TNB Research @ 30

TNBR@30 30 Success Stories

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Since 1993, TNB Research Sdn. Bhd. has been devoting time and effort to understanding customers’ needs in order to provide the best available services in a timely and effective manner.

Our Research & Development Centre, which specialises in the energy and environmental sectors, provides a centralised, one-stop shop for technical solutions and innovation.

In the last 30 years, the company has launched numerous technologies, methods, and inventions that are equivalent to top worldwide bodies - capable of making us proud.

This book collects 30 success stories from our high-quality technology products, which include asset management, power generation, sustainability, smart grid, renewable energy, and green technology.

Each of these stories illustrates our hard work and dedication to meeting the demands of our consumers, while consistently improving our services in order to contribute to TNB’s overall success.

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Words from Dr Mohd Hariffin Boosroh

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30 SUCCESS STORIES

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For the past 30 years, our team at TNB Research (TNBR) has been all about making energy better.

We have been working hard on brilliant ideas, like cleaner power and smart solar systems, to make the world greener. This book is a testament to our achievement and dedication.

Throughout this journey, we offer solutions such as the creation of mini-hydro plants and highly efficient power systems. We’re also looking into smart grids, which are the technologies that make things run more smoothly.

CURE, or CO2 Utilisation Using Renewable Energy system, is one of our important milestones. It converts 90% of CO2 into methane, a useful resource for producing clean fuel.

This is consistent with the National Energy Transition Roadmap objectives and demonstrates our commitment to a more sustainable future.

But that’s not all. TNBR is also working to improve environmental engineering solutions such as waste to energy, water management and climate change.

To understand further, I sincerely suggest that you read and appreciate this book.

Thank you, and terima kasih, for believing in us. InshaAllah, by His grace, we shall continue to thrive for the next 30 years and more.

Dr. Mohd Hariffin Boosroh MANAGING DIRECTOR TNB Research Sdn. Bhd. 007

TNB Research headquarters by Dr Hazha Abdul Hamid.

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Success Stories 013

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Floating Solar Photovoltaic (FSPV) Page 017

Boiler Tube Life Assessment Test System Page 043

Shallow Trench Eco Material (STēM) Page 073

Hardware-inthe-Loop (HIL) Simulation Page 091

Battery Energy Storage Solution Page 111

CO2 Utilisation System Using Renewable Energies Technology (CURE) Page 021

Catalyst & Anode Materials for Solid Oxide Fuel Cells Page 049

Smart Street Light Page 075

Coordinated Voltage Control System (CVC) Page 093

LSS Testing & Commissioning Page 115

Boiler Optimisation Prediction Tools Page 027

Biodiversity Conservation Page 055

Advance Fault Analysis (AFA) System Page 079

EV Smart Charging Page 097

Failure Investigation Page 117

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Bahari Turbine Page 029

Microbio Fuel Cell (MFC) Page 059

Smart Terminal Block Page 083

Lightning Data & Early Warning System Page 101

Oversea Submarine Cable Investigation (ORSTED) Page 121

Green Sediment Brick Page 033

Tenaga Predictive Emission Monitoring System (T-PEMS) Page 063

Smart Voltage Detector Page 085

LPS & Earthing Measurement/ Assessment Page 103

RBI & OSH Implementation for Power Plants Page 125

Digitalisation Initiative - Geographic Information System Page 037

Mobile Aqua Treatment Plant (MAT-P) Page 067

SF6 Disposal Technology Page 089

Virtual Energy Management Page 105

Drone Services Page 129

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Floating Solar Photovoltaic (FSPV) A cutting-edge technology that is receiving a lot of interest is the floating solar photovoltaic (FSPV) system. This creative method, which uses technology akin to that of conventional ground-mounted solar PV systems, uses underutilised water surfaces to generate electricity.

The photovoltaic system benefits greatly from the installation of solar panels on water, which is usually cooler than land and operates more efficiently at ideal temperatures. Additionally, using the water’s surface for the solar PV system frees up land for future development as well as other possible uses.

The advancement of this FSPV technology is one of Malaysia’s game-changing options for economical green hydrogen production. TNBR pioneered the first pilot-scale FSPV system in Malaysia in 2017 through its specialised unit Renewable Energy and Green Technology (REGT), and has since been at the forefront of exploring and growing this technology.

TNBR is currently investigating the application of this technology in hydroelectric reservoirs and offshore waterways, demonstrating its commitment to sustainable energy solutions. The advancement of this FSPV technology is one of Malaysia’s game-changing options for economical green hydrogen production.

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TNBR proprietary catalyst for optimum methane production.

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CO2 Utilisation System Using Renewable Energies Technology (CURE) Power generation is a major source of CO2 emissions in Malaysia. A signatory to the Paris Climate Change Agreement, Malaysia seeks to reduce CO2 emissions by 45% from 2005 levels by 2030. Carbon Capture and Utilisation (CCU) technology is an important tool for achieving this goal.

Tenaga Nasional Berhad (TNB) and the Malaysia Electricity Supply Industries Trust Account (MESITA) are funding the CO2 Utilisation System Using Renewable Energies Technology (CURE) innovation. Using our unique catalyst, this novel CURE system can convert up to 90% of CO2 into methane (CH4).

Green hydrogen, which was produced in this study by an electrolyser system powered by in-situ solar panels, mixes with CO2 to produce methane. The generated methane can be used to produce compressed natural gas, a clean and adaptable fuel for power plants that promotes a circular economy for a more sustainable future.

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CURE: Carbon capture using renewable energy.

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Optimizing methane production. A researcher fine-tuning the gas flow for the reactor.

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Boiler Optimisation Prediction Tools This project presents an advanced combustion monitoring and prediction tool tailored for contemporary boiler systems. It is designed as a robust tool that diagnoses and pinpoints boiler problems, empowering troubleshooting to reduce maintenance time and to optimise operations. One of its key features is the real-time monitoring capability. This is complemented by a predictive model that forecasts furnace gas temperatures, emissions, pulveriser mill outlet temperature, economiser outlet temperate, air heater outlet temperature and combined induced draft fan openings - eight hours in advance - providing invaluable insight into potential operational issues. These predictive features enable risk mitigations when introducing new coal types and consuming blended coal in boilers.

Validation work is conducted by a competent team.

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Bahari Turbine The Bahari turbine employs three unique steps. For starters, it eliminates the requirement for a bucket splitter by utilising prior Pelton technology, i.e. individual buckets. Second, it reduces the injector aperture by at least half the size of the Pelton injector aperture. Finally, it employs thin injector apertures such as elliptical or rectangular injector apertures.

By removing the bucket splitter, the Bahari turbine gets an advantage over the Pelton turbine. This is due to the fact that without a bucket splitter, the average Bahari turbine saves between 0.5 and 4.0% of its power loss. Savings are greater for low-capacity installations.

With double the number of injectors but a narrower injector aperture, the Bahari turbine has a 0.5% higher injector power loss.

However, when combined with the use of elliptical injector apertures, these result in significant improvements over the Pelton. First, the smaller buckets make the Bahari turbine approximately 30% lighter than the Pelton counterpart. As a result, decreased weight bearing heat dissipation. Second, the total bucket wetted area is approximately 30% less than the Pelton equivalent. This translates to a 30% reduction in surface drag friction power loss. Pelton’s typical bucket surface friction is 2.7%. As a result, the Bahari turbine might save 0.9% of the power lost by the Pelton turbine. Third, the use of elliptic injector apertures allows the Bahari turbine to have design flexibility that the Pelton turbine does not have, namely the capacity to modify injector aspect ratio while maintaining the same aperture area to further optimise turbine performance.

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The smaller buckets make the turbine about 30% lighter than the Pelton counterpart.

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Green Sediment Brick The Cameron Highlands is where TNB performs dredging on a regular basis to counteract sedimentation. Every year, around 200,000 m3 of sediment from Ringlet Reservoir is dredged. To address the issue of sediment waste, a research and development project was carried out to investigate the various uses of these sediments.

