International Power Engineer May 2025

May 2025

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SHARING

THE LOAD

How the transformation of energy companies will benefit consumers and the climate

Apply here for a FREE magazine subscription DATA-LED DECISIONS

CABLE CAPACITY

AI’s growing role in utility asset management

How new testing methods are reducing in-service failures

CONTENTS

Welcome Spring is the season for energyrelated exhibitions and we have previewed three of them in this issue.

All Energy in Glasgow is the biggest, encompassing renewables such as wind, solar, biomass and other sectors involved in decarbonisation.

The International Power Engineer team have been beavering away to get the magazine ready to hand out to attendees on the ground. We hope you enjoy it.

The magazine has almost entirely transitioned to focus on renewables in a bid to reflect changes in the industry. Please get in touch if you would like to contrbute articles related to these sectors. The cover story ‘Sharing the load’ (page 6) provides fascinating insight into a future of energy provision in which everyone contributes to a flexible AImanaged grid. As Neel Kulhar from tech company Kazula explained this may provide opportunities for customers to tailor their energy use to earn a “buck or two.”

Biomass to energy now makes up approximately 60% of renewable energy provision in the UK and France, although the French market is more advanced with over 1,000 biogas plants. ‘A blooming market’ on page 10 looks at the state of play of this industry in more detail, exploring government forecasts and objectives.

Talk of AI is everywhere, and Data-led decisions on page 26 looks at the work that AI specialist Sharper Sharp is doing with utiities.

We have run our first industry profile with Daniel Matter the managing director of regular IPE contributor Mems AG on page 22.

Do get in touch if you would like a profile in an upcoming issue!

Nicola Brittain Editor

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– MAY 2025 – COVER

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Sharing the load The agile distributed future of energy provision

WASTE TO ENERGY

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Ocean power A look at subsea sustainable technologies

20

Cable capacity The benefits of new cable testing methods

A blooming industry An overview of the UK's biogas industry

TRANSMISSION & DISTRIBUTION

14 15 16

Signs from above Tips on maintaining electricity tower signage

Electric actuators How a product boosts heat supply efficiency

Call for innovation Ensuring safety and efficiency with hydrogen

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CONTENTS

OPERATION & MAINTENANCE

SHOW PREVIEW

22

46

26 30 32

Industry profile Daniel Matter provides his insights

An evolving beast A closer look at AI and grid maintenance

Solar challenge Gaps in data pose the biggest challenge for solar power

48 50

Global Offshore Wind Shaping the industry’s direction

All Energy A show brings all collaborators together

World Hydrogen For hydrogen players to share practice

38

A coat for all seasons Expanding the lifespan of assets

SAFETY

36 38 40 43

Preventing hydrogen leakage The importance of pressure relief valves with rupture discs

Find the pulse A technology platform that enhances safety

Safer by design The value of gas mapping

Safe and sound Why electric boilers are often the safest

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SHARING THE LOAD How technology is changing utilities

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COVER STORY

SHARING THE LOAD

The transformation of energy companies into agile, decentralised providers will benefit consumers and the climate. Nicola Brittain reports

Annemarie de Jong

Vattenfall

Glenn Waterson AGL Energy

Neel Gulhar Kaluza Kaluza

Santiago Banales Iberdrola

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COVER STORY

U

tilities are currently in flux, transitioning from topdown companies with a clear demarcation between supplier and recipient, to companies that rely on software and AI to allocate resources between and among customers in a flexible ecosystem where all parties play an active role. A recent webinar titled ‘Digital transformation in energy – a blueprint for success’ explored the ways in which energy companies are changing, the similarities between companies across the world, and how they might make the transition work best for the benefit of customers, clients and the climate.

The host Juliette Foster, owner of digital agency Magnus Communications outlined the challenge: “Implementing new systems will involve solving complex data migrations, managing operational shifts and enabling cultural change.”

Consumers want access to data around how much energy they are using to help them make better financial choices

HOW ENERGY COMPANIES ARE TRANSFORMING

Panelist Santiago Banales managing director of energy company Iberdrola, a company operating in Brazil, Australia, the UK and Spain among other countries, explained that energy companies have historically been run by electro-mechanical engineers in a very traditional way. “These managers were operating a critical service and faced heavy regulation. This led to a very risk averse culture. There has been change over the last 20 years and this has accelerated recently, to an agile, decentralised structure.”

Banales argued that energy companies should adopt four key approaches to achieve a successful transformation: 1) An overhaul of their IT system, enabling a decentralised model with more freedom and capacity. ) An HR transformation with 2 employment of software specialists like those working at Microsoft or Google, rather than the traditional mechanical engineers.

3) Transition to an agile model. Energy companies

Electric car users may be rewarded for modifying usage with a flexible grid

will need to make ongoing iterative changes as the landscape shifts.

4) Focus on engaging all the stakeholders of the system including customers.

MANAGING CUSTOMER-CENTRIC SYSTEMS

Banales’ focus on engaging all the system stakeholders, including customers, was a theme for the other webinar attendees too. Glenn Waterson general manager of retail transformation for AGL Energy, an Australia-based energy company, explained that this was a central focus of his organisation. He explained that the company operates 40,000 km

of transmission lines for 9 million consumers in the eastern seaboard of Australia and that this presents great opportunities. “We expect more than 50% of this population will want to be prosumers, meaning they’ll want to be involved in the electrification transition and decarbonisation.” He continued: “Similarly, one in three households currently has solar power, we are currently looking at how best to use and store this energy.” He went on to explain how customer are playing a more active role in their energy consumption. “Consumers want access to data and information on how much energy they are using.

This helps them make better choices.

People want to be able to use that data to ensure affordability and cost of living.”

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COVER STORY

Annemarie de Jong head of delivery for European energy company Vattenfall currently works in Germany and explained that the market shows many similarities to the Australian market described

by Waterson. “We are seeing an acceleration of the green energy transition alongside the German government’s commitment to meeting net zero by 2045, it has just allocated €800m for this process.” However, she warned that operators need to balance ambition with reality because there were legacy systems and even societal issues that might temper the progress. Like Waterson, de Jong argued that the digital customer experience has become a game changer. “Customers want transparency, control, good experience and personalisation.

As such the need and demand for a green digital bundled offering is rising. Digital companies like Octopus are reshaping the landscape with their technology models.”

The Helios Power Ai Solutions project in Huddersfield Yorkshire

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THE ROLE OF TECHNOLOGY

Neel Gulhar chief product officer for software company Kaluza also spoke at the event. Kaluza develops AI driven software that enables allocation of and redistribution of energy on a grid using data. Gulhar explained that a big issue for the industry faces is that although a wopping $210bn is being spent on software globally, it’s likely that this money isn’t going to be used effectively. “A lot of companies are still using software created for a different age with a different set of problems.

For example, the automated back office was set up in the 80s to digitalise paper processes. Similarly, when smart meters were first brought into the market, data storage was expensive but this isn’t the case any more since cloud storage is so cheap. We need to find a better way to spend this money,” he said.

THE FUTURE OF THE GRID

The future of the grid, according to Neel, will be the management of

data. He gives the recent shut down of Heathrow airport as an example of an issue that might be resolved by a data-managed grid. “Despite being one of the busiest airports in the world, the substation was closed for almost a day recently because of a power outage.” As he explained, data and AI could solve the issue. “In the near future instead of having to shut down, airports will be linked to all players in an energy system, including customers with electric vehicles or excess energy from solar panels. All parties will be invited to share their power which might be redirected to an airport. There would be a data strategy managing and consolidating all these elements. “Knowing what’s going on with the grid will mean they consumers can earn a few extra bucks,” he said.

For more information visit: www.kaluza.com and group.vattenfall.com

Vattenfall IDNO has provided grid connection for Helios Power Ai Solutions project at a solar installation site in Huddersfield, Yorkshire in the UK. The company is partnering with sustainable infrastructure specialists Serconnect Ltd and the project will deliver a new 11 kV point of connection to allow Ai to scale without putting strain on the grid.

The project aims to promote the use of renewable energy by combining Ai and blockchain, which help manage and secure data, to create a system where people are rewarded for using or supporting sustainable energy from windfarms, solar, Battery Energy Storage Systems (BESS) or other sources, also known as token- based ecosystems.

Helios Power Ai Solutions are working to make Ai more sustainable by providing access to distributed data centres which are fed power from these renewable assets. By doing so they aim to enable Ai to scale up and grow in usage without putting strain on the grid. Stewart Dawson, managing director at Vattenfall IDNO said “This is our first project with Serconnect, and we look forward to building a strong partnership and delivering many more together.”

