EQ INTERNATIONAL

In

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Increasing Cell Efficiency Wit With Rearside Technology

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Special Mirror for CSP

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Bearing Selection Techniques Techniq Wind Turbines

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Implementation of REC Mec Mechanism in India

INTERNATIONAL Issue#01 | January-February 11

Cellulosic Ethanol – The Future Of Biofuel R j Rejuvenating ti India’s I di ’ Thermal Th l Power P Plants With Integrated Retrofit Solutions

UL Unveils India's Largest Photovoltaic Test Facility Underwriters Laboratories (UL) has unveiled India’s largest state-of-the-art photovoltaic (PV) lab. This lab is capable of testing to UL, IEC and other international standards thereby helping manufacturers access global markets. It will serve manufacturers and power plant developers by providing a full portfolio of testing services for solar PV, concentrated PV products and balance of systems as per the requirements of National Solar Mission Testing & Certification Services for Manufacturers of: 1. Crystalline Silicon PV Modules and Panels 2. Thin-Film PV Modules & Panels 3. Concentrated PV 4. Building - Integrated PV Modules and Panels 5. Building - Integrated PV Mounting Systems 6. Junction Boxes 7. Inverters & Charge Controller 8. Batteries

Services for Powerplant Developers, EPC & System Integrators: 1. Design Qualification for Stand Alone PV Systems 2. PV System Installer Training Program 3. Condition Monitoring Services for PV Power Plants

For more information, please contact: Hitesh Jain UL India Pvt Ltd

T:: 91.9717488144 / E:: Hitesh.Jain@in.ul.com T:: 91.80.41384500 / E:: Customerservice.in@in.ul.com

EDITORIAL T

here is no substitute for growth. It is an entailment but not at cost of climate change. One and all believe the fact but when it comes to implementation stark contrast in opinion comes to fore.

Just as Copenhagen Summit, it was obvious from Cancun Summit that developed world and

developing countries are in fray over carbon taxing. With the differences coming wide open, the summit concluded without any substantial outcome. The delegates discussed and deliberated each aspect of the climate change, carbon emission and carbon pricing in detail but to no avail.

If we take a cue from Economics, it advocates putting price on carbon emission or taxing energy consumption, which involves emissions. It also suggests that that the price of carbon should be similar across the world otherwise carbon emission could shift from one country to another.

Even though the Economics furnishes need of carbon pricing, many developed and developing countries are denying it on pretext of one or the other reason.

While US, Japan and other developed countries stated that they won’t implement price on carbon, if developing countries do not follow the suite, China has other excuse.

China opines that the impact of climate change is due to carbon emissions that took place across the world in last 250 years. China has least emissions in the earlier years. For that matter today emissions of the China are one third that of North America. Considering the fact, China should be given liberty to emit more carbon to ensure sustainable industrialization and economic development of its citizens. With brewing resentment over these issues, Cancun summit concluded without underlining on any consensus.

While the carbon pricing issue is still hanging on fire, in India with an aim to increasing share of renewable energy in total energy consumption of the country, Central Electricity Regulatory Commission has notified regulatory framework for Renewable Energy Certificate Mechanism. Under the mechanism target for renewable energy purchase for FY 2009-10 has been set as 5%. This target increases by 1% every year for the next 10 years. This implies that National Action Plan for Climate Change envisages renewable energy to constitute approx 15% of the energy mix of India in 2020. It is expected to be Rs 10,000 crore market by 2012.

In view of the figure it seems that RECs will be the largest incentive for the Indian Renewable Energy Investors.

With an electronic platform to buy and sell RECs, this is one of the most transparent subsidy mechanisms put in place by the Indian government to incentivize clean energy investments. With two revenue streams – viz. from electricity sale and REC mechanism, the Indian renewable energy sector will be one of the most lucrative investment destinations globally.

While the government leaving no stone unturned to ensure promotion of renewable energy in India, there are some issues which have to be addressed. The industry is on learning curve and it is difficult for it to foresee. In recent bidding system, the developers in an attempt to get the projects proposed aggressive bids.

India’s Central Electricity Regulatory Commission (CERC) had set the feed-in tariff for CSP plants at Rs 15.31/kWh ($US0.32). Against the tariff bidders for first phase have offering discounts between Rs.3.07 (US$0.07) per unit, as in the case of Corporate Ispat, to as high as Rs.4.82 (US$0.1), in the case of Lanco Infratech. Likewise, for solar PV the CERC tariff was Rs 17.91. Companies offered discount of upto Rs 6.96, putting a question mark on the viability of the project.

In such condition it seems that there is a roadblock before you kick-start the journey. Government and industry should come out with some solution on the issue. Though today industry is in sixes and sevens but we are sure it will find a solution to the problem soon.

With these updates, we leave you with the very first edition of EQ International that elaborates about power plant optimization, renewable technology, REC mechanism, climate change et al.

Anand Gupta Editor & CEO

VOLUME 1 | ISSUE 1

CONTENTS

FirstSource Energy INDIA PRIVATE LIMITED

17 Shradhanand Marg, Chawani Indore – 452 001 INDIA Tel. + 91 731 255 3881 | Fax. +91 731 2553882 www.EQmag.net

EDITOR & CEO:

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PUBLISHING COMPANY DIRECTORS: ANIL GUPTA

ANITA GUPTA

Editorial Department: NITI PARIKH niti.parikh@EQmag.net

ZOHA MAHDI zoha.mahdi@EQmag.net

Editorial Contributions:

Alok Nigam, Anish Wastrad & Rhushikesh Kathe, Vijaya KLNR Pingali & Sandeep Venkatraman, Sharad Saxena, Torsten Knoedler, Vikas Almadi, Dipl.-Ing. Jens Ehrler, R. Subramanian, Francesco Orioli, Matthew B. Turi, Christopher S. Marks, Rainer Weiss, Ralf Herrmann, G S Krishnan, Jennifer Holmgrena, Richard Marinangelia, Terry Markera, Michael McCalla, John Petria, Stefan Czernikb, Douglas Elliottc, David Shonnardd, Mediratta, Vishal H Pandya, Martin Lord, Sam Saimbi, Mike Davies, Deepak, Konnur, Rajshekharan, Surjit Mohapatra, Neha Pahuja, Ajay D’Souza

Sales & Marketing:

GOURAV GARG gourav.garg@EQmag.net

Solar Power

Solar Power

22

34

Lanco Solar : Pioneering The Indian Solar Era

Increasing Cell Efficiency With Rearside Technology

Cover

Subscriptions:

PIYUSH MISHRA piyush.mishra@EQmag.net

Advertising Sales Germany, Austria & Switzerland:

UL Unveils India's Largest Photovoltaic Test Facility Underwriters Laboratories (UL) has unveiled India’s largest state-of-the-art photovoltaic (PV) lab. This lab is capable of testing to UL, IEC and other international standards thereby helping manufacturers access global markets. It will serve manufacturers and power plant developers by providing a full portfolio of testing services for solar PV, concentrated PV products and balance of systems as per the requirements of National Solar Mission

ERHARDT EISENACHER Eisenacher Medien Tel. +49-228-2499860 Fax. +49-228-650076 info@eisenacher-medien.de

Testing & Certification Services for Manufacturers of: 1. Crystalline Silicon PV Modules and Panels 2. Thin-Film PV Modules & Panels 3. Concentrated PV 4. Building - Integrated PV Modules and Panels

Bio Fuel

5. Building - Integrated PV Mounting Systems 6. Junction Boxes

Layout and Design:

7. Inverters & Charge Controller

MOH SUHAIL KHAN

8. Batteries

Services for Powerplant Developers, EPC & System Integrators:

Publishing:

1. Design Qualification for Stand Alone PV Systems

ANAND GUPTA

56

2. PV System Installer Training Program 3. Condition Monitoring Services for PV Power Plants

Printer:

PRINTPACK PVT. LTD. 60/1, BABU LABHCHAND CHHAJLANI MARG, INDORE- 452009 (MP) PH. +91-731 2763121 FAX.+91-731 2763120 Disclaimer,Limitations of Liability While every efforts has been made to ensure the high quality and accuracy of EQ international and all our authors research articles with the greatest of care and attention ,we make no warranty concerning its content,and the magazine is provided on an>> as is <<basis.EQ international contains advertising and third –party contents.EQ International is not liable for any third- party content or error,omission or inaccuracy in any advertising material ,nor is it responsible for the availability of external web sites or their contents The data and information presented in this magazine is provided for informational purpose only.neither EQ INTERNATINAL ,Its affiliates,Information providers nor content providers shall have any liability for investment decisions based up on or the results obtained from the information provided. Nothing contained in this magazine should be construed as a recommendation to buy or sale any securities. The facts and opinions stated in this magazine do not constitute an offer on the part of EQ International for the sale or purchase of any securities, nor any such offer intended or implied Restriction on use The material in this magazine is protected by international copyright and trademark laws. You may not modify,copy,re produce,republish,post,transmit,or distribute any part of the magazine in any way.you may only use material for your personall,Non-Commercial use, provided you keep intact all copyright and other proprietary notices.If you want to use material for any non-personel,non commercial purpose,you need written permission from EQ International.

Cellulosic Ethanol – The Future Of Biofuel

For more information, please contact: Hitesh Jain UL India Pvt Ltd

T:: 91.9717488144 / E:: Hitesh.Jain@in.ul.com T:: 91.80.41384500 / E:: Customerservice.in@in.ul.com

6-20

39

Heralding a new dimension to product

Solar Power

safety, testing and certification

Interview 24

“Solartie: Integration Of Grid Interconnection Technologies”

26

Energy Yield Optimization Of A Pv Plant

arena, Underwriters Laboratories (UL) recently announced the opening of its testing and certification facility for Photovoltaic (PV) equipment in Bangalore.

EQ Business & Financial News

Interview 28

“Hensel Has An Edge In Electrical Installations In Difficult Environments”

30

Automation In Solar Power Plants Grid-Connected Pvpower Plants’ Performance Optimization

CONTENTS CSP

Wind Power 46

40

Special Mirror For Csp Increases Efficiency

Plasma Gasification

Bio Fuel 58

32

Opportunities For Biorenewables In Petroleum Refineries

Grid-Connected PVpower Plants’ Performance Optimization

36

Surge Protection For Photovoltaic Systems

39

Ul India Opens Largest Photo-Voltaic Testing & Certification Facility In Bangalore

42

Challenges In Providing Concentrated Solar Thermal Systems For Industrial Applications

Renewable Energy Market Implementation Of Rec Mechanism In India

54

66

“Plasma Gasification Technology Has Immense Potential”

Conventional Power 68

Rejuvenating India’s Thermal Power Plants With Integrated Retrofit Solutions

It In Power 71

74

Power Plant OPtimization –Realizing Bottomline Improvement And Improving Carbon Foot Digsilent Power System Analysis Software

Energy Overview 76

The Indian Energy Sector Likely To Quadruple By 2020

Making Wind

Climate Change 79

Policy & Regulation 63

Bearing Selection Techniques As Applied To Mainshaft Direct And Hybrid Drives For Wind Turbines

Wind Power

Climate Change Negotiations In Cancun In Retrospection : A Progress Or Regress

Coal 81

Non-Coking Coal Shortage To Result In Over-Fourfold Rise In Imports

84-86 Product Section 88-89

Conference & Events

87

Directory

90

Advertiser Index

EQ

Business & Financial News

BEScom’s Truly, It’s Vibrant Gujarat!

Pilot Project On Smart Grid To Be Launched In April 2011 It won’t be an exaggeration, if we say that Vibrant Gujarat Summit 2011 was money spinning machine. As far as power and energy sector is concerned investment to the tune of Rs 3,34,479 crores has been confirmed during the most talked about summit.

Bangalore Electricity supply Company Limited (BESCOM) is all set to launch Pilot project on smart grid. Central Power Research Institute (CPRI) is assisting BESCOM in this ambitious project. The pilot project is expected to be launched in April 2011.

Actis, Gis To Invest In GVK Energy Renowned PE fi rm Actis and an affiliate of the Government of Singapore Investment Corporation (GIC) have inked a pact with GVK Energy for investment of Rs 698 crore investment in the latter company.

According to the deal both the companies would fund Rs349 crore each. Actis and GIC’s affiliate will bring in Rs218 crore each as the first tranche of investment, as per the company statement.

Rajasthan government to come up with new solar policy by Feb 15, 2011 6

With the conventional energy sector booming across India, Gujarat Government have signed MOUs for as many as 47 projects including coal

based and hydro plants. With these projects get completed the capacity addition in State of Gujarat would be of around 63560 MW. Though no timeline is outlined for completion of projects, as it depends upon project to project, but this will surely bring sea change in Gujarat Energy scenario, said R S Shah, Superintending Engineer, Gujarat Power Corporation Limited.

For that matter timeline for

such a huge investment could not be ascertained because there are many parameters involved. The companies have yet to procure the land. While land acquisition process is there,the major factor would be environment clearance. Though it is rooted through State government but ultimate authority is with Union government. As the process is long it takes substantial time.

Above all ample time is needed to ensure equipment supply, said senior official Mr Chorera.

GEA Group Inaugurates New Plate Heat Exchanger Manufacturing Facility In Chakan, Pune The MDAX listed GEA Group, one of the largest product and system providers for food and energy processes in the world, recently announced the launch of its 3rd manufacturing facility in Pune in India after Vadodara and Bangaluru. With revenues worth 4.4 Billion Euros and a presence in over 50 countries with global production and R&D centers, the new facility is a testament to GEA Group’s strategy to expand its worldwide presence.

The Pune plant has been set up with an investment of over Rs.100 Crores and a built up area of 6500 sq. meters is GEA Group’s third plant in India. This new plant is aligned with GEA Group’s global manufacturing processes and quality standards.

The Pune plant will manufacture Plate Heat Exchangers (PHE) of all types and will cater to India and Asia Pacific Markets.

Speaking on the occasion, Mr. K.P Glockner, President

and Spokesperson, GEA PHE Systems said, “We are happy to announce the launch of our new plant in Pune. It’s aligned with our global strategy of investing in growth markets. We have specifically located the plant in Pune because of its proximity to Mumbai and availability of good infrastructure and manpower.” This new plant will open new employment opportunities for approximately a hundred people,” he added.

L&T reports 40% Y-o-Y growth Larsen & Toubro reported Gross Sales of 11418 crore, for the quarter ended December 31, 2010, registering a growth of 40% y-o-y. Execution of various jobs on hand, is on schedule.

Order inflow of ` 13366 crore

EQ INTERNATIONAL JANUARY/FEBRUARY 11

during the quarter ended December 31, 2010 takes the company’s order book to ` 114882 crore as at December 31, 2010.

Profit after Tax (PAT) for the

quarter ended December 31, 2010 excluding exceptional and extraordinary items, stood at ` 811 crore, recording an increase of 16% over the corresponding quarter of the previous year.

www.EQmag.net

Business & Financial News

CSP Today to open up new SCHOTT Solar to deliver vistas 200,000 SCHOTT ASI modules to Premier Solar India CSP Today will hold second e d i t i o n o f C SP To d ay Concentrated Solar Thermal Power Summit in New Delhi on April 13-14, 2011.

Aimed at taking CSP market to new heights in India, the speakers would share international experience in ensuring the financial viability of the CSP project.

How international experience can be implemented in India.

Discussions would also be held on developing cost effective and quality supply chain industry in India.

Additionally, the objective of the event is to bring international CSP giants and Indian CSP industry on one platform and

opening up new opportunities in India.

The first edition of the CSP today concentrated Solar Thermal Power Summit was a success, wherein around 275 delegates had participated.

This year the conference would offer opportunity to the delegates to interact with each other for six long weeks instead of just two days. The organiser has introduced online e-networker platform that will assist the delegates to broaden their horizon and understanding of the CSP technology, market & innovations. For more details contact-Maria Slough, Event Director, t: +44 207 3757187, e: maria@csptoday.com

BHEL secures major turnkey contracts for GridConnected Eco-friendly Solar Power Plants Bharat Heavy Electricals Limited (BHEL) has won major contracts for setting up three eco-friendly Grid-Connected Solar Power Plants with a cumulative capacity of 6 MW on turnkey basis as part of the Jawaharlal Nehru National Solar Mission (JNNSM) of the country. Valued at over Rs.780 Million, the orders for setting up the three Grid-Connected Solar Photovoltaic (SPV) Power Plants of 2 MW capacity each, has been placed on the company

by Indiabulls. The orders come close on the heels of another major turnkey order for setting up Grid-Interactive Solar Power 8

Plants of 1100 kW capacity in the Lakshadweep islands.

Indiabulls has selected Crystalline Photovoltaic (C-SI PV) technology for these solar power plants which is well proven and has the longest operational experience across the world. The power plants will consist of arrays of thousands of photovoltaic panels made of crystalline silicon that will absorb sunlight and convert it into electricity that will be fed into the main grid. DC power generated by the solar panels will be converted into AC by inverters and fed into the grid through transformers.

EQ INTERNATIONAL JANUARY/FEBRUARY 11

SCHOT T S olar will b e delivering 200,000 SCHOTT ASI photovoltaic modules to India. The customer Premier Solar is a long-term partner of SCHOTT Solar and its order breaks three records at once: The order is the largest so far for SCHOTT Solar in Asia as well as the largest ever for SCHOTT Solar Thin Film GmbH from a single customer worldwide. It is also the most comprehensive contract concluded by SCHOTT AG in India. The delivery of the first modules took place today – SCHOTT Solar and Premier Solar chose this date to officially announce their contract. The contract comprises a total volume of 20 megawatts (MW), out of which 10 MW are to be supplied in 2011, the second half in 2012.

The signing of the contract was marked in Hyderabad, where Premier Solar’s HQ is located. The event took place in the presence of the government minister of the Indian state of Andhra Pradesh for major industries, sugar, commerce and export promotion, Smt. J Geetha Reddy, along with the German visitors Dr. Martin Heming, CEO at SCHOTT Solar AG, and Dr. Robert Kuba, Managing Director of SCHOTT Solar Thin Film GmbH “This project gives us the opportunity to contribute to climate protection in India. At the same time, Premier Solar’s order will help us to continue

expanding our visibility on the Indian market”, said Heming.

Further details of the project were announced at a press conference immediately after the event. The PV modules will be installed in 2011 by Premier Solar’s new EPC division, Premier Solar Power Tech, in a grid-connected ground mount system. Thanks to this PV system, clean solar energy will be produced to serve over 40,000 households.

“We d e cid e d to g o ahead with SCHOTT modules because of their proven durability and reliability as well as the company’s longstanding experience in thin film technology and their industryleading 30-year warranty”, commented Chiranjeev Saluja, Managing Director of Premier Solar. SCHOTT Solar’s ASI thin film technology is the result of many years of experience and up-to-the-minute production standards.

The record-breaking order is part of grid-connected power plants to be installed under the Ministry of New & Renewable Energy (MNRE) Phase I of Jawahar Lal Nehru National Solar Mission of India. The country is aiming to secure its energy supply in the long term and continue to reduce its dependence on fossil fuels by setting itself the goal of deploying 20 gigawatts of solar power by the year 2022.

www.EQmag.net

Business & Financial News

SGS Receives Vestas Award for Successful Completion of 99 MW CLP Wind Power Project at Theni, India Vestas Wind Systems A/S, the world’s largest wind turbine manufacturer, seller, installer and servicing company, honored SGS with an award as recognition of its contribution towards the successful execution of a wind power project at Theni, India.

The Theni Wind Farm project was developed by CLP India Pvt. Ltd., one of the major wind farm project developers in India. Located in the south western part of Tamilnadu, a southern state of the country, the facility consists of 60 Vestas V82 geared wind turbines. Each turbine has a capacity of 1.65 MW IEC Class IIB machine with a blade diameter of 82 m. After a six-month long completion period, the Theni Wind Farm

was offi cially opened in May, 2010.

Acting as contract engineer during project execution, SGS was responsible for ensuring that all activities were carried out at the site by the contractor in line with the final agreement.

In doing so, SGS supervised the quality of construction works, the fulfillment of the technical parameters and kept the project within the scheduled time and contracted price.

To minimize the client’s risks, SGS provided dedicated project monitoring including milestone monitoring, soil investigation report review, document review, confirmation of incoming materials and equipment and fi nal machine

commissioning. SGS worked closely with the teams from Vestas and CLP and presented progress reports on a daily, weekly and monthly basis to ensure that 100% quality was maintained without accepting any quality or budget related compromises.

Throughout challenging conditions such as frequent rain during the initial part of the project, inadequate infrastructure to transport the equipment and laborious land clearance works, the project was completed on time and on budget.

SGS assembled the appropriate team of experts and placed them permanently on site in order to implement and execute the project in accordance with the

requirements of the client. During this process, SGS supervised all construction related activities from checking the location of foundations through to the review of excavation related activities until witnessing the concrete testing.

The project was rounded up with electrical related works. In this task, SGS was responsible for ensuring proper installation of the transformers, the fuse, the surge arrester, stringing work, grounding and generator. SGS verifi ed that the protection systems, control panel, power panel, cable, internal and external line met the requirements set in the drawings and specifications.

Moser Baer’s Anuppur thermal power plant attracts investment of Rs. 580 crore from a Macquarie SBI Infrastructure Fund and SBI MB Power (Madhya Pradesh) Limited (MBPMPL) recently announced that the Macquarie SBI Infrastructure Fund (MSIF) and the State Bank Of India (SBI) on behalf of the SBI Macquarie Infrastructure Trust will together invest Rs. 580 crore (approx US$130million) in MBPMPL’s Anuppur Thermal Power Plant.

MBPMPL - a step down subsidiary of Moser Baer Projects Private Limited is developing a 2,520 MW thermal power plant in multiple phases at Anuppur, Madhya Pradesh

with an investment of Rs. 13,700 crore (USD$ 3 billion). With the current investment from MSIF and SBI, the first phase of 1,200 MW which is anticipated to cost Rs 6,240 crore is fully funded.

MBPMPL has already tiedup debt of Rs 4680 crore for the first phase of the project in Nov 2009 with SBI and Axis Bank as the lead banks. The 2520 MW Thermal power plant is expected to be commissioned in phases by the end of 2014.

The EPC contract for phase 1 of the project has already been awarded to Lanco Infratech

10 EQ INTERNATIONAL JANUARY/FEBRUARY 11

Ltd and construction at the site has commenced. This project is strategically located near major coal fields of South Eastern Coalfields Limited and is close to power deficit markets of Maharashtra, Gujarat and Madhya Pradesh.

Lajpat Shrivastav, CEO, Thermal Business, MBPPL said “Since Madhya Pradesh today faces a 17.7% power deficit, our power project will significantly address the state’s requirement of power and will additionally create large employment opportunities and augment the

socio-economic development in district Anuppur and in the region.”

Varun Bajpai, CEO, SBI Macquarie Infrastructure Management Pvte Ltd, said that having successfully completed investments in Adhunik Power and Natural Resources, VIOM Networks Limited and other investments, MSIF and SBI (on behalf of the proposed Domestic Fund) have committed over US$600 million in year 2010.

Edelweiss acted as the financial advisor to MBPMPL on the transaction. www.EQmag.net

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Business & Financial News

Customer From India Orders 400 Mw In Cell Production Lines

KEC International Wins Orders Worth Rs.980 Crore In Substation Segment

At the end of September a contract was concluded between the Indian corporation Jain Solar Energy Pvt Ltd and the process equipment supplier Gebr.

Schmid GmbH + Co. for two cell production lines with a total capacity of 13,200 cells/h.

Overall Factory Control System.

The final expansion stage will be installed in two phases: the delivery of the lines is hereby planned for the second and third quarter of 2011.

KEC International Ltd. (KEC),

When ordering the cell production lines, Jain Solar Energy Pvt Ltd has also opted for the Selective Emitter technology. The special feature of this technology: the high phosphorous doping on the cell is selectively etched and remains only in those places where contacts are subsequently printed.

to the tune of Rs 980 crore from

These production lines make up the first joint project between the business partners Jain Group and the Schmid Group. The sum which will be invested in the final expansion phase totaling 400 MW lies in the threefigure million euro range. The cell production system is one of the most modern of its kind worldwide featuring the process cluster system which means it can produce at a very attractive CoO (cost of ownership) rate.

The individual process clusters are hereby interconnected by the Montech Intralogistic System which is controlled by the Schmid

Furthermore, the new space-saving Schmid directplasma PECVD cluster concept will also be applied. This enables a high throughput rate with unique availability on a very small footprint.

The Switch has more than 5,000MW of installed wind

The two orders received from

This is the biggest ever order

KEGOC are for the execution,

in the Substation segment of KEC.

Transmission & Distribution EPC business & one of the leading Infrastructure EPC company, has won 3 new substation orders Kazakhstan Electricity Grid Operating Company (KEGOC) and Power Grid Corporation of India Ltd. (PGCIL). These orders follow orders worth Rs.

including rehabilitation, of total

French Solar Energy Major ‘Solairedirect’ Enters India Solairedirect, France’s first and

roadmap to cut this cost to Rs 6

leading pure play solar power

per unit within two years.

operator has announced its

Thierry Lepercq, Chairman

foray into India. The company

Solairedirect Group says “Thanks

provides end-to-end solar energy

to its vertically integrated and

solutions for turnkey projects

technology innovative model,

including project development

Solairedirect has proved itself

and engineering, construction

a leader in solar power projects

and installation, financing,

in Europe, both in terms of costs

power capacity in the global

operation and maintenance.

and bankability. We are now

market and in solar solutions

Solairedirect has already

keen to scale up this model in

the company’s focus is on high-

constructed about 50MW solar

India, and contribute to meeting

power level applications starting

parks with 24MWp as the largest

the country’s huge power needs,

at 500kW. “Our strategy is to

solar park. Solairedirect has

as an Indian company with

provide effi cient and reliable

raised over 300 million euros in

Indian talent, partners and

technology to help India achieve

equity and project financing and

capital. Our goal is to prove

the government’s energy goals

have already reached an LCOE

and to meet the country’s

(levellized cost of energy) of Rs

growing energy needs also in

9 per unit on projects in France,

the future,” Kurttila explains.

with a technology and industrial

The Switch enters India’s booming wind and solar market The Switch, a Finland-based new energy technology company, announced the expansion of its international presence by establishing a wholly-owned The Switch India office in Chennai.

Pertti Kurttila, VP, Supply at The Switch: “India’s growing wind and solar power market is highly attractive for us.

1,018 crore won last week.

38 substations spread across the North East and South of Kazakhstan. The first order is for 21 substations of voltage levels of 1150 KV, 500 KV & 220 KV. The second order is for 17 substations of voltage levels 500 KV, 220 KV & 110 KV. These orders will be executed over a period of 33 months. The orders have been received in a consortium with a local Company. The total value of these orders is Rs. 942 crore.

a global leader in Power

12 EQ INTERNATIONAL JANUARY/FEBRUARY 11

that Solairedirect India can be at the forefront in the race to mass-scale competitive solar power”. www.EQmag.net

Business & Financial News

Vedanta Group signs ~USD 191 mn agreement with Suzlon for 150 MW wind projects in India Suzlon Group has signed an agreement with Hindustan Zinc Limited, a Vedanta Group company and the world’s largest producer of zinc, to set up, operate and maintain 150 megawatt (MW) of wind power projects across the states

will be purchased by the

of Karnataka, Maharashtra,

Managing Director, Suzlon

Rajasthan and Tamil Nadu.

Energy Limited, said, “The

The project entails a total investment of approximately Rs. 865 crore (~USD 191 mn).

The cumulative capacity of 150 MW will be completed in two phases – the fi rst 50 MW by March 2011, and remaining 100 MW progressively by September 2011 and be supplied with a mix of Suzlon’s S82–1.5 MW and S88–2.1 MW wind turbine models. The power generated

respective state’s distribution utilities at the prevailing feed-in tariff under a long term power purchase agreement.

Speaking on the order, Mr. Tulsi R Tanti, founder, Chairman and

Vedanta Group is one of India’s leading industrial houses, and we are very pleased to be their partner of choice. This order underlines the acceptance of wind energy as a viable and profitable solution to meet the increasing appetite among large corporations for reducing their carbon footprint, and meeting energy needs in sustainable manner.”

Lanco Achieves Financial Closure For Andhra Pradesh Project Lanco Kondapalli Power Private

with a debt of Rs. 1,827 Crores

Limited, a subsidiary of Lanco

and an equity of Rs. 783 Crores.

Infratech, developing 732 MW

A consortium of six banks and

(2x366) gas based power

financial institutions, with

project, in Andhra Pradesh, has

Axis Bank in the Lead, are

achieved financial closure. The

providing the debt required for

project, estimated to Cost Rs.

the project.

2,610 Crores, would be financed

www.EQmag.net

Business & Financial News

CLP India signs $288 million ECB financing agreement for its 1320 MW Jhajjar Power Plant CLP India has entered into a

MW (2x660 MW) power project

of its kind in CLP’s generation

for India, involving overseas

financing agreement with The

in Jhajjar, Haryana – making it

portfolio in Asia Pacifi c and

investment in the power

Bank of Tokyo –Mitsubishi

one of the first coal-fired power

one of India’s first supercritical

industry from banks based out

UFJ, Ltd., China Development

generation projects in India to be

power plants.

of Japan and China. The total

Bank Corporation, The Export-

project-financed by a consortium

Import Bank of China, The Hong

The

of foreign banks, since the

Kong And Shanghai Banking

five lenders is providing

Dabhol power project. Installed

Corporation Ltd. and Standard

approximately USD 288 million

with supercritical technology,

(INR 13 billion) in financing.

Chartered Bank for its 1,320

the project will be the largest

This marks a landmark project

consortium

of

investment in the Jhajjar project – including the financing of the first phase project – amounts up to approximately USD 1.3 billion (INR 60 billion).

Trina Solar Announces India Solar Power Plant Completion with Lanco Solar Trina Solar Limited, a leading

power plants in the country and

integrated manufacturer of

the first such for the State.

solar photovoltaic (PV) products

Trina Solar was the

from the production of ingots,

exclusive supplier of the high

wafers and cells to the assembly

performance PV modules to

of PV modules, announced

power the solar plant located

recently through its subsidiary,

in the Indian state of Gujarat.

Changzhou Trina Solar Energy

The western Indian state of

“We are pleased to work with Lanco, one of India’s leading integrated players with considerable experience in EPC, construction and power generation,” said Ku Jun Heong, Director of Sales and Marketing (Asia Pacifi c) at Trina Solar. “India is one of

India’s solar potential under the National Solar Mission.”

“We are excited to work with Trina Solar, a recognized global leader in solar PV modules, on this project,” said Mr. Sai Baba, CEO of Lanco Solar. “Leveraging our in-house

Co. Ltd., the completion of a 5

Gujarat is emerging as a hub of

MW solar power plant developed

solar power generation due to its

the most promising solar growth

Lanco as a leader in the solar

by Lanco Infratech Limited

abundant open space, high solar

markets, announcing its goal to

industry, we hope to strengthen

(“LITL”), one of the fastest

radiation and keen Government

achieve 22 GW of solar energy

our partnership with Trina

growing business conglomerates

support to promote Gujarat as

by end of 2022. We believe our

Solar to provide sustainable,

in India. The project is one of

an investment destination for

partnership with Lanco will play

innovative and cost effective

solar energy.

a signifi cant role in fulfilling

energy solutions.”

the largest single-location solar

expertise to establish and grow

India-Finland to Expand Cooperation in Energy India-Finland to Expand

renewable energy. They agreed

today and included Director of

Sust ainable Development

Cooperation in Energy Dr.

that there is tremendous scope

International Affairs, Ministry of

Summit (DSDS) organized by The

Farooq Abdullah, Union Minister

for understanding and exchanges

the Environment and Forest and

Energy and Resources Institute

for New & Renewable Energy

in the sphere of renewables,

Political Advisor to the Minister,

(TERI). The Finnish Minister

during his interaction with Ms.

especially bio-fuels, waste

Ministry of Environment &

invited Indian renewable energy

Lehtomaki, Minister of the

to energy and in sustainable

Forests of Finland.

companies and entrepreneurs to

Environment of Finland stressed

development. The delegation led

on potential cooperation between

by Ms. Paula Lehtomaki called

the two countries in the field of

on Dr. Farooq Abdullah, here

14 EQ INTERNATIONAL JANUARY/FEBRUARY 11

collaborate with their Finnish The Finland Minister is in

counterparts to the mutual

Delhi for attending the Delhi

benefit of both countries. www.EQmag.net

Business & Financial News

2 X 0.834mwe Biogas Based Power Plant At Jalgaon Comes Into Operation Clarke Energy India Private Limited (CEIPL), authorized Distributor & Service Provider for GE Energy’s Jenbacher gas engine division has commissioned 2 x 0.834MWe (using 2 x JGS 316 GS BL, 415V gas gensets) power plant at M/s Jain Irrigation Systems Limited (JISL), Jalgaon for their iconic waste-to-energy project using

BIOGAS as fuel. JISL’s fruit and vegetable processing unit, having capacity of 400 tons per day generates approx. 200 tons per day of waste. The waste, almost entirely biodegradable being a useful source of biomethanation has been used to generate biogas under suitable anaerobic conditions.