The study resulted in the creation of Green Sediment Bricks, which are manufactured from a combination of sediment (sand and silt), concrete, and water. The bricks measure roughly 215 mm x 102.5 mm x 65 mm, with a 3.2mm variance from the standard specification. They weigh approximately 3.3-3.5kg and are available with or without colour.

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The construction of the prayer hall in Kampung Abu, which is located in Ulu Jelai, Cameron Highlands.

The surau used approximately 4,000 green sediment bricks and took around 3 months to complete.

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Digitalisation Initiative Geographic Information System Digitalisation using Geographical Information System (GIS) applications is one of the initiatives to assist projects and services in TNB Research Sdn. Bhd. By delivering services such as GIS analysis, remote sensing image processing, UAV mapping, and web GIS development, GIS has provided solutions for environmental, engineering, and energy transition applications. As we move into the digital era, our GIS services have changed dramatically to meet the demands of a data-rich and networked society.

The Civil Engineering & Geoinformatics unit at TNBR has expanded its services to drive innovation and improve spatial data-informed decision-making by developing web-GIS and GIS data integration across a wide range of applications including disaster management, water engineering, slope study, and spatial intelligence.

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Boiler Tube Life Assessment Test System Boiler tubes, reformer tubes, and radiant tubes in power and chemical plants operate in a complicated environment comprising high temperature, pressure, and corrosive atmosphere. Thermal degradation, creep, steam side oxidation and overheating, sigma phase embrittlement, temper embrittlement, and high temperature corrosion are all common problems with these tubes.

TNBR has built capability and expertise resources to conduct high temperature tube life assessments. The life evaluation employs a variety of approaches, including laboratory, in-situ, and analytical testing. Our research experience is not restricted to investigating new inspection procedures or modifying methods for ongoing improvement in test accuracy; the majority of our test data is gathered into guidelines or references for remaining life prediction.

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The SOFCs are a low-pollution, high-efficiency electrical power generating technique.

Catalyst & Anode Materials for Solid Oxide Fuel Cells Solid Oxide Fuel Cells (SOFCs) are advanced electrochemical devices that generate electricity by efficiently converting the chemical energy from fuels like hydrogen, natural gas, or hydrocarbons into electricity via a solid ceramic electrolyte sandwiched between the anode and cathode. They are a low-pollution, high-efficiency electrical power generating technique. The SOFCs play a critical part in the transition to cleaner and more efficient energy systems, thereby contributing to a more sustainable and greener future.

To embrace the benefits and versatility of SOFCs, we have a wide range of SOFCs equipment, including screen printing, millings, tape casting, furnaces, hydraulic presses, and electrochemical impedance spectroscopy. We investigate the properties of various anode, cathode, electrolyte, and catalyst materials in order to build material research capabilities. We also investigate fuel cell stack technology with a demonstration of a short stack and a 1kW SOFCs stack.

Furthermore, the fabrication, sintering, testing, and analysis of catalyst and electrode materials at the laboratory scale are carried out in our material testing laboratory, which is well-equipped with sample preparation machines for microstructure analysis, a SEM/EDX instrumentation for materials characterisation, a high-end light microscope, and a glow discharge spectrometry instrument for material composition analysis.

At TNBR, we embark on SOFCs technology to accelerate the energy transition to a cleaner and greener power production source. Picture a small yet extremely efficient SOFCs power plant.

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The SOFCs play a critical part in the transition to cleaner and more efficient energy systems.

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The properties of various anode, cathode, electrolyte, and catalyst materials are investigated.

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Biodiversity plays a crucial role in sustaining life and maintaining ecological balance.

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Biodiversity Conservation Our organisation is committed to the conservation, management, and enhancement of natural resources, as well as the promotion of sustainable development goals. Our research and services include wildlife conservation, aquatic life management, water quality, bioremediation, environmental impact assessment, and socioeconomic studies.

Natural resource conservation, limnology research, aquatic resource management planning, analysing the impact of hydrogen sulphide, ecotourism, and environmental testing laboratory services are all part of our present project.

Among the services we offer include Environmental Impact Assessments (EIA), Environmental Site Assessments, Social Impact Assessments, Environmental Compliance Audits, Environmental Monitoring, and Erosion & Sediment Control Plan (ESCP) Monitoring & Auditing.

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Efforts to conserve and protect biodiversity involve a combination of strategies.

Visits and programmes for biodiversity conservation are part of moral and ethical obligations.

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Microbio Fuel Cell (MFC) A Microbial Fuel Cell (MFC) is a bio-electrochemical device that uses microorganisms, most commonly bacteria, to oxidise organic matter, resulting in electron release and the generation of electrical current that can be used as energy. MFCs are used in wastewater treatment, bioenergy production, and environmental monitoring, demonstrating their utility in sustainable energy and environmental preservation.

At TNBR, preliminary research has been conducted to investigate the utilisation of water from hydro dam reservoir lakes in Cameron Highlands as a potential electrolyte and the use of bottom ash from TNB Janamanjung as electrode components. For this exploratory work, two 100-liter setups of Constructed-Wetlands MFC and Granular Activated Carbon MFC were created.

The MFC is a device that uses microorganisms to oxidise organic matter.

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The bottom ash from TNB Janamanjung is being used in the the R&D work.

Preliminary research is conducted to investigate the utilisation of water from hydro dam reservoir lakes in Cameron Highlands.

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Tenaga Predictive Emission Monitoring System (T- PEMS) The evolution of the Power Plant Emission Monitoring System from active thermal power plants is a mandatory obligation under the Malaysian Environmental Quality (Clean Air) Regulations 2014.

At present, two technologies are available to constantly monitor these pollutants. The more traditional one, known as the Continuous Emission Monitoring System (CEMS), uses sampling, handling, and analysing equipment to measure emission concentrations from exhaust gas. Whereas the new one, known as Predictive Emission Monitoring System (PEMS), is a software-based technology that leverages digital innovation to monitor emissions levels for regulatory compliance.

PEMS enables accurate pollution monitoring, lowering initial investment and ongoing operational expenses owing to maintenance activities and spare parts while minimising interference with plant operations. PEMS gives plant owners and operators greater cost control by avoiding unanticipated costs caused by unpredicted faults in traditional hardware analysers.

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The evolution of the emission monitoring system makes work lighter and easier.

At the launch of T-PEMS in Sultan Ibrahim Power Plant, Johor.

PEMS enables accurate pollution monitoring and lowers initial investment, among others.

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12 MAT-P The Mobile Aqua Treatment Plant (MAT-P) is a pilot automated mobile water treatment system that uses intelligent green technology to construct a system capable of quickly and affordably demineralising and filtering various types of raw water sources on-site to produce drinking and demineralised water.

A 20’ container with a water processing capacity of 1,000 L per hour or 1 m3 per hour may accommodate MAT-P’s six features (chemical treatment, filtration treatment, membrane treatment, ultra-violet, fuzzy logic, and IOT).

To assess treatment processes in small-scale operations, MAT-P pilot testing programmes will have a significant impact on the final system design and treatment effectiveness. Most minor community water quality issues can be resolved in individual plants and units through imaginative uses of triedand-true techniques and technology. These are useful reference materials for planning a full-scale facility and confirming performance prior to largescale development.

Furthermore, by reducing our environmental and water footprint, MAT-P can contribute in the transition to sustainable development. Future mobile water treatment technologies that are efficient can also be sold in developed countries.

Plants in the MAT-P series are used for demineralisation, water reclamation, and wastewater treatment. TNB Connaught Bridge Sdn Bhd developed the demineralised plant MAT-P DMin5501. Demineralised plants that do not use chemicals are a great way for power plants to reduce chemical consumption while still generating demineralised water of the same quality as traditional demineralised plants. The MAT-P DMin5501’s technological combination includes reverse osmosis, mixed bed, activated carbon filter, and sand filter. If the silica content is less than 20 parts per billion, this facility can generate 20-25 cubic metres per hour.

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A 40’ and 20’ container with a high water processing capacity per hour can accommodate MAT-P’s six features.

Most minor community water quality issues can be resolved in individual plants and units through imaginative uses of tried-and-true techniques and technology.

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MAT-P is a pilot automated mobile water treatment system that uses intelligent green technology.