WASTE TO ENERGY

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SHARING

How the transformation of energy companies will benefit consumers and the climate

LIMIT

DATA-LED DECISIONS

CABLE CAPACITY

AI’s growing role in utility asset management

How new testing methods are reducing in-service failures

LIGHTER, FASTER, FURTHER An evolving approach to composite design

MOTOR TECHNOLOGY: ENDURING SPACE 36

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CURATED CROPS How one company is developing more resilient cotton strains for industry

HOW ONE STARTUP IS DEMOCRATISING CARGO LOGISTICS

Blending form and function for a sophisticated multi-terrain EV

Powering the fight against climate change

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March 2025

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DELIVERING WITH DRONES

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TURNING THE TIDE

METROLOGY IN MOTION

DISTRACTED DRIVING

Unlocking the circular economy potential of electric and hybrid vessels

How advanced 3D metrology devices are improving vehicle quality and safety

Delivering crucial data to drivers without impacting attention

AGAINST THE GRAIN

THE PERFECT READY MEAL

Dealing with combustible potential when drying grain

Inspection technologies that keep food safe, compliant and tasty

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WASTE TO ENERGY

G IN

M O

Y O R L T B S A U D IN Biogas looks set to grow exponentially over the coming years, here we look at some key statistics and government pledges related to the UK’s industry

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as from biomass or biowaste is one of the least talked about forms of energy production, at least in International Power Engineer. But actually the market has grown 3% a year between 2010 and 2023 and the International Energy Agency forecasts that deployment will need to increase by 8% a year from 2022 to 2040 if it is to be on track with net zero targets.

Biomass forming energy comes from live organic matter such as plants and wood and is used to create electricity, heat and fuels. There are various terms used for energy generated in this manner, With biomass describing live matter and biowaste describing the same matter when dead or a waste product - biogas is the end result. If carefully managed, these products are regarded as ‘renewable’ since resources are relatively easily replenished. Such biomass can either be burned directly or processed into biogas.

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THE MOST USED RENEWABLE

According to the International Energy Agency (IEA), bioenergy accounts for 55% of the total global renewable energy supply and more than 6% of the total global energy supply. It is the largest source of renewable energy in the world. The same organisation also said that renewables made up 15% of final energy consumption in the UK in 2022, and around 60% of renewable energy was derived from biomass.

France, a country that has a fastdeveloping biomass sector also relies on biogas for 60% of its renewable energy. The UK currently has around 723 biogas plants, including both operational and under-development projects, according to the Word Biogas Association. This compares with 1705 plants in France according to gas operator Terega. The ecoysystem in France is the “most developed in Europe” according to Mems AG managing director Daniel Matter.

Biogas makes up 60% of total renewable energy generated in the UK

Countries with a large land mass such as China and India are the countries with the largest biowaste / biomass industries according to the organisation.

UK GOVERNMENT STRATEGY

According to The Biomass Strategy report released by the UK government in 2023, the short-term strategy of the government (2020s) will continue to facilitate sustainable biomass deployment through a range of incentives and requirements covering power, heat and transport.

In the medium term (to 2035) the government intends to further develop biomass uses with a view to transitioning to uses such as Bioenergy with Carbon Capture and Storage (BECCS). These will be critical to meeting net zero and offsetting more traditional sectors.

For more information visit: www.iea.org

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WASTE TO ENERGY

PROTECTING NEW INDUSTRIES Here Dräger tells us how the company provided flame and gas detection for a biowaste to hydrogen plant

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any of the contributors to International Power Engineer are developing products for the biowaste to fuel industry, and Flame and gas specialist Drager is no exception.

The company recently reported a case study regarding a hydrogenfrom-biowaste production facility based in the Midlands that utilised its flame and gas detection. The company was keen to ascertain if the planned gas and flame monitoring system which covered the storage tank and compressor area of the site was both fit for purpose and in line with the appropriate standards and regulations.

STORAGE TANKS

A total of four storage tanks and eight compressors at the site process the hydrogen at 300 times standard atmospheric pressure until it is piped onto lorries in the nearby loading bays for onward transportation.

Financial margins at the production facility were extremely tight, creating significant pressure on costs, but the project engineer wanted peace of

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mind that the planned fire and gas monitoring and detection provision was adequate and suitable.

Furthermore, the site owners wanted to ensure that should the worst happen, in the form of a fire or gas leak, they could be certain that they had taken every precaution to ensure that their health and safety provision was adequate and appropriate.

MAPPING AUDIT

Dräger was asked to conduct a fire and gas mapping audit to consider the planned monitoring and detection coverage across the site, as well as identify any ‘blind spots’, and advise on both the appropriateness of the current position and set up of the system’s devices and whether any further coverage was needed in order to meet coverage requirements.

Using a 3D drawn model of the site using mapping software, the coverage visibility of each flame and gas detection device could be superimposed, with the ability to move the direction of each detector in the modelling software to determine not

only the optimum location for each device to achieve best coverage, but also the best directional positioning.

The eXida certified software then produced a clear visual diagram with green areas showing the site locations that were adequately covered by flame and gas monitoring, and any blind spots highlighted in red.

The project manager proposed six flame detectors, however the fire and gas mapping process not only confirmed that the flame detection coverage could be achieved with five flame detectors and delivering coverage of 99% – a coverage level that the customer felt was acceptable and would provide the required coverage. The fire and gas mapping process determined one flame detector was surplus to requirements and could be removed without any adverse impact on site safety, saving the customer several thousands of pounds.

For more information visit: www.drager.com

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TRANSMISSION AND DISTRIBUTION

SIGNS FROM ABOVE How durable signage makes for safe transmission towers

W

hen a widespread power outage occurs and highvoltage transmission lines require immediate repairs, the electric utility often sends a skilled technician to the location by helicopter to speed the repair process.

Helicopters, along with drones, are also utilised for monitoring, inspecting, and maintaining transmission towers and power lines. Linemen often work on transmission lines that are not de-energised, allowing for an uninterrupted power supply.

SAFETY FIRST

Working near high voltage lines poses significant electrical hazards. The pilots and crew must adhere to strict safety protocols to avoid accidental contact with live wires.

According to manufacturer of industrial identification for 76 years Tech Products, Inc., clear signage is vital to a successful operation.

“When a technician is suspended hundreds of feet above ground, or a drone must fly close to the line, having easily readable, visible signage ensures the crew is at the correct location and understands the potential dangers and hazards in the area,” says Tech Products general manager Daniel O’Connor.

SIGNAGE AT TRANSMISSION TOWERS

Transmission towers require aerial observation tower/pole identification tags, crossing signs, warning signs, as well as various other crucial tags and markers. Towers and other restricted areas also need to display warnings of the deadly electrocution and fall hazards to prevent unauthorised access or attempts to climb the structure from the ground.

READY RAIN OR SHINE

Because of the importance of identifying the correct tower, aerial surveillance markers must be readily visible for many years despite continual exposure to sun, rain,

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High impact polyolefin plastic is a durable material for signage

snow, sleet, wind, and even corrosive elements like acid rain. Unfortunately, traditional painted and laminated identification products frequently fade or delaminate when continually exposed to outdoor weather or punishing conditions.

The alternative is more durable signage made of high impact polyolefin plastic like the Everlast brand from Tech Products. Everlast signs and tags display text or pictograms that are permanently embedded through the entire thickness of the substrate. UV stabilisers and antioxidants are added to provide complete protection and weather resistance in all climates.

For optimal visibility at a distance, polyolefin plastic aerial observation tags come in sizes ranging from six inches to 12 inches, the largest in the industry.

“We always make sure our signs are OSHA/ANSI compliant,” says O’Connor. “However, it is not just what

the sign says, but also its colours. A safety red must stay red for the life of the sign, or it may no longer be considered compliant with OSHA regulations, even if it has been twentyfive years,” says O’Connor.

With the stakes of quickly restoring power to urban areas so high today, utilities need to effectively utilise industry best practice signage, tags, and markers to help their technicians quickly, safely identify and resolve any issues in transmission towers and poles.

Those that do so will benefit greatly over the long term from increased uptime and safety while substantially reducing labour, maintenance, and potential liability.

Author: Del Williams, a technical writer based in Torrance, California.

For more information visit: www.techproducts.com

TRANSMISSION AND DISTRIBUTION

ELECTRIC ACTUATORS BOOST HEAT SUPPLY EFFICIENCY

Retrofitting Auma electric actuators maximised process efficiency in Nokianvirran Energia biomass power plant

Auma’s work with a biomass power plant in Finland sees electric actuators automating valves that were previously manually operated

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y retrofitting Auma electric actuators, the Nokianvirran Energia biomass power plant in Finland significantly increased its degree of automation and thus maximised process efficiency.

STEAM COGENERATION PLANT BENEFITS FROM AUTOMATION

Nokianvirran Energia Oy built a steam cogeneration plant in Nokia in 2016.

The plant uses renewable wood-based fuels from the region. It produces process steam for a paper mill and a tyre manufacturing plant, as well as district heating for a large energy company in the region.

The plant operator was facing the challenge that it took around 30 minutes to start up the boiler from zero to full power, using valves that had to be operated manually. The desire for more automation meant that Auma SA multi-turn actuators with intelligent AC 01.2 actuator controls were added during a plant overhaul in

2022. The actuators now enable the system to be started up in just six minutes.

PROFIBUS INTERFACES IN THE ACTUATOR CONTROLS Thanks to Profibus interfaces in the actuator controls, the actuators are remotely controlled with Profibus DP from the central control room.

In areas subject to heavy vibration or high process temperatures, the actuator controls were mounted on wall brackets at a distance from the actuators to protect the electronics.

By retrofitting previously manually operated valves with electric Auma actuators, the degree of automation at the Nokianvirran Energia biomass power plant, Finland, was significantly increased.

For more information visit: retrofit.auma.com

AUMA PROJECT MANAGEMENT

The Auma team took care of the entire project management, from on-site data acquisition to planning, order processing, installation and commissioning. Thanks to tailormade adapters the actuators could be perfectly adapted to the existing valves with only minor field modifications required.