Gamesa To Come Up With Three Manufacturing Facilities Near Chennai Gamesa, one of the leading wind turbine manufacturers in the world, is planning to set up three manufacturing units in India for making wind blades, Nacelles and wind turbine towers. These three new facilities will come up near Chennai, with an investment of Rs 1500 cr. The blade manufacturing facility will make large blades for MW (2MW) size turbines. The facility would come in operation in first half of

2011. The other two facilities for making Nacelles and wind turbine towers would be set up in months to come.Gamesa had started its operation in India with wind turbine facility of 200 MW. There is a plan to scale it up to 1000MW in couple of years. Gamesa has orders for 100 MW, which is expected to close till the end of FY 211 by 200 MW. In next fiscal, Gamesa is eying for 650 MW order.

Developing Standards/Practices For Offshore Wind Industry Developing standards and practices for the offshore marine contracting industry has proved vital in ensuring consistently high levels of safety and risk management. At the inaugural Offshore Wind Support Journal Conference, Hugh Williams, Chief Executive of the International Marine Contractors Association (IMCA) will be exploring the possibilities for ‘knowledge transfer’ between the traditional offshore energy sector and the rapidly emerging offshore wind industry.

The importance of the rapidly expanding industry is confirmed by the increasing involvement by a wide range of IMCA members. This in turn led to IMCA holding a renewables workshop with ‘Safety in Marine Operations’ as its theme in Amsterdam in October 2010.

“Offshore safety is of paramount importance, and standards and practices have important roles to play in effective safety management,” explains IMCA’s Chief Executive, Hugh Williams. “We hear a great deal about ‘technology

transfer’ between the offshore oil & gas and marine renewables sectors; instead, I will be looking at ‘knowledge transfer’ between these highly complementary indus tries at Februar y ’s conference.

“As more of our members (marine contractors, equipment suppliers, clients and consultants) are becoming involved in the offshore wind sector, they will bring with them the standards and practices commonly adopted globally in the offshore oil and gas industry. It is important that the offshore wind sector learns about these, and adopts

– and where necessary adapts – them to ensure maximum safety levels.

“Many marine operations are involved, for example: survey, towage, lifting and installation, cable laying, trenching/burial, diving, crew transfer and maintenance. Often several vessels are on location at the same time, with simultaneous operations (SIMOPS). Much of IMCA’s existing guidance – coupled with industry standards and accepted practice - applies just as much to offshore renewables as to offshore oil and gas activities.”

ACCIONA Energy Closes The Financing Of Its Third Wind Farm In India In Record Time ACCIONA Energy has closed the long-term financing of the 56.1-MW Tuppadahalli wind farm that it is building in Karnataka state (south-west India) with Infrastructure www.EQmag.net

Development Finance Company Limited (IDFC), a leading Indian infrastructure fi nance company. The agreement has been completed in three months, a record for this type of operation.

The financing is structured through the project finance modality for a sum of 2,000 million rupees (33.3 million euros at the current exchange rate), which represents around 60% of the total investment in

the project. The amortization period has been set at 14 years, one of the longest ever granted in India for project finance in the wind power sector.

EQ INTERNATIONAL JANUARY/FEBRUARY 11

15

Business & Financial News

Essar Group And China Development Bank Corporation (CDB) Signs A Memorandum Of Understanding Essar Group recently announced that it has signed a Memorandum of Understanding with the China Development Bank Corporation.

The MOU provides for granting priority to the project proposals initiated by Essar. The project proposals shall focus on the fields of power supply, shipping, steel, Oil and Gas and Business Process Outsourcing (BPO).

The MOU was signed by Mr. V Ashok – Chief Financial Officer of Essar Group and Mr. Gao Jian – Executive Vice President

CDB in New Delhi.In order to strengthen and consolidate the mutual relationship, both parties look forward to carry out cooperation on the principle of mutual benefit and within the scope of the field of operation of each of Essar and CDB through this MOU. The MOU provides for mutually exploring opportunities in the area of financial cooperation, Information and cultural activities cooperation a n d o t h er c o o p er a tio n .

AMSC revenue for third quarter increased to 42% American Superconductor Corporation, a global power technologies company, reported record financial results for the third quarter of its fiscal year 2010 ended December 31, 2010.

Revenues for the third quarter of fiscal 2010 increased 42 percent to $114.2 million from $80.7 million for the third quarter of fi scal 2009. Gross margin for the third quarter of fiscal 2010 was 40.7 percent, which compares with 37.5 percent for the third quarter of fiscal 2009.

AMSC generated net income of $16.0 million, or $0.33 per diluted share, for the third quarter of fiscal 2010. This compares with net income for the third quarter of fiscal 2009 of $5.2 million, or $0.11 per share. The company generated non-GAAP net income of $19.8

million, or $0.40 per diluted share, for the third quarter of fiscal 2010. This compares with non-GAAP net income of $9.1 million, or $0.20 per share, for the third quarter of fiscal 2009. Please refer to the financial table included below for a reconciliation of GAAP to non-GAAP results.

Cash, cash equivalents, marketable securities and restricted cash at December 31, 2010 were $260.5 million. This compares with $131.2 million as of September 30, 2010 and $155.1 million as of March 31, 2010. The sequential and yearover-year increase was driven by the company’s November 2010 follow-on stock offering.

The company reported backlog as of December 31, 2010 of approximately $883 million compared with $956 million as of September 30, 2010 and $546 million as of December 31, 2009.

16 EQ INTERNATIONAL JANUARY/FEBRUARY 11

Commenting on the MOU Mr. V Ashok- CFO, Essar Group said, “This is a major step towards strengthening our existing trade relations with China. This will enable both Essar and CDB to leverage their mutual strength.

Essar Group has recently placed an order to purchase equipments worth US$ 3 billion from China.”Mr. Deep Banerjee – Resident Director - China, Essar Group said, “China has been one of the major sourcing hubs for Essar Group for close to

a decade now. It has since then developed a most diversifi ed sourcing portfolio to the tune of approx. US$ 3-4 billion.”The MOU further states that both parties shall jointly and closely cooperate in mutual information exchanges on cultural matters, and if necessary, carry out publicizing activities. If possible, both parties shall publicize the brand images of the other party and mutually organize cultural activities.

BHEL maintains growth momentum; Achieves 31 per cent jump in bottomline in the Q3 of 2010-11 Bharat Heavy Electricals Limited (BHEL) has maintained its growth momentum in the third quarter of fiscal 2010-11, with a quantum jump of nearly 31% in its Net Profit (PAT) at Rs.14,032 Million, compared to Rs.10,726 Million in the corresponding period in the year before.

The company has also recorded a topline growth of nearly 26% with its Sales/ Income from Operations at Rs.9,280 Crore, as against Rs.7,386 Crore of last year.

Profi t Before Tax (PBT) for the quarter stood at Rs.20,655

Million compared to Rs.16,443 Million in the same period in the previous year, an increase of nearly 26%. With this, BHEL has maintained its track record of earning profits uninterruptedly for nearly four decades without a break. Notably, BHEL’s turnover has increased by three times and net profit by four times in the last five years.

With a highest-ever order book position of Rs.1,580,000 Million at the end of the third quarter, the company expects to achieve robust growth in 201011 and beyond.

www.EQmag.net

Business & Financial News

AMSC Receives $9 Million PCI Ltd. In JV With Follow-On Order For Wind European Giant RPS S.P.A Turbine Electrical Control Systems From India’s Inox Wind American Superconductor Corporation, a global power technologies company, recently announced that it has received a $9 mill ion follow-on order for the supply of wind turbine electrical control systems from Inox Wind Limited (IWL), part of India’s Inox Group of Companies. In August of 2010, Inox placed an initial order for 17 of AMSC’s wind turbine electrical control systems, which, as the “brains” of the wind turbine, monitor and control its operation and the flow of zero-emission electricity to the power grid.

The systems are being utilized in 2 megawatt (MW) doubly-fed induction wind turbines that Inox is manufacturing under a global

AMSC Windtec™ license.

“India has one of the fastest growing economies in the world,” said Devansh Jain, Director of Inox Wind Limited. “When considering our rapid urbanization and industrialization combined with our need to reduce pollution and increase electricity generation, it is imperative that we continue to promote and produce zeroemission electricity from sources such as wind. Our partnership with AMSC has enabled us to enter full-scale manufacturing quite rapidly, taking us one step closer to our goal of becoming a leader in the global wind power marketplace.”

90% of Original Efficiency Even After 25 Years!

While the solar world is going ga ga over the efficiency of Solar PV, Schott Solar has set an example. A category of its solar modules has achieved 90% of the original efficiency even after 25 years of operation. Model PQ 40 (previously reconised as AEG PQ 40) was studied by Fraunhofer Institute for a long term. The study revealed that the model has achieved over 90% of its original performance. A power www.EQmag.net

measurement in accordance with IEC 60904-1 was performed for a total number of 20 SCHOTT PV modules, model PQ40 (previously AEG PQ40), which were manufactured in 1984.

The measurement accuracy for the power measurements is +/_ 3%. The PV modules have been under operation as ISE since 1984. Upon delivery in 1984, the nominal value was 38.4 Wp, disclosed Amit Barve, General Manager Schott Solar.

Riello PCI India Pvt. Ltd. is

of Riello / Aros UPS

joint venture Company between RPS S.p.A, Italy– the leading European Company in Power Protection Technology & PCI Ltd. –the pioneers in India and an International front runner in the fi eld of technology based solutions in Power & Energy domain. RPS S.p.A is the fourth largest UPS manufacturer in the world ranging from 1kVA to 6400 KVA. Commitment towards excellence in this highly specialized sector of uninterruptible power supply is our trademark and the key to our success. Our UPS systems will be sold under the brand name

According to Padma ShriShriSurinder Meht a , Founder Chairman PCI Ltd “There were several reasons for PCILtd. to enter this joint venture. Firstly, present environmental conditions are of great concern, particularly for developing countries like India. It’s high time that we opt for environment friendly power Protection Systems and keeping in line with this Corporate Social Responsibility we strategically planned to get into this joint venture with RPS S.p.A, Italy –initiators of green UPS systems”.

Suzlon Among Winners Of Gigaton Awards At Cop16 Suzlon wins Giagaton Award.

The Gigaton Prizes were developed and awarded by the Carbon War Room, a non-profit organization that harnesses the power of entrepreneurs to implement market-driven solutions to climate change.

The awards ceremony took place during the World Climate Summit and was co-hosted by Sir Richard Branson and José María Figueres and sponsored

by ECCO2, in partnership with Fuseproject and Televisa.

“Today marks an important milestone in the fi ght against climate change,” Branson, who is the co-founder of the Carbon War Room, said in a statement.

“These companies demonstrate the potential the business community has in developing innovative solutions that are good for the environment and the economy.

New Assembly Plant In India From Avanti Avanti Wind Systems has opened a factory in Chennai in India. Initially the factory will be dedicated to assembling Avanti’s ladder systems. Later on, the factory will also complete production of lifts for wind turbines.

“Avanti Wind Systems is now firmly established in India, and the new factory in Chennai helps confirm that we are now especially committed to the Indian wind energy market,” says General Manager for Avanti India, Thomas Fejfer.

EQ INTERNATIONAL JANUARY/FEBRUARY 11

17

Business & Financial News

Suzlon Group Crosses 15,000 MW In Wind Installations Across The World

Jaypee Gearing Up For Commissioning First Unit Of 1000mw Hydro Power Project

Suzlon Group, the world’s third leading wind turbine manufacturer, announced that it has crossed 15 GW (gigawatt) of cumulative installations in 25 countries worldwide, amounting to 9 per cent of the world’s total wind power installations. The cumulative power generation from the 15 GW capacity has the potential to light up more than 13 million households every year.

Jaypee group is all set to commission the first unit of the 1000 MW Karcham Wangtoo hydropower project on Satluj River by March 2011, six months before the schedule.

The Suzlon’s Group’s 15 GW of worldwide installations includes 10 GW by Suzlon Energy Limited and 5 GW by REpower Systems AG – in which Suzlon Energy Limited is a majority shareholder with a holding of over 90 per cent. It covers Group onshore and offshore installations worldwide. Speaking on this significant milestone, Mr. Tulsi R Tanti, founder, Chairman and Managing Director – Suzlon Energy Limited, said: “The 15,000 MW mark is a great

achievement for the Group and a testament to the trust placed in us by our stakeholders. Global wind potential is estimated at 72,000 GW – more than four times the current world energy consumption –and we have barely scraped the surface. all over the world.”In past the 15 years, Suzlon has grown from strength to strength Harnessing this potential means providing for a clean, green future, sustainable livelihoods, and very important – energy security.

Meanwhile, news that Gamesa has taken majority stake in Suzlon was making rounds in media glare. However, Suzlon in a statement to National Stock Exchange maintained that the said news reports published in the media were speculative in nature and inaccurate. When official from Suzlon were contacted for the comment they remained mute over the issue.

Acclaimed as one of the largest hydro power plants in the country, the project is expected to be completed six months before schedule. It is run

of the river generation plant, where the main course of the river from the confluence of Baspa River with Satluj River has been dammed at Karcham in Kinnaur district of Himachal Pradesh and diverted through a tunnel to utilize the head for generating electricity at the underground powerhouse at downstream Wangtoo.

Soham Raises $ 60 Mn From Macquarie SBI Infra Fund Soham Renewable Energy India Pvt is reported to be raising up to $60 million from Macquarie SBI Infrastructure fund.

The fund would be utilized to complete ongoing projects of the entity, as per the sources.

Soham Renewable Energy India Pvt Ltd is undertaking commissioning of a mini hydel

project -Mahadevapura Mini Hydel Scheme on Cauvery River. All clearances required to start project construction have been obtained. The company is also expected to commission a mini hydel power project at Mudabidri, with a capacity of 17 MW, in Dakshina Kannada district.

BHEL Joins Hands With Abengoa To Develop CSP Projects Bharat Heavy Electricals Limited (BHEL), the largest engineering and manufacturing enterprise in India in the energyrelated infrastructure sector and Abengoa, Spain, the European leader in solar and other energyrelated projects, have joined hands to develop state-of-theart Concentrated Solar Power projects in India.

To this effect, an agreement was signed in Seville, Spain, by Mr. B.P. Rao, CMD, BHEL and Mr. Santiago Seage, Chairman and CEO, Abengoa Solar alongwith CEOs of Abengoa group companies, Abener and Teyma, Mr. Manuel Velverde and Mr. Martin Salgado. Mr. R.K. Srivastava, Executive Director, BHEL and other senior

18 EQ INTERNATIONAL JANUARY/FEBRUARY 11

offi cers Abengoa group were were present on the occasion.

The

agreem en t

will

enable both the organisations to leverage their capabilities in offering EPC solutions for Concentrated Solar Power (CSP) projects in India, as well

projects in other parts of the world.

Through this agreement, BHEL and Abengoa are aiming at significantly contributing to the cause of reduction in global warming through the use of CSP technologies.

as give them the opportunity to explore cooperation in energy www.EQmag.net

Business & Financial News

BTU International to Debut Gamesa Next Generation Thermal Seeks Advice From Morgan Processing Equipment For Acquiring Wind Assets In India BTU International is all set to introduce new TRITAN™ dual-lane metallization fi ring system. This state-of-the-art system features increased throughput at 3600 wafers per hour, an edge-grip transport system, and a temperature spike faster than 3 seconds.

The 90 MW metallization firing system also features BTU’s unique TriSpeed™ technology, allowing users to take advantage of superior ramp rates--up to

200ºC per second--while not compromising the drying and cooling sections of the profile.

The three-belt, three-speed system provides revolutionary control of profile development.

BTU also will highlight its meridian™ in-line diffusion system, the leader in in-line diffusion. This system is the industry’s most successful in-line diffusion system with well over 2 GW in customer commitments.

Spainish giant Gamesa Corp. has appointed investment bank Morgan Stanley India Co. Pvt. Ltd for consulting on acquisition wind power assets in India.

Though Gamesa’s Indian arm declined to comment on it but a senior executive from Morgan Stanley confirmed the mandate.

However, he declined to divulge nitty-gritty of it.

L&T To Announce Hydropower Project In Himachal Corporate giant Larsen and Toubro (L&T) has been allotted a hydropower project that was earlier granted to Moserbaer Projects Ltd in Lahaul and Spiti district of Himachal Pradesh, as per a report released by IANS. However, when L&T officials were contacted they kept mum saying that announcement in this regard would be made very soon.

Reliance, Tata Bid For BGR Energy Declares Hydro Projects In Himachal Substantial Growth Considering the potential of Hydro in Himachal, conglomerates like Reliance Power, Tata PowerSN Power joint venture, Larsen and Toubro (L&T), Essar Power, ABG Shipyard and GMR Infrastructure are aiming at hydropower projects in Himachal Pradesh.

Reliance Power alone has shown interest in most of the hydro projects located mainly in Lahaul and Spiti and Kinnaur

districts, said the sources.

GVK Power, Reliance Power, L&T and Tata Power-SN Power are in the race for getting Dugar and Purthi projects.

Reliance Power has also bid for 130 MW Rasil, 94 MW Teling, 81 MW Tinget, 60 MW Patam and 44 MW Shangling, all in Lahaul and Spiti, and 130 MW Sumte Kothang and 104 MW Lara Sumta, both in Kinnaur.

Net sales of BGR Energy grown to Rs.1251 Cr during the quarter, a 97 % increase over Rs.635 Cr registered during the same period of the previous year. Balance of Plant (“BOP”) and Engineering, Procurement and Construction (“EPC”) business contributed 95 % of the revenue during the quarter.

The Company’s Profit after tax for the third quarter witnessed growth of 103 %, at 87.55 Cr. up from Rs.41.91 Cr for the same period last year. The operating margin was at a healthy 11.77

%. EPS has witnessed growth by 109 %, from Rs.5.82 in Q – 3 of 2009-10 to Rs.12.14 for the same quarter in 2010-11.

construction management to long-term operations. Tarun Munjal, managing director of meeco India in a report mentioned that by the end of this year, the goal is to build a

portfolio in excess of 10 MWp. He adds: “In the next three years, meeco India’s objective is to achieve a portfolio of 50 MWp across different states in India.”

Mecco Plans PV Parks In India The Switzerland based meeco Group has announced its plans to install photovoltaic (PV) parks in India over the next three years.

www.EQmag.net

The parks would be developed by meeco India Private Limited. The company will undertake responsibilities right from financial structuring, engineering, procurement,

The company consistently proved its capacity for on time execution and delivery of large EPC and BOP projects of 500 MW and 600 MW capacity and well poised to execute 660 MW and 800 MW units.

Outlook for the Current year: The current Order book of Rs. 9317 Cr. enables the Company to sustain its growth momentum in the near term.

EQ INTERNATIONAL JANUARY/FEBRUARY 11

19

Business & Financial News

NHPC Surpasses Excellent Moser Baer Starts India’s First Domestic Production MOU Target by 10.8% in Of Yukita Brand Junction third Quarter Boxes In Partnership With Yukita Electric Operating Power Stations of NHPC Limited, India’s premier hydropower company and a ‘Mini Ratna’ Category-I Enterprise of the Government of India have once again surpassed the ‘Excellent’ MoU generation target during the 3rd quarter (Oct’10-Dec’10) of the current financial year. The Power Stations together have generated 3069 Million Units (MUs) during the 3rd quarter surpassing the

‘Excellent’ MoU target of 2770 MUs by 10.8%. The cumulative generation for the three quarters is 15941 MUs (Million Units) till December 2010 against the ‘Excellent’ MoU target of 15461 MUs. In order to achieve the ‘Excellent’ rating for 201011, a challenging MoU target to generate 18000 MUs of energy has been set by the Company as against 17200 MUs set for last year.

Alstom Wins Contract Via NASL To Retrofit Air Quality Control System In India Alstom, a world leader in the supply of equipment and services for electricity generation, has announced in India that it has been awarded a contract via its joint venture company NASL worth approximately €20 million (approx Rs. 120 cr.) from the National Aluminium Company Ltd.(Nalco) to retrofit the electrostatic precipitators (ESPs) at five units of its captive power plant in Angul Orissa. The ESPs at Angul was originally supplied by BHEL and the units were commissioned between 1985 and 1989. The upgrade will reduce particulate emissions from the plant to well below the 150 mg/Nm3 requested by the Environment Pollution Control

Board, thus allowing NALCO to conform to India’s environmental requirements.

The contract scope includes the design, engineering , supply, erection and commissioning of the mechanical and electrical components of the ESPs, including the control system and the ash handling system. Out of the entire aforesaid contract, APIL’s scope of work would be Rs 74.16cr. The contract will be executed through, NASL, a joint venture company of Alstom and National Thermal Power Corporation (NTPC).

The first unit is expected to be commissioned in 2012, with the fifth one being completed in 2014.

20 EQ INTERNATIONAL JANUARY/FEBRUARY 11

In its bid to create a robust solar PV eco-system in India, Moser Baer India Limited (MBIL), a cutting edge techmanufacturer, present in the entire PV value chain (cell / module manufacturing to commissioning of solar farms / applications), has commenced production of junction boxes, a critical component in solar PV installations, at its facility in Greater Noida. This has been made possible by utilizing MBIL’s existing assets and core competencies along with the new know-how of Yukita Electric Wire Co. The capacity of this state-of-the art facility is 2.5 million premium quality junction boxes which has been achieved at a low incremental capex cost.

These junction boxes would cater to the requirements of both domestic and global solar PV market through Yukita’s global marketing and sales network.

Speaking about this significant d evelo pment R atul Puri Executive Director, MBIL said,

“The global demand for junction boxes is estimated at around 112 million, of which India is estimated to account for more than 5 million. Moser Baer’s junction box manufacturing initiative will help the industry to address to this requirement domestically.

For the first time, the Indian solar PV players have the opportunity to use ‘Made in India’ junction boxes. MBIL has been able to establish this state-of-the-art facility at a low investment cost owing to its existing high-tech manufacturing capabilities.

Speaking about the tie-up Dr. G. Rajeswaran, Group Chief Technology Officer, MBIL said “Continuing with the vision of Moser Baer to offer quality products at optimum price, we have started manufacturing junction boxes for Solar PV in India. This facility would help in easier access of premium quality junction boxes to the solar PV players in India at globally competitive prices.”

21 Hydro Projects To Come Up In The Himachal In all 21 small hydro power plants would be developed in Himachal Pradesh this year, as per official information.

The plants with combined capacity of 66MW would commence power generation by end of 2011. According to the

information received Himurja had allotted 485 projects, having combined capacity of 1,214 MW to the IPPs in the state. Out of the 485 projects, around 35 projects of 138 MW have already started energy production.

www.EQmag.net

SOLA R P OW E R

Lanco Solar : Pioneering The Indian Solar Era Alok Nigam, Vice President, Business Development, Lanco Solar Pvt. Ltd.

Lanco Solar successfully integrated its 5 MW operating Solar Photovoltaic (PV) Plant to the grid in Gujarat, out of 35 MW to be commissioned by end of 2011. With an additional project pipeline of 100 MW Solar Thermal and 6 MW Solar PV under National Solar Mission, and selected as an EPC Contractor to several key Solar Power developers, Lanco Solar has embarked on a mission to turn India’s solar dream into a reality.

L

anco Group is one of the largest

execution and grown third party turnkey EPC

PV industry is further classified into two

business conglomerates in India with

order book, Lanco Solar has emerged as a

technology options- Crystalline Silicon and

interests in power, construction & EPC,

leading player in Indian Solar Industry.

thin film, each having its own set of merit and

infrastructure and renewable. With an aim to deliver sustainable, innovative and cost effective solution across the entire Solar Power Value Chain, the Group has taken

demerits. For the first 5MW, Lanco Solar

Gujarat 5 MW Solar Farm- An Overview

considerable strides in the solar industry

To kick start the solar power development

during the year gone by, in manufacturing

initiative in the state of Gujarat, the

as well as project development. Lanco Solar

Government invited proposals for setting

will be the first Indian company to effectively

up Solar farms in the state. In the 1st Phase,

integrate the entire Solar Value Chain in

Lanco Infratech Limited was allocated 35

India right from polysilicon to module

MW, based on its technical expertise and

manufacturing, as well as undertaking

execution capability.

project development, turnkey EPC and O&M services.

has chosen to go with Crystalline Silicon technology.

The major challenge in Solar Projects globally is getting adequate land acquisition, as the land requirements for Solar projects is fairly large (around 6 Acre/MW for Solar PV). To further bring down the levelized cost of electricity (LCOE), economies of scale can be achieved by developing single location large scale plant. However, acquiring single

The first 5 MW, in the state of Gujarat, has been commissioned in December, 2010,

patch of large piece of land becomes even tougher.

Lanco is setting up a fully-integrated

feeding AC output to a 11/66 KV switchyard,

manufacturing project for high-purity

which in turn is connected to GETCO

Site selection is yet again a critical

polysilicon, silicon ingots/ wafers and modules

Bhadrada 66/11kV substation. The entire

consideration. The historical generation data

in it’s own SEZ facility in Chhattisgarh. The

power off take is carried out by GUVNL

for Indian sites is not readily available for

project is the first of its kind in India with

based on preferential tariff declared by

past 30 years (minimum sample size required

1250MT of polysilicon and 80 MWp of wafer

the State. This photovoltaic farm is spread

to fit in a probabilistic distribution curve) as

production slated for completion by mid-

across 27 acres of land in Bhadrada, with the

the industry being nascent in India, there

2012. However, the module manufacturing

site perimeter running to around 2.8 kms.

are not enough ground mounted insolation monitoring system. The satellite data

facility of Lanco Solar is slated to commence production by April 2011, so as to cater to domestic demand under National Solar

Technology and Site Selection

Mission.

recorded by Homer, NASA and 3 tier show a fair amount of deviation among them.

To get more visibility on irradiation levels,

The Solar Power technology can be classified

Lanco Solar has installed its own weather

With 5MW Solar PV farm already

into two broad areas- Solar Photovoltaic

mast insolation measurement system in

commissioned, over 136 MW of own solar

(PV) and Solar Thermal, with the former

different parts of the country to obtain real

power project under various stages of

having 70-80% of global market share. The

time insolation data trends.

22 EQ INTERNATIONAL JANUARY/FEBRUARY 11

www.EQmag.net

The EPC Challenge The major challenge faced in the installation of Solar PV plants as compared to

such accuracy and precision that further realignment of modules was not required once they were installed.

installation of any other conventional or non

The multi crystalline modules, with a

-conventional power plant is site preparation.

rated capacity of 230Wp and an efficiency

Solar Power at the site is produced from

of 14.10% generates DC output. All the

Solar Photovoltaic panels aligned at high

modules are connected using DC cables,

level of precision and accuracy to each other

selection of which forms a very important

and mounted on fixed steel structures. The

part as well from safety point of view.

solar power generation is very sensitive to

The cables at Lanco Solar PV plant have

module alignment, an uneven field or impact

been selected on the basis of their flexible

of external shading on the solar panels,

installation and safety features. The cables

hence engineering and design stage play

are UV Protected, halogen free, fl ame

an extremely vital role in development of

retardant and self extinguishing and can

solar parks.

withstand short-circuit temperature of 250 0 C and an operating temperature up to

Project Specification In any solar project, there are several ways of mounting modules on structures, which could be fixed, seasonal tilt, or tracking. In seasonal tilt or tracking structures, modules track the sun, either seasonally (seasonal tilt) or continuously through the day (tracking), thus increasing the generation from the plant. However, selection of the type of mounting structure is based on trade off between incremental higher generation vis-à-vis higher cost in fabricating movable structures, along with the increase in technology risk associated with it.

90 0 C for normal operation for 25 yrs.

The power plant is also equipped with adequate junction boxes, switch gears, fuses, other overload and lightning protection arrangements, etc. to comply with the best in class safety practices. The junction box contains bypass diodes that protect the module from reverse current during hours of darkness, shade or when covered by leaves or dust. The junction box assembly houses the diodes and DC cable in the “removable” top cover of the housing to facilitate ease of field repair or replacement in the event of damage or wear. The top cover and base module are secured together with a locking

For Lanco’s first 5MW plant in Bhadrada,

mechanism to prevent accidental exposure

fixed tilt mounting structures were chosen to

of high-voltage contacts. The photovoltaic

install the panels. Each structure was large

array, containing number of modules, are

enough to place 24 modules on it. The vast

linked via fuses or circuit breakers and

area of mounting structures, about 908 in

an EMC-filter (to filter out the harmonics

number, was made of hot dip galvanized

generated during DC-to-AC conversion). The

steel, and the array layout, was put with

current in each string (fuse) can be measured

www.EQmag.net

separately. DC current being generated by modules is fed into a containerized inverter, which converts incoming DC power into AC power.

Containerized inverters come in compact form and have plug-and-play capability, which significantly reduces the project timeline, and generally because of their large capacity and in built transformer, reduce power losses as well. The container is connected to the grid via the internal medium-voltage switchgear. Four inverters of similar capacity, i.e. 1.25 MW each, have been arranged in a decentralized fashion across the Solar Power plant. The decentralized inverter arrangement is ideal as the site is in a Y-shaped layout, thus reducing significantly the cable losses and additional cable cost.

All the activities (on the DC side or AC side) are monitored and controlled from the control room. The control room features HT-LT switchgears, auxiliary and emergency power system , power evacuation metering,on line provision of data transfer and a MS Windows 2000 based HMI(Human Machine Interface) SCADA system and a viewers gallery. The SCADA system in Solar Power plant enables remote monitoring of String health, generation trends for each inverter on daily, weekly and monthly basis, alarm, and other standard real time remote controlling features.

Thus, putting all these equipments together result into 80 lakh units of carbon free electricity annually, year after year, for 25 years.

EQ INTERNATIONAL JANUARY/FEBRUARY 11

23

“SolarTie: Integration Of Grid Interconnection Technologies” I India is one of the fastest growing and rapidly modernizing economies in the world.

We simply cannot accept power outages, particularly when solutions are available W ttoday. Stating this Sudhir Gadh, Country Manager-India, American Superconductor Corporation & Perry Schugart, Director of Power Converter Business, American C Superconductor Corporation in an interview with EQ International, discussed about the importance of grid interconnection solutions in India. Excerpts....

EQ : Could you please elaborate about SolarTie and its technology?

Perry Schugart : AMSC’s SolarTie™ grid interconnection solution is a utilityscale system designed specifically for megawatt-scale solar photovoltaic (PV) power plants. The SolarTie solution combines two of AMSC’s proven and proprietary technologies - D-VAR® STATCOM solutions and PowerModule™ power converter systems - that are today connecting over 15 gigawatts (GW) of renewable energy to the grid. This amounts to about 10% of the world’s wind generated electricity.

the developer loses revenue and the consumer can experience power quality issues or outages.

In addition, there may also be financial penalties for the plant owner if the plant is not generating power to the grid or missing its power production quota.

the grid – power purchase agreements can have penalties for missed power production if the source of the disruption is unknown

The SolarTie is the most robust solution on the market. It will stay online and ride through disturbances.

Moreover it will support the grid during a disturbance to minimize the disruption in power production. The longer and more consistently a PV plant stays online, the more consistent power it provides to homes and businesses in India and the more revenue it provides to the developer.

EQ : How SolarTie is different from the other available inverters in India?

EQ : What business does AMSC expects from launch of SolarTie in India?

Perry Schugart : India’s grid faces significant challenges in respect to frequency and voltage excursions that are caused, in part, as a result of insufficient generation. The inverters being used in India today are mostly commercial or industrial types; they are small, lack the robustness of the SolarTie and not suited for utility environments. This means that they are unable to stay online during a disturbance and that they cannot support the grid when support is needed most.

Sudhir Gadh: Solar energy has tremendous potential in India. India’s topography and climate allow for large-scale solar plants.

For example, the Thar Desert, which has been set aside for solar power projects, is sufficient to generate 700,000 to 2,100,000 MW of electricity. The country plans to install 20,000 MW of solar PV and solar thermal power plants across the country by 2022. Moreover, the proposals for the first 1,000 MW projects to be completed by 2013 have already been approved.

To India, this means that PV plants with these types of inverters are tripping offline. Each time a plant is tripped offline,

We expect India to be an important market for AMSC’s SolarTie grid interconnection solution.

Sudhir Gadh (R), Country Manager-India, AMSC & Perry Schugart(L), Director of Power Converter Business, AMSC

By coupling best-in-class power converter capabilities with AMSC’s worldrenowned dynamic reactive compensation technology, the SolarTie product represents the industry’s first fully optimized solution for utility-scale PV power plant developers.

With a base rating of 1.7 megawatts (MW) and a turn-on voltage of up to 1,000 volts (VDC), the SolarTie solution is one of the most robust power inverter systems available in the market.

In highly dynamic grid environments like India, the robustness of the SolarTie can maximize power generation time and therefore revenue generation. Less tolerant systems can trip offline during even minor grid disturbances.

Additionally, there is added assurance with the SolarTie systems’ ability to capture and document grid disturbances that can impact the plants ability to deliver power to 24 EQ INTERNATIONAL JANUARY/FEBRUARY 11

www.EQmag.net

EQ : Did you launch SolarTie in China?

If yes, what is the response it is getting there?

Perry Schugart : Yes, we launched SolarTie globally. China has been a leader in renewable energy and in the last decade, has adopted wind energy much faster than any other country in the world. We expect that China will follow a similar path for solar energy and will also be an important market for AMSC’s SolarTie. EQ : AMSC is recognized for wind offerings in India. Had the Solar Mission have encouraged to venture into solar space?

Sudhir Gadh : The Jawaharlal Nehru Solar Mission is a visionary step by the Government of India, as it focuses on leveraging the abundant solar resources to help India to take care of its huge gap in power generation and demand.

We are extremely excited about the solar power opportunity in India, and have therefore focused our development and marketing efforts, to offer a product that ideally takes care of the climatic, market and technical requirements for solar farms in India. We are confident that in a couple of years, we will be as well recognized in

the solar space, as we are in the wind space in India.