Visitors are briefed on the mobile treatment’s flow.

A 40’ container with reverse osmosis system.

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Shallow Trench Eco Material (STēM) Shallow Trench Eco Materials (STeM), a newly designed backfill material, uses Coal Bottom Ash (CBA) and slurry Coal Fly Ash (CFA) as an alternative backfill material to traditional sand for filling shallow trenches. By successfully managing waste from TNB’s business operations, this invention intends to help TNB’s ESG (Environmental, Social, and Governance) strategy.

STeM has the potential to reduce the amount of failures connected with cables buried in shallow trenches, especially those caused by third-party damage. As a result, it can help to improve the performance of MVUG (Medium Voltage Underground) cable networks.

Overall, this advancement provides an environmentally friendly way to backfilling shallow trenches, as well as waste utilisation and possible performance improvements in TNB’s operations.

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Smart Street Light Grid of The Future (GOTF) is a critical enabler for achieving the goals of the Reimagining TNB (RT) programme.

One of the aspects mentioned in the GOTF is Smart Street Lighting (SSL), which is a component of Smart City solutions that use communication networks to allow TNB to potentially play beyond the kWh. SSL is expected to offer value to TNB by delivering effective control and monitoring solutions for TNB street lights, cost savings and efficiency gains in street light maintenance.

For example, faster reaction to malfunctioning lights and fewer night patrols (rapid response and repair).

TNB benefits and values SSL in a number of ways, including increased control by replacing manual switching with flexible individual switching and dimming.

Additionally, it conserves energy by accurately monitoring the TNB network and keeping a constant light output. Reliable and efficient street lighting solutions also improve the customer experience.

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Automatic Fault Analysis (AFA) System The traditional and manual fault analysis approach is arduous, time consuming (usually from 2 to 24 hours), and repetitive. High operating expenses (OPEX) are necessary for maintenance tasks like manual data collecting at the substation and transmission tower patrolling to detect the fault.

It may result in a longer restoration time due to the delay in locating the fault and probable hidden failure.

As a result, through an internal research seeding fund, TNBR created an inhouse Automatic Fault Analysis (AFA) System in 2020.

AFA is a system that can identify, correlate, analyse, and deliver detailed fault analysis information for speedier decision making during an unplanned outage or restoration process.

The internally built AFA system results in an RM24 million cost savings in Capital Expenditure (CAPEX) and High Operating Expenditure (OPEX).

The AFA system does extensive fault analysis, allowing for speedier system restoration and lowering the risk of power system instabilities.

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Smart Terminal Block A smart and contemporary grid is essential in supporting TNB SP2050 energy transition for a secure, dependable, and efficient renewable energy transport. TNB Distribution Network has recognised IEC61850 digital substation as one of the projects for Smart Grid Readiness.

IEC 61850 is a standard that addresses the communication and integration issues that substations face. This standard supports the interoperability of Intelligent Electronic Devices (IEDs) from different manufacturers and makes use of Ethernet-based communication networks.

The smart terminal block provides an inexpensive method for converting electrical hardwire signals between switchgear and control room into IEC61850 signals. This extends IEC61850’s benefits to the process level, such as online signal status and the ability to perform live maintenance.

This project creates a test setting for process level communication in TNBR. Three smart terminal block brands are examined, and two are used in the test setting. A smart terminal block connects the switchgear simulator to the Bay Control Unit. The switchgear simulator communicated successfully with the Bay Control Unit.

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Smart Voltage Detector Electrical accidents are Malaysia’s fourth leading cause of accidental fatality. 56.7% of all electrical mishaps (including fatal and non-fatal) happened during utility installation and repair work.

These occur because the majority of operators believed the system was dead and it was brought back to life. There is no warning mechanism in place if operators fail to follow safety measures.

The Smart Voltage Detector (SVD) is a wearable gadget equipped with sensors that detect electromagnetic signals from primary equipment’s live parts before the user mistakenly contacts them. Wearable smart voltage detector with smart live sensor alarm, tested and validated to be the last line of defence for operators working in high-voltage situations.

The wearable glove has a vibrating alarm, LED alert, and battery and power-on indicators.