An Auma SA multi-turn actuator with intelligent AC 01.2 actuator controls

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TRANSMISSION AND DISTRIBUTION

CALL FOR INNOVATION How to ensure safety and efficiency when working with hydrogen

The future of Hydrogen: Jumo works as a development partner with clients

The future of hydrogen: Jumo works as a development partner with clients

T

he transition to renewable energy is accelerating, with hydrogen emerging as a key component in global decarbonisation efforts. As industries move towards sustainable solutions, hydrogen’s ability to store and transport renewable energy makes it an essential element in the shift away from fossil fuels.

Jumo, a leader in measurement and control technology, is actively participating in the hydrogen economy’s rapid development. “We see hydrogen as a promising technology for the future and want to be part of its dynamic growth,” says Rainer Moritz, Jumo’s market segment manager for renewable energy. By aligning its product portfolio to meet the unique requirements of hydrogen applications, Jumo is positioning itself as both a supplier and a strategic development partner.

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THE ENERGY TRANSITION

We see hydrogen as a promising technology for the future and want to be part of its dynamic growth

Hydrogen is expected to play a crucial role in replacing fossil fuels across multiple industries, from transportation to largescale energy storage. The production of hydrogen through electrolysis—using renewable energy sources to split water into hydrogen and oxygen—offers a clean and scalable alternative.

However, for hydrogen to be adopted on a broad scale, innovative technologies and infrastructure must be developed. This extends beyond electrolysis and fuel cells to include systems that can replace natural gas, synthesise e-fuels, and ensure CO2-free industrial processes. “Many companies are facing challenges when integrating hydrogen into their operations,” Moritz explains. “New suppliers, technical solutions, and specialised expertise are required – especially when working with explosive gases.”

TRANSMISSION AND DISTRIBUTION

Reliable measuring technology ensures stable processes

ENSURING SAFETY AND EFFICIENCY

Safety and efficiency are critical when working with hydrogen. High-purity water production for electrolysis and precise monitoring of pressure, temperature, and conductivity are essential. Reliable measurement technology ensures stable processes, reduces risks, and enhances system longevity.

“Our digital pressure and temperature sensors play a crucial role in monitoring thermodynamic processes safely and effectively,” Moritz says. “These systems are not only explosion-proof but also help optimise efficiency in hydrogen production and storage.”

Jumo also certifies and adapts its existing products for hydrogen applications, ensuring compliance with industry standards. This has allowed the company to maintain stable production with only minor facility modifications while scaling up output to meet increasing demand.

A BROADER PERSPECTIVE ON RENEWABLES

With global interest in hydrogen increasing, production facilities must scale efficiently. Jumo has adapted its manufacturing processes to meet rising demand, certifying products for hydrogen applications while optimising existing production capabilities. “We work closely with customers to develop tailored sensor and automation solutions for their specific hydrogen and renewable energy needs,” Moritz adds.

As hydrogen infrastructure expands, collaboration between technology providers, industry leaders, and regulatory bodies will be essential. Companies must invest in research, innovation, and standardisation to unlock hydrogen’s full potential, he says.

The renewable energy transition requires long-term commitment, and hydrogen is poised to play a pivotal role. By combining expertise, cutting-edge technology, and industry partnerships, the path toward a cleaner, more sustainable energy system is becoming a reality.

Let’s work together!

Scan to learn more.

For more information visit: www.jumo.co.uk/web/applications/renewable-energy

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TRANSMISSION AND DISTRIBUTION

OCEAN POWER A look at sustainable, innovative technologies for new underwater markets

U

nderwater conditions are some of the most complex that component manufacturers might need to consider, since products working in these environments need to be watertight, able to withstand pressure, be corrosion resistant and stable.

SUBSEA ENERGY STORAGE SYSTEM (ESS): A MILESTONE IN OFFSHORE INNOVATION Leading provider of advanced underwater technologies, SubCTech, has established itself as a key innovator in the maritime industry since its founding in 2010 by applied

Subsea products need to withstand pressure, be watertight and corrosion resistant

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physicist and CEO Stefan Marx.

Among SubCtech’s most impressive achievements is the development of its Subsea Energy Storage System (ESS), which represents a new era in offshore power supply. The 2 MWh ESS (up to 6 MWh) was developed to meet the increasing demand for sustainable and autonomous energy sources in the oil and gas industry. With a Technology Readiness Level of 6 (TRL 6) according to API17Q standards, the system has been successfully deployed in a real-world offshore project where it has demonstrated both its technical viability and operational effectiveness.

The ESS is a fully integrated

solution capable of supporting underwater infrastructure and remote systems that require long-duration energy storage without constant maintenance. Following its successful field deployment, one of SubCtech’s major clients ordered additional systems, further validating the ESS’s commercial and technological value. The system helps operators to reduce their reliance on expensive land-umbilicals, offering not only financial savings but also a significant reduction in environmental impact.

OCEAN POWER PRODUCTS: SOLUTIONS FOR SUBSEA APPLICATIONS

SubCtech’s Ocean Power product line is tailored to meet the demands of a wide range of applications, including offshore oil and gas operations, marine environmental monitoring, and deepsea exploration. These solutions are also critical for the effective operation of autonomous underwater vehicles (AUVs), subsea vehicles (SUVs), and remotely operated vehicles (ROVs).

At the heart of this product family lies the PowerPacks series — a highly flexible, modular Li-Ion battery system engineered for reliability, safety, and long-term performance, according to

TRANSMISSION AND DISTRIBUTION

the company.

SubCtech’s PowerPacks are durable and versatile with a focus on longevity, with some units capable of operating for up to 25 years. These systems are built to perform in the harshest underwater conditions, including high pressures, extreme temperatures, and isolated deployments where maintenance is not feasible for extended periods.

PowerPacks are particularly valuable in deep-sea environments, where energy reliability is critical for the successful operation of complex instrumentation.

Safety and compliance are essential pillars of SubCtech’s approach. All PowerPacks are tested and certified according to international standards including UN T38.3, MIL-STD, DNV, and API17F. These certifications ensure that SubCtech’s products are not only safe to transport – including by air cargo – but also meet or exceed industry expectations in terms of performance and reliability. CEO Stefan Marx notes: “Our batteries undergo rigorous testing for thermal resilience, shock resistance, vibration endurance, and electromagnetic compatibility (EMC) to guarantee the highest safety and functionality.”

Each unit includes intelligent safety features such as overvoltage and undervoltage protection, overheat shutdown, automatic balancing, and short circuit protection. Additionally, AI-based diagnostics enhance system reliability by reducing false alarms and identifying potential issues before they can cause operational interruptions.

Unlike conventional alkaline primary batteries, Li-Ion PowerPacks deliver higher energy density, greater charge cycles, and better performance under

Li-Ion PowerPacks deliver higher energy density charge cycles than conventional batteries

SubCTech’s approach is rooted in a strong engineering culture

peak loads and sub-zero temperatures — making them suitable for highdemand subsea operations.

GLOBAL GROWTH AND SUSTAINABILITY INITIATIVES

As the global shift toward renewable energy and low-carbon technologies accelerates, SubCtech is scaling its operations to meet increasing demand. The company currently employs 80+ skilled professionals and plans to expand its production capacity by 2025 to accommodate new projects and market opportunities. This growth aligns with SubCtech’s broader mission of delivering environmentally responsible solutions that contribute to the global blue economy.

“Our UN T38.3-certified batteries are approved for air transport and shipped worldwide thanks to our efficient logistics and professional sales network,” says Stefan Marx. “We aim to provide fast, tailored service to our customers, no matter where they operate.”

SubCtech is also strengthening its supplier partnerships, enhancing quality assurance, and investing in the digital transformation of its manufacturing and monitoring systems. These

initiatives ensure that the company remains at the forefront of technological innovation, according to the company and can continue to deliver high-quality, future-ready solutions.

FUTURE OUTLOOK: DRIVING INNOVATION

Looking ahead, SubCtech remains committed to advancing its core business areas: Ocean Power and Ocean Monitoring Systems. The company is actively exploring new partnerships and research initiatives to expand the application of its technologies in renewable energy projects, subsea infrastructure, and long-duration oceanographic missions.

SubCtech’s approach is rooted in a deep understanding of underwater environments, a strong engineering culture, and a vision for a sustainable future. The combination of advanced battery technologies, proven reliability in harsh environments, and a dedication to environmental responsibility has helped made SubCtech a trusted partner for its international clients.

For more information visit: www.subctech.com

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TRANSMISSION AND DISTRIBUTION

CABLE CAPACITY New testing methods for cables significantly reduce the risk of in-service failures

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n effective site commissioning test of an HV cable system is one which reliably identifies laying and installation related lifelimiting defects while, also, not introducing damage into the cable system. The combination of near power frequency AC withstand and partial discharge testing for commissioning testing (site acceptance testing) of HV cable systems prior to energisation has been performed since the 1990’s.

Near power frequency (NPF) is defined as the frequency range of 10 - 300Hz where breakdown and PD inception voltages vary less than 10% of that at 50/60Hz (CIGRE TB 841). The methodology is field proven globally for identifying life-limiting defects and, therefore, significantly reduces the risk of in-service failures post energisation in any HV cable system. Unlike other voltage waveforms, NPF tests apply realistic, operationally-related electrical AC stresses continuously to the cable system end-to-end. Field data acquired over more than 20 years of testing has shown the importance of applying constant, continuous voltage at NPF for 60 minutes (or more) for identifying Inter-array offshore cable testing

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laying installation defects in HV cable systems (CIGRE TB 728).