We, of course, hope that the actual implementation of the Solar Mission will be in line with the announced plans and timelines.

EQ : What are India’s current grid codes?

Are they suffi cient? Or do they need to be improved?

Sudhir Gadh : The use of renewable energy in India is increasing manifold, and it has therefore become imperative that government and regulatory boards introduce Grid code standards for all forms of Renewable energy that ensure a safe and technically reliable connection.

We expect new grid codes to come into effect shortly. These codes will undoubtedly cover wind farms and since solar is the next big wave in India, we strongly encourage that these codes simultaneously cover solar as well. It is only logical to prepare for the future and appropriately plan all renewables into the grid code.

With improved grid codes, grid operators can maintain a safe and reliable electricity supply throughout India.

EQ : AMSC entered the India market a couple of years ago – how is AMSC’s

experience in India?

Sudhir Gadh : AMSC entered Indian market a couple of years ago by offering their megawatt-size wind turbine designs to Indian manufacturers, and we have achieved our desired objectives. Our Wind Licensee has achieved successful prototype production and has started full scale commercial production of wind turbines in India using our technology.

Regarding the Indian Wind Turbine market-we anticipate a sustained growth in the market size, and we are confident of achieving a strategic position in this market with very high market penetration in years to come. We also expect our Indian Licensees to successfully start exporting Wind Turbines to other countries.

We have since introduced our other products in India, such as our Amperium™ superconductor wire, D-VAR dynamic reactive compensation technology and – of course – SolarTie, our grid interconnection solution for utility scale PV plants.

The response from the Indian market for these products has been very encouraging and we expect to build strong business with these products as the country increases its renewable energy use and improves its power grid.

SOLA R P OW E R

Energy Yield Optimization of a PV Plant Anish Wastrad & Rhushikesh Kathe, Sgurr Energy India

The energy yield prediction of a solar PV plant essentially depends on irradiation available for conversion. Modules should capture maximum irradiance to ensure optimum yield.

T

here are certain parameters that a designer can change to ensure optimum functioning of the plant resulting in a higher Performance Ratio (PR) and Capacity Utilization Factor (CUF). This article focuses on parameters affecting energy yield and how they can be optimized.

The capability of a PV plant to generate power depends on the availability of solar resource at a given site. Solar insolation data should ideally be recorded on site to gain precise information and develop closest prediction of long term energy yield. Data is also available in the form of ground based meteo stations and satellite derived data.

These data however come with uncertainties that should be taken into account.

Ground based measurement stations interpolate data from nearby measurement stations and sometimes even from satellite derived data if the desired site is not within a certain range from the meteo station. Satellite derived data is generally recorded for a grid of 1˚ x 1˚. This could lead to deviations in the final energy yield that can be obtained from a PV plant.

Apart from measuring onsite insolation, the power generated by a PV plant is also dependent on the angle at which the modules are tilted. As a rule of thumb, the tilt angle may be lat +15 for winter optimization and lat -15 for summer optimization. For yearly 26 EQ INTERNATIONAL JANUARY/FEBRUARY 11

optimization, the modules may be tilted at an angle equal to the latitude, however expert opinion on this matter is recommended as optimum tilt is site specific and may vary for different locations. PV modules perform best when they are positioned normal to the direction of incident radiation. This will ensure that the PV modules collect maximum sunlight for conversion into energy. Peak hours for conversion lie approximately between 9 am to 3 pm, hence it becomes

important that module orientation to be optimized to harvest maximum sunlight during these peak hours.

As the tilt angle increases, so does shading on the modules behind them. This inter-row shading mainly occurs during early mornings and late evenings and is very crucial as output of the entire PV module may be governed by the output from the shaded cell. Pitch and tilt of modules should be such that the shading limit angle is least.

This arrangement will ensure maximum

utilization of sunshine hours available at a specific site. In this case, tilt and pitch are directly proportional to each other – a lower tilt angle will require a lesser pitch.

This article focuses on optimizing energy yield of a PV plant and its dependence on pitch and tilt variation.

Variable Parameters Influencing Yield

A PV plant is governed by various losses that restrict its potential to generate maximum energy. Losses in a PV plant, apart from others, may include losses due to: 1. Soiling 2. Shading (horizon, near and inter-row) 3. Temperature 4. Module mismatch 5. Module quality 6. Wiring losses, etc. www.EQmag.net

Amongst these losses, inter-row shading is the only loss that is not site dependent and can be optimized by the designer to attain maximum yield. Inter-row shading as mentioned above depends on the module tilt angle and pitch distance.

Optimization of yield • Dependence of Irradiance on tilt angle PV modules should be tilted to capture maximum sunlight. Irradiance will increase if the PV modules are perpendicular to the direction of incoming radiation.

In an independent study, it was found that

varying the tilt angle increases the amount of irradiation on an inclined surface, however, maximum is achieved at only one tilt after which irradiation on a surface decreases as seen in Figure 1. The study was performed for a site with latitude of approximately 22˚.

It is visible from the graph that the maximum irradiation on the PV plane was obtained at a tilt higher than the latitude.

• Role of pitch and tilt in inter-row shading As mentioned earlier, pitch and tilt angles are directly proportional. A lower tilt is favorable in summer, but to optimize yearly, tilt may need to be increased. A study performed shows inter-row shading at various pitch and

tilt angles for the same site. Figure 2 shows that the inter-row shading is more dependent on pitch than on the tilt angle.

• Dependence of Yield on pitch and tilt Yield of a PV plant is dependent on interrow shading as well as irradiation available on the inclined plane. Tilt optimization may increase resource availability whereas interrow shading will cause an increase in losses.

A combination of the two may be optimized to maximize yield. An optimized solution may increase the Capacity Utilization Factor (CUF) and Performance Ratio (PR) of a PV plant.

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“Hensel Has An Edge In Electrical Installations In Difficult Environments” M R Mr. Rudolf Cater Technical Director, Gustav Hensel GmbH & Co. KG “Hensel is the preferred choice of Indian customers for electrical installations in “diffi cult environments. Hensel products are developed for distribution of electrical energy in the low-voltage range especially for application in the industrial sector and where particularly high requirements are made on the encapsulation of electrical functions”, said Mr. Rudolf Cater - Technical Director, Gustav Hensel GmbH & Co. KG in an interview with EQ International.

EQ : Hensel is moving with great strides in India. What is the market share is it having in India today? What growth do you anticipate with full fledged implementation of JNNSM? Hensel established its own presence in India in 1999 in a very small way with a Liaison Office. In a short span of 12 years, Hensel is the preferred choice of Indian customers for electrical installations in “difficult environments”.

Hensel expects to play its role in the successful implementation of JNNSM by providing customers and stakeholders with professional photovoltaic distributors that meet the relevant national and international standards. We are confident that our existing customers who value quality and trust the Hensel experience will repose faith in us for their projects.

EQ : What is the key expertise Hensel have for distributing power in low voltage areas?

Hensel products are developed for distribution of electrical energy in the lowvoltage range especially for application in the industrial sector and where particularly high requirements are made on the encapsulation of electrical functions. At this, it is basically about environmental influences like humidity, 28 EQ INTERNATIONAL JANUARY/FEBRUARY 11

dust and mechanical impact as well as atmospheric conditions like a high ambient temperature in production sites or in outdoor installation including the necessary UVresistance.

electrical shock. It has to be considered that the enclosure including the cable entries has to be tested for insulation voltage which is defined by the maximum operating voltage of the PV generator.

Hensel products solve this task with high class thermoplastic material for the enclosures in IP degree 65 to 67 which guarantee the functional integrity of the installed electrical devices. All functions are tested according to the valid safety standards IEC 61439-1 and IEC 61439-2 “Power switchgear and controlgear assemblies”

Hensel generator junction boxes are tested for this application upto 1000V DC and fulfil all the above mentioned conditions.

EQ : Can Hensel power distributing system bring down the cost of distribution?

Next to the safety, which is connected with the application of Hensel solutions, the products offer assembly advantages especially distributors or doing field installation which in summary reduce costs for this part of the electrical installation technique. Moreover, there is a reduction of costs effected by the long life of the products because they are corrosion-resistant to the environment hence the usability is considerably higher than life time of the installed switchgear components EQ : Could you please explain about technology of PV generator junction boxes?

Generator junction boxes are used to collect the electric current, generated in the photovoltaic modules and conducted over string wires, and leads it centrally into a solar inverter collector.

At this the generator junction box has to be equipped next to the terminals with the appropriate safety techniques according to the model of the module. Here it must be considered that the permitted heating limit for those devices corresponding with the required quantity in the enclosure must not be exceeded.

Since the photovoltaic installations on the DC-side are in most cases an unearthed grid and the voltage is higher than 120V DC, the generator junction box has to be double insulated to assure the protection against

EQ : Please elaborate about the PV Solar inverter collectors?

If there are several solar inverter collectors used within the framework of a PVinstallation it is necessary to “collect” them on the AC-side to connect them over a cable with the public grid or the consumer grid. The task of a solar inverter collector enclosure is to protect the cable to the solar inverter against short-circuit and to install the required protection devices in a way that even with special operating conditions the devices still work safely. Here it has to be noticed that in difference to “normal installation” the circuits are heavily used for a long time with current at the same time and according to this the power loss has to be considered.

Hensel solar inverter collectors are tested according to the defined operating currents and the maximum pieces of installed MCB´s and regard the above mentioned special conditions, especially by the arrangement and rating of the outgoing terminals.

Depending on the kind of installation it can be necessary to install a surge protection on the AC-side as well as on the DC-side to make sure that in case of thunder-storm the plant and here especially the electrical components cannot be destroyed.

If necessary the protection units used in the generator junction boxes and in the solar inverter collector distributors have to be matched with the producer of the solar inverters and the producer of the PV plant. When arranging the enclosures and the distributors it has to be regarded that they are not installed where the sun is shining on them directly, because of not influencing the operation security of the installed devices by high ambient temperature. www.EQmag.net

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SOLA R P OW E R

Automation In Solar Power Plants • •

Vijaya KLNR Pingali, PMP, Group Technical Specialist, Semiconductor, Solar, Industrial and Office Automation Practice, HCL Technologies Ltd Sandeep Venkatraman, Senior Technical Lead, Semiconductor, Solar, Industrial and Office Automation Practice, HCL Technologies Ltd

The role of technology in common life has remarkably increased over the time improving the quality of life. However, this has resulted in increased energy consumption.

Increasing energy consumption is resulting in depletion of conventional energy sources which are predominantly fossil fuel resources. The governments globally are favorable and exploring alternate energy sources.

W

hile Japan had made the initial advancements in using Solar PV technology, Germany and Spain lead penetration. Indian government has recently launched an ambitious plan to encourage the use of solar energy in India.

Even as some parts of the world are inching towards grid parity in the next 2-5 years, solar technology needs the government incentives to make meaningful penetration. This is the time where all the stake holders should collectively improve the processes and remove inefficiencies in the system. HCL Technologies Ltd (HCLT), being an engineering company is focusing on engineering solutions to optimize the plant performance and eliminate operational inefficiencies.

The plant performance can be optimized by: • Maximizing the incident radiation on the modules • Identifying underperforming equipment/ units • Automating control mechanism using PLC/SCADA based system

Maximize the incident Radiation For the Solar power plants, tracking the sun is important for maximizing the solar irradiance and thus the power generation.

30 EQ INTERNATIONAL JANUARY/FEBRUARY 11

HCLT is the first engineering services company to establish EMI/EMC test lab.

We did so to offer Concept to Manufacturing (C2M) facility to our customers. Using this lab, we help with climatic testing and regulatory compliance test certification (CE, FCC, cTUVus, GS, UL). The trackers we design for our customers are tested in our lab and are certified for different regions.

We also have a low volume manufacturing facility where we can manufacture the trackers for our customers.

• Single Axis Tracker

Identify underperforming equipment/units

The modules are usually installed facing east and the tracker follows the sun. The 1-axis tracking gives significant yield improvement. Most of the single Axis trackers need to have manual adjustment for offsetting the season movement.

The major aspects of operations and maintenance are

Trackers with ± 5° accuracy can deliver greater than 99.6% of the energy delivered by the direct beam and 100% of the diffuse light.

• Resolve the problems as they are identified

• Two Axis Tracker When you are using concentrated photo voltaic technology or using the trackers to reflect the mirrors for Solar Thermal tower power plants, incident angle becomes more critical and we may want to use a two-axis tracker.

HCLT develops trackers for client specific requirements. We have helped our customers with design of tracker control system, electronics, enclosure, sensors and motors.

• Preventive maintenance • Identify the problems as they occur • Analyze the problems that occur

• Put preventive measure in place to minimize the impact of problem reoccurrences Modules and Inverters are the most important components of a solar power plant. Any problems with either of these have a serious impact on the overall power plant. There are several possible problems that may occur with both of these components.

Effective monitoring system can help identifying possible problems earlier and hence resolve them earlier. The following table lists some of the possible problems a module and inverter may face: www.EQmag.net

Component

Problem

Module

Glass Breakage, Hot-Spot, Open-circuit, Short-circuit, Cell degradation

Inverter

Dry Join, Melted Wires, O verh ea t , Rever sin g Battery Polarity

Most of the problems reduce the efficiency of the module/inverter. Some of these problems can be identified if the modules/ inverters are monitored closely.

• Data Acquisition Sensors and meters can be used to capture the data.

mathematics based rules to identify the problems.

It is acceptable if the monitoring system allows the user to create one or many types of the rules mentioned above. However, it is warranted that the system can learn or be improved over a period of time.

• Monitoring

It will be good if the issues identified can be assigned to appropriate technicians quickly and they be informed. This will result in speedy resolution of the issues.

Monitoring solution has to balance the two types of errors while identifying problems and raising alarms:

HCLT has developed an advanced renewable power plant monitoring solution that offers many of these and more.

A good monitoring system will consists of four functions:

The rules can be categorized as:

• Limit based rules - Problem assumed when the module output is beyond lower and upper specifications limits.

• Peer comparison – Problem assumed when a module output is significantly less than that of its peers • SPC charts violation rules – Problem identified using Statistical Process Control charts. When Nelson’s rules or Western Electric rules are violated, it is an indication of a problem.

• Model based rules – Use physics and

• Report problem when there is no problem

a

When the monitoring solution reports an issue when there is no problem, the technician spends efforts to analyze the problem and eventually finds that there is no problem.

On the other hand, when the monitoring solution does not identify a problem that is impact the system performance, the sys tem will produce less than optimal output which is a direct loss. Since balancing these two situations is challenging, the monitoring solution should use active user feedback to learn and balance between the two types of errors intelligently and should use the technician feedback and the collected data to modifying existing rules and synthesize new rules.

Automated control mechanism using PLC/SCADA based system HCLT help its customers automate several operations related to material/ resource consumption and control. Few of the services that may be important are: • Control System Integration Services SCADA , RTU, ups tream dat a computation.

• Integration with Plant Control Systems with all popular Asset Management Applications

• Distribution SCADA implementation and integration with Network Operation Center The Advanced Renewable Plant Monitoring System for Solar Power Plants developed by HCLT addresses all the issues highlighted in this paper keeping in

• Reporting Reporting is another important part of the whole system. While good looking dashboards and reports are important, remote information availability is very important to optimize onsite resources and maximize the benefits.

• Dashboards The data is aggregated and the summary is presented visually so that analysis and inference is easy. The dashboards to allow defect root cause analysis along with other

www.EQmag.net

When there is an issue, the issue should not only be logged onto the server but the appropriate technician should also be informed.

Data is collected from various sensors and the control systems. The predefined rules are applied to identify under performance and possible system health issues.

• Does not report a problem when there is a problem

• Rule Definition

reports and charts are important. The monitoring system should be able to highlight the plants/modules/inverters that are under performing and/or requires attention.

perspective the needs of a power plant.

In addition, HCLT designs Single Axis and Dual Axis hardware trackers to maximize the incident solar irradiation on a panel.

Put together, the solution will increase plant performance in terms of efficiency, reduce downtime, reduce supervision cost and provides advanced forecasting.

EQ INTERNATIONAL JANUARY/FEBRUARY 11

31

SOLA R P OW E R

Grid-Connected PV Power Plants’ Performance Optimization Sharad Saxena, CEO, Chemtrols Solar Pvt. Ltd.

The Jawaharlal Nehru National Solar Mission (JNNSM), launched recently by the Government of India, has provided an impetus to the development of Solar Photovoltaic (PV) Power Plants in our country for generation of electricity.

A

few states have also declared their own incentive plans to attract investments in such projects. The Central Electricity Regulatory Commission (CERC) has released the regulations on recognition and issuance of Renewable Energy Certificates (RECs), which is expected to emerge as an alternative mechanism for generation of revenues in addition to the preferential tariff mechanism that is the basis of most projects permitted until now. REC is conceived as a market based instrument to promote renewable energy (RE) and to facilitate compliance to the Renewable Purchase Obligation (RPO) by the obligated entities.

Why optimize?

The basic technology, design and engineering of PV power plants, is now well developed and proven, thanks to the experience gained during the past few years in Europe and USA. Countries like Germany, Spain and Italy have demonstrated the feasibility of Solar PV power generation in spite of the fact that the solar irradiation levels at most places in these countries are much lesser than the tropical countries like India. The success of PV power generation projects in the west has prompted investors to move rapidly towards development of similar projects in India with the support of policy framework announced by the government.

32 EQ INTERNATIONAL JANUARY/FEBRUARY 11

One must not, however, lose sight of the fact that there are challenges which are to be overcome to ensure that the plant is built within the committed schedule, operates optimally and remains feasible over its complete life period (25 years).

These challenges can be classifi ed into commercial (relating to permissions and clearances), financial (relating to equity and debt financing) and technological (related to design optimization, selection of components etc.).

While the solar radiation is available in plenty almost all over India all through the year, there are certain other climatic (e.g. high temperatures), environmental (dust and grime) and infrastructural conditions (unstable grid etc.), that could make the yield of the PV plant lesser than what would be expected. It is necessary to optimize the design after due consideration of all these factors. This paper however, does not intend to be a guide for designing a power plant.

A number of well designed software are available that help in the design process and gives a fairly accurate estimation of the annual energy generation. This paper aims to recommend a few steps that can be taken to optimise the performance of the power plant. These steps may seem to be minor but, if overlooked, could result in avoidable losses. An attempt is made to simplify the technical aspects, as much as possible, to

benefit even the not-so-technically inclined reader.

A power plant built with modules with crystalline Silicon (c-Si) cells is assumed for discussion. However, there are pros and cons of using various types of modules viz, c-Si, Amorphous (a-Si), CIGS, CdTe etc., and a proper cost benefit and risk analysis needs to done before selecting the type of cells/modules to be deployed. Presently, the most common type remains the crystalline silicon based modules, although some thin film technologies are fast catching up.

The key components of a grid-connected PV power plant are PV Modules (also called Panels), foundations & mounting structures, cables & junction boxes, gridconnected Inverters (also called grid-tied or grid-synchronised), monitoring System, low voltage switchgear & components, medium voltage apparatus and transformer yard for connecting to grid. Below are a few important considerations which must be borne in mind during installation and commissioning of the power plant to ensure optimal performance.

Tilt angles, spacing of structures and avoiding shadows Shadows are not only caused by poles, trees and buildings but also by the module mounting structures themselves on other www.EQmag.net

structures, if the spacing between rows is not adequate and if seasonal lengthening of shadows has not been taken into account.

It is advisable to use shadow simulation software, which can show the movement of shadows at any time of the day of any month in the year. This helps in optimizing the distance between rows and consequently area occupied by the array structures.

Leaves, birds and bird droppings that may fall directly on the modules can also cause shadowing of one or more cells in a module, and reduce the current output from that module. If many modules are affected in this manner, the performance of the plant can reduce considerably. Periodic cleaning is a must to avoid such losses. Sprinkler systems should only be used if the water quality is good, lest the stains left by water on the modules shall reduce the transparency of the glass and reduce output. If fixed structures are used, the tilt angle of the modules should be kept as the latitude of the place.

Fixed Structures or Tracking systems The energy yield of a PV module with crystalline silicon cells is maximum if the sunlight is incident perpendicular on it. Thus if the surface of the module is made to track the sun, the energy yield increases. However, the decision to select either a fixed structure or a tracking system must be done after a careful cost-benefit analysis over the life time of the project. The tracking system can either be single-axis which track the sun from dawn to dusk, or dual-axis which also tracks the annual path of the sun and makes seasonal adjustment of the tilt angle for optimal alignment to the sun at all times.

In addition to the additional cost, tracking systems consume energy, have moving parts and therefore require periodic maintenance.

In the event of a failure, the tracker may get stuck in a poor-yield position resulting in severe reduction in energy yield until the fault is rectified. One must weigh the gain in energy yield against the cost of acquisition and maintenance of the tracking system before taking a decision. One of the alternatives suited for Indian conditions could be to use a fixed structure which can be adjusted seasonally (say every 4 to 6 months) to account for the change in the position of the sun.

Minimise losses due to Array Mismatch The array is formed by connecting the www.EQmag.net

modules in a series parallel configuration to match the input DC voltage of the inverter.

Generally, modules are specifi ed with a tolerance of +/- 2% to +/-5% or -0%/+5% . In each case the difference in electrical characteristics of one module to the other could be up to at least 4%. It is important to make sure that the modules are sorted for Imp (current at maximum power at STC) for strings and for Vmp for parallel. Modules in the same string should have Imp within a range as narrow as possible.

Get power from low light too!

Most PV designers specify the PV modules only in terms of electrical characteristics at Standard Test Conditions (STC), which is 1000 W/m2 irradiance, 25 0 C cell temperature and AM 1.5. However, the modules often perform under different conditions. While selecting PV modules, one should ask for the low light characteristics of the module, say at 800 W/m2, 500 W/ m2 and 200 W/m2. Choose the module with best performance in low light, even if more expensive, as these pay back faster with extra generation in low light (early hours in the morning and late hours in the afternoon, as well as cloudy periods and monsoon days etc).

Power loss due to temperature The ambient temperatures in India could go as high as 50oC in many of the high solar irradiation areas. The cell temperature during such times will be even higher and could reach 65oC to 70oC. The power output of the module reduces by about 0.42% to 0.48% for every oC rise in cell temperature.

Thus at a cell temperature of 70 oC, a 230Wp module may only produce about 185W! It is important to select PV modules with lower temperature coefficient for power.

This aspect is more important in tropical countries with high temperatures than the European countries.

Optimizing Inverter Losses Inverters are available in large capacity as central inverters (generally 100KW to 500KW) or as String inverters for a string or as micro inverters for each module. Each concept has advantages and disadvantages.

Most large power plants are built with central inverters due to their lower cost/W.

Decentralised inverters (string and micro) are preferred generally for systems which may have sub-arrays with different orientation or tilt angles or modules with partial shading at times, as may be the case with most rooftop systems. Choose inverters, which have a large input DC voltage range and low cut-in limit so that it could start at lower power limit, and there are minimum loss of power due to under-voltage and overvoltage from the array.

It is preferable to use the master-slave concept while using the central inverters in large size power plants. The total power is divided by the number of inverters. One inverter is the master device and starts operating in the low irradiance level. When the irradiance increases, the power limit of the master inverter is reached, and the next inverter also gets connected. The advantage of this concept is that the efficiency is high even in the low light conditions as compared to a case when only one central inverter is used for the whole system. The increase in efficiency often offsets the higher cost of the master slave concept.

Minimizing cable losses The inverters should be placed as near to the array as possible in order to minimize the length of the DC cables. The string inverter concept based design is better in this regard.

Considerable power loss can happen (about 2%) if care is not taken to select the right cross section of the cables and ensuring minimum distances for the DC cables. Losses in AC cables are minimal.

Operation and maintenance Dusty winds and presence of suspended particulate matter is quite high in most parts of our country. A film of dust can degrade the performance of modules considerably. It is advisable to ensure cleaning of panels on a periodic basis to keep the front surface clean.

Preventive maintenance of all components according to the suppliers manual must be carried out as per plan to keep the performance of the plant in top gear.

A well designed grid-connected PV power plant will certainly yield a higher Performance Ratio (PR) if the above considerations are borne in mind. PR is the well recognized quality factor which describes the relationship between the actual and theoretical energy output of the PV power plant.

EQ INTERNATIONAL JANUARY/FEBRUARY 11

33

SOLA R P OW E R

Increasing Cell Efficiency With Rearside Technology Torsten Knoedler, spokesperson, Centrotherm

The predominant overall target of the PV industry is to reduce production costs in order to achieve grid parity. Grid parity is the term used to represent the competitiveness of solar electricity with conventional electricity from the grid - and therefore the end of PV’s dependence on subsidies.

T

o achieve lower overall production costs for its customers centrotherm photovoltaics focuses on both maximum efficiency and minimum silicon consumption at the same time. An optimized production sequence and minimum consumption of other costly components further contribute to minimizing total

“Our strategy of concentrating on effi ciency-enhancing technology updates along the photovoltaic value chain is proving worthwhile. It also allows existing customers to benefit from the use of new

cost of ownership. Therefore centrotherm’s turnkey production lines utilize the latest production technologies.

In comparison to many other turnkey suppliers, centrotherm’s production concept is based on the work center and cluster concept. This allows a maximum of fl exibility by just adding or removing production capacity as needed.

This has real advantages over the inline concept which is much more likely to cause bottleneck situations and reduce production output. The work center and cluster concept allows centrotherm’s customers to extend and reorganize their production line in the short term with minimal impact on the current throughput and process quality.

Based upon this concept, it is easily possible to introduce new technologies in existing production lines.

34 EQ INTERNATIONAL JANUARY/FEBRUARY 11

technology by expanding their capacities and reducing their manufacturing costs through efficiency gains”, comments Dr. Peter Fath, Management Board member responsible for Technology and Marketing at centrotherm photovoltaics AG. Therefore centrotherm is following an ambitious technology roadmap to increase the effi ciency of their turnkey lines by around 0.5% per year for monocrystalline silicon and by around 0.3% per year for multicrystalline silicon. In line with this roadmap centrotherm has already

introduced the selective emitter technology.

Next year this will be combined with a new rearside technology called centaurus and in the following year a new metallization technology will be introduced to fulfil the efficiency targets. “Additionally we continuously improve the production equipment towards lower costs, higher throughput and better yield performance”, explains Dr. Fath.

A s the first step of cen tro therm ’s technolo gy roadmap, centrotherm has launched their selective emitter technology in the market in 2009. The selective emitter is an improvement of the solar cell’s front side. Currently, above 90% of global solar cell production uses screen printing to contact the solar cell’s front side. In this process metal (Ag) pastes are printed in a grid pattern and later they are sintered to contact the phosphorous (n-type) emitter layer on the solar cell. The phosphorous content and distribution of this emitter layer has a very strong influence on the solar cell performance. Unfortunately the emitter dependencies on each performance parameter of the solar cell are contradictory.

The higher the phosphorous content, the lower is the contact and lateral resistance www.EQmag.net

which leads to a better filling factor. Furthermore, the lower the phosphorous content, the better are the emitter properties which are responsible for a higher current and voltage of the device. Thus, the emitter diffusion is always a compromise. The aim is to achieve voltage and current levels which are as high as possible while establishing a reasonable contact.

To improve the solar cell performance, the selective emitter technology divides the emitter region on the front side into areas of high and low phosphorous concentration. The low concentration area is exposed to light and the high concentration area establishes a good contact underneath the metallization.

That leads to an improvement of above 5 mV in voltage (VOC) and about 0.4 mA/cm² in current (JSC).

Since spring 2010 there are two different centrotherm technologies available to create selective emitter structures. The advanced “diffusion through oxide” technology uses a three step process sequence. An oxide layer on the solar cell front side is locally opened using the c.LAS laser tool. The slight laser damage caused by this technique is afterwards chemically removed by means of a wet chemical process. Within the following single diffusion step, the low and high resistance areas are diffused in parallel.

The “one step laser diffusion” technology is the low-CAPEX alternative.

It uses the phosphorous glass layer as doping source to increase the phosphorous content locally after a light phosphorous diffusion.

The same centrotherm c.LAS tool is used in this technology.

Both technologies are available as upgrades and complete turnkey lines. They have the potential to enable producers of solar cells to run a stable and cost efficient production at efficiency levels of up to 18.5% (mono) and more than 17 % (multi).

Actual standard industrial solar cells with screen printed Al-BSF back side are efficiency limited by the rear surface recombination velocity and the light absorption in the Al-back side. To reduce both losses, the surface recombination and www.EQmag.net

a cost effective, industry proven standard production equipment. The local opening of the dielectric layer for contacting the back side with a standard aluminium screen printing process is done by a high-throughput laser system, which suits for the throughput of current production lines.

the absorption, centrotherm started the development of a new passivated back side with the target of industrial producibility in mid of 2009. The result of this development is a solar cell rear side with local aluminium BSF in combination with a dielectric passivation and refl ector which reduces the surface recombination velocity as well as it enhances the internal light reflection.

The reduced surface recombination velocity increases the open circuit voltage Voc from about 625 mV to about 635 mV for the combination with a conventional emitter. The improvement of the internal light reflection leads to a gain in the short circuit current density Jsc of about 1.0 mA/cm² to about 37.8 mA/cm². The internal light reflection will become even more important in view of the trend to thinner wafers in industry.

In combination with a selective emitter the open circuit voltage Voc can further be increased to about 645 mV and the short circuit current density Jsc to above 38 mA/ cm². Achieved conversion efficiencies above 19 % on 156x156 mm² monocrystalline (cz) wafers were independently confirmed by the Fraunhofer-ISE CalLab, Europe’s largest solar research institution, for such solar cells.

All required processes for the centaurus technology are suitable for industrial mass production. Also an upgrade of existing conventional production lines is possible.

Momentarily this centaurus technology is going to be transferred into an industrial production line which is equipped with the required additional process equipment.

For the deposition of the dielectric layer a modified centrotherm PECVD-furnace is used. The passivation quality of this dielectric layer is strongly dependent on the wafer surface pre-treatment which is realised by

The roll-out of the centaurus technology to the market will already be started in 2011. The rapid market penetration is advantaged by the use of standard screen printed contacts. These contacts allow standard interconnection and module assembly techniques for the centaurus solar cell technology.

The subsequent roadmap step, an improved front side metallization, has already been started this year. It accompanies the continuous improvement in screen printing towards smaller fingers and better aspect ratios. With the new metallization the contact resistance and line resistance of the metallized grid area will be significantly reduced.

“By choosing centrotherm turnkey lines and upgrades, the customer can be sure to receive state of the art technologies combined with a beneficial cost structure.

As pioneering thought leaders and pace setters offering high-tech products in the solar sector, we spent our effort to keep our clients on the way to success”, comments Dr. Fath.

The German centrotherm photovoltaics AG is the world’s leading technology and equipment provider for the photovoltaics industry. The company equips well-known solar companies and new sector entrants all over the world and especially in Asia with turnkey production lines and single equipment to manufacture crystalline silicon solar cells and modules as well as CIGS thin film modules. As a consequence, centrotherm photovoltaics has broad and profound technological expertise and provides key equipment at almost every step of the photovoltaics value chain. As a supplier, centrotherm photovoltaics guarantees its turnkey customers important performance criteria such as production capacity, solar cell efficiency, and completion deadlines.

EQ INTERNATIONAL JANUARY/FEBRUARY 11

35

SOLA R P OW E R

Surge Protection For Photovoltaic Systems Vikas Almadi, Managing Director, Vrinda Nano Technologies Pvt. Ltd Dipl.-Ing. Jens Ehrler, Technical Product Manager, DEHN + SOHNE Germany

The Photovoltaics is no longer in its infancy and has become firmly established in the global energy mix. Though the share of photovoltaic’s in the total energy generation is still relatively low, but all signs point to its expansion.

F

or that matter, the slowly but consistently changing environmental awareness of the developed and developing nations, financial incentives for operators of PV systems are considerably driving the market of photovoltaic’s (PV).

For many system operators a PV system is the ideal case, combining the interests of environmentally friendly power generation with economics.

To ensure that the operator of a PV system receives the desired returns on his investment for the installation and operation of the PV system in the long term, special attention should not only be paid to the choice of technologies for solar modules and inverters available on the market but to the protected and continuous operation of these devices in all weather conditions for decades.

As the PV systems are installed in the open, they are exposed to all weather conditions. The operator should particularly take this into consideration. What is the use of the high effi ciency of an inverter, if a single thunderstorm destroys all dreams of a return on investment within the planned operating time of the PV system “as quick as a flash”?

In order to prevent such a technical and financial total loss, responsible designers and EPC contractors of PV systems do plan investment in proper lightning and surge protection measures of the plant from the very beginning into the system concept. The power plant can be as small as a roof top system or telecom installation or a MW size plant. Fig. 1 gives an overview of lightning 36 EQ INTERNATIONAL JANUARY/FEBRUARY 11

Fig. 1: Lightning and surge protection measures for a PV system installed on a structure [1]

and surge protection measures for a smallsized PV system.

Safety requirements for the protection of persons and material assets are of crucial importance. PV systems have a special status due to their D.C. source which depends on the intensity of illumination.

The D.C. system requires special attention and the rules of A.C. system cannot simply be implemented here. Some facts to be taken into consideration are as follows: • PV Systems with a low or average output are characterised by very high D.C. voltages up to 1000 V and direct currents in the range of some 10 A. In large-sized PV systems higher voltages and currents may be present depending on the topology.

