Pimagazine Asia Vol 4 Issue 5

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

VOLUME 4 ISSUE 5

LET THE ...

SUNSHINE

ASIA’S NUCLEAR BOOM A BOOM OF NUCLEAR POWER IS UNDERWAY IN MAJOR ASIAN COUNTRIES

THE POWER OF MORE W E H AV E A N I N D E P T H INTERVIEW WITH CUMMINS

STUXNET COMING TO A TOWN NEAR YOU?

SPECIAL REPORT

STANDBY POWER?

A LOOK AT ASIA’S POWER USAGE

Editors Note Welcome to another great edition of Pimagazine Asia. This edition we have changed things slightly.

Due to changing policy and delays in information, we have not provided you with a country overview for this edition, for that we apologize, but we have made up for it with some great feature and interviews that I’m sure will keep you all happy. As we go to press our staff are preparing for a trip to Mumbai and the Intersolar India exhibition. If your local or visiting, pop by and meet the team, its always nice to catch up with colleagues and clients.

In this edition, we have some coverage of the Indian solar market. The new Modi government has stepped up the pace in developing all aspects of its Power sector.

Solar as usual, is playing an increasing role along with the transmission sector.

We speak with Schneider and Alstom in this edition and learn a little more about the new technology and its role in Asia.

Remember, please keep us informed of news on your company, promotions, product launches, contract wins and pilot projects.

We have an exceptional platform via our print and online resources.

Make sure you follow us on twitter @ pimagazineasia, all our latest news is released here and on our homepage, www.pimagazine-asia.com.

I hope that you enjoy this edition, again we have provided something for everyone. We look forward to your thought, views and comments.

Thanks for reading

Charles Fox, Editor

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Contents

Inside This Issue

20

34

38

56

Features

Regulars

12

India Solar Solar Power

06

News The latest headlines

16

India The Polysilicon Industry

66

Upcoming Events

20

Nuclear Boom Looking at Nuclear Power around Asia

30

Made From the Original Fearn速 Direct air cooled condenser tubes (DACC)

34

Standby Power Asia

04 | POWER INSIDER VOLUME 4 ISSUE 4

42

Ansaldo Energia Gas turbine upgrade

48

Stuxnet Coming near you?

56

HDVC Technologies Energising electrical grids

Interviews & Opinions 08

Case Study Pt Adaro Indonesia

38

Cummins Interview Power of More

50

Schneider Electric Pankaj Sharma Interview

62

Mycometer Interview Detecting Bacteria

Bench test your energy costs.

Cogeneration with MWM gas engines makes energy economical again.

We work hard, day in and day out, to improve the excellent efficiency and reliability of our gas engines and power generators. Because every bit of progress we make helps our customers cut their energy costs even faster. www.mwm.net

Regulars

Thailand

News from around Asia

More Clean Coal for Thailand Re-emphasizing that natural gas extracted from the Gulf of Thailand would dry up in the next 6-7 years, Ratanachai Namwong, deputy governor of the Electricity Generating Authority of Thailand (EGAT) Power Plant Development, said there is a need for Thailand to build new electricity plants powered by clean coal.

Here is a brief summary of the most recent big stories from in and around Asia. Please ensure you are a regular subscriber to our weekly newsletter to stay ahead of breaking news from the region. Keep up to date by following us on Twitter @pimagazineasia Largest solar plant in Central Asia in spring 2019 “Uzbekenergo” plans to build the first heliostation in Central Asia with the capacity of 100 MW and output of up to 200 million kWh of electricity per year. The project worth USD 310 million will be funded by Asian Development Bank, Fund for Reconstruction and Development of Uzbekistan, and “Uzbekenergo”.

Alstom wins $57 Million China Hydro contact Alstom was awarded a contract worth €57 million1 by The Hainan Pumped Storage Power Generation Co. Ltd. to equip Hainan Province’s first pumped storage power station. Alstom will provide three 200 MW units – pump turbine, motor generator with other key equipment – to the 600 MW new plant. The first unit is due to enter commercial operation on Dec, 2017.

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Thailand Thai firm wins $350m Myanmar deal Thailand’s Green Earth Power Company has signed an agreement with the government to move forward on its plans to spend US$350mbuilding a 220-megawatt solar-power generating station near Minbu in Magwe Region. According to Green Earth managing director, U Aung Thiha, the facility will sit on 850 acres that are not suitable for agriculture with a completion date planned for 2017.

“The first stage will see 50 megawatts of electric power produced by March 2016, with the total development time lasting three years,” he said.

News Desk

Bangladesh Blackout hits Bangladesh A massive nationwide power blackout hit Bangladesh after a transmission line failed, leaving homes, businesses and shops in the densely-populated country without electricity. Power was restored in some parts of the capital Dhaka after several hours, and authorities said they hoped to have electricity back on across the nation of 155 million by Saturday evening. Local media said the problem stemmed from a technical problem at an electrical substation that was distributing power from India, but government officials would not confirm the reports.

Japan Alcatel-Lucent opens new Network Centre in Tokyo The Alcatel-Lucent Customer Network Center (CNC) is a first-of-its-kind in Japan – one of the world’s most advanced telecommunications markets – and has been created to make networking trends, most notably the trend towards cloud-based networking, tangible for customers. In the CNC, Alcatel-Lucent customers can participate in interactive demonstrations and co-creation opportunities that lead to the creation of new business models.

Vietnam Trilliant & EVN HCMC sign contract Trilliant has signed a contract with EVN HCMC, a subsidiary of EVN, the largest power company in Vietnam, for a smart grid project. The announcement was made following the contract signing ceremony in Ho Chi Minh City, which was attended by Mr.Tran Khiem Tuan, Deputy General Director of EVN HCMC, Chief of Staff Clark Jennings and Regional Manager Mark Dunn from the U.S. Trade Development Agency (USTDA), and Trilliant.