However, it is imperative that voltage levels and durations are as per Clause 16.3 of IEC 60840, IEC 62067, and IEC 63026 and that PD testing is performed as per recommendations in CIGRE TB 728. Specifically, data collected over more than 20 years has shown that, given the distribution of break-down voltages and partial discharge inception voltages measured, it is important that test levels for 66kV-115kV cables are at 2U0, where U0 references the rated line-to-ground voltage, and that for 132kV and above the test level is 1.7U0 for an effective test (CIGRE TB 728).

For platform- and inter-array cable systems rated 138kV and below, it is important that distributed partial discharge monitoring is performed continuously in conjunction with the withstand test. This particularly the case for terminations, where the AC withstand test may not result in dielectric failure during the 60 minutes withstand test and thus life limiting defects will be identified via PD. Distributed PD tests further allow for pre-maturely terminating a test (meaning that failure under test

is avoided), which then reduces repair times, costs and allows for quick recommissioning testing following repair.

Today’s solutions for offshore commissioning testing of IAC systems involve modular, DNV certified resonant test sets. Each component weighs less than four metric tonnes and can be stacked to minimise space requirements on the OSS. For PD measurements, sensors and battery-operated monitors connected to the fiber-patch panel in each WTG, can be installed while terminating, thus minimising efforts and costs for testing.

Similarly, for testing of export cable systems, modular mobile test systems exist, allowing for testing of up to 100km lengths of 275kV rated cable systems as per IEC recommendations.

For export cable systems, PD measurements should be obtained on the termination end as well as on the transition joints.

Authors: Mark Fenger, Austin Radford, Raed Ayoob & Michael Heiting

For more information visit: www.kinectrics.com

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INDUSTRY PROFILE:

DANIEL MATTER

In this, International Power Engineer’s first industry profile, we ask the CEO of technology company Mems AG about his history in the industry, what drew him to creating gas sensor technology and how the company has evolved

Gas QS static transparent

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OPERATIONS AND MAINTENANCE

WHAT IS YOUR ROLE WITH MEMS AND HOW LONG HAVE YOU BEEN WITH THE COMPANY?

I founded company Mems AG in 2003 as a spin-off from ABB corporate research Switzerland – where I worked as a project manager for more than 10 years with large teams developing sensors for various applications in the fields of pulp & paper, oil production and metering.

With initially seven employees, we spent the first 10 years developing and certifying a static gas meter for household applications. This type of meter is now used in more than 10 million homes worldwide.

In 2008 we started to develop gas quality meters. These have multiple certifications are approved for billing applications, and are used worldwide.

I currently manage the company together with Marco Siragna and my successor Markus Nägele – a collaboration that is wonderful and gives us a lot of pleasure. At the end of the year and with myself already well into retirement age, my colleagues will take over the management of the company.

PLEASE TELL US WHAT INSPIRED YOU TO GETTING INVOLVED IN THE POWER INDUSTRY?

Right now, approximately 80% of the world’s energy needs are still being catered to by fossil fuels such as coal, oil and natural gas. With our gas quality measuring devices, we help to optimise gas-powered processes and machines to maximise efficiency, durability, exhaust gas reduction and safety.

WHAT IS YOUR EDUCATION AND TRAINING BACKGROUND AND HOW DOES IT FIT WITH YOUR WORK AT MEMS? I started with an apprenticeship as an electrician. I then completed a degree in electrical engineering at a university of applied sciences and then studied physics at a technical university (ETHZ) in Switzerland.

I then completed a dissertation in aerosol science and trained as a secondary school teacher.

Gas QS Flonic

I currently manage the company together with Marco Siragna and my successor Markus Nägele – a collaboration that is wonderful and gives us a lot of pleasure

HOW DO YOU KEEP YOUR SKILLS UP TO DATE AND HOW HAVE THE DEMANDS OF YOUR CLIENTS CHANGED OVER TIME? We work with the whole team on innovative projects in hydrogen, biogas, LNG, methanation and ammonia – this means we are always up to date on the latest technology.

WHAT HAVE BEEN THE MAIN CHANGES IN THE POWER INDUSTRY IN THE 35 YEARS YOU HAVE BEEN WORKING IN IT?

Efficiency and emissions reduction have become very important for companies with a strong ethical focus.

What I have noticed, however, is that

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many companies and organisations philosophise about solutions but only a few actually push ahead with implementation.

WHAT CHANGES DO YOU PREDICT FOR THE NEXT FIVE OR TEN YEARS IN THE INDUSTRY?

Further conversion to renewable energy sources and more efficient processes. Increased efficiency and the smart use of resources can save the most energy – but fossil fuels will continue to play a decisive role for many years to come.

WHICH IS THE PROJECT YOU HAVE BEEN MOST PROUD OF WORKING ON AND WHY? I am most proud of the fact that we, a team of around 20 people, have developed a complex, patent-

protected series of products with our own financial resources and that these are in use throughout the globe.

WHAT ARE THE BIGGEST CHALLENGES CURRENTLY FACED BY THE INDUSTRY AS A WHOLE?

In the discussion about the important topic of CO2 reduction, the biggest challenges will be in sector coupling and energy storage, i.e. the time lag between energy over- and undercapacities. Depending on the existing infrastructure and geographical conditions, these issues represent a huge challenge for many countries around the world both technically and financially.

For more information visit: www.mems.ch/en

In the discussion about the important topic of CO2 reduction, the biggest challenges will be in sector coupling and energy storage

The Gas QS Flonic V2 and the Gas QS static transparent

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NEW INDUSTRY HERE DANIEL PROVIDES INSIGHT INTO THE WORK MEMS HAS BEEN DOING IN BIOGAS AND HYDROGEN We are mainly represented in Europe and have about a dozen customers with the gasQS static in their biogas plants. Compared with all other measuring devices known to us, we measure the CH4/CO2 ratio in these plants with very long-term stability – meaning they work for many years without any service or calibration work.

The hydrogen sector is divided into several areas. For example, the gasQS flonic is used to measure the calorific value, density and compressibility and the hydrogen content in natural gas distribution networks. The gasQS flonic is OIML R140, class B certified and can therefore be used worldwide for energy billing. Two out of five gas network operators in Switzerland have started to convert their existing measuring technology to our measuring devices.

The gasQS static can be used for hydrogen admixture in natural gas networks and for determining the purity of hydrogen up to class 3.0 – a three-digit number of such measuring devices are successfully in use. There are gas engine and gas turbine manufacturers who use the gasQS static to measure the hydrogen content in natural gas or the methane content of LNG boil-off and thus regulate the ignition angle of the machines. i.e. optimise the efficiency of the machines.

How has the work with hydrogen measurement changed and how is it likely to change in future?

The topic of hydrogen has become much more important in the last three years or so. While we initially supplied our gasQS technology for field test projects and pilot plants, our measuring devices are now in use in several functionally optimised plants and applications. In the near future, we expect that other companies and individuals involved in the topic will move from talking about it and presenting films to implementing it – actions instead of words!

OPERATIONS & MAINTENANCE

. . . . . . .

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AI is transforming the utilities sector through innovative applications

DATA-LED DECISIONS Kirsty McDermott from Sharper Shape explores AI’s role in next-generation utility asset management

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n an era flooded with AI buzzwords, the utility sector faces a critical question: are we maximising AI’s potential or merely discussing it?

Utilities face significant challenges with aging infrastructure, extreme weather, rising operational costs and increased demands for reliability. AI offers a promising solution to these issues.

Recent advances show how AI can revolutionise asset management for utilities. Automated systems can now accurately identify and assess components on utility poles, streamlining inspections and minimising human error. These systems not only detect defects with high precision but also enhance maintenance efficiency, reduce downtime, and extend the lifespan of

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critical assets. This shift from talk to action signals the next step towards the future of utility management.

AI IN ACTION

To turn the theoretical into the practical, we can examine how AI technologies are already impacting the utility sector through innovative applications. For utilities especially, AI technology is no longer merely an experimental tool, but a proven solution. At Sharper Shape, we’ve been embedded in automating asset management for utilities for over a decade, honing what AI can look like and what it can provide for businesses with hundreds of miles of powerlines in the most remote locations. And of course, the industry has come a long way in the past ten years. Comparably, think of the smart phone you carried

Sharper Shape has been automating asset management for utilities for a decade

with you in 2014 versus Apple’s latest iPhone 16.

The most advanced software goes far beyond the machine learning that your summer intern could train in a couple of hours. And that’s not to undermine the work of interns, but today we’re deploying highly sophisticated tools that organise

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H2-content? Calorific value? Methane number? Z-Factor?

Using our gasQS™ technology you can determine numerous gas properties with high precision and within shortest time.

Suitable for hydrogen shares up to 100 %

Simple installation and system integration

Fast measurement, short response time

www.mems.ch

Robust with low maintenance, no carrier gas

OPERATIONS AND MAINTENANCE

huge quantities of reality data into useable workflows. In recent years, many utilities have already made the first step to limit reliance on outdated physical maps and instead found themselves relying on a digital equivalent – vast volumes of unorganised, siloed data which is unmanageable and expensive to store.