• The short circuit current is not multi-fold

higher than the nominal current, contrary to A.C. sources rather the value of short circuit current is almost the same as the nominal current in PV systems. It is thus a challenge for the implementation of short circuit protection measures through fuses or switchgears for the protection of persons and material assets in PV systems.

• At present, it only seems feasible to protect the PV system by means of a double and reinforced insulation in the generator circuit. However, here too, the special conditions of an electrical installation, which is almost completely located outdoors, have to be taken into consideration.

• Not only rain, frost, UV radiation, heat, storms, hail and thunderstorms www.EQmag.net

pose a permanent threat to the system, but also damage caused by rodents, birds and, not least, vandalism have to be considered when dimensioning the system.

Another aggravating factor for PV systems is that hardly any long-term experience is available for the different technologies. It is only due to the early support of PV technology in European countries e.g. in Germany that first long-term results on the Fig. 2: Installation of surge protective devices in the fault-resistant Y circuit operating performance of PV reduces the failure probability in the systems and the equipment event of a fault in the generator circuit used become known bit by bit.

Experienced engineers of all companies involved in the PV sector are utilising the results gained from practical experience for the improvement in system performance. Same applies to lightning and surge protection solutions for PV systems too.

brakes and Friction

and Hydraulic Power Units

Brief History of designing of Surge protection devices in PV application: The fast technology changes that happened to PV technology in total applied to the protection systems for PV too. Fast improvements took place to make the protection devices suitable for PV application.

This development can be easily understood based on the following brief history: When PV systems were commercially used for the first time in the mid-1980s, varistor-based surge protective devices were installed for protecting the equipment of the generator circuit. The design of these protective devices and their interconnection were implemented according to the rules for low-voltage systems on the A.C. side, as, may be, only protection systems for AC systems were available at that time (please recall the difference of application of AC and DC systems).Definitely it did not work at all.

Only the first huge boom in the PV sector in the mid-1990s made it clear that, when dimensioning surge protective devices, it cannot be assumed that the system is in faultless condition during its complete service life. Even if the insulation fault is not taken into account while using the double and reinforced insulation, this fault is not rare due to the specific installation environment and may cause serious damage to equipment. Considering the fact that D.C. voltages and direct currents are present in PV systems and may flow to other adjacent earthed parts of the system in the event of a fault, this can be compared with a D.C. arc formation during electric welding. And indeed, faulty equipment is often partly or even completely burnt up.

The first reaction to these results was to dimension the surge protective circuit according to the so-called Y circuit with an additional spark gap connected in series to the existing devices in order to electrically isolate varistor-based surge protective devices.

This type of protective circuit considerably reduced the probability of overloaded protective devices in case of an insulation fault. Unfortunately this benefit was only short-lived. With the ever increasing PV voltages in ranges between 600 and 1000 V it became www.EQmag.net

and a world of possibilities With eleven manufacturing facilities globally located in the US, UK, Italy, China, Japan, and India, and with over 1,800 employees, Carlisle Brake & Friction is the leading provider of high performance braking solutions to the off-highway, high performance racing, aerospace, and alternative energy markets, serving over 100 leading original equipment manufacturers in 55 countries.

We design and build dry disc caliper brakes, drum brakes and mechanical brakes for both service and park applications.

Additionally, we manufacture both wet and dry friction materials used for brake linings, clutches, fuel cells, and transmissions. We also design and deliver hydraulic actuation systems, including hydraulic valves, master cylinders, adjustors, and boosted master cylinders.

Our proven experience and commitment to the global marketplace makes Carlisle Brake & Friction the right choice for your new brake or friction design, no matter where you are in the world or what you want to be.

To learn more about Carlisle braking systems contact your local sales office or visit www.carlislebrake.com United Kingdom +44 1495 767 300 United States +1 812 336 3811 The Netherlands +31 316 59 65 00

China +86 21 6100 5222 India +91 44 4299 4351 Japan +81 46 247 7564

wind turbine brakes

Fig. 3: First surge arrester for PV systems with combined disconnection and short-circuiting device

necessary to adapt the protective circuit again in 2002. The fault-resistant Y circuit with three protective paths with varistors made it possible to achieve optimal surge protection and fault tolerances even for PV systems with higher voltages (Fig. 2).

Despite the success of this solution, however, one disadvantage remains: The inner workings of the surge protective devices used were originally designed for A.C. voltage applications. To avoid confusion when reading this article, it should be pointed out here that up to now there is no product

Fig. 4: Modular surge protective device type DEHNguard M YPV SCI 1000 with three-step d.c. switching device for PV systems

standard for the use of surge protective devices in D.C. circuits, not to mention in PV systems. But what does it mean that the surge protective devices were originally designed for A.C. voltage systems? To prevent that an overloaded varistor in the surge protective device is a likely source of fire in the circuit, the varistor is commonly disconnected from the circuit by means of a thermal disconnection device. Dimensioning such a disconnection point for A.C. voltage systems does not pose a challenge for an experienced manufacturer of protective devices. However, this might be difficult to implement for A.C. voltage applications and particularly for the current and voltage characteristic of a PV current source. A D.C. arc, which may occur while opening a conventional thermal disconnection device, cannot be extinguished using AC systems- and can simply lead to fire. Even the alternative use of over current protective devices arranged in series to the 38 EQ INTERNATIONAL JANUARY/FEBRUARY 11

The new development of the surge surge protective devices fails as the shortcircuit current cannot be defined at the place arrester type DEHNguard M YPV SCI of installation when the damage occurs. allowed incorporating all experience of the (please recall that the value of short circuit last three decades into one single device. current is not multi-fold higher in case of PV Both the fault-resistant Y circuit consisting systems).Most of the concerned and reliable of three protective paths with varistors EPC contractors were looking for further innovation in Surge Protection system which should be PV specificDC application based SPD. This SPD was supposed to exhibit DC performance in all Fig. 5: Switching phases of the surge protective device with three-step d.c. switching device conditions i.e. while switching ON or while switching off OR even for reducing the failure probability of the while failing in order to avoid any threat arrester and the tried and tested combined disconnection and short-circuiting device of FIRE. were integrated into the device concept.

A surge protective device with combined disconnection and short-circuiting device, In order to ensure disconnection from the launched in 2007, was the first surge arrester grid in the event of a fault, an additional fuse, which was adapted to the special features which was specially designed for PV systems, of PV systems from the very beginning. A was integrated into the short-circuit path.

D.C. arc, which may occur while opening a This allows the user to remove and replace an conventional thermal disconnection device, overloaded protective path without special was reliably extinguished by means of a tools, current flow and arc formation. Fig. short-circuiting device arranged in parallel 6 shows the switching phases of the threestep d.c. switching device accommodated in to the surge protective path.

DEHNguard M YPV SCI. This device is the first device to combine This development achieves the aim of surge protection requirements with fi re combining effective surge protection for PV protection requirements. systems with personal and fire protection.

Safe use of surge protective devices The Technically suitable protection Overvoltages and fire did not pose a problem mechanism using surge protection devices anymore. Shortly after using the arrester, however, it became evident that there are application-specific characteristics, which turned out to be difficult in practice.

For example, replacing an overloaded arrester in practice requires Fig. 6: Use of a surge protective device with three-step d.c. switching device knowledge of the consisting of a combined disconnection and short-circuiting device with integrated fuse for safe isolation in case of overload specific internal circuit of the device. If the installer removes a short-circuited arrester which is fit for DC & also PV application without disconnecting the PV system from should be considered to achieve real the grid, an imminent risk of arc formation protection solution for investments in PV exists. Various safety instructions on the power plants. device and in the installation instructions as well as mechanical covers for the terminals of the device refer to this special feature.

In practice, disconnecting the PV system from the grid at the place of installation of the surge protective devices is not always feasible.

Reference [1] DEHN protects photovoltaic systems.

Publication DS109/03.08. DEHN + SÖHNE, Neumarkt. www.EQmag.net

SOLA R P OW E R

UL India Opens Largest Photovoltaic Testing & Certification Facility In Bangalore Underwriters Laboratories

Heralding a new dimension to product safety, testing and certification arena, Underwriters Laboratories (UL) recently announced the opening of its testing and certification facility for Photovoltaic (PV) equipment in Bangalore.

T

his state-of-the-art lab is UL’s 5th

get necessary certification of PV modules

looking for, without neglecting the safety

global footprint and has been set up

and other balance of systems equipment to

and performance of the PV module”.

with an investment of USD 4 million.

various national and international standards

The lab is equipped with environmental

like UL, IEC, EN etc., thereby assisting their

chambers, sun simulators and instrumentation

entry into the global markets.

from global leaders like ESPEC, Spire Corporation and Agilent. It is capable of testing and certifying 48 families of PV modules in a year. Apart from testing for certification, this facility can also support testing for product development, quality control and performance assessment for PV power plants.

India, UL has four other PV testing facilities

Director & Vice President, UL Emerging

in Ise City, Japan, San Jose, California

markets mentioned that “There is a growing

(U.S.), Suzhou, China and Zeppelinheim

demand for PV equipment globally driven by

(Neu-Isenburg), Germany.

government and industries striving for the development of sustainable energy sources.

And since India too has joined the race this lab will enable the Indian PV manufacturers to get access to the state-of-the-art facility

significantly increased and will continue to

evaluating and improving the quality and

grow as a sustainable energy source. With

performance of their products. “

Solar Mission) setting forth aggressive goals for deployment of solar power in India, there is a strong need in the Indian industry to have a full-fledged test facility for PV modules and other balance of systems and also to support the local manufacturers aspiring to reach global markets with their products.

This lab will enable Indian companies to www.EQmag.net

1980s. Apart from this facility in Bangalore,

R A Venkitachalam – Managing

Globally the demand for PV systems has

the JNNSM (Jawaharlal Nehru National

UL is engaged in formulating PV equipment safety specifi cations since the

Additionally, UL is working with various governmental departments and industry bodies in India to understand the needs of the manufacturers and users of Photovoltaic equipment in an attempt to provide proactive solutions to the industry problems. Some examples are the training courses conducted

In addition, Jeffrey A Smidt, VP &

by UL University - the training and consulting

GM, Global Energy, UL states, “UL is

arm of UL and provision for local engineering

installing , large-scale network of PV test

support to PV manufacturers as well as

facilities in the key PV markets globally

supporting professionals in extending their

and India as one of the most important

skills to qualified PV module installers in

emerging PV markets must be part of that

India. Similarly UL is working with other

essential network.” He also added “it is

organization like BEE, QCI, UNDP, TERI,

our focus to support manufacturers around

SESI and SEMI under various initiatives.

the world with the market access they are EQ INTERNATIONAL JANUARY/FEBRUARY 11

39

CSP

Special Mirror for CSP Increases Efficiency R. Subramanian, Director Sales & Marketing, Saint - Gobain Glass India

With government of India announcing Jawaharlal Nehru National Solar Mission (JNNSM), solar thermal technology has received a lot interest.

For solar power to be viable in India there has to be a reduction in costs which can be achieved through economies of scale, attracting stakeholders to participate in the complete solar ecosystem and last but in fact most importantly by leveraging the disproportionate effect of component efficiencies in viability of the solar projects.

R

eflector is a key element of solar thermal plant. If we talk about reflector first thing that comes to mind is glass mirrors. Glass mirrors have several advantages and track record to make it the most preferred choice of material as reflectors.

The key in glass / mirror is to use components with higher transmission / reflection. For an example in case of mirrors 1% increase in refl ection of mirrors adds 750 additional hours over the 25 years useful span of a power plant. Assuming a DNI of 2100 kwh / sqm & capacity of 10GW by 2022, this small increase in refl ection results in additional production of 100 Mw. It is now easy to see that the savings that accrue by a 1% increase in reflection significantly exceeds the investment costs of the mirrors.

In the past normal mirrors were used as reflectors for solar thermal applications. As these mirrors were not designed to withstand outdoor conditions, it used to lead to corrosion and loss of reflectivity depending on the harshness of the environment sooner or later. Various protection mechanisms have been tried in the past by various players to overcome these problems but these have not been successful due to one or a combination of failures such as

High performance parabolic mirror from Saint-Gobain Glass

Normal Mirrors

Solar Grade Mirrors

Design only

For interior applications applications in

Designed for solar outdoor

Substrate

Float Glass

Solar Grade Extra Clear Glass with highest Light Transmission

Reflection

Upto 86% depending on 93% reflection the thickness used

Durability against Exterior

No

Yes

Exterior UV Durability

No

Yes

Moisture Entry

Possible

No

Tested Protective coating to withstand external conditions

No

Yes

Weathering test

No

Yes

Weather and conditions

Table of Comparison of Solar Grade Mirrors Vs Normal Mirrors

40 EQ INTERNATIONAL JANUARY/FEBRUARY 11

www.EQmag.net

delaminating, moisture entry, seepage, improper protection, failure of protective coating and loss of reflection due to exterior UV radiation etc.

Specially, designed mirrors to withstand extreme conditions are now available suitable for all the various technologies in concentrated solar thermal applications.

These mirrors are produced on a special substrate especially manufactured for solar applications. Further these mirrors are designed for outdoor applications.

The performance parameters that define the success of a solar grade mirror is High reflectivity + Distortion free + Durability in exterior conditions and UV

High reflectivity This is achieved by using as substrate glasses with high energy transmission. These glasses have very low iron content that provides it with this performance. Some premier glass manufacturers today produce special solar grade glass.

Distortion Free Distortions in glass can lead to unfocussed reflections leading to suboptimal performance. Distortions in glass can occur due to body defects, surface defects or non uniform thickness of glass. These distortions need to be eliminated during the manufacture of glass.

Durability If silver is exposed to atmosphere it is oxidized and this leads to black spots, corrosion resulting in a severe loss of reflectivity. Today very specialized industrial processes and superior coating technology is used in the protection of the silver. External UV also leads to a loss in reflection. Thus solar grade mirrors need to also be exterior UV durable.

Environment friendly Today solar grade mirrors are available that is environment friendly without compromise on the performance. These mirrors use the latest technology and eliminated the use of harmful material like copper, lead and formaldehyde The most important contributor to make solar viable and achieve Grid Parity is the efficiency of components especially the mirrors. The various stakeholders need to be educated on the disproportionate effect of component efficiency on the viability of the solar projects. Under the Jawaharlal Nehru national solar Mission (JNNSM) there is a need to set the right standards for the components.

This will also prevent cheap low efficiency sub-standard imports and help India to take the high ground like in the IT sector. There is a need to mandate minimum performance for components and support this by encouraging a complete manufacturing ecosystem in India through incentives and to create a Testing and component rating facility along with Industry. www.EQmag.net

CSP

Challenges in Providing Concentrated Solar Thermal Systems for Industrial Applications Francesco Orioli, Soltigua, Italy

In consideration to insights from the industry, key challenges have been identified that must be tackled during the planning, designing and building phases of solar process integration.

S

oltigua has synthesized its approach in the structured framework which is shown in fig.1 and which will be followed in the remaining part of this article, where we will illustrate some of the points by drawing examples form a real Indian case study.

Assess • Site assessment Preliminary to any other consideration is the site assessment, both in terms of its available solar irradiation throughout the year and in terms of the space available.

the data can also be imported from the clients or by other third party sources.

The site assessment normally focuses on the area available for the solar field.

Its shape and orientation have to be taken into account in order to make a realistic assumption about the solar field layout and power output. Industrial settings do not necessarily allow the same regular areas usually available to large CSP plants. This is particularly true in India!

The available surface could be on the ground or on the industrial client’s roofs. In the latter case, structural assessments need to take place. The concentrating collectors’

the case of parabolic troughs, the impact of wind has to be assessed and verified.

In order to facilitate the roof installation of solar concentrating collectors, Soltigua has complemented its parabolic trough product line with a Fresnel type collector, which is much less affected by the wind (see fig.2). Also, the Fresnel collectors have less reciprocal shadings and generate a higher yield for every gross square meter of surface available for the solar field, thus optimizing their use in roof mounted applications. By including both parabolic troughs and linear Fresnel collectors in its product portfolio, Soltigua can provide the optimal solar solutions for almost every field setting, be

Fig.1: CST industrial applications PROCESS

TEMPERATURE[°C]

Washing Pasteurization Sterilization Drying Cooking Extrusion and Drying Heat treatment Boiling Distillation Drying Bleaching and drying

80 – 150 80 – 110 130 – 150 130 – 240 80 – 100 150 – 180 150 – 180 95 – 105 110 – 300 150 – 180 130 – 180

Industrial cleaning

Washing Heat treatment Bleaching Dyeing Steam Washing

80 – 100 80 – 130 60 – 100 100 - 160 150

Commercial sector

Air conditioning

All

Electricity generation/Polygeneration

Food and beverages

Plastics Chemical

Paper

Textile

180 250-300

Purely indicative information. Soltigua does not guarantee its accuracy

INDUSTRIAL SECTOR

© Soltigua 2011 – All rights reserved

The first data is normally drawn from publicly known international databases, but 42 EQ INTERNATIONAL JANUARY/FEBRUARY 11

weight may not provide the most critical challenge to the structure. Particularly in

it a ground or a rooftop application.

www.EQmag.net

PTM – parabolic trough collector

Purely indicative information. Soltigua does not guarantee its accuracy

Fig.2: Soltigua’s product portfolio

FTM – linear Fresnel collector*

COMMON FEATURES • • • •

Modular design Selectively coated receiver Weather-resistant mirrors Sun tracking drive and motor

• Hot-dip galvanized frame • PLC- based controller • Fluid: hot water (up to 110°C) or thermal oil

• Working pressure: up to 8 bar • Maximum fluid working temperature: 250°C • Electric panel at 230 V

© Soltigua 2011 All rights reserved * =–available first half 2011

• Process assessment The industrial process is then also assessed both in terms of its load profile and its existing energy source.

In the fi rst case, daily, weekly and annual profile of the industrial operations has to be considered, in order to optimize the allocation of thermal storages. For example, in order to utilize the solar energy generated on Sundays in processes which operate 6 days a week, appropriate energy storage systems can be put into place.

The energy source assessment addresses both the economic and the technical issues.

In economic terms, rule of thumb is that processes using electricity, LPG or

economic assessment that takes into account all the factors listed so far and provides a clear indication of the range of the expected payback time.

As this assessment is updated in the following phases, the industrial client can keep track of the economic impact of the different planning and design options.

the solar field is adjusted so that the steam is heated at the temperature and pressure required by the process.

An alternative setting may be to have the solar field to work in series to the existing boiler. This setting may be optimal when the solar field must only provide the pre-heating of a condensate.

• Solar fi eld working conditions

Plan • Integration concept Industrial integration needs to be tailored to the specific unique needs of a given client.

This said, some broader solar integration concepts can be identified for the initial planning of solar solutions.

The process thermal load profile throughout the day is a key input for the solar field working conditions. For example, the discontinuous load of batch processes has to be dealt with care in order to maintain optimal solar operating conditions.

Soltigua usually run a detailed hourly simulation of both the load and the solar

1. ASSESS

2. PLAN

4. INSTALL

•Site assessment Solar radiation Avail.space & constraints •Process assessment Load profile Existing energy sources • Preliminary economics

•Integration concept •Solar field working conditions •Optimal solar field size

•Attention to details (e.g. insulation)

3 DESIGN

•Operating strategy •Mirror cleaning •System mainten.

•Control logic •Primary&secondary loop • Local norms (e.g.structural)

5. OPERATE

HX

Based on: x Field experience in own premises

x Worldwide projects assessment

Purely indicative information. Soltigua does not guarantee its accuracy

Fig.3: Soltigua’s solar design method

© Soltigua 2011 – All rights reserved

diesel will have a more rapid payback time because of the high cost of each KWh being used. However, we have also found cases where specific technical issues (e.g. the low effi ciency of the existing boiler) made it attractive to shift to solar from wood.

• Preliminary economics At the end of this first phase Soltigua provides the industrial company with a preliminary www.EQmag.net

For example, the steam generation layout shown in fi g.3 can be applied in a very similar way across a wide variety of industries and processes. Core to this integration concept shown is the fact that the “solar boiler” (i.e. the heat exchanger from the solar field to the process steam) is working in parallel to the existing boiler.

The flow of the steam being processed by

radiation , in order to account for their varying profiles.

On the basis of this accurate simulation, Soltigua will then tailor an optimal storage strategy to the process specific needs.

• Optimal solar fi eld size Taking into account the factors examined EQ INTERNATIONAL JANUARY/FEBRUARY 11

43

Steam main Solar Field

Fresh water make-up Short term Stora ge

3 more process units

Process Unit

Steam boiler

Indirectly fired steam boiler

HX

Condensate return Solar Field*: 1’080 smq Peak power**: 652 kW (605 W/sqm – K = 60%)

Effluents

Fresh water make-up *= due to space constraints /

above and including consideration of the scale economies that can be achieved by installing larger fields, Soltigua then plans the optimal solar field size.

processes of the food industry may for example prohibit the use of certain thermal oils. In these cases,food-compatible high performing thermal fluids can be used.

Design

Install

• Control logic Once a given integration concept has been chosen, the specifics of the system operating logic must be designed, in order to guide the physical design of the primary and secondary loop and to optimize the tradeoffs between simplicity and optimization.

On this latter topic, the features of the existing system are a very important input to be taken into account.

• Primary and secondary loop The control logic and the set-up of the primary and secondary loops implies selecting specific components such as heat exchangers, valves and , in the case of solar cooling installations, absorption chillers.

Soltigua can offer a complete solution to the client, but we let it open the possibility for a joint effort on the system together with the client, particularly in cases where the industrial process requires a high degree of specific know-how.

• Local norms The input of the client’s technical department is the key in the activity of ensuring full compliance to local norms. Beyond the mentioned structural requirements, it is worth checking norms such as fi re and pressure regulations. Some industrial 44 EQ INTERNATIONAL JANUARY/FEBRUARY 11

Attention to details is the key for minimizing the challenges of the installation phase.

This is a hidden but very real technological challenge for CST applications, where the performance requirement on the system is much higher than in traditional flat plate collectors, and where the size of the installation is usually much smaller than in large CSP applications.

In order to address this challenge Soltigua has developed some specific feature, such as a modular design of the receiver tube, which is flanged and does not require specialized local welding on site.

The substitution of welding with mechanical assembly eliminates a source of complexity to be dealt with on the installation site.

Also, the use of a fully automated tracking system is not prone to installation errors of tracking supporting sensors and does not require periodic calibrations.

Operate • Operating strategy Falling within the boundaries of the designed control logic, the operating strategy can be an important source of yield maximization.

In particular, an optimized control strategy can help companies to reap the solar yield of days of very variable weather when the actual provision of energy to the industrial process is highly sensitive to operating rules.

Purely indicative information. Soltigua does not guarantee its accuracy

Fig.4: Steam integration concept

The experience of the industrial process manager is the primary input of the operating strategy and can be supported by Soltigua data recording and analysis which can be provided together with the initial supply or at a later point in time, as a performanceenhancing tool.

• Mirror cleaning Mirro r cleanin g operating cost can be factored into the very early economic assessment of the solar integration.

Our experience suggests that even in very challenging industrial environments a simple monthly cleaning with water can very often be sufficient.

This said, mirror cleaning being almost the only operation which needs to be performed more often than once a year, keeping track of mirror cleaning operations can be a useful way to ensure the existence of a written document where all the maintenance history of the solar field can be recorded.

• System maintenance As mentioned above, very little maintenance is required by the solar system.

Our collectors are designed in such a way that all operations can be performed by the personnel normally in charge of an industrial process, with no need of external specialized people. However some specific training is advisable since it permits to minimize any potential downturn period.

An overview of the technical challenges encountered in our CST track record so far has been presented.

While not necessarily encompassing all the possible situations experienced by the readers, we hope that we have given them a useful framework to identify the most significant challenges that lie ahead of those who are considering the solar integration for their industrial systems.

Even more importantly, we also hope that we have given to the readers the confi dence that those challenges can be successfully overcome. www.EQmag.net

INDIA WEAVING ENERGY DREAMS AROUND THE SUN PV+Solar India Expo 2011 will be held on April 19-21, 2011 at Bombay Exhibition Centre, Goregaon (E), Mumbai, the Financial /Commercial Capital of India. PV+Solar India Expo 2011 provides an ideal opportunity for global players in Photovoltaic, Solar Thermal, Solar Architecture, Photovoltaic Equipment, Products, Materials, and Systems, to display their products and capabilities to explore enormous Business Opportunities in India and neighbouring South Asian countries. Concurrently with the Exhibition, a 2-day International Conference and two Technical Workshops would also be organised.

Organised by Electronics Today, India's FIRST Techno-Economics Electronics monthly journal, and the Pioneer Electronic Exhibitions Organiser in India, now in 43rd year of publication, PV+Solar India Expo 2011 is sponsored by Ministry of New and Renewable Energy, Government of India, Department of Information Technology, Ministry of Communication and IT, Government of India, Maharashtra Energy Development Agency and Solar Energy Society of India (SESI).

Sponsors : Ministry of New and Renewable Energy Government of India Department of Information Technology Ministry of Communication and IT Government of India Maharashtra Energy Development Agency Solar Energy Society of India Media Partners :

April 19-20-21, 2011 Bombay Exhibition Centre, Mumbai, India For details contact:

Website : www.electroniocstoday.org

104, Andheri Industrial Estate, Off Veera Desai Road, Andheri (W). Mumbai 400 053, India Tel. : 91-22-2673 0869 / 70 / 71 / 72 Fax : 91-22-2673 0547 / 48 E-mail: electoday@vsnl.net sswarn@bom5vsnl.net.in

W IND P OW E R

Bearing Selection Techniques As Applied To Mainshaft Direct And Hybrid Drives For Wind Turbines Matthew B. Turi and Christopher S. Marks, The Timken Company

As wind turbine manufactures gain experience with turbine and gearbox designs, they are elevating the need to improve the reliability of drivetrains, employing an architecture that optimizes the cost structure of turbines and towers.

W

ind turbine generator designs have historically utilized a modular architecture (Fig. 1a, ). Several departures from that traditional design approach aim to improve turbine reliability and cost. Two of the most common architectures include direct drive and mid-speed hybrid drive turbines. Direct

support the main shaft. Options include a single bearing position system utilizing a tworow bearing or a multiple bearing position system. For each position, the bearing type and conďŹ guration must also be determined.

For larger turbines, viable alternatives include combinations of spherical, cylindrical and tapered roller bearings. Table 1 lists

discussed many times. Due to elevated axial loading and inability to optimize in preload, use of SRBs may result in unseating effects, abnormal load distribution between rows, roller skewing, roller retainer distress, excessive heat generation and roller smearing.

Fig 1. Modular drive train configuration. Source: NREL/TP-500-41160

drives tend to result in more upfront cost, but can reduce complexity by eliminating the gearbox. Hybrid drives also focus on simplifying the gearbox and generally result in lower tower top mass.

A key consideration in turbine design is the selection of the bearing system used to 46 EQ INTERNATIONAL JANUARY/FEBRUARY 11

various main shaft bearing arrangements available based on the turbine drive train architecture.

Concerns, when using spherical roller bearings (SRB) in main shaft ďŹ xed positions as compared to preloaded double-row tapered roller bearings (TRB), has been

Preloaded TRBs allow for improved system stiffness and are available with modified internal geometry to operate effectively in high misalignment conditions.

In addition, cylindrical roller bearings (CRB) work well with TRBs, providing additional radial capacity and stiffness that allows for www.EQmag.net

a more power-dense arrangement. These and other advantages of TRB and CRB arrangements make them a better solution for multi-megawatt turbines.

and modular designs (high speed). These designs can significantly reduce tower top mass as a ratio to power output. Also, these

This paper will expand on bearing selection requirements for main shaft positions in direct drive and hybrid drive turbines.

DIRECT AND H Y B R I D DRIVES There is significant wo rk wit hin t h e industry to understand real operating loads on turbines, gears, shafts and bearings in the field. Standards have been developed to help the industry design more reliable turbines with improved performance, but there is still room for further improvement.

designs target a good balance between gearbox and generator size to achieve optimal use of space atop the tower.

DIRECT/HYBRID DRIVE CONSIDERATIONS Some challenges faced by direct drive turbine

While work continues in understanding environmental conditions and a turbine’s reaction to those conditions, there are new designs focused on making a system more robust against unknown c h a ll e n g e s a n d / o r eliminating the sources of reliability problems.

A direct drive turbine that eliminates the gearbox entirely has to meet certain considerations.

To be able to generate adequate power at low Fig 3. Hybrid drivetrain example with two-row TRB mainshaft. speeds, generators Source: DNV-GEC tend to become larger, heavier and more expensive. Typical bearing manufacturers and bearing suppliers in solutions have been three-row CRB designs managing the loads and stresses in a compact with two axially positioned rows in light space. Stress internal to the bearing is a preload, and one radial row mounted in function of the weight of the hub/blade and clearance. Unitized two-row TRBs are also rotor assembly, along with external loading a viable and advantageous solution. during operation. Therefore, for any type Hybrid drives use mid-speed generators and of wind turbine architecture, it is critical will employ one or two planetary stages to that wind turbine manufacturers provide achieve generator speeds between those an accurate assessment of fi eld loading typically found with direct drives (low speed) to the bearing manufacturer. Inadequate www.EQmag.net

inputs into bearing life models may result in improper bearing life analysis and potentially lead to premature bearing damage.

Lubrication of critical race/roller surfaces is another issue requiring special design consideration.

Most bearings in the direct drive mainshaft market are grease lubricated. Care needs to be taken to select the proper grease that will not migrate away from roller/race surfaces and lead to seal leakage. This may need to be balanced with the ability of lubrication control systems to work with the specified grease.

These systems should be designed to ensure proper lubrication of each row and prevent bearing lubrication starvation due to flow blockages.

Whether to supply a bearing with a full complement of rollers or to include a cage or separator is another critical design decision.

Full complement designs will use more rollers in the same design space, thus will have increased load carrying capacity.

Rollers will contact each other at the roller body, so appropriate surface treatment may be necessary to avoid surface damage during use. For full complement designs, surface treatment s can be incorporated to provide surface hardness improvements and ultralow surface finishes allowing improved lubricant film thickness generation at relatively low speeds. The type and method of lubrication will also influence the decisions on applying a full complement bearing. Incorporating a cage on ultra-large bearings may provide benefit in roller guidance, lubricant distribution and elimination of roller body contact.

Direct drive main shaft bearings also need to have properly designed features that EQ INTERNATIONAL JANUARY/FEBRUARY 11

47

In order to develop a duty cycle from time series data for these load conditions, two methods can be utilized to generate duty cycles – an independent or dependent reduction. In an independent reduction, each load is binned separately for a specific RPM bin. A load histogram can then be generated for each load using the previously discussed technique. An equivalent load for each resulting load histogram can then be calculated. Finally, a duty cycle can be constructed with the corresponding combinations of independent equivalent loads.

Fig 4. Life versus bearing setting – two-row bearing system.

allow for efficient handling and installation.

The size of the bearings can create logistical challenges and bearings need to be installed

BEARING SELECTION FOR DIRECT DRIVES AND HYBRID MAINSHAFTS

properly to avoid issues that can cause longterm performance problems. Some bearings are designed to have bolt-on features for attachment to the nacelle structure, hub and rotor assemblies. Without an external shaft or a press fit into the housing, bolt designs are critical to maintain bearing clamp, and in some cases, alignment of bearing races.

Bearing setting is another critical aspect for proper performance. In a tapered nonadjustable (TNA) design, bearing suppliers can carefully control the designed setting.

In fact, the only factor outside the bearing supplier’s control that can impact the operating setting is external clamp load.

For a turbine mainshaft application with two separate rows, setting is the responsibility of the turbine assembler.

Several methods for achieving a desired final setting may be employed, but bearing size needs to be considered for several reasons, including proper measurement of initial parameters, accurate assessment of adjustments needed to achieve final setting and determining the final assembly effect on setting. We will cover the importance of bearing lateral setting later in this paper.

48 EQ INTERNATIONAL JANUARY/FEBRUARY 11

BEARING FATIGUE DUT Y CYCLE The bearing fatigue duty cycle received from the customer can have a significant influence on the size and geometry of the mainshaft bearing designs. A concern is that adding conservatism by oversimplification of the duty cycle will result in a negative cost structure. Some manufacturers use hundreds of conditions in the duty cycle.

Others may use tens or only a single condition in the duty cycle.

Duty cycles usually are generated using design programs to model the wind turbine system, typically with an output at 20-Hz. The high frequency of data provides a vast number of snap shots of the system, even for short time intervals. All this data must be sorted and binned in useful categories, using the arithmetic average bin value, for fatigue analysis. A five second excerpt of data from the graph has been added in to show the variation of the data. The complete data is then sorted into bins and the time durations in each bin is summed to determine the percent of time each condition contributes to the duty cycle.

While an independent duty cycle is simpler to create it may not always maintain the proper relationship between specifi c load combinations. This type of load case may result in an over-predicted bearing life due to lost load/moment relationships. This is where a dependent duty cycle reduction can be beneficial. In a dependent reduction, loads are binned dependently based on importance of effect to bearing life, where low importance loads can generally be equated to as few or as little as one equivalent load. Bin size should be determined methodically for the speed and loads by understanding the effect on the bearing system. The following recommended order of importance of the data for proper bearing analysis can be utilized in either reduction case: RPM (due to effects on the development of the lubrication film thickness).

Pitch Moment, My Yaw Moment, Mz Radial Load, Fz Axial Load, Fx Radial Load, Fy Once the low priority load bins have been defined, higher importance load data can then be binned in subset histograms of appropriate size for each lower importance load bin. A duty cycle can be constructed from the dependent relationships and analyzed with an advanced bearing fatigue calculation program with Miner’s Rule to determine the bearing L10a fatigue life.

