investing in technology to ensure compliance here. Equally important though, is for the domestic and commercial end user to be aware and conservative in their use at the receiving end of the transmission and distribution lines. Datuk Loo Took Gee highlighted this as

another critical area in working towards a sustainable Malaysia. One of the biggest demands on power within the residential market is for air conditioning systems, fridges and chillers, all are vital in operation and constantly in use throughout the humid region on a daily basis. Many units are aging and extremely inefficient in operation, but in a country where the average wage is RM3000 a month (and RM700 for plantation workers) consumers have far higher priorities than the replacement of units that are working in a reliable manner, with the majority of their earnings going on basic necessities and family provisions. To accelerate and encourage domestic users to replace aging units, guidance and assistance will be required. The Secretary General stated that “50 million ringgit has been allocated for rebates to domestic users who purchase new energy efficient products such as 5-Star rated refrigerators, air conditioners or chillers” with the vision of “creating a culture of efficient use of energy among general public and business entities and to save daily energy costs for consumers through reduced energy consumption whilst simultaneously managing growth energy demand.” The notion is positive from KeTTHA, but only 100,000 rebate vouchers for 5-Star rated refrigerators and 65,000 vouchers for 5-Star rated air conditioners have been allocated to states across Malaysia. Rebates will be awarded on a first-come, first-served basis to qualified domestic consumers, which begs the question - will this really be enough to kick start the remainder of a country with a population of almost 28,000,000 to take notice of energy efficiency and follow suit with subsequent upgrades with no help from the government? The Secretary General stated that a “significant allocation of subsidy funding would be dedicated towards improving transmission and distribution, renewable energy and energy efficiency” and hoped that “strong policy measure and incentive would eventually ensure that a quality supply service would be available to the end user in every state across Malaysia.” She insisted there “would be close examination of complaints numbers, aiming for a sizeable performance increase.”

The imporTance of sarawak Loo Took Gee finished her opening address by touching on perhaps the most significant, reliable and powerful renewable resource available in Malaysia, hydropower throughout the resource-rich Sarawak. The Secretary General stated that “plans were in place” and the “federal government across planning, environmental and energy sectors have much future discussion for totalling and utilizing up to 28,000MW in hydro power resources.” The “Sarawak Corridor of Renewable Energy” which stretches 320km from Bintulu to Mukah, is a new development corridor in the Malaysian state, which represents a stimulation of hydro power development in the region. “SCORE” aims to accelerate the state’s economic growth, focusing on five major growth nodes, Tanjung Manis, Samalaju, Mukah, Baram and Tunoh. It singles out 10 key industries for development. These include tourism, oil, aluminium, metals, glass, fishing, aquaculture, livestock, forestry, ship building and palm oil. Overseas interest is key to the development of SCORE with investment now totalling about US$30 billion in the aluminium, the polysilicon, and minerals-based industries as well as agriculture including aquaculture and the halal hub. Chinese investors have recently pledged US$11 billion, as 1Malaysia Development Bhd (1MDB) whollyowned by the Malaysian government (specifically set up to drive strategic initiatives for long-term sustainable economic development and promotion of foreign direct investment for the project) and The State Grid Corporation of China (SGCC), China’s leading power transmission and distribution company, sealed an agreement to jointly venture into major projects for the development. The availability of renewable solutions allows Sarawak to price its energy competitively, encouraging investments in power generation and other energyintensive industries which essentially becomes a catalyst for the strong industrial development forecasted, and the economical benefits that follow. The posiTion of The power generaTor The Malaysian state owned utility company is Tenaga Nasional Berhad. It is the country’s largest generator, currently providing electricity for 7.6 million customers, with an estimated RM71.4 billion in assets. Their accumulated capacity, accounts for 53% of Malaysia’s total portfolio. TNB’s core businesses comprises of generation and transmission & distribution of electricity. With a total installed generation capacity of about 12,000 MW (including SESB & Kapar Energy Ventures). In Peninsular Malaysia, TNB contributes to 55 per cent of the total capacity through six thermal stations & three major hydroelectric schemes with 21 dams in operation, in addition to managing & operating the National Grid, a comprehensive transmission network that is also interconnected to Thailand & Singapore. Dato’ Ir. Azman Bin Mohd is the Chief Operating Officer of TNB, and was the company’s voice at the prestigious keynote opening session for Power Gen. He has been with the corporation for 31 years working his way up the ranks through a variety of responsibilities, starting initially as an engineer at Mentakab in Pahang.

14 november/december 2011 power insider

PI_NovDec_Malaysia_Powergen.indd 14

20/12/2011 22:19

CONFERENCE & EXHIBITION IMPACT EXHIBITION & CONVENTION CENTRE, BANGKOK, THAILAND 3 – 5 OCTOBER 2012

A n n ive r s a r y

CO-LOCATED WITH:

TOWARDS A SECURE ENERGY FUTURE INVITATION TO EXHIBIT Celebrating its 20th Anniversary in 2012, POWER-GEN Asia has established itself as the premier conference and exhibition dedicated to the power generation and transmission and distribution industries. Attracting 7,000 delegates and attendees from over 60 countries from across South East Asia and around the world, it is the leading industry event to meet and network with senior executive and industry leaders. Thailand’s GDP is predicted to see a 5.6% growth, leading to a 6% growth in peak power demand between 2012-2016 to 35,600 MW and 44,200 MW by 2021. With current capacity of around 28,500 MW, and despite current energy imports from neighbouring countries, Thailand will see a shortfall in capacity in the next few years. To gain access to the opportunities within the power industry of Thailand and wider region, you should ensure your presence at POWER-GEN Asia 2012. We invite you to celebrate 20 years of POWER-GEN Asia with us in Bangkok, Thailand from 3-5 October 2012. For exhibition and sponsorship opportunities contact:

For information about participating at the conference contact:

Kelvin Marlow Exhibit Sales Manager T: +44 (0) 1992 656 610 C: +44 (0) 7808 587 764 F: +44 (0) 1992 656 700 E: exhibitpga@pennwell.com

Mathilde Sueur Conference Manager T: +44 (0) 1992 656 634 F: +44 (0) 1992 656 700 E: paperspga@pennwell.com

WWW.POWERGENASIA.COM OWNED AND PRODUCED BY:

0085_PGA12_A4_AD.indd PI_Powergen_Asia_Ad.indd 115

PRESENTED BY:

09/09/2011 21/12/2011 16:34 07:39

powergen malaysia

He took proceedings from Datuk Loo Took Gee and began by discussing the “global issues that have had significant impact on the operations of power generators.” Dato’ Ir. Azman Bin Mohd talked of the “incidents invoked by climate change, concern of the carbon footprint, the recent unrest across the Middle East, the Australian floods and of course the nuclear disaster in Japan.” The consequences of this ongoing chain of events was particularly apparent to TNB on paper, when their recent financial results, announced on the 22nd of July 2011, recorded a net loss of RM440.2 Million in 3rd Quarter FY2011, the main reason was put down to severe gas curtailment. It is does not make comfortable reading at corporate level for South East Asia’s biggest utility, particularly as the net profit for the FY2011 9 month period denotes a reduction of 67.9% in comparison to the corresponding period in FY2010. Dato’ Ir. Azman Bin Mohd mentioned that “the company was facing real challenges to fulfil its responsibility, and major infrastructure development was required to continue progressing with a quality service, against imposing challenges with rising fuel cost and strong environmental concern from the public.” Operational issues at plant level were also mentioned, considering the fiscal implications of Long Term Service Agreements with OEMs, being more conservative in fuel use, and looking closely at ways to improve efficiency of existing plants through turbine optimization, all can play a significant role to the overall financial performance of a power generator. Fossil Fuel supply chain Energy supply security was highlighted by Dato’ Ir. Azman Bin Mohd, although not being over

confident he agreed with Lee Took Gee stating “Resource availability differs from country to country but whether gas, coal or oil, economical use by the generator is critical in the fuels perseveration, and maintaining affordable electricity.” Gas will continue to be the main source of power in Malaysia, but in coming times, consideration of conservative use and a reduction in exports must be adhered to. The peninsular production fields are being depleted at an annual rate of 12%, meaning that for one of the first times in its history, Malaysia will become a net importer by 2020. The gas prices are currently being subsidized but under the tenth five year plan they will be phased out to all users by 2015, whereas electricity demand is expected to continue rising with a 3% increase over the next ten years. Dato’ Ir. Azman Bin Mohd talked of the knockon effect from the Fukushima incident, which must be considered in financial forecast and operational outlook, “The earthquake in Japan, and aftermath felt globally with Germany’s decision to close all nuclear plants will see an significant increase of coal fired thermal plants around the world, this will ultimately put pressure on prices from miners, resulting in inefficiency across the supply chain.” With higher generation costs already incurring in TNBs recent financial results it poses an indication of the challenges that the company will have to face in future. The dwindling gas reserves combined with disruption that the Fukushima Daiichi accident caused to the supply chain are already having repercussions in Malaysia, with an untraditional shift towards coal. A joint venture 300MW coal fired plant is planned for the picturesque region of Sabah with state owned subsidiary Sabah Electricity.

It is much needed to cope with the demand of an increasingly popular tourist destination, but there is local opposition to the proposal, and twice before in the last three years, plans were shot down by the federal Department of Environment. In addition to this, a new 1000 MW coal plant will be needed on the peninsular by 2015 to ensure adequate supply in forecast with social and economic growth. There is also expansion plans for the colossal Manjung coal fired plant. For ease of coal imports it is sited on a man-made island off the coast of Perek. Coal is forecasted to equal the generating capacity of gas in Malaysia by 2020, but plans are ongoing to construct facilities for importing LNG, to ensure the power sector does not become over reliant on coal in consideration of growing environmental concern. Correlation, backing and integration are needed with KeTTHA to ensure that a successful subsidy structure can be implemented in consideration of renewable and alternative energy. Dato’ Ir. Azman Bin Mohd looked towards Lee Took Gee and delivered to her directly when he said “Support is a necessity from the government, we need to address supply and demand to ensure the countries continued social development.” It is a valid statement and a notion that needs to be adopted with power generators and policy makers across Asia Pacific. Electricity supply will undertake multiple changes in the foreseeable future in providing reliable and affordable energy for the end user, and unity at the highest levels is critical to achieving these goals. alternative and smart energy TNB have shown positive moves and ambition in this area, through investment in renewable energy

16 november/december 2011 power insider

PI_NovDec_Malaysia_Powergen.indd 16

20/12/2011 22:20

OP16 generator sets in a multiple installation at an oil & gas field in Siberia

Robust Reliable Radial design Compact & lightweight The 2MW-class OP16 gas turbine is sophisticated in its simplicity â&#x20AC;&#x201C; a robust design for extreme reliability; featuring a unique all-radial configuration, efficient flow path and advanced metallurgy. U LT R A L O W E M I S S I O N S

H I G H T E M P E R AT U R E C L E A N E X H A U S T G A S

FLEXIBLE FUEL OPTIONS

LOW MAINTENANCE COST

HIGHEST EFFICIENCY IN CLASS

H I G H AVA I L A B I L I T Y

The OP 16 is available in single and multiple installations, suitable for continuous or standby duty. Supplied as a standard package, configured to all climatic conditions and operations. Operates well on renewable bio fuels in addition to traditional liquid & gas fuels.

Cogeneration Oil & Gas Onshore/Offshore Marine Auxiliary Power

!OPRA T U R B I N E S

G LO B A L C U S TO M E R S E R V I C E S

PI_Issue_6_OPRA_ad.indd 17

WWW.OPRATURBINES.COM

info@opraturbines.com

31 (0) 74 245 21 21 LO N G T E R M S E R V I C E AG R E E M E N T S , 2 4 - H R - O N CA L L , R E N TA L O P T I O N S

21/12/2011 22:22

powergen malaysia

projects including biomass and a solar hybrid system. TNB also added a wind turbine technology to the hybrid plant, installed in Pulau Perhentian Kecil in Terengganu. The plant harnesses the strong wind presence on the island to power two 100 kW wind turbines. Providing remote access to areas such as the Perhentian Island enables the popular tourism destination to thrive and gives consumers a reliable supply, furthering the area’s social and economical development. Malaysia has a distinctive advantage in comparison to other regions in the biomass field, as the country is a leading palm oil producer, it is cost-effective and commercially viable to use empty fruit bunches (EFB), found in abundance in oil palm mills, to produce energy. The Malaysian palm oil industry generates an estimated 140 million tonnes of biomass every year in palm oil production from more than 400 hundred mills, of which EFB comprised 20 million tonnes. If harnessed correctly the EFB can easily generate 1015% of the country’s total energy requirements in an environmentally friendly and sustainable manner. In recognition of this key resource in the countries alternative energy push, TNB recently signed a deal with Malaysia’s largest plantation operator, The Felda Global Group, to form a 60:40 joint-venture company, FTJ Bio Power Sdn Bhd. Around RM120mil will be invested to set up a plant that will generate electricity

using purely oil palm empty fruit bunches. The construction of the plant is taking place on a 4.2ha site in Jengka 9, Pahang and is expected to be fully completed in December 2012. The plant will be able to generate 12.5 MW of electricity, utilising EFB accumulated in the process of producing crude palm oil from seven of the eight mills owned by the Felda Global Group in the Jengka area. This project represents an important step in partnerships between plantations and generators, demonstrating the potential dividends available to both parties, hopefully setting a trend for others to consider opportunity here. Dato Azman Bin Mohd discussed the relevance in the introduction of a feed in tariff, by stating “it will come in to play on the 1st of December 2011, and will hopefully represent a market driver for the installation of small renewable energy projects, giving us the chance to align green agenda with the government.” There is no denying that this initiative is well overdue for the country, introduction of the feed-in tariff (FiT) to Malaysia began as early as 2004, and finally culminated in the passing of the RE and SEDA Acts 2011 in April 2011. Some say this process has taken far too long to finalize, as countries such as Thailand and Taiwan have seen great success with its implementation in multiple developments across small renewable energy projects. Although in comparison to the Philippines,

who have been delaying the launch of a Renewable Energy Act passed in 2008, it will feel like a relief for many small renewable energy developers to finally have the support required to progress with projects, and have the potential for return of investment available in a designated time period. Malaysia’s policy includes specific targets for capacity of each technology, increasing year by year. The effects of this structure can be extremely positive in easing reliance on a limited number of large scale thermal power plants to several different generation outlets, and Azman Bin Mohd stated that “it will also bring along commercial discipline to the market.” Of course it is not just a simple case of building a plant connecting it to the grid and expecting instant profit, consideration of the necessary infrastructure for grid connection is critical. Dato’ Ir. Azman pointed out that “electricity generated from renewable energy power plants, is often susceptible to intermittent supply and needs to be effectively and efficiently integrated into the national grid to provide reliable and uninterrupted electricity to consumers.” He also mentioned that “integration of renewable energy with traditional sources requires new technology, and development of a smart grid is a vital component.” Globally, at this stage the world is still pioneering Smart Grid technology and as a user, from a financial perspective, caution may be the way as far as complete installation and reliance is concerned,

18 november/december 2011 power insider

PI_NovDec_Malaysia_Powergen.indd 18

20/12/2011 22:20

due to the numerous technologies being introduced. Dato’ Ir. Azman was of a similar opinion, saying that “Once you commit to smart grid, you may find yourself in a situation where a newer and more advanced technology is introduced. Following on from that there is no one solution that fits all. For example what’s optimal in our pilot project in Bukit Bintang, may not be optimal for use in Bayan Lepas and therefore there must be much time and research put into the emerging technologies in Smart Grid, and this is where TNB Research is currently playing an active and lead role.” Dato’ Ir. Azman Bin Mohd went on to finish his address by stating “We are going to be cautious in implementing Smart Grid as it is still very expensive, compounded by the fact that the technology is still evolving and emerging and has not yet matured. The Smart Grid system is just one of several initiatives capable of reducing asset base to provide the same reliability, standard and performance. We are not pursuing Smart Grid systems for the sake of it being an intelligent solution, but more importantly because it will help us to efficiently deploy our asset base.”