The next stage is truly AI-optimised systems which work through the entire inspection process from planning through to reporting, combining and interconnecting data as it does so, providing a clear and actionable plan giving utilities move oversight than ever before.

One such platform is the Asset Insights module from Shaper Sharpe. By automating the detection and assessment of infrastructure components, employing advanced machine learning algorithms to scan utility poles and other assets AI solutions provide exceptional accuracy. This technology not only identifies defects such as cracks or corrosion but also assesses overall asset health, allowing utilities to prioritise maintenance and repair tasks effectively.

The real-world application of such

technologies is already showing promising results. For example, utilities using AI-driven systems report a substantial reduction in both the time and cost associated with routine inspections. By automating these processes, AI helps utilities redirect valuable human resources towards more complex issues that require human insight.

ADDRESSING THE CHALLENGES

While AI offers substantial improvements, adopting it in utility asset management is not without its challenges. Integrating advanced AI systems into existing operational frameworks often presents hurdles in the form of employee training and data compatibility and system integration.

Utilities, and AI service providers, must address these technical challenges head-on, ensuring that their existing processes can seamlessly connect with AI technologies to fully leverage their capabilities.

Merging AI technology with legacy systems poses a significant challenge. Many utility companies operate on outdated platforms that are not readily compatible with the

The real world application of AI technologies is showing promising results

latest AI software, requiring extensive customisation and sometimes complete system overhauls. This integration process demands not only technical expertise but also a strategic approach to ensure that new and old systems communicate effectively without disrupting ongoing operations.

Additionally, for AI to be effective, it requires high-quality, structured data. Utilities often have vast stores of unstructured or inconsistent data, making it difficult to leverage AI effectively. Establishing robust data governance and quality control is essential to prepare for AI integration.

The process of cleaning and organising data can be resourceintensive but is critical for maximising the benefits of AI. Training and change management also play crucial roles in the successful implementation of AI.. Utility workers must be trained not only on how to use new systems but also on how to interpret AI-generated insights effectively. In an industry with an experienced workforce, the cultural shift towards data-driven decision making can be substantial and requires careful management to align staff with new technological processes.

Furthermore, the upfront cost of implementing AI can be a barrier, particularly for smaller utilities or regional cooperatives. However, the long-term cost savings, increased efficiency, and improved asset management performance justify the investment. To mitigate these costs, some utilities opt for phased implementation strategies, starting with the most critical assets to generate quick wins and establish the value of further investment.

Overcoming these challenges requires a proactive coordinated effort between AI solution providers and utility companies, focusing on seamless integration, comprehensive training, and strategic investment to ensure that AI tools deliver on their promise to transform utility asset management, while remaining flexible and scalable to best suit the utility’s needs.

For more information visit: www.sharpershape.com

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OPERATIONS AND MAINTENANCE

SOLAR CHALLENGE

A recent survey exploring the development of the solar industry finds that it is facing challenges around gaps in data and understanding of smart technology Fluke’s Solmetric PVA-1500HE2 Kit

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new survey from provider of industrial tools and integrated software, Fluke UK highlights key challenges for the solar industry. The survey found that improving panel efficiency, transitioning from reactive to predictive maintenance, and adopting smart technologies were the key factors at play. Crucially, data emerges as the driving force behind innovation and operational efficiency, offering solutions to these pressing challenges.

SURVEY DETAILS

The survey, conducted by Censuswide on behalf of Fluke, engaged over 400 solar OEMs, technicians, and installers across the UK, Germany, Spain, and the US to gain insights into their perspectives on the pressing challenges facing the industry. The survey results also highlighted attitudes toward emerging trends and their expectations for how the future of solar energy is likely to evolve in the coming years.

The research found that nearly twothirds of respondents (63%) believe

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solar will become the dominant energy source in their country. However, it also highlighted significant challenges that must be overcome to turn this optimistic vision into reality and pave the way for a solar-powered future.

“The adoption of smart technologies is going to be critical for companies to gain a strategic edge,” says Vineet Thuvara, chief product officer, Fluke.

“Businesses are increasingly keen on automating their maintenance operations, with approaches like condition monitoring and predictive maintenance, and those that don’t utilise new AI enabled technologies - and their capabilities for collecting more data and gaining more knowledge - will be left behind.”

One of the challenges is the need to rapidly shift from reactive maintenance to a more proactive approach. With 91% of those surveyed reporting concerns about the efficiency of the current generation of solar modules and 39% of respondents identifying inverter failures as a common issue, it’s clear an effective maintenance strategy is a necessity. Nearly a third of all respondents described their current

maintenance strategy as reactive, while more than half indicated that implementing predictive maintenance was a key priority.

Thuvara continued, “the next step, and the best way of overcoming the the solar industry’s challenges, lies in the use of smart tools to analyse this data, and benchmark new data against historical data to detect issues before they risk causing failures. This is where using advanced diagnostic tools, and training technicians on how to use them will help maximise solar panel and maintenance efficiency.”

Fluke’s Solmetric PVA testing kit [pictured’ analyses and benchmarks solar panel data.

SKILLS SHORTAGE

The skills shortage emerged as a significant concern, especially as data tracking through smart technologies becomes more integral to the solar industry’s future - 59% of respondents emphasised the importance of training technicians to effectively use advanced diagnostic tools to meet evolving challenges. Additionally, 53% highlighted the need for more focused

OPERATIONS AND MAINTENANCE

A significant majority of those questioned expected that the solar energy industry would continue to grow

Two-thirds (63%) of all respondents predict that solar will become the dominant energy source in their country

through diverse strategies, including investments in module optimisation software and collaborations with research institutions. Notably, 45% of respondents see the integration of AI in solar panel design, optimisation, and maintenance as a promising opportunity for advancement.

For more information visit: www.fluke.com

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training in electrical troubleshooting and diagnostics, underscoring the urgent need to equip the workforce with the skills to navigate the industry’s technological shift.

More positively, nearly all respondents are taking proactive steps to improve system efficiency

Additionally, 36% are eager to adopt AI-powered diagnostics to enhance maintenance efficiency. However, challenges remain: 28.7% are still relying on a reactive maintenance approach, with over 52% depending on external services rather than inhouse maintenance teams. . Fluke’s Will White, solar application specialist, said: “Organisations are continuing to search for solutions to tackle persistent supply chain issues, aiming to find the sweet spot between adaptability, transparency, affordability, and accessibility. It’s positive to see that the industry remains confident in finding this sweet spot to enable solar to be the dominant renewable energy source in the future.”

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LNG terminal water pipeline

A COAT FOR ALL SEASONS

How to expand the lifespan of assets that are vulnerable to corrosion

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n the ongoing battle against corrosion, the pursuit to extend the lifespan of assets has led to a consideration of corrosion prevention rather than just protection. Concerns regarding coating performance often lead to disputes over responsibility, involving manufacturers, contractors, and project timelines, potentially compromising quality.

However, when analysing the suitability of a visco-elastic coating system, the performance conditions shoud be considered as well as the ability to be applied in often difficult

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in-field conditions during the design and engineering phase.

Advancements in coating technologies, particularly those incorporating coatings commonly known as visco-elastic coating, coatings, more specifically polyisobutene (PIB) based coatings, are proving efficient and safer to apply than comparable products while reducing the need for maintenance over the lifetime of an asset.

CONVENTIONAL COATING SYSTEMS

The conventional method of corrosion

prevention involves creating a barrier over the material surface to shield it from the environment. Traditionally, liquid coatings such as epoxies and paints are frequently used to coat many different above and belowground assets. However, these coatings often need to bond to a substrate with a specific surface profile creation through abrasive blasting, and thus, require stringent surface preparation and application QA/QC before, during and post application. Within a practical application environment, for any type of coating technology, the

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wetting phase is crucial for achieving adhesion. For liquid coatings to achieve good adhesion, they need both a clean surface and an optimal surface anchor profile. The anchor profile allows for the increase in total surface area and allows for mechanical bonding of the liquid coating within the peaks and valleys of the profile. With respect to industry standards, a near-white metal finish (SSPC-SP 10 or Sa 2 ½) is required to have a rust and debrisfree substrate, while creating a profile sufficient for the liquid coating to penetrate and create a strong bond with the substrate.

MANAGING A CHALLENGING APPLICATION PROCESS

With surface preparation being a key factor to the overall success of a coating, there would be a benefit to both contractors and end-users to specify and apply technology which is effective without the need for a long surface preparation and application checklist. PIB-based coatings do not age or degrade and stay in a viscous Obvious corrosion on a boiler’s interior

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state throughout their lifetime. A design feature of the coating system through the use of this coating technology is the inherent nature of the compound being noncuring, non-crystalline, and a fully amorphous low-viscosity material (ISO, 2016). The non-crosslinkable, liquid-like polymer with a low glass transition temperature offers key advantages, mainly in its ability to provide immediate and constant wetting of the surface, forming an instant barrier that blocks oxygen and water, thereby preventing corrosion.

The non-crystalline nature, with a glass transition temperature below -60˚C (-76˚F), ensures that the corrosion protection adhesive compound maintains its fluid-like nature of wetting the surface at all times. This includes any movement with thermal expansion or contractions, pressure expansions and contractions, asset vibrations and movements.

For more information visit: www.sealforlife.com

Condensing lines

A DEEP DIVE:

THE STOPAQ SELF-HEALING COATING Products like the Stopaq viscoelastic PIB-based coating, penetrate surface pores almost instantly and effectively, ensuring lasting adhesion.

The PIB-based coating products offer compatibility to various substrates, often demonstrated with adhesion on steel, polyethene, polypropylene, and coal tar enamel, resulting in cohesive fractures which always leave a protective compound on the substrate, ensuring the coating’s robustness and longevity. In fact, the surface preparation requirements only require the removal of loose existing coating (if any), the removal of larger debris particles and oil or grease on the substrate. If applied to a metal substrate, the surface only needs to have a minimum hand tool cleaning SSPC-SP2 (St. 2) or power tool cleaning SSPC-SP3 (St. 3) finish. The reduction of stringent surface profile requirements also leads to the reduction of inspection points and steps required to achieve the necessary cleanliness and restrictions for the success of traditional coatings. The additional benefits of using simple tools for surface preparation include: reduction of workspace, access to hard-to-reach places, reduction in the need for complex and specific abrasive blasting equipment or media, reduction in energy requirements, reduction of waste, and no shutdown requirements or loss in productivity.

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PREVENTING HYDROGEN LEAKAGE How pressure relief valves with rupture discs can stem hydrogen leakage

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ydrogen is rapidly gaining traction as a clean, efficient, and versatile energy source, making it a key player in the global transition toward sustainable energy. However, its unique properties present specific challenges, particularly its tendency to leak. In hydrogen systems, even minor leakage can pose serious safety, environmental, and economic concerns. One critical area of focus is the prevention of leakage through safety devices such as pressure relief valves (PRVs).

A rupture disc in PRV

WHY HYDROGEN LEAKS SO EASILY

Hydrogen H2 is the smallest and lightest of molecules, composed of two protons and two electrons. The small molecular size makes it far more likely to escape containment than other gases. There are three main reasons for its high leakage potential: S mall molecular size: Hydrogen molecules can penetrate microscopic imperfections in materials or poorly sealed connections that would easily contain larger gases. ow viscosity: This allows L hydrogen to flow and spread more easily, increasing the likelihood of escape through small gaps or poor seals. igh diffusivity: Hydrogen can H diffuse quickly through many materials, including metals, leading to a phenomenon known as hydrogen embrittlement over time.

These factors combine to make hydrogen highly prone to leakage.

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A critical step in hydrogen system design As hydrogen systems scale up and become more widespread, attention to detail in design is crucial. Preventing hydrogen leakage isn’t just about plugging holes, it’s about understanding the unique behaviour of the gas and engineering solutions that meet those challenges.

Using rupture discs in combination with pressure relief valves is one such simple and cost-efficient solution. This prevents leakage, enables easier testing, reduces maintenance costs, and extends equipment life. For any industry moving toward hydrogen, this pairing should be a standard part of the containment strategy.

SAFETY

THE RISKS AND COSTS OF HYDROGEN LEAKAGE

Hydrogen leakage isn’t just a technical nuisance—it’s a serious safety and economic concern.

Safety hazards: Hydrogen is extremely flammable, and even a small leak can result in explosive mixtures with air. Adding to the danger, hydrogen flames are nearly invisible to the naked eye.

Undetected leaks can lead to catastrophic events if not managed properly.

Economic and environmental impact: Every leak represents a direct financial loss. Beyond the cost of lost hydrogen, maintaining systems to prevent or detect leaks adds significant operational expenses. Environmentally, while hydrogen itself is clean, its production, especially when fossilfuel-based, has a carbon footprint.

Minimising losses is vital to making hydrogen a truly sustainable energy solution.

A Fike rupture disc

The benefits of rupture discs

COMMON LEAKAGE POINTS: PRESSURE RELIEF VALVES

One of the most common, yet often overlooked, sources of hydrogen leakage is through pressure relief valves (PRVs). PRVs are essential safety devices, designed to open when system pressure exceeds safe limits, then reclose to maintain system operation. However, PRVs are particularly vulnerable to hydrogen leakage owing to their design.

Most PRVs use metal-to-metal seals to achieve leak tightness. Because hydrogen molecules are so small and mobile, they can ‘weep’ through these seals. Over time, valve components wear down, increasing the rate of leakage. Even valves designed with soft seats (such as O-rings) to improve sealing can degrade under long-term hydrogen exposure, losing their effectiveness owing to permeability and chemical interaction with the gas.

THE SOLUTION: PAIRING PRVS WITH RUPTURE DISCS

To address the challenge of leakage through PRVs, many hydrogen systems now incorporate rupture discs as an added layer of containment.

Rupture discs are non-reclosing safety devices that burst at a predetermined pressure, providing a one-time release point. While a PRV can be completely replaced by a rupture disc, the reclosing nature of a PRV is often a desired feature in the overpressure protection system design.

When installed upstream of a PRV (between the PRV and the process), the rupture disc acts as a barrier under normal operating conditions.

This setup significantly reduces leakage, as rupture discs are typically much more leak-tight than PRVs.

Enhanced leak prevention: A well-chosen rupture disc, especially one made from hydrogen-compatible materials like austenitic stainless steels or Inconel 625, can virtually eliminate leakage under normal conditions Material cost savings: With the rupture disc shielding the PRV from constant hydrogen exposure, more cost-effective PRV materials such as carbon steel or standard stainless steel can be used, reducing system cost.

Operational efficiency: This setup allows for in-situ PRV testing. By pressurising the volume between the PRV and the rupture disc to the opening pressure of the PRV it can be tested without removing it from the system. As a rupture disc can withstand a back pressure it will not open, or be damaged, during this process.

For more information visit: www.fike.com

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SAFETY

FIND THE PULSE How Explosion Power’s technology platform enhances boiler efficiency

C

ontinuous boiler cleaning using shock pulse technology remains at the heart of technology manufacturer Explosion Power’s platform.

However, it is now only one part of a broader, integrated approach based on digitalisation, analytics, and tailored consulting. The platform follows a clear mission: to sustainably increase the efficiency of boiler systems around the world.

At the centre of this approach is the seamless interaction of five key components: tailored con-sulting, continuous boiler cleaning, data analysis, predictive maintenance and optimisation of boiler operation.

Together, they create measurable added value for operators of energy and industrial plants.

BOILER CLEANING TECHNOLOGY WITH DIGITAL INTELLIGENCE

Explosion Power’s automated Shock Pulse Method enables safe, efficient, and interruption-free removal of fouling on boiler surfaces, according to the company. The method is proven to reduce downtime, stabilise operation, and significantly lower maintenance costs.

What truly sets the platform apart, however, is its integration of digital capabilities. Each SPG unit is equipped

with sensors and connectivity features that feed real-time data into a central analytics hub.

REAL-TIME DATA ANALYSIS FOR INFORMED DECISIONS

With its proprietary SPG LogView software, Explosion Power provides a user-friendly interface for real-time analysis of cleaning and operating data. Operators gain instant insights into the current device status.

This data-driven transparency enables precise diagnostics and forms the foundation for predictive maintenance – a key factor in ensuring high plant availability.

PREDICTIVE MAINTENANCE INSTEAD OF REACTIVE INTERVENTIONS

Another advantage of the platform is its intelligent maintenance planning.

With the help of digital analyses, service interventions can be scheduled proactively, spare parts can be procured on time, and resources can be deployed efficiently. This minimises unplanned downtime and extends the lifecycle of equipment.

Explosion Power further supports plant operators with practical maintenance training and a reliable global spare parts service.

A thorough consulting process Explosion Power is adamant that its ongoing partnerships with clients are as integral to its business as the provision of technology.

The company supports projects from the initial concept through commissioning, troubleshooting and maintenance. With many years experience in the field, the company is able to offer tailored consulting and customised solutions for a wide range of plant types. Explosion Power provides benefits to its customers in the form of sustainable efficiency improvements, lower operating costs, and maximum availability of service.

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The company offers optimisation based on data

OPTIMISATION BASED ON REAL OPERATING DATA

The platform not only helps maintain performance it actively improves it, according to the company. By analysing operating data from the SPG system and the boiler itself, the company generates tailored recommendations for adjusting cleaning intensity levels and operation cycles.

One major outcome of this optimisation is the extension of boiler operation periods between manual cleanings. This translates to higher availability, greater thermal efficiency, and a reduced environmental footprint.

In an industry where efficiency, availability, and sustainability of energy plants are key priorities, Explosion Power claims it is setting new standards. It is a pioneer in the field of Shock Pulse Technology and has evolved far beyond traditional cleaning technology. With a compre-hensive technology platform, Explosion Power now offers solutions that optimise the entire lifecycle of boiler systems – from planning and operation to predictive maintenance.

A DURABLE PLATFORM

Explosion Power’s platform shows how traditional industrial technologies can be reimagined through digitalisation, analytics, and service.

Providing these products requires a holistic understanding of a customer needs, technical capabilities, and economic capacity.

At a time when efficiency and sustainability are critical challenges, Explosion Power provides a solution that goes beyond cleaning delivering reliable, high-performance, and environmentally friendly energy generation for its customers.

For more information visit www.explosionpower.ch

SAFETY

Predictive solutions for sustainable boiler efficiency.

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SAFETY

Randall Williams, fire and gas mapping engineer Draeger Safety UK

SAFER BY DESIGN Randall Williams, fire and gas mapping engineer, Draeger Safety UK, explores the value of fire and gas mapping

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n a high-risk environment, a fire and gas detection system provides a crucial layer of protection for the key areas of health and safety for any operator in the power generation industry. Although detection and control systems have advanced significantly in recent years, even the best fire and gas detection system is ineffective if the field sensors are not positioned correctly.

A methodical approach (fire and gas mapping) to designing the sensor locations can provide the confidence that the highest standards of safety have been adhered to in order to protect both colleagues and facilities from toxic and flammable gas hazards,

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Fire and gas mapping can be an effective way of providing reassurance for operators in the industry

as well as fire risks.

Fire and gas mapping can be an effective way of providing added reassurance for operators in the industry. It can determine whether detection devices are positioned accurately and effectively, and whether coverage is sufficient to protect the occupants and process.

Documentation of the location design aligns with UK regulations, including the Management of Health & Safety at Work Regulations 1999 and the Fire Safety Order 2005.

Beyond regulatory compliance, a robust fire and gas mapping approach also demonstrates an organisation’s commitment to safety and reputation,

SAFETY

Illustration showing flame detection coverage

fostering trust and upholding ethical responsibilities.

The fire and gas mapping process employs a consultative approach to conduct a site specific analysis of each setting’s unique challenges and conditions. Hazard mapping software is then employed to model existing and potential flame and gas detection at the site to identify aspects such as any blind spots and also ensure the field device locations are suitable and sufficient to meet the required coverage. The software can verify certain areas are covered by more than one device (also known as a ‘voting detector’), which is useful to rule out false alarms or provide additional confirmation should the actions to be taken in the event of an incident be significant, such as a plant shutdown.

CASE STUDY: BIOWASTE PRODUCTION FACILITY A hydrogen-from-biowaste production facility based in the Midlands was designing its flame and gas detection.

In particular, the company was keen to ascertain if the planned gas and flame monitoring system which covered the storage tank and compressor area of the site was both fit for purpose and in line with the appropriate standards and regulations.

A total of four storage tanks and

eight compressors at the site process the hydrogen at 300 times standard atmospheric pressure until it is piped onto lorries in the nearby loading bays for onward transportation.

Financial margins at the production facility were extremely tight, creating significant pressure on costs, but the Project Engineer wanted peace of mind that the planned fire and gas monitoring and detection provision was adequate and suitable.

Dräger was asked to conduct a fire and gas mapping audit to consider the planned monitoring and detection coverage across the site, identify any ‘blind spots’, and advise on both the appropriateness of the current siting of the system’s devices and whether any further coverage was needed in order to meet coverage requirements.

For further details of this case study see page 12.

CASE STUDY: POWER GENERATION OPERATOR

A large operator in the power generation industry wanted to conduct a flame and gas mapping exercise focused on a 50 metre high tower where there were concerns that risks from Hydrogen Sulphide (H2S) could endanger personnel.

Although the operator was confident that the gas detection

system was effective in its coverage of the site, concerns had arisen that, in the event of a gas escape, there could be potential for a toxic gas cloud to block the main safe exit for workers, resulting in a lessthan-ideal 50 metre climb down an emergency exit ladder.

The flame and gas mapping consultation confirmed that this was indeed a risk that the current detection system did not address adequately, and as a result the consultation advised that extra detection on the stairwell (the main escape route) would be set to provide an early alert for personnel if, in the event of an incident, their escape route could be blocked.

As these examples show, fire and gas mapping is an important ‘best in class’ consideration for fire and gas safety, both at the start of a project, and at subsequent stages as factors or concerns at a site change. It can not only provide peace of mind but also give reassurance in relation to detector siting and coverage, therefore reducing unnecessary detection devices and lowering overall costs.

For more information visit: www.draeger.com

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YOUR GUIDE TO DISTRIBUTORS, SUPPLIERS AND MANUFACTURERS IN THE INDUSTRY

APROVIS Energy Systems

Barnbrook Systems

Integrated Global Services (IGS)

Innovative gas and exhaust gas treatment.

Since its foundation in 2000, APROVIS has been operating successfully as a medium-sized company on the national and international market. We are constantly developing further.

A leading provider of problem-solving innovative solutions for the aerospace, defence, and industrial sectors. Delivering highquality systems and advanced technologies, ensuring reliability and performance across all applications. Partner with us for excellence.

Headquartered in Virginia, U.S., IGS is an international provider of surface engineering solutions. It executes projects around the world and has 35+ years of experience helping customers solve metal wastage and reliability problems in mission-critical equipment.

T +49 9826 / 65 83 – 040

T +44 1329 847722

T +1 888 506 2669

E info@aprovis.com

E sales@barnbrook.co.uk

E info@integratedglobal.com

W www.aprovis.com/en/home-en/

W www.barnbrooksystems.com

W www.integratedglobal.com

Certas

OPSIS

Rotork

A premier provider of high-performance lubricants and lubrication solutions and services.

Catering to industries including automotive, aerospace, and manufacturing, delivering tailored solutions that enhance equipment performance and operational efficiency.

OPSIS AB is a globally active manufacturer of innovative systems for air quality monitoring and industrial gas analysis. We provide our customers with reliable and cost-effective measurement systems and services for a wide range of applications.

A market-leading global provider of mission-critical flow control solutions for the industrial actuation and flow control markets. We help customers improve efficiency, reduce emissions, minimise their environmental impact and assure safety.

T 0800 371910

T +46 46 72 25 00

T +44 (0) 1225 733200

E info@certaslubricants.com

E info@opsis.se

E mail@rotork.com

W www.certaslubricantsolutions.com

W www.opsis.se

W www.rotork.com

GET INVOLVED e advertising@setform.com t +44 (0)207 253 2545 SafeLane Global Limited

Seal For Life Industries

With 30+ years’ experience in demining, explosive and unexploded ordnance disposal, SafeLane Global provides end-to-end consultancy in explosive risk mitigation on land or at sea.

Services include: Threat assessments, surveys, investigation, clearance, and ALARP certification.

Seal For Life, part of the Henkel Adhesive Technologies Group, offers the most diversified protection, maintenance and repair solutions in the market. With fourteen distinct brands offering a broad range of products servicing multiple industries across the globe.

T +44 1594 368 077

T +31 599 696 170

E info@safelaneglobal.com

E info@sealforlife.com

W www.safelaneglobal.com

W www.sealforlife.com

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SAFETY

SAFE AND SOUND Del Williams tells us why electric boilers are often the safer option for engineers

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or consulting engineers tasked with planning, designing, and supervising construction projects for a wide range of industries, each decision can impact the safety of the project.

There are many types of boilers for an engineer to choose from and countless variables to consider before making a decision. One of the main points to keep in mind, however, is the safety it can offer a project.

In this piece, writer Del Williams interviews manufacturer of industrial and commercial boilers Acme engineering and manufacturing vice president Robert Presser, who offers insights into the value of electric boilers.

ELECTRIC OR GAS?

High voltage electric boilers are inherently much safer to use than traditional, combustion-fuelled boilers, which can emit harmful vapours, leak gas, and even cause explosions and fires.

In gas-fired boilers, explosions can result in the ignition and instantaneous combustion of highly flammable gas, vapour, or dust that has accumulated in a boiler. The force of the explosion is often much greater than the boiler combustion chamber can withstand. Minor explosions, known as flarebacks or blowbacks,

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SAFETY

can also suddenly blow flames many feet from firing doors and observation ports, seriously burning anyone in the path of a flame.

“With gas burning boilers, any gas leak can increase the risk of an explosion wherever there are fuel lines, fumes, flames, or storage tanks.

So, gas units must be continually monitored or periodically inspected,” says Presser.

“By contrast, increasing or decreasing the temperature in a gas fired boiler is a slower process because it takes time for the heat in the boiler to rise or dissipate before reaching the targeted output,” says Presser.

solar/wind energy consumption, and fuel boiler replacement.

Natural gas-fired boiler emissions pose potential hazards in the form of emissions. In addition, fossil fuel burning boilers can face potentially dangerous operational issues stemming from excessive heat accumulation.

Gas-fired units emit not only the notorious greenhouse gasses carbon dioxide (CO2) and methane (CH4), but also dangerous nitrogen oxides (NOx), carbon monoxide (CO), and nitrous oxide (N2O), as well as volatile organic compounds (VOCs), sulphur dioxide (SO2), and particulate matter (PM).

SAFE AND CLEAN

In addition to safety, high voltage electric boilers also offer superior control of energy output. The control system automatically monitors factors such as water level, steam pressure, conductivity, and electrical imbalances so energy input and adjustment are precise, and virtually immediate.

These zero-emission, high voltage electrode boilers are used in diverse environments for applications such as centralised heating, power plants, nuclear stations, swing-load balancing,

Modern electric boilers eliminate many of these risks, so can dramatically improve both operator and environmental safety.

Today, there is growing interest in utilising a new generation of these boilers as an environmentally friendly decarbonisation solution. Companies across the globe are considering using electric boilers to become carbon neutral in alignment with COP26 UN Climate Change Conference targets.

The transition to electric boilers also aligns with US goals to achieve a

Understanding how to select, specify, and install electric boilers for the specific situation will conserve substantial energy

The electric boiler design eliminates many environmental issues associated with fuel burning boilers

THE WAY FORWARD

carbon pollution-free power sector by 2035 and a net-zero emissions economy by 2050.

A CASE FOR ELECTRIC BOILERS

The lack of combustion risk and inherent safety that comes with lower emissions, electric boilers are often a safer bet than gas boilers.