The SVD also has smart live sensors that detect electromagnetic impulses from live elements of primary equipment, with a detection range of 50cm that can be programmed.

It can detect voltages ranging from 240V to medium voltage and has been tested in both real and simulated high-voltage environments.

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18 SF6 Disposal Technology SF6 gas is a fantastic electrical insulator. However, with a predicted atmospheric lifetime of 3,200 years, it has a Global Warming Potential that is 22,800 times worse than CO2.

The Electromagnetic Plasma (Non-Thermal) Technique is introduced to reduce SF6 gas emissions to the environment.

What exactly is Plasma? A normal gas atom has an equal amount of positive and negative charges. As a result, each atom is electrically neutral because the positive charges in the nucleus are surrounded by an equal number of negatively charged electrons.

When the addition of heat (or other energy) causes a number of atoms to loose some or all of their electrons, plasma is produced. The remaining components of those atoms have a positive charge, and the detached negative electrons can move freely.

These atoms, as well as the ensuing electrically charged gas, are referred to as “ionised.” Plasma is formed when enough atoms are ionised to sufficiently alter the electrical properties of a gas. Plasma reacts to and produces electromagnetic forces.

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Performing HIL Simulation Test.

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Hardware-in-the-Loop (HIL) Simulation Power system operations are growing more complex as distributed energy resources (DERs), variable renewable energies (vREs), and emerging technologies are integrated.

To address this complexity, real-time hardware-in-the-loop (HIL) simulation has evolved as a useful tool that allows engineers to evaluate multiple control schemes or custom applications in a safe and regulated environment.

HIL simulation provides accurate models and dynamic scenarios to utilities, assisting in decision-making processes for optimal power system operation. Furthermore, utilities can thoroughly test sophisticated control tactics with realistic simulations without risking actual grid instability or jeopardising security.

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Coordinated Voltage Control System (CVC) The Coordinated Voltage Control (CVC) system is intended to adjust reactive power control equipment such as generators, LSS plants, OLTC transformers, shunt capacitors and reactors remotely, in order to obtain ideal voltage profiles and minimise system losses. This system allows for wide-area voltage coordination, which ensures effective voltage and reactive power management.

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The TNB-CVC system has a hierarchical voltage control architecture, with each component addressing a distinct part of the control problem. The first tier, Tertiary Voltage regulation (TVC), optimises the entire system for optimal voltage regulation. Secondary Voltage Control (SVC), the second tier, coordinates regional control devices. Meanwhile Primary Voltage Control (PVC), the third layer, executes and organises local control (for example, within a power plant).

The TNB-CVC system encompasses the whole TNB power grid, which is separated into numerous control zones and control activities are regionalised.

The TNB-CVC system is implemented using a hierarchical voltage control architecture, each addressing a different aspect of the control problem.

The first tier, Tertiary Voltage Control (TVC), performs global system optimization for optimal voltage control. The second tier, Secondary Voltage Control (SVC), coordinates regional control devices. The third tier, Primary Voltage Control (PVC), executes and coordinates local control (e.g. within power plant). The TNB-CVC system encompass the entire TNB power grid where the transmission grid is divided into several control zones and control actions are regionalized.

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EV Smart Charging Electric Vehicles (EV) represent a paradigm shift towards sustainable mobility, with Electric Vehicle Charging Stations (EVCS) playing a critical role in the ongoing transformation.

Malaysia is actively promoting EV adoption, with a goal of installing 10,000 EVCS by 2025.

To promote TNB’s involvement in Malaysia’s EV ecosystem, TNBR actively participates in EV-related R&D projects. In 2017, TNBR successfully created and built an EV charging station powered by solar energy, allowing the EV to be charged without contributing additional demand to the grid.

TNBR prioritises information transmission through extensive training programmes in addition to technical improvements.

These programmes are intended to educate and raise public knowledge about EV technology, enabling wider understanding and application. In the future, TNBR is actively investigating the possibilities of hydrogen storage as a replacement for Battery Energy Storage Systems (BESS) in EVCS applications. This forward-thinking strategy demonstrates TNBR’s dedication to staying on the cutting edge of technical breakthroughs, assuring the sustainability and efficiency of Malaysia’s EV infrastructure.

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Lightning Data & Early Warning System The Lightning Detection System Laboratory (LDS) is a TNBR research facility dedicated to monitoring lightning activity in Peninsular Malaysia in real time. When it was established in 1994, its initial objective was to operate and oversee the LDS Network, which attempted to eliminate disruptions caused by lightning on the TNB Grid system. Over time, the LDS has found increasing uses within TNB and beyond, serving a variety of functions such as lightning research, protection, and problem mitigation.

Among the products offered by LDS is the Lightning Data System (LD365). This service provides historical data reports on lightning strikes in Malaysia, including data from both Cloud to Ground and Cloud to Cloud lightning strikes. It can be used to validate lightning strike claims or for research purposes. The Lightning Early Warning System (LEWS) is another product available, marking a notable milestone as TNB’s first system of its kind. It is the first step towards realising the aim of the R&D Programme of attaining real-time monitoring and assessment of lightning-related risks to system reliability and operation.

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LPS & Earthing Measurement/Assessment Virtual Energy Manager (VEM) offers end-to-end digital solutions to help customers improve their energy efficiency.

VEM is a digitalised solution that can gather and analyse real-time energy data and support a Physical Energy Manager (PEM) with data analysis, monitoring and control, reporting, benchmarking, and offering advice on energy management strategies and best practices.

It provides end-to-end solutions for energy optimisation, including integrated and automated tracking and monitoring, as well as the added value of transforming buildings and business operations to become smarter through data analytics and machine learning.

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Virtual Energy Management Virtual Energy Manager (VEM) offers end-to-end digital solutions to empower customers in energy efficiency* Virtual Energy Manager (VEM) is a digitalised solution that can collect and analyze energy data in real-time and assist a Physical Energy Manager (PEM) on data analysis, monitoring and control, reporting, benchmarking and providing expertise on energy management strategies and best practices.

VEM offers end to end solutions in with integrated and automated tracking & monitoring for energy optimization, with added value of transitioning buildings / business operations to become smarter with data analytics and machine learning.

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Battery Energy Storage Solution A virtual power plant is a concept that entails a network of energy storage devices and distributed generation resources within a certain geographic area, usually on the distribution side.

These resources are being integrated together to tackle utility and customer challenges such as peak load (peak tariff) and maximum demand reduction, spinning reserve, frequency management, anticipating sufficient supply to meet demand, and minimising renewable resource intermittency. Retailers can now own a group of virtual plants to leverage against frequency regulation/response/spinning reserve, consumer end maximum demand reduction, and consumer end peakoff peak tariff reduction, in addition to generation businesses.

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LSS Testing & Commissioning The commissioning test for large-scale solar installations is an important step in the deployment of renewable energy infrastructure, as it ensures the efficient and reliable operation of solar power plants. This thorough testing procedure entails a thorough study of the complete system, from individual solar zones to total grid integration, with the main purpose of validating functionality, identifying any concerns, and optimising operating parameters.

Because of the far-reaching effects on the path to achieving a net-zero carbon footprint, commissioning tests are required for large-scale solar installations. These tests are intended to ensure a smooth transition from construction to operation, ensuring that the solar installation performs at peak efficiency, according to Malaysian Grid Code, Safety Standards, and meets environmental standards.

The significance of commissioning tests in the global quest for net zero emissions cannot be overstated. Large-scale solar arrays, when properly optimised through thorough commissioning, play an important role in the shift from traditional energy sources to sustainable alternatives. Commissioning tests, by assuring the dependability and efficiency of these solar assets, play an important role in boosting investor trust, attracting finance, and supporting the scalability of solar projects, thereby expediting the worldwide transition to a net-zero carbon future.

To date, TNB Labs has achieved tremendous success in the commissioning of large-scale solar (LSS) projects, as evidenced by the successful start-up of over 10 projects spanning the LSS 1 to the LSS 4 sch.

The commissioning test plays an important role in the shift from traditional energy sources to sustainable alternatives.