most prominent technology manufacturers. He has been with MHI for over 35 years beginning with technical roles in the development of high efficiency gas turbines. He began by expressing the appreciation for overseas support shown to Japan globally, during their time of crisis in March, and mentioned that “the situation at the Fukushima Daiichi was improving.” It was reassuring to see his positive spirit, after what can only be described as times of great sorrow for the country during the past 6 months. He discussed how Asia as a continent took a very fast recovery from the global financial shock of the Lehmann Brothers collapse in September 2008, but insisted that in order to continue its development with a sustainable society it was vital for “economic growth, environmental protection and energy security.” The latter being of momentous importance, and possibly present’s the biggest challenge for the Asia in its progression, with real collective responsibility on the power generators themselves. Mr. Tsukuda also mentioned that “After the earthquake incident, the significance in the role of manufacturers becomes critical in diversifying the supply to give end users variable options.” It is a valid statement as the end user must make assessment on input fuel use in new developments based on efficiency, power output and total cost of ownership, looking at the available technology to them, and will invest accordingly, weighing up the benefits for the best possible outcome in long term operation. The diversification options are certainly advancing, and will continue to do so as we move forward, with research and development teams in corporations globally, representing some of the most innovative engineers and scientists on the planet. Mr. Tsukuda touched on MHI’s own ambition in this area, with the feasibility well underway into realization of a Japanese National Project in the development of a 1700oC-class gas turbine inlet temperature. He stated that with “ultra modern combined cycle power plants, levels of 61% efficiency have been achieved, when the 1700oC-class is ready for market between 2020 and 2030 we will be able to access levels of up to 65% efficiency.” With unconventional gas resources becoming readily available in shale and coal bed methane exploration, it will undoubtedly have a starring role to play in the future energy mix,

but we must not disregard gases counterpart and current monopoly power resource in Asia, coal. At present there is 157 GW of gas generating capacity across the continent, whereas coal represents almost five times that figure at 515 GW, with both experiencing continued shared growth in the future mix. Effort is being ploughed into the development of high efficiency gas generation technologies but R+D into high efficiency coal powered solutions is equally important. Exploring retro fit alterations for the vast thermal portfolio in operation, in addition to solutions for new builds is critical for the regions role in environmental preservation. “Coal is the globes most abundant energy resource, development across integrated gasification combined cycle and ultra supercritical power plants are a necessity in moving forward” stated Mr. Tsukuda, a statement that was echoed around the exhibition floor with visitors and exhibitors alike. That is not too exclude the role that renewable energy has to play in the future, there are some world changing technologies and concepts available at a relatively youthful stage. Mr Tsukuda highlighted the potential, “Geothermal is an inexhaustible resource with high availability regardless of the weather.” For every negative, there is a positive and the jumble of tectonic plates underneath Indonesia, Philippines and Japan present highly active areas for earthquakes but also a wealth of access to geothermal power, enough to completely dismiss nuclear power. Mr. Tsukuda talked of the most the common renewable energies “Wind is the most widely used alternative energy and offshore turbines are being developed to produce between 7-11MW, solar PV has seen unprecedented growth with preferential government policies, and utilizing biomass in pellet format to co-fire with coal has seen huge success in Europe, why not exploit it here, where we have access to such a wealth of feedstock.” Education, development, support and integration is key to the success in implementation for all these available technologies in power generation, what remains clear, is that to ensure Asia’s energy security, economic growth and environmental protection they all have a significant role to play. asean grid The ASEAN grid has been a topic of much discussion

Manufacturing the future Mitsubishi Heavy Industries Senior Executive Vice President, Mr. Yoshiaki Tsukuda was the final heavyweight to take the Penwell opening keynote stage, representing a perspective of one of the region’s power insider november/december 2011 19

PI_NovDec_Malaysia_Powergen.indd 19

20/12/2011 22:20

powergen malaysia in recent years as it appears in the recent months that things are starting to take speed. Heads of ASEAN Power Utilities and Authorities (HAPUA) are continuing to identify, monitor and pursue bilateral and cross-border interconnections that will later develop and form part of the regional grid. Members of The HAPUA Brunei Darussalam

Department of Electrical Services, Ministry of Development

Cambodia

Electricité du Cambodge

Indonesia

PT PLN (Persero)

Laos

Electricité du Laos

Malaysia

Tenaga Nasional Berhad

Myanmar

Department of Electric Power

Philippines

National Power Corporation

Singapore

Singapore Power Ltd

Thailand

Electricity Generating Authority of Thailand

Vietnam

Electricity of Vietnam

“It is true there has been new interest and improvement in the development of an interconnecting ASEAN super grid.” said Yoshiaki Tsukuda, “There are more than 40 transmission links which need to be built, and Mitsubishi Heavy Industries are part of a consortium conformed to build the necessary infrastructure across areas where countries are not in a position to build the link, there are some bi-lateral links connected, but the next step is multi-lateral between Malaysia, Singapore and Indonesia.” Datuk Loo Took Gee also spoke of a recent meeting in Bandar Seri Begawan, Brunei, between participating governments to discuss the status of the ASEAN power grid, she indicated that plans are very much in place to move things forward. Although there are still stumbling blocks ahead with development of a framework for the ASEAN electricity industry and harmonization of cross-border commercial, financial, regulatory legal frameworks & technical standards. The tnext meeting will look to cover these issues in addition to studies related to taxation and the conflicting tariff systems, but also the regulation on the private participation in the APG project, which inevitably will be a noteworthy factor in the success of the initiative. There is no denying that the grids implementation will be hugely important in Asia Pacific’s continued social and economical development, but the countries involved have such differing policies and standards on energy, the timeframe for completion will undoubtedly be extensive. CritiCal issues panel disCussion To round up PowerGen Kuala Lumpur’s opening ceremony, Mr. Sri Jegarajah CNBC’s energy correspondent in Asia Pacific took the role of moderator to quiz the keynote speakers in a roundtable format as to the critical issues facing the future of Malaysia’s power sector. Sri Jegarajah was very frank in his approach,

Asia Pacific Connection

Revised Earliest COD

1) Peninsular Malaysia - Singapore (New)

2018

2) Thailand - P.Malaysia • Sadao - Bukit Keteri • Khlong Ngae - Gurun • Su Ngai Kolok - Rantau Panjang • Khlong Ngae – Gurun

Existing Existing (Newly Proposed) (additional) 2016

3) Sarawak – Peninsular Malaysia

2015-2021

4) Peninsular Malaysia - Sumatra

2017

5) Batam - Singapore

2015-2017

6) Sarawak - West Kalimantan

2015

7) Philippines - Sabah

2020

8) Sarawak - Sabah – Brunei • Sarawak –Sabah • Sabah – Brunei • Sarawak – Brunei

2020 Not Selected 2012-2016

9) Thailand - Lao PDR • Roi Et 2 - Nam Theun 2 • Sakon Nakhon 2 – Thakhek – Then Hinboun • Mae Moh 3 - Nan - Hong Sa • Udon Thani 3- Nabong (converted to 500KV) • Ubon Ratchathani 3 – Pakse – Xe Pian Xe Namnoy • Khon Kaen 4 – Loei 2 – Xayaburi • Thailand – Lao PDR (New)

Existing (Exp.) 2012 2015 2017 2018 2019 2015-2023

10) Lao PDR - Vietnam

2011-2016

11) Thailand - Myanmar

2016-2025

12) Vietnam - Cambodia

(New) 2016

13) Lao PDR - Cambodia

2011 (New) 2015-2017

15) East Sabah - East Kalimantan

Newly Proposed

16) Singapore – Sumatra

2020

20 november/december 2011 power insider

PI_NovDec_Malaysia_Powergen.indd 20

20/12/2011 22:20

putting forward the questions that the packed out auditorium, were desperate to understand from the people who matter and can make a difference. He wasted no time in asking Yoshiaki Tsukuda about the future of nuclear power in Asia. Mitsubishi’s senior executive did not remain coy in response and made known that there is a temporary moratorium on further nuclear power in Japan, but not completely ruling out the energy source, he also said that manufacturers and government will be working a lot closer in coming years when it comes to research, development and implementation, to make the plants safer, learning from mistakes in the past. Mr. Tsukuda insisted that nuclear power would be part of the future energy mix, but said there was time needed to discuss and evaluate the role it would play, by producing technology and solutions strong enough to ease the worries of public opposition. Sri Jegarajah also posed this question to Datuk Loo Took Gee of KeTTHA, in relation to the government’s stance on nuclear power, probing the potential for a first nuclear plant in Malaysia. The secretary general stated that during 2021, they would be exploring the possibility of introducing nuclear power in Malaysia. She explained that the volatile and rising price of oil has forced them to investigate an alternative base load source, and nuclear in relation to the amount of power generated versus the cost of fuel input would be attractive. “How much of an effect will the aftermath of Fukushima have on plans to introduce nuclear in Malaysia?” Sri put forward to the panel, Loo Took Gee replied that it would undoubtedly be significant, but insisted that they have a role in government to educate the general public as to the safety measures being taken and technology available to ensure the absolute minimal risk in accident. Loo Took Gee also mentioned that the main challenge would be to engage public opinion accordingly through debates and thought sharing. She said that increased interchange from all concerned would be the only way for successful nuclear development, communicating the benefits in reduction of CO2 and most importantly from a consumer’s perspective, the positive impact it would

have on electricity pricing. To reiterate the timeframe involved, Loo Took Gee stated that realistically it could be longer than 10 years before the relevant treaties and Nuclear Co-operation Agreements are signed to allow the country to even purchase the necessary equipment. Sri Jegarajah quizzed Tenaga’s Dato’ Ir. Azman Bin Mohd on the generators plans to integrate renewable energy into their suite. The Chief Operating Officer replied that LNG would represent an important transition fuel in working towards a strong renewable portfolio, but they were also avidly working on IGCC technology, as coal could not be discarded. Sri understandably put across the concerns felt by many in the environmental issues associated with coal, asking about carbon capture and storage potential. Dato’ Ir. Azman Bin Mohd laid the facts bare about the somewhat controversial technology, stating “that although at the outset it’s seems attractive, there are many complications in how to manage the squeezed carbon dioxide.” He also stated that other components are needed to make it work successfully with the implementation of policy and framework. In Asia itself there are currently no CCS facilities, Australia has the Otway Project in Victoria and Chevron’s Gorgon LNG plant is adopting a similar concept. Under these types of geo-sequestration, CO2 from power plants is compressed into a liquid and pumped underground. Rock formations have been described as giant sponges that will soak up the CO2, with hope that the dense fluid will remain locked away indefinitely. These projects will be under much scrutiny, as Asia watches and waits to see their success for their own developments. The exhibiTion Floor Following the issues addressed in the keynote, the exhibition floor opened to its biggest audience yet. Spread across two large halls, it comprised of a fantastic blend in the most advanced technologies and concepts, across gas turbines, reciprocating engines, HRSG, cooling towers, service and repair, full EPC service providers and many other components suppliers. Noteworthy booths included conglomerate solution providers GE, Doosan, Pratt & Whitney,

Howden, MWM and of course the Dutch Pavilion all providing very warm cocktail receptions and highly insightful customer interactions in relation to the technology on display. GE used the event to launch the new Flexaero LM 6000 PH gas turbine, their newest product in the FlexEfficiency portfolio , continuing their creation of advanced technologies. DP CleanTech, the regions leader in biomass power plants presented their capabilities with differing feed stocks, demonstrating their impressive footprint in the region, a notion of importance in correlation with the biomass developments that South East Asia is forecasted to see in coming years. The curtains to Penwell’s three day gathering came to a close as Nigel Blackaby presented the best paper awards. The continuing and significant role that coal has to play in the region is seeing a sharp rise in demand for ultra advanced, environmental friendly combustion and emission solutions, in consideration of this, decorations were handed to Kevin McCauley of The Babcock and Wilcox Power Generation Group and Dean Huff of Burns & McDonnell. Kevin’s ‘Advancements in Commercialscale OxyCoal Combustion for Carbon Capture Power Generation’ paper was selected as the winner in the conference’s Environmental Challenges and Fuel Options track and Dean’s ‘Supercritical and Ultra-Supercritical Boilers-How High is Too High’ was also presented with an award. In recognition of the renewable aspect Poyry’s Akarin Suwannarat took the prize for his study on ‘Wind Power Development in Thailand.’ POWER GEN Asia proved again to be the benchmark for energy exhibitions in the continent. The access to technical and political knowledge sharing combined with the otherwise inaccessible executive networking, was second to none, enabling the show to once again live up to its billing. Next year will see the premier event find itself in the heart of Thailand, residing at the Impact Exhibition and Convention Centre in Bangkok between the 3rd and 5th of October 2012, a date on the power industries calendar, that is surely not to be missed. power insider november/december 2011 21

PI_NovDec_Malaysia_Powergen.indd 21

20/12/2011 22:21

INDONESIA LNG

INDONESIA’S FOOT ON THE GAS? BY CHARLIE FOX

INDONESIA IS NOW THE 3RD FASTEST GROWING ECONOMY AMONGST THE WORLD’S WEALTHY INDUSTRIAL COUNTRIES AND MAJOR EMERGING MARKETS (G20). A US INVESTMENT BANK SAID THE BRIC ECONOMIES (BRAZIL, RUSSIA, INDIA AND CHINA), WHICH HAD BEEN FUELLING GLOBAL GROWTH FOR SEVERAL YEARS SHOULD NOW INCLUDE INDONESIA.

22 NOVEMBER/DECEMBER 2011 POWER INSIDER

PI_NovDec_Indonesia.indd 22

20/12/2011 22:27

nother securities house has ingeniously invented the term “Chindonesia”. China, India and Indonesia, as Asia’s economic bulwarks. The Jakarta stock exchange index, in US dollar terms, has risen by around 95% making the bourse the world’s second-best and Asia’s best performer. Indonesia’s GDP growth is expected to reach 5% in 2010, 6% in 2011 and potentially 7% in 2012. As the end of oil looms, there is global recognition that cleaner and renewable energies will inevitably power the future. With the largest natural gas reserves in the Asia Pacific, what will it take to get Indonesia’s gas above ground? Oil prices skyrocketed to more than $100 a barrel with the political unrest in Libya and the Middle East. The reign of Gaddafi and oil, the uprisings highlight, is undeniably petering out. Consumption of oil is rising so fast that oil companies must discover a new billion-barrel oil field every two weeks. While lifestyles have not shifted drastically in response to dwindling resources there is growing recognition that reserves are finite. Indonesia is a case in point – the former OPEC member is now a net importer of oil. Demand is outstripping supply by 7% on average across the archipelago. THE HOME FRONT For many outside of the capital city, rolling blackouts are a weekly if not daily occurrence. Signifying the strain, state-owned electricity company PT PLN has since March offered cheap tariffs from 11 pm to 7 am in attempt to curb demand and encourage businesses to shift their operating schedules into the wee hours. It’s an innovative short-term fix, but hardly offers a comprehensive solution. At the same time, President Susilo Bambang

Yudhoyono has pledged to cut carbon emissions by 26% by 2020 and the Energy and Mineral Resources Ministry is espousing a “paradigm shift” in energy consumption. The ministry recently offered incentives on renewable energy, but a mere 5% of the country’s energy is currently drawn from renewable sources such as hydro and solar. “Realistically it is going to take a long time for renewable energies to become a large chunk of the energy mix globally, mostly because they are starting from such a low baseline. Natural gas is very attractive for that reason,” says Mark Thurber, an associate director of Stanford University’s energy and sustainable development program. Gas has come a long way from the days it was burnt off at oil fields as an unwanted byproduct. Experts are hailing the substance as a potential bridge to renewables and are quick to advertise the fact it emits 50% less carbon emissions than oil and coal. “If we look at the demand and trends, natural gas is now entering its golden period,” Fatih Birol, a chief economist at the International Energy Agency told a gas conference in Jakarta in mid-February. Its green credentials - excluding a recent damning report on an LNG plant in Pennsylvania -coupled with the decline in oil and its apparent ubiquity, are making natural gas the obvious alternative. “The supply picture of gas has changed dramatically over the past five years. Some people are saying that gas is more or less unlimited. There are differing opinions on this, but unconventional gas opens a lot more potential. It’s a really appealing field of fuel,” explains Thurber, referring to new technologies that allow tiny particles of gas to be blasted from shale.

POWER INSIDER NOVEMBER/DECEMBER 2011 23

PI_NovDec_Indonesia.indd 23

20/12/2011 22:28

INDONESIA LNG

The conundrum Only one-third of natural gas basins have been explored in Indonesia and these alone give it the biggest reserves in the Asia Pacific – at least on paper. The problem is that extracting natural gas is a costly and infrastructure-intensive process. “We enjoy telling people we have 350 trillion cubic feet (tcf ) of gas, but now we have to face the reality: Where is it?” says Satya Yudha, a lawmaker from Commission VII, which oversees energy affairs. “Indonesia is dependent on fossil fuels, but we don’t have the infrastructure to support our reserves. We are living on these reserves, but in energy terms we are starving,” he says. Unlike oil, you can’t just turn up with a tanker, load up and drive away. Transporting gas requires expensive pipelines or LNG plants that liquefy the gas so it can be exported by sea. Again, LNG plants are needed on the receiving end so the liquid can be turned back into gas. In short, natural gas equals billions of dollars in long-term investment and it’s unclear how the government and the industry will reconcile the conundrum.

“The challenge for Indonesia, and every gasproducing country, is encouraging businesses to invest in gas by building infrastructure and expanding supply, while at the same time ensuring the domestic market also benefits,” says Stanford’s Thurber. While eastern Indonesia in particular has been identified as a frontier for deep-water activities, the government is struggling to balance its domestic commitments and lure investment in the sector. Article 33 of Indonesia’s Constitution requires the state to ‘control’ important branches of production and natural resources. As an indication of the hurdle that this represents, a parliamentary revision of the 2001 law on oil and natural gas permitting the liberalization of the gas market was rejected by the Constitutional Court in mid-2007 on the basis that it contradicted the clause. “We want to promote investment in the region, but when investors have explored those areas they often don’t come up with prices that will sell domestically. Companies will exploit if they can get $10 per mmbtu (one thousand British thermal units), but they won’t,” says Satya.

Creating a pricing scheme that is viable to both developers and the public is the only way huge resources in eastern Indonesia can be monetized, he argues, adding that fuel subsidies have sheltered the public for too long and made everyone unreceptive to realistic pricing. The majority of the country’s gas is currently drilled offshore Bontang in East Kalimantan and from the Arun field in Aceh, which shipped its first LNG in 1978 but is estimated to have reserves adequate for only three more years. More recently the Tangguh field in Papua has come on stream to provide a third source. It is likely there are five or six more gas fields the same size as these, says Kurtubi, an economist at the University of Indonesia. “But because investment is so low don’t expect too much unless the government changes the system,” he says. The business view The lack of infrastructure is not the only problem in the oil and gas industry. Oil and gas exploration is beleaguered by inefficiency; burdensome bureaucracy and vested interests, to the point that some industry

24 november/december 2011 power insider

PI_NovDec_Indonesia.indd 24

20/12/2011 22:29

sources say things were better when Suharto was around. The introduction of the cabotage principle, by which domestic shipping would have to carry domestic cargoes, was seen as representing a major threat to the industry, with most vessels used in the oil and gas offshore business coming from overseas. The energy ministry in the end managed to have the industry excluded, but not before a degree of panic. “In order to attract that level of investment for natural gas, stability is required whereby terms are understood, agreed upfront and consistently applied throughout the life of an investment,” says Terry S. McPhail, president and general manager of ExxonMobil Affiliates in Indonesia. “It is important that such policies not be driven by shortterm politics but by the long-term energy needs of the country. In order to commit funds, a predictable environment is needed to assure the expected return. Unexpected changes in the regulatory environment raise questions, create uncertainty and work against investor confidence,” he says. Capitalizing on Indonesia’s huge natural gas deposits will require progress on these issues if the country is to become part of a dynamic gas market within the region. ExxonMobil Indonesia estimates that during the next 25 years the energy demand in Asia Pacific will grow by 65%. China’s doubling gas consumption and a proposed trans-ASEAN gas pipeline alone point to the potential. Kurtubi, who holds a PhD in mineral resources from an American university and is widely recognized as an expert in the field, argues that gas regulator BP Migas should be abolished altogether to make the sector more friendly to foreign investors. “The government should negotiate with investors in order to reach a win-win situation where, for example, 50% of natural gas can be exported and the rest is dedicated for domestic use,” he says. A 2004 contract signed with China, where gas is sold for 3.5 mmbtu on a flat rate for the next 25 years, is a national disservice, he says. “The pricing formula must be linked to crude oil. Right now the price of gas being sold from Kalimantan is 15 mmbtu, five times more than the China deal. That is a good price. If that is the case we are happy to export our gas, we don’t want the Chinese case to happen again,” he says. Some new resources are coming on stream, but not without a struggle. At the Cepu Block in Central Java, ExxonMobil and Pertamina each hold a 45% participating interest and four local government entities hold the remaining 10%. The partners are currently working to establish a plan to develop the Cepu gas fields to supply gas to the domestic Java market, explains McPhail. While he admits that every market has its own unique challenges, he says these solutions do not come pre-assembled. “They require effort and cooperation among governments, suppliers and consumers to develop each individual market solution,” he says, noting that regardless of the challenges, natural gas will be a leading source of energy in the future. “Natural gas has proven its ability to evolve over time to meet the needs of global markets, including Asia, and it will continue to do so as we move into the future,” he states.

industry right now, may have even greater potential than natural gas. CBM is a form of natural gas, or methane that is extracted from coal beds. In recent decades CBM has become widely used in countries such as Australia, Canada and the US. In America CBM accounts for around 10% of natural gas production, but Asia’s methane reserves remain largely untapped. Logistics and extraction costs, the same factors that impede the exploitation of natural gas, also apply to CBM. China has an estimated 30 trillion cubic feet of CBM, about three times the reserves in the US, while preliminary studies show Indonesia has at least 450 trillion cubic feet. The prospects have major oil companies hot on the trail. “Indonesia offers a couple of non-conventional resources that could have a significant impact,” says ExxonMobil Indonesia’s Terry S. McPhail. “Coal bed methane (CBM) represents one of those resources. Government estimates are that Indonesia’s CBM gas potential is far greater than the potential of natural gas. Therefore, it is definitely worth further investigation to explore and develop,” he says, adding the industry is working with the government to determine the best way to optimize the resource. On the old problem of demand and supply, McPhail

says all options need to be assessed. “We are going to need everything we can to throw into the energy supply mix, whether it is fossil fuels, non-renewables or renewables.” The Government is also committed to maximizing the country’s considerable renewable energy resources, providing unique opportunities for international suppliers of the latest sustainable technology. New power plants to be built will be ones generating green energy such as geothermal and hydropower plus gas fired plants. The country has capacity in hydropower of 64,000MW but is currently utilizing only 5,000MW and has 45% of the world’s geothermal energy resources. Renewable Energy Indonesia 2011 will provide direct access to the leading executives, from both the public and private sector, responsible for Indonesia’s sustainable development program including; geothermal, hydro, natural gas, bio-fuels, solar and wind. indonesia’s energy reliance • oil: 48.8% • gas: 22.2% • geothermal: 1.5% • hydro: 2.9% • coal: 23.5%

Methane bounty Coal-Bed Methane or CBM, a buzz word in the power insider november/december 2011 25

PI_NovDec_Indonesia.indd 25

20/12/2011 22:29

ASIA AERODERIVATIVE

GE ENERGY’S OVERVIEW OF ASIA’S AERODERIVATIVE BUSINESS David Teng - GM Aeroderivatives, GE Energy Asia Pacific

David, welcome to the Indonesia and Malaysia focused edition for Pi Magazine Asia. Q: Can you provide us with a brief outline of GE Energy’s and the Aeroderivativebusiness for the continent? A: GE Energy has more than 100,000 employees in over 100 countries and a diverse portfolio of product and service solutions in all areas of the energy industry including coal, oil, natural gas, and nuclear energy; renewable resources such as water, wind, solar, and biogas, as well grid modernization and energy management technologies. GE Energy has been in this continent since the 1900s, supplying Philippines and Japan with some of the countries’ first generators and steam turbines. For our Aeroderivative business, we have a fleet of over 300 units in the Asia Pacific region.

Q: In what ways are the power industry and specifically the gas turbine market changing? A: Distributed energy – the ability to provide grid-independent power in areas with limited infrastructure – is playing an increasingly important role in the current energy landscape and especially in the ASEAN region where governments are targeting to increase electrification rates in the rural areas. There is also an increased availability and steady price drive interest in natural gas as a cleaner alternative for power generation. Along with the increasing demand for natural gas, our customers continue to demand the most efficient, rapid and flexible gas turbines to run on their local resources. GE continues to commit to technology innovation in this space, and today we represent nearly half of the entire land-based gas turbine market.

26 NOVEMBER/DECEMBER 2011 POWER INSIDER

PI_NovDec_GE.indd 26

20/12/2011 22:34

resource pressures especially for water, metals, and rare earth—materials which are needed for power generation. GE plays a pivotal role in helping industries overcome these economic and resource constraints with new technology such as integrating gas with renewables, increasing energy efficiency with smarter systems to bring cost of electricity down and accessing & delivering new fuel sources for fuel diversity.

Q: Economic strain is being felt by many power generators at present with western nations in turmoil, What role do you have as a technology provider to ensure the power industries continued development? A: Globally, electricity demand is projected to grow by 85% and in developing countries such as Indonesia, its electricity demand is expected to grow by more than 9 percent a year for the next several years. Vietnam is forecasting a 7.5% to 8% annual economic growth over the next five years and a healthy power infrastructure is vital to supporting that growth. So despite the fact that the economic strain would have some impact on financing of power generation projects, portfolio investments in energystill need to be made to meet thegrowing energy demand in this region. Apart from economic strain, the world faces

Q: The term ‘operational flexibility’ is commonly used across the industry, what does it mean to yourselves at GE? A: At GE, flexibility refers to a turbine’s ability to quickly ramp power up and down to meet varying grid supply or demand. This will help to reduce the plant’s annual operating cost.Operational flexibility also mean means that turbines can start quickly, minimizing fuel burn and emissions while capturing advantageous electricity pricing opportunities; hence improving plant revenue. In addition, the ability to turn power down to low levels while maintaining emissions guarantees and minimizing fuel burn such as during overnight periods would mean lower consumption of fuel needs and better cost savings for the plant.

Q: Indonesia represents a challenging market, with such a sporadic grid and gas infrastructure, what can be done to increase the electrification percentage? A: Today, approximately 70 million Indonesians are without electricity. To close this gap, the Indonesian government has plans to connect an additional 1.3 million households per year to the grid, through the year 2025.There are many ways to increase the electrification percentage, one of which would be to look at distributed energy solutions. They are relatively small scale and can utilize not only natural gas, but coal bed methane and farming &landfill waste as fuel. One small gas engine can help power up a remote village in Indonesia and even in cities where captive power is in demand. One such site that’s using GE’s Jenbacher engines is the Plaza Indonesia complex in Jakarta. Another way would be looking at the development ofrenewable energy (RE) and using alternative fuels apart from natural gas. In fact, Indonesia possesses 40% of the world’s geothermal reserves and a high amount of untapped Coal Bed Methane (CBM) reserves. However, for these resources to be tapped into and utilizedthere needs to be a clearer development roadmapand financing plans.

Q: The newest member of the Flexaero range, was unveiled at POWER-GEN Asia, what makes the LM 6000 PH model different to other products on the market? A: The FlexAero offers an unprecedented combination of flexible and efficient technology that can be installed in less than 70 days once delivered on site. It also operates without the need for water, which helps relieve the stress on Asia’s water resources. It is the most efficient, most flexible and most reliable Aeroderivative gas turbine available. It starts in five minutes, runs without water (DLE [Dry Low Emission] Technology) and operates with industryleading efficiency. This combination of unprecedented speed, flexibility and efficiency enables local businesses and communities to utilize natural gas supplies, creating grid-independent power while reducing emissions and water waste.

Q: The industrial sector is a critical segment for the country, dependant on continuous power. How do you cater for their need to achieve security in supply? A: Power needs for Indonesia’s industrial sector is expected to grow 5 to 6 percent in 2011 and GE Energy has advanced technologies that can help ensure a stable and continuous supply of power. GE Energy has provided our 9E gas turbine to Independent power producer PT CikarangListrindoin Indonesia, adding 114 megawatts of power for Cikarang’s power plant. The power plant helps to meet the power needs of Indonesia’s industrial sector by supplying nearly 700 megawatts of electricity to the national grid and a wide range of companies in five industrial estates. GE’s Jenbacher Gas Engines is also ensuring uninterrupted electric power for an industrial park on Indonesia’s Batam Island which has tenants POWER INSIDER NOVEMBER/DECEMBER 2011 27

PI_NovDec_GE.indd 27

20/12/2011 22:34

asia aeroderivative

from the paper, electronic manufacturing and textile industries.The Jenbacher engine will operate on a 24 hour basis to supply electricity to the estate and the local grid. In case of failure of the grid, it switches automatically to Island mode operation and by doing so it guarantees an uninterrupted power supply to the industry at the estate. Q: Coal is the predominant source of power for Indonesia, with such vast availability, reducing its use, cutting CO2 and increasing the gas portfolio is no easy task, what is required to do this?

A: While it is true that Indonesia has an abundant supply of coal, relying heavily on a single and finite energy source would not be sustainable in the long term. The Indonesian government has outlined plans to develop Indonesia in terms of its energy sustainability- developing renewable, clean energy and energy efficiency in Indonesia. A goal was set to increase renewable energy’s share of the country’s energy mix to 17% by 2025, compared to today’s 3.4%. But as mentioned previously, clearer development roadmap and financing plans have to be present.

Q: What are the recent achievements for the Flexaero range in Indonesia? A: Based on previous LM6000 models, the FlexAero is an engineering innovation based on proven technology. The LM6000 has a product heritage of over 1,000 units shipped, +21 million operating hours and over 99% reliability. In Indonesia, we have recently announced the sale of two 41-megawatt LM6000-PG aeroderivative units to PT KartanegaraEnergi Perkasa (KEP), owner of the Senipah Power Plant, located 70 kilometers from Balikpapan, East Kalimantan. This will be the first installation of the technology in Asia and the second in the world, following a project at Turlock, Calif., which recently was commissioned. Q: Malaysia is currently adopting strong green policy, what are your thoughts on the marketplace? A: The Malaysian Government’s decision to focus on encouraging the growth of renewables(RE) in Malaysia is timely given its push to transform the nation into a high income nation by 2020 and the fact that the focus on renewable energy is gaining ground in ASEAN as a whole. Malaysia is currently pushing for a renewables target of 4GW by 2030. The feed-in tariff mechanism in particular has proven extremely successful in other countries like Germany for example, where it has accelerated RE

28 november/december 2011 power insider

PI_NovDec_GE.indd 28

20/12/2011 22:35

Fast-track EmErgEncy PowEr

Delivering Customized Turnkey Solutions

EngInEErIng

LogIstIcs

InstaLLatIon

oPEratIons

Over 400 MW throughout Asia Malaysia Indonesia Philippines Sri Lanka Pakistan Japan India

PI_Issue_6_APR_ad.indd 28

In emergency situations that cause power plant or transmission line outages, fast-track temporary power generation is often required to support the electrical system and avoid costly outages. Rapid mobilization of equipment and resources is crucial to guarantee that businesses, industries, and households receive a consistent supply of electricity. APR Energy offers an immediate solution to our customers by providing customized fast-track power generation solutions utilizing a variety of technologies and comprehensive services. APR Energyâ&#x20AC;&#x2122;s power generation technologies are all based on rapidly deployable modular designs and are engineered for fast-track installation. All components of the mobilization, installation, operation, and maintenance services are provided by APR Energy to ensure our customers receive a reliable and efficient supply of power.

21/12/2011 07:59

asia aeroderivative

jobs in the economy. We have found that for RE initiatives to succeed there needs to be long-term policies that match the lifecycle of the investment to drive the growth of renewable power generation. While there has been delay and reduction in FiT (Feed-in-tariff), the current steps taken by the Malaysian Government has gained traction and allowed some biogas, biomass and hydropower projects to take off. GE believes that significant opportunities exist for the growth of power generation from solar power and biomass in Malaysia in the near future. Q: What are the most significant projects you have been involved in for this particular country? A: In Malaysia, GE Energy provided the first gas turbine and compressor technologies for Malaysia LNG Dua in the early 1980s. Malaysia LNG Tiga was the first LNG Plant in the world to install and operate GE 7EA Heavy Duty Gas Turbine technology which drove main refrigerant compressors. Now, GEâ&#x20AC;&#x2122;s technology is well established there with more than 100 gas turbines installed in the country, including our aeroderivatives gas turbines and our steam and hydro turbines

to generate 33 percent of their energy by 2020. Q: What exciting new technologies can we expect to see from GE Energy in the future? A: GE has 4 global research and developments centres worldwide with a U.S $5.7B technology spend so far and 700+ renewable energy patents filed since 2002. Recently, full-size, thin film solar panel developed by GE has been independently certified as the most efficient ever publicly reported with the highest-ever reported efficiency of nearly 13% on a full-size CdTe (Cadmium telluride) thin film solar panel. Apart from FlexAero, we have also just launched the FlexEfficiency 50 Combined Cycle Power Plant, designed for world leading baseload efficiency and to bring more renewables onto the grid. At the center of the FlexEfficiency 50 plant is the 9FB Gas Turbine which, in combined cycle configuration will generate 500+ MW of cleaner, efficient energy. Each year GE invests billions of dollars to

drive and promote the adoption of clean energy technology and we will continue to do that so that our customers can enjoy better savings and efficiency for their projects. Q:What is your opinion on Asiaâ&#x20AC;&#x2122;s energy outlook for 2030? How do you envisage the industries development? A: Energy demand is projected to grow three to four folds in China and India between now to 2030. Industrial growth will be strong in ASEAN, particularly in mining and petrochemical industries. Fossil power generation is going to be strong in Asia Pacific as we see >60GW of fossil plant addition in the region over the next 10 years. Gas power generation may also increase with increased gas availability through unconventional gas such as coal bed methane in Indonesia and shale gas in China. It is also supported by an increase in environmental concerns and local protests against fossil fuel plants.

Q: Renewable technologies are gaining pace globally, how are GE Aeroderivatives accommodating for the increasingly important role they have to play? A: The biggest challenge for wind and solar power is that it is intermittent and variable, meaning that power is only generated when the wind blows or the sun shines. Flexible technology like the FlexAero can be turned on and off as energy is needed, enabling customers to reliably meet energy demand regardless of weather conditions. One recent project that we are excited about is at the EME Walnut Creek. GE supplied five LMS100 aeroderivative units to Edison Mission Energy for the 500-megawatt Walnut Creek project in Southern California. These are among 19 LMS100 machines that GE will ship for projects in Southern California between now and the end of 2012. The new projects will total nearly two gigawatts of highly flexible power generation to integrate renewables and provide grid reliability, helping Southern California Edison and the Los Angeles Department of Water and Power achieve their goals 30 november/december 2011 power insider

PI_NovDec_GE.indd 30

20/12/2011 22:37

Thereâ&#x20AC;&#x2122;s a new force making waves

in the offshore renewable industry. CTC Marine Projects brings 20 years of expertise in submarine power cable installation to the Offshore Renewable sector. With an owned vessel fleet and the world's largest suite of high technology marine trenching vehicles, it has the versatility to deliver innovative 'right first time' solutions for subsea cable installation and burial.

+65 6329 9642

PI_Issue_6_CTC_Marine_ad.indd 31

commercial@ctcmarine.com

www.ctcmarine.com

21/12/2011 08:02

BWE BIOMASS

TODAY’S TECHNOLOGY CAN SOLVE POLITICAL CHALLENGE HOW TO DIMINISH THE RISK OF INSTABILITY AND ENSURE TOTAL FLEXIBILITY IN ASIA’S ENERGY-SUPPLY

e live in a world, where the needs of taking global political and economical decisions are more vulnerable than ever before. Each market has very different demands according to different market interests. Therefore, the major challenge for today’s governments and utility owners is, how to make the right choices from the palette of energy production in order to ensure energy-supply, and how to reduce carbon emissions so as to meet global targets. Energy security relates to economical security in the context of energy decision making, and if the demand only relies on a short-term power-investment strategy, then the risk of sudden price fluctuations and instability in power-supply for a variety of economical and other reasons - is imminent and threatening. Their concern is understandable, but neither it is fully logical or necessary. MULTI-FUEL HYBRID TECHNOLOGY There is already a successful high-tech solution in use, which can be adopted right away in Indonesia, Malaysia or any other part of the world. That is, what the Danish International high-technology company, Burmeister & Wain Energy A/S (BWE) has been doing for the last two decades and who has become a leading expert in today’s field of power business. BWE is applying hybrid multi-fuel technology when designing steam boilers in both existing and newly built power plants across the world. These hybrid boilers are capable of burning both fossil and biomass fuels individually and simultaneously. This technology gives utility owners 100% effectiveness in availability, total flexibility, the opportunity of constantly taking advantage of

fuel-utilization and stability in the energy-supply regardless of any political or economical changes occurring in the future. HIGHEST EFFICIENCY BWE has developed and specialized in design of Ultra Super Critical (USC) steam boilers for large utility power stations. A technology, that is the most advanced and efficient technology available on the market with a proven plant net-efficiency of above 47 %. In addition, with co-combustion of biomass into coal fired boilers, BWE is able to provide high efficiency boilers for biomass combustion as one of the world’s only suppliers. The challenge of designing a high efficient large scale boiler capable of operating with biomass from 0% to 100% is a task, that BWE has proven to master to perfection. BIOMASS CONVERSION WITH PROVEN TECHNOLOGY AND OPERATIONAL FLEXIBILITY The history of BWE in the field of biomass boilers has its origins as early as in the second half of the 19th century, when B&W supplied its first biomass fired boilers – in those days mainly in the form of bagasse fired units to the sugar mills in the former Danish West Indies: St. Thomas, St. John & St. Croix (today’s Virgin Islands). The last 20 years the Danish energy sector has undergone a dedicated biomass utilization process, combined with cleancoal technology. BWE has contributed to this development with technologies for Pulverized Fuel (PF) and grate firing. Today BWE supplies combustions systems as well as tailor made steam generators for both

untreated biomass in the form of bales or chips (grate firing) as well as pre-treated biomass in the form of pellets (for PF firing). Both methods are characterized by fuel interchangeability, pollution control, low auxiliary power consumption and extremely low maintenance cost. PF and grate firing can be applied separately or combined, both for new plants and retrofits of existing boilers as well. MAJOR PLAYER AND LEADING POSITION BWE has been one of the major players in the Danish power production industry, developing unique technologies in cooperation with Danish utility companies, particularly focusing on highly efficient coal and biomass combustion and co-combustion. Brilliant examples of these technologies are shown in Avedøre power plant (DONG) and Amager power plant (Vattenfall). The example of Nordjylland power plant with the world record in efficiency gives Danish technology a leading position in the world boiler market. BWE’s aim is to guide politicians and utility owner’s making the right long-term decisions in the question of energy-investment. With a “clean” long-term strategy of investing in hybrid multi-fuel boilers for power plants, Asia could take a great step towards not only securing the energy supply in the region’s increasing energy demand, but also protect the global environment and reach the region’s future carbon-emission targets. BWE is ready to be a part of Asia’s economic growth. GRATE FIRING The BWE water cooled vibration grate offers a very reliable technology for combustion of biomass in

32 NOVEMBER/DECEMBER 2011 POWER INSIDER

PI_NovDec_BWE_Rev2.indd 32

20/12/2011 22:42

AvedĂ¸re Unit 2 (2002), the largest biomass fired power plant in the world, incorporating a BWE once through, Benson, tangentially fired Ultra Super Critical (USC) boiler. The picture is owned by DONG Energy.

POWER INSIDER NOVEMBER/DECEMBER 2011 33

PI_NovDec_BWE_Rev2.indd 33

20/12/2011 22:42

BWE BIOMASS

a less refined form – this could be wood chips, straw, palm kernel shells and other agricultural by-products. BWE has experience of developing vibration grates and the related fuel handling systems and boiler design since the middle of the 1980’s. Today the grate fired biomass boiler offers a uniquely constructed and robust design, with components designed for plant life. The capacity range of vibrating grates is 30-150 MW thermal input, but grate firing can be combined with PF burners to enable even larger boilers sizes. BIOMASS BOILERS WITH BEST PERFORMANCES The chemical composition of biomass involves special combustion issues that must be handled particularly slagging and corrosion. Increased ashdeposits on super-heaters with low melting points and salt contents of e.g. potassium chloride are a challenge. BWE is capable of addressing these issues based on experience from the history of biomass firing in Denmark, where both wood and straw has been fired in biomass boilers for decades. Today, design data for dedicated BWE biomass boilers are up to 540°C live steam temperature at 115bar with expected plant lifetime of 200.000h, proving industry leading performance and lifetime. Text: Constantly increasing utilization of biomass with outstanding reliability IN-HOUSE DESIGN The BWE biomass boilers are laid out with large super-heater pitch to allow slagging, corrosion resistant materials with proven lifetimes and effective soot blowing systems. Initiatives are applied in the critical areas to maximize availability and minimize operational costs. In order to ensure tailor-made customer solutions, key components are designed and developed in-house to a level of high details. BWE is a leading supplier all of the critical components: Boiler design, APH/GGH, Burners, Vibration grate, Straw lanes. Low-NOx PF FIRING Biomass PF firing offers the possibility of using various biomass fuels either as 100% biomass firing or as co-firing with e.g. coal, with a very high efficiency on boilers up to 1000MW. Biomass characteristics require dedicated solutions that differ from coal firing systems. BWE offers advanced biomass fuel preparation, handling, dosing and firing systems based on our extensive experience in PF firing. The BWE biomass PF burner is an individually multiple controlled Low-NOx burner. Biomass is grinded by traditional roller mills or hammer mills and the feeding to the burners is done as direct or indirect firing. The burners apply advanced air staging and high adjustability to achieve low NOx formation and stable ignition. BWE burners are designed with multi-fuel capability at the clients request to allow combinations of biomass, coal, natural gas and oil on the same burner.

CASE STORIES: COAL-TO-BIOMASS CONVERSION Herning power plant (1982) The plant is a great example for coal-to-biomass conversion. BWE converted the unit from 100% fossil firing to 100% biomass firing. After the conversion the boiler has got the ability to fire a total of 240 MW from biomass reducing the CO2 emissions of the plant by 325,000 tons/year compared to 100% coal firing. Wood chips are fired at a water cooled vibration grate (130MWth). Wood dust from pellets is fired on Low-NOx PF burners (125MWth), which can also use natural gas and HFO. Consumption in 2010 was: 267.000 tons of wood chips + 61.000 tons of wood pellets.

PF FIRED BOILERS WITH MULTI-FUEL HYBRID TECHNOLOGY Avedøre power plant Unit 2 (2001) Avedøre Unit 2, owned by DONG Energy, is one of the most efficient, fuel-flexible, and environmentally friendly power plants in the world. A genuine hybrid multi-fuel power plant with 800MWth capacity. The Ultra Super Critical tower boiler is designed for 100% coal, 100% natural gas, 100% HFO and 80% wood pellets. Wood pellet consumption in 2010 was 642.000 tons. Total plant electrical efficiency: 51%

Wh wa un at is t de

Th fre ne

Conversion history: 1982: Coal/HFO 2000: Gas/HFO 2002: Wood chips/Gas/HFO 2009: Wood dust/Wood chips/Gas/HFO

GRATE FIRED BOILERS Ensted plant (1998) Currently operating plant in Denmark with new BWE water cooled vibration grate installed in 2007. Capacity is 81 MWth and straw consumption in 2010 was 125.000 tons. Emlichheim (2013) BWE´s straw fired biomass boiler (grate fired) currently under construction with commissioning in 2013 in Emlichheim, Germany, with 50 MWth capacity and 522°C live steam temperature. This is the first straw fired power plant in Germany, which will supply process steam and electricity to a nearby process installation as well as district heating to Emlichheim city and electricity to the grid. (See 3D model)

In ■ ■

Plant concept by DONG Energy, visited by delegation during COP15

■

Amager power plant Unit 1 (2009) Amager power plant Unit 1, owned by Vattenfall, applies state-of-the-art hybrid multi-fuel technology with design for 4 very different fuels. The 350MWth capacity can be achieved with 100% coal, 100% HFO, 100% wood pellets or 90% straw pellets, all fired as pulverized fuel on BWE Low-NOx burners. Consumption in 2010 was: 120.000 tons straw pellets + 168.000 tons wood pellets.

b g p o

Below: 3D model of BWE´s straw fired biomass boiler (grate fired) currently under construction with commissioning in 2013 in Emlichheim, Germany.

34 NOVEMBER/DECEMBER 2011 POWER INSIDER

PI_NovDec_BWE_Rev2.indd 34

In m

20/12/2011 22:42

We make a difference to the environment In BWE we consider fossil fuels combined with biomass an important measure to reduce CO2 emissions 100% fossil fuel (NG)

Why does continue to promote fossil fuels when everybody wants to get rid of them? Because in Denmark has developed a unique technology making it possible to utilize fossil fuels and biomass at the same time in utility boilers all over the world. An example of this is the 415 MW boiler of Avedøre Power Plant, Unit 2, in Copenhagen, delivered by and owned by DONG Energy.

approx 4070 CO2 t/24hrs

The use of ’s technology makes it possible to obtain fuel flexibility, free choice of fuel for economic optimization, full utilization of carbon neutral energy and a significant reduction of CO2 emissions. ’s burner and boiler technologies should be used when building new boiler plants or retrofitting existing plants. In this way, ■ ■ ■

is able to:

70% biomass carbon neutral energy

bring the world a large step closer to a cleaner environment guarantee a green sustainable growth provide time for the development and implementation of economically feasible alternative energy technologies.

30% fossil fuel (NG) approx 1221 CO2 t/24hrs

Green Technology = Green Growth

member of the

PI_NovDec_BWE_Rev2.indd 35

Group

Lundtoftegaardsvej 93 A ■ DK-2800 Kgs. Lyngby Tel. +45 39 45 20 00 ■ info@bwe.dk ■ www.bwe.dk

20/12/2011 22:43

wind turbine lubrication

36 november/december 2011 power insider

PI_NovDec_Mobil.indd 36

21/12/2011 06:46

Mobil industrial lubricants: Beijing Wind PoWer Tour T

he presence of wind energy is making unprecedented progress in Asia across installation, turbine building and component manufacturing. For the third year running the continent was the world’s largest regional market for wind turbines, with capacity additions amounting to in excess of 19 GW. As the wind industry in Asia develops, performance characteristics of components are under increasing pressure to excel in demanding locations such as arctic winter conditions in the Hebei province of China, and the extreme summer heat present for the wind farms of Maharashtra in India. Wind turbines are highly engineered and sophisticated pieces of machinery, for an operator the importance of using the right lubricants cannot be overstated, being a decisive factor in a turbines performance figures, longevity and service life. Pi Magazine Asia travelled to the Beijing Wind Power Exhibition to understand more about the importance of this topic for the industries continued development, taking a unique insight into the efforts of Mobil Industrial Lubricants, a pioneer of synthetic lubricant technology. We talked frankly with Mike Hawkins, Mobil SHC Global Brand Manager, and Glen Sharkowicz, Mobil’s Global Industrial Business Development Advisor, two executives with a combined 40 years experience of the lubrication industry. We looked closely at the Mobil SHC synthetic gear oil, a product specifically designed for the wind industry.

India is also a major focus for us. We have a growing presence in India and an established legacy of working side-by-side with the leading OEMs and component builders located in the country. Glen: We also have a presence in other markets that are beginning to emerge, such as Japan and Korea, which have the infrastructure for industries from shipbuilding to information technology and wind turbines. PIMA: The wind industry in South Korea is an interesting topic; do you have a presence and see it as a growth market? Mike: ExxonMobil has a presence in nearly every market around the world, with a more than 100-year history of delivering lubrication excellence. This legacy has allowed us to build and sustain leadership positions across many industrial sectors in markets around the world, including South Korea. An essential component of ExxonMobil’s success is that our fundamental approach and commitment remains the same in every market we serve. Every day, we are focused on ensuring that we remain at the forefront of lubrication technology and

deliver to all of our customers, the highest level of application expertise. By doing so, we can ensure that our products provide exceptional performance and can effectively help our customers maximize their productivity and stay ahead of the competition. piMA: Where are your major manufacturing hubs in (for wind turbine gear oils) Asia? Glen: We have manufacturing operations around the world that develop the range of our product lines. Our Mobil SHC-branded synthetic lubricants used in the wind industry are primarily manufactured in Europe and the United States. Through our extensive global reach, we have a distinct competitive advantage in that we can provide products to our customers when and where they need them. piMA: What goes into research and development of your products in the wind industry? Mike: ExxonMobil puts significant resources toward research and product development efforts. In the wind industry, there are many examples of

piMA: Where are the biggest markets for MIL in Asia Pacific at the moment? Mike: We see significant growth opportunities now and in the future across the Asia Pacific region. Not surprisingly, we continue to see substantial demand for our flagship Mobil SHC brand of synthetic lubricants. We are committed to this region, and are very proud of our history of success and legacy of technology leadership that is well established here. Looking at individual countries, China is a priority market, based on its size and rapid growth. It’s also an epicenter for leading original equipment manufacturers and component builders in the wind industry. power insider november/december 2011 37

PI_NovDec_Mobil.indd 37

21/12/2011 06:46

wind turbine lubrication

how the technology leadership we have achieved, in part through years of research and development, is recognized in the marketplace. For example, your readers may know that our flagship Mobilgear SHC XMP 320 synthetic gear oil is used to lubricate more than 40,000 turbines worldwide and is recommended by the majority of the world’s 12 leading wind turbine builders. Glen: When you consider the complexity of wind turbines and factor in ExxonMobil’s rigorous development, research and validation processes, it’s easy to understand why bringing lubricants to market can take many years. At ExxonMobil, we are very proud to use an advanced, scientifically engineered formulation approach that helps leverage the company’s leading technology and application expertise to deliver lubricants that are optimized for the intended applications. We call this ExxonMobil’s “Balanced Formulation Approach.” This comprehensive process enables us to develop lubricants that deliver exceptional performance across all critical areas for each application-such as oxidative stability, component wear protection, corrosion control, filterability, water tolerance, micropitting, shear stability and extreme temperature performance. From the start, we collaborate with leading manufacturers to understand their equipment and most demanding lubrication needs. Our scientists then select advanced technology base stocks and carefully design additive systems to

complement the excellent lubrication properties of these base fluids. We then put our technology-driven lubricant candidate through a comprehensive range of industry standard laboratory tests. Some lubricant development programs would end here. We supplement industry-standard testing with full-scale, dynamic testing of industrial equipment. These proprietary tests are designed to stress the lubricant candidate under conditions that are even more demanding than it is likely to experience in severe operating environments. Finally, we follow in-service testing protocols to validate the performance of our candidate in extensive field demonstrations. While this commitment to research and development takes time and significant resources, it is an essential ingredient of our success in many sectors, including the wind energy marketplace. piMA: From your experience as the market front runner in lubrication of wind turbines, what would you say are the most important consideration areas? Glen: The gearbox is a key and integral part of the turbine. With our Mobilgear SHC XMP 320, we are proud to say that we have one of the most advanced and popular gear oils in the wind turbine marketplace. It is important to remember that grease applications are also essential. Something as simple as the pitch bearing, operating at a low temperature, that doesn’t allow the blade to pitch, could trip the turbine offline. Also,

with offshore turbines in the arctic-like conditions, it’s essential to have a lubricant that has good low temperature properties. Without that cold weather performance, the turbine could possibly trip and go offline. Mike: We strive to keep our customers’ uptimes and productivity as high as possible. We do this because the potential consequences that can result from poor lubrication are significant. For example, if you have a gearbox failure, you are talking about as much as half a million dollars for its replacement, plus labour. Today, we offer a wide range of lubricants that are formulated to deliver exceptional protection of all parts of a wind turbine, including greases to lubricate bearings and hydraulic oils that help pitch rotor blades. The powerful combination of our leading-edge lubricant technology and robust application expertise is what enables us to help the wind energy industry become more cost competitive worldwide. piMA: The strenuous operating conditions apparent in the offshore wind field have brought much debate on component integrity in gearboxes, with significant developments taking place in direct drive turbines. Does this have an effect for your products in this particular sector? Glen: Technology is evolving quickly. Direct-drive turbines have been on the market for some time and they certainly have an appeal for offshore wind turbines. However, there are pros and cons to direct-drive turbines in comparison to more

38 november/december 2011 power insider

PI_NovDec_Mobil.indd 38

21/12/2011 06:47

traditional options. There are size limitations either way. For offshore, you want to make the turbine as big as possible, so the benefit of direct drive is that there is no gearbox, but the benefit of a gearbox is that it’s a known entity. With Mobilgear SHC XMP 320, we obviously have one of the leading gear oils for geared turbines. But we also have greases, such as Mobil SHC Grease 460 WT, which is ideally suited for offshore turbines. Among the most critical factors you need to be mindful of in off shore applications include salt spray, wide temperature ranges, and the requirement to start up quickly at low ambient temperatures. As the offshore market develops and matures, we will need to continue investing and enhancing our own leading-edge technology, considering the extreme environments. piMA: What are biggest challenges from a lubrication perspective concerning the modern wind turbine? Glen: As gearboxes become larger, they are expected to transmit more energy. So OEMs began manufacturing case-hardened gears with a very hard steel surface. These gears created the phenomenon called micropitting, which is a surface fatigue condition that causes destructive gear wear. Recognizing this at a very early stage, we led the industry in addressing micropitting protection in the gear oil. However, wear protection is just one part of the picture. That’s why we believe ExxonMobil’s “Balanced Formulation Approach” is the best approach. Because it is a comprehensive approach that factors all areas of performance. piMA: Does it make for more challenges when turbine builders obtain components from a variety of differing sources? Glen: It certainly adds more complexity to the process. But essentially, the end goal remains the same, which is to have a turbine that runs with increased consistency and reliability. We have had strong relationships with leading

equipment builders for more than 100 years, working closely with all parties to understand their needs, in terms of what do they want out of the lubricant. We provide these insights to our research and development teams, so they can account for various operating environments. For example, we need to work on high temperature performance if these turbines are going into a desert environment. Likewise, as I mentioned before, when considering offshore environments, you need to ensure that your product delivers the appropriate cold weather protection and startups. piMA: What is the difference between Synthetic and Mineral lubrication solutions? Mike: As many leading companies have come to recognize, synthetics offer distinct advantages over conventional, mineral fluids, including - better performance in extreme temperatures, increased energy efficiency and extended oil life. Mineral oil is a product refined from crude, whereas synthetic-based lubricants take basic chemicals, using catalysts to form something very specific in terms of molecular structure.

This gives you properties, such as excellent thermal and oxidation stability, and some of the energy efficiency benefits through low traction co-efficient differences. The main difference is that a synthetic lubricant has a better viscosity index, protecting you at a higher end temperature, but also giving you flow at lower temperature. The average mineral oils for the heart of the gearbox provide 18-24 months (oil life) of coverage, but the industry has moved more toward synthetic lubricants, and with Mobil SHC products, you are looking at three to four years oil life, and our nextgeneration product will be even longer. piMA: Do you tailor formulations as per turbine and operating environment? Mike: Actually, one of the attributes that our customers appreciate most about our lubricants for wind turbines is that they are available globally and they are globally consistent. From the outset, we factor in the widest possible application and relevance, so what we go to the market with is a globally standardized product. We don’t formulate products for regions, so if a customer buys Mobilgear SHC XMP 320 for a site in India, China or anywhere else in the world, it will be the same quality and deliver the same exceptional performance. piMA: Do you have any programs related to oil analysis so users can see the condition of their lubricant, understanding when a change may be necessary? Glen: Yes. We have a program called Signum Oil Analysis and it is globally available. A maintenance engineer will take an oil sample and have it examined in the lab. The results will then be sent electronically to the end user. Sample comments are provided as required to help identify potential problems, list possible causes and recommend actions for follow up. One of the unique aspects about the program is that we have extensive data that has been developed historically over a wide range of applications, which we can go back to and really look at trends. The delivery method via the internet, email or going on to power insider november/december 2011 39

PI_NovDec_Mobil.indd 39

21/12/2011 06:47

WIND TURBINE LUBRICATION

the website, can quite easily be instantly shared with the customer group. PIMA: Do you think there is capacity for electronic real time oil analysis in wind turbines? Mike: It is an interesting area. It has been talked about for a long time, but the technology is still emerging. For wind turbine operators that want to enhance their oil monitoring capabilities, an effective potential solution is to use our Signum Oil Analysis program in conjunction with vibration testing and temperature sensors. As Glen noted, Signum Oil Analysis provides users with a comprehensive overview, which is perfect for a management report, and to tell the end user when it is time to make a change. PIMA: What would you consider MIL’s value proposition to be? Glen: We take a holistic approach that goes beyond selling just products and offer our customers the opportunity to enhance productivity. We have the experience, the application expertise and leading-edge technology that deliver real performance benefits to the end user. All of these credentials play a key role in helping to drive our customers’ success and the continued popularity of our Mobil SHC synthetic lubricants in the wind industry and many other industrial sectors.

PIMA: You have recently released the Mobil Energy Efficiency logo. Can you explain what this means? Mike: I was in Beijing around April, when we launched the Energy Efficiency Logo into the market place. The logo is a self-certification of lubricants that can deliver energy efficiency benefits by having lower traction coefficient levels and better lubricity. Those are certain lubricants that pass our rigorous testing to certify them; it is a complementary logo that represents an emphasis on energy efficiency. As businesses and societies place more emphasis on sustainability, we are making it easier for our customers to choose products that not only deliver exceptional performance, but also offer potential energy efficiency benefits. Glen: It is important to note that this is not for every available product; it is very specific products that we have documented benefits around energy efficiency. We are very confident in these particular products in certain applications, in comparison to what you will find in the general market. I am proud to say that recently, we announced the expansion of our line of “energy-efficient” industrial lubricants with the introduction of two Mobil SHC high-performance synthetic oils – our new Mobil SHC Gear Series and our enhanced Mobil SHC

600 Series. These lubricants were developed through extensive research and testing with leading OEMs, and are expertly formulated to optimize the performance of equipment operating in extreme conditions and deliver significant energy efficiency benefits. In laboratory testing, using industrial gearboxes, these new Mobil SHC lubricants delivered energy savings of up to 3.6 percent, compared with conventional oils.*

Mobil, Mobil SHC and the energy efficiency design are trademarks of Exxon Mobil Corporation or one of its subsidiaries.

*Energy efficiency relates solely to the fluid performance when compared with conventional reference oils of the same viscosity grade in circulating and gear applications. The technology used allows up to 3.6% efficiency compared with the reference when tested in a worm gearbox under controlled conditions. Efficiency improvements will vary based on operating conditions and application.w

40 NOVEMBER/DECEMBER 2011 POWER INSIDER

PI_NovDec_Mobil.indd 40

21/12/2011 06:48

S:7”

S:10”

We can take wind turbines to new heights.

1004_EXOD_Wind_Misc2011_AD.indd 1 PI_Mobil_Ad.indd 2

This mechanical prepared by

MRM Worldwide Safety: 7” x 10”

This mechanical should not be modified in any way without prior written direction from MRM Worldwide.

Client: Exxon Mobil

Job Number: EXOD0011 C

12/7/11 12:36 PM 21/12/2011 07:34

case study: inshore rov

cAse study: inshore rov

hibbArd inshore Hybrid AUV/ROV Entering Tunnel for Inspection

Profiling Sonar showing crown failure in tunnel

Profiling Sonar showing loss of material at crown and heavy sediment in bottom of tunnel

he act of inspecting and maintaining the underwater portions of hydroelectric dams has presented unique challenges since the first facilities came on line in the late 1800s. Until the mid-1980s, the options for inspection were to either dewater the portion of the dam to be inspected or to use commercial divers to perform the inspections where safe and possible. Dewatering of long tunnels and high head dams in particular, presents a number of large challenges. Plant downtimes are typically long, fisheries are impacted, and the structure can be stressed. The draining of water removes the added structural support normally provided by the water pressure and allows materials to dry and contract potentially expediting cracking and degradation. Since the mid-1980’s, however, fewer inspections involving dewatering have had to be undertaken as technological advances have continued to occur in the underwater robotics systems known in the industry as remotely operated vehicles (ROVs). These advances in ROV technology have allowed inspection and maintenance work that was previously very difficult or impossible to perform due to low visibility, deep water, long distance confined entry, or potential underwater hazards now to be completed in a fully-flooded state with little risk to human life and minimal generating outage times. Performing inspections in this manner provide additional benefits as well. The shortened, reduced-flow time periods or outages required due to today’s technology minimize environmental impact to valuable fisheries,

and undue stress is not placed on the structure by removing the water. Today, it is widely accepted that underwater inspection of critical assets should be a major component of the preventative maintenance plan of any hydroelectric facility. There are three recent jobs completed by Hibbard Inshore that illustrate various considerations as to why it is a major advantage for power generating companies and their insurance providers to perform regular inspection of the underwater assets at their facilities. Rather than dewatering, all three of the inspections in this study were performed with ROVs. These vehicles were fitted with color and low-light monochrome video along with multiple forms of sonar to allow potential flaws to be identified in the structures. The vehicles were each specified to the particular project based upon access considerations, depth of the structures, allowable outage/reduced flow time period, distance the vehicle would have to swim during the inspection, and data the customer wished to obtain during the inspection. In this paper we will explore these three cases: • A relatively new hydroelectric facility with long range tunnels and deep shafts in Asia • A hydroelectric facility with a large tunnel collapse in the Americas • A hydroelectric facility feeding critical manufacturing that could not be shut down for inspection The first case discussed here involves a facility with

a tunnel of over 5 km and depths in excess of 300 meters. Due to the long distance of the tunnel and the deep water at the facility, this inspection was carefully planned to utilize the latest ROV capabilities because it would have been a major setback in the region to have to take the facility offline for dewatering. The facility provides not only the power for the local cities and towns but also is a source of revenue for the region. Because of the length of the tunnel and access constraints, previously available technology would only allow for a portion of the tunnel to be inspected effectively. This facility required inspection because its warranty period with the construction company for the facility would expire shortly, and the owner wanted to be sure the facility was both built properly as indicated in the as-built drawings and was standing up to the rigors of operations prior to warranty expiration. Like with many pieces of technology, ROVs have continued to grow more capable while experiencing reductions in size and overall cost. The reduction in size has increased the number of areas they can access as well as the cost of shipping and operations. These advances allowed for the inspection to be completed in early 2011. The ROVs used were a Hibbard Inshore modified Sub-Atlantic Navajo with a 5km tether and a deep rated Seabotix LBV which were able to complete the long tunnel inspection along with inspections of several other structures while minimizing facility outage time. These systems were shipped via air

42 november/december 2011 power insider

PI_NovDec_Hibberd.indd 42

21/12/2011 06:50

20+ km Hibbard Inshore Saab Hybrid AUV/ROV

freight to meet the project timeline during the region’s dry season, and the smaller size of the vehicle systems allowed them to be easily trucked from the airport into the mountainous region of the facility. The inspection was completed during several scheduled outages to inspect portions of the structure in a scheme designed to reduce the total outage of the plant and to fit within the daily outage limits. The inspection was accomplished through not only using video cameras and appropriate lighting but also using multiple sonar units and data acquisition software to increase the speed of inspection while still accurately identifying significant flaws and features. Since sonar uses sound waves to detect reflective surfaces, it can be used to identify features such as open cracks, joints, concrete spalling, sediment buildup, rock or concrete loss, out of round conditions (in the case of pipe), and general shape anomalies that differ when compared to as-built drawings. These features can often be seen on sonar from longer distances than a video camera can see allowing the vehicle to quickly assess the structure. The vehicle was driven through the tunnel utilizing its sonar to detect the presence of these types of features, and upon finding one on the sonar, visual confirmation was completed by flying the vehicle directly to the area of interest for a close look with its cameras. Cross-sections were taken at many of these points for dimensional measurement purposes. During the inspection, the ROV was able to locate a number of features that would potentially jeopardize the operation of the facility in the future

were they not rehabilitated. From the inspection, sizes and locations of these features were determined, and the owners were able to put a repair plan in place to be financed under their warranty claim saving them a potentially difficult situation down the road. The second case involves a facility where the construction warranty had recently expired. This facility contacted Hibbard Inshore after a loss of generating capacity was experienced shortly after seismic activity in the region. Due to the loss of generating capacity, it was thought that the intake tunnel may have experienced a small blockage due to material shaking loose during the seismic event. At this facility, the intake tunnel was approximately 10 meters in diameter and close to 5 kilometers in length. The entire tunnel needed to be inspected in a very short outage period to allow generation to continue while quantifying the amount of damage, if any, to the tunnel. Hibbard Inshore utilized a Sub-Atlantic ROV with 2.2 km tether to undertake this inspection. The ROV was inserted into the tunnel from two access points, at the Surge Shaft and at the Intake. This allowed the use of the shorter range tether and the smaller shipment size allowed for expedited shipping at a lower cost to the customer. Upon entry into the tunnel, the ROV inspected in both upstream and downstream directions from the Surge Shaft on consecutive days and then was picked up and moved to the Intake in order to access the tunnel at that point. During the inspection, it was found

‘TOdAy, IT IS wIdely AccepTed THAT UndeRwATeR InSpecTIOn Of cRITIcAl ASSeTS SHOUld be A mAjOR cOmpOnenT Of THe pReVenTATIVe mAInTenAnce plAn Of Any HydROelecTRIc fAcIlITy.’

that the damage to the tunnel was more extensive than expected. Due to the extent of this finding, it was determined that the tunnel would need major repair in order to continue to function. The Hibbard Inshore findings were able to tell the owner the extent of the damage so that estimates could be done for the cost of repair and submitted to the insurance company. The inspection allowed the engineers to evaluate the situation to determine as to whether the conditions were pre-existing and exacerbated by the seismic activity or solely due to that particular event. In events such as with this inspection, power insider november/december 2011 43

PI_NovDec_Hibberd.indd 43

21/12/2011 06:53

case study: inshore rov 5 km Long Range Navajo and 600 Meter Rated LBV ROVs with Hibbard Crew

the technology is available to make determinations about the condition of the tunnel in a quick manner with minimum effect to production prior to warranty expiration allowing owners to have confidence in the lifespan of the asset and the insurer to minimize risks. The final case where the technological advances of ROVs have been able to make a major difference in tunnel inspection is a case where a major manufacturer had a hydroelectric facility that generates 24 hours per day, 7 days per week in order to meet the high energy needs of the metals facility. Because of this generating schedule and the

fact that 100% of the plantâ&#x20AC;&#x2122;s power output is always used, the plant had little opportunity to slow the flow of water through their intake tunnel which was over 15 km in length. They required their inspection to be done while maintaining a minimum flow to continue to provide power to critical assets during the inspection. In order to complete this inspection, a very powerful Saab Hybrid AUV/ROV was utilized. This vehicle is designed to run in either autonomous underwater vehicle (AUV) configuration or in a standard, tethered ROV configuration. As opposed to typical ROVs which are powered through their tethers, this vehicle has an onboard battery system allowing its tether to be used only for control and data transmission. Not having to run power to the vehicle allows the tether to be much smaller, weigh much less, and create less friction. The tether was only 3.6 mm in diameter keeping the tether weight quite small. These are all important considerations when inspecting long tunnels in flow, and the reduced weights also were helpful for onsite logistics because the facility was in a remote region requiring much of the equipment to transport via helicopter. Because of this design and the high power of the vehicle, a flow of 0.8 m/s was able to be maintained while the vehicle completed the inspection within two separate eight hour periods. The vehicle was

outfitted with stability and tracking programs to allow it to stay level in the flow as well as to know exact distance from known stationing at any given time. It also has a true 6 degrees of freedom allowing it to stand on end to maneuver through vertical sections as sometimes found near powerhouses or rock traps. The Hibbard Inshore Saab vehicle additionally carried imaging and dimensioning sonar units along with video cameras. The combination of sensors along with the high thrust, real-time control, and stability of the vehicle allowed the tunnel to be truly inspected for the first time since its commissioning. Because of this technology, the plant was able to continue production with only a very minimal slowdown preserving the revenues of the manufacturing facility. These three jobs highlight just a few of the types of vehicles available to aid power generation facilities in lifespan assessment of their underwater and hard to reach assets. In addition to the long tunnel vehicles, vehicles exist for more standard inspections such as for the face of dam, head gates and seals, intake structures, steam and nuclear plant intakes and discharges, lower outlets, and downstream aprons. Vehicles also exist that can aid in deep water dredging in front of units, deep water temporary bulkhead placement to allow work on valves or turbines, and inspection of dry tunnels where walkthrough has been deemed to potentially be unsafe. The common thread is that the improvement of technology has opened up a whole new realm of possibilities for companies to gather information about their generating assets and to implement important maintenance solutions at key times so that the facilities are able to maintain production for longer durations than ever before.

44 november/december 2011 power insider

PI_NovDec_Hibberd.indd 44

21/12/2011 06:53

SUBSCRIBE NOW

CLICK ON www.pimagazine-asia.com

PI_Subs_page.indd 13

21/12/2011 08:18

permanent magnet alternators

Direct Drive Permanent magnet generator (DDPmg), beyonD winD generator aPPlications David Beč váč , President and CEO of TES Electric Machines (a division of TES VSETIN)

ermanent magnet alternators (PMA’s), permanent magnet generators (PMG’s), permanent magnet motors (PMM’s), are not new technologies, in fact, they have been around for a while. So what is the attraction for the renewable energy? As it relates to wind energy, “most” directdriven, medium speed and high speed PMG’s offers excellent availability and productivity so critical to wind generation. This is the result of the ability of PMG’s to offer relatively high efficiencies in the full range of loads. Conventional generators with copper stator and copper rotor are simply no match, from 25% load to 75% load compared to PMG’s. The higher efficiencies of PMG’s become very important for the wind farm operator, a 2% to 4% efficiencies increase over conventional generators during low wind velocity or intermittent wind velocities, may

well be the difference of making the debt service requirement. TES Electric Machines is an innovative and technological leader in rotating electric machine since 1919, located in Vsétin Czech Republic. Our core businesses have been hydro generators, and lately wind generators, with other emerging sources. We have successfully designed, developed, and manufactured high speed synchronous wind PMG’s (Neodymium magnets) from 500 kW to 3 MW. We are particularly pleased of our R&D department who has eliminated the cogging phenomenon, thereby, reduced the overall mechanical stress inherent to PMG’s. Furthermore, the magnets are uniquely fixed inside the rotor with our own patented designs. As a result of our R&D, and stateof-the-art technology, our measured and tested

efficiency at 100% load is 97.9%, 75% load 97.8% and at 50% load 97.4%, quite impressive, indeed, all achieved with the lowest noise level. We are the European leader of conventional hydro generators from a 100 kW up to 15 MW, from 100 RPM to 1500 RPM. We work with most hydro turbine manufacturers around the world, and we are constantly listening to their requests, ideas, and visions. The fundamentals of our modus operand is problem solving through tailored state-of-the-art technology in total sustainability, we know how, we are truly a value-adding partner to our customers. There are typical issues in hydroelectric development that a turbine manufacturer faces from time to time on certain projects. Firstly, developing projects with low or very low pressure heads that can be problematic, and secondly developing projects inside residential areas where conventional generator noise may become an obvious concern. The first topic requires the uses of gearboxes to increase the rotational speed of the generator, thereby, reducing the size and cost of a conventional generator while optimizing the overall efficiencies at various loads. They are three well known concerns with gearbox; a) reliability b) cost and c) noise. The second matter is related to noise, medium to high speed conventional generators are noisy by the nature of their design, and as it relate to higher efficiencies, consequently, the trade-off is noise! Based on the lessons learned through the development of our own wind PMG’s, we had identified solutions for some problematic hydroelectric projects generator’s requirement. To resolve the problems faced by some projects for the turbine manufacturers, we decided to propose Direct Drive PMG’s (DDPMG) for hydro generators. Two types of DDPMG are part of our range for hydro generators, low speed DDPMG from 20 RPM to 80 RPM, and high speed DDPMG 600 RPM to 1500 RPM. The reason is rather simple; our R&D department realized that there were numerous

46 november/december 2011 power insider

PI_NovDec_TES.indd 46

21/12/2011 06:55

design synergies between wind, and hydro generators for low speed Direct Drive and High Speed Direct Drive synchronous PMG’s. Consequently, we were able to offer a problem solving solution for the benefit of our customers, for low or very low heads hydro with our DDPMG’s with much higher efficiencies from 25% load through 100% load. Those projects became developable without the use of a gearbox, and reduced noise level. The question that comes to mind is the higher cost of DDPMG’s compared to conventional generator, indeed, that is correct although the higher added cost of a DDPMG’s is offset by the cost saving of a gearbox. An interesting technical aspect of the DDPMG’s hydro for low speed, for some projects we were able to delete the use of a Full Power Converter for grid compliance that are necessary with PMG’s and variable speed. Instead, we cleverly used the adjustable blades of the Kaplan turbine, as well as gates vanes regulation (if available) to regulate the DDPMG’s allowing for variable speed capability in response to head drop with flow variations. As a result, the variable speed capability of the generating unit insures an efficient and stable compliant integration with the grid under variable heads or flows. The second problem solving solution was for hydro projects to be developed inside residential area, resulting in DDPMG’s for high speed and low speed projects. We were able to duplicate the same benefits as it relates to much higher efficiencies of

PMG’s, thus, maximized energy yields. One of the most important benefits of all was the reduced noise level, consequently, the reduction in noise allows for the licensing and permitting of the project. Of course, as for low head projects, the utilization of PMG’s lead to higher cost when compared to conventional generators. We have to run a pragmatic analysis of the higher cost of DDPMG’s, first an obvious direct benefit, the maximized energy yields due to better efficiencies will allows for a rapid offset of the added cost, second, when noise is an issue, the choice is clear. In conclusion, are PMG’s going to replace the conventional hydro generators? No, PMG’s for hydropower have a specific exponential market niche for “special” applications and developments. The R&D development to production for wind PMG’s and hydro PMG’s that TES Electric Machine implemented, made us aware that our PMG’s technology can be applied to an emerging source. It is Marine Energy or Ocean Current Energy / Tidal Energy where our DDPMG’s can be utilized. The principle of operations and technical parameters are similar to low wind and hydropower DDPMG’s, with very low RPM, between 20 RPM to 40 RPM. Indeed, application for PMG’s goes beyond wind generator.

‘TES ElECTrIC MaChINES IS aN INNOVaTIVE aND TEChNOlOgICal lEaDEr IN rOTaTINg ElECTrIC MaChINE SINCE 1919, lOCaTED IN VSéTIN CzECh rEPuBlIC. Our COrE BuSINESSES haVE BEEN hyDrO gENEraTOrS, aND laTEly wIND gENEraTOrS, wITh OThEr EMErgINg SOurCES. ‘

David Beč váč , President and CEO of TES Electric Machines (a division of TES VSETIN) Email: dbecvar@tes.cz - www.tes.cz power insider november/december 2011 47

PI_NovDec_TES.indd 47

21/12/2011 06:55

DIAGNoSTIC MoNITorING

Case stUDY Cs027

CS027_Mise en page 1 11-11-25 14:13 Page2

Parameter Correlation reveals abnormal stator DisPlaCement Pole Graph

Pole Graph

Pole Graph 1200

2400

1100

15.5

2300

1000

15.0

2200

14.5 14.0 13.5

13.0 12.5

900

Abs. vibration (um p-p)

Displacement (um raw)

Air gap (mm)

16.0

2100 2000 1900 1800

700 600 500 400 300

1700

12.0

800

200

1600

100

11.5

56/1

40/90

56/1

Pole: 20 / Turn: 60

Legend

Value 12.27 mm 13.14 mm 14.64 mm 15.43 mm

Input Air gap 000 Air Gap 090 Air Gap 180 Air Gap 270

0 56/1

40/90

Pole: 20 / Turn: 60

Location Generator (Top) Generator (Top) Generator (Top) Generator (Top)

Legend

Value 1672.41 um 1931.26 mm

40/90

Pole: 20 / Turn: 60

Input Location MGG 000 Upper guide bearing MGG 090 Upper guide bearing

Legend

Value 574.65 um p-p 882.34 um p-p 835.46 um p-p 910.77 um p-p

Input Core 022 Core 112 Core 202 Core 292

Location Stator core Stator core Stator core Stator core

Figure 2: Pole measurement graphs showing behavior of air gap (left), generator guide bearing (center) and stator core vibration (right) during start-up and field excitation.

At Cursor

0o 56 600

163.68 um raw Phase: 251o

500

Turn(s):

400

Type:

42 90o

28 29 180o

Pole, 145 turn(s)

Comment:

100

Measurement

200

270o 14

1 / 37

Zoom:

300

Turn: 1 40.13 RPM

Graph

Vibration:

Sensor Location:

Start up test

Relative Shaft Vibration Upper guide bearing

Smax

Value:

524.582 um raw At 145o

Turn:

Mode

Rotation:

CCW

Nominal

Air Gap:

15 mm.

Power:

52 MVA

Speed:

128.57 RPM

Pole Graph

Pole Graph 1200

2400

1100

15.5

2300

1000

15.0

2200

14.5 14.0 13.5

13.0 12.5

900

Abs. vibration (um p-p)

Displacement (um raw)

Air gap (mm)

16.0

2100 2000 1900 1800

700 600 500 400 300

1700

12.0

800

200

1600

100

11.5

56/1

40/90

56/1

Pole: 20 / Turn: 60

Legend

Value 12.27 mm 13.14 mm 14.64 mm 15.43 mm

Input Air gap 000 Air Gap 090 Air Gap 180 Air Gap 270

Pole: 20 / Turn: 60

Location Generator (Top) Generator (Top) Generator (Top) Generator (Top)

Legend

Value 1672.41 um 1931.26 mm

13.5

Input Core 022 Core 112 Core 202 Core 292

Location Stator core Stator core Stator core Stator core

2060 2040 2020 2000

Shaft also moves back

1980

13.0

PI_NovDec_Vibrosystm.indd 48

Value 574.65 um p-p 882.34 um p-p 835.46 um p-p 910.77 um p-p

2080

Opposite sensors switch back

Displacement (um raw)

Air gap (mm)

14.0

Legend

Trending Graph

15.0

48 november/december 2011 power insider

40/90

Pole: 20 / Turn: 60

Input Location MGG 000 Upper guide bearing MGG 090 Upper guide bearing

Trending Graph

14.5

0 56/1

40/90

1960 2002-07-18 20:00:00

2002-07-18 23:00:00

2002-07-19 02:00:00

Date: 2002-07-18 Time: 18:00:01

2002-07-19 05:00:00

2002-07-19 08:00:00

2002-07-18 20:00:00

2002-07-18 23:00:00

2002-07-19 02:00:00

Date: 2002-07-18 Time: 18:00:01

2002-07-19 05:00:00

2002-07-19 08:00:00

Trending Graph

2080

15.0

14.0

13.5

2060

Displacement (um raw)

Opposite sensors switch back

14.5

Air gap (mm)

on all four accelerometers his case demonstrates excessive movements of • Core vibration still very high and beyond both rotor and stator components. Since it fails tolerances when machine stabilizes VibroSystM rotor stability requirement, making CS027_Mise en page 1 11-11-25 14:13 Page1 • Accurate evaluation of rotor rim condition conclusive data interpretation becomes more and stator shape difficult due to high rotor challenging. In spite of this, and with the ability CASE STUDY CS027 axis instability of the ZOOM® system to correlate synchronized measurements from various parameters it was The data revealed an important difference Parameter Correlation Reveals Abnormal possible to make an evaluation of the machine between displacement values recorded by the Stator Displacement condition. The system provided the right probes on the shaft and the sensors in the air Commissioning: 1968 Nominal Air Gap: 15 mm Bearing Layout: Lower Generator Machine Refurbishment: Francis Turbine Guide information to direct2002the investigationTurbine of Type: the cause gap: Generator Guide Bearing displays a shaft Data Power: 52 MW Speed: 128.6 rpm of the problem and undertake corrections. displacement of ≈470 μm towards the 25° area, This case demonstrates excessive while air gaprotorresults indicate a displacement of movements of both and stator After components. Since(1830 it fails VibroSystM 1.83 mm μm) towards 25° area as well. Excitation rotor stability requirement, making conclusive data interpretation becomes of 1360 μm which can be This leaves a difference more challenging. In spite of this, and partly by the with the abilityexplained of the ZOOM system to fact that each parameter is correlate synchronized measurements measured at different from various parameters it waselevations and parts on the possible to make an evaluation of machine (guide bearing below rotor vs. upper stator the machine condition. The system provided theOddly, right information direct wall). the toobserved displacement is not in the investigation of the cause of the problem undertake corrections. the and same angle as that of the minimum air gap area In the summer of 2002, a ZOOM (155°) before excitation. This behavior is contrary to system from VibroSystM was installed as typical part of a major refurbishment on a magnetic imbalance. Therefore, some other 34 year-old hydroelectric machine. The Before system monitors air gap, shaft vibration factor must be influencing the machine behavior. Excitation and stator core vibration among other Verification of trends over the following 24 hours parameters. Unusual behavior was Figure 1: The large circular orbit displaces towards the 25° angle and changes to an elongated path in the 90°-270° axis, rubbing of shaft againstorbit the bearing segments. towards the 25° recorded during a Start-up/Cold test as Figure 1:indicating The large circular displaces inof Figure 3 shows that the stator shape quickly part the re-commissioning. angle and changes to an elongated path in the 90°-270° axis, Comparison of Pole measurement results onthe Polar, Orbit andsegments. X-Ygraphs for generator guide bearingto vibration, air gap, andwithin the first 3 hours as returns its position indicating rubbing of shaft against bearing stator core vibration revealed the following: it heats up while the shaft moves back ≈395 μm • High shaft vibration beyond tolerances at Generator Guide Bearing before and after excitation • Important shaft displacement andachange of orbitsystem shape at Generator Guide Bearing against In the summer of 2002, ZOOM close indicating to the rubbing position before excitation. This leads us the bearing segments from VibroSystM was atinstalled as part of a major to think that a stator looseness/ weakness problem • Significant air gap reduction field excitation • Important rotor displacement at field excitation in adifferent angle than where minimum air gap an occurs refurbishment on a 34 year-old hydroelectric plays important role. The orbit now resembles • Alarmingly high stator core vibration before and at field excitation, exceeding the range on all four accelerometers machine. The system monitors air gap, shaft a back and forth balancing of ≈205 μm pk-pk in • Core vibration still very high and beyond tolerances when machine stabilizes • Accurate evaluation of rotor rim condition and stator shape difficult due to high rotor axis vibration and stator core vibration among other theinstability 135°-315° axis, and the stator core vibration The data revealed an important difference between displacement values recorded by the probes on the shaft and the sensors parameters. Unusual behavior high. Both parameters remain in the air gap: Generator Guide Bearing displayswas a shaftrecorded displacement of ≈470 µm towardsremains the 25° area,alarmingly while air gap results indicate a displacement of 1.83 mm (1830 µm) towards 25° area as well. This leaves a difference of 1360 µm which can be partly during a Start-up/Cold test as part of the reabnormally high under all normal operating explained by the fact that each parameter is measured at different elevations and parts on the machine (guide bearing below rotor vs. upper stator wall). Oddly, the observed displacement is not in the same angle as that of theconditions. minimum air gap area (155°) before stator core and shaft vibration commissioning. Obviously, excitation. This behavior is contrary to typical magnetic imbalance. Therefore, some other factor must be influencing the machine behavior. Comparison of Pole measurement results on are too high and above tolerances1 for a newly CS027_Mise en page 1 11-11-25 14:13 Page2 Polar, Orbit and X-Ygraphs for generator guide refurbished machine and undermine the mid-term bearing vibration, air gap, and stator core vibration reliability of the machine. An in-depth investigation revealed the following: should be initiated before a major failure occurs. • High shaft vibration beyond tolerances at A thorough visual inspection of the rotor rim-to Generator Guide Bearing before and after excitation • important shaft displacement and change of orbit shape at Generator Guide Bearing indicating rubbing against the bearing segments • significant air gap reduction at field excitation • important rotor displacement at field excitation in a different angle than where Figure 2: Pole measurement graphs showing behavior of air gap (left), generator guide bearing (center) minimum air gap occurs and stator core vibration (right) during start-up and field excitation. Figure 2: Pole measurement graphs showing behavior of • Alarmingly high stator core vibration before air gap (left), generator guide bearing (center) and stator core vibration (right) during start-up and field excitation. and at field excitation, exceeding the range

2040 2020 2000

Shaft also moves back

1980

13.0

1960 2002-07-18 20:00:00

2002-07-18 23:00:00

2002-07-19 02:00:00

2002-07-19 05:00:00

2002-07-18 20:00:00

2002-07-19 08:00:00

Value 13.77 mm 12.96 mm 13.81 mm 15.05 mm

Date & Time 2002/07/18 17:21:... 2002/07/18 17:21:... 2002/07/18 17:21:... 2002/07/18 17:21:...

Generator GEN5 GEN5 GEN5 GEN5

Parameter Air gap Air gap Air gap Air gap

2002-07-18 23:00:00

2002-07-19 02:00:00

2002-07-19 05:00:00

2002-07-19 08:00:00

Date: 2002-07-18 Time: 18:00:01

Date: 2002-07-18 Time: 18:00:01 Legend

Input Air gap 000 Air gap 090 Air gap 180 Air gap 270

Legend

Value 2022.83 um raw 2009.40 um raw

Date & Time Generator 2002/07/18 17:21:... GEN5 2002/07/18 17:21:... GEN5

Parameter Input Displacem... MGG 000 Displacem... MGG 090

CASE ST

Verification of trend following 24 hours in Fig that the stator shape quic shaft moves back ≈395 µm position before excitation. to think that a stator weakness problem plays role. The orbit now resem and forth balancing of ≈2 in the 135°-315° axis, an core vibration remains ala Both parameters remain high under all norma conditions.

Obviously, stator cor vibration are too high tolerances1 for a newly machine and undermine reliability of the machine. investigation should be in a major failure occurs. visual inspection of the spider and stator frame-t interfaces will provide clu metal powdering from fre as cracks in welds and c The addition in the ZOO displacement sensors on t of the stator behind air ga highly recommended to the primary cause. In th stator core vibration, shaft air gap parameters shou monitored with alarms a detect any sudden deterio

In this particular case warranty repair was init which the refurbishmen dismantled the mach Operation resumed 70 da over the first 24 hours. It shows that the unit quickly performance improved. Shaft vibration air gap parameters are now well within assembly tolerance returns towas itsgreatly original position withinand 3 hours. core vibration remains abnormally high and beyond critical tolerances. Both the owner and the contractor highly app key information the ZOOM system provided to fix the machine and fine-tune it during the second re-commissioning. Figure 3: Trend graph of air gap and shaft position behavior over the first 24 hours. It shows that the unit Figure 3: toTrend of 3air gap and shaft position behavior quickly returns its originalgraph position within hours.

spider and stator frame-to-foundation interfaces will provide clues: signs of metal powdering from VibroSystM guidelines are based on 25 years experience with dynamic air gap fretting, well as cracks andTolerances cement grout. measurementas and data interpretation, as well as in on thewelds Guide for Erection and Shaft System Alignment, Canadian Electrical Association (CEA) and the Guideaddition technique – Division Normalisation, VP Ingénierie, Hydro-Québec The inÉtudes theet ZOOM system of displacement www.vibrosystm.com sensors on the upper part of the stator behind air gap sensors is highly recommended to help identify the primary cause. In the meantime, stator core vibration, shaft vibration and air gap parameters should be closely monitored with alarms and trends to detect any sudden deterioration. In this particular case, an enforced warranty repair was initiated during which the refurbishment contractor dismantled the machine again. Operation resumed 70 days later and performance was greatly improved. Shaft vibration and air gap parameters are now well within assembly tolerances1, yet stator core vibration remains abnormally high and beyond critical tolerances. Both the owner and the contractor highly appreciated the key information the ZOOM system provided to fix the machine and fine-tune it during the second re-commissioning. 1

1 VibroSystM guidelines are based on 25 years experience with dynamic air gap measurement and data interpretation, as well as on the Guide for Erection Tolerances and Shaft System Alignment, Canadian Electrical Association (CEA) and the Guide technique – Division Études et Normalisation, VP Ingénierie, Hydro-Québec

CASE STUDY CS027

‘In The summer oF 2002, a Zoom sysTem From VIbrosysTm was InsTalled as ParT oF a major reFurbIshmenT on a 34 year-old hydroelecTrIc machIne. The sysTem monITors aIr gaP, shaFT VIbraTIon and sTaTor core VIbraTIon among oTher Obviously, stator core and shaft ParameTers. vibration are too high and above unusual tolerances for a newly refurbished behaVIor was recorded machine and undermine the mid-term reliability of the machine. An in-depth durIng a sTarT-uP/cold investigation should be initiated before ParT a TesT major failure as occurs. A thorough oF The revisual inspection of the rotor rim-tocommIssIonIng.’ spider and stator frame-to-foundation Verification of trends over the following 24 hours in Figure 3 shows that the stator shape quickly returns to shaft moves back ≈395 µm close to the position before excitation. This leads us to think that a stator looseness/ weakness problem plays an important role. The orbit now resembles a back and forth balancing of ≈205 µm pk-pk in the 135°-315° axis, and the stator core vibration remains alarmingly high. Both parameters remain abnormally high under all normal operating conditions.

interfaces will provide clues: signs of metal powdering from fretting, as well as cracks in welds and cement grout. The addition in the ZOOM system of displacement sensors on the upper part of the stator behind air gap sensors is highly recommended to help identify the primary cause. In the meantime, stator core vibration, shaft vibration and air gap parameters should be closely monitored with alarms and trends to

21/12/2011 06:56

PI_NovDec_Vibrosystm.indd 49

21/12/2011 07:03

diagnostic monitoring

CASE STUDY CS016

DETECTing AnD DiAgnoSing A RoToR DESign Weakness on new Hydrogenerators

Commissioning: 1999 power: 42 MW speed: 112.5 rpm nominal Air Gap: 11 mm/0.433 in. stator Bore dia.: 6.45 m/253.94 in. Turbine Type: Bulb / Kaplan nbr Blades: 4 Bearing Layout: Generator Guide Turbine Guide

his case demonstrates the usefulness of monitoring new machines during commissioning using VibroSystM air gap technology to detect generator anomaly. At this new 5-bulb unit hydroelectric project, the utility insisted the generators be fully equipped with a ZOOM system. Within months of its commissioning, the first generator experienced a rotor-stator contact resulting from rotor rim failure. At that time, the monitoring system was not operational due to project constraints. The utility insisted the monitoring system be implemented as soon as possible for both the unit return to service and the commissioning of the remaining bulb units. While at site to complete installation and commissioning of the ZOOM system, VibroSystM technician and the plant supervising engineer reviewed data acquired by the system on the other machines. They found an irregularity in the air gap results of one unit. At Full Load, the air gap sensors were measuring different rotor shapes (Figure 1). Sensor at 225째 angle (bottom) was providing the most dramatic result. Comparison of each sensor at

Figure 1: Signature graph of generator at Full Load showing a significant variation for the sensor at 225째 (blue curve) between poles #29 and #52.

different operating conditions, ranging from Speed No Load (SNL) to Full Load (FL) demonstrated a transient bump between poles #29 and #52 resulting from a loose section of the rotor rim (Figure 2). With gravity helping, the loose rim section protruded into the air gap when rotating towards the bottom, then returned to its position when passing at the top (Figure 3). This cyclic flexing was imposing stress on the rotor rim components. The

Figure 2: Signature graph of rotor profile at various operating conditions facing sensor at 225째 and comparison with result 9 days earlier.

maximum bump amplitude (most critical air gap) occurred when rotor pole #39 passed in front of the sensor at 225째 angle. Comparing these results with data recorded at Full Load nine days before clearly showed that the situation was deteriorating very quickly and that a failure could potentially occur at any time. Meanwhile, the vibration monitoring instrumentation did not reflect these changes. The plant supervising engineer realized the similarity with the previous incident and immediately alerted Head Office. Using the remote access capability of the ZOOM system, Head Office engineers reviewed data, agreed that another rotorstator contact was imminent and ordered the machine stopped. They urgently contacted the generator manufacturer and faxed them plotted results. The utility requested the manufacturer inspect the rotor rim. Two days later, engineers from the manufacturer and the utility were on site to investigate. The engineers found the rotor rim and rotor-tospider attachments in much worse condition than the unit that sustained the first incident. Several bolts broke during percussion tests. The cyclic imbalance overstressed the bolts, thus further loosening the rim. A detailed generator design review was performed and modifications were implemented on all five machines. The compression bolts were replaced by ones with higher elasticity and the rotor rim-tospider interface strengthened. Rotor performance is now systematically monitored and air gap alarms have been fine-tuned to effectively warn of air gap

Figure 3: Polar graphs of rotor profile 9 days apart measured by sensor at 225 degrees (right) angle. Note the bump protrusion in the area between poles #29 and #52.

ThIS caSe demoNSTraTeS The uSeFuLNeSS oF moNITorINg New machINeS durINg commISSIoNINg uSINg VIbroSySTm aIr gaP TechNoLogy To deTecT geNeraTor aNomaLy. aT ThIS New 5-buLb uNIT hydroeLecTrIc ProjecT, The uTILITy INSISTed The geNeraTorS be FuLLy equIPPed wITh a Zoom SySTem. wIThIN moNThS oF ITS commISSIoNINg, The FIrST geNeraTor exPerIeNced a roTorSTaTor coNTacT reSuLTINg From roTor rIm FaILure.

loss. No abnormal changes have been detected since and the machines behave within set guidelines. This case clearly demonstrates that air gap monitoring is capable of predicting an imminent air gap failure so that preventive action can be taken. It also shows that critical air gap change can occur within a matter of weeks for which periodic off-line testing is insufficient. Air gap data was instrumental in analyzing and diagnosing the problem, and monitoring it afterward. The system was beneficial to both the utility and the manufacturer. In addition to getting a return on its investment before all units were even commissioned, the utility experienced the powerful capabilities of the ZOOM system. It was provided with valuable information to enforce warranty terms. Meanwhile, the manufacturer was able to quickly identify the design weakness and find a solution, then implement corrective actions on all units to ensure no other units would fail, and therefore avoid paying additional penalty due to forced outages.

Figure 4: Illustration of pole #39 (most critical of the loose section) path over one rotation relative to its position facing sensor at 45 degrees.

50 november/december 2011 power insider

PI_NovDec_Vibrosystm.indd 50

21/12/2011 07:03

PI_Issue_6_MWGroup_ad.indd 51

21/12/2011 08:08

MALAYSIA SOLAR PV

FROST & SULLIVAN: MALAYSIA TO BE ONE OF THE HOTTEST DESTINATIONS FOR SOLAR PV IN ASIA RENEWABLE ENERGY TO BE THE FASTEST GROWING MARKET IN MALAYSIA

52 NOVEMBER/DECEMBER 2011 POWER INSIDER

PI_NovDec_Solar_PV.indd 52

21/12/2011 07:11

he implementation of feed-in-tariff (FiT) policy will bring the required momentum to accelerate solar PV market growth in Malaysia. Malaysia aims to become the second largest producer in solar manufacturing by 2020 and is emerging as the favoured country for new PV manufacturing units. Investments in solar PV power projects for 2012 is estimated at US$72 million, a 194% growth over 2011 and close to 12 MW of solar PV power is to be added in 2012, a massive year-on-year increase of 242.9%. According to Ravi Krishnaswamy, Vice President of Energy & Power Systems, Frost & Sullivan Asia Pacific, banks are actively considering large-scale solar power projects as the next wave of investment option as they are well-equipped to understand risks better now. Government support through a subsidy rationalization program that gradually removes subsidies from items such as fuel, gas, electricity and tolls bring their rates close to market rate, making

solar power look less expensive in the long term. “Falling global prices for PV modules could also aid the growth of grid connected solar market in Malaysia,” he said. CONVENTIONAL POWER AND UTILITY WILL REMAIN THE LARGEST MARKET The shortage of gas will continue till Q3 2012 and is expected to get better after the commissioning of Malacca’s regasification project. Krishnaswamy commented, “However the recently agreed cost sharing mechanism between TNB, Petronas and the Malaysian government, will alleviate TNB’s position. TNB will be looking to diversify its source of power in order to overcome supply challenges with any one fuel source.” “Approval for tariff hikes in tandem with gas price increase will help TNB to strengthen its financial performance and thus focus on investments in other areas of value chain including transmission and distribution,” he continued. The market for electrical equipment will remain

strong with the transformers and switchgears segment alone representing a US$520 million market in Malaysia for 2012. Malaysian companies including GLCs and private ones will actively look for investment opportunities in power sector in Southeast Asia and South Asia. ENERGY EFFICIENCY Malaysia presents immense opportunity for energy efficiency (EE) and energy management services because of the energy intensive process and manufacturing industries. The Malaysian government has taken a major step by passing an EE law that will be the framework for promoting EE improvements. The market is expected to be US$298.5 million in 2012, representing a 13% y-o-y growth due to increased awareness regarding sustainable development. Currently, the commercial sector is the largest market, but the industrial sector is likely to gain momentum in 2012.

POWER INSIDER NOVEMBER/DECEMBER 2011 53

PI_NovDec_Solar_PV.indd 53

21/12/2011 07:13

LOW IMPACT HYDRO

LOW-IMPACT HYDRO: ‘AS MUCH INFORMATION AS POSSIBLE’

LOW IMPACT HYDRO (SMALL HYDRO) AN OVERVIEW FROM POWERGEN ASIA 2011 BY DANIEL ROGERS

54 NOVEMBER/DECEMBER 2011 POWER INSIDER

PI_NovDec_Hydro.indd 54

21/12/2011 07:21

arawak Energy. Considerations, Positives and negatives. Graeme Maher Sarawak Energy. Following PI Magazine’s involvement at the Power Gen Asia exhibition in Kuala Lumpur this September, I was fortunate to spend some time at some of the discussions that took place on hydro power. Here I look at a discussion that was held with Sarawak energy. Alongside their many large Hydro power projects, Sarawak Energy; in 2011 are reopening their focus and drive toward that of mini-hydro studies. One major factor for this decision was due to the fact many of the ruralised villages are still unaffected by electrification and are unreached by the state grid. Although 75-80% are now electrified, many of which by those of Sarawak Energy stations, villages still powered by diesel generators is something the Malaysian Federal Government are looking to address. In Sarawak the consideration and vision toward mini-hydro power follows the influx of completed projects throughout and since the 1980s in which 10 mini hydro projects were constructed throughout Sarawak. However, not all of these projects were met with success. Batu Lintang was one of these failures. This plant itself was planned to generate 100 KW but with it being constructed below the areas flood level was never going to accomplish this feat. Replacing equipment on a regular basis proved costly, especially considering its remote location and troubles getting parts and people to site in the first place. The Kota plant toward the North of Sarawak was also one such project that was problem ridden. The intake of this plant was not covered with a rake and so during floods and heavy rains, which are not uncommon in Sarawak, the intakes would regularly become clogged. This, along with the fact that a major human error occurred in terms of the turbines being installed horizontally rather than vertically as in the plans, again meant it was always going to be hard to ensure this project was successful. The Kejin was another plant that had to be shut down in Sarawak. This was mainly due to the access. The only road into the plant was via a 4KM dirt track through jungle terrain. The road itself was overgrown and often was such all the way from the plant to transmission lines. Maintenance, repairs and operations proved difficult because of this and inevitably lead to the plants closure. With the abundance of experience and lessons learned as shown above, the future mini-hydro projects completed by Sarawak Energy of course need many more planning and consideration points to reduce and eradicate all of the problems mentioned. Flood levels and power station placement are one of these issues. Within this, consideration is also required surrounding the fact that flood risk areas are typically increasing throughout the Asia Pacific. Ensuring placement can utilise as much intake and energy production as possible is ideal. But being hampered by the energy source the plant is trying to exploit is off course problematic. Non conservative designs need to be ironed out at planning stages also. With some of the early projects mentioned above, problems with rural placement were widespread and inevitable and should have been evaluated a lot more closely. Construction machinery would have proven to be difficult to get to many

ruralised sites in the first place. Although the heavy machinery involved may have been able to overcome and force through many objects enabling initial construction, when it came to maintenance and the repair of these sites, smaller vehicles and work men, who may not have been used to these terrains, were sometimes unable to carry out their work, or even get close to the power stations in the first place. Rural placement may be easier in terms of distribution to these ruralised areas, but in terms of the overall placement considerations, these issues again need to be fully addressed and considered early on in the planning stages. Trash rakes are also an important part of small hydro developments. More so in locations where heavy rain fall, jungle make-up and over-hanging trees are in abundance. This may be harder to evaluate upon first glance of planning projects. Debris from falling trees for example may not be in constant flow in any of the potential sites. However, rainy seasons, the amount of rain and landscape of the areas themselves need to be considered. To be able to make sure as much information as possible is gathered, making multiple trips, especially in times of the harshest of weathers, is going to be an important part of the process, not just for trash rakes implementation considerations but for the entire initial development stage.

‘ALONGSIDE THEIR MANY LARGE HYDRO POWER PROJECTS, SARAWAK ENERGY; IN 2011 ARE REOPENING THEIR FOCUS AND DRIVE TOWARD THAT OF MINIHYDRO STUDIES. ONE MAJOR FACTOR FOR THIS DECISION WAS DUE TO THE FACT MANY OF THE RURALISED VILLAGES ARE STILL UNAFFECTED BY ELECTRIFICATION AND ARE UNREACHED BY THE STATE GRID.’

With these considerations in mind, Mr. Maher concluded that gathering as much information as possible is paramount for any and all future projects for Sarawak Energy as it should be for any company looking to develop and implement low-impact hydro. Flood levels; gaining access not just within development stages but throughout the plants entire life cycle; also planning power plant evacuation i.e. ensuring safety if necessary to quickly and safely get out is as important as getting in; thinking about the grid at an early stage. This final point was an important thought provoking close. Ensuring that when the grid does affect the area electrified by these small hydro developments, the plants themselves can be easily accessible to connect also. With these considerations taken into account at very early stages, proves how there is certainly place for both large and small hydro to continue to play an important role in the electrification of rural areas. Such considerations have also led to TNB, by 2015, aiming to produce, 290mw by mini-hydro. TNB already has 36 mini-hydro plants but only 21 are operational, nationwide. They realise a huge advantage of mini-hydro plants is that it they do not have the same kind of adverse effect on the environment as large-scale hydro dams. The list of associated environmental and humanitarian impacts are by no means hidden when it comes to large scale hydro developments. This is a clear reason for Governments to look toward low impact as a viable alternative. One which is often relatively easy to establish. Another advantage TNB realises of hydro plants is that power can be generated, as per demand, by managing the flow of river water, which means less wastage of energy. The projects focused on by TNB for these Minihydro plants, in most cases, do not require a dam or barrage to store water, instead water is captured from a waterfall through a weir which is then channelled through a 1.65 kilometre long pipeline which connects to the plant. One such project that TNB have based some of their future plans on is The Sungei Mentawak mini-hydro power station on Pulau Tioman. This facility has an installed capacity of 0.5 mw. TNB acknowledges Mini-hydro plants of such capacity require an investment of around RM70 million. POWER INSIDER NOVEMBER/DECEMBER 2011 55

PI_NovDec_Hydro.indd 55

21/12/2011 07:22

low impact hydro • economic Conditions • environmental; e.g. the lives and habit of local fish and wildlife. • electrical Boundary; Grid stability and time frame, is the plant connected currently and will it be so in the near or far future.

In the last 12 months, the Pulau Tioman plant generated 1,460,590 kilowatt hours of energy and helped reduce TNB’s diesel cost and emission by RM864,698 and 11,684.72 kilogramme, respectively. Clearly helping the government meet their focus and drive to move away from Diesel Powered Generators and have the grid of Malaysia benefit the majority of the population. (http://komunitikini.com/pahang/minihydro-power-plants-key-to-future-power-production) To enforce such projects, lessons learned as shown above, need to be addressed alongside new age choices and experience when it comes to the OEM and hardware considerations for these future projects and their implementations. Bernhard Mueller (sales) Thomas Eiper (design and layout) Alongside the points covered in terms of these choices toward the placement of the dams themselves, personnel from Andritz shed light on considerations required in order to make choices for the Turbines also. As a starting point, the amount of water and the speed of flow can effect this. Higher Head schemes for example, and them benefiting from the implementation of Pelton turbines is one straight forward example of how these choices are made by the landscape and layout of the plant itself. In order to do this, operators must make the use of the jet of water in which the runners are shaped to capture as much energy as possible. The table below helps show in terms of a very basic level how decisions can be made in terms of turbine choices and their applications. As basic as this shows in terms of Head, Flow and Output, individual projects of course need individual consideration. As well as the installation of any specific turbines, the risk of flooding needs to be considered and if the chosen turbine can cope with the harshest of water flows the specific site produces. Now with the abundance of turbines Andritz for example have to offer, careful and individual decisions need to be

made to ensure the plants produce as much energy as possible in the safest possible way, and from an investors perspective, in as quickest possible time. The refurbishment of existing hydro plants throws up as many question points and highlighted areas as new developments. The replacement of turbines has to bring an increase of efficiency (changing for lower power outage would be a complete waste of time). Low impact on the existing buildings and civil structure must also be taken into account. This addresses the issue of fast implementation as well. If structural work needs to be completed as well as the major work of replacing a turbine in the first place, this could take months until power would start being produced again, something none of the parties involved would be particularly happy about. New projects, in terms of turbine considerations again need to manage the need for fast implementation. Funding and EPC time constraints envision being able to use the plants fairly soon after the turbine is in place and so getting it to the site and connected has timely pressures. With the fact that mini-hydro plants are such a healthy resource of green energy, economical considerations in terms of Low Voltage generators being involved and ensuring the turbine efficiency to run alongside these is yet another planning consideration. As well as the issues highlighted by Mr. Maher about the site placement, underground considerations are as equally important. The material and sedimentary factors of potential sites can have a determining position when it comes to the development itself and also the turbines used; for example how many, placement and turbine type. Andritz themselves concluded that five key points of consideration are required before a turbine implementation choice is established: • Hydraulic Considerations • site Conditions; material levels both above surface and underground

Here we can see a clear link to that of Sarawaks’ experience and previous struggles. Each plant needs to be looked at individually whether this is for an existing project turbine upgrade or for a new project for tender. The site assessment process must be as in depth as possible. Taking the time to collect as much information as possible throughout the planning process will prove the most defining factor of whether the plants are a success. Building on the focus toward these Low-Impact developments are the initiatives we can see in Thailand. Thailand it seems has an especially limited access to fossil fuels to go with a high demand for electricity which has meant a necessity to look at hydro power investment. Existing irrigation dams have been a key area for such investment particularly from EGAT (Electricity Generating Authority of Thailand). With 4000 such dams throughout the country, very few have been installed with hydropower facilities. Six such plants have been selected by EGAT to utilise the existing water channelling and achieve value added investment. The Chao Phraya Hydropower project is one such example whereby a consortium of Italian and Thai Development Public Company have merged to engage in this idea. Channelling the water through a hydro plant complimenting the existing irrigation systems achieves maximum usage of this valuable energy source. One which can give valuable input for future projects and plans across the region. Irrigation dam exploitation is yet another important building block in the hydro-power structure. One which is guaranteed a future for the coming years. Across all of these discussion points and developments throughout the South East Asian developing markets, funding continues to be an issue. By addressing the many considerations shown above, and ensuring that indeed as much information as possible is gathered at and from any potential sites for these Low-Impact hydro projects means investors can be as reassured as possible that these projects for tender and the investment involved is more than worthwhile. Low impact hydro is a proven resource for primary and developing markets within Asia. One that is receiving both investor interest and government focuses due to the nature of how the plants can both electrify those that may otherwise depend on costly and environmentally unfriendly alternatives, as well as being in many cases, as shown in Thailand and the scheduled projects from TNB, be fairly low in cost to implement. This is one energy source that is always going to be available and utilising, where applicable, is without doubt a worthy strategy. As I am sure that you can gather from the overview, hydro power throughout Asia and pacific offers great opportunities for countries that have a wealth of hydro potential, but also faces numerous challenges. Through working together and educating governments, hydro power will certainly be a key technology for RE energy implementation over the coming years.

56 november/december 2011 power insider

PI_NovDec_Hydro.indd 56

21/12/2011 07:22

ď&#x20AC;

POWER GENERATION ď&#x20AC; Repair : Refurb : Rewind Australian Winders can offer complete inspection, testing, cleaning and overhaul of all your power generation equipment from hydro through conventional cooled to high voltage liquid cooled units. Fast 24 hour response globally with a full service onsite workshop, testing equipment, dry ice cleaning and induction braze welding.

Complete turnkey project capable including coil or bar supply We are able to supply high quality large machine coils and bars for any size project, plus any re-design requirements or reverse engineering to upgrade the capability of your generator. We offer project management, self sufficient winding teams, or just supplemental project labour at cost effective rates. Australian Winders can provide inexpensive solutions for your power generation equipment service allowing you to get back in service quickly saving considerable lost revenue.

Visit us at www.australianwinders.com.au For personal assistance from one of our specialists: Perth, Australia +61 412 989 173

PI_Aussie_Winders_Ad.indd 57

21/12/2011 07:28

POWER PLANT MAINTENANCE

THE ASIAN DEVELOPMENT BANK: MAINTAINING WHAT WE HAVE DANIEL ROGERS

he Asian Development Bank for many years have realised that maintenance is as an important factor for the Power Industry as investment into new projects. By letting those plants that had received initial investment deteriorate means productivity and investment opportunities seem totally unworthwhile. A recent example where this has been three times a day, are caused by aging and inefficient power plants. “When there is a shortfall due to a breakdown or maintenance of power plants, the city suffers from outages, which are happening right now,” said Ethel Natera, Visayan Electric Company (VECO) spokesperson. “If we don’t interrupt our customers’ power supply, there will be a problem in the whole system, resulting in a breakdown.” “If any plant goes down, then there will be outages because there is no more reserve supply,” said Jaime Jose Aboitiz, VECO executive vice president. According to government compiled data, peak power demand is 1,175 highlighted can be seen via the reports conducted in Cebu City in Cebu, Philippines.

The city’s rotating brownouts, as frequent as tMW, while the total power supply is only 1,140 MW. Addressing these issues and concentrating funding toward those plants where maintenance proves an issue means these brownouts and power shortfalls will prove less of a problem for years to come. The ADB are fully aware of this and have initiatives in place for that very reason. Clearly this is not something however that is going to happen overnight. The deployment of renewable energy sources and the realization of energy efficiency projects often require substantial amounts of money, in order to plan the project, purchase and install the equipment, as well as to train staff for the operation and maintenance of the system installed. However with the issue of maintenance and training requirements implemented at an early stage, is without doubt going to improve projects

success and insure at planning and design stages that the relevant investment for these sectors are taken into account and accustomed for. This inevitably will mean that the issue of maintenance say 5 or 10 years down the line where plants are deteriorating and in some cases too far gone to serve their purpose, should in theory never be such a predominant issue and one which individually needs investment and government expenditure. In Pakistan for example, The Minister for Water and Power, Mr. Syed Naveed Qamar, showed great appreciation of the role of ADB for improvement in energy sector and said the support of the bank for energy efficiency programme which is heavily influenced by maintenance considerations, would help save energy and reduce transmission and

58 NOVEMBER/DECEMBER 2011 POWER INSIDER

PI_NovDec_ADB_Maintenence.indd 58

21/12/2011 07:24

: E

distribution losses. He asked the ADB to help in the Tubewell Efficiency Programme by replacing existing motor pumps with new improved ones. Mr. Qamar also asked for providing guarantee facility for wind power projects. The minister also briefed the delegation regarding new energy sector improvement initiatives like operation and maintenance contract of Generation companies through private sector and conversion of existing IPPs to cheaper fuels. Rune Strom, Director for Energy of ADB also

discussed current status of power sector reforms, energy efficiency programmes, central power purchasing agency, independence of distribution companies, and proposed amendments to the Nepra act. With these initiatives making major headways in the region again proves the realisation of how operational and maintenance cost need to be addressed in order to guarantee and protect the success of existing and current power plants throughout the Asia Pacific. The Bank however has conveyed to Pakistan its

serious concerns over slow progress on a $1.2 billion project for rehabilitation of generation companies (Gencos) of Wapda, putting a question mark on the government’s efforts to facilitate these enhancements. “Due to poor maintenance of the power stations, Gencos have lost nearly one-third of their capacity and nearly 17 per cent of their thermal efficiency due to plant degradation,” a senior official said, quoting a technical study. Most of the units are capable of running both on gas and oil, but were operating on

POWER INSIDER NOVEMBER/DECEMBER 2011 59

PI_NovDec_ADB_Maintenence.indd 59

21/12/2011 07:24

POWER PLANT MAINTENANCE oil only due to shortage of gas. The Muzaffargarh station has lost more than 40 per cent of its generation capacity, while the capacities of Jamshoro and Guddu have come down by 32 and 31 per cent, respectively. Some of the units have lost up to 63 per cent of their generation capacity. The resolution of problems at these power plants alone can significantly bridge the demand-supply gap, which if synchronised with improvements in the distribution network, can further overcome power shortages. Again these stations and the improvements and maintenance issues involved are an important focus and drive the ADB for the near future for its Energy and Power Division. With the workings the ADB are pushing forward in Pakistan and the close relationship it has with the government there, one would hope these shortfalls are ironed out sooner rather than later. The issue of maintenance and the relevant investment required to implement it, is no new phenomenon for the ADB. As early as the late 1970s the bank had the focus and realisation that maintenance was an important factor for plant success: The bank carried out a Regional Energy Survey in 1979-1980 that endorsed its focus on the development of indigenous energy resources and improvement of the efficiency of energy utilization. The survey recommended that the Bank should increase lending to this sector and mobilize co-

financing resources for its projects, which it did. It also recommended that resources should be allocated for energy master-planning, preparation of energy conservation programs, development of renewable energy resources, and training of staff and managers who could implement these programs. Several studies and related activities have been undertaken with regional technical assistance funds to assist in the development of the lending program since the mid 1980’s. These included studies on improving the efficiency of power system operations, the analysis of regional electricity demand, power plant maintenance and management, electric power system expansion planning, increased utilization of natural gas resources, energy conservation, and a regional study on solar power. These studies assisted the Bank in expanding lending to the sector during 1988-1992. The focus now for the ADB is changing from major irrigation projects to those concentrating on rehabilitation and maintenance. Lessons learned from these past studies along with up to date focused initiatives have meant lending and investment opportunities are increasingly available and very much part of the Banks push across Asia. Utilising and maximising existing plants that, in many cases would have already received funding in some way from the Bank, proves a valuable point for future lending and one that for projects for tender are in many ways required to write in to their early plans.

CARBON MARKET INITIATIVE One such way in which this is shown as a continuation of these ideas is how the ADB will also continue to implement its Carbon Market Initiative (CMI). According to the Bank, CMI aims to support sustainable development goals of its developing member countries (DMCs), address global climate change concerns and assist developed countries meet their emissions reduction commitments to the Kyoto Protocol. Under the CMI, countries that are exceeding their required carbon emissions buy carbon credits from other countries who have unused them, this is also known as carbon trading, by providing funds for forest plantation and/or maintenance. Such plantations are assumed to absorb the excess carbon emissions of the buying country. With maintenance proving a key requirement for these types of country trading abilities, more than simple investment arms are looking toward the maintenance sector. Maintenance of course is always going to be required, no plant is going to run without problems (however minor) for its entire life cycle. This is why focus is on the enhancements and required work forces and machinery to cater for the power plants needs. The ADB want to preserve their investments and understand maintenance is of major priority for this reason.

‘MAINTENANCE OF COURSE IS ALWAYS GOING TO BE REQUIRED, NO PLANT IS GOING TO RUN WITHOUT PROBLEMS (HOWEVER MINOR) FOR ITS ENTIRE LIFE CYCLE. THIS IS WHY FOCUS IS ON THE ENHANCEMENTS AND REQUIRED WORK FORCES AND MACHINERY TO CATER FOR THE POWER PLANTS NEEDS.’

60 NOVEMBER/DECEMBER 2011 POWER INSIDER

PI_NovDec_ADB_Maintenence.indd 60

21/12/2011 07:25

Hydropower stands or falls with the valve

VAG valves stand reliably Valves come first in the generation of hydro power. They provide direct protection to turbines while indirectly preventing incalculable subsequent risks for human beings and plants.

Planning and operating hydropower plants means taking on responsibility. Deciding on VAG valves is deciding on maximum safety. Because VAG valves stand reliably.

www.vag-group.com 路 we move water

PI_VAG_Ad.indd 15

21/12/2011 07:48

An innovative Swiss company providing reliable Measuring, Monitoring and Diagnostic Systems SEnSorS

PMS – dATA

cMS - condiTion

And condiTionErS

AquiSiTion ModulE

MoniToring SofTwArE

aiR gap tRaNSmittER

pmS-100

Non contacting sensors for air gap measurements from 2-65 mm.

Fully programmable protection and monitoring / diagnostic systems.

ProJEcTS

hydRo powER gENERatioNgENERatoRS & tuRbiNES

FibERoptic accElERatioN SENSoR Non metallic and electrically non-conductive fiberoptic acceleration sensors

pmS-200-Ew Specific data aquisition System for endwinding monitoring

RuNNER clEaRaNcE pRobE Runner clearance probes for water gap measurements

pmS-200-ag data aquisition System for airgap monitoring

pmm-300

liNEaRizEd vElocity SENSoR Electro dynamic low frequency velocity sensors for bearing vibration measurements

Standalone «all-in-one» 4 channel protection and monitoring system for mini / compact hydro

tmS-SERiES paRtial diSchaRgE SENSoRS Sensors for partial discharges measurements

Route des Daillettes 6 Case postale 198 CH-1709 Fribourg Switzerland

PI_MCM_Ad.indd 62

miNES & cEmENtRy plaNtS-RiNg motoRS

cost effective permanent installation up to portable pRpd analyser

Phone : + 41 26 401 84 56 Fax : + 41 26 401 84 57 info@mc-monitoring.com sales@mc-monitoring.com

FoSSil & NuclEaR plaNtStuRbo gENERatoRS

gEaRlESS wiNdmillS

Think ahead Move forward www.Mc-MoniToring.coM 21/12/2011 07:37

PI_TES_Ad.indd 63

21/12/2011 08:14

PI_Issue_6_Cummins_ad.indd 64

21/12/2011 08:09