“With the jet type electrode boilers, there are no combustion hazards because there are no flames, fumes, fuel lines or storage tanks, which minimises the risk of explosions and fires,” says Presser.

In case of an electrical short, the breaker that protects the high voltage circuit trips in a matter of milliseconds, protecting the boiler and the electrical network. There is no chance of electrical mishap or fire from the boiler.

“Electric boilers, and specifically the electrode units, are inherently the safest boiler design today. These units do not need an operator because if anything goes wrong, the breaker trips, preventing further escalation of the issue,” says Presser.

Since the design does not rely on combustion, it does not create emissions that would endanger the operator or environment. In addition, the design eliminates common environmental problems associated with fossil fuel burning boilers such as fuel fumes, fly ash, and large obtrusive exhaust stacks.

Although consulting engineers are experts in their designated fields of expertise, keeping up to date with the latest developments in advanced electric boiler technology can provide significant advantages in providing hot water and steam for a variety of industrial purposes.

Understanding how to select, specify, and install electric boilers for the specific situation will conserve substantial energy, space, and resources compared with fuelfired options. In addition, it will not only facilitate project success but also a safer environment that helps combat global warming.

For more information visit: www.acmeprod.com

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E X H I B I T I O N A N D CO N F E R E N C E

14-15 MAY 2025 | SEC GLASGOW Be part of the UK’s premier clean energy event Join the brightest minds in the industry, explore forward-thinking technologies, and equip yourself to lead the charge toward a net-zero future!

LEARN FROM THE EXPERTS

Get actionable insights and strategies from industry-leading conference speakers.

EXPERIENCE CUTTING-EDGE TECHNOLOGIES Explore the latest innovations and find solutions tailored to your needs.

EXPAND YOUR NETWORK

Build valuable connections with industry leaders, suppliers, and peers across the entire energy supply chain.

Time is running out - secure your place today and help engineer a sustainable, net zero energy future, together!

REGISTER NOW www.all-energy.co.uk/setform

SHOW PREVIEW

GLOBAL OFFSHORE WIND

The show will focus on action needed to meet 2030 goals

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n 2024, Global Offshore Wind celebrated the sector’s coming of age’ and that it seemed to have reached maturity and scale.

This year, the conference, to be held at London’s Excel centre on the 17th and 18th June, will focus on the urgent actions needed to reach UK and global offshore wind deployment goals for 2030.

The programme titled “mission: possible”, aims to highlight the urgency and ambition of reaching clean energy goals over the next few years, while also emphasising they are within reach.

The show will benefit from keynotes from prominent speakers such as Dr Caoimhe Archibald, minister for the economy, Northern Ireland; Jane Cooper, deputy CEO and director of Offshore Wind, RenewableUK; and Rebecca Evans cabinet secretary for the economy, energy and planning, Welsh government.

The show organisers expect to welcome over 5,000 attendees from over 50 countries working in offshore wind. These delegates and exhibitors will include government agencies, global developers and

innovative technology suppliers.

The show aims to help attendees grow their professional network with numerous opportunities to meet potential customers, collaborators and suppliers. One such event is a newcomer’s breakfast to be held on the 17 June, an opportunity to meet people new to the field or those transitioning into renewables.

For more information visit: www.renewableuk.com/events/ global-offshore-wind-2025/ gow25/

Index to advertisers

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Fike

35

JUMO

9

45

Dräger

33

Kinetrics

17

Aprovis

25

Global Offshore Wind

49

Mems

27

Auma Retrofit

13

Heico Fasteners

25

Seal Saver

5

Böhmer

11

HILCO

IFC

Stopaq

29

Certas

OBC

HILCO

IBC

SubCtech

21

Explosion Power

39

IGS

39

World Hydrogen 2025

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All-Energy Exhibition & Conference

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PRODUCED BY:

IN PARTNERSHIP WITH:

ln the business of building businesses

THE WORLD’S LARGEST & MOST SENIOR HYDROGEN EVENT

HEAR FROM OVER 400 LEADING HYDROGEN EXPERTS AND GOVERNMENT OFFICIALS

NETWORK WITH OVER 15,000 GLOBAL ATTENDEES ACROSS 3 EVENT DAYS

EXPLORE A WORLD CLASS EXHIBITION AND OVER 700 EXHIBITORS

THE INDUSTRY’S MOST INFLUENTIAL EVENT, WORLD HYDROGEN 2025 SUMMIT & EXHIBITION RETURNS TO ROTTERDAM FOR THE LARGEST EVENT YET. JOIN THE LARGEST AND MOST GLOBAL HYDROGEN-FOCUSED EXHIBITION IN THE WORLD, VISIT THE H2 TECH SERIES, EXPLORE THE SITE VISITS TO THE PORT OF ROTTERDAM AND HEAR FROM TOP HYDROGEN EXPERTS ACROSS 3 FULL DAYS OF CONTENT!

SHOW PREVIEW

ALL ABOARD FOR THE ALL-ENERGY EXHIBITION AND CONFERENCE A Glasgow-based show that grows year-on-year All Energy will feature over 600 speakers and 270 exhibiting organisations

I

t is nearly time for the UK’s largest renewable and low carbon show, The All-Energy Exhibition and Conference, scheduled for May 14th and 15th to take place at the SEC, Scotland’s largest exhibition centre, located on the banks of the river Clyde in Glasgow.

Last year, attendance records were broken by 21%, and the show welcomed 11,736 people to explore the buzzing aisles, conference halls and show floor theatres. This matches past trends, as attendance numbers have been climbing since the show started in 2001.

During its first year the All-Energy Exhibition and Conference hosted less than 50 exhibitors and 350 visitors, it is now more than 20 times the size and renewable energy has become a mainstream topic.

Many exhibitors came from the UK and Northern Ireland last year and the majority of these are expected to return, However, the

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show is international in nature with attendees expected from the Czech Republic, Denmark, France, Germany, Ireland, Italy, Luxembourg, Monaco, the Netherlands, Norway, Portugal, Sweden and the US. The show’s focus will be on renewable and low-carbon energy, and will feature over 600 speakers and 270 exhibiting organisations.

Exhibitors such as ABB, Danfoss, Omicron and Roxtec are just some of the companies attending.

support them in their businesses.

CONFERENCE TOPICS

Those newer to the industry will be encouraged to make use of the educational content featured this year.

The Future Talent Hub and Green Skills Zone will be there to provide resources for those interested in becoming more deeply embedded in the sector.

Topics such as wind, solar, hydrogen and decarbonisation will be covered by expert-led sessions and keynote speakers, and they will drill down into issues llike renewable energy forms, grid infrastructure, hydrogen and energy storage.

Free-to-attend conference sessions are predicted to total over 140 hours aimed to inspire attendees and

NETWORKING OPPORTUNITIES

The show will provide many networking opportunities, as delegates will include industry leaders, developers, policymakers and researchers. Attendees will be able to meet face-to-face and conduct business in an accessible setting.

RESOURCES FOR ATTENDEES

For more information visit: www.all-energy.co.uk

#RUKGOW25 17–18 June 2025 Excel London

Mission: Possible Delivering a clean energy future

Save the date

SHOW PREVIEW

WORLD HYDROGEN SUMMIT – POWERING THE HYDROGEN ECONOMY

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ne of the industry’s most influential events, World Hydrogen 2025 Summit & Exhibition returns to Rotterdam to deliver its largest show yet, taking place on 20-22 May 2025 at the Rotterdam Ahoy, Netherlands.

Organised by the Sustainable Energy Council and RX Global, in partnership with the Dutch Government, the Province of South Holland, the City of Rotterdam and the Port of Rotterdam, World Hydrogen 2025 is recognised as the official meeting place for those involved in the hydrogen industry.

2025 marks the midway milestone where progress must be assessed and benchmarked against industry and decarbonisation goals. The show will attempt to determine whether the industry is on track. Delegates will join 15,000 global industry experts

to exchange key insights, build new alliances and sign bold agreements that will kickstart the next wave of hydrogen project developments into the 2030s.

The World Hydrogen Summit welcomes over 400 global ministers, CEOs and CTOs to tackle the industry’s most pressing challenges.

As we move from feasibility studies into the T&Cs, the second half of the decade is set to deliver projects over the line and see the emergence of a global hydrogen trade system. From demand creation to infrastructure development, certification to finance and reaching FID, global leaders at the forefront of hydrogen projects will share real case studies and strategies to unlock efficiencies and scale, further cementing the bankability of projects.

New and expanded for 2025, the

World Hydrogen Exhibition will now feature three large hydrogen technology stages allowing visitors to explore short presentations from leading companies in the industry on the exhibition floor. Spanning six exhibition halls, visitors can network and build relationships with over 700 exhibiting companies across the two exhibition days. Attendees can expect to meet new collaborators and partners Download the brochure to see what to expect at the show - the largest yet.

Register your place to get involved with one of the world’s best known hydrogen focused events.

Scan QR code for link to additional registration info...

Key themes and topics lobal governments leading the creation of a hydrogen economy G Hydrogen bankability, investments, subsidies Decarbonising hard to abate sectors through low carbon hydrogen applications Renewable hydrogen production Low carbon hydrogen production with CCUS Electrolyser developments Clean hydrogen storage infrastructure, transportation & distribution Hydrogen supply chain development

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