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Failure Investigation The task of conducting a thorough examination to identify the root cause of various types of failures on TNB and nonTNB assets falls to the Forensic Engineering Group (FEG).

To identify the primary cause of accidents, the FEG team conducts extensive laboratory work using a range of techniques. These approaches include site inspection, speaking to the person in charge or a witness, and conducting a number of tests and exams in the lab, including disassembly, electrical, mechanical, and materials tests. Every test provides a distinct viewpoint on the aftermath of the disaster.

These studies are essential in helping the team solve the challenge and identify the main reason for a failure. The FEG’s findings are crucial for customers’ insurance and warranty claims as well as mitigation plans.

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Oversea Submarine Cable Investigation (ORSTED) A submarine high voltage power cable is important for connecting and transferring energy generated from offshore wind turbine fields to the onshore power grid. The submarine cable is made and loaded onto a cable laying barge before being laid to the sea bed at the predetermined location. During submarine cable laying for the Offshore Wind Farm in Taiwan, severe bending damage occurred, which resulted in the removal of the bending damaged cable section. During the jointing works, water infiltration was found inside the cable, prompting for an investigation into the incident. The investigative team included TNB Labs and TNBR experts, as well as client and cable manufacturer representatives. A portable wearable camera was used to record and broadcast the investigation live to the foreign counterpart.

The FEG team conducted a thorough laboratory examination, employing a variety of techniques to pinpoint the source of the water infiltration. Teardown microstructure examination, Energy Dispersive X-Ray, Fourier Transform Infrared (FTIR), and teardown examination were all used to solve this mystery.

Cable barge installation.

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Cable sample received.

Portable Wearable Camera.

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RBI & OSH Implementation for Power Plants Traditionally, inspections were conducted on a defined period basis by the plant owner and inspection team, regardless of the level of risk or possibility of failure occurring.

With the advent of big data and predictive analytics, the Risk-Based Inspection (RBI) approach now enables plant owners to continuously improve plant safety by categorising the risk level of each piece of equipment in relation to industry standards of equipment reliability. Plant owners can reduce the work and cost of inspection and rectification by focusing on high-risk areas in advance and strategically.

Recognising the importance of RBI for TNB power plants, TNB LABS has developed inhouse RBI solutions that are customised to each TNB power plant. The goal is to assist TNB power plants in managing the long-term integrity of their assets, and obtaining approval from the Malaysian Government Safety Regulator (DOSH) to extend the required inspection interval.

As a team, understanding the importance of RBI is crucial to improve plant safety.

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TNB LABS has developed in-house RBI solutions that are customised to each TNB power plant.

Tedious work as well as cost of inspection and rectification can be reduced by focusing on high-risk areas in advance.

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Drone Services Drones are rapidly being used for exploration in today’s world, and they provide numerous benefits to the companies who use them.

The technology allows for increased efficiency, safety, access to isolated places, cost-effectiveness, greater data collection, and better accident response.

TNBR Drone Team now has eight different types of drones and is ready to provide aerial photography and videography, as well as aerial mapping.

Drones can also perform accurate aerial mapping with GPS, structured analysis, and autonomous pesticide spraying beneath powerlines.

TNBR can use these services to perform real-time inspections to identify problems and act more swiftly to resolve them, among other things.

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THINKING E ES

30 Success Stories

TNBR@30 Publisher TNB Research Sdn Bhd, No 1 Lorong Ayer Itam Kawasan Institusi Penyelidikan, 43000 Kajang Selangor Darul Ehsan.

First Edition April 2024 ISBN 978-629-99076-1-9 TNB Research Ahmad Mumtaz Ali, Dr. Mohd Shafiq Zakeyuddin, Nor Aishah Abbas, Mohamad Faiq Md Amin, Mohamad Iqbal Mohd Asri.

Thinking Eyes Bazuki Muhammad, Shuhada Elis.

All rights reserved. This book, or parts thereof, may not be reproduced in any form or by any means, electronic or mechanical, including photocopying, recording or any information storage and retrieval system now known or to be invented, without written permission from TNB Research Sdn Bhd and copyright holders. The authors’ moral rights have been asserted.

TNBR@30 | 30 Success Stories