Typically, bearing manufacturers are provided the binned duty cycle from wind turbine OEMs and/or gearbox manufacturers.

Equally important as the correct time series data is the method of the reduction. While each manufacturer can have its own method www.EQmag.net

for the reduction of time series data, it is also important that they understand the significance of the reduction methods on the load/moment relationship on predicted bearing life.

BEARING LIFE CALCULATIONS Bearing life calculations have evolved from basic catalog calculations (load and speed effects) to very sophisticated calculations that include many different environmental conditions that impact life. The catalog calculations were sufficient in very basic bearing sizing but would not model actual operating conditions and many assumptions made for catalog calculations do not hold true in real world operation.

and bearing fitting practice.

the impact on bearing life.

Load zone influence on catalog life is determined through the use of a life multiplication factor. The factor is 1 at 180 degree load zone. The factor increases in slight preload. Since TRBs are usually mounted in pairs, their individual load zones are interdependent. Thus, system life depends on the operating setting in each row under a given condition. In multiple condition duty cycles, the load zone can change dramatically and will affect bearing performance. This factor takes into account the change in roller loading on bearing life.

A two-row TRB solution can be installed with initial preload in the system. Controlled preload is advantageous from the standpoint of optimizing bearing life through load sharing between rollers for a given duty cycle.

A reduction in bearing preload on the unseated bearing will lead to a reduction in load zone for a range of conditions. One might conclude to increase the dimensional preload beyond 0.30 mm to ensure both rows are well-seated under the heaviest loads, the preload would need increased significantly

A comparable spherical two-row bearing will tend to have one row-carrying load while the other may be unloaded. This is mainly due to the inability to set the bearing in initial preload. Lack of roller load sharing could cause reduced fatigue life in service.

Optimization of bearing load zones in wind turbine applications has several benefi ts. Loads can be balanced among available rollers to reduce loads on the maximum loaded roller in certain conditions.

When a system is not optimized or uses bearing types which don’t allow for the load zone control similar to TRBs, fewer rollers may be carrying the bulk of the load.

Bearing companies have developed inhouse analytical programs to better evaluate the environmental effects influencing bearing life. It is suggested that wind turbine manufacturers contact their Life Reliability a1 20-year L10 Life 30-year L10 Life Keeping rollers engaged approved bearing suppliers L10 90 1 175,000 263,000 with race surfaces also prevents for advanced bearing life premature damage from L5 95 0.64 274,000 411,000 analysis. There are several skidding/smearing. This happens 97 0.47 376,000 564,000 life adjustment factors included L3 when rollers move through the 98 0.37 478,000 717,000 in advanced bearing analysis L2 unloaded zone and are being in Syber, a proprietary finite L1 99 0.25 706,000 1,060,000 pushed by the cage, rather than element based computer Table 2. L10 life requirement for various reliabilities. being driven by traction from simulation software of the to dramatically increase the load zone above the rotating raceway. Roller surface and author’s company. In addition to load and race surface will then see contact when the 110 degrees. speed, other major life influencers are: roller moves back through the loaded zone.

Peak life tends to be in slight preload This contact will cause adhesive wear, and Load zone (bearing fits and setting) where optimum roller sharing occurs. also increased tensile shear forces beneath T h e r m a l e f f e c t s (o p e r a t i n g When analyzing bearing life for a two-row the surface of the race/rollers. The tensile temperatures, thermal gradients, lube arrangement, it is more appropriate to focus shear forces can lead to formation of axial sump temperatures) on system life, which is a measure of the life cracks. associated with both bearings and accounts Lubrication effects The basic design of a TRB, plus the for the likelihood of either bearing reaching Misalignment/race stress (functions of a failure point. ability to optimize setting in preload, will housing and shaft stiffnesses – radial, work to avoid skidding/smearing damage and In a two-row TRB system, a net thrust axial, and tilting) also help balance load between the rollers force will exist that will cause one row to of both rows.

Fatigue propagation rate be seated while the other is unseated. This directionally-dependant net thrust force is Bearing geometry factors the sum of the external thrust applied to THERMAL EFFECTS the system plus the tow-induced thrusts Temperature can impact bearing life in generated by radial loads on the TRBs. multiple ways, all of which must be taken into By design, a radial load applied to a TRB BEARING LOAD ZONE account when trying to perform advanced will create thrust forces with magnitudes Load zone is an angular measurement of relative to the outer raceway angle. Fig. 4 life calculations. Areas in which thermal the load distribution in a bearing and is a includes individual row life for seated and gradients can impact are listed below: direct indication of how many rollers per setup (unseated) bearings.

Lubricant viscosity row share the applied load. There are a Operating setting A previous technical paper compared vast list of factors that determine what the operating load zone is, including initial lateral two-row TRBs versus two-row SRBs in the Bearing arrangement setting, applied load, operating temperature, fixed position of a wind turbine mainshaft.

Dissimilar material thermal expansion structural properties of the shaft/housing One focus of the paper was load zone and www.EQmag.net

EQ INTERNATIONAL JANUARY/FEBRUARY 11

49

Because lubricant viscosity is a function of temperature it is important to properly assess operating temperatures in order to predict proper film thickness.

Thermal gradients between shaft and housings impact axial shaft expansion/ contraction which can result in a change of setting between two bearings. In addition to axial shaft expansion, radial expansion of the bearing raceways can occur. Because TRB raceways are designed on an angle, a radial expansion of the raceway can be equated to an axial movement of the raceway. Both of these thermal effects will ultimately impact the operating setting of the bearing. In a case where two bearings are wide spread, the change in relative shaft and housing length due to thermal expansion, ΔL, is large compared to a close couple TDO or TDI style bearing assembly.

Finally, differences in material properties can mean larger relative displacements for even small thermal gradients when compared to similar materials, making thermal effects even more important to consider for proper advanced life prediction.

LUBRICATION For direct drive mainshaft bearings, grease is a very viable solution due to low operating speeds. Although grease may result in a thinner film thickness, it is the preferred option for direct drive applications. It will have a lower chance of leakage, will not migrate as easily, and will exclude contaminants more effectively than oil.

Common considerations for the grease selection process include: Higher viscosity (ISOVG 460 or 320) is better for maintaining good film strength

grease from the bearing rather than relying on back pressure to force it out. This can also keep internal pressures lower and may help increase expected life of contacting lip seals.

MISALIGNMENT/RACEWAY STRESSES Bearing life can be negatively affected by excessive shaft and housing misalignment.

High loads and overturning moments can cause this to happen. Misalignment will increase edge stresses in roller bearings and could cause early damage in the bearing in the form of geometric stress concentration (GSC) spalling. TRBs and CRBs can be designed with special profiles to alleviate edge stresses under given conditions. This is another reason for the importance of an accurate assessment of wind turbine loading.

Stresses are higher near the center due to race and roller crowning. Relatively high loading can cause load truncation at the ends of the contact area and misalignment can cause stress imbalance along the raceway.

The final graph shows typical stress plots for edge stress conditions.

For catalog calculations, the impact on bearing life is handled through the use of a life factor and this factor is generally 1 for a misalignment of 0.0005 radians. It is greater than 1 for lower levels of misalignment and will reduce life when misalignment is greater than 0.0005 radians.

RELIABILITY REQUIREMENTS There have been many bearing life

expectations from various customers. Some have used 150,000 hours, while others have used 175,000 or even 200,000 hours life calculation for which 90 percent of the population will reliably survive (e.g. L10).

The required calculated L10 for a 20-year design life would improve with increasing reliability requirements. As seen in Table 2, taken from ISO281:2007, in order to obtain the required reliability of 150,000 hours at a higher reliability level, the calculated L10 will increase. Also shown in Table 1 are the required L10 for a 30-year design. Another way to state this would be that the reliability factor, a1, is multiplied by the L10 to attain the Ln life of 175,000 or 263,000 hours for the 20- or 30-year calculated life, respectively.

It is important to understand that the reliability requirements are defi ned for failure by subsurface fatigue spalling.

There are other types of bearing failures that may occur in the application that are not considered using traditional fatigue durability analysis. These include, but are not limited to: Scoring: Scoring may occur on a roller bearing if the end of the roller contacts an improperly lubricated flange or if a high rib contact stress or improper contact geometry exists.

Scuffing: Scuffing traditionally occurs when there are insuffi cient traction forces between the roller and the raceways resulting in gross sliding at the contact. As the heat generation increases, the surfaces adhere and cause transfer of the material. The sliding is caused by low bearing preload or a low load zone, high speeds and/or light loads.

Synthetic base oil with high viscosity index (VI) will provide better lubrication over a larger temperature range Excellent water, rust, oxidation, and corrosion resistance is important for extended grease life Low-temperature operation with adequate pumping may be required in some applications Lubrication control systems are a way to ensure effective re-lubrication over time and to make sure each bearing row is receiving grease. Newer systems have features that will inject grease with two separate ports, directing lubrication at each bearing row.

Also, bearings can be designed with features that take a more active role in removing used Fig. 5. On-apex design of a TRB.

50 EQ INTERNATIONAL JANUARY/FEBRUARY 11

www.EQmag.net

Micropitting: Micropitting is similar to macropitting, except occurring on the micrometer scale. The small pits on the surface are due to the increased stresses that occur on the microscale when lubricant films are thin compared to the surface texture resulting from the finishing process. This issue is grossly accelerated when sliding occurs on the surface simultaneously with the thin lubricant films.

Structural issues: Structural issues may be related to sections of the inner or outer raceways that may be used as structural members to transmit the load instead of using a housing or shaft to transfer the load.

Brinelling and false brinelling: Brinelling results from permanent deformation or yielding in the part. False brinelling is commonly seen when the rollers are not rotating and oscillate back and forth along the direction of the rotational axis of the roller.

DESIGN OF THE TRB TRBs achieve true rolling motion by being designed on apex as in Fig. 5. Lines drawn extending the inner and outer raceways towards the centerline will intersect on the centerline. The roller’s size (body length, small- and large-end diameters, and body included angle) along with its relative position to the centerline, will define the bearing series. A single roller could be used in many different series by adjusting its angular position relative to the centerline. This allows for optimization of the radial and axial load carrying capability. Resultant forces act perpendicular to the raceway. Since race surfaces are not parallel, there will be an effective seating force that ‘pushes’ the roller into the rib. The seating force aids in roller alignment during operation. Excessive seating forces can cause sizeable rib forces resulting in increased heat generation and early bearing damage.

A typical double-row TRB single main bearing for mainshaft applications is composed of a double outer race, two inner races (or cones), two rows of rollers and a retainer for each roller row. The intersection of the bearing centerline and the angled dashed lines define the bearing spread for counteracting the overturning moments.

There are many design considerations www.EQmag.net

required for two-row TRB for mainshaft applications. Designs should be balanced in order to obtain a bearing that is optimized for performance, price and manufacturing. The primary features of the bearing that must be considered in the design phase are: • Mean pitch diameter (average of the bore and outside diameter of the bearing) • Included cup angle (E) • Included roller angle (F) • Mean roller diameter [(LED+SED)/2] Optimization of the overall design takes skill and experience because these factors are closely interrelated. Bearing envelope size will usually be dictated by turbine designers, but upfront work with bearing suppliers will make the most effective use of available space. Designers and application engineers will balance features affecting load carrying capability relative to radial, axial and overturning moments, combining predicted bearing life, system stiffness, powerloss and heat generation, load zone maintenance, setting, lubrication, and handling and maintenance issues into an optimized solution.

RETAINERS AND UNITIZATION There are several options in bearing designs for mainshaft bearings in regards to roller unitization. Bearing cages can have some performance benefi ts. Full complement designs (no cage or separators) have power density benefits, but need to be engineered with care due to roller body contact during operation and also can complicate assembly and setting procedures.

Manufacturing of “L” style cages in sizes typical for mainshaft bearings in direct and hybrid drives may be accomplished through precision cut processes such as: Full machining Forming technology CNC controlled precision cutting

A traditional closing in process may not be feasible in this size range. This can be overcome with a means of axial retention to hold the rollers in place after assembly.

The inner race assembly can then be handled separately from the outer race without a need of unitization. Another option is a cut-

and-weld cage design that avoids the closing in process.

As mentioned previously, use of a cage will lower the bearing rating when compared to an identically sized full-complement design, but there could be other advantages related to better grease distribution including elimination of contact between roller bodies (rollers will contact cage which is made of softer material and generally will not wear roller surface) and roller guidance through unloaded zones.

For full-complement designs, there are several considerations that must be taken into account during the design process, including: Maximum allowable speed is limited to prevent metal transfer from roller to roller/race.

Engineered coatings on rollers will allow for increases in speed and will enhance bearing performance by altering the surface finish and improving the lambda ratios. The bearing life should be improved, particularly in low lambda conditions, by reducing adhesive metal transfer.

Unitization will simplify bearing setting, installation and removal, and may help eliminate incidental damage to rollers during turbine assembly.

The use of CRB/SRB designs in mainshaft confi gurations, especially hybrids which may have a very large outside diameter (OD) size, is related to roller size. Large rollers operating in a system with excessive clearance may be more prone to skidding/ smearing damage compared to a preloaded TRB.

SEALS Sealing is more critical in direct drive generator wind turbines than hybrid and other drivetrain designs. The seals need to control grease/oil leakage and also exclude contaminants from entering the bearing.

Direct drive generators can be damaged if lubricants leak from the bearing seals into the generator. Seals are also critical in off-shore applications where exposure to salt water spray causes a harsh operating environment.

Contacting lip polymer seals are likely to control leakage better than noncontacting labyrinth seals, but care must EQ INTERNATIONAL JANUARY/FEBRUARY 11

51

be taken in designing the seal for ability to meet life expectations for wind turbines in the field. Non-contacting labyrinth seals, when designed and applied properly, should give more confidence in meeting long-life targets. Concerns that must be addressed for labyrinth seals are control of lubricant leakage and robustness to system deflections to avoid labyrinth element contact.

A two-row TRB bearing supplied with a preset lateral setting, seals and lubrication takes complexity out of the turbine manufacturer’s assembly process and allows the bearing manufacturer to maintain tight control of the characteristics that factor into final bearing assembly.

CONCLUSION There is a strong drive in the industry to improve wind turbine reliability. Proper bearing design and application are key factors in helping to increase turbine uptime and reducing maintenance costs. Accurately defining system loading and environmental conditions and translating them for use into advanced analytical programs is a key first step to achieving improvements.

For mainshaft designs in mid-speed hybrids or direct drive turbines, TRBs provide features that address concerns relating to bearing life/capacity, stress and roller load management, reduction of skidding and smearing, improving system stiffness and simplifying the turbine assembly process. The authors’ company has significant experience in advanced analysis to help achieve the desired improvements.

Reliability, European Wind Energy Conference, May 2007 2) Dinner, H., Trends in Wind Turbine Drive Trains, KISSsoft GmbH, Switzerland 3) Lucas, D., and Pontius, T., Designing Large Diameter Close-Coupled Two-Row Tapered Roller Bearings for Supporting Wind Turbine Rotor Loading, Hannover Fair, 2003

Involving bearing suppliers in the design process can lead to better use of available package space for the bearings and allow for a more optimized turbine design.

4) Bhatia, R., and Springer, T., Using Histograms in the Selection Process for Tapered Roller Bearings, International Off-Highway Meeting, Milwaukee, 1981

ACKNOWLEDGMENTS

5) Ionescu, L., and Pontius, T., Mainshaft Support for Wind Turbine with Fixed and Floating Bearing Configuration: Tapered Double Inner Row Bearing vs. Spherical Roller Bearing on Fixed Position, 2005

The authors would like to extend sincere appreciation to several individuals who helped formulate the ideas discussed in this paper, including Timken associates Jim Charmley, Gerald Fox, Michael Kotzalas, Doug Lucas and David Novak.

REFERENCES 1) ButZterfield, S., McNiff, B., and Musial, W., Improving Wind Turbine Gearbox

6) Oyague, F. Gearbox Modeling and Load Simulation of a Baseline 750kW Wind Turbine Using State-of-theArt Simulation Codes, NREL/TP-50041160, Feb. 2009

5 - 7 MAY 2011, PRAGATI MAIDAN, NEW DELHI, INDIA www.power-genindia.com

INVITATION TO PARTICIPATE Register now for this unique business opportunity which has already sold 80 per cent exhibition space and expects 7000 high calibre attendees.

Take advantage of the vast growth in India and by exhibiting at POWER-GEN India & Central Asia and network with the major players in the Indian and international power sector.

POWER-GEN India & Central Asia is one of the region’s most important power industry events and the largest ‘POWER-GEN’ conference and exhibition outside of Europe and North America

Who will by your audience?

Well established as the region’s premier event, POWER-GEN India & Central Asia 2011 provides the ideal opportunity to discuss the important technical and logistical issues related to the modernization of India’s power infrastructure, as well as how to meet the country’s exponential growth in energy demand.

POWER-GEN India & Central Asia comprises a world-class exhibition floor offering unrivalled networking and business opportunities for attendees and exhibitors alike, plus the chance to present the latest equipment and pioneering technologies for the Indian and international energy sectors.

• Policy-Makers from the Energy Sector • Electricity Boards/ Power Utilities • Independent Power Producers (IPPs) • Energy Managers and Consultants • EPC Contractors • Venture Capitalists • Coal & Gas Operators • OEMs • Operations & Maintenance Managers If your organization is currently working or considering operating, investing or developing business in India and Central Asia, then an exhibiting presence at POWER-GEN India & Central Asia 2011 is essential to establish or further your business interests in one of the world’s most dynamic power markets.

Exhibition and Sponsorship Sales Kelvin Marlow T: +44 1992 656 610 F: +44 1992 656 700 E: kelvinm@pennwell.com For further information, please visit www.power-genindia.com

GEARING UP FOR THE POWER CHALLENGE OF INDIA’S 12TH PLAN Co Located

Event Organisers

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W IND P OW E R

Making Wind Rainer Weiss, Application Manager and Ralf Herrmann, Product Manager at Semikron

Wind turbines featuring power electronics are becoming increasingly popular all over the world. Semikron provides application-specific solutions combining power electronics with customer support.

W

ind power generation is being replacing it. Especially in countries where the launch of wind farms that are as large as steadily employed all over the energy demand is high, recent years have seen 35 km2. In order to guarantee grid stability, the requirements with regard to world, particularly in Asia and the USA, with offshore reactive power supply and grid applications playing an increasingly stability in the case of grid voltage important role. What good are the dips have become increasingly tight. perfect location and high wind For this reason, when new WPU’s are being installed, synchronous speeds, however, if the power generation system does not feature or asynchronous generators with properly matched components. full-size converters are increasingly SKiiP Intelligent Power Modules being used, because they support the are optimised for use in wind power grid in the event of power outage. units. An integrated approach The inverter is directly controllable, and flexibility in thinking – these provides optimum synchronisation unique capabilities are what enables to grid frequency of 50 or 60 Hz, Semikron to meet the ever increasing and can both compensate harmonic demands that the move towards fullreactive power and produce reactive size power conversion systems in Figure 1: Different climatic requirements exist, depending on the intended power compensation. In addition, location of the WPU. For instance, the extreme climate conditions in wind power applications results in China and Mongolia are somewhat conflicting as regards temperature synchronous generators can feature for components and applications: and relative humidity, which is why the power electronics system used a large number of many poles (>50), higher currents, parallel operation here has to be adapted to meet these very requirements. making gears in the drive part, and more effective cooling. which was one of the most common causes or malfunction in the past, Around 80 percent of the wind superfl uous. power units featuring electronic control systems installed worldwide now use a doubly-fed asynchronous machine which is fed by an inverter via the rotor current. The major advantage of this machine is that it only has to be designed for around 20 percent of the rated output of the WPU, since 80 percent of the power is generated in the stator winding, which is directly connected to the grid. One shortcoming here, however, is the high-maintenance slip ring contacts and the indirect control (system). In the event of grid disturbances, very high rotor current are needed to keep the grid stable in such difficult situations.

Technological progress is one of the main reasons why regenerative energy is not only used in addition to conventional energy generation means, but is in fact increasingly

In inverters used in all kinds of systems, a rated voltage of 690 V is commonly used for reasons of economy, as well as to achieve optimum efficiency. A common type of power converter comprises IGBTs with a blocking voltage of 1700 V; a transformer is used for power adjustment to the 20 kV grid.

Far more costly 3.3-kV modules are barely used because here, too, the system requires transformers, making the overall solution too expensive.

More power, more power electronics Figure 2: 88% of the total 1,471 MW of offshore wind power (as per 2008) is generated using SKiiP modules (Source: http://www.renewableenergyworld.com)

54 EQ INTERNATIONAL JANUARY/FEBRUARY 11

Wind turbines are being designed to cover an increasingly larger power range, although the location is the all-important factor for the output. www.EQmag.net

In onshore wind turbines 3 MW turbines have proven to be most economic, while offshore wind farms with an output of 5 MW and above are the better solution. If both types of wind power units – doubly-fed asynchronous machine and synchronous/asynchronous generator with a full-size converter – are to be able to provide the same output, the power of the full-size converter has to be five times higher. This in turn means that five times the power electronics is needed.

As, however, the low output frequencies of doubly-fed asynchronous machines have to be taken into account, this is normally reduced to an increase by a factor of 3 – 3.5.

Power electronics is not only becoming increasingly popular, however. In fact, the requirements they have to meet are changing constantly, too. Owing to the fact that in doubly-fed asynchronous machines the semiconductor heats up differently at low temperatures, the protective mechanism has to be adapted to be able to deal with this.

Extreme climatic conditions are a further cause of new and changing demands that components have to meet. Off-shore wind turbines are subjected to high humidity levels, while wind power units in Texas, for instance, are exposed to elevated temperatures.

Consequently, the cooling systems used have to be designed differently. It is therefore important that the development of cooling solutions for individual applications be based on an extensive pool of experience.

complex, and results in financial loss due to loss of income during downtimes where no electrical energy is produced. Reliability throughout the WPU’s minimum service life of 20 years is down to the SKiiP modules and their reliable high quality packaging technology. This is an important merit, especially given the increasing tendency towards offshore wind farms.

Figure 3: SKiiP 4, maximum reliability and prolonged service life in compact designs

Of the WPUs installed worldwide by the end of 2009, totalling an output of 122 GW, 57 GW feature solutions developed

by Semikron. The wealth of experience in the wind power sector that the power electronics market leader has built up over the years does not, however, stop at the mere supply of IPM modules. In fact, Semikron is also actively involved in the design of new WPUs, where the company’s experience and synergy effects are highly beneficial. Consultation in the area of system protection, for example overcurrent or overvoltage protection, are also part and parcel of the Semikron service portfolio.

Semikron also manufactures inverter subsystems, which is why the developer of modules for WPU’s boasts considerable expertise in the area of individual component dimensioning. This know-how is important for the manufacturers of inverters, as it helps them configure the DC link circuit properly, so as to ensure that this not only meets the application specifications, but also achieves

The right know-how to combat common problems The efficiency of an inverter lies at between 98 and 99 percent. A 6 MW fullsize converter will therefore display losses of around 100 kW. The heat produced in these compact systems proves to be a major problem for the electronic components in terms of cooling. If the coolant is too cold, this will cause condensation to form with the coolant condensing on the heatsink. This must be taken into account, especially in regions with high humidity levels.

A further challenge is the overvoltage that occurs during commutation of the huge currents. As modules designed for currents of 500A and above have a relatively large spatial expansion, their stray inductances are not negligible. To combat these two problems not only is an intelligent, well thought through cooling concept needed, but also an optimum DC link design. Expertise, experience and optimised applicationspecifi c modules which help fully exploit the power of the wind are needed to ensure that minimum effort is called for to meet the requirements of operators of WPUs.

www.EQmag.net

Figure 4: In comparison to standard leaded modules with base plate, SKiiP 4 IPM has a 7,5 times higher temperature cycling capability.

a prolonged service life.

Improvements in design and packaging technology Different locations mean different requirements and problems. This is something Semikron is very aware of and has factored in to the improvement of its IPMs. The SKiiP family is already in its 4th generation. Maximum reliability and prolonged service life in compact designs is top priority in wind turbines, especially because system maintenance is costly and

Thanks to the optimum chip distribution on the insulating substrate (DCB), the lowinductance module design and symmetric current distribution, the power density of SKiiP modules is around 20 times that of competitor products. All SKiiP modules come as a unit comprising heat sink, power electronics and gate drivers. Customers have two standard heat sinks to choose from, or may opt for a custom-developed heat sink solution.

Growth and full-size converters are the key trends Wind turbines featuring power electronics are becoming increasingly popular all over the world. China and the USA, for example, rely heavily on wind power to meet ever increasing energy demands. In countries with attractive energy subsidy schemes, a clear increase in the number of wind turbines can be seen.

Another clear trend is the move away from doubly fed asynchronous machines towards full-size converters, as the latter allow more easily for operator requirements to be met and grid quality to be increased.

Semikron is fully aware of all of these challenges and requirements, boasting years of experience in the wind power sector.

Power electronics market leader Semikron produces power electronic products for the wind power sector, designs and manufactures its own products, and offers development support to its customers. For 20 years, Semikron has contributed to all-important synergy effects resulting from its cooperation with leading wind turbine manufacturers.

Semikron plays a key role in wind power generation and will continue to do so in the future.

Both the increase in the number of wind turbines and the trend towards full-size converters has led to an increase in demand for power electronics. With its innovative products, Semikron considers itself well equipped to deal with the resulting new challenges, setting new standards in wind power technology.

EQ INTERNATIONAL JANUARY/FEBRUARY 11

55

B IO F U E L

Cellulosic Ethanol – The Future Of Biofuel G S Krishnan, Regional President, Novozymes India

The term “biofuels” normally refers to either bioethanol or biodiesel. Bioethanol is made with the help of enzymes and subsequent fermentation, and is based on crops or other biomass.

B

iodiesel is made from vegetable oils. Other types of biofuels such as bio-butanol are in the process of development.The conversion processes of all types of source stocks into biofuel is a complex process. Biofuels can be classified into two types : Starch biofuels are produced from crops such as corn, wheat, barley, rye, sorghum, and cassava. The technology is in place and all commercial production of bioethanol is currently from starch. Crops are essential for food and feed production, but they also contain elements that can be used for energy and for other commodities. There are many methods to produce biofuels and, done the right way, it is possible to produce sustainable energy while ensuring food and feed production to meet the global needs.

Cellulosic biofuels are produced from feedstocks containing cellulosic biomass – such as the stalks, leaves, and husks of corn plants, wood chips, or sawdust – but the process is a bit more complicated. Unlike agricultural products like corn and wheat grain that are also used for fuel production, biomass contains a lot of lignocellulosic fibers.

These fibers make processing biomass more difficult than its starch-based counterparts – but not impossible. Cellulosic biofuels may also be produced from energy crops such as switchgrass, or municipal waste.

Lignocellulose is a matrix mainly composed of cellulose, hemicellulose, and lignin. The cellulose and hemicellulose can be converted with enzymes into fermentable sugars.

Lignin, or its residues from the pretreatment processes, can result in inhibition that slow down the enzymatic reactions as well as the alcohol fermentation process.

Cellulose consists of long chains of glucose molecules, not unlike starch, but connected 56 EQ INTERNATIONAL JANUARY/FEBRUARY 11

by a different type of chemical bond that is more resistant to hydrolysis. The structure of cellulose makes it difficult to degrade, which is (in part) the purpose of pre-treating substrates prior to enzymatic hydrolysis. The purpose of pretreatment is to loosen up this structure, providing access to the cellulose and allowing the enzymes to break down the cellulose into its component sugars.

hydrolysis. Typically, an initial physical or chemical pretreatment is applied to open the fi ber structure, followed by the use of enzymes to liberate the C6 from the cellulose and in some cases C5 sugars from the hemicellulose fractions. Afterwards, the sugars can be fermented and further processed into ethanol.

Enzymes help in biofuel production

High oil prices and energy security are propelling governments and consumers alike to demand ethanol as fuel for cars. Due to increasing demand for fuel ethanol, the market for enzymes used to produce the fuel is also growing rapidly. Not only is bioethanol a renewable resource; it also burns cleaner than gasoline and produces fewer harmful greenhouse gases.

For many years, enzymes have been providing a big helping hand in streamlining biofuel production. Enzymes are biological catalysts in the form of proteins that catalyze chemical reactions in the cells of living organisms.

They have evolved - along with cells under the conditions found on Earth, and satisfy the metabolic requirements of an extensive range of cells. Enzymes optimize the conversion of grains such as corn, barley, wheat and rye into fuel ethanol, plus enzymes that assist the conversion of biomass for cellulosic ethanol.

Making fuel from biomass To make ethanol out of biomass feedstock, the sugar components that are hidden in the substrate must first be liberated.

Biomass is composed of three major fractions: cellulose, hemicellulose, and lignin. Cellulose and hemicellulose contain sugars in polymeric form that can be converted by enzymes into monomers for subsequent fermentation. But the hard, wood-like lignin component of the plant protects the fibers against microbial and enzymatic attack by preventing the cellulose and hemicellulose from reacting with water and swelling. Hence, the use of biomass as a raw material requires disruption of the lignin so that the cellulose and hemicellulose fractions become accessible for enzymatic

The need for biofuels

Biofuels are currently the only currently available option for large-scale reduction of CO2 emissions from transportation. Use of ethanol in transportation helped reduce US greenhouse gas emissions by approximately 20 million tons in 2008 alone - equivalent to taking more than 5 million cars off the road.

Among the biofuel sector, there are distinct advantages of encouraging Cellulosic biofuel, which offers a number of benefits to the society. Cellulosic ethanol can be produced from a vast selection of readily available feedstock resources –corn cobs, wheat straw, sugar cane bagasse, and woody biomass. It will reduce CO2 emissions by more than 90% over conventional petroleum-based fuels Moving ahead in the fuel ethanol industry means that we must not only optimize the ‘first-generation,’ starch-based processes used today; we must also prepare for the next generation of biofuels based on cellulosic biomass www.EQmag.net

B IO F U E L

Opportunities For Biorenewables In Petroleum Refineries Jennifer Holmgrena, UOP-Honeywell, U.S.A Richard Marinangelia, National Renewable Energy Laboratory, U.S.A. Terry Markera, Pacific Northwest National Laboratory, U.S.A. Michael McCalla*, John Petria, Stefan Czernikb, Douglas Elliottc, David Shonnardd, Michigan Technological University, U.S.A.

Biofuel production is expanding worldwide because of increasing petroleum prices; government mandates and incentives; and commitments to greenhouse gas (GHG) reduction. Despite this growth in biofuel production there is so far little integration of biofuels production within petroleum refineries.

Su ga rs

The segregation of biofuel production feeds and products in existing or new refining these highly oxygenated feedstocks increases their cost since existing operations.

• Producing biofuel compatible with infrastructure for distribution and production the existing transportation and fuel The production of biofuels is expanding of fuels is not utilized. Biofuels could more worldwide at a rapid pace due to factors infrastructure quickly alleviate a signifi cant amount of cited above. The future widespread use of The goal of this study was to identify the increasing demand for petroleum biofuels depends on solving several issues profitable processing options for if economical opportunities integrating biorenewable feeds for blending or co-processing Feedstocks Products CO2 and fuels into existing refineries them in traditional petroleum Fermentation Dehydration Sugars Ethanol C6 Sugars by addressing these issues. Many refineries could be identified Enzyme Distiller’s Grain HO options were identified including Conversion and developed. Recently, a US Starches the production of liquid transport Department of Energy funded Acid or Enzyme Green fuels through co-processing and Hydrolysis collaboration between UOP, the Gasoline modular production plants.

National Renewable Energy Direct Lignin, Conversion Hydrotreating Cellulose & Processes to convert these Laboratory, and the Pacific oil H O o Bi Hemicellulose Pyrolysis/Thermal feedstocks into chemicals, Northwest National Laboratory Depolymerization Green Fischer Tropsch Lights Diesel hydrogen, and to produce power completed an evaluation of the HO Syngas Gasification Alcohol Synthesis were also considered. Details economics of biofuels integration FCC of promising processing options in petroleum refineries. The Natural were defined and followed with FAME or purpose of this project was to Hydrotreating Oils FAEE HO performance estimates. This identify economically attractive CoOptional Transesterification Feed Petroleum procedure usually required proof oppor tunities for biofuels Glycerine

of principle experiments in batch production and blending using Figure 1. Overview of Biofuel Production and continuous pilot plants with petroleum refinery processes. online analysis of products to Economic analyses were conducted such as: provide data for models and correlations to assess a variety of potential processes • Identifying a large, con sistent quantity to estimate commercial performance. From and configurations using process modeling of renewable feedstock these estimates the potential business value of and proof of principle experiments. The biorenewable integration was evaluated and main focus of the study was the production • Producing biofuels at costs competitive several variables were found to significantly of fuel, power, chemicals and hydrogen with other fuels affect the capital cost and net present value from two broad feedstocks: vegetable oil • Transporting the biobased feedstock or (NPV) of the various processing approaches, and pyrolysis oil. The impact of biofuels fuel to distribution centers such as: integration on refinery GHG emissions was also examined. Many promising opportunities • Developing new technology to produce • A stand-alone process vs. co were identified for integrating biorenewable fuels from the unique composition of processing C5

/C

6

2

2

2

2

58 EQ INTERNATIONAL JANUARY/FEBRUARY 11

www.EQmag.net

applied and several were economically attractive without Vegetable Oils Produced from soybeans, corn, canola, palm 194,000 33,500 subsidies such as Recycled Products Yellow grease, brown (trap) grease 51,700 33,800 pyrolysis oil and Animal Fats Tallow, lard, fish oil 71,000 32,500 b rown g rea s e.