Korea KEPCO test AMSC’s Cable Devens-based AMSC said Korea Electric Power Corp. (KEPCO) is testing a cable that uses AMSC’s trademarked wire at a smart grid demonstration site on Jeju Island, a province of South Korea.

The high-temperature superconductor cable uses AMSC’s Amperium HTS wire.

According to AMSC, such cables are “power dense and have zero resistance, making them an ideal solution to moving large amounts of power underground and with a minimal footprint.”

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Case Study

PT ADARO INDONESIA PT Adaro Indonesia produces one of the cleanest fossil fuels in the world.

Ultra low levels of sulphur, ash and nitrogen mean its ‘Envirocoal’ branded product is in demand with the global power industry, where it’s used as a direct feed or mixed with other types of coal.

These environmental attributes have in turn been extended and integrated into the company’s approach to doing business.

Recycling mine water

Perhaps the most striking illustration of Adaro’s Corporate Social Responsibility (CSR) approach is a new initiative to recycle wastewater from its mines into clean drinking water.

Energy and water, probably mankind’s two most vital resources,

08 | POWER INSIDER VOLUME 4 ISSUE 5

are closely linked. In the villages of Padang Panjang and Dahai, closest to the mines, this interdependence has a profound impact. Wastewater, primarily from rainfall, is continually pumped from the mine to settling ponds, where it is treated before being released into local waterways.

But Adaro, following Reduce, Reuse and Recycle principles, has now built a treatment plant that produces drinking water of the highest standards.

The benefits to villagers are significant. Most people in rural Indonesia get their water from rivers and streams; and wells if they can afford it. But these settlements sit in low-lying areas where a lot of the standing water is stagnant, creating continuous health issue. A 15km network of pipelines built by Adaro

now transports potable water from the treatment plant to the heart of the villages, all year round. The firm’s employees and more than 5500 villagers alike benefit.

Encouraging self-sufficiency But what has made this scheme a multiple award-winner is the way in which the treatment plant is managed. Planning long-term, Adaro aims to help create sustainable and independent

Pt Adaro Indonesia just one example of projects where Adaro is combining environmental management and rehabilitation with community development.

“Most people in rural Indonesia get their water from rivers and streams; and wells if they can afford it”.

Magic cars

post-mine communities.

To encourage self-sufficiency, the facility is governed and run by the community themselves. Board members from the community are elected at village meetings.

PT Adaro Indonesia and other industry experts then train them on water supply management techniques. To encourage a sense of responsibility towards its new plant, the water is not given away for free. Customers pay for their water at locally affordable rates, and the funds are in turn collected and used on village improvements. This is

They range from sponsoring dozens of local students through university, to running a biodiesel plant to replace diesel in dump trucks, to re-using water from the reclaimed Paringin mine to cultivate freshwater shrimp and tilapia fish.

And its free, mobile cataract surgeries, nicknamed ‘magic cars’, have returned the sight or significantly improved life quality for more than 3600 people.

The multiplier effect

The company is keenly aware of the multiplier effect its work has on the economy, education, health and the environment everywhere it operates.

And it makes business sense.

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Case Study - Fossil Fuels

“We cannot increase our production if we cannot manage our surroundings,” says Garibaldi Thohir, President Director of PT Adaro Energy.

“That is why I spend most of my time dealing with CSR and the development of the local area.

If we can better develop surrounding communities, then those communities will feel that Adaro belongs to them.”

Recycling waste water from mines into clean drinking water

The multiple benefits of clean coal PT Adaro is Indonesia’s second largest coal mining company.

It’s based in South Kalimantan Province and is a major exporter to global energy markets and a supplier to the domestic power and cement industries. Its Envirocoal branded product has the lowest ash content of any coal produced for global export.

10 | POWER INSIDER VOLUME 4 ISSUE 5

This matters to countries like Japan, for example, which has limited capacity for ash disposal. Low ash levels also cut deposits in boilers, boosting thermal efficiency and reducing maintenance costs.

Likewise, Envirocoal’s ultra-low nitrogen and sulphur content has multiple environmental benefits, saving the cost of

removing nitrous oxides from flue gases and desulphurization units - which can account for up to 20% of the total capital expenditure of a new power station.

To read more about PT Adaro’s CSR initiatives visit www.adaro.com

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Feature

IndIa Solar India can have an installed solar power capacity more than six times what it plans to have over the next ten years.

India has the potential to install 145 GW of solar power capacity across various project sizes by 2024.

The report states the capacity addition potential across four plant sizes: residential rooftop (1-5 kW), industrial and commercial rooftop (10-500 kW), utility-scale projects (5-50 MW) and ultra mega solar power projects (1-3 GW).

In August, MNRE circulated a draft of the Ultra Mega Solar scheme to local governments that sketched the basic mechanics of the strategy, stating: ‘Solar power projects can be set up anywhere in the country, however

12 | POWER INSIDER VOLUME 4 ISSUE 5

the scattering of solar power projects leads to higher project cost per MW and higher transmission losses. Individual projects of smaller capacity incur significant expenses in site development, drawing separate transmission lines to nearest substation, procuring water and in creation of other necessary infrastructure. Also it takes a long time for project developers to acquire land, get change of land use and various permissions, etc. which delays the project’.

A large capacity addition is possible, as conventional fuels like coal are getting expensive and scarce. The leveled cost of energy (LCOE) from

solar energy is now at par with that of imported coal. While the LCOE for imported coal is expected to increase with a compounded annual growth rate of 12% over the next ten years, the LCOE for solar power is expected to fall with a CAGR of 4%. Solar power will match LCOE of new domestic coal-fired power plants in 2019.

Commercial, industrial, and utility-scale projects have the highest potential in capacity addition over the next ten years.

Industries are struggling to procure the required electricity through conventional means, even if they are ready to pay a premium; additionally, they also face high tariffs from distribution companies.

Utility-scale projects would also be highly successful as the

India Solar business model is a tried and tested one. Almost the entire solar power capacity operational in India today is the result of competitive bidding organized by state utilities looking to procure solar power.

Both these segments, industrial rooftop and utility-scale, can see up to 42 GW capacity addition each by 2024.

Residential rooftop segment represents up to 35 GW capacity

“With over 15% of the world’s population, India’s demand for electricity is already significant”.

ability to absorb the resulting electricity remain.

The Indian government has planned ultra mega solar power projects with capacities of up to 4 GW. This segment could see up to 27 GW of cumulative capacity added by 2024. Such projects are being planned across India, and will also be supported by dedicated transmission corridors. The central government has announced a financial package of $83 million for four such projects this year.

‘Charanka Solar Park’ – and Rajasthan – ‘Bhadla Solar Park’ – as models for the parks to be constructed as part of the “Ultra Mega Solar” scheme. The draft proposal describes the Charanka Solar Park in Gujarat “as a pioneering first-of-its-kind large scale solar park in India with clear land and transmission connectivity.”

addition by 2024. While the rooftop systems can be installed within days, the supporting external infrastructure for, say, net metering takes time. While a number of state governments have issued net metering regulations, and also provide financial assistance to homeowners, doubts over the grid’s

The Charanka Solar Park has a capacity of 590 MW, out of which 20 developers, according to the MNRE, have already commissioned 224 MW. While the figure of 145 GW seems too high and based on theoretical calculations rather than ground realities, the report does rightly

project the massive potential that the Indian solar power market offers.

Under the National Solar Mission, India plans to have a cumulative installed solar power capacity of 22 GW. The Ministry of New and Renewable Energy hopes to have 100 GW capacity installed by 2030.

With over 15% of the world’s population, India’s demand for electricity is already significant.

The MNRE will identify the land for the proposed solar parks in each state and select the state agencies for administering a grant providing to support construction of the parks.

For example a small village in India recently installed a solar electric operating system. Dharnai, in India’s northeastern Bihar state, did more than join a reliable energy grid — it became India’s first village powered entirely by solar electricity. A few months ago, Greenpeace and two other NGOs that work in the area (BASIX and CEED) started building a solar power micro-grid to serve the village, and after a few months of testing, the autonomous 100 kilowatt system officially went online not long ago.

The Dharnai grid serves about 450 homes, housing 2,400 residents, Greenpeace says, as well as roughly

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Feature - India Solar 50 businesses, streetlights, water pumps, two schools, health care center, and other public and private ventures. It has a battery to store excess electricity, for use during the sunless hours.

Germany reaching the milestone of (at least briefly) meeting more than half its electricity needs through solar is probably a bigger feat, but projects like this in India and China will do more over the long term to counter the harmful climate effects of fossil fuel consumption.

And bringing reliable electricity to a town or village for the first time feels like a much bigger deal than switching from nuclear to solar power. It changes every aspect of life, from safety and health to entertainment and economic progress.

Governments around the Asian region are almost certainly watching the success of India’s Solar programs and many are following suit.

But what does it mean for international manufacturers?

India has dropped plans to impose an anti-dumping duty on solar panel imports, a move that is likely to help mend frayed commercial ties with

the United States before Prime Minister Narendra Modi meets President Barack Obama this month.

Days before Modi took office in May, a quasi-judicial body ordered the imposition of the duty on panels imported from the United States, China, Taiwan and Malaysia to protect domestic solar manufacturers.

“The Charanka Solar Park has a capacity of 590 MW, out of which 20 developers, according to the MNRE, have already commissioned 224 MW”.

The order issued had set duties of between 11 and 81 U.S. cents per watt following an investigation which started in 2011. The ruling had to be published by the Finance Ministry within a stipulated time

frame to take effect.

“There was no notification.

We allowed it to lapse,” Nirmala Sitharaman, the trade and junior minister for finance, said, without elaborating.

India and the United States set great store by the economic potential of their ties, but their relationship has been fraught in recent years over trade policies and patents.

The move over solar panels comes two days after the Modi administration said it was trying to speed up clearances for all pending patent applications and working on an intellectual property rights (IPR) policy - seen by analysts as another step towards smooth things over with Washington.

Dropping the duty removes one sticking point ahead of Modi’s meeting Obama in Washington on Sept. 29-30, but it will upset Indian manufacturers who say rivals benefit from subsidies and sell their products at artificially low prices.

The guarantee of 25 year warrantees is a certainly going to stay, but what India is planning to protect its manufacturers is another thing.

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Feature

The Polysilicon Industry in India India needs solar power, for that to be cheaper you need to produce polysilicon: Solar power makes sense for India. The case for investment in the solar industry has been made many times, even by Pimagazine in 2011. To sum up some of the key advantages, India has the best natural resource for producing solar power, with over 3000 hours of sunshine every year. The abundance of flat, arid (and therefore un-farmable) land means that there is the space to produce large-scale solar parks. Solar parks also are built with exceptional speed, with the solar park in Charanka going up in just sixteen months (Bloomberg), meaning that labour costs are significantly cut. For these reasons, India is possibly the biggest growth market in the world for solar power, particularly solar photovoltaic (PV). What is costly, however, is the initial cost of electricity generation; solar power is up to four or five times more expensive than fossil fuels. With solar PV technology, costs are racked up even before the technology is ready to start producing electricity, with India sourcing all of its PV panels from abroad.

This is because of the production of polysilicon, a vital component in the production of PV panels. Energy intensive and very specialist, the cost of buying in PV panels with vital polysilicon makes many projects unfeasible, but this is an issue that has drawn much attention from policy makers and component suppliers in recent years, especially after the announcement of the Jawaharlal Nehru National Solar Mission, and it’s aims to install 20,000MW of solar generated energy by 2022.

The Global Situation for Polysilicon The opportunity for polysilicon industry in India: And so far one place has been successful… Lanco Solar will be first on the map with a fully integrated Solar PV plant in India, opening a factory for the manufacture of polysilicon, ingots, wafers, PV cells and PV modules in the Chhattisgarh State Industrial Development Coporation, near Charvardhal village. Lanco Solar plan to be fully operational by this year, and produce equipment with the capacity of 200MW per year. Lanco Solar will be supported by GT Solar International, who will be providing polysilicon production equipment to the new plant.

The first of it’s kind, but not producing anywhere near the capacity to meet the National Solar Mission’s targets, what Lanco have done has shown that it can be done but there is still room for potential investment. However, there are a number of factors to consider before moving forward: Time: Typically, a polysilicon plant will take between 19-24 months to go from design to full operation.

Focus on Solar Grade Polysilicon: because the electronics industry is unlikely to move away from established players, new plants should focus on producing solar grade polysilicon.

Integration: in Asia, the manufacture of solar grade polysilicon has had three generations. The first manufactured the polysilicon based on rejects or scrap from the electronics industry, whilst the second are PV product manufacturers who are backward integrating their supply chain. They could then improve their margins because they had the entire supply chain under their control. However, what they learnt from this is that the manufacture of polysilicon is completely different from everything else on their supply chain. Third generation polysilicon manufacturers were chemical industry players and could use that knowledge and experience to produce low cost polysilicon. However, long term commitment to full capacity manufacture to long term supply contracts with PV businesses may put them at a disadvantage; they will not realise the best margins at boom tmes because they don’t own the downstream value chain.

Economies of scale: plant capacity decisions will need to be made carefully by investors. Despite some plants in Asia now having productions capacities of 3,00-10,000 tons a year, such a high amount in India would be a huge risk. Investors will have to weigh up their risk appetite, previous experience of the sector, finances, human resources and marketability when assessing a new plant’s capacity.

Capital cost: whilst the cost of building a plant in the developed world may cost as much as $125 per kilogram of polysilicon capacity, building in the developing world may produce significant cost savings.

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Polysilicon India Market: The investor needs to decide early whether the polysilicon produced in their new plant will be sold locally or globally.

Pricing: another key decision will revolve around which currency to price the product, with exchange rate fluctuations affecting the investor and client in opposite directions. Transparent and flexible contracts will need to be built.

There are also a number of technological considerations. Siemens CVD looks set to dominate 80% of the polysilicon manufacture for the next five years. New entrants into the market are therefore recommended to select a low risk process route for their facilities. However, this technology and the feed material manufacturing technology is offered by many licensors, many of which are ex-employees of established players. Useful parameters for choosing a licensor are as follows: - Previous productivity, capital and operating costs in the plants established by them in the past.

- Commercially proven energy consumption per kilogram of polysilicon.

Other technological considerations include: - The Environmental and safety considerations, - The local availability of equipment and raw materials, - Post-commissioning support for the upgradation of the process, Achieving the lowest possible power consumption per kilogram of polysilicon, which is impacted by factors such as selection of feed material for CVD deposition, energy integration that reuses waste heat, the selection of equipment and technology and process optimization, which in some companies through good R&D capability supported by a pilot plant and a strong technology team, has been shown to achieve production levels of 15-20% about the name plate capacity.

“To sum up some of the key advantages, India has the best natural resource for producing solar power, with over 3000 hours of sunshine every year�.

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The final set of considerations revolves around India’s infrastructure: Electrical power: The CVD process needs high quality electric power for its operation, but the Indian grid suffers from fluctuations in voltage and frequency and long power cuts during times of supply shortfall, as well as breakdowns in power supply. Supply from 220KV lines appears to be free from these problems, but investors need to take care.

Standby Power Supply: As most standby power systems take nearly a minute to restore power (which would be too late to save a batch in production) and because of the high cost of maintaining a standby power supply, the provision of one is pretty much ruled out. Captive Power Plants are often seen as a solution for the problems of cost and quality of grid supply, but capex requirements of a CPP create disadvantages for Indian projects.

Costs of Electrical Power: Due to the varied and high cost of electricity in India (between INR 3.00 (US$0.07) to INR 5.50 (US$0.12) per KWh), projects without subsidies need to be evaluated carefully.

Manpower: India is full of quality engineering talent, so adoption and adaptation of state of the art technology is quick, but training simulators for engineering personnel can be advantageous.

Plant Location: Two major factors may cause issues in India; proximity to a source of low cost electrical power and continuous availability of water for cooling needs.

Having weighed up all these factors and considerations, Lanco Solar have been successful in building a fully integrated Solar PV plant. How successful they are in production remains to be seen, and there are still plenty of opportunities to invest, which a number of key players in the Solar PV industry are currently planning to do: -The Yash Birla Group have acquired a 600 acre site near Kurnool in Andhra Pradesh to set up a polysilicon and solar power generation unit. The Rs 10,000 crore investment will need further investments of Rs 9,000 crore in order to produce a capacity of 15,000 tonnes of polysilicone and 50MW per year.

-BHEL is likely to join forces with BEL for a 10,000 tonne per year polysilicon manufacturing facility, and are looking at locations in Karnataka and Andhra Pradesh. Their aim is to set up an integrated Solar PV cell facility and acquire polysilicon manufacturing technology. They’re aim is to blow Lanco Solar out of the water with a whopping 1,000MW of solar power per annum.

-Horizon Solar PVT Ltd. are experienced suppliers of polysilicon, and have a fair degree of market power, comfortable selling future production under long-term contracts. They plan to open polysilicon plants in both India and the Middle East in two phases. Horizon’s capacity aims are between 6000-12000 tonnes.

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Feature

ASIA’S NUCL A boom of nuclear power is underway in major Asian countries despite Japan’s experience with Fukushima.

Growth in China continues unabated; India is planning and making major nuclear power investments; challenges in South Korea will not impair long-term growth; and emerging Asian countries are also expressing interest.

The story of nuclear power in Asia overall is one of consistency and growth for the first decades of the 21st Century.

Japan, South Korea, China, and India have been leaders in nuclear construction and technology development.

These countries have kept nuclear development active when it otherwise would have waned. In the future, these nations plan to be leaders in nuclear technology export as well.

In analyzing the outlook for near-term growth of nuclear power globally, it is no surprise that Asia will be the unquestioned leader. As we consider the drivers of growth, most Asian countries fulfill them all: rapidly developing economies, fast growing populations, high energy and electric power demand growth, relatively poor indigenous energy resources, and strong central governments.

“Most people in rural Indonesia get their water from rivers and streams; and wells if they can afford it”.

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Nuclear Boom

CLEAR BOOM With roughly 70 new plants under construction worldwide and 150-200 more in the planning stages in 2014, most of these new units are to be sited in China, India, and South Korea. These, and several smaller countries to be discussed below, are seeking to meet their high electric demand growth with a diversified generation portfolio that includes nuclear reactors.

However, Asia is truly a multi-dimensional region, and it is impossible to ‘broad brush’ the trends of Asian countries when it comes to nuclear. Consider, for instance, the differing attitudes, commitments, and plans of China, India, South Korea, and Japan. These are the largest countries from which to tell the story of nuclear in the region, and the view varies dramatically for each nation. Yet, to complete the story we must also address Indonesia, Malaysia, Pakistan, Bangladesh, Thailand, and Vietnam.

Historically, it could be said that Asian countries, especially Japan and South Korea, kept nuclear new build alive during the 1990s and early 2000s. This was a time when new nuclear construction practically stopped in the West. The trends of that time created the major vendors we still see today headquartered in those countries: Toshiba, Hitachi, MHI, Korea Electric Power Co. (KEPCO), Doosan, and others. It is also this history of nuclear technology development in the region that is now leading to the export ambitions of these companies. Thus, the role of Asia in determining the future of global nuclear power is destined to only grow in the coming decades.

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Feature - Asia’s Nuclear Boom China Two Westinghouse AP1000 reactors are curerntly under construction at the Sanmen Nuclear Power Station in eastern Zhejiang Province, China Two Westinghouse AP1000 reactors are curerntly under construction at the Sanmen Nuclear Power Station in eastern Zhejiang Province, Nowhere is the future of nuclear power more evident than in China.

However, it has not always been that way. As with its economic expansion, which only really accelerated in the 1990s, China’s nuclear power program was a bit of a late bloomer. Premier Li Peng, who by many is considered the “grandfather of the Chinese nuclear power program,” issued a dictate during his tenure for the country to promote reactor development. It was decided early on that pressurized water reactor (PWR) technology would be the primary reactor choice in China and the country would look to first import but then localize the technology in order to attain mass production.

Two companies were given the permission to develop nuclear power: China National Nuclear Corp.

(CNNC) and China Guangdong Nuclear Power Corp., which has now changed its name to China General Nuclear (CGN). CNNC and CGN took slightly different approaches to developing their first nuclear plants. CNNC focused on the promotion of domestic reactor designs, which led to the first 300-MW unit completed at Qinshan Phase I in 1994. Some of the main components for this CNP-300 unit came from abroad, such as the reactor vessel manufactured by MHI of Japan, but CNNC rightfully claimed intellectual property to the design. CNNC doubled the size of this design to become the CNP-600, of which four are now operating and another two are under construction.

CGN, on the other hand, signed a contract in the late 1980s with France’s Framatome (now AREVA) for the construction of two 900-MW PWRs at the Daya Bay site. With financial investment by Hong Kong’s China Light & Power (CLP), the Daya Bay project saw its first unit completed in 1994. The relationship between CGN and AREVA has grown over the years and allowed for the near complete localization of the French PWR technology. The initial result of this was the CPR-1000 design, which is a standardized 1,000-MW PWR, of which nine are now operating and another 15 are under construction. AREVA is also building two EPRs with CGN at the Taishan site, which is likely to lead to the companies working together on EPRs in the UK and possibly elsewhere. Westinghouse is currently building four 1,100-MW AP1000 nuclear reactors, two each at the Sanmen and Haiyang sites in China. Operations are scheduled for 2015 and 2016.

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Nuclear Boom In total, China now has 20 operating reactors for about 18 GW in capacity. There are also another 28 units under construction, which will bring the total capacity to 46 GW by 2019. There are numerous other projects on the drawing board, with upwards of 100 units potentially being added by 2030. Questions remain over the country’s ability to reach the government’s official target of 58 GW by 2020 as determined in a revamped plan after Fukushima, but the long-term expectation is that China will remain committed to rapid growth of nuclear power to satisfy extremely high energy demand coupled with clean air requirements. Given that the current and likely future level of nuclear power will still be far less than 5 percent of the total electricity mix, it is hard to underestimate the expansion capability in the country.

“In total, China now has 20 operating reactors for about 18 GW in capacity. There are also another 28 units under construction, which will bring the total capacity to 46 GW by 2019”.

One of the main factors that will determine the role of nuclear power in China over the long-term is the location of the plant sites. After Fukushima, the government decided to only allow construction on coastal sites. If and when the ban on inland sites is lifted, this should allow for even more new projects to begin. Moreover, the selection of reactor technologies will be a critical issue, as the post-Fukushima safety requirements have made it impossible for CNNC and CGN to continue to rely on the previous Generation II designs. Advanced domestic designs are now being developed, but this process has caused a slowdown in near-term project starts.

A final factor that is being watched closely by many observers of the Chinese nuclear industry is the recent drive by many of the leading companies to expand into the international nuclear market. CNNC and CGN both have taken a stake in the Hinkley Point C project in the UK, and they have additional ambitions in Romania, South Africa, Argentina and elsewhere.

Over the coming decades, it is likely that China will help to shape the future of nuclear power more than any other country. Both in terms of domestic expansion of nuclear power capacities as well as the role of Chinese companies in the international marketplace, its position in the industry is destined to grow dramatically.low, are seeking to meet their high electric demand growth with a diversified generation portfolio that includes nuclear reactors.

However, Asia is truly a multi-dimensional region, and it is impossible to ‘broad brush’ the trends of Asian countries when it comes to nuclear. Consider, for instance, the differing attitudes, commitments, and plans of China, India, South Korea, and Japan. These are the largest countries from which to tell the story of nuclear in the region, and the view varies dramatically for each nation. Yet, to complete the story we must also address Indonesia, Malaysia, Pakistan, Bangladesh, Thailand, and Vietnam.

Historically, it could be said that Asian countries, especially Japan and South Korea, kept nuclear new build alive during the 1990s and early 2000s. This was a time when new nuclear construction practically stopped in the West.

The trends of that time created the major vendors we still see today headquartered in those countries: Toshiba, Hitachi, MHI, Korea Electric Power Co. (KEPCO), Doosan, and others. It is also this history of nuclear technology development in the region that is now leading to the export ambitions of these companies. Thus, the role of Asia in determining the future of global nuclear power is destined to only grow in the coming decades.

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Feature - Asia’s Nuclear Boom Japan No country in Asia has received more attention about its nuclear power program over the past three years than Japan. However, it is important to put the Fukushima accident into perspective, especially as it relates to Japan’s history with nuclear power and prospects for the future.

Japan was the first country in Asia to develop nuclear power for peaceful purposes, beginning back in the early 1960s when the first reactor was brought online at Tokai. Japan’s utilities teamed up to import a number of western reactor technologies, including Westinghouse’s PWR and GE’s boiling water reactor (BWR). About half of the country’s utilities followed Tokyo Electric Power Co. (TEPCO) and chose BWRs, whereas the other half followed Kansai Electric Power Co. and chose PWRs. Thus, Japan is unique among the world’s major nuclear power users in that it has a high percentage of BWRs. The real impetus for the rapid deployment of reactors in Japan was the Arab oil embargo of 1973, when the government realized that it was over-reliant on oil for electric power generation. From the mid-1970s through 2000, Japan built 47 reactors reaching a peak nuclear generating capacity of nearly 48 GW from 55 units in 2008 (roughly 35 percent of total power supply). Although the first of these units still relied heavily on foreign vendors, by the 1980s, Japan’s three major suppliers – Hitachi, Toshiba, and MHI – had completely mastered the relevant technologies. By the 1990s, Japan had become an exporter of critical reactor components.

Of course, the trajectory of nuclear power in Japan changed dramatically after the massive earthquake and tsunami of March 11, 2011. Five separate nuclear power stations were directly impacted by the natural disaster, but TEPCO’s Fukushima Daiichi plant, which housed six BWRs, was the most severely damaged leading to the partial meltdown of three reactor cores and multiple hydrogen explosions that damaged four of the units.

Since 2011, Japan’s public has become extremely skeptical of nuclear power, leading the government to become much stricter in its regulatory oversight of the industry. A newly created Nuclear Regulation Authority (NRA) has implemented very rigorous requirements on the remaining 48 operable reactors in the country, all of which have stayed offline for inspections and safety upgrades since 2012. As of August 2014, applications have been submitted for the restart of 20 units, and the NRA has already approved the restart of the first two units at Kyushu Electric Power Co.’s Sendai plant. If the final approvals go smoothly, Sendai 1 & 2 could be back in operation before the end of 2014.

With the reactor restart process now somewhat clearer, the main question relates to the long-term usage of nuclear power in Japan. Many of the country’s reactors are approaching their 40th year of operation, and there is uncertainty over whether the NRA will allow plants to operate beyond that. Moreover, several nuclear plant sites are being evaluated for possible earthquake faults, and this could doom some of the existing plants. Meanwhile, there are still two reactors in Japan under construction – Shimane 3 and Ohma 1 – and many believe that these will be allowed to be completed. As such, it is still too early to tell how many reactors will continue to operate in Japan over the long-term, but it would seem likely that somewhere around 30 to 40 units could remain on the grid for the coming decades. Nevertheless, if Japan’s public remains largely opposed and the country’s leaders are unwilling to push through a strong pro-nuclear agenda, it is possible that the total amount of power from nuclear will slowly decline after 2020.

Japan is a highly advanced economy but has nearly no domestic sources of energy. The total cost of replacing the currently offline reactors is estimated to have run over $100 billion since 2011. These costs will only continue to rise, along with carbon and other air emissions, if the nuclear plants are not returned to service for the long-term. Many politicians, including Prime Minister Shinzo Abe, fully understand this reality. The difficulty for Japan’s government will be in convincing enough of the public that nuclear power remains a necessary option for energy supply despite the risks.

“From the mid-1970s through 2000, Japan built 47 reactors”.

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Nuclear Boom

South Korea The Republic of Korea (ROK) or South Korea, has been a unique growth story for nuclear power. Not only has in-country nuclear construction continued throughout the time when North America and western Europe did not grow, but also technology advancement and a government-level commitment to export has propelled ROK into an emerging position in the global nuclear industry, challenging rivals in several countries.

Today, South Korea’s 23 licensed plants comprise a strong nuclear industry that has a good safety and reliability record and operates at high utilization rates. The majority government-owned KEPCO owned all of the fossil, nuclear, and hydropower operating plants until a few years ago when restructuring occurred. As its nuclear industry has developed, South Korea has been growing a strong and highly self-sufficient nuclear supply chain.

Companies such as Doosan Heavy Industries are able to provide large forgings and many other components required by its industry.

The government sees the potential for nuclear power technology to provide for the country’s energy needs as well as a growing export. South Korea’s vibrant economy has seen electricity consumption growth rates that have exceeded 8 percent for some years and are expected to continue in the 2.5 percent range through 2020. Revised government targets see some 29 percent of generation from nuclear by 2035. It will take another 20 units to meet that target in addition to the five to six projects underway today. Because real estate is at a premium, the policy is to add additional units at existing sites.

KEPCO’s success in winning the competition for the United Arab Emirates’ first four units in 2009 should also be noted. These are expected to be the first of many anticipated units to be constructed in the Middle East in the coming decades. Its APR1400 is now considered a leading design for the future in Asia, as well as other global locations.

Between 2012 and 2013, serious safety and certification issues surfaced in the South Korean nuclear industry.

At least five plants were taken offline to replace components that did not meet quality standards. The resulting shutdowns for investigation and replacement of components created electric power shortages through a serious summer heat wave with harsh results. As of mid-2014, South Korea seems to have concluded this negative chapter in its nuclear history and is renewing its development activities both inside and outside the country.

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Feature - Asia’s Nuclear Boom India The Republic of India, the world’s second most populated country and largest democracy, is an important nuclear country, both as a weapons state and generating a significant amount of nuclear power. While the country today operates 21 nuclear power plants and has six under construction, it is making plans for many more. India’s energy policy calls for 25 percent of electricity to be generated from nuclear by 2050. This will be an enormous challenge, but India is a vast and rapidly growing country.

India’s nuclear power industry is completely owned and run by the federal government. Operating organizations include Nuclear Power Corporation of India Limited, Department of Atomic Energy, and the nuclear regulator, the Atomic Energy Regulatory Board. The six reactors under construction total over 4 GW and have startup dates between 2014 and 2016.

The new Modi government is targeting 17 GW by 2022, a more conservative target than the previous administration wanted, but still a huge leap. Today, the country has a significant lack of electric power generation capacity to meet demand. Brownouts and rolling blackouts for load shedding are a regular occurrence in many parts of the country, often in the evening between 5 and 10 PM. Because of its strong growth rate and rising standards of living, continued high demand growth for electric power is forecast. But, because of the need to diversify away from coal (now some 70 percent) and to clean up the environment, nuclear and hydropower are favored.

India will struggle to meet its generation growth targets and improve its electric supply reliability. Investments on the order of $40 billion have been identified, including every form of generation and significant improvements in the electric power grid. More recently, some have even put the investment required as high as $85 billion for nuclear.

Bringing in outside technology and assistance will be necessary if India is to meet such aggressive growth targets.

For these reasons, the country is now looking more to the outside world for modern nuclear power technology and, where available, for investment capital. Talks are ongoing with Rosatom, GE, Westinghouse, AREVA, and possibly others.

“India’s nuclear power industry is completely owned and run by the federal government”.

The recently completed Kudankulam 1 reactor is the first of two to be brought on line. It is a Russian VVER-1000 design and brings the number of operating reactors to 21. Kudankulam 2 is also under construction and Units 3 and 4 are in planning, but not yet started. The majority of new reactors under construction are domestic pressurized heavy water reactors (PHWRs), which are now in the 700-MW class. R&D on a larger PHWR domestic design of 1,000 MW is also reportedly underway.

India’s national policy favors nuclear power as a growing share of total generation planned to be 25 percent by 2050.

India’s own heavy water technology developed during its two decades of isolation is a source of national pride.

While most do not want to see its local technology pushed aside, it will be important to bring in more outside vendors if the nuclear program is to be modernized and growth challenges met.

Yet, India has one of the most stringent liability laws of any country. Perhaps it was the memory of Bhopal that led the government to pass this law. This liability challenge has become a common complaint of global suppliers as they look to enter India. We must watch the progress over the next few years to see if both internal and external investments will be made quickly.

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Feature - Asia’s Nuclear Boom Pakistan As one of the few non-signatory states to the Nuclear Nonproliferation Treaty, Pakistan has remained outside the reach of the international commercial marketplace. However, this has not stopped the country from developing nuclear power, as it currently operates three reactors – one small CANDU unit imported from Canada in the early 1970s and two CNP-300 units from China. China’s CNNC is now building two more of these 300-MW units at the Chasma site, and there are plans to build a larger 1,000-MW advanced CNNC design at the Karachi site. Pakistan is wracked with shortages of electricity, and the country desperately needs energy to foster economic development. Given these realities, the country will continue to look to China, the only reactor exporter willing to do business in Pakistan.

Beyond the basic commercial considerations, the benefit for China to building in Pakistan is that it offers a relatively amenable test bed to prove its capabilities as a full-fledged nuclear exporter.

Taiwan Taiwan’s history with nuclear power dates back to the 1970s, when it first imported two BWRs from GE. As an island with a rapidly expanding economy and few domestic sources of energy, Taiwan turned to nuclear power to provide nearly 20 percent of its electricity for the past three decades from six reactors at three nuclear power plants. A fourth nuclear power station at Lungmen has been under construction since 1999; however, the project has been challenged by changes in the domestic political situation over the past 15 years. There is a strong anti-nuclear movement in Taiwan, and this antagonism has grown since the Fukushima accident. Major protests in the spring of 2014 led the current government to mothball the Lungmen project for the time being. Unit 1 of the two GEH advanced boiling water reactors (ABWRs) has completed pre-operational testing but was recently sealed and could remain so for another three years. Construction on Unit 2 has been halted. The government is now preparing for a public referendum to decide the fate of the Lungmen project. If protestors get their way, the country could be completely nuclear-free by 2030. At the same time, without many good options for replacing this power, there are many in Taiwan who are still hopeful that opinion will shift again in support of nuclear.

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Nuclear Boom Others Apart from the existing nuclear power countries in Asia, there are numerous others that are interested in developing this power option for the future. Of these potential newcomers, there are only about a handful that can be considered serious contenders. The most advanced in terms of developing a nuclear power and regulatory program are Vietnam, Bangladesh, Malaysia, Indonesia, and Thailand. Other nations, such as Philippines, Singapore, Mongolia, and Cambodia, are either much further out in their preparation or have decided against pursuing nuclear after weighing their options.

Vietnam is perhaps the most intriguing story pertaining to nuclear newcomers in Asia. As a country with a fast growing economy and a population hungry for a modern, energy-intensive lifestyle, Vietnam’s government approved a plan in 2011 to commission ten reactors by 2030. To reach this goal, a contract has already been signed with Rosatom to build two units, and negotiations are continuing with Japanese vendors for another two-unit plant. Meanwhile, Vietnam recently concluded a 123 Agreement for nuclear cooperation with the U.S., which could open the way to future exports as well. Financing nuclear plants remains a challenge for Vietnam, but there is a strong will and need for nuclear power development.

In Summary It is clear that the growth story for nuclear in the foreseeable future will mostly focus on Asia. That is where the factors of population growth, energy and electric power demand, and favorable government policies are converging to make a diversified generation mix a necessity.

As we look back a decade from now, Fukushima, while it has seriously affected nuclear power in Japan, may prove to be only a brief pause in the development of the nuclear growth of Asia. While it has negatively impacted the industry worldwide, Fukushima will by no means halt, or even slow, the growth of new nuclear power overall in Asia.

Meanwhile, the Asian growth story will not just be centered on the domestic expansion, because a number of Asian countries already have well-developed nuclear supply chains, globally recognized reactor designs and leading vendors and suppliers. Countries like Japan, South Korea and China are likely to remain or become world leaders in nuclear power and their influence will be felt worldwide.

“Pakistan is wracked with shortages of electricity, and the country desperately needs energy to foster economic development”.

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Feature

Direct air cooleD conDenser tubes (Dacc) maDe ® from the original feran

Last year, one of the most famous manufacturers of the so called “Clad Materials” by cold rolled bonding, the german company Wickeder Westfalenstahl, celebrated its 100 year anniversary. And it is nearly this time that the company is producing the aluminum clad steel – today called FERAN® - as the first patent for this material combination derives from the 1920. Apart from other applications within the automotive industry or in household appliances, one application where the important properties of the Clad Material FERAN® are needed is in direct air cooled condenser tubes for the direct dry cooling of power plants.

Wickeder Westfalenstahl supplies FERAN® for this special application for more than 20 years. Over 1.000 power plants have been equipped with the original FERAN® with a 100% operation reliability. FERAN® for power plant cooling tubes from Wickeder Westfalenstahl has become the material standard for DACC.

But what is a Clad Material and what are the benefits of FERAN® for the application of direct air cooled condenser tubes?

In general a Clad Material is a two- or multi-layer metallic composite consisting of different metal strips that are bonded together under high pressure. A lot of combinations are available at Wickeder Westfalenstahl, for example clad combinations made from steel and copper, steel and nickel, steel and brass or steel and bronze, compounds made from stainless steel and copper, or also compounds without any steel, e.g. copper clad aluminum – only to name a few. Hereby the properties the individual material alone does not offer are designed by a clever combination of different materials in a “custom made“ clad compound. The advantages of the individual materials are combined together. Have a look at one example: the copper-steel-copper cladding. This Clad Material combines the strength of steel with the good electrical conductivity of copper – that´s why this material is used for many applications in the electrical industry.

In the case of FERAN® the Clad Material consists out of the combination of an aluminum and a steel strip.

For the DACC a tube is needed with a stable and medium resistant steel surface on the inner tube side and an aluminum surface on the outer side. The one side aluminum clad steel, FERAN®, fullfills all these requirements.

Steel as a sophisticated and inexpensive base material ensures the required strength, tightness and the medium 30 | POWER INSIDER VOLUME 4 ISSUE 5

Fearan resistance for the tube body. Aluminum on the outer side of the tube acts as a transition material, allowing the fin material out of aluminum to be joined to the aluminum-surface.

In recent months other producers of aluminum clad steel appeared on the market. But quality and performance of the Wickeder material FERