Generators:: Pushing For Maximum Efficiency

The magazine for the international power industry
March 2016
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POWER-GEN India 2016
Generators:
SHOW ISSUE
Pushing for maximum efficiency

INDIA POISED FOR
RENEWABLES BOOM
ANALYSIS OF INDIAS
DIESEL GENSET SECTOR
TURKEYS DYNAMIC
POWER POTENTIAL
TECHNOLOGY TRENDS
IN NOx REDUCTION
www.PowerEngineeringInt.com
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POWER ENGINEERING INTERNATIONAL

MARCH 2016/// VOLUME 24/// ISSUE 3
Contents
Industry Highlights
36
Diary
32
Project & Technology Update
36
Ad Index
Features
4
India needs over $140 billion in energy investment per year to 2040. P16
Credit: World Energy Council
22
Turkey: a dynamic market full of potential
It is evident that DSOs will need a bigger toolbox to

move from their traditional connect and forget concept
towards one of connect and manage.
We explore what makes Turkey such an attractive energy

market, what untapped potential it still has, and how
geopolitical problems could play out.
26
12
Generators: pushing for perfection
India will be the engine of energy growth

So says the International Energy Agency. We look at the
IEAs forecast for the Indian power sector and hear from
players active in the country.
20
NOx reduction: latest trends and thinking

To address the important obligation of NOx reduction,
there is a spectrum of conventional best available
techniques and pioneering new technologies available
to the power industry.
The efficiency of large plant generators is almost 99 per

cent, but manufacturers are striving to squeeze every
extra drop of efficiency out of their machines.
16
Repowering the role of DSOs
29
Conserving water in coal plants

At its flagship Medupi power plant, South African utility
Eskom is keenly aware of the need to reuse as much
water as possible.
Focus on Indias diesel genset sector

Find out what is driving growth in the diesel generator set
market in India, who are the major players and where
there are still potential business opportunities.
On the cover
How generator manufacturers are striving for 100 per cent efficiency and reliability. P12. Photo credit: Voith Hydro.
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1603pei_1 1
Power Engineering International March 2016
3/11/16 10:17 AM
Industry Highlights
his month marks the fifth anniversary of
removal function by providing an alternate
the Fukushima nuclear accident that was
path for cooling water supply, arranging for
caused by a devastating earthquake
passive cooling or identifying an alternate
and tsunami on the east coast of Japan.
heat sink.
The OECD Nuclear Energy Agency has
Fukushima demonstrated that the ability
released a report outlining the lessons learned
of nuclear plants to maintain containment
since Fukushima. It also deals with what work
integrity could be challenged by severe natural
still needs to be done, not just to further
hazards. In response, some NEA member
strengthen safety in and around nuclear
countries have refocused their efforts on
power plants but also in the event of another
upgrading plants with respect to containment
so called Act of God such as an earthquake.
venting and hydrogen mitigation.
As NEA director-general William Magwood
In other countries, new or improved
says: The great lesson of Fukushima is that
filtered vents or filtering strategies are being
we cannot predict every natural event but
implemented or considered for use during
plants have been made more resilient and
venting to limit containment pressure. Some
better prepared for the unexpected than they
are introducing a different hydrogen mitigation
were five years ago.
strategy or improving the existing one.
The report states that prior to Fukushima,
On
the
strengthening
of
regulatory
nuclear operators and regulators had carried
frameworks, the NEA notes that there has
out detailed assessments of the potential
been a particular emphasis on ensuring that
internal hazards and risks of a plant, but spent
a clear and comprehensive legal framework
less time considering external risk factors
exists to allow the operator of a nuclear plant
such as natural disasters.
and its government if necessary to quickly
As
result,
post-Fukushima,
NEA
react and adapt to the specific circumstances
member countries have used the latest
of an event in order to ensure timely and
data technology to identify and consider
financially
plausible combinations of sequential and
victims.
consequential events.
The
NEA
stresses
adequate
compensation
Fukushima highlighted the challenges

involved in managing the consequences of
consequences of an earthquake had indeed
a large-scale accident. As time progressed,
been considered by the Japanese they just
radiological
never expected that such an earthquake
became increasingly evident, while decisional
would be accompanied by a tsunami: The
responsibilities were shifting from central to
accident did not reveal any unknown initiators,
that
the
regional and local governments.
and
social
consequences
sequences or consequences. However, the
Even countries not directly affected by
combination and the severity of initiating
the accident spent significant resources on
events had never occurred before, and the
understanding the rapidly-evolving situation
evolution of the accident in three different
so they could help their expatriates in Japan,
units simultaneously was also new.
and address concerns over people, cargo
It is the need to plan for such catastrophic

natural events that form the basis for much of
the report.
and food arriving from Japan.

The
Japanese
government
was
challenged by the need to not just tackle
Ensuring that heat can be removed from
the immediate accident but also dedicate
the core in the event of an extreme natural
resources to formally and informally address
event has led some countries to consider
questions from other countries and from
bunkered safety systems, designed to resist
international organizations.
such extreme natural events.
The
NEA
therefore
concludes
that
Many countries have now installed or are
emergency management planning should
considering strategic placement of portable
take into account the Japanese experience
equipment that can be quickly positioned
in terms of the training and resources required
and
to be appropriately prepared to manage the
emergency
cooling. Some
countries have enhanced the decay heat
1603pei_2 2
Kelvin Ross
Editor
www.powerengineeringint.com
to
potential
provide
Fukushima highlighted
the challenges
in managing a
large-scale accident
Follow PEi Magazine on Twitter:

@PEimagzine
Follow me: @kelvinross68
collection and flow of information.
3/11/16 10:17 AM
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Elbistan lignite power station: Turkey is targeting more energy from lignite-fired plants
Credit: MHPS
Special Focus: Turkey
Dynamic market
offers plentiful
opportunities
Prompted by a fasttrack programme
of liberalization and
privatization, Turkey
has become one of the
worlds go-to destinations
for power companies.
Kelvin Ross explores what
makes the country so
attractive, what untapped
potential is still has, and
if there are geopolitical
problems on the horizon
conomic
rising
such as Russia and Azerbaijan for its power,
positive
Turkey has taken steps to wean itself of this
demographic trends and the
dependence and this has translated into a
rapid pace of urbanization have
new drive for lignite plants and renewables.
per
expansion,
capita
propelled
income,
energy
demand
in
strategy over the ownership of power assets,
The countrys energy demand is estimated
selling off many previously state-owned plants
to increase by around 4 per cent a year until
This has resulted in a lot of what Jochem
capacity expected to hit 100 GW by that time.
calls newcomers not newcomers to Turkey,
This energy boom is attracting power
but newcomers to the power sector who were
players from around the world to the Turkish
already established in Turkey in another area of
market. With a European market that has
industry. Some are family holding companies
stalled for many equipment suppliers, what
actively seeking sound investments.
makes Turkey attractive, says Dr Matthias
opportunities
Power Systems Europe, is that something is
companies have a certain perspective for
happening in the first place.
their plants they want to keep the plants in
has
translated
into
and
challenges:
These
order but they are not experienced in dealing
power
with these assets how a tender is conducted
consumption and in turn energy companies
and the quality of, say, Chinese equipment
can smell business.
over European equipment. Sometimes we
After years of relying on gas from countries
1603pei_4 4
This, he adds, has brought its own
Jochem, chief sales officer at Mitsubishi Hitachi
growth
to private investors.
2023, with the current 70 GW of installed
He says that Turkeys steady economic
The government has also changed its
Turkey to an all-time high.
have to face unusual requests or deadlines.
3/11/16 10:17 AM
1603pei_5 5
3/11/16 10:17 AM
On the subject of Chinese imports, he says

there is a much greater influx in Turkey than
any other European country. Nonetheless,
he stresses that Turkey is a new game its a
good market for us. Turkey is dynamic.
Mete Malepe, general manager of GE
Power in Turkey, says that Turkey is in our top
10 or 12 countries in the world for power. Its a
significant country for us.
GE set up a regional hub in Turkey in the
early 1990s. Since then it has established a
very strong presence in the gas turbine market
More than half of the gas fired power plants
in terms of MW, and also in terms of the number
Bandirma gas-fired plant in Turkey
Credit: MHPS
of units, are GE technology, says Malepe.

Istanbul is now the headquarters for all of
Eastern Europe for GE Power Services, which
supports gas turbines, steam turbines and
market in the world with about 1 GW of
has been able to support with reforms that
renewable technology.
installations, so even in those technologies
have created a highly competitive and
that were once considered a luxury and we
dynamic market.
It is also strong in the wind sector and

following
the
acquisition
of
the Alstom
only saw in places like North America and
Turkey is also one of those countries
business, it has a presence in coal projects
Europe, we are seeing significant investment
offering private investors favourable conditions
with steam turbines as well as some hydro
and growth.
in terms of feed-in tariff for power generation
business.
Malepe says that five years ago Turkey
from renewables. The incentive regulatory
was ripe for new business because the
framework, the economic growth of the
particularly
government was worried about an energy
country that paved the way to an increasing
indigenous coal. One of the priorities of the
crisis because of not having enough supply.
energy demand, made the Turkish energy
Malepe says: In the coal area, the

government
is
supporting
government is to reduce imports of energy
Now you have a much more established,
products to improve the trade balance of the
liberal market in Turkey. At the same time,
market attractive for investments.

Exergy has been active in Turkey since 2011
country, so gas but also imported coal is an
significant capacity has been added and
when it participated in the consortium for the
issue.
some of the electricity pricing has come down,
Pamukren 1 and Pamukren 2 geothermal
But he stresses that gas is not dead at
so the economics are not as attractive as they
plants. Since then it has established a 100 per
all. We have over 1600 MW currently being
were five years ago. But the fundamentals are
cent wholly-owned Turkish subsidiary.
constructed in gas.
there: the economy is growing, the population
This was a winning choice and gave us
He says gas makes sense for Turkey
is growing, electricity demand is growing and
an additional competitiveness deriving from
because with more and more renewables
the kWh per person in Turkey is still very low
offering a Made-in-Turkey production, says
in the market, you are seeing more and more
compared to the average in Europe.
Spadacini.
variability, and gas power plants are very good
Claudio Spadacini, chief executive and
Exergy is also the first supplier of organic
at fast ramping up and down to support that.
founder of Italian company Exergy, agrees
rankine cycle (ORC) solutions for power

generation from geothermal sources in Turkey.
However, he says that we are definitely
that Turkey has become one of the fastest
seeing more and more interest from investors
growing and most attractive energy markets.
and developers in renewables, primarily wind.
He attributes this to the privatization of
Turkey last year was the number 10 wind
power assets, which he adds the government
Marianna Caputo, marketing manager

at
Italian
cooling
technology
company
SPIG, believes that Turkey is one of the

most attractive and favourable investment
environments in the world.
She says that the governments massive
programme of restructuring and liberalization
has created a strategically-located huge
energy market that has become more
competitive, offering several opportunities.
She adds that Turkey plays a significant
role in the global economy and world trade,
standing out as a promising emerging market
alongside the so called BRIC club countries.
Manisa combined heat and power plant

Credit: Wrtsil
However, she observes that this status

needs important steps still to be taken such
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TURKEYS VISION FOR 2023 INCLUDES:

o
o
o
o
Raising the total installed power

capacity over 100 GW
Increasing the share of renewables to
30 per cent
Maximizing the use of hydropower
Increasing installed capacity based on
wind power to 20 GW (an additional
15 GW)
Installing power plants that will provide
600 MW of geothermal and 5 GW of
solar energy
Significantly enlarging the transmission
o
o
o
o
o
capacity of the high voltage grid

Reaching a power distribution unit
capacity of 158,460 MVA
Extending the use of smart grids
Raising the natural gas storage capacity
to 5 billion m3
Establishing an energy stock exchange
Commissioning nuclear power plants
(two operational with a third under
construction)
Increasing coal-fired installed capacity
from the current 14.5 GW to 30 GW
as to accelerate its innovation and R&D
government should
capabilities aimed at transforming the country
energy policy to encourage foreign investors.
why the Turkish market is where almost all the
into a centre of excellence. To sustain its
Ycel Hurkal, general manager at Wrtsil
geothermal technology suppliers currently are
economic growth in the long term, the country
Energy Solutions in Turkey, says that the
needs to boost its structural transformation.
countrys transition to a free market has been
The SPIG Group started operating in
fortify
its
Turkey has significant wind power potential

Credit: GE
promising
an obvious necessity.
investing for binary plants.

Gisbert at Siemens agrees that Turkey
ranks seventh in the world and first in Europe
Turkey in the 1990s and in 2004 set up a local
The Turkish power market was driven by
subsidiary. Since then, Caputo says we saw
governmental companies, therefore it was
However, he adds that as important as
an overall progress in the emerging market
controlled as monopoly for a long time. As a
renewables are for Turkeys energy strategy in
and a significant expansion in the power
fast-growing market, it became evident that
the coming years, technologies in such fields
generation sector, driven by a steady growth
the ever-increasing demand for electricity
as waste processing and greenhouse gas
in the country.
could not be met solely by public resources
reduction are also often cited together with
and the additional resources needed to meet
this new form of power generation as critically
this demand required extensive investments.
important supplementary practices.
Turkey has attracted a large number of

foreign investors who brought their know-how,
innovative products and experience, helping
to fuel the countrys development.
in terms of geothermal energy.
Wrtsil has been active in Turkey since
Sustaining the environment by resorting
1994 and reached 4 GW in established
to renewable resources is accompanied by
Peter Gisbert, vice-president of sales for
capacity by the end of 2015. Its most
a number of measures and regulations that
Eastern Europe with Siemens Power and Gas
significant growth came between 2000 and
are either currently in effect or will soon be in
Division, maintains that Turkeys biggest energy
2010 due to the liberalization and privatization
effect, including lowering carbon emissions,
asset is quite simply its location: Turkeys
of the market.
increasing generation/transmission efficiency
geopolitical position in the middle of three
Hurkal says the liberalization constantly
continents is a great opportunity to build
increases the competitiveness of the market,
new energy corridors. Turkey is geographically
while privatizations offer a variety of investment
He adds that privatizations will have a
located in close proximity to over 70 per cent
opportunities which also serve the purpose of
hidden capacity increase effect. He explains
of the worlds proven gas and over 70 per cent
increasing competitivity.
that the increased share of private entities
of oil reserves, in particular those in the Middle
and promoting the use of waste management

technologies.
So where is the uptapped power potential
in the electricity generation sector from
in Turkey? Exergys Spadacini says it is
32 per cent in 2002 to 75 per cent in 2015 has
undoubtedly in renewables: If we consider
had a positive effect. Privatized power plants
and
the renewable potential in Turkey wind,
perform significantly better after takeover. After
consumer markets and stands as a key
solar, geothermal and hydro the country is
rehabilitation and replacement periods, the
country in ensuring energy security through
exploiting only 2030 per cent of it.
overall capacity factor is expected to increase
East and the Caspian Basin.

It thus forms a natural energy bridge
between
the
source
countries
diversification of supply sources and routes,
This number is expected to increase,
considerations that have gained increased
as the Turkish government has made it a
from 45 per cent to 80 per cent.

Siemens is celebrating its 160th year of
significance in Europe today.
priority to bring the share of renewables in
business in Turkey this year. Its first activity was
Gisbert agrees that Turkey offers investors
the countrys energy mix up to 30 per cent
the supply of telegraph equipment in 1856
favourable incentives, such as feed-in tariffs,
by 2023, and Spadacini says one of the most
followed by Dolmabahce Gazhane power
purchase guarantees, connection priorities
interesting renewable energy potential areas
plant in 1906 to provide electricity for lighting
and license exemptions. However, he observes
is geothermal.
Istanbuls streets.
that
in
The total geothermal theoretical electricity
Today Siemens has over 3500 employees
Turkeys energy market is little longer than in
potential of Turkey is 2500 MW. The total
and two manufacturing plants in Turkey and
other investment areas such as construction
electricity production from geothermal at
the company claims it is involved in around
so local and foreign investors may evaluate
the end of 2015 was approximately 600 MW,
one third of Turkeys installed power capacity
alternative countries. He believes Turkeys
so theres still a huge market to seize. Thats
in terms of products and solutions.
1603pei_8 8
the return-on-investment
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and central Turkey, investments will continue

as long as the general world economics allow
growth.
Caputo at SPIG is not so sure. Turkey
is facing challenges both at home and
region-wise, because of the current difficult
international environment. Moreover, Turkeys
economy needs deep structural reforms to
boost productivity and transparency.
The countrys political and economic
stability
are
highly
vulnerable, while
its
security faces rising threats from regional

Gas turbine for Hamitabat combined cycle power plant
Credit: Siemens
Islamist extremists. The continuing domestic

political uncertainty and tensions influence
the countrys growth. This may negatively
Gisbert says that another step taken
potential for the utilization of wind power in
affect consumer confidence and investment
by the Turkish government towards a more
Turkey is up to 30 per cent higher compared
sentiment,
competitive energy sector is the establishment
to Europe.
the political issues will be solved. Turkey
an
energy
stock
exchange. Once
Is there anything be it policy or market-
operational, it will not only enhance the
driven
liberalization of the market, but also ensure
opportunities in Turkey?
transparency and help maintain a healthy

balance between supply and demand.
that
Spadacini
would
says
stimulate
further
depending
on
how
needs a stable government and deep

structural reforms in order to restore investor
confidence.
that
despite
the
Jochem cautions that political ups and
government support and regulations which
downs have paralyzed decision-making
On untapped potential in Turkey, Wrtsils
are not done so effectively in most other
and getting the green light for large energy
Hurkal says the projection of the future power
countries, private investors still find some
projects.
market shows that established capacity has
difficulties in the bureaucratic process.
However, Gisbert says that Siemens believes
to reach 120 GW in 2023. This means that
Getting a license is a difficult and long
that the Turkish electricity market will continue
there might be a 15,00020,000 MW project
process. To foster the growth of the energy
to be a strategic sector for the investors and
potential for the coming years in addition to
market and meet the 2023 target, some
the financiers due to sound fundamentals in
nuclear power plants, which will have a total
measures should be introduced to speed
the long term.
15,000 MW of installed capacity with three
up the bureaucratic procedure. The current
Current political situations in neighbouring
nuclear power plants in 2023.
incentives that are in place should be
countries and Turkeys current foreign policy
extended beyond 2020 with increased rates
are heavily affecting the power market in
for feed-in tariffs.
Turkey, but he adds that regarding Turkeys
He says the drive to reduce gas imports

means that the government believes that
existing gas plants are enough and there
He adds that the grid structure is also a
internal and external dynamics, we are used
shall not be additional big investments on this
key factor which requires constant upgrade
to experiencing some fluctuations and crisis in
type of fuel.
in order to allow for addition of new installed
the market.
He expects to see growth in solar and
capacity, especially renewable energy-based
It is Turkeys dependence on Russian
wind together with coal, and also adds that
power plants, since all renewable resources
natural gas that he sees as the most fragile
reciprocating
other than geothermal are intermittent and
situation.
engine-based
natural
gas
power plant investments may continue as
will require adaptation to existing grids.
peaker plants, due to their fast ramp-up
Of Turkeys annual gas imports, Russia

accounts for 55 per cent, Iran 19 per cent,
and -down capacity, short delivery time and
Political tension
Azerbaijan 13 per cent, Algeria 9 per cent
flexibility.
Turkeys proximity to the troubled hot spots
and Nigeria 4 per cent. And natural gas is
Gisbert says that a growth area will be solar.
of the Middle East have seen it make the
the source of 48 per cent of total energy
There are already structured comprehensive
headlines all too often in the past year or so,
production.
incentives for wind, hydro and local coal.
and these developments cast a shadow over
Structuring a solar policy with special solar-
the power sectors potential.
Gisbert says Turkey needs to strengthen its

political and economic relationship especially
related incentives may ramp up the solar
Spadacini says that considering the
with natural gas exporter countries. Although
market. Todays annual solar investment is
geopolitical location of Turkey, there is constant
there is no risk in supply of natural gas currently,
50 MW but with a structured policy there is a
political tension among the neighbouring
the price level of imported gas should be
500 MW-a-year market for the coming years.
countries in the region which will affect
optimized to produce profitable electricity and
investments in the east and southeast regions
ongoing CCPP investment in Turkey.
He also sees Turkey as an important market

for new opportunities in onshore wind power.
of Turkey.
According to estimations of the German
But he adds that considering that most
Foreign Trade and Inward Investment Agency,
of the industrial zones are located in the west
10
1603pei_10 10
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for more information
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Generator design
Pushing
for
perfection
The efficiency of large fossil
fuel plant generators is
almost 99 per cent but
manufacturers are striving
to squeeze every extra drop
of efficiency out of their
machines, writes Paul Breeze
Manufacturers are now making generators that can cope with frequent starts and stops
Credit: Ansaldo
he generator that is mounted
increased financial return. It all depends on
day, says Nigel Daft, Senior Electrical Design
at the end of the gas or steam
the market, explains Dr Gunar Klaus, head of
Engineer at the company.
turbine shaft in a fossil fuel plant or
engineering at Siemens generator plant Erfurt.
Large generators of the type used in coal
the machine connected to a wind
Some markets value an increase in
and natural gas-fired power plants can be
turbine shaft is the element in the
efficiency. These are usually the markets of
up to 2000 MVA in generating capacity. While
generation process that converts
the developed world where operating costs
efficiencies for these machines are close to
are important and capex is available. In other
99 per cent, the size means that any losses are
The technology upon which the modern
markets the investment cost is the bottom line;
still significant. A 400 MVA generator that might
generator is based dates from the middle of
these markets generally do not support these
be typical of a combined cycle power plant,
the nineteenth century and, in the intervening
small gains in efficiency.
with an efficiency of 98.9 per cent, will lose
mechanical energy into electrical energy.
years, generator design has been perfected
4.4 MW.Virtually all that power will be dissipated
to such an extent that the machine is by far
Non-steady operation
as heat there might be a little sound energy
the most efficient element of the whole power
There
area, however, where
as well, resulting from vibrations. All the
generation train.
significant design improvements are important
dissipated heat energy must be removed from
The efficiency of large generators is almost
whatever the market, and these relate to
the generator if it is not to overheat.
99 per cent, says Rdiger Stein, chief engineer
machine reliability. While reliability is normally
There are several sources of loss. One is
for the Generator Product Line at GE Power
high, when power plants are being used for
the resistive loss in copper windings of the
Services. With efficiency that high, it is easy to
grid support duties which involve much more
stator and rotor of the generator. Then there
imagine that there is little more to be gained.
frequent starts and stops as well as regular
are magnetic losses from eddy currents
But, as Stein points out, the losses in a 900 MW
output ramping, the traditionally high reliability
within the steel components of the two
generator are still of the order of 9 MW. A ten
can be compromised.
major components of the machine, rotor
is
another
per cent loss reduction, the equivalent of a
Non-steady-state operation of this type
and stator. In most generators the rotor is an
0.1 per cent efficiency gain, would provide
can lead to a variety of stresses that design
electromagnet that must be excited using a
nearly 1 MW of additional output.
modifications may alleviate. With more fossil
small amount of electrical energy from the
Improving efficiency by 0.1 per cent is
power plants being asked to provide this
generator, another energy loss. Finally there is
possible, even with such highly efficient
type of service, all generator manufacturers
the cooling system that is introduced in order
machines.
Whether it is cost-effective is
are now making machines that can cope
to carry away the heat. Depending upon
another matter, depending on the balance
with this type of duty cycle. Brush is typical.
the size, this will involve air cooling, hydrogen
between
Our machines are designed for two starts a
cooling, water cooling or a mixture of the
12
1603pei_12 12
the
additional
cost
and
the
3/11/16 10:17 AM
Generator design
three. Cooling can introduce more parasitic
pushed the boundary of air cooled generators
losses so optimization of the cooling regime is
as far as they can. Forty years ago a 50 MVA
also important if losses are to be kept as low
machine would have been built with hydrogen
as possible.
cooling, says Stein. Today the main generator
When
looking
at
optimization
of
makers are producing air cooled machines of
generator, there are complex interactions
up to 400 MVA. These modern machines can
to consider. Take the resistive losses. The
be used to replace many older hydrogen and
resistance of the copper windings depends
even water cooled generators, reducing both
essentially on the amount of copper. Adding
lifecycle costs and reliability.
more copper by optimizing the size of the slots
For the moment, 400 MVA appears to be
that hold it or reducing the volume taken up
the practical limit for air cooling. This is already
by the high voltage insulation tape used to
a massive machine in size and weight, and
insulate the copper from the stator core will
removing the heat using air is a challenge.
reduce the electrical resistance of the winding
The cooling of the stator windings in these
and so reduce resistive losses. This will lead to
machines
lower heat dissipation in the winding which
that the cooling air never comes into direct
will reduce its operating temperature, and
contact with the copper, but instead cools the
this will again lower the resistance because
insulated surface and the core components
resistance rises with temperature.
in contact with the insulated winding bars.
is
normally
indirect, meaning
John Yagielski, consulting engineer for
Direct air cooling is possible, but it would add
Generator Systems Integration at GE Gas
to the complexity of the design and may
Power Systems, lists several areas where
not currently be cost-effective. So, for larger
improvements can further reduce losses.
machines, hydrogen cooling will remain
Improved insulation materials, for example,
common up to around 700 MVA, after which
offer two advantages. First they can be
direct water cooling of the stator is used to
thinner, allowing more room for the copper
allow ratings up to 2000 MVA.
windings. Secondly, they

thermal
offer
conductivity, which
improved
means
that
Generator refurbishment
cooling efficiency is also improved. Higher
The refurbishment of older generators to
strength rotor steels support field windings with
extend their lifetimes represents a significant
increased copper cross section, reducing one
business for many of the main manufacturers.
of the largest components of loss. New core
A major refurbishment will normally upgrade
materials can also provide slightly improved
the performance at the same time.
magnetic
performance
magnetic
losses.
with
reduced
By using newer materials not available
modern
when the machine was originally built,
analytical techniques can be used to improve
it may be possible to optimize the stator
the cooling flows.
slots for example, to add more copper.
Meanwhile,
Replacing the windings is common during
Cooling system optimization
refurbishment. Cooling flows can be optimized
Cooling a generator is vital in order to keep
too
it within its operating window and to ensure
while diagnostic maintenance can reveal
resistive losses are minimized. For smaller
vibrational issues that can be resolved by
generators, air cooling is preferred.Air cooling
some structural redesign. This is a pretty large
is much simpler,says Daft.Air cooled machines
business, admits Dr Klaus.
with
advanced
design
techniques,
usually employ a mixture of passive cooling
However, there are limits. For example, the
systems and airflow fans attached to the
steel core of the stator cannot be changed.
rotor of the generator. This keeps the moving
Or, as Stein puts it: The iron is fixed for an old
parts to a minimum, reducing life-cycle costs.
generator. There will often be cases where it
When air cannot provide sufficient cooling
is better to install a completely new generator,
then hydrogen cooling can be introduced.
in the same footprint as the old machine but
Hydrogen is up to ten times more efficient than
providing both higher efficiency and a higher
air but requires an extensive hydrogen cooling
rating.
system to be installed as well as casing design
One area in which all power plant
changes to ensure safety. This entails a cost in
machinery designers are being challenged is
terms of energy loss and reliability.
adapting existing technology for grid support.
For this reason all manufacturers have
1603pei_13 13
This is true for generators as much as for gas
Generators are being constantly refined

Credit: GE/Voith Hydro
13
3/11/16 10:17 AM
Generator design
speed asynchronous generator to be used.

Alternatively a medium speed gearbox and
generator may be chosen.
Then there is the matter of speed variation
to take into account.The wind is rarely constant
and the drive train must be able to cope with
gusts. This is most commonly handled today
with
doubly-fed
induction
generators, a
relatively old-fashioned technology that was

considered a dying breed during the 1990s
but which has found a new lease on life as
manufacturers have learned how to make
better versions of these machines.
Today, Sakki says, these have become
Improving efficiency by even 0.1 per cent is possible with todays highly efficient machines
Credit: Voith Hydro
relatively standardized with 4-pole machines in

the 1.5 MW2 MW range and 6-pole machines
at 2.5 MW and above. The alternative is to
turbines and coal plants with complex steam
can also be an issue, particularly with two-
use a full power frequency converter with an
cycles.
pole machines where the size means that the
induction or permanent magnet generator, a
natural frequency is close to twice the grid
solution that is more expensive but potentially
frequency.
offers greater reliability and the ability to satisfy
Fossil fuel plants, particularly those based

on gas turbines, can provide grid support to
back up renewable generation from wind
An additional problem, Yagielski notes,
or solar power, but this involves many more
results from the large power factor and voltage
The efficiency of wind turbine generators
startups and shutdowns and more changes
variations found when units are acting in a
is somewhat lower than large generators.
in output that would have been typical in
grid support role. Faults in the core materials
Siemens direct drive wind turbines achieve
a similar plant ten or 20 years ago. These
can lead to both losses and stresses which
an efficiency of around 9095 per cent,
increase the levels of stress within machinery,
are exaggerated by these variations, so it has
dependent on specific working point, says
with the potential for early failure, increased
become important to eliminate as far as
Arwyn Thomas, head of electrical design
wear rates and higher maintenance costs.
possible any faults within the core.
for
The biggest challenge is to cope with
grid requirements.
wind
generators
in
the Technology
Department of Siemens Wind Power and
the thermal stress, explains Daft. For example,
Wind turbine generators
it is necessary to introduce slip planes to
While the development of large generators
He believes permanent magnet generators
accommodate the thermal expansion of the
takes place in very small steps, one market
are the key to higher efficiencies in both direct
copper in the stator as the load changes and
where major advances in generator design
drive and geared drive trains.In offshore wind
the temperature rises.
are taking place is in the wind turbine market.
turbines, permanent magnets generators are
Another area of concern is the rotor end
As Raimo Sakki, product manager for ABB
already the dominant generator type, he
cap which holds the windings in place.
wind generators, points out, Wind is still a
points out. The potential efficiency advantage
Expansion of steel components represents
young segment.
is already demonstrated by medium speed
a challenge too. The generator shaft in a
become completely standardized yet and
offshore
100 MVA generator might grow up to 4 cm
manufacturers are still experimenting with
which can reach 98.3 per cent efficiency.
as its temperature rises; there must be room
different drive train configurations.
Technologies have not
Renewables Division.
permanent
magnet
generators
The variety of options makes wind a
for that. In addition, when there is a turbine
Many options are possible, and each has
much faster-moving market in terms of
attached to one end, its shaft will expand too.
an impact on generator choice. The drive
technology that the large fossil fuel market. But
to
train may include a gear or do without a
manufacturers in both are finding they have to
ascertain where the natural frequencies of
gear. For direct drive systems with no gears,
adapt to changing conditions and demands.
generator components fall. When load is
the slow rotational speed means that a
While the gains that can be made in the large
changing frequently and rapidly, a natural
synchronous generator needs many poles.
machine market are tiny, each improvement
frequency is more likely to be excited, adding
This can be achieved with a permanent
in efficiency might reap an increase in output
stress and wear to components. Analysis
magnet generator or with a conventional
that is equivalent to a medium sized wind
allows designers to take measures to ensure
multipole synchronous generator, similar to a
turbine.
that the natural frequency of the generator
slow speed hydropower generator. If the drive
support structure is a long way from that of
chain includes a gearbox that increases the
Paul Breeze is a journalist specializing in the
the rotor.
rotational speed of the shaft, other options
power sector.
Vibrational
Specific
analysis
components
is
important
may
also
be
open up.
strengthened to reduce the potential for
A large three-stage gearbox will provide
movement. Vibrations in stator end winding
a gear ratio of up to 100:1, allowing a high
14
1603pei_14 14
3/11/16 10:17 AM
CONFERENCE & EXHIBITION
19-21 JULY 2016
SANDTON CONVENTION CENTRE, JOHANNESBURG,

REPUBLIC OF SOUTH AFRICA
CREATING POWER
FOR SUSTAINABLE GROWTH

KEY POWER HUB FOR PAN AFRICAN STAKEHOLDERS
Join high-level decision-makers from government and the private sector at POWER-GEN & DistribuTECH Africa 2016 conference &
exhibition. Supporting sustainability in the pan-African power sector, the event aims to serve as the continents premier knowledge
sharing and networking hub for the power generation and distribution sectors across sub-Saharan Africa.
Hear from over 100 expert international speakers as they discuss the latest technical developments, benchmark case studies and
important issues such as: Project Funding; Asset Management; Infrastructure Development; Integration of Renewables; Procurement
Best Practice; Financing Models and Deal Structuring.
Running alongside the conference, the exhibition floor will showcase cutting-edge products and technologies by over 80 leading local
and international companies including Eskom, Ansaldo Energia, Rosatom, Seimens, Steinmuller Africa and Turkish Renewable Pavilion.
To register or for further information, visit www.powergenafrica.com
Owned & Produced by:
Host Utility:
Supporting Association:
1603pei_15 15
3/11/16 10:17 AM
The IEAs Fatih Birol at COP21 in Paris

Credit: IEA
India Focus
India will be the

engine of global energy
demand growth
So says International Energy Agency chief Fatih Birol. Kelvin Ross looks at the IEAs
forecast for the Indian power sector and hears from players active in the country
ndia is set to contribute more than any
electricity. The IEA states that to ensure that
universal electricity access and anticipated
other country to the rise in global energy
energy is a spur, rather than a hindrance, to
demographic trends that will make India the
demand over the next 25 years, according
Indias
must
most populous country in the world, India has
to the International Energy Agency.
redouble efforts to bring capital into the sector,
to make provision for nearly 600 million new
particularly in more efficient and low-carbon
electricity consumers by 2040.
But even so, its energy demand per
capita in 2040 would still be 40 per cent
below the world average, says the IEA.
advancement, policymakers
technologies.
Over the same period, the IEA estimates
In a forecast of the India energy sector, the
that some 315 million people, almost the
Indias energy transformation requires
IEA calculates that India needs more than
population of the US today, will be added to
three things: investment, investment and
$140 billion in energy investment per year to
Indias urban population.
investment, says IEA executive director Fatih
2040, around $110 billion per year in energy
This, it says, will accelerate the switch to
Birol.
supply 75 per cent of which is required to
modern fuels and the rise in appliance and
A lot is being done already to overhaul
meet Indias burgeoning need for electricity
vehicle ownership while pushing up demand
the energy regulatory system and get the
and a further $30 billion a year to improve
for construction materials. The Make in India
incentives in place this is vital, as India will
energy efficiency.
programme that aims to transform India
need to call upon a wider range of investors
Taking into account the achievement of
into a manufacturing powerhouse can help
and sources of finance than it has in the past.

And he stressed that India will be the
engine of global energy demand growth.
India is moving to the centre stage of
world energy. Some 600 million people will be
connected to electricity in the next 25 years.
Although its energy demand has almost
doubled since 2000, some 240 million people
one in five citizens still lack access to
16
1603pei_16 16
India One solar thermal power plant

Credit: Brahma Kumaris
3/11/16 10:18 AM
India Focus
modernize the economy and create jobs for

the growing workforce, and also has major
implications for energy use.
This will see Indias coal demand growth
rocket, with most of it met by expanded
domestic production. Oil demand will also
increase according to the IEA, more than in
any other country and be nearly 10 million
barrels per day by 2040, although this will be
via imports, particularly from the Middle East.
However, the growth in energy provision
is not confined to fossil fuels. The IEA predicts
India will become the worlds second-largest
market for solar PV. More than half of the new
India has to make provision for nearly 600 million new electricity consumers by 2040
Credit: Siemens
electricity generation capacity to 2040 is

projected to come from non-fossil fuels, led by
solar and wind power.
The potential of renewables in India
De said that SkyPower has committed to
Last month, SkyPower signed four power
and the price tag needed to realize it
build 18 GW of solar projects in India by 2022.
purchase agreements with the Indian state
was highlighted by a panel of energy and
We see India as a very competitive market
of Telangana to build and operate a total of
financing experts at the World Future Energy
but is has fantastic opportunities. There are
Summit in Abu Dhabi in January.
challenges in terms of the grid, some states
200 MW of solar projects.

Over
the
previous
months, SkyPower
The potential is huge the number of
are not so easy to do business in, and it would
had secured 400 MW of solar PV projects in
gigawatts is mind-boggling, said Amit De,
be nice if regulation was more streamlined,
Madhya Pradesh and Telangana.
senior strategist at Canada-headquartered
but renewables will change the face of power
solar developer SkyPower Global.
generation in India.
India is a world leader in deploying solar,

not only with its significant targets but through
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1603pei_17 17
17
3/11/16 10:18 AM
India Focus
energy targets, $20 billion of capital will need

to come into the market each year.
Last year it was $11 billion, so we need to
double that number.
He added that India was the only major
economy in the world that has power market
growth of between 4 and 5 per cent. Not
even China, he said, could compete with that.
Vikas Dawra, managing director of Yes
Bank, Indias fifth largest private sector bank,
stressed the urgency of a renewables rollout:
India is embracing the potential of windpower
Credit: Land Rover Our Planet
One third of Indians dont have access to the
Firstly, volume if the volume is there
renewable projects in India. Its executive vice-
grid thats 330 million people.

Mytrah Energy is a company specializing in
its very actions, says SkyPowers president

Kerry Adler.
the business will come; second, spread
president Bob Smith told Power Engineering
He adds that SkyPower is committed to
spreading renewables throughout the country
International:I am delighted that the IEA have
making a powerful contribution to Indias goal
is needed; third is technology and fourth is
confirmed what we at Mytrah have been
of generating 100 GW of solar power by 2022.
infrastructure.
saying for some time that India is the most
At the World Future Energy Summit, Pranav
He said India had gone from zero
Mehta, chairman of the National Solar
renewables to 5000 MW in just a few years
Smith said that the combination of rapid
Energy Federation of India, said there was
and we are going to have 20 times
economic growth and a relatively low per-
exponential growth in India for renewables,
as much.
capita consumption places India at the
and added that the growth would be built on

four pillars.
exciting power market in the world.
Ashish Sethia of Bloomberg New Energy
centre of the world energy stage, with demand
Finance said that for India to fulfil its renewable
growth exceeding all other countries over the

next 25 years.
He said that Mytrah had been attracted
by the rapidly growing market, and the lack
of large government subsidies, and had
built a portfolio of 578 MW of wind power
in India over the last five years. Wind is costcompetitive with fossil fuels in India and has
the great advantage of being very quick
to construct an ideal solution for a rapidly
growing market.
Mytrah has commissioned the first phase
of a wind farm in Rajasthan.
The 50 MW project will ultimately see the
installation of 24 Suzlon wind turbines of
2.1 MW each. Phase one of the project
comprises an initial 16.8 MW, with the
remainder following this year.
Mytrah now has a wind power portfolio of
560 MW across six Indian states Rajasthan,
Gujarat,
Maharashtra,
Andhra
Pradesh,
Karnataka and Tamil Nadu.

Ravi Kailas, Mytrah chairman, said the
project is the first part of 200 MW of additional
capacity which we have planned for the 2016
wind season.
He added: The demand for renewable
energy in India continues to increase, with a
government target of 170 GW by 2022.
The IEA says India needs over $140 billion in energy investment per year to 2040
Credit: World Energy Council
18
1603pei_18 18
3/11/16 10:18 AM
1603pei_19 19
3/11/16 10:18 AM
The manufacturing and residential sectors are the biggest users of diesel gensets in India
Credit: Cummins
India Focus
Growth areas for

diesel gensets
The hot spots for expansion and the drivers behind this
growth are highlighted by Vipul Tiwari
ndias diesel genset market has witnessed
Gujarat/Maharashtra Border-Surat-Hazira Port
Urban Transformation (AMRUT) programme,
steady growth because of power supply
section road in Gujarat, are propelling growth
which
shortages, rising long-term infrastructure
in the rental diesel genset market in India.
500 cities.
investments and unreliable grid supply.

Rapid
growth
in
heavy
industry,
infrastructure, telecommunication
and
the information technology sector is expected

to further escalate this demand over the next
five years.
envisages
the
development
of
The residential and manufacturing sectors
Growth in demand for diesel gensets from
dominate the diesel genset market in India,
the manufacturing sector is projected to be
and cumulatively accounted for more than
fuelled by the booming auto component
52 per cent of the market share in 2014.
industry.
With an increasing number of real estate
India is projected to become the second
construction projects and anticipated growth
largest steel producer in the world by the end

of this year.
Diesel gensets are mainly used as a source
in foreign investments in newly-launched
of emergency power supply during instances
smart city projects in India, the demand for
of supply shortages, or in places that are not
diesel gensets is expected to grow through to
power supply for running processing units,
connected to the grid.
2020.
machining, resin moulding, pressing, welding
The
market
continuous
and assembling, which is also expected
for uninterrupted power supply from various
to positively influence the countrys diesel
with improved engine life and other features
manufacturing facilities such as automobile
gensets market in the coming years.
such as synchronization with the grid, remote
and auto components is also expected to
monitoring and control, and automated data
drive market growth over the course of the
Leading players
analysis.
next five years.
Kirloskar Oil Engines (KOEL), Cummins India,
of
witnessing
requires
gensets
production
been
industry
In addition to this, the growing demand
increasing
has
This
diesel
Due to the high cost of diesel gensets,
The
residential
sector
comprising
Ashok Leyland and Mahindra Powerol are
houses, residential
industrialists and manufacturers prefer renting
domestic
apartments
among the leading diesel genset players
them, either on a monthly or hourly basis.
and buildings dominates the diesel genset
operating in India. Kirloskar is expected to
across
market in India and demand is expected to
maintain its leadership position in the coming
the country, such as the implementation of
be fuelled by massive development plans
years it is increasing its focus on expanding
the four-lane Bhopal-Biaora road and the
such as the Atal Mission for Rejuvenation and
its dealership network, offering 24/7 support
Various
20
1603pei_20 20
construction
projects
3/11/16 10:18 AM
India Focus
services
and
addressing
client
queries
through call centres.

Moreover,
the
Mahindra Powerol is a key player in the

Indian diesel genset sector
Credit: Mahindra Powerol
among the major markets for diesel

gensets in this region.
companys
long-term
The western region
service agreement programme for customers,
holds
Bandhan, is
largest position in the
expected
to
aid
KOEL
in
the
second
strengthening its market presence through
Indian
2020.
market as it has the
diesel
genset
Cummins India offers diesel gensets in the
maximum number of
range of 7.5 kVA3000 kVA, 40 kVA biogas
industries in the country,
gensets and 15 kVA gensets that can be run
including iron and steel,
on vegetable oil and Pongamia (SVO).
automobile,
Cummins has a large distribution network
and
chemical
petrochemical,
in the country and the companys products
jewellery, textiles, cement
are marketed and distributed by three
and pharmaceuticals.
channel partners Jakson, Sudhir Gensets

and Powerica.
Maharashtra and Gujarat

account for the maximum share
Ashok Leyland operates under LEYPOWER
(750.13000
in driving the diesel genset growth in
kVA). Low rating diesel
for selling its diesel gensets in India the
western India. Though the power deficit
company provides diesel gensets in the
in the western region is decreasing year-on-
in the market, being used in the telecom
10 kVA2250 kVA range and Mahindra
year, the demand for diesel gensets remains
sector for backup power in grid-connected
& Mahindra operates its power business
constant as they are used as a reliable source
areas and also as a main source of power in
under
of backup power.
non-grid areas.
Mahindra
Powerol. The
company
gensets constitute a major share
offers diesel gensets in the range of 5 kVA to
A large number of companies operating
India is the second largest mobile phone
500 kVA and since 2002 has sold 270,000 diesel
in the general engineering, automobile,
market in the world with 500 million users
generators and industrial engines. Mahindra
chemical, pharmaceutical, textile and IT
and 700,000 telecom towers and these
Powerol distributes its products through 70
sectors are based in Maharashtra. In 2013-
towers require continuous power supply on
retail showrooms and the companys major
14, Maharashtra
around
average, the countrys telecom tower network
end users include telecom, government and
30 per cent of Indias export of jewellery,
consumes over 11 billion kWh annually, and
defence organizations, the banking and retail
textiles, leather goods and pharmaceuticals.
this is likely to increase to 17 billion kWh by the
industries and utilities.
accounted
for
The power deficit in Gujarat is also
end of this year.
declining. However, demand for diesel gensets
The Telecom Regulatory Authority of India
Growth regions
is increasing due to the booming construction
(TRAI) wants TELCOS to switch from diesel
High power deficit and rapid industrialization
sector. The presence of large refineries and
gensets to renewable sources of power, as this
in the southern parts of the country such
petrochemical
would save millions of litres of diesel and, in
as Bangalore, Hyderabad and Chennai
requires reliable standby, emergency and
has made the region the largest demand
mobile power that continues to boost the
generator for diesel gensets.
demand for diesel gensets.
complexes
in
this
region
The manufacturing and auto component
turn, millions of rupees a year.

TRAI also emphasizes that around 10 per
cent of towers operate on pure diesel and
85 per cent of the towers are connected to the
industries in Tamil Nadu, the information
Sector segments
technology
bio-
The Indian diesel genset market is broadly
However, 10 per cent of the towers have
technology and pharmaceutical businesses
classified into four segments on the basis of
regular power supply and, for the rest, their
in Andhra Pradesh and tourism and general
kVA rating: low (575 kVA), medium (75.1
power is supplied by diesel gensets.
engineering in Kerala and Puducherry are
350 kVA), high (350.1750 kVA) and very high
industry
in
Karnataka,
electricity grid.
The medium rating of diesel gensets is

the second largest category used in India.
However, demand for these machines is
anticipated to decline due to their shrinking
application in telecoms sector.
Vipul
Tiwari
is
Research
Consultant
with TechSci Research, a global market

research
offices
in
and
consulting
Canada, the
company
UK
and
with
India.
www.techsciresearch.com
Some Cummins India gensets run on vegtable oil
Credit: Cummins India
1603pei_21 21
21
3/11/16 10:18 AM
Distribution system operators
Credit: Fotolia
Repowering
the role of DSOs
In the smart energy world, DSOs are
becoming active system managers of the
distribution grid, writes Hans ten Berge
he power sector is undergoing

a
complex
and
customers in a smarter grids context.
long-term
allowing market parties to enable customers
The discussion about the renewed role
to optimize the way they use energy and
of DSOs takes place as new policymaking
benefit from it while keeping costs and
In the past, predictable flows
objectives are increasingly driven by the
complexity at acceptable levels.
in the electricity network did not
willingness to pursue more competition and
require extensive management
create new market opportunities.
transformation.
and monitoring tools.
New tools for new challenges
Under this new scenario, DSOs must
A network evolution has already started and
With the expansion of renewables across
continually adapt and extend their central
this is only the beginning. In a changing
Europe, the power system reality has changed
role in facilitating an open and competitive
context made up of distributed generation,
drastically. This change, together with the fact
market. Being at the heart of the changes
self-/micro-generation, electric transport, more
that customers are moving to the centre of the
that are happening within their own networks
active customers and smarter distribution
new value chain, has led to rethinking the way
and with a deep understanding of how their
grids, DSOs are establishing a foundation
distribution system operators (DSOs) should
own distribution systems work and operate,
of smarter network monitoring, improved
operate and plan their networks.
DSOs are in a position to act as neutral energy
metering, control and automation to best fulfil
market facilitators and co-ordinators of all
their security of supply obligations.
These
changes
take
place
in
the
framework of energy industry liberalization
customers.
As smart metering deployment increases,
and decarbonization of the economy, as well
In the future evolution of energy networks
as revolutionary ICT developments. DSOs are
towards a smarter grid concept, DSOs are
customers play a more active role in demand
consequently moving away from their role
responsible
distribution
response and energy efficiency, flexibility
as passive network operators towards active
system
quality, technical
must be stimulated and correctly valued. This
system management of the distribution grid.
efficiency and cost-effectiveness through the
way, customers will be able to benefit from
They are taking on a more active co-ordinating
intelligent use of technology.
the services they may be willing and able to
role in facilitating markets while continuing to

provide a stable and high-quality service to all
22
1603pei_22 22
for
guaranteeing
stability, power
DSOs are key to upgrading and operating

an
increasingly
more
complex
network,
distributed
generation
expands
and
provide to local systems.

Meanwhile, DSOs are facing complex grid
3/11/16 10:18 AM
operations, characterized
by
increasingly
intermittent and bidirectional energy flows,

whilst at the same time being responsible
for system quality and security in their core
business. As a result, DSOs are reorganizing
themselves in terms of new organizational
business models, re-training of crucial staff,
digitalization of grid operations and other
important managerial issues.
New
elements
distribution
are
connected
already
to
triggering
the
more
active grid management. By using flexible

ICT techniques to enable smart grids, DSOs
have begun to manage capacity in their
network. Although the role of DSOs will not
fundamentally change, it is evident that they
DSOs are in a position to act as neutral energy market facilitators, says Hans ten Berge
Credit: Fotolia
will need a bigger toolbox to move from the

traditional connect and forget concept
towards one of connect and manage.
DSOs have also begun signing flexible
open market must be further developed in
and technical landscape is also affecting
contracts for network customers. These flexible
most European countries in order for flexibility
grid planning. This is mainly due to network
network customers are remunerated for the
to achieve its full benefits and enable DSOs
customers who can or will be in a position
services they provide and are helping network
to reach their potential in active system
to offer flexibility services directly, or through
operators manage certain grid issues such
management.
suppliers and aggregators, to the DSO through
as network congestion or voltage constraints.
While grid operation is changing due
procurement processes. These procurement
As things stand, flexibility procurement on an
to network innovation, the new economic
services will increase customer involvement in
1603pei_23 23
3/11/16 10:18 AM
sound
both
regulatory
traditional
methodology
and
covering
innovation-related
assets. Regulatory schemes must incentivize

DSOs to be efficient, to deliver long-term
investment
according
to
predictable
and consistent regulatory framework and

to make efficient trade-offs between active
system management and physical grid
reinforcement.
Minimizing costs
Performing these new roles will evidently
lead to extra costs related, inter alia, to the
introduction of smart grid solutions and the
increasing complexity of data handling. The
new energy reality requires energy regulators
DSOs will need a bigger toolbox to move to the connect and manage concept
Credit: Fotolia
to ensure that all these changes benefit

customers and other network customers.
Policy, regulations, roles and procedures
demand response. Along with the availability
much better observability and operability of
have to be set taking into account efficiency
of increased information, using the distribution
the distribution grid, thus speeding up the
and non-discrimination. The new setup must
network more flexibly and having more precise
achievement of smart grids.
make sure that costs are minimized whilst
and timely information at hand will guarantee
As competition and choices increase for
competition is nurtured and a level playing
that grid capacity is optimized during the
the customer, new data privacy challenges
field is guaranteed for all market participants.
network planning process. Grids that are
emerge. The transformation will lead to a
Amongst growing concerns about high
more efficient will not only help DSOs to
ramp-up in information and data flows,
electricity tariffs across the EU, it is important
better plan their grids, but also make it easier
leading to the need for appropriate measures
to limit and avoid any unnecessary extra
for policymakers to achieve environmental
to be established to guarantee secure, neutral
costs. Any proposal of creating new regulated
targets.
and efficient data management.
entities such as separate and regulated data
In
transmission
hubs should be carefully assessed to make
Data handling is top priority
network, in which connected customers
sure that the benefits of new solutions are truly
It is under this new scenario that the
and connection points to other networks
superior to any resulting increase in the cost
importance of secure, high quality and
are
and/or complexity of the system.
robust data management techniques has
usually characterized by a large number of
DSOs are the impartial market facilitators
become apparent. Smart meters, distributed
customers, self-generators and larger-scale
enabling access to, and use of, the distribution
generation, storage facilities, demand-side
(distributed) generators. The connection of a
grid. They will share relevant information with
response, smart charging and ICT solutions
greater number of generation resources, such
all parties and create an adequate level
installed in the grid are producing more
as renewables, to satisfy demand requires
playing field in which competition is fostered
and more data that has to be adequately
substantial growth in the size and complexity
and new energy services can be provided on
managed and protected.
of distribution grids.
a competitive basis while still respecting data
A key part of the DSOs role in facilitating the
very
the
few, distribution
privacy. DSOs must also make sure that the

whole system is as resilient as possible against
goal of any data management system does
to meet their needs and choices in terms of
cyber-attacks and other privacy violations. In
not revolve only around ownership, but rather
connection, quality, security and continuity
summary, DSOs are adapting to this evolving
around correct and fair information sharing
of power supply. Hence, DSOs are ideally
environment,
in an efficient, transparent, non-discriminatory
suited to manage very large numbers of
changes in the way they operate and plan
way. In order to manage their networks in a
connection points and to balance local grids.
their networks to face future challenges. The
more active way, policymakers need to clarify
DSO activities must therefore be separate
DSOs role will not fundamentally change, but
the DSO involvement in data management.
from and complementary to those of TSOs,
will have to be repowered and strengthened.
no
contact
point
are
customers, DSOs are in a unique position
is
technical
networks
energy market is thus data management. The
there
the
with
for
Clearly,
As
contrast
implementing
the
required
one-size-fits-all
bearing in mind that DSOs are the only players
approach to data management. Different
capable of exploiting the benefits of a local
Hans ten Berge is Secretary-General of
data hubs, formats and market models have
approach in terms of grid management and
European electricity trade group EURELECTRIC.
been and are being implemented in different
customer support.
www.eurelectric.org
EU Member States.The evolution of technology
To meet the challenges ahead, national
and ICT systems, alongside the deployment
energy regulators must make sure that
of smart meter infrastructure, will enable
DSOs are properly incentivized through a
24
1603pei_24 24
3/11/16 10:18 AM
21-23
JUNE 2016
MICO - MILANO
MILAN, ITALY
EUROPE
DISCOVER THE POTENTIAL FOR YOUR BUSINESS IN

EUROPES EVOLVING ENERGY SECTOR
The changing European power sector is seeing established forms of generation being
repurposed and innovative technologies become mature. Discover how the two come
together and where your business fits in at
POWER-GEN Europe and Renewable Energy World Europe in Milan this June.
Tap into the strategic debate in the conference rooms and the technological innovation on the exhibition
Identify what the latest trends are, where growth is expected and who will need your expertise.
Come to Milan and realize your business opportunities in Europes new energy landscape.
Visit www.powergeneurope.com to find out more
Under the Patronage of the Italian Ministry of Economic Development
Owned and Produced by:
Presented by:
1603pei_25 25
3/11/16 10:18 AM
Measures to cut emissions are an intricate mix of limits, targets and caps
Credit: The Linde Group
Emissions control
NOx reduction: latest

trends and thinking
There is a spectrum of conventional best available techniques and pioneering new
technologies available to the power industry to address the important obligation
of NOx reduction, writes Stephen Harrison
equirements for reducing air
industrial emissions into a single, clear and
pollution emissions have been
coherent legislative instrument
evolving
over
the
past
For companies already operating above

and beyond this benchmark, there will be no
two
One of the main reasons for the new
change required to their operating protocols.
decades and today are an
directive was the inadequate and incoherent
For instance, in Sweden and Denmark, where
intricate mix of limits, targets and
implementation of best available techniques
a tax on nitrous oxide (NOx) and sulphur oxide
caps.
(BAT) to optimize all-round environmental
(SOx) is in place, very little additional impact
performance across the EU.
is likely.
In many parts of the world, industries
emitting pollutants must not only comply with
previous
The impact of the IED is therefore more
rigid emission limits, but also need to provide
provisions were spread across seven different
likely to be felt in countries like France, the UK
emissions data to numerous different agencies
legal instruments was deemed to place
and certain member states in Eastern Europe,
and bodies in order to comply with disparate
unnecessary
which have lagged behind more progressive
legislative formats and reporting systems at
companies, particularly those with operations
the regional, national and international level.
spanning several countries across the EU.
The
European
Commissions
Additionally,
the
fact
administrative
that
burdens
on
environmental legislation.
The IED not only describes how measuring
Industrial
Many primary industrial sectors in the EU are
and monitoring of emissions should take place,
Emissions Directive (IED), which took effect
already well regulated in terms of emissions,
but seeks to increase the use of best available
over 2014 and 2015, is aimed at standardizing
but the aim of the IED is to harmonize and
techniques through its BAT Reference (BREF)
the maximum emission levels across a very
standardize how they are regulated and
documents.
broad range of industries, including the power
how BAT is utilized across the entire region
The BAT approach is aimed at identifying
industry, throughout the European Union.
by setting minimum emissions benchmarks
and applying the best technology available
and improving the quality and consistency of
worldwide and applying it as cost-effectively
implementation.
as possible on an industrial scale to reduce
The IED reorganized and coalesced seven

existing and overlapping directives related to
26
1603pei_26 26
3/11/16 10:18 AM
Emissions control
emissions and achieve a high level of

environmental protection. The IED principally
covers control of pollution to air and water
and focuses on 13 specific pollutants and
their compounds to air: NOx; sulphur dioxide
(SO2); carbon monoxide (CO); volatile organic
compounds (VOCs); metals; dust, including
fine particulate matter; asbestos; chlorine (Cl);
fluorine (F); arsenic (As); cyanides; substances
and mixtures that have been proved to possess
carcinogenic or mutagenic properties, or
properties that may affect reproduction via
the air and polychlorinated dibenzodioxins
and polychlorinated dibenzofurans. For many
industries, much of the impact for emissions
The LoTOx process is applied at a controlled temperature zone within the scrubbing system
Source: The Linde Group
to air will be focused on four pollutants NOx,

SO2, CO and VOCs.
NOx reduction technologies
most important benefits is the very significant
and applicable without significant de-rating
The LCP directive, one of the seven existing
reduction
indirect
of the combustion furnace. Alternatively,
EU directives that now forms part of the IED,
greenhouse gas emissions, including CO2 and
replacement of the existing combustion
requires member states to legislatively limit
NOx. CO2 emissions can be reduced by up to
equipment can be done, but this is obviously
emissions from combustion plants with a
50 per cent, and NOx emission levels of below
capital intensive.
thermal capacity of 50 MW or greater. The
50 mg/MJ can be reached.
The
link
between
legislation
and
according to changes in temperature and
for the removal of high levels of NOx is
air/fuel
mixing,
modifications to the
combustion
to drive the development and raise the profile
impact
of new pollution control technologies around
the
the world. The BREF documents which outline
very frequently also
BAT will herald new lower Emissions Limit Values
the
(ELV) that will necessitate investment in more
operability
advanced pollution control measures.
furnace.
process
not
emissions,
efficiency
of
only
but
the
While some claim there is no cost-effective
This renders NOx

control a technically
removing NOx from their emissions, there is
c h a l l e n g i n g
a spectrum of conventional BAT and also
undertaking that calls
some newer, more pioneering technologies
for an understanding
available to the power industry to address the
of
important obligation of NOx reduction.
around
as
these
control
Selective
and
Selective
technologies
include
unit
operations
such
Catalytic
Reduction
(SCR)
Non-Catalytic
Reduction
complex
issues
combustion
chemistry and plant

operations,
as
the
as
well
economic
issues related to plant
(SNCR), which are both outlined in the BREF
fuel
consumption
documents, and innovative, newly introduced
and
maintenance.
approaches
NOx
such
as
low
temperature
oxidation NOx removal technology.

A common approach to controlling NOx
by
reduction
combustion
modification
Others simply sell you a product

we offer a solution.
and
means to sustain the economic viability of
of
NOx can also be treated post-combustion

and the most commonly specified technique
directives like the IED which define BAT will serve
Some
and
However, since emissions vary widely
technology is clear. The roll-out of regional
pollution
direct
is
emissions is to modify the basic combustion
limited, typically in the
process within the furnace. By using oxygen
3050
per
cent
instead of air in the production process,
range,
and
must
which removes the nitrogen ballast, energy
be
efficiency is not only increased, but one of the
where it is effective
implemented
A control and shut off technique you can rely on.
of which are fossil-fuel power stations.
both
OHL Gutermuth
directive applies to large thermal plants, many
of
Customized
Valve Design
MADE IN GERMANY
SOLAR
ESD
TURBINE
alves
Best V 67
8
since 1
OHL Gutermuth Industrial Valves GmbH

Helmershuser Strae 9+12 63674 Altenstadt / Germany
Phone +49.60 47. 80 06-0 Fax +49.60 47.80 06-29
www.ohl-gutermuth.de og@ohl-gutermuth.de
1603pei_27 27
27
3/11/16 10:18 AM
Emissions control
SCR, a technology designed to facilitate
SOx and other acid gases. Irrespective of
principles as a blueprint or starting point for
NOx reduction reactions in an oxidizing
NOx removal, for control of these pollutants,
their own local legislation. This is why many of
atmosphere. It is called selective because it
air pollution control devices such as wet and
the changes taking place in environmental
reduces levels of NOx using ammonia as a
dry scrubbers are required to remove them.
legislation in the EU reflect developments in
reductant within a catalyst system.
Integrating the LoTOx process within such air
the US, where authorities like the Environmental
The reducing agent reacts with NOx to
pollution control devices is relatively simple
Protection Agency (EPA) are also striving to
convert the pollutants into nitrogen and
and truly results in a multi-pollutant removal
level the playing fields across industries.
water. SCR has been adopted effectively in
system.
For example, a trend that is likely to be
lowering NOx emissions from gas-fired clean
Inside a wet or dry scrubber, N2O5 forms
taken up in the EU in the future is the move
flue gas streams. However, in treating dirty gas
nitric acid that is subsequently scrubbed by
towards speciation analysis in the VOC
streams from industrial processes involving
aqueous spray and neutralized by the alkali
arena. Speciation analysis is defined as the
kilns, furnaces and combusting coal or oil
reagent. The conversion of higher oxides
separation and quantification of different
with SCR, there is a risk of the catalyst being
of nitrogen into the aqueous phase in the
chemical forms of a particular element.
compromised by chemical poisons in the flue
scrubber is rapid and irreversible, allowing
Until
gas, or blinded by the dust and particulate
an almost complete removal of NOx, in the
concentrations was thought to be sufficient
matter also resident in the flue gas.
region of 9095 per cent even as high as
for environmental considerations, but now it
98 per cent from flue gases.
The low
has been recognized that it is important to
temperature region of the customers process,
operating temperature allows stable and
understand the toxicological properties of
so if it is not included in the original design
consistent control, regardless of variation in
the samples various components in order to
of the furnace, later installation will require a
flow, load or NOx content, and acid gases or
manage environment risk more accurately.
major rework of the process. The intermediate
particulates have no adverse effect on the
technology of selective non-catalytic reduction
performance of the LoTOx process.
SCR must be integrated into a high
recently, determining
total
element
This trend might lead to a closer focus on

substances like benzene or toluene or oxides
is also applicable in the high temperature
LoTOx is highly versatile NOx removal
of nitrogen, since nitric oxide, nitrous oxide,
regions impacting the clients process. SNCR
process but ideally suited where the removal
and nitrogen dioxide each play a different
does not make use of a catalyst, but requires a
required is greater than 80 per cent or where
role in the ambient air in terms of the pollution
highly defined temperature region to provide
stack emissions must be below 20 ppm.
they cause.
a reaction with ammonia. This technology is
LoTOx process offers inherent flexibility in NOx
A chemical additive like ammonia (NH3) is
capable of achieving a 5060 per cent NOx
removal. In most gases, simply increasing
also very likely to come into the measurement
removal.
the amount of ozone injection may meet
species, because it is added to a lot of raw
increasingly stringent regulations or limiting
combustion gas processing operations which
tiered NOx emissions.
use SCR or SNCR technology to reduce NOx
The effective temperature for reduction

of NOx through a SCR catalyst is in the
range of 200C to 400C and for SNCR to
emissions. Some speculate that the focus
be effective, the ammonia injection and
Greater flexibility
in the EU may extend at some future date
reduction needs to be in the range of 900C to
The benefits of this technology include
to regulate the emission of metals such as
1100C. Additionally, retrofitting NOx reduction
increased capacity, greater flexibility in the
mercury, as is already the case in the US.
solutions such as SCR or SNCR can often be
choice of feeds, increased conversion rates
In line with the consistent trend towards
disruptive of the industrial process and can
and reduced emissions. Since this technology
lower emissions levels, it is clear that, as in the
have negative implications with respect to
is a post-combustion solution that treats the
US, the scope of emissions legislation in Europe
operations and costs.
flue gas at the end of the customers process,
will extend ever wider to cover more factories
At the pioneering spectrum of NOx removal
it does not interfere with the process in any
that have not yet been greatly impacted by
solutions for the power industry is Lindes LoTOx
way.The system does not utilize a fixed catalyst
regulation. Ultimately, it is possible that within
technology, which stands for low temperature
bed and does not impact system hydraulics,
the next decade, the impact of EU emissions
oxidation and has been specifically developed
making it robust and reliable, capable of
legislation will impact any operation burning
for the control of NOx emissions. LoTOx, which
operating without maintenance for periods of
material on an industrial scale.
works on dirty exhaust gas streams to oxidize
two to three years between refinery shutdowns.
Advancements in emissions legislation will
and then capture NOx, is a selective, low
It is also able to manage unit upsets without
therefore continue to challenge combustion-
temperature oxidation technology that uses
impacting overall reliability and mechanical
based companies as well as industrial gas
ozone to oxidize NOx to water soluble and
availability.
companies like Linde to be able to supply
very reactive nitric pentoxide (N2O5).The LoTOx
The ozone required is produced from
process is applied at a controlled temperature
oxygen on site in response to the amount
zone within the scrubbing system.
of NOx present in the flue gas generated by
Stephen Harrison is Global Head of Specialty
the combustion process and the final NOx
Gases and Specialty Equipment at Linde
emission required.
Group.
LoTOx
does
not
require
additional
scrubbers but can leverage those already

installed to remove other criteria pollutants
As often happens when legislation is
such as SOx. Dirty gas means gas with other
updated in a specific country or region, other
criteria pollutants, typically particulate matters,
countries outside its range adopt certain
28
1603pei_28 28
products that underpin its requirements.
3/11/16 10:18 AM
Medupi is one of Eskoms flagship power plants

Credit: Ovivo
Coal-fired plants
Running Head
Conserving water at
the worlds largest
air-cooled coal plant
rought
At its flagship Medupi

power plant, South
African utility Eskom
is keenly aware of the
need to reuse as much
water as possible,
writes Drew Robb
plagues
water so that clean water can be safely fed
much of South Africa. It is
currently
back into the condensate circuit and to the
one of a couple of dozen
boiler for the production of steam. Thus steam
countries in the world facing
is maintained at the highest quality which, in
extreme water stress.
turn, maximizes power output and longevity
That is one of the reasons
why the countrys state-owned electricity
of the complete steam-condensate circuit

including turbine and condenser.
provider Eskom elected not to build a water-
The CPP is designed to produce treated
cooled coal plant to solve its ongoing
condensate with cation conductivity less than
electricity shortage. Instead, it is well on the
0.1 S/cm, chloride less than 1 g/l (less than
way to building the worlds largest air-cooled
1 ppb) and silica less than 5 g/l (less than
coal plant.
5 ppb).
Known as the Medupi Power Plant, it still

has to use river or reservoir water to produce
Technology showcase
steam for its six massive Alstom turbines. But
The Medupi plant is located at Lephalale in
actual water usage is minimized by reusing
Limpopo Province, in the northern part of South
as much of the water as possible. The lack of
Africa. Once complete, this baseload facility is
abundant water means Eskom must carefully
expected to provide about 12 per cent of the
utilize every drop of water it draws from local
nations power generation capacity.
supplies any waste must be minimized.
1603pei_29 29
The 4790 MW plant will be the biggest
To ensure it achieves that goal, Eskom has
dry-cooled power station in the world. It is
installed an Ovivo Condensate Polishing Plant
composed of six Alstom STF100 steam turbines,
(CPP) at all six units.This technology eliminates
each capable of producing 794 MW. Alstom
the requirement for boiler blowdown by
which is now part of GE is also supplying
removing contaminants from condensate
its ALSPA Series 6 control system, while GEA
29
3/11/16 10:18 AM
Running Head
Coal-fired plants
recently renamed Kelvion is providing the

air cooled condensers (ACCs), and Hitachi is
suppling its supercritical boilers.
The plant will have six separate power
islands, known as Units 1 through 6, with Unit
6 recently beginning commercial operation.
Each unit consists of a boiler, turbine, generator
and balance of plant equipment.The steam is
superheated to 560C at a pressure of 241 bar.
Reheat steam conditions are 50.5 bar and
570C. Steam flow at nominal load is around
617 kg per second. The condenser back
pressure is 141 bar at a temperature of 23.7C.
Medupi water treatment plant
Credit: Ovivo
The Hitachi supercritical boilers are oncethrough Benson type and at Medupi they
burn local bituminous coal. Their capacity for
steam is 2288 t/h per boiler. A series of low-NOx
The first stage of condensate polishing
regeneration stations and a spare charge
burners with staged combustion are used to
utilizes cartridge filters to remove most of the
of regenerated resin is sent back to the
burn the coal.
particulates (see Figure 1).
service vessel. Each resin charge can last
After using all the useful energy from the
Service vessels containing ion exchange
approximately
steam, it is sent horizontally to the air cooled
resins are used to remove impurities before the
regenerations.
condensers. A massive steel and concrete
water is fed back into the boiler. Eskom chose
There are four Ovivo external regeneration
structure supports the ACC modules which
a system with separate vessels for cation and
stations, two for cation resin and two for
use GEAs A-tube arrangement in order to
anion resins to give maximum flexibility of
anion resin. Each regeneration station has
maximize the volume of galvanized tubing
operation.
a regeneration vessel and a hold vessel. The
subjected to cooling.
regeneration vessels feature an optimized
the condensate by exchanging dissolved
dished nozzle-plate design on which resin is
across these tubes to cool the steam
impurities for hydrogen and hydroxide ions, as
supported.
down to the desired temperature to bring
the water passes through the service vessels.
This arrangement retains the resin while
about condensation. The condensate feed
The resin also acts as a filter to remove any
allowing free flow of air or liquid. The open
extraction pump has both a fixed and a
remaining particules.
nature of the dished nozzle-plate also allows
continually
blow
variable speed drive.
remove
contamination
between
air
fans
resins
months
in
Enormous
The
three
By utilizing separate vessels for resin, the
removal of fine particulate matter using a
anion vessel can be bypassed at those
combined air scour/rinse down technique.
Condensate polishing
times when condensate temperatures rise
An acid and caustic regeneration chemical
Eskom selected Ovivo after having successfully
higher than those recommended by the
recovery system cuts down on the use of virgin
used its technology at other sites. That gave
anion resin manufacturer. Failure to place the
resin regeneration chemicals.
the utility the confidence that its condensate
anion vessel offline during short periods when
would be treated effectively to achieve the
temperatures spike can shorten the longevity
recovery of resin transfer, resin cleaning
feedwater quality required in the water-steam
of the resin.
and resin rinse water for reuse during the
cycle.
The
regeneration
system
maximizes
As the resin becomes exhausted, it slowly
next regeneration in order to minimize the
The CPP treats 100 per cent of the
loses its capacity to exchange ions which
generation of waste water and the need for
condensate flow under normal operating
reduces its ability to exchange contaminants.
fresh
conditions. This removes iron and copper
Eventually, it reaches the point when the
Towards the end of regeneration, an optional
corrosion products, as well as dissolved
quality of the water deteriorates. Technicians
step enables circulation of dilute ammonia
cationic
while
can detect such an occurrence by measuring
solution through the resin to improve treated
allowing ammonia ions to pass through, when
water quality parameters such as cation
condensate quality.
operated in the ammonia cycle, maintaining
conductivity.
and
anionic
impurities,
a high pH to protect the condenser.
A rise in cation conductivity indicates
demineralized
water
replenishment.
Demineralization
A closed-loop system exists where recycled
that more contaminants are present in the
Eskom places a heavy emphasis on obtaining
condensate is sent to the coal-fired boilers
treated condensate and the resins require
the best quality demineralized water for boiler
which produce steam. This steam is fed
regeneration. When cation conductivity or
make-up for supercritical boilers. Accordingly,
through the turbines to generate electricity.
other process parameters, such as silica
the full spectrum of water treatment methods
The ACCs cool the exhaust steam, causing
or
is utilized. Pre-treatment processes include
it to condense. That condensate, however,
condensate is deteriorating, the cation or
clarification
contains contaminated water which must
anion resin is automatically transferred from
demineralization process includes gas transfer
be cleaned before the loop is continued.
the service vessel to one of the external
membrane (GTM) technology followed by
30
1603pei_30 30
Power Engineering International Month Year
sodium, indicates
quality
of
treated
and
ultra-filtration, while
the
3/11/16 10:18 AM
Coal-fired plants
Running Head
100% flow if CPP shut down
Condenser Tank
10% recycle if CPP on
Pre Polishing
Filters
4 x 25%
5m rating
Condensate
Booster Pumps
3 x 50%,
870m3/h each
Cation
Sevice
Vessels
4 x 33%
Anion
Service
Vessels
4 x 33%
Condensate
Extraction Pumps
Figure 1: Condensate polishing stages
continuous electro de-ionization (CEDI).

Initially conceptualized as a Zero Liquid
Effluent Discharge (ZLED) plant, all liquid
the ion exchange units are discharged into
before they can impact materials and
the fly ash tailings and neutralization sump
equipment in the rest of the circuit, while
respectively.
minimizing water wastage.
effluents from the water treatment process
The neutralization sump comprises two
at Medupi were going to be treated in an
equi-sized cells, each with a wet volume of
in water side corrosion, turbine deposits,
evaporator/crystallizer
to
approximately 750 m3. Basic neutralization
turbine corrosion and deposition of solids
recover as much water to the demineralized
using caustic lye or sulphuric acid is employed
in the reheater. In addition, startup times are
water circuit as possible and co-disposing the
as the only treatment effected in the effluent
improved as the plant manager is able to
final crystalline solution with fly ash tailings.
system. Once the batch pH reaches a terminal
verify water quality almost immediately upon
But after considering the capital and
value inside the target range (6 < pH < 8), the
startup. This contributes to a lowering of fuel
operating costs associated with these thermal
effluent is discharged to Eskom for use in its
consumption as less time is spent idling before
processes, the decision was taken to sink
boiler ashing system. A significant volume up
moving the plant up to full load.
all water treatment plant effluent into the
to 60 per cent of this effluent is chemically
Another gain from the Ovivo system is
stations wet ashing system. This is Eskoms
bound on the tailings dam in reaction with
that it has allowed Eskom to harness alkaline
standard approach for the disposal of saline
course and fly ash coming from the boilers.
oxygenated treatment (AOT) cycle chemistry.
system,
aiming
liquid effluent at their existing coal-fired power
Further
benefits
include
reduction
This allows the plant operator to maintain
Unit 6 commissioning
the condensate at the higher pH levels
Currently, all effluent from the water
Despite some delays that have impacted the
recommended for air cooled condensers. In
treatment plant is collected in the neutralization
plans for Medupi to come online, Unit 6 is now
addition, this oxidizing environment provides a
sump. This includes spent backwash and
in commercial operation by Eskom. The results
protective oxide fill on metal surfaces in contact
chemically enhanced backwash effluent from
of the condensate polishing process are the
with corrosive pre-polished condensate.
the ultra-filters, brine from reverse osmosis (RO)
removal of 99.99 per cent of iron and copper
Eskoms preference for separate resin
and concentrate from the CEDI modules.
corrosion products, as well as cationic and
vessels means no resin separation is required
anionic impurities.
so regeneration time is minimized. The use of
stations.
Sections
for
clarifier/thickener
and
dissolved organics scavenging anionic ion
As most condensate contaminants enter
an external regeneration system eliminated
exchange address suspended solids and
the system via the air-cooled condensers, the
any risk of chemicals being inadvertently
organic carbon concentrations.The underflow
CPP is located immediately downstream of
introduced into the steam-water cycle. By
from the clarifier and spent regenerant from
the ACC tank. This takes care of contaminants
employing auxiliary cation units in the anion

regeneration stations, anion rinse water can
be recycled.
Now that Unit 6 of Medupi is running,
Eskom will gradually commission and bring
the other units onto the grid. When completed,
almost 4800 MW of power will be available.
This provides a much needed boost to South
Africa in the face of occasional load shedding
and a dwindling reserve margin.
Drew Rob is a freelance journalist specializing
in the energy sector.
As much water as possible is reused at Medupi power plant

Credit: Ovivo
1603pei_31 31
Power Engineering International January 2013
31
3/11/16 10:18 AM
Project Update
Volkswagen CHP plant marks Chinese first for MAN Diesel
A new gas-fired combined heat and power
coal boilers so CO2 emissions will be reduced
plant has been officially opened in China.
by 59,308 tonnes each year.
The plant runs on four sets of MGT 6200, the
The plant also marks the first market entry
latest range of gas turbines by MAN Diesel &
of MAN Diesels latest gas turbine series in
Turbo, and powers a car manufacturing facility
China. The company says that additional
operated by SAIC Volkswagen Automotive Co.
use of the waste heat for producing process
Prof
Jochen
of
steam increases the plants overall efficiency
The
to more than 80 per cent. The steam is used at
inauguration of this combined heat and
the production works of the Volkswagen joint
power system is a landmark for our car
venture in China.
Volkswagen
Heizmann,
Group
president
China,
said:
production in China.
Dr Uwe Lauber, chief executive of MAN
biggest car production sites in the country,
The new plant not only provides steam
Diesel & Turbo, said: We have inaugurated
which is low in greenhouse gas emissions and
and electricity for our Car Plant 3 here at SAIC
a gas-fired power plant that covers almost
utilizes more than 80 per cent of the invested
Volkswagen, it also means we no longer use
25 per cent of the energy needs of one of the
fuel energy.
Weir wins controls

contract for
EDFs French
nuclear reactors
REG Bio-Power utilizes used

cooking oil to run Cat engines
A French subsidiary of the UK-headquartered
REG Bio-Power has now spent over a year
The Whitemoor site itself is unmanned
successfully producing carbon neutral power
most of the time, with the control system
from used cooking oil at an 18 MW plant in
being remotely managed by Finning. When
the UK.
the generators need to be started up, Finning
engineering group Weir has won a multi-
The plant in Whitemoor, North Yorkshire,
engineers can run them from a central control
million euro contract to replace pneumatic
uses 10 Finning Cat 3516 BHD engines to
room and let REG know that the operation
controls for the main steam isolation valves on
produce power. The engines are fuelled with
was successful.
28 EDF nuclear reactors in France.
used cooking oil, which is collected by REG
Once a call comes in from the National
Weir Power & Industrial France said the
from restaurants, food processing plants
Grid that power from the site is needed, the
deal covers design, prototyping and testing,
and household waste recycling centres in
Finning operators need to have the generators
plus the supply of 84 new items and their
partnership with local councils and waste
running at full load in just four minutes. The
installation and commissioning.
contractors.
engines need to start on demand and must
seven-year
After being collected, the used oil is taken
modification programme will ensure future
to a REG recovery facility where it is filtered into
safety and integrity of flow control equipment
a proprietary biofuel called LF100. Once the
Finning which is the sole distributor of
throughout the enhanced operational lifetime
biofuel has been produced it is transported to
Caterpillar engines in the UK has also agreed
of the EDF reactors.
REGs Whitemoor facility where it is burned in
an operation and maintenance contract with
the Cat engines and the electricity is fed into
REG that will last until 2022, covering not just
the National Grid.
the engines but also the sites boilers, pumps
The
company
said
the
Weir added that the programme will be

rolled out simultaneously across seven sites
with an estimated 18,000 man hours.
While the engines supplied by Finning are
Weir Power & Industrial Frances nuclear
standard, off-the-shelf units, the fuel system
director for Europe, Stephane Lamotte, said
is specially designed, says Mark Radford,
the project was a significant milestone for
project manager at Finning.
our French nuclear business and reflects
Reliability is also a major concern for REG
our capabilities to offer a safe, competitive
as the Whitemoor site has been contracted to
and comprehensive flow control technology
supply the UKs Short-Term Operating Reserve
which will significantly upgrade the main
programme, which is designed to supply the
steam isolation valve controls across EDFs
National Grid with enough power to cope with
French fleet.
unexpected spikes in demand.
32
1603pei_32 32
also go off load at a set time, or REG may be

subject to penalties.
and high voltage equipment.
3/11/16 10:18 AM
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3/11/16 10:18 AM
Technology Update
Above Surveying flies into the solar inspection market
UK solar developer Push Energy has joined
Above Surveyings Geo-referencing Aerial
forces with camera drone manufacturer
Pyranometer technology allows the company
Buzzflyer to form Above Surveying, an aerial
to capture irradiance data which is then
thermographic inspection service company
combined
specializing in solar PV.
and temperature gradient information to
Above Surveying says that it combines its

self-developed technology and unmanned
aerial vehicle platform, unique inspection
method
and
specially-designed
analysis
software to provide an accurate, consistent
with
thermographic
imagery
categorize changes and defects right down

to the cell level across an entire solar plant.
The company claims this brings a new level
of precision to aerial thermographic surveying.
Above
Surveying
managing
director
and valuable service which goes beyond
Will Hitchcock said: Our experience shows
the
that even a solar plant with zero string
limits
of
traditional
thermography
and
ground-based
eyeball
inspection
errors and a healthy performance ratio will
typically relied upon throughout the industry.
almost certainly have a surprising number of
The company says its technology allows
defective modules. Our unique technology
asset owners and O&M technicians to quickly
allows us to identify and categorize these
understand, pinpoint and resolve anomalies
defects with speed and efficiency so they can
and defects across vast areas of solar panels,
be addressed and optimum performance
so ensuring optimum performance.
restored.
NM Group sees Patrol+ helicopter service take off

NM Group, a solutions provider to utilities, has
launched Patrol+, a helicopter inspection
service.
Using
latest
lightweight
NM
Groups
imaging
LiDAR
systems
technology
processing
and
alongside
technology, the
service collects geospatially-located asset

information and enables accurate and costeffective detection of hardware defects on
wooden poles and steel structures, safety
issues on the line or corridor, and accurate
data from the aircraft and exporting it through
on the network. The results are presented in
location of structures.
a series of analyses to provide a simple set of
such a way that they can be actioned via a
NM says the service enhances existing
intelligent defect reports. These are then used
work management system and integrated
patrols by taking the geospatially located
to more effectively manage risk and reliability
into an asset management system.
E.ON develops energy storage system with Solarwatt

E.ON is developing an energy storage system
E.ON said the potential for electricity
retrofitting with storage devices. The deal
storage devices in Germany is enormous. In
with Dresden-based Solarwatt is the first
Munich-headquartered E.ON said today
just a few years nearly 100 per cent of solar
step in what E.ON board member Bernhard
that the first models of the domestic system
arrays may be sold with a storage device. In
Reutersberg said was a plan to become a
designed to store electricity from rooftop solar
addition, the countrys more than 1.5 million
leading provider of electricity storage systems
panels will be rolled out in a few months.
existing solar arrays offer huge potential for
in Germany.
with German company Solarwatt.
34
1603pei_34 34
3/11/16 10:18 AM
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1603pei_35 35
3/11/16 10:18 AM
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2123 June
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Policy Priorities for Energy Storage

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Power Engineering International March 2016

removal function by providing an alternate

the Fukushima nuclear accident that was

path for cooling water supply, arranging for

caused by a devastating earthquake

passive cooling or identifying an alternate

and tsunami on the east coast of Japan.

The OECD Nuclear Energy Agency has

Fukushima demonstrated that the ability

released a report outlining the lessons learned

of nuclear plants to maintain containment

since Fukushima. It also deals with what work

integrity could be challenged by severe natural

still needs to be done, not just to further

hazards. In response, some NEA member

strengthen safety in and around nuclear

countries have refocused their efforts on

power plants but also in the event of another

upgrading plants with respect to containment

so called Act of God such as an earthquake.

venting and hydrogen mitigation.

As NEA director-general William Magwood

In other countries, new or improved

says: The great lesson of Fukushima is that

filtered vents or filtering strategies are being

we cannot predict every natural event but

implemented or considered for use during

plants have been made more resilient and

venting to limit containment pressure. Some

better prepared for the unexpected than they

are introducing a different hydrogen mitigation

were five years ago.

strategy or improving the existing one.

The report states that prior to Fukushima,

nuclear operators and regulators had carried

frameworks, the NEA notes that there has

out detailed assessments of the potential

been a particular emphasis on ensuring that

internal hazards and risks of a plant, but spent

a clear and comprehensive legal framework

less time considering external risk factors

exists to allow the operator of a nuclear plant

such as natural disasters.