Pyrolysis Oil Made from pyrolysis of waste biomass (cellulosic) 1,500 750 Raw vegetable oils Table 1. Availability of biorenewable feedstocks in the U.S1,2,3,4,5 were not attractive without subsidies • The availability of government study was fast pyrolysis but the quantity subsidies of pyrolysis oil is currently very low since until crude prices are > $70/bbl. commercial production is still at an early The properties of biorenewable • Crude oil prices stage. feedstocks were compared to petroleum Government subsidies were required as shown in Table 2. The to make some of the processes biggest difference between economically attractive but biorenewable and petroleum several of the options were 50000 feedstocks is oxygen content.

Liquid Transport Fuels favorable without subsidies. All Diesel Biorenewables have oxygen 40000 options become more attractive Available Oil/Grease levels from 10-40% while with high crude oil prices.

Cellulosic Waste petroleum has essentially none 30000 Although high oil prices making the chemical properties make many of these options of biorenewables very different 20000 economical the processes from petroleum. For example, identified in this study varied these feedstocks are often 10000 in the amount of commercial more polar and some easily development required to entrain water and can therefore 0 Current Potential produce biofuel. A schematic be acidic. All have very low showing several options sulfur levels and many have for biofuel production from Figure 2. Availability of biorenewable feedstocks in the U.S6,7 low nitrogen levels depending different biomass sources in on their amino acid content shown in Figure 1. Some of the routes The study took into account both during processing. Several properties are are already in commercial practice, such feedstock costs and the projected prices incompatible with typical refinery operations as ethanol from the fermentation of corn or of potential products. Prices of raw such as the acidity and alkali content so sugar cane. Others can be developed in the vegetable oils, greases, and pyrolysis oils that processes were identified to pretreat near term such as the deoxygenation of plant were determined and used in the economic many of these feeds before entering refinery oils to produce a “green” diesel fuel. Several assessment. The costs ranged from $16/bbl operations. routes have a considerable longer timeframe for pyrolysis oil to $>75/bbl for raw vegetable for commercialization due Refining Petroleum Biorenewable to technical challenges or Opportunities for Crude Typical Resid Soyoil Yellow Grease Pyrolysis Oil feedstock availability. Many Vegetable Oils and of these processing routes % C 83-86 84.9 77.6 76.4 56.2 Greases for producing biofuel from %H 11-14 10.6 11.7 11.6 6.6 vegetable oil and pyrolysis oil %S 0-4 (1.8avg) 4.2 .0006 .04 A large number of options are discussed in this paper. %N 0-1 (.1avg) .3 .0011 .03 .3 were identified for processing Amount produced in the U.S. (bpd)

Amount available for fuel production in U.S. (bpd)

kbpd

Biorenewable Feedstock Definition

Study Basis and Methodology

%O

-

-

10.4

12.1

H/C

1.8-1.9

1.5

1.8

1.8

Density

.86(avg)

1.05

.92

.89

TAN

<1

<1

2

30

The first question addressed ppm alkali metals 60 6 100 100 was the availability of Heating value kJ/kg 41,800 40,700 37,200 37,200 biorenewable feedstocks at Table 2. Typical Properties of Petroleum and Biorenewable Feedstocks 2005 levels. Table 1 shows the U.S. availability of several biofeedstocks while Figure 2 compares the oils. Each economic analysis was primarily global volume of petroleum-based liquid based on a West Texas Intermediate (WTI) transport fuels with available vegetable oil crude feedstock price of $40 per barrel, a and greases in 2005. For example, vegetable level considerably lower than the recent oils and greases could only replace a very >$60/bbl price. The cost of each potential small fraction of transport fuel. However, biofuel was compared to this crude feedstock the potential large supply of lignocellulosic price after incorporating a number of factors biomass could supply a high percentage of including capital costs; transportation costs; future liquid transport fuels if commercial CO2 credits; subsidies; and cetane and processes were available to convert these octane numbers. Most of the feedstocks feeds. One such process evaluated in this looked promising when current subsidies were www.EQmag.net

36.9

vegetable oils and greases in refineries as shown in Figure 1.4 3. One is catalytic cracking to 1.23 produce either green gasoline 78 or green olefins, depending 100 on the process conditions and 15,200 catalysts, to produce fuel or valuable chemicals such as ethylene and propylene.

Likewise, these oils could be deoxygenated using existing hydroprocessing technology to produce a high-cetane green diesel product.

Different fits for the production of biodiesel in refineries were also evaluated but are not discussed in this paper.

C a t a l y t i c C r ac k i n g o f Vegetable Oils and Greases Processing options for the catalytic cracking EQ INTERNATIONAL JANUARY/FEBRUARY 11

59

Feed

Application

Process

Product Biodiesel (FAME)

Methanol

Biodiesel

Biodiesel Vegetable Oil & Grease

Vegetable Oil & Grease

Green Diesel

Glycerol H2 Diesel Hydrotreater

Diesel

Green Gasoline

Vegetable Oil & Grease

Catalytic Cracker

VGO Vegetable Oil & Grease

Green Olefins

Catalytic Cracker

VGO

Figure 3. Processing routes for vegetable oils and grease

of vegetable oils and greases were identified and one example is shown in Figure 4, where a pretreatment unit is required to remove catalytic poisons such as alkali metals and other problematic components such as water and solids. The pretreated feed can then be coprocessed with crude to produce gasoline and other products. Furthermore, a modified catalytic cracking process can produce high value products such as ethylene and propylene.

Estimates for each processing option are shown in Tables 3 and 4. Vegetable oil and greases produce gasoline yields very competitive with petroleum crude with reduced yields of heavier and often undesirable products such as LCO and CSO. Such processing also produces a significant amount of water and/or COx as a consequence of feedstock deoxygenation.

Results were similar for olefins production where vegetable oil and greases can produce competitive yields of ethylene and propylene with reduced amounts of gasoline, LCO, and CSO. RON values are slightly higher for processing vegetable oils in both catalytic cracking schemes while coke yields are slightly higher for gasoline production. In either case the use of vegetable oils and greases in catalytic cracking units is feasible and attractive.

VGO

Vegetable Oil/Grease

C2=

1.5

1.9

C3P

0.7

0.8

C3=

4.0

4.5

C4s

7.9

6.5

Gasoline

45.5

44.9

LCO

17.5

11.3 12.7

CSO

19.5

Coke

3.4

4.5

Water/COX (Est.)

0

12.7

RON of Gasoline

92.1

94.8

Table 3. Estimated green gasoline yields

60 EQ INTERNATIONAL JANUARY/FEBRUARY 11

3.2.

Hydroprocessing Vegetable Oils and Greases to Produce Green Diesel

requirements are variable depending on both the degrees of unsaturation on the fatty acid chains and the deoxygenation mechanism which itself depends on the choice of catalyst and processing conditions.

Hydrodeoxygenation produces water and requires one hydrogen molecule for each oxygen removed while decarboxylation removes one carbon to produce CO or CO2. Breaking the triglyceride backbone produces propane or lighter hydrocarbons.

The yield of a high cetane and low sulfurcontent green diesel product is >98% on a volumetric basis.

The use of existing hydroprocessing technology was evaluated for the deoxygenation of Gasoline vegetable oils and greases to produce a paraffinic diesel fuel through two Light olefins promising processing Green diesel is a fully-deoxygenated options. As with catalytic cracking, co-processing paraffinic feed and has several advantages in existing units requires a pretreatment over biodiesel, also produced from vegetable oil, as shown in Table 6. It is produced as unit to remove alkali metals and Light Ends hydrogenate units of unsaturation Gasoline Catalytic VGO on the fatty Cracker LCO acid chains.

CSO The pretreated feed is then fed Vegetable Pretreater to an existing Oil & Grease hydrotreater to Remove alkali metals, solids, and water produce a high cet ane diesel Figure 4. Processing approach for catalytic cracking of vegetable oil and grease produc t.

An alternative is to produce the green diesel in a separate modular unit where processing a high-cetane, straight-chain paraffin but conditions are optimized for the vegetable- its cold-flow properties can be adjusted by oil-based feedstock. This modular unit could the appropriate level of isomerization. The be constructed at an existing refinery or at product cetane number can reach as high as remote locations. The paraffinic product 80-90. Biodiesel, a fatty acid methyl ester could be blended with the hydrotreated diesel (FAME), contains a significant amount of or could serve as a high quality diesel fuel on oxygen that lowers its heating value and its own. This latter approach is attractive contributes to higher NOx emissions for for feedstocks containing high percentages concentrated blends. There are some of free fatty acids or when transportation other differences in product properties of the feedstock is prohibitively high since not identified in the table. The production construction near the feedstock source and of FAME yields a signifi cant amount of the choice of proper metallurgy will solve contaminated glycerol byproduct that needs a commercial outlet while green both issues. diesel produces light hydrocarbons from Performance estimates for a green diesel the triglyceride backbone. The production process are shown in Table 5. Hydrogen of biodiesel requires a less flexible range of vegetable oil feedstock and fatty acids VGO Vegetable Oil/Grease must be removed prior to transesterification.

C2P+Methane 4.1 4.0 Highly unsaturated fatty acids chains result C2= 8.6 8.6 in a less stable biodiesel product since oxidation occurs at the double bonds when C3P 2.0 2.0 stored for extended periods of time. Green C3= 22.0 22.2 diesel has several property advantages over C4s 15.0 13.4 biodiesel and will likely be preferred by Gasoline 27.3 22.7 vehicle manufacturers.

LCO 9.5 4.9 Diesel/ Green Diesel

CSO

5.0

3.0

Coke

6.5

6.5

Water/COX (Est.)

0

12.7

RON of Gasoline

94.8

96.8

Table 4. Estimated green olefins yields

Economic Analyses of Vegetable Oil and Grease Processing Economic comparisons for the various www.EQmag.net

processing options for vegetable oil and greases are shown in Figure 5 and Figure 6. First, a comparison of estimated capital Products Vol % Naphtha

< 1%

Vol % Diesel

>98%

Cetane Number

80-100

ppm S

<10

included and brown grease does not require subsidies to be an economically-viable feed for any of the products, because of its low cost. However, subsidies would have a significant impact on the viability of processing soy-based products.

Refining Opportunities for Pyrolysis Oil

Table 5. Performance Estimates for Green Diesel Process

Fast pyrolysis is a thermochemical process with the potential to convert the large costs is shown in Figure 5. These costs volumes of cellulosic biomass available in the represent U.S.A. Gulf Coast erection to UOP U.S. and globally into liquid fuels and feeds. standards for new equipment on a January A solid biomass feedstock is injected into a fl uidized Biodiesel (FAME) Green diesel bed with high heat transfer %O 11 0 capability for short contact Density g/ml 0.883 0.78 times followed by quenching Sulfur content <10ppm <10ppm to condense a liquid biooil Heating Value (lower) MJ/kg 38 44 in 50-75% yields with gas % change in NOx emission +10 0 to -10 and char forming the balance.

Cloud Point C -5 -5 to -30 The biooil contains the Distillation 10-90% pt 340-355 265-320 thermally cracked products Cetane 50 80-90 of the original cellulose, Table 6. Comparison of Biodiesel and Green Diesel Properties hemicellulose, and lignin fractions present in the 2005, open shop (non-union) labor basis. biomass. It also contains a high percentage The equipment costs have an anticipated of water, often as high as 30%. The total accuracy of -15%/+30%. The estimated oil is often homogeneous after quenching but erected cost (EEC) is a factored cost, which can easily be separated into two fractions, a

Table 7 shows an estimated performance for hydroprocessing pyrolytic lignin to produce biofuels based on experimental results. These estimates were used as a basis for economic calculations. The naphtha and diesel are produced along with a large amount of water and CO2 due to water removal and deoxygenation. As with the vegetable oil the consumption of hydrogen and yield of CO/CO2 will vary depending on the mechanism of deoxygenation.

The economics for producing fuels from pyrolytic lignin are shown in Table 8, assuming $18/bbl pyrolysis oil ($16/bbl +$2/ bbl transportation charges) and two crude oil prices: $40 & $50/bbl.

The value of producing liquid transportation fuels from pyrolysis oil is sensitive to both the price of the crude and feedstock. The sensitivity to feedstock price decreases with increasing crude oil price as shown in Figure 7 where the years required for payback of the capital investment is shown for several different prices of crude and pyrolysis oils. This figure is based on a capital cost of $30 MM for a hydrotreating/ hydrocracking unit producing 1,010 bpd of gasoline. Producing fuel becomes economically attractive for $18/bbl pyrolysis oil at a crude price of $50/bbl. As pyrolysis

200 200

40 40 40 Stand Stand alone alone Pretreat Pretreat ++ Coprocess Coprocess

30 30 30

100 100

$M

$M $M

0

20 20 20

-100

10 10 10 00

-300

Biodiesel Biodiesel

Biodiesel

Green Green Diesel Diesel

Green Diesel

Green Green Gasoline Gasoline

Green Gasoline

Figure 5. Capital costs of biofuels production from oils and greases.

includes installation, associated bulk items (such as instruments, electrical, piping, and civil), indirects, and contractor’s home office expenses. The EEC has an anticipated accuracy of -30%/+50%. The table shows that producing biodiesel has higher capital costs since it requires a more complex processing plant.

Figure 6 summarizes the economic analyses of biofuels and chemicals production from oils and greases comparing the NPV’s of four products as a function of feedstock.

Biodiesel is the least cost-competitive product for any feedstock, due to the high capital cost of biodiesel production. The effects of potential subsidies on NPV are www.EQmag.net

Soy-Unsubsidized Soy-Unsubsidized Soy-subsidized Soy-subsidized Yellow Yellow Grease Grease Brown Brown Grease Grease

-200

Biodiesel

Green Diesel

Green Gasoline

Green Olefins

Figure 6. NPV comparison of biofuels and chemicals 8,9,10,11

water soluble fraction and a heavier pyrolytic lignin fraction. The addition of more water allows the pyrolytic lignin fraction to be isolated and the majority of it consists of the same phenolic polymer as lignin but with smaller molecular weight fragments.

Pyrolytic lignin is a better feedstock for liquid fuel production than the watersoluble fraction because of its lower oxygen content and therefore the study focused on evaluating it as a potential feedstock for the production of highly aromatic gasoline.

Commercial outlets for the water-soluble oil were identified and evaluated, such as the production of hydrogen and as a fuel for power generation. These latter applications will not be discussed here.

oil price decreases, producing fuels from pyrolytic lignin becomes attractive at lower crude oil prices.

Feed

Wt%

bpd

Pyrolytic Lignin

100

2,250

H2

4-5

Products Lt ends

15

Naphtha

30

1,010

Diesel

8

250

Water, CO2

51-52

Table 7. Performance estimates for the production of naphtha and diesel from pyrolysis oil

EQ INTERNATIONAL JANUARY/FEBRUARY 11

61

$40/bbl Crude bpd

$/D

$50/bbl Crude $/D

c ategories included.

are

The results of the analysis are shown in Figure Products Lt Hydrocarbons 64T/D 19,303 23,164 8. In general, the Naphtha 1,010 52,520 62,510 green product s Diesel 250 12,000 15,000 have much lower Other Utilities -4,800 -5,760 total environmental Net 12,843 28,734 impact scores than Annual Value $4.2MM $9.5MM petroleum diesel Table 8. Performance estimates for the production of gasoline and diesel from primarily because pyrolysis oil of significantly Life Cycle Analysis of lower production of Vegetable Oil Processing climate-active CO2. Of the biofuels, green Options diesel and green gasoline (from catalytic A life-cycle analysis (LCA) of the various cracking of vegetable oil) have the lowest vegetable oil processing routes was conducted environmental impact and CO2 production. at Michigan Technological University using The environmental impact of biodiesel production is higher due to the methanol Years requirement which 8 is produced from 7 natural gas through $18/bbl Pyrolysis oil 6 an energy-intensive $14/bbl Pyrolysis oil process with a strong 5 environmental 4 burden.

3 Feed

Pyrolytic Lignin

2,250

40,500

40,500

H2

21.4 T

25,680

25,680

2 1

Summary

Many economically a t t r a c t i v e $40/bbl $50/bbl $60/bbl opportunities were Figure 7. Years to payback for conversion of pyrolytic lignin to gasoline. identified in this study for the integration of biorenewable the SimaproTM LCA program. LCA is a feedstocks and biofuels in petroleum method to determine and compare the refi neries, particularly for two promising environmental impact of alternative products feedstocks: or processes “from cradle to grave”. In this 0

case, the scope of the analysis was from extraction through combustion. For analysis purposes, it was assumed that all fuels have

00 50

• Vegetable oils/greases to produce green diesel, gasoline, or chemicals • Pyrolysis oil to produce green gasoline

Vegetable oil can be processed in the shor t term 50 using commercially available refining 00 t e c h n olo g y b u t will be limited to 50 producing a small fraction of liquid 0 transport fuels due Petroleum Biodiesel Green Green to a limited amount Diesel Diesel Gasoline of feedstock.

Figure 8. LCA – single environmental impact score.

Pyrolysis oil processing requires the same performance in transportation more commercial development and is also use. The primary focus of the analysis was limited by the availability of pyrolysis oil on fossil energy consumption and emission since commercial production is still in its of greenhouse gases, though other impact

Points

00

62 EQ INTERNATIONAL JANUARY/FEBRUARY 11

infancy. In the long term, however, the potential volume of pyrolysis oil could replace shortages in petroleum fuel since it can process the large amount of cellulosic biomass available.

Acknowledgements We would like to acknowledge the U.S. Department of Energy for partially funding this study (DOE Project DE-FG3605GO15085).

References 1. ERBACH, D.C., GRAHAM, R.L , PERLACK, R.D., STOKES, B.J., TURHOLLOW, A.F., WRIGHT, L.L. Biomass as a Feedstock for a Bioenergy and BioProducts Industry: The Technical Feasibility of a Billion-Ton Annual Supply. DOE/USDA, 2005.

2. GREENE, N. Growing Energy: How Biofuels Can Help End America’s Oil Dependence. NRDC, 2004.

3. LYND, L.R. Liquid Transportation Fuels.

World Congress on Industrial Biotech and Bioprocessing, Orlando, FL, April 20-22, 2005.

4. TYSON, K.S. Oil and Fat R&D. Presentation by NREL to UOP, 2003.

5. BOZELI, J., MOENS,L., PETERSEN, E., TYSON, K.S., WALLACE,R. Biomass Oil: Analysis Research Needs and Recommendations. NREL/TP-51034796, 2004.

6. LARSEN, E.D. Expanding roles for modernized biomass energy. Energy for Sustainable Development, 2000, V. IV, No. 3, October 2000.

7. BARCHART.COM WEBSITE, Commodity Fundamentals, Tallows and Greases, http://www2.barchart.com/comfund/ tallow.asp.

8. RADICH, A. Biodiesel Performance, Costs, and Use. Energy Information Administration, 2004. http://www.eia. doe.gov/oiaf/analysispaper/biodiesel/ 9. SCHNEPF, R., STALLINGS, D., TROSTLE, R., WESCOTT, P., YOUNG, E. USDA Agricultural Baseline Projections to 2012, Staff Report WAOB-2003-1, 2003.

10. NATIONAL BIODIESEL BOARD. Tax Incentive Fact Sheet, 2004.

11. ADEN, A. Biodiesel Information for UOP. Memorandum prepared for UOP

by NREL, 2005.

www.EQmag.net

POLICY & REGULATION

Implementation of REC Mechanism in India Rajesh K Mediratta, Vice President, Business development, India Energy Exchange Limited Vishal H Pandya,Director, REConnect Energy Solutions (P) Ltd.

Central Electricity Regulatory Commission (CERC) along with Ministry of Power (MoP) unveiled implementation of Renewable Energy Certificates (REC) mechanism in India on November 18, 2010.

W

ith the formal commencement of this new mechanism, a new market segment has been introduced in India. This paper attempts to bring a holistic perceptive about the implementation of REC mechanism and latest developments surrounding it. This paper also touches upon various other initiatives by Indian Energy Exchange and its role in future REC and Electricity Authority Market in India.

FOR

BACKGROUND Since 1980s, India has taken many cognitive steps for promoting the use of renewable energy in various applications including electricity generation, cooking, heating, water pumping for industrial, domestic as well as commercial applic ations. The growth of investment in renewable energy sources in India has been supported through a host of fi scal incentives and other promotional policies and regulatory impetus provided by key nodal agencies like Ministry of New and Renewable Energy (MNRE), Central Electricity Regulatory Commission (CERC) and Ministry of Power (MoP) and the Govt. of India (GoI).The support for promoting renewable energy sources has been a www.EQmag.net

central theme in many statutory documents like The Electricity Act – 2003 (EA), the National Electricity Policy (NEP), the National Tariff Policy (NTP), the Integrated Energy Policy (IEP) and the National Action Plan on Climate Change (NAPCC). Of these, the most prominent policy support given to promotion of renewable energy was

through NAPCC which envisages mandatory purchase of 5% renewable energy by all the distribution licensees and open access customers for FY 2009-10 at national level under central Renewable Portfolio Obligation (RPO) framework and increase in RPO obligation by 1% each year for next 10 years.

Notification (Regulation/Order/Report)

Timeline

FOR Report on Policy for Renewable (Recommends REC Mechanism)

Nov-2008

MNRE Report of REC Mechanism (Proposes a framework)

Jun-2009

FOR

FOR-Draft model regulation for SERC under section 86(1)e of the Act

Oct-2009

CERC

Draft regulation on Terms and conditions for determination and issuance of REC for RE generation Regulation,2009

Nov-2009

CERC

F on terms and conditions for determination and issuance of REC for RE generation Regulation,2010

Jan-2010

CERC

Designation of a central agency – NLDC

Mar-2010

NLDC

Draft - Procedure/guidelines for accreditation, registration and issuance (Draft)

Mar-2010

CERC

Final detailed procedure under REC mechanism submitted by the Central Agency (NLDC)

Jun-2010

CERC

Determination of Forbearance and Floor Price for the REC framework

Jun-2010

CERC

Draft- Determination of Fee and Charges payable for Accreditation, Registration and Issuance

Aug-2010

MNRE

Indian Energy

Rules and Bye-laws approved by CERC for

Exchange (IEX) introducing REC Market Segment

Sep-2010

CERC

Draft- CERC (Terms and Conditions for recognition and issuance of Renewable Energy Certificate for Renewable Energy Generation) (First Amendment) Regulations, 2010.

Aug-2010

CERC

Final Notification - Determination of Fee and Charges payable – CERC

Sep-2010

CERC

Final- CERC (Terms and Conditions for recognition and issuance of Renewable Energy Certificate for Renewable Energy Generation) (First Amendment) Regulations, 2010.

Sep-2010

CERC

Detailed Procedure for Accreditation, Registration & Issuance – 1st Amendment

Nov-2010

Formal announcement of the commencement of REC Mechanism at National Level (Accreditation begins at state level)

Nov-2010

CERC / MoP

EQ INTERNATIONAL JANUARY/FEBRUARY 11

63

To realize the aforementioned objectives as envisaged in NAPCC, the CERC, in consultation with Forum of Regulators (FOR ), introduced regulation on Renewable Energy Certificates (RECs) to promote generation of Renewable Energy in India.

Salient points of the proposed Regulation and FOR’s recommendation are as follows:

repository and any other function incidental to the implementation of REC Mechanism. Registration with the Central Agency is mandatory to participate in REC mechanism.

Figure 1: Eligibility criteria for an RE Generator to participate in REC Mechanism

• Each State Electricity Regulatory Commission (SERC) to develop mandatory Renewable Portfolio Obligation framework for it’s respective state (As per Sec. 86 (1)(e) of the Electricity Act)

(including peak hours) even if it was injected in off-peak hours

PROCEDURE TO PARTICIPATE IN REC MECHANISM

• Under RPO framework, obligatory entities like distribution licensees, open-access consumers and captive consumers would require to consume certain percentage of their energy from renewable sources of energy (Solar and Non-Solar both) • Obligatory entities can purchase Renewable Energy Certificates (REC) to discharge their renewable portfolio obligation

• Accreditation: An RE generator is required to get accredited from its respective State Nodal Agency (SNA).

As on January - 2011, states like Maharashtra, Gujarat, Chhattisgarh, Tamil Nadu, Kerala etc. have already started accepting application for accreditation. Two biomass projects from Chhattisgarh and one project from Gujarat have already been accredited.

• Registration with the Central Agency: National Load Dispatch Center (NLDC) - Central Agency which is responsible for registration of RE generator, issuance of REC, maintaining accounts and

This initiative triggered series of activities by various other statutory bodies. The same is summarized in the following table.

SALIENT FEATURES OF REC MECHANISM

REC Mechanism: A Glance The most important aspect in the proposed REC mechanism is the eligibility criteria for an RE generator to participate in REC mechanism as this determines which & how many RE generators would be eligible for REC mechanism. Following figure explains the eligibility criteria for RE generator to participate in REC mechanism.

Participation

Voluntary

REC Denomination

1 MWh

Validity

365 Days after issuance

Categories

** - Banking becomes promotional if the RE generator gets to utilize the banked energy at any time

Response from various states on REC In compliance with the various provisions mentioned above, SERCs across the states have undertaken initiatives for promoting RE generation through renewable portfolio standards and other promotional policies related with feed-in tariff, access to transmission for RE projects, wheeling and banking facilities etc. Following table shows a glimpse of some of the latest modifications in state level RPOs specified by respective SERCs in accordance with model guidelines issued by FOR.

1. Solar REC

Trading Platform

Power Exchanges only

Banking

Not Allowed

Borrowing

Not Allowed

Transfer Type

Single transfer only, repeated trade of the same certificate is not possible

compliance

* - Wheeling becomes promotional if a captive consumer is paying lesser wheeling charges than equivalent open access consumer

• Trading of RECs: RECs shall be traded only through Power Exchange and not in any other manner. As per the approved Business Rules, RECs will be traded on every last Wednesday of a month.

2. Non-Solar REC

Penalty for Non-

Price Guarantee

‘Forbearance’ Price (Maximum Price) •

Non-Solar REC: 3900 Rs/REC

•

Solar REC: 17000 Rs/REC

Through ‘Floor’ Price (Minimum Price) •

Non-Solar: 1500 Rs/REC

•

Solar: 12000 Rs/REC

Price Discovery

As per Power Exchanges’ Business

Mechanism

Rules for REC

64 EQ INTERNATIONAL JANUARY/FEBRUARY 11

• I s su an c e of REC: Within three months from electricity generation, an RE producer shall apply to Central Agency for issuance of RECs in its account. Upon verification of actual electricity generation from respective SLDC, Central Agency, within fifteen days of application, shall issue RECs into applicant’s account.

* All data as on January 24, 2011.

From Table.1, it is apparent that almost all the SERC have acted very progressively and proactively in implementing REC mechanism and RPO framework in their respective states. Further, in almost all the states, RPO has been made compulsory with heavy legal penal provisions on the defaulters.

This aspect is very important for REC market development point of view as this will ensure demand side participation which as of now every stakeholder is skeptical about. www.EQmag.net

State

Status of Regulation

2010 RPO Obligation*

RPO on CPP?

RPO on OA Users?

Penalty ?

Andhra Pradesh

-

-

-

-

-

Assam

Draft

1.35% + 0.05%

Yes

Yes

Yes (RECmax)

Bihar

Final

1.25% + 0.25%

Yes

Yes

Yes (RECmax)

Chhattisgarh

Draft

4.75% + 0.25%

Yes

Yes

Yes (RECmax)

Delhi

-

-

-

-

-

Gujarat

Final

4.75% + 0.25%

Yes (>5MW)

Yes

Yes (RECmax)

Haryana

Draft

1.25%

-

-

-

Himachal Pradesh

Final

10% + 0%

Yes

Yes

Yes (RECmax)

J&K

Final

1%

-

-

-

Jharkhand

Final

1.75% + 0.25%

Yes (>5MW)

Yes

Yes (RECmax)

Karnataka*

Draft

9.75% / 6.75 + 0.25%

NA

NA

To be determined by State Commision

Kerala

Final

2.75%

Yes

Yes

Yes (RECmax)

Madhya Pradesh

Final

0.80% + 0%

Yes

Yes

Yes (RECmax)

Maharashtra

Final

5.75% + 0.25%

Yes

Yes

Yes (RECmax)

Meghalaya

-

-

-

-

-

Orissa

Final

4.5% + 0%

Yes(>5MW)

Yes

Yes (RECmax)

Punjab

Draft

-

Yes

Yes

Yes (RECmax)

Rajasthan

Final

8.5% + 0.25%

Yes

Yes

Yes (RECmax)

Tamil Nadu

Final

13.75% + 0.25%

Yes

Yes

Yes (RECmax)

Tripura

Draft

0.9% + 0.1%

Yes (>5MW)

Yes

Yes (RECmax)

Uttarakhand

Final

4% + 0%

Yes

Yes

Yes (RECmax)

Uttar Pradesh

Final

3.25 %+ 0.25%

Yes

Yes

Yes (RECmax)

West Bengal

Final

2% + NA

NA

NA

REC not recognized

JERC for Goa and UTs

Final

0.75% + 0.25%

Yes

Yes

Yes (RECmax)

JERC for Manipur and Mizoram

Final

1.75% + 0.25% (Man) 4.75% + 0.25% (Miz)

Yes

Yes

Yes (RECmax)

Nagaland

Draft

14.75% + 0.25%

Yes

Yes

Yes (RECmax)

Table 1: Response of SERCs towards REC mechanism and RPO

Implementation of REC Mechanism

The Way Forward The Electricity Act in 2003 envisaged open access for 1 MW and above category electricity consumers and the same got realized very long wait of almost 7 years and that too, after inception of Power Exchanges.

REC mechanism involves four stage processes starting from accreditation to trading. Following ďŹ gure illustrates tentative timelines for each stage of REC mechanism. In this, Accreditation and Registration are one time activity and requires good amount of paperwork. Considering the preparation time for application and specified timelines in CERC guidelines for Accreditation and Registration, as per conservative estimate, Figure 2: Timeline for REC Mechanism getting RE project registered at Central level may take about 1.5-2.5 Compared to that, REC mechanism has picked months time. Issuance and Trading are up a tremendous pace and speed from the routine activities where trading would be conceptualization to actual implementation. carried out on a monthly basis at power This has been possible only because of honorable CERC and SERCâ&#x20AC;&#x2122;s prompt and exchange platform. www.EQmag.net

positive response towards the mechanism.

Various other statutory bodies like NLDC, FOR, MoP and MNRE have also come together and have provided a very strong support for the mechanism. Even though few states have started with the mechanism, the REC mechanism is still at its nascent stage of development as many other states are yet to start accreditation process. Further, as RE generators are small in size (MW capacity) and large in number, this need lot of market awareness activities and stakeholder sensitization programs by trading platforms like IEX and service providers like REConnect to bring all the stakeholder together and make the mechanism a success.

EQ INTERNATIONAL JANUARY/FEBRUARY 11

65

“Plasma Gasification Technology Has Immense Potential” “Delivering comprehensive energy solutions to develop, build and operate competitive, net zero emission bio-energy plants that deliver base load power, SAIP is a next generation renewable energy production company that works in a win-win partnership with municipalities, local governments and a full ecosystem of partners,” said Rajeev Sharma, CEO Solena ABSi India Private Limited (SAIP).

In an interview with EQ International, Sharma also elaborated upon the plasma gasification and vitrification technology.

EQ : What is the “Indo-US agenda for Co-Creation”?

“The Indo-US agenda for co-creation is formulated to engage and encourage small and medium sized companies from India and the United States to cooperate in a mutually

build and operate net zero emission bio

ABSi Corporation. SAIP was formed in

energy plants, SAIP is a next generation

2008 to bring clean, renewable energy to

energy production company that works

the communities of India. ABSi leads SAIP’s

in partnership with municipalities, local

efforts and has had a presence in India since

governments and a full ecosystem of

2006.”

partners.

beneficial manner. Specifically, small and

“Using proven, patented plasma gasification

medium sized companies are taken into

and vitrification technology, SAIP

EQ : What are the key benefi ts of SAIP’s solutions?

converts all forms of biomass into clean,

“SAIP’s renewable energy solutions allow

renewable energy and fuel with neutral

for an adaptable business model that

carbon emissions. Feedstock from biomass

accommodates a wide range of energy

and other organic wastes provide a distinct

requirements, whether urban or rural. SAIP

advantage for businesses, industries,

can deploy either large, centralized power

utilities and municipalities seeking to

plants for municipalities generating “multi-

produce consistent, base load power both

hundreds” of megawatts of electricity derived

economically and efficiently.

from biomass and inorganic waste such as

energmarketplace in India. Delivering

“SAIP is a joint venture of two United States

municipal solid waste or agricultural waste,

comprehensive energy solutions to develop,

based companies—the Solena Group and

or scaled down energy power plants in a

consideration because they are innovative in nature and have immense capabilities as well as profit and growth opportunities.”

EQ : Could you please explain about SAIP’s activities?

“SAIP is actively engaged in bringing innovative solutions to the renewable

66 EQ INTERNATIONAL JANUARY/FEBRUARY 11

www.EQmag.net

the process is the use of plasma that is produced in a controlled environment (using plasma torches developed by NASA in the US) and is able to generate temperatures up to 5,000 degrees C . At these extreme temperatures in a partially deprived oxygen reactor, there is no combustion but complete molecular dissociation of all organic compounds and thus its conversion into a bio-syngas. This bio-syngas can be used to produce electric power (BioPower) and second-generation liquid bio-fuels using the well-established Fischer Tropsch method.

“Regardless of the type of biomass sources used, there is no negative impact on the environment.

Compared to conventional coal-fired and other fossil fuel power plants, SAIP’s plasma gasifi cation solution produces no air pollutants such as SVOCs (dioxins/furans), no toxic fumes, no heavy metals, no hazardous ashes, no bottom ash or fly ash Rajeev Sharma, CEO Solena ABSi India Private Limited (SAIP) with US President Barack Obama

distributed, decentralized grid configuration

sharing. SAIP’s strategic partners and team

with plants as small as 2 MW.

of experts provide a complete solution for

“SAIP can also deploy captive power generation systems to replace conventional, legacy sources of energy. An example of a captive system would be heavy industry, such as a steel plant, using biomass-based renewable energy to replace coal or natural gas to produce electricity.

all stages of the project development cycle from conceptual design to plant operations and maintenance. SAIP’s technical team

or flue gas as do incinerators or boilers. SAIP’s technology is a viable, cost-effective way to meet today’s rigorous permitting regulations and to reap the environmental, societal and economic benefits of combating global climate change.”

brings experience and expertise in the design, building, and operating of renewable energy facilities to each and every one of SAIP’s projects to ensure reliable, efficient and safe production of bio-energy.

EQ : On which projects is SA IP working?

“SAIP is working on five projects currently.

“Our smaller systems represent a significant

It has recently come into agreement with

paradigm shift where energy generation

North Delhi Power Limited (NDPL) to

consumed. These smaller systems are ideal

EQ : What is plasma gasifi cation and vitrifi cation technology?

for rural communities where access to the

“Plasma gasification and vitrification (SPGV)

energy grid is limited or unavailable.

is the advanced technology that SAIP uses

“SAIP focuses on delivering this range

to produce power through an Integrated

of solutions in a dynamic Partnership

Plasma Gasification and Combined Cycle

Engagement Model. In this model, SAIP and

(IPGCC) system by the gasification of

it’s ecosystem of partners can also engage

waste streams, such as biomass, urban or

municipalities in a Public Private Partnership

industrial and agricultural waste, and even

and deliver benefits such as equity or revenue

tires, discarded plastic and e-waste into a

is localized to areas where the energy is

produce up to 40 MW of clean renewable energy, using SAIP’s patented plasma gasification bio-energy solution, into NDPL’s distribution network of North and Northwest Delhi. It is also working on a Bio Jet Fuel production project with British Airways. The other projects in hand include: a 240-MW plant in a large US city, five 40-MW plants in the Western US, and 90-MW plants in two major European cities.”

synthetic fuel gas (bio-syngas).The key to www.EQmag.net

EQ INTERNATIONAL JANUARY/FEBRUARY 11

67

CONVENTIONAL POWER

Rejuvenating India’s Thermal Power Plants With Integrated Retrofit Solutions Martin Lord, Sam Saimbi, Mike Davies-Alstom Power, UK

India has plans to significantly increase its generating capacity. A portion of this additional generation is expected to come from the modernisation of existing installations to increase power output. Alstom’s experience in integrated renovation and modernisation of thermal plants could play a major role.

I

ndia currently has an installed generating capacity of more than 152,000 MW. However, power demand continues to grow and shortages in energy and peaking requirements continue to plague the country.

The government has embarked on an ambitious plan to add 78,700 MW during the 11th Plan (2007-2012) and 94,431 MW during the 12th Plan (2012-2017).

With the high investment requirement in green fi eld power stations, resource constraints and environmental concerns, there is also an urgent need for optimal utilisation of existing generating capacity.

Many of India’s thermal power plants have outlived their normal life and are not operating at their full potential. Renovation and modernisation (R&M) and life extension (LE) of existing power plants is therefore considered an economical option.

In addition to improving generation and providing life extension, other benefi ts of R&M include improvement in environmental emissions and improvement in availability, reliability and safety.

A large number of 200/210 MW units are at the end of their normal design life. The potential for enhancing their rated capacity by 4 to 8 per cent and efficiency by 5 to 10 per cent is significant.

Integrated solutions Alstom has developed fully integrated 68 EQ INTERNATIONAL JANUARY/FEBRUARY 11

solutions for life extension that have the potential to achieve efficiency improvement and greater reliability for fossil fired power stations.

Integrated retrofit solutions differ from the traditional (component) retrofit approach in two key areas.

Firstly they address the whole plant or sections of the plant with the optimum combination of service, retrofit and new

Alstom has developed fully integrated solutions for life extension that have the potential to achieve efficiency improvement and greater reliability for fossil fired power stations.

equipment solutions within existing plant constraints.

Secondly they are not constrained to a specific outage or investment window but can be engineered to span several years, optimised to provide the highest return over the life of the plant. This allows capital expenditure to be phased-in over time while ensuring equipment specifi cations

are developed, technically optimised for equipment installed through the duration of the project.

At one plant in South Africa, Alstom identifi ed an economic solution for life extension, which also increased the capacity of each of the six units from 350 MW to 400 MW. Four of the six units have been successfully upgraded and have exceeded guarantees.

Initial assessments A critical success factor for R&M projects is thorough preparation in the early project development phase. Clearly extensive rehabilitation work in existing plant poses very specifi c risk concerns which, unless adequately understood and countered, could result in extended outages and substantial cost overruns for both supplier and operator.

In the worse case, this could lead to a supplier blackout and a market breakdown.

To ensure therefore that this critically important but nascent market is allowed to evolve, it is essential that risk mitigation measures are jointly developed by supplier and customer in advance, and that commercial risks are intelligently apportioned and managed between the parties.

Alstom has developed integrated solutions for R&M and life extension of these units covering risk mitigation and performance enhancement methodologies assessed over www.EQmag.net

the entire spectrum of power equipment: boiler, turbine, generator, turbine auxiliaries, boiler auxiliaries, instrumentation and control and balance of plant.

Plant Risk Assessment (PRA) The PRA methodology evaluates risks, which can reduce availability and performance and impacts revenue generation. Based on a plant survey in conjuction with plant operation and maintenance staff, the tool combines expert knowledge and known damage mechanisms in a customised Failure Modes and Effects Analysis (FMEA) framework.

Each area of the plant is assessed. This typically takes three to five days, and the risk exposure calculated in terms of lost generation, personal injury, environmental impact and cost of repair. For each risk the main drivers have been identified, e.g. design, age and condition of plant, maintenance strategies and personnel.

As such, root causes can be quickly identified. The scoring system provides a basis to compare different areas of the plant, boiler, turbine, generator, BOP, etc on a common platform. As a reduction of risk in one area can be compared to another, the

analysis of any steam turbine cycle. The core of the system is a robust simultaneous solver for non-linear equations that, in combination with calculation elements, provides an extendable tool for meeting current and future needs. Calculation elements are provided for steam turbines, condensers, feed heaters, motors, pumps, generators and other cycle components and can be customised to allow accurate modelling of any steam cycle.

A special strength of the ALPRO system is that a model can be created in ‘design mode’ and calibrated to accurately reflect either the original design performance of an existing cycle, or more usefully, the performance of an existing cycle as determined from recent test data. Such a model can then be run in ‘off design’ mode to predict how the cycle will perform under different operating conditions and/or with some components (e.g., steam turbines) replaced by modern, retrofitted components.

Using the ALPRO system in this manner permits rapid optimisation of an overall cycle retrofit solution.

Similarly, the Alstom proprietary Reheat Boiler Performance Programme (RHBP) is used to evaluate both the present and future operating conditions of the boiler.

process of boiler and turbine integrated optimisation can begin.

Turbine retrofit High pressure turbine. Over and above life extension, reliability and maintenance, an HP turbine retrofit can increase the efficiency of the cylinder leading to increase overall output and effi ciency. This improvement may also be combined with an increase in the main steam flow to further increase output.

Further improvements may be obtained by eliminating the risk of solid particle erosion by the application of state-of-theart blading technology and by changing the mode of operation by going from partial arc to full arc for plants which are base loaded. By changing from partial to full arc, an additional benefit in heat rate of the order of 0.1 - 0.2 per cent can be achieved.

Conversion to full arc operation might also be of interest for cycling units if the unit can be operated in a sliding pressure mode and the load range is above 85 per cent of maximum continuous rating (MCR).

When increasing steam flow, the redesign of the flow passing capacity of the HP turbine in conjunction with a boiler analysis can also be used to minimise carry-over and thus improve performance and reliability of the plant.

Boiler reheat operation. Reheat temperature is very important both from a heat rate and power consideration. A change in hot reheat temperature affects power considerably more than the same reduction in main steam temperature.

Typical 200 MW Machine of Russian OEM Design

best return for a given investment can be evaluated.

It can be used to model both Alstom and non-Alstom boilers.

This methodology provides a high level quantative assessment of the plant without any disruption to operation. It compliments other tools by quickly providing an overview of the complete plant condition and the basis to prioritise investments for the best return prior to detailed engineering analysis.

When steam turbine modifications are being considered, the effects on the boiler operation must be accurately modelled so that the full benefit of the steam turbine changes can be realised.

Holistic plant analysis Thermal optimisation. The Alstom proprietary turbine cycle programme (ALPRO) enables thermodynamic performance prediction and

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To accomplish this, current, accurate plant and boiler operating data is needed to properly calibrate the RHBP. Note that all intermediate steam and water temperatures are an essential part of this calibration process. Once the RHBP is calibrated using recent test data, the new steam turbine conditions can be input and the iterative

Increasing HP turbine efficiency results in a decrease in exhaust temperature (cold reheat). The effi ciency increase through an HP turbine retrofit would typically drop the cold reheat temperature by 8 – 11°C. In order to maintain hot reheat temperature at design levels, extra heat has to be added in the reheater and it is often necessary to redesign or add reheater surface.

It is this additional heat added (in the region of 3 - 4% above the existing reheater duty that contributes to the power advantage of HP retrofitting. If reheater spray water is being used then the amount of water required (assuming no other operational or plant changes) will reduce, further improving heat rate.

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69

Low pressure turbine. Modern LP turbine designs offer significant efficiency improvements over existing designs due to the application of state-of-the-art Computational Fluid Dynamics modelling in blade design.

These models take into account the complex

steam temperatures. The retrofit welded LP rotor design eliminates stress corrosion cracking.

The free-standing last stage blade eliminates the problems caused by damping wires and satellite, with significant

three-dimensional behaviour of the steam

performance improvement over the existing

flow. Particularly large improvements can

Baumann stage. This is achieved with a

be made by replacing inefficient Baumann

signifi cant reduction in scope compared

stages or last stages utilising lacing wires

to the full module solution, removing the

with modern, free-standing last stage

requirements for the new gland steam

blades.

system, turbine drains modifi cation, HP

Typical retrofit solutions

Stator Bar Connection

all issues and most complete life extension.

and IP steam chests and other auxiliary equipment.

When considering the turbine plant, an

This calls for an extensive retrofit scope in

Renovation and modernisation is a key

existing 200 MW Russian designed unit

addition to the turbine modules themselves.

requirement of the Indian power sector and

can be used to provide examples of typical

The scope includes:

successful implementation requires the use

retrofit solutions.

Typical issues with these machines are: • Highly stressed HP and IP rotating blade stages that can reduce their lifetime • Shrunk-on-disc IP last stages and

• New gland steam system

risk mitigation methodologies. The critical • Turbine drains modification

task of risk mitigation also requires an open

• New turbine controller

dialogue between supplier and operator.

• HP and IP steam chests and actuators

LP rotor with high stress level in the

• New control oil unit, new jacking oil

hub region causing stress corrosion

system, lube oil modifications including

cracking

main oil pump

• Baumann stage with very low efficiency • Damping wires and stellite coating on LP rotating blades that can break free, thus damaging condenser tubes and necessitating plant outages

• New turbine pedestals • Minor foundation modification to accommodate steam admission system Minimum cost solution: Alstom has developed a re-blade solution for this type of machine re-using the existing rotor,

• Single shell HP & IP casings, which lead

casings and blade carriers, which with the

to high thermal stresses, hence reduced

application of modernised blading technology

lifetime and extended start up times

with integral shrouds and improved sealing

• Low cycle fatigue cracking of the HP & IP casings and valve chests • Gland steam system design with second gland steam condenser, which leads to high thermal stresses on the ‘hot’ sides of the HP & IP end glands

surpasses the effi ciency of the original equipment and addresses life extension of the highly stressed blading.

Economically optimised solution: Where a plant runs typically in a base load environment, the low cycle fatigue cracking is less of a problem, and therefore a suitable

• Lack of check valves at HP exhaust

solution could be an inner block retrofit for

• Control system that does not meet

the HP and IP cylinders. In the majority of

current requirements

life extension applications across a range of power plant sizes, an inner block retrofit is

Alstom has a range of solutions to suit

the most economic solution.

this type of machine, depending on the plant operator’s drivers and budget.

This gives equivalent efficiency benefit to the full module replacement, with full

Best technical parameters: A full module

life extension of rotors, blading and inner

turbine retrofi t would achieve the best

casings, which are the prime concern for

technical parameters i.e. highest efficiency,

creep life limitation as they are highly

maximum service interval, rectification of

stressed and subject to the main and reheat

70 EQ INTERNATIONAL JANUARY/FEBRUARY 11

of dedicated tools, processes, experience and

To exploit the full potential of existing equipment, it is not sufficient to just optimise the components on an individual basis. It is necessary to take a systematic and holistic approach and look at the complex interaction between key components and assess how best to deliver an optimised, integrated solution.

Piecemeal modifi cations in various subsystems is benefi cial only if technical optimisation has been carried out beforehand and the subsystem installation is conducted behind a detailed and carefully constructed installation plan, taking account of all other works. Otherwise, sub-optimised solutions may result.

To maximise the benefits of the integration process, plant operators should interact with suppliers early in the development of the project and prepare a request for quotation (RFQ) in a manner suffi ciently open to enable suppliers to optimise their offer. It is also important that sufficient preparatory work and plant information is made available for suppliers to bid confidently.

With its and rich experience in R&M thermal plants, Alstom is well positioned to play an effective role in India’s plans to meet its generating capacity targets.

www.EQmag.net

IT IN POWER

Power Plant Optimization – Realizing Bottomline Improvement And Improving Carbon Footprint Deepak, Konnur.VP solutions, IBM India/South Asia

World Energy Council notes the following - “The challenge is both to improve the performance of the existing generating plant stock and to build enough – but not too much – new generation and transmission capacity to meet growth in demand”

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hermal power plants continue to be the major source of power generation in India and many other developing countries. This will continue to be so for the next decade or two especially in India since the renewable penetration and nuclear will indeed take time, and for technologies to mature to store, dispatch and integrate renewable into the grid. However, shrinking fuel resources, CO2 pressures and volatile fuel prices have forced everyone in the sector to minimize the cost of power generation without compromising on the productivity.

Maximizing the efficiency with which the

fuel is converted into electricity has become very critical. Therefore, today the power sector strategy has shifted from “Generation Maximization” to “Performance optimization & Generation maximization”.

If India has to achieve per-capita power consumption comparable to that of developed www.EQmag.net

countries or even catch up with China, one of the key goals that would accelerate our journey would be improving effi ciency in generation, transmission and distribution.

Performance Monitoring is Critical Equipment performance of power plants or any process industry degrades with time and due to the influence of the operating environment. If left unattended, the system performance and the operating efficiency continuously deteriorates, thereby resulting in higher operating cost and higher emission and CO2 impact. Hence it is important to monitor the plant performance continuously, correlate historical data, design curves and the current performance metrics to understand the operating efficiency level, decrease the risk and cost of new and complex capital-intensive construction projects, decrease schedules, and facilitate operational excellence.

By monitoring the equipment performance and other parameters, and analysing using mathematics models or input/ output methods the performance can be monitored and deterioration or deviation from operating curves can be identifi ed and alarms and operator intimation and maintenance planning can be scheduled to retain the performance characteristics.

Conventional Performance Monitoring Conventional performance monitoring focussed on the plant in isolation and aimed at optimizing or improving performance of the primary and auxiliary equipments. The software systems were point solutions that were mainly supplied by equipment vendors or engineering design companies. However these tools always looked at the system in isolation.

Plant performance monitoring, analysis, diagnostics and optimization, was a set of tools that enabled power plant operations personnel to have in-depth understanding of current operations and provided insight into areas for improvement.

Energy Markets, ABT and Plant Performance – An Integrated Approach to Plant Information Management, Efficiency Improvement and Analytics In India with Energy Markets, ABT Regime and day ahead and spot markets coming into play, it is important that these requirements also get integrated into the conventional power plant performance system. To achieve this, it is important that one integrates the conventional plant performance system as part of a larger generation control center and enterprise business analytics play.

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71

• Middleware

Key plant performance monitoring functions Include: • Efficiency calculation of primary & auxiliary equipments in a power plant • Identify equipment degradation and controllable losses • Define key performance Indicator linked to plant efficiency and monitor online • Heat b alan ce analysis validation of process data and accounting of instrumentation errors • Overall p ower plant performance & expected performance • Impact & what if analysis on plant performance • Semantic models of plant equipments and connectivity • Seamless Integration with plant control & monitoring sys tems like DCS / DAS systems To achieve this, it is important that the overall value proposition is defined within the overall digital plant structure and where the generation optimization, plant information management and analytics are integrated with dash boards at various operational to board level giving insight into the operations, and alarms when any of the key performance parameters go off-track.

• Real Time Data Acquisition from Plant Control System and Auxilliaries Real-time data acquisition of fi eld data from all the control system, auxiliary equipment and sensors is the first critical step in implementing real-time solutions.

The interfaces to acquire data include field protocols like Modbus, Profibus, Profinet, OPC and in select cases native drivers to the devices or the control systems are built.

• Time Series Historian This would be the central data store for the solution, complemented by the RDBMS. The time series historian should be scalable, robust time series historian on a distributed platform to ensure storage and retrieval of process information with 100% fidelity and high performance.

• Deci sion Support System Decision support system would be the central component of the performance monitoring & analysis solution.

72 EQ INTERNATIONAL JANUARY/FEBRUARY 11

Middleware enables to integrate the multiple applications, enables scalability and provide for CIM/XML Model based exchange.

• Asset Management There is overwhelming historical evidence that power generation companies can reduce operating expenses, optimize capital, enhance earnings and significantly reduce operational risk by implementing a comprehensive Enterprise Asset Management (EAM) program. EAM gives utilities that ability to: o Standardize data formats o Integrate data across systems and operations o Obtain an enterprise-wide, portfolio viewpoint of their assets o Analyze, optimize and balance financial investment with operational excellence The asset management solution areas would be reliability centred maintenance, condition monitoring, integrated supply chain, work management.

Performance Calculation covers up following set of equipments and more • Heat Recover y Steam Generators • Economizers • Super-Heaters • Evaporators • Steam Turbine • Heat balance analysis • Boiler • Heat balance analysis • Gas Turbine • Heat Balance Analysis • Engines • Hydro Turbine • Condenser • Feedwater Heater • Deaerators • Air Heater • Pump • Cooling Tower

Analytics Business Intelligence and performance management empowers decision making and improved business performance through the timely access, analysis and reporting of actionable, accurate, and personalized

information. Advance analytics and optimization enhances organizational performance by applying advanced mathematical modelling, deep computing, simulation, data analytics and optimization techniques to improve operational efficiency.

Power plant efficiency monitoring and an integrated architecture enable generation companies to achieve bottom line impact, while achieving green objectives. From a conventional approach of isolated silo’s of pure plant effi ciency to an integrated approach of a Digital Plant provides utilities with enhanced visibility into operations, regulatory compliance and bottom-line impact.

Deepak Konnur, Vice President Solutions, Energy & Utilities Industry, IBM India Pvt. Ltd. is responsible for driving growth in Intelligent Utility Network, Business, Infrastructure and ISV solutions for all E&U accounts in India to bring IBM’s innovative technology, services and solutions to the energy industry.

Deepak has 28 years of international experience in the electricity sector in diverse functions such as feasibility studies and formulation of power system master plans, project planning, project appraisal, project execution and contract management, utility restructuring, commercialization and utility management, power regulation, distribution automation, energy economics and energy efficiency, HR policies, competency evaluation, training and change management, construction, operation and maintenance of large power transmission and distribution systems.

Prior to Joining IBM in March 2007, Deepak was working with North Delhi Power Ltd. (Joint venture of TATA Power) as Head of Group, Information Technology (CIO) & had also had a long stint in MSEB. Deepak is an Electrical Engineer and has done post graduation in Business Administration.

Deepak is a Qualified External Assessor for TBEM (Based on Malcolm Baldrige Business Excellence Model) Deepak has keen interest in high altitude trekking, photography and traveling.

www.EQmag.net

IT IN POWER

DIgSILENT Power System Analysis Software Rajshekharan, Power Systems Consultant, KLG Systel

DIgSILENT has set standards and trends in power system modelling, analysis and simulation for more than 20 years. The proven advantages of PowerFactory software are its overall functional integration, its applicability to the modelling of generation, transmission, distribution, industrial systems, power plants as well as marine and aerospace Industries.

P

owerFactory is the ideal tool for studying the grid integration of new generation-technologies. It is easy to use, fully windows compatible and combines reliable and flexible system modelling capabilities with state-of-the-art algorithms and a unique database concept.

Besides, the stand-alone functionality, the Power Factory engine integrates smoothly into any GIS, DMS or EMS supporting open system standards.

PowerFactory Applications Power Transmission PowerFactory offers a complete suite of functions for studying large interconnected power systems integrating new technologies for power generation and transmission such as wind generation, virtual power plants, HVDC-VSC or FACTS. The fast and robust load flow algorithm can be applied to any

74 EQ INTERNATIONAL JANUARY/FEBRUARY 11

AC or DC network topology. It uses highly accurate models including various types of

security, stability and economics of complex power transmission systems.

Typically required functions include: • Load flow/Contingency analysis/OPF

PowerFactory offers a complete suite of functions for studying large interconnected power systems integrating new technologies for power generation and transmission such as wind generation, virtual power plants, HVDC-VSC or FACTS.

• Nodal price and marginal cost indices • Short circuit analysis (IEC 60909, ANSI C37, multiple fault analysis) • Reliability assessment • Integrated stability and transient (EMT) simulation • Small signal stability analysis, also for very large networks • Transmission system protection coordination and simulation • In t er f a c e s t o SCADA / En er g y Management Systems Power Distribution

MW and Mvar-controllers. Power Factory’s functions can be applied to improve the

Different phasing technologies, such as single-wire earth return, two-phase, biphase or classical three-phase systems, www.EQmag.net

have created a need for multi-phase distribution system modelling. PowerFactory provides the most comprehensive modelling features for studying all kinds of phasing technologies, meshed or radial topologies and railway supply systems connected to public distribution systems. In order to reduce network unbalance, improve quality of supply and optimize distribution networks, PowerFactory offers a large variety of functions, such as multi-phase load fl ow analysis, short circuit analysis (IEC 60909, ANSI C37 and multiple fault analysis), harmonic analysis, time-domain simulation and reliability assessment. Other standard features include the modelling of distributed generation and virtual power plants, voltage drop analysis, branch loading calculation, daily load curves and the consideration of LV load diversity. This is complemented by an easy-to-use protection coordination wizard.

Other important aspects are: • Open tie optimization • Optimal capacitor placement • Cable reinforcement strategies • Quality of Supply Analysis • Geographic Information Systems (GIS) • Network Control Systems (SCADA)

Industrial Systems Industrial power systems supplying refineries, paper-mills, car factories or other plants with high power quality requirements benefit from high precision PowerFactory load flow www.EQmag.net

algorithms, short circuit calculation features, 4-wire modelling, harmonics analysis and filter design options.

Other relevant functions include: • Motor starting, voltage sag analysis and plant re-acceleration • Protection coordination and settings verification • Stability analysis and electromagnetic transients

Distributed Generation Generation at distribution levels defines entirely new challenges for distribution planning engineers due to reverse power flows, voltage drops and extreme variations in equipment loading. Various generation technologies are possible, such as synchronous and asynchronous cogeneration units, PV-cells, wind turbines, fuel cells and micro-turbines. Typical studies include steady-state and dynamic analyses, taking into consideration time-varying correlated or un-correlated energy sources.

PowerFactory is the ideal tool for analyzing the impact of distributed generation on the network. It combines classical distribution system analysis functions such as voltage drop calculation, unbalanced network, load and generation modelling, selectivity analysis, etc. with the power of a highly modern analysis tool featuring dynamic simulation functions and reliability analysis.

Full support is available for developing and analysing the impact of virtual power plants and new control techniques on distribution networks.

Wind Generation Complex studies for the integration of wind generation into distribution and transmission networks are becoming increasingly important. PowerFactory, the de-facto standard in wind generation modelling, combines extensive modelling capabilities with advanced solution algorithms, providing the analyst with tools to undertake the full range of studies required for grid connection and grid impact analysis. The modelling capabilities of PowerFactory allow the inclusion of complex control dynamics, new generator technologies, blade control and wind turbulence.

Detailed wind turbine models • Doubly-fed induction generator models (DFIG) • Converter driven synchronous machine models (CDSG) • Squirrel-cage induction generator models • Manufacturer-specifi c high precision model with built-in control code • Power electronic devices and grid harmonic analysis • Generator protection and Crow Bar modelling • Blade control • Wind turbulence and gust models • Stability and EMT analysis • Integrated modelling of large wind parks

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75

ENERGY OVERVIEW

The Indian Energy Sector Likely To Quadruple By 2020 Surjit Mohapatra, Lucintel

The consumption of energy in India has grown steadily over the past several decades, with the exception of the last two years of economic slowdown. Per capita energy consumption in India is still very low in comparison to that of the United States or China.

I

f India’s gross domestic product grows at 8 percent per annum, the per capita energy consumption is likely to grow at a higher rate.

All economic activities depend upon the availability of a number of energy streams, which are converted into various economic outputs. Thus, economic output heavily depends on the available energy sources in nature and the sources of technology available to convert that energy into a form that can be used to produce goods and services. All other factors of production, such as capital and labor, play a supportive role in this conversion, directing and amplifying energy to produce those goods and services.

Before the eighteenth century, all economies derived their energy primarily from organic, non-renewable sources and the growth of those economies depended on the supply of those various sources of energy. Today, economies are still dependent on the supply of energy, but the sources of power have grown to include renewable energy sources, such as Wind Energy, Solar Thermal Energy and Solar Photovoltaic Energy.

Lucintel’s new market study, “Indian Energy Sector: Macro-Economic & Risk Analysis-Risk, Potentialities and Opportunities”, analyzes and identifies India’s energy sector and outlines its areas of opportunity in the coming decade.

India’s coal production is expected to grow at a CAGR of 4% from 2009 to 2020. The natural gas sector has gained increased importance in India, especially over the last decade. The share of natural gas in the energy mix for India is expected 76 EQ INTERNATIONAL JANUARY/FEBRUARY 11

to be approximately 25% by 2025. The oil segment is also a major contributor of the primary energy mix. India already imports over 75% of its crude oil requirements.

Energy consumption from all sources is expected to increase signifi cantly in the coming years. According to Lucintel’s analysis, the Indian energy sector is likely to grow fourfold by 2020. The Working Group on Power for 11th Five Year Plan (2007-12) has estimated a total investment of $170 billion in the Indian electricity sector.

During the nineteenth and twentieth century economic growth was basically driven by technology, though energy played a major role. Now, in the age of science and information technology, the world is once again exploring alternative sources of energy and trying to manipulate various energy sources to produce economic outputs. Availability of energy is the key to sustaining economic development. The availability of commercial energy has a direct impact on the quality of services in the fields of education, health and food security. Macroeconomic health of a country requires long-term supplies of energy that are reliable, sustainable and affordable.

Looking at the Indian economic scenario, the Indian economy continues to sustain high growth momentum as the real GDP picked

up in the year 2010-11. As per the latest estimates released by the CSO, the real economy expanded by 8.9 percent during the second quarter (July to September) of 2010-11, compared to 8.7 percent during the same period of 2009-10. Robust economic fundamentals and stringent financial measures allowed the Indian economy to regain growth momentum quickly after the global economic meltdown. This growth was mainly driven by the manufacturing sector with a growth rate of 16.3% in Q4 of 2009-10 where as mining output grew by 14.0% in March, 2010 while manufacturing grew by 10.8 % in the fiscal year 2009-10. Basically, these sectors are the major energy consumers in any economy. The Indian economy is likely to grow at an average rate of 8 percent in the next decade led by manufacturing and service sectors, which are the major consumers of energy. The industrial sector alone accounts for 52% of India’s commercial energy consumption.

India ranks sixth in the world for total energy consumption, but still its per-capita energy consumption is0.399 Mtoe, while the USA’s per capita energy consumption is 7.038 Mtoe. Even the world average for per capita energy consumption is 1.643 Mtoe, which is signifi cantly higher than that of India. Higher economic growth will lead to higher per capita income and higher energy consumption. This necessitates accelerating the development of the sector to meet its growth aspirations. The Indian economy is mainly driven by the service and industrial sectors. The higher growth trajectory of www.EQmag.net

India’s economic development tends to accelerate the consumption of energy. This needs a balanced approach towards all the energy sources like coal, hydropower, oil and gas, renewables, nuclear, etc. If we look at the GDP growth rates of different years and consumption of different energy sources, with the increase of GDP by one percent, primary energy consumption is likely to increase by 0.9 percent, while electricity consumption is likely to grow by 0.8 percent. Historically, growth in energy consumption follows the trend of economic growth; however: energy intensity, which is a measure of energy consumption per unit of GDP, is highest in comparison to other developed and developing countries in the world. Hence, there is huge scope for energy conservation, as well as a huge investment opportunity in the electricity efficiency industry.

The distribution of primary commercial energy resources in India is quite uneven.

Approximately 70% of the total hydro potential is located in the Northern and Northeastern regions of the country, while the Eastern region of the country hosts nearly 70% of the total coal reserves in the country. The Southern region has 6% of the total coal reserves and 10% of the total hydro potential, but has most of the lignite deposits.

Considering the primary energy consumption mix of Indian energy, coal energy is the major contributor to the Indian energy mix. However, the relative percentage of the consumption of coal and oil is likely to fall in energy mix, as the consumption of natural gas, nuclear energy and renewable energy is likely to increase at a more rapid rate by 2020(Fig-1). The total primary energy consumption is 514 Mtoe (Million Tonnes Oil Equivalent) while it is likely to grow to about 1000 Mtoe by 2020.

If we look at the pattern of energy production, coal and oil account for 54% and 34% respectively with natural gas, hydro and nuclear contributing to the balance. In power generation, coal contributes nearly 62%, while 70% of the coal produced every year in India is used for thermal generation. Looking at the past trend and future optimistic view on economic growth, we estimate that the consumption of primary energy is likely to grow faster than expected. More specifically, the growth rate of electricity consumption is likely to grow faster than the growth of GDP. If we consider the correlation between GDP growth and electricity consumption in the country, it is less than one at present; however: this correlation may not likely to hold true with a higher growth projection www.EQmag.net

for GDP. When the economy grows at a faster rate, the industrial sector is bound to increase at a faster pace and thus, demand for electricity is likely to grow at a much faster rate than expected. Approximately 400 million people are still living without electricity, which will boost investment in this segment to fulfill the dream of providing electricity to all.

Though India is rich in coal and renewable energy resources such as solar and wind, India is a net importer of coal and other fossil fuels. Increasing demand for electricity will increase India’s import dependency. To better meet this demand, India will have to increase the presence of renewables in its energy mix as well as open its energy sector for private participation.

Of late, the economic reforms and liberalization has gradually opened coal, oil, natural gas and electricity sector to private participation. The Government of India has come up with various policies related to this.

Pricing was deregulated in the coal and oil sectors. In the electrical power sector, most of the state electricity boards have started their reform process. To reduce the country’s dependency on imports for energy, the Indian government has started promoting the renewable energy sector with various policies related to renewables.

Governmental efforts in Indian energy sector The Government of India has recently come out with the Integrated Energy Policy, which aims to bridge the prevailing gap in the demand and supply of energy for the short, medium and long term perspectives.

The Government has started promoting competition between private and public players wherever possible in the energy market. The motivation behind this Energy Policy is to meet the demand for energy services for all sectors at competitive prices, while ensuring that all households are provided with electrical power. The demand should also be met through safe, clean and convenient forms of energy at the least-cost in a technically efficient, economically viable and environmentally sustainable manner.

With the Electricity Act 2003, the government of India is making it mandatory for the State Electricity Regulatory Commissions (SERC) to set targets for distribution companies to purchase a certain percentage of their total power requirement from renewable energy sources called Renewable Purchase Obligation (RPO); however: this RPO is not clear about the interstate transfer of renewable energy.

The RPO doesn’t provide proper guidelines to the states to bridge the gap between surplus and deficit energy as per required RPO targets.

To overcome this problem, the government of India devised a new policy in 2010 entitled the Renewable Energy Certifi cate (REC) Mechanism. The REC Mechanism will enable and recognize interstate renewable energy transactions which will further promote and develop renewable energy sources.

The REC Mechanisms is a new policy in India which will address the mismatch between availability of standard renewable energy resources in state and the requirement of the obligated entities to buy renewable energy for meeting the renewable purchase obligation (RPO). The policy is a market based instrument designed to promote renewables in India, which will help renewable energy producers sell electricity to power distribution companies other than those that are in their own state.

The REC demonstrates that an electricity generator has produced a certain quantity of power from a renewable energy source such as wind, solar, biomass, waste to energy etc.

Technically one REC is treated as equivalent to 1 MWh. Under this mechanism, the states with RPO targets requiring the purchase of renewable energy can obtain an REC to satisfy its RPO target requirements. This mechanism is also present in numerous other countries, including Italy and the USA, though these policies are structured differently to meet the needs of their respective local economies. This mechanism will clearly benefit India’s renewable energy companies, such as Suzlon Energy, Vestas, and TATA-BP Solar. This mechanism may also prove helpful in providing support in meeting the 15% renewable energy target, established by the Central Electricity Regulatory Commissions (CERC), by 2020.

Considering above facts, Lucintel has come to the conclusion that business and investment activities in the energy sector are likely to grow substantially in India. International investors are looking for opportunities to invest in the Indian energy sector. Considering the energy demand, the sector needs an investment of approximately 160 billion US dollar in the next five years. India has been trying to improve its efficiency in all segments of the energy sector, regardless of whether it is conventional or renewable energy. As a result, India’s energy sector is witnessing a steady increase in foreign investment and business arrangements for the import, licensing and use of energy-related technologies from other parts of the world.

EQ INTERNATIONAL JANUARY/FEBRUARY 11

77

CLIMATE CHANGE

Climate Change Negotiations In Cancun In Retrospection : A Progress Or Regress Neha Pahuja, Centre for Global Environment Research, TERI.

Copenhagen was a setback in climate negotiations since it failed to realize a unanimous outcome and the mandate of the Bali Action Plan (BAP). While the process was criticized for its lack of transparency and not being inclusive, the substance of the outcome, the Copenhagen Accord, was only ‘noted’ and not adopted by the Parties. The outcome, thereby, lead to mistrust amongst Parties and other stakeholders.

T

he Copenhagen Accord, for its legal

and respective capabilities ; and c) national

status or the lack of it, did not hold any

interests, that is, fully taking into account

good but could provide useful inputs

as it was representative of the political will.

A great challenge for Cancun, therefore, was to restore faith in the multilateral process and to forge an agreement that operationalizes elements of the Copenhagen Accord in conjunction with the two parallel tracks (Adhoc Working Group on Long Term Cooperative Action (AWG-LCA) and the Adhoc Working Group on Kyoto Protocol (AWG-KP)) under the BAP. It was also an opportunity to correct the imperfections of the Accord by further elaborating on many of its elements. Another and most important challenge was to restore lost faith in multilateral process.

Both the process and the substance were, therefore, important for a successful outcome at Cancun. This entails that while the

The draft was received well by all but one Party, with some level of compromise by majority of Parties on account of being able to achieve progress. Bolivia was the only Party to oppose it, stating that the text does not reflect converging opinions. The COP presidency, however, gaveled down Bolivia, to reach the substantive outcome, the so-called ‘Cancun Agreements’.

process achieves a delicate balance between

economic and social development and poverty eradication as the first and overriding priorities .Outcome at Cancun was nothing less than complex both in terms of the process and the substance.

In terms of the process, while the negotiations leading to the ‘Cancun Agreements’ took place under the AWG-LCA 13 and AWG-KP 15, the Mexico government also facilitated number of consultations and parallel processes, such as the Cartagena Dialogue, throughout the year to enable constructive progress in negotiations.

At Cancun, while number of sub groups (read contact groups) were formed under the AWGs from the very beginning of the talks, informal consultations, facilitated by pairs of ministers from both developed and developing country Parties, took place in the later half to progress on issues including

transparency and efficiency, the substance

shared vision, adaptation, mitigation, finance

brings clarity over scope and future of climate

the climate system within a time frame

and technology transfer amongst others. The

negotiations. Further any outcome is ideal

suffi cient to allow ecosystems to adapt

progress in these consultations was reported

if it meets the criteria of a) environmental

naturally to climate change, to ensure that

in informal stocktaking plenary convened by

effi cacy, that is, success of the outcome

food production is not threatened and to

COP President and later presented as ‘draft

to achieve the ultimate objective of the

enable economic development to proceed

texts’ reflecting Parties’ work under the

Framework Convention on Climate Change

in a sustainable manner ; b) equity, that

AWGs. The draft was received well by all but

(FCCC) which is to stabilize greenhouse gas

is, equitable sharing of burden and efforts

one Party, with some level of compromise

concentrations in the atmosphere to prevent

of Parties in accordance with the common

by majority of Parties on account of being

dangerous anthropogenic interference with

but differentiated responsibilities (CBDR)

able to achieve progress. Bolivia was the

78 EQ INTERNATIONAL JANUARY/FEBRUARY 11

www.EQmag.net

only Party to oppose it, stating that the text does not reflect converging opinions. The COP presidency, however, gaveled down Bolivia, to reach the substantive outcome, the so-called ‘Cancun Agreements’. The outcome has since been hailed for having restored faith in the multilateral process after the setback in Copenhagen.

This has, at the same time, also opened new debates, such as ‘what does consensus based decision making entail’, ‘how different (read convenient) are the decision making rules based on: general agreement, voting and consensus’, ‘does a consensus based decision making rule provide veto power to

technology, and capacity building. The agreement captures the progress, though incremental, in a framework comprising of new institutions and their work plan as basis of future negotiations which, at best, highlights the spirit of compromise in the negotiations at Cancun. The following section analyses the progress on elements of BAP in Cancun Agreements in light of the three criteria (environmental efficacy, equity and national interests) and put forth certain issues to be considered in the future.

A shared vision for long-term cooperative action: All Parties recognized the need of deep cuts in global greenhouse gas emissions

Durban in 2011. Similarly, agreed to only work towards identifying a timeframe for global peaking of emissions based on the best available scientific knowledge and ‘equitable access to sustainable development’ by Durban. The progress, therefore, was nothing but incremental which failed to resolve on crucial elements of the shared vision probably for the lack of clarity on the nature of outcome.

An agreement would have scored high on environmental effi cacy, if the nature, level and scope of deep-cuts were known, whereas, the Cancun Agreement has only postponed the decision to Durban. The

Attendees at dialogues with Heads of State panel: Keeping long term ambitions on the fight against Climate Change, at the Moon Palace venue

each Party’. It needs to be noted that the COP has never been able to adopt a decision in its rules of procedure in this regard.

However, there exists a need to rethink the basis of decision making in the rules of procedure before a similar issue arises again in the future.

In terms of substance of the outcome, the ‘Cancun Agreements’ builds upon the Copenhagen Accord and the other track to cover the main elements of the BAP, namely: a shared vision for long-term cooperative action, adaptation, mitigation, fi nance, www.EQmag.net

so as to hold the increase in global average temperature below 2°C and also recognized the need to consider strengthening this longterm global goal on the basis of the best available scientific knowledge, including in relation to a global average temperature rise of 1.5°C in its first review, to begin in 2013 and conclude by 2015. In this context, it only recognized the need of deep cuts (and not the specific cuts) and further agreed to only work towards identifying a global goal for substantially reducing global emissions by 2050 to be considered in next COP in

agreement further adds ambiguity to the basis of equity, by qualifying it as ‘equitable access to sustainable development’, something which could neither be defined nor be measured. Instead, a win-win reference could have been equitable access to ‘global atmospheric space’. The shared vision further recognizes that the time frame for peaking will be longer in developing countries, as their social and economic development and poverty eradication are the first and overriding priorities but qualifies it further that a ‘low-carbon development strategy is EQ INTERNATIONAL JANUARY/FEBRUARY 11

79

indispensable to sustainable development’, which could be seen as an important regress in position as far as our National interests are concerned.

The agreement captures the progress, though incremental, in a framework comprising of new institutions and their work plan as basis of future negotiations which, at best, highlights the spirit of compromise in the negotiations at Cancun.

Mitigation: Mitigation with respect to developed countries and developing countries as elaborated in the Cancun Agreements may result in significant changes in the international climate regime. For it is the first time, that even developing countries are obliged to undertake emission reduction, targets and actions pledged under the Copenhagen Accord. The Agreement hence anchors these pledges (since the INF document does not exist yet, this is an operational assumption) in the formal FCCC process. According to few studies, these pledges are inadequate in terms of environmental efficacy as even if implemented effectively will set the world on a 3-4o C path. It is much evident therefore that the bottom up pledges, that replace science based top down approach, are inadequate to achieve the stated global target of limiting to 2o C. On equity, there has been a major compromise by the developing world as while the developed country Parties’ have managed to escape, through their voluntary pledges, the legally binding commitments under the second commitment of Kyoto Protocol for now, they have also succeeded in introducing some form of obligation on the developing country Parties. This entails blurring of the principle of CBDR that called for developed country Parties to take the lead. Further, this raises questions on the future of Kyoto Protocol and its second commitment period and may be perceived as a step backward by postponing a decision on a second commitment period indefinitely through a new regime which is flexible and 80 EQ INTERNATIONAL JANUARY/FEBRUARY 11

voluntary. Domestically, it is still not clear of the extent of these pledges since India’s pledge under the Copenhagen Accord had caveats associated with it. Further, the level and scope of these pledges will decide the required resources and regulations for effective implementation of these pledges.

Important here is to also understand spillover effects on the developmental goals of India and work out if the agreement was truly in our National interest!

Adaptation: The Cancun Agreements establishes the Cancun Adaptation Framework, which is set of institutional arrangements to enhance adaptation efforts by all Parties. It also establishes a work program to consider ‘approaches to address loss and damage associated with climate change’. The key elements, however, will only be clear through the next year’s work plan and its outcome.

Technology: The Cancun Agreements set up a technology mechanism comprising of Technology Executive Committee, Climate Technology Centre and Climate Technology Network with a broad mandate including research and design, deployment and diffusion, development of national system of innovation and technology action plans amongst others. However, the Cancun Agreement does mention the issue of intellectual property rights (IPR), which has been one of the crucial issues in the negotiations so far. This certainly has a bearing on our National interests as the issue has considerable influence over access to and cost of technology that will be required for the transition necessitated by the new regime (read obligations). In effect, this would have implications of the efficacy of the developing country pledges in general.

Besides, there are other issues that need to be addressed such as the linkage between the technology mechanism and finance mechanism, the relationship between the technology executive committee and the Climate Technology Centre and Network etc. A program of work has been established further these discussions and resolve them by 2011. This issue was taken up during ministerial discussions where draft decision text was finalized.

Finance: The Cancun Agreement, formally, establishes the Green Climate Change fund as an operating entity of the financial mechanism of the FCCC with a committee set up to design various aspects

of the fund and the World Bank as interim trustee. The agreement also incorporates the finance goals set in the Copenhagen Accord that is 30 billion USD as fast-start finance for 2010-12 and to mobilize 100 billion USD by 2020. While these goals in itself seem inadequate, given the global estimates of costs, the additional qualifi cation ‘in the context of meaningful mitigation actions and transparency on implementation’ may reduce it even further. This has resulted in further obligation on the developing country Parties on account of MRV (measure, report, verify) and ICA (International consultation and analysis). However, there was no decision on the sources of the fund which has been an impasse in negotiations.

Challenges and way forward: It is much evident that the Cancun Agreement is not the end as much has to be achieved in the coming year. But it was important to be able to restore faith in multilateral process and was an epitome of compromises where in nations readily accepted any incremental

The cancun agreement incorporates the finance goals set in the Copenhagen Accord that is 30 billion USD as fast-start finance for 2010-12 and to mobilize 100 billion USD by 2020.

While these goals in itself seem inadequate, given the global estimates of costs, the additional qualification ‘in the context of meaningful mitigation actions and transparency on implementation’ may reduce it even further.

progress falling way short of their initial demands. However, it is important to reinstate that in doing so Parties must not renegotiate on the agreed principles and provisions of FCCC but built on that. Further, International community must also restore credibility of science in Durban by some form of agreement on future commitment and the Kyoto Protocol.

www.EQmag.net

COAL

Non-Coking Coal Shortage To Result In Over-Fourfold Rise In Imports Ajay D’Souza Head, CRISIL Research

India’s non-coking coal imports will grow fourfold over the next 5 years as the growth in demand for non-coking coal is expected to significantly outpace the rise in domestic production.

W

ith 63 GW of coal-based power capacities expected to come up during this period, demand for non-coking coal will increase at a compounded rate of around 11 per cent, whereas constraints in coal mining will limit supply growth to a meagre 3.2 per cent. The resulting shortage will continue to drive power generation companies to acquire coal assets abroad.

Sharp increase in powergenerating capacities to drive demand for non-coking coal

Due to the large additions in coal-based capacities, CRISIL Research expects the total demand for noncoking coal in India to rise from 541 million tonnes in 2009-10 to 910 million tonnes by 2014-15.

Ministry of Environment and Forests (MoEF) will constrain output from coal companies, resulting in a shortage of the commodity.

In July 2010, the ministry classified 126 of 582 coal blocks identified by a government study as ‘No Go’ areas, implying that it will not give forest clearance for mining in these areas. Until the MoEF finalises this regulation, coal mining in these areas will be on hold. The mining No-Go classification will adversely affect the expansion plans of India’s largest coal producer Coal India Ltd – 168 proposals of CIL, with an estimated combined production potential of 160 million tonnes, were awaiting forest clearance as of December 2010.

Massive additions in coal-based power for non-coking coal in India to rise from 541 generation capacities, which account million tonnes in 2009-10 to 910 million Moreover, a study undertaken by the for 80-85 per cent of non-coking coal tonnes by 2014-15.

Central Pollution Control Board, constituted consumption in the country, will drive up under the MoEF, identified ‘critically India’s requirement of non-coking coal at a compounded annual rate of 10.9 per cent Constrained output will lead polluted’ industrial clusters in India, based on over the next 5 years. About 77 per cent of to an increasing shortage of its methodology for computing pollution level in an industrial cluster – the comprehensive the 82 GW generating capacities that are non-coking coal environmental pollution index (CEPI). Due likely to come up over Generation capacities, break-up by coal and other fuel sources Power generation, break-up by coal and other fuel sources to the moratorium on this period will be coal (2009-10) (2009-10) production declared based. Coal has been in these clusters on the fuel of choice for Other the basis of the CEPI 33% Other large power plants in index, the MoEF will not Coal based 47% India, as reliability of 53% approve any greenfield coal supply enables Coal based or brownfield industrial 67% p ower - g en er a tin g projects, including coal companies to operate mining, in these areas. their plants at load The critically polluted factors as high as 75- Source: CEA, CRISIL Research clusters identified by 80 per cent, leading the board include seven to stable returns on investment. Due to the Production of non-coking coal in India will, coalfields of CIL, comprising about 64 per large additions in coal-based capacities, however, rise by only 3.2 per cent CAGR, cent of the company’s total proved reserves.

CRISIL Research expects the total demand as stringent regulations enforced by the The CEPI moratorium has forced CIL to cut www.EQmag.net

EQ INTERNATIONAL JANUARY/FEBRUARY 11

81

its production targets for 2010-11 from 460.5 million tonnes to 440 million tonnes, and scale down its target for 2011-12 from 486 million tonnes to 447 million tonnes.

domestic coal. This trend is, however, set to change with imported coal-based capacities expected to account for about 8 per cent of the country’s total capacities by 2014-15.

Power-generating companies such as Adani Power, Tata Power, and JSW Energy, which have substantial capacities based on imported coal in the pipeline, have already secured coalmines abroad, thereby mitigating their fuel price risk. The acquisition of

Imports of non-coking coal will rise fourfold To bridge the rising shortfall, India’s noncoking coal imports will rise significantly from 44.3 million tonnes in 2009-10 to

Coal mining in India requires significantly long gestation period The progress of development of captive coal blocks – mines allotted to private and public sector companies directly engaged in power, steel, or

Expected demand, supply and imports of thermal coal (million tonnes)

cement production – has been

(million tonnes)

dismal. Only 17 of the 208

1,000 225

coal blocks allotted by the

800 175 600 125

400

Government of India since 1993 have commenced production as of 2009-10.

200

75

0

25

Coal blocks in India take an 2009-10P

2010-11F

2011-12F

2012-13F

Demand

2013-14F

Supply

2014-15F

average of 6-7 years to begin production as against the

Imports (RHS)

norm of 3-4 years laid by the

Source: CEA, CRISIL Research

government. Inordinate delays coal assets abroad by domestic generation companies has shown a rising trend, with at least four major asset acquisitions having already been announced in 2010-11.

203.2 million tonnes in 2014-15. The share of imports in total demand for non-coking coal will increase from around 8 per cent in 2009-10 to 23 per cent in 2014-15.

Overseas coal asset acquisitions by Indian companies

requires multi-level approvals – at district, state, and union

(per cent)

located in forest areas are,

10.0

therefore, prone to greater

8.0

delays.

6.0

Land acquisition is the second

25 20

8.3

7.6 6.3

15

biggest hurdle in the timely

4.4

4.0

2.4 4.1

Forest clearance, which

biggest hurdle. Coal blocks

(Gigawats)

1.3 2.1

reasons for the slow pace of

government levels – is the single

Growth in imported coal-based capacities

5

and land acquisition are the key mine development.

Rising import dependence will drive players to continue to seek coal assets abroad

10

in obtaining forest clearances,

2.0 8.1

12.8

16.9

20.1

0

0.0 2009‐10 E 2010‐11F 2011‐12F 2012‐13F 2013‐14F 2014‐15F Imported coal based capacities (GW)

commissioning of coalmines.

Coal mining companies can acquire land either through the state government or through direct negotiation with landowners.

Imported coal based capacities % of Total capacities (RHS)

Direct negotiation can speed up

Source: CEA, CRISIL Research

land acquisition as dealing the In the case of non-coking coal, import dependence currently does not have a major bearing on domestic power tariffs as imported coal-based capacities comprise just about 3 per cent of India’s total generation capacity and bulk of the demand is for blending – imports by domestic coal-based power stations to make up for the shortfall of 82 EQ INTERNATIONAL JANUARY/FEBRUARY 11

With the domestic supply scenario only expected to worsen over the next several years, power sector players are expected to continue to seek coal assets not only in the traditional coal export hubs of Indonesia, South Africa, and Australia, but also in the emerging coal-rich regions such as Mozambique.

state government is a lengthy process involving multiple rounds of public hearings with landowners before government records officially notified a land transfer.

www.EQmag.net

Overseas coal asset acquisitions by Indian companies

Player

Country

Investment Type

Ownership %

Year

Price Paid

Proven / Inferred

(Million USD)

Reserves (Million mt)

Essar Global

USA

100% stake in Trinity Coal

100

2010

600

200

JSW Energy

South Africa

49.8% stake in South African Coal Mining Holding (SACMH)

49.8

2010

85

n.a.

Adani Power

Australia

Mine for cash and royalty

2010

500

1200

Adani Power

Indonesia

Rail & port project for coal

2010

1650

2000

JSW Energy

South Africa

Stake in mining company

2009

n.a.

n.a.

GMR Energy

Indonesia

100% stake in mine

100

2009

80

100

85

2009

n.a.

1000

Coal India Ltd

Mozambique

85% stake in 2 mines

Tata Steel

Mozambique

JV with Australia’s Riversdale Mining

2009

800

NA

Adani Power

Indonesia

Stake in mine and tie-up

2008

n.a.

140

Reliance Coal Resources Pvt Ltd

Indonesia

100 per cent stake in 3 mines

2008

n.a.

2000

100

Tata Power

Indonesia

Stake in 2 coal mines

30

2008

1100

n.a.

GMR Infra

South Africa

Stake in Homeland Energy

10

2008

30

400

JSW Energy

Indonesia

JV with local mining Co.

50

2007

n.a.

300

Gujarat NRE coke

Australia

Stake in 2 coal mines

2007

46

260

Source: Press reports and CRISIL Research

CEPI moratorium, mining No-Go regulations, to delay coal projects The tough stance of India’s Ministry of Environment and Forests (MoEF) – it has imposed a moratorium on coal production and slower grant of forest clearances to new and expansion projects – is further constraining the supply of coal and worsening an already difficult scenario for coal mining in the country.

In 2010, the ministry classified 126 of the 582 coal blocks covered by a government of India study as ‘No-Go’ areas for mining.

This implies that the ministry will not give forest clearance for mining in these areas as they had gross forest cover greater than 30 per cent of their total land area.

Despite abundant coal conflicts with forestland, which Forest cover in top coal bearing states country’s total land area. A (per cent) 50 bearing states in India have 37.3 nationwide average forest cover 40 31.4 28.7 Jharkhand, Orissa, Chhattisgarh 30 18.9 together hold about 75 per cent 20 14.6 11.0 account for about 30 per cent 10

41.3 25.2 10.3

7.6

reserves, mining in India directly covers about 21 per cent of the majority of the top coal-reserve a forest cover greater than the of 21 per cent. For instance, and Madhya Pradesh, which of proved coal reserves in India, of the country’s forest cover.

The ‘No-Go’ classification in mining is likely to have severe 0 repercussions on the country’s premier coal producer Coal India Jharkhand Orissa West Bengal Chhattisgarh Madhya Pradesh Ltd (CIL). The company’s expansion plans are likely to be hit, as the ministry may not approve several new mines and expansion % of proved coal reserves Forest land as % of total land projects that are awaiting clearances, if they are located Source: Ministry of Coal, Ministry of environment and forests Several large coalfields where CIL within the classified areas. is currently conducting mining activities fall under the ‘No-Go’ classification. These include large projects such as North Karanpura in Jharkhand, IB Valley in Orissa and Chhattisgarh, Singrauli Coalfield in Madhya Pradesh and Uttar Pradesh, and the Talcher coalfield in Orissa.

As of December 2010, 113 proposals of Coal India were awaiting Stage-I forest clearance, and 55 proposals were awaiting Stage-II forest clearance. Coal India estimates that these projects have a combined production potential of 160 million tonnes.

The move by the Central Pollution Control Board of India to impose a production moratorium in ‘critically polluted’ industrial areas will also constrain coal supply over the next 3 years. On the basis of the CPCB’s comprehensive environmental pollution index (CEPI), which measured pollution levels in about 88 industrial clusters, the ministry declared 43 of the clusters as ‘critically’ polluted. Consequently, the MoEF will not approve greenfield or brownfield industrial projects, including coal mining, are in such areas. The 43 industrial clusters include seven coalfields of CIL, including Chandrapur, Korba, Jharia, Talcher, Singrauli, Raniganj, and IB Valley, which together comprise about 64 per cent of CIL’s total proved reserves. The CEPI moratorium has forced CIL to cut its production targets for 2010-11 from 460.5 million tonnes to 440 million tonnes, and scale down its target for 2011-12 from 486 million tonnes to 447 million tonnes. www.EQmag.net

EQ INTERNATIONAL JANUARY/FEBRUARY 11

83

PRODUCTS Exor’s Newest HMI Series Available In India Now Exor has launched the new eTOP300/400

modules for fieldbus systems and network

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PRODUCTS Cooper Bussmann Introduces New Range Of ‘PV Strings Protection’ Fuse-Links For Solar Power Installations

Solar String Fault Currents

Cooper Bussmann has designed a new range of High Speed Fuse-Links specifically for the protection of Solar Photovoltaic strings.

The Fuse-Links are manufactured in the popular 10x38mm cylindrical package thus facilitating the use of modular fuse-holders, PCB clips and open style fuse blocks. With Solar Fuse & Holders

ratings from 8A to 20A at 1000V DC (which covers 4”, 5” and 6” solar cell systems), the Fuse-Links are ‘gPV’ category which allows for full range protection(over-loads down to 1.3 x Ir and short circuits). The specific performance of the Cooper Bussmann PV fuse is designed around the operational, environmental and potential fault conditions of PV strings. The Fuse-Links are tested and approved to IEC 60 269 and packaged in material which is 100% recyclable.

These are offered alongwith matching IEC Modular Fuse-holders, also rated for 1000V DC. Cooper Bussmann is confident that the introduction of these unique PV Fuse-Links

Combiner Box

& Holders for use in PV Combiner box (or Junction box) will assist design engineers in ensuring safety without sacrificing performance in this fast growing and ever evolving Solar PV energy markets and applications.

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EQ INTERNATIONAL JANUARY/FEBRUARY 11

85

PRODUCTS Fluke Scopemeter® 190 Series Ii Portable Oscilloscopes Engineered For Harsh Industrial Environments Fluke Corporation, the global leader in portable electronic test and measurement technology, has introduced the Fluke ScopeMeter® 190 Series II handheld portable oscilloscopes, the first fourchannel scopes designed for harsh industrial environments.

These new portable scopes are the first safety rated for CAT III 1000 V / CAT IV 600 V environments. The four input channels are fully isolated from each other to perform differential floating measurements, a critical consideration for troubleshooting fixedinstallation three-phase power electronic devices like variable speed motor drives.

The Fluke ScopeMeter chassis is sealed from the environment with no cooling slots or fans to expose the instrument. It carries the International Protection (IP) -51 dust and drip proof rating so it’s tough enough to use safely on the factory floor and in

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The Fluke 190 Series II oscilloscope meets the growing need for four-channel portable oscilloscopes in industrial environments. Power electronics are used increasingly in solar and wind energy generation and to maximize efficiency or reduce power consumption especially in heav y- duty elec tro - mechanic al applications. With the new Fluke 190 Series II ScopeMeter, users can see more and fix more using all four channels.

Their fast sampling rate, up to 2.5 GS/ sec and 400 pico second resolution, helps users capture electrical noise and other disturbances to diagnose exactly what is going on. With100 MHz and 200 MHz models, they deliver the bandwidth needed to cover both today’s needs, and tomorrow’s.

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• View and measure pulse width modulated waveforms (PWM) for reflections and transients.

These new test tools are convenient and user-friendly. New, high-performance Li-ion battery technology keeps the Series II ScopeMeter on the job for up to seven hours.

An external charger and easy-access battery door makes it simple to swap batteries and extend usage. Two USB ports, electrically isolated from measurement input circuits, make it easy to capture and share waveforms.

Users can conveniently store data to a USB memory device or easily connect to a PC via the USB port and transfer waveforms or screen images for data analysis or archive.

non-magnetic, non-conductive and have a compact stream line construction. They are resistant to salt water, gasoline, alcohol, oil,

Novoflex introduces Cable Glands suitable for plastic or rubber insulated, un-armoured, plastic or rubber over sheathed cables. These glands are manufactured from a high grade engineering thermoplastic, an inherently strong compound that is self extinguishing, self lubricating, vibration proof, impact resistant and corrosion resistant. They are 86 EQ INTERNATIONAL JANUARY/FEBRUARY 11

grease, easter keyton, benzene, common solvent, weak acids & alkalies. They are available in different sizes to suit different diameter of cables. The glands operate in -25º C to +85º C. Tensile strength of the glands is 595 Kg/cm² and volume resistivity is 1.5 x 1012 ohm-cm. www.EQmag.net

DIRECTORY More info in tel. +91 731 2553883

Single module Dimensions: 55 mm width x 65 mm height Price: 650 euros / year

RENEWABLE ENERGIES

www.EQmag.net

Double module Dimensions: 55 mm width x 150 mm height 117 mm width x 65 mm height Price: 1,000 euros / year

SENSORS

EQ INTERNATIONAL JANUARY/FEBRUARY 11

87

INDIA SOLAR ENERGY SUMMIT Date: February, 17-18, 2011, Place: New Delhi Organiser: Lnoppen TEL: 86 21 6085 1000 Email: Catrionas@noppen.com.cn

INTERNATIONAL CONFERENCE ON WIND ENERGY 20 BY 2020 Date: Feb 15 - 17, 2011 Place: New Delhi Organiser: IWPA TEL: 9840400024 Email: secretary.general@windpro.org

THERMAL POWER INDIA Date: Feb 19-20, 2010 Place: Lodhi Road New Delhi Organiser: India Core TEL: 011-45652708 Email: cvjv1933@yahoo.com

RENEWTECH INDIA 2011 Date: Feb 17-18, 2010 Place: Mumbai Organiser: MCO-Winmark Exhibitions Pvt. Ltd Phone: +91 - 22 - 2660 5550 Email: sales@renewtechindiacom

POWER ELECTRICITY WORLD ASIA Date: March 21 - 25, 2011 Place: Singapore Organiser: Terrapinn Phone: (65) 6322 2757 Email: yeeling.chua@terrapinn.com

INDIA ENERGY SECURITY SUMMIT Date: Mar 3-4, 2011 Place: New Delhi Organiser: IPPAI Phone: 91 11 43734478 Email:Suparna@ippaimail.org

EWEC Date: March 14 - 17, 2010 Place: Brussels Organiser: EWEA Phone: 32 2 213 1803 Email: ankiza.gakunu(at)ewea.org

SNEC PV POWER EXPO 2011 Date: 22 - 24 February 2011 Place: Shanghai, China Tel: 86 15821149946 E Mail: teresa.wen@snec.org.cn URL: www.snec.org.cn

GRID TECH 2011 Date: 19th â&#x20AC;&#x201C; 21st April 2011 Place: Pragati Maidan, New Delhi , India Organiser: Power Grid Corporation of India Ltd. Tel: +91-124-2571797 Email: gridtech2011@powergridindia.com

PV+SOLAR EXPO Date: April 19-21, 2011 Place: Mumbai, India Organiser: Electronics Today Tel: +91 22 2673 0869 Email: sswarnbom5.vsnl.net.in

HANNOVER MESSE Date: April 4-8,2011 Place Hannover, Germany Organiser: Deutsche Messe Tel: 0511 89-31203

WIND POWER INDIA 2011 Date: April 7-9, 2011 Place: Chennai Organisers: WISE, GWEC & IWTMA TEL: Tel: +91-20-26613832 Email: info@windpowerindia.in

INTERSOLAR MUNICH Date: June 8-10, 2011 Place: Munich, Germany Organiser: Solar Promotion International GmbH Tel.: +49 7231 58598-0

GREEN POWER 2011 Date: June 16 - 17 Place: Bangalore Organiser: CII Tel: 918008477675 Email: d.suresh@cii.in

POWERGEN INDIA & CENTRAL ASIA 2011/ 2ND RENEWABLE ENERGY WORLD INDIA/ HYDROVISION INDIA 2011 Date: May 5 -7, 2011 Place: Pragati Maidan, New Delhi Organiser: Penwell Corporation Tel: +44 1992 656 610 exhibitpgica@pennwell.com

88 EQ INTERNATIONAL JANUARY/FEBRUARY 11

www.EQmag.net

INTERSOLAR NORTH AMERICA Date: July 12-14,2011 Place: San Fransico Organiser: Solar Promotion International GmbH Tel.: +49 7231 58598-0

SOLAR POWER INTERNATIONAL 2011 Date: Oct 17-20,2011 Place: Dallas, USA Organiser: SEIA & SEPA

5TH RENEWABLE ENERGY EXPO Date: August 10-12, 2011 Place: New Delhi Organiser:Exhibitions India Tel: +91 11 4279 5000 sandhyad@eigroup.in

26 EUPVSEC Date: Sept 5-9, 2011 Place: Hamburg Germany Organiser: WIP-Renewable Energies Tel: +49 89 720 12 735 pv.conference@wip-munich.de

SOLARCON 2011 Date: Nov 9-11,2011 Place: Hyderabad, India Organiser: Semi, India http://www.solarconindia.org/index.htm

ELECRAMA 2012 Date: January 20-24, 2011 Place: Mumbai, India Organiser: IEEMA Tel: +91-22-2493 0532 / 6528 / 6529 elecrama@ieema.org

New Energy Husum Date: March 15-17, 2011 Place : Husum, Germany Organiser : Messe Husum Telephone +49 4841 90 2-480 soenksen@messehusum.de

Genera 2011 Date: March 11-13, 2011 Place : Madrid, SPAIN “Organiser: Energy and Environment Internacional Trade Fair” Telephone : (+34) 91 722 30 00 genera@ifema.es

2nd Concentrated Solar Thermal Power Summit IndiaCSP Today Date : April 12-13 2011 Place : New Delhi, India Organiser: CSP Today Telephone : +44 (0)207 375 7187 maria@csptoday.com

Expo Energetica Date : Feb 16-18, 2011 Place : Valencia , SPAIN Organiser : Feria Valencia y Five Continents Exhibitions, S.L Telephone : (+34) 902364699 www.egetica-expoenergetica.com

Power Gen- Europe Date : June 7-9 2011 Place : Milan , Italy Organiser : Pennwell Telephone : +44 1992 656 617 exhibitpge@pennwell.com

Coal trans Date : March 8-9, 2011 Place : New Delhi, India Organiser : Euromoney Energy Events rollichon@euromoneyplc.com

4th Renewable Energy Finance Forum - India Date : May 24-25, 2011 Place: New Delhi , India Organiser : Euromoney Energy Events www.euromoneyenergy.com

2nd Renewable Energy Finance Forum - Canada Date : April 5-6, 2011 Place : Toronto, Canada Organiser : Euromoney Energy Events www.euromoneyenergy.com

5th Renewable Energy Finance Forum - Central and Eastern Europe Date: March 01- 02, 2011 Place: Warsaw, Poland Organiser : Euromoney Energy Events www.euromoneyenergy.com

Free Listing of your Event Conference and events are listed free-of-charge,so please feel free to get in touch to tell us about your event. We would also be happy to provide you with free copies of magazine for distribution at your events.(while stock last). Please send your conference information to : Mr. Piyush Mishra at piyush.mishra@EQmag.net www.EQmag.net

EQ INTERNATIONAL JANUARY/FEBRUARY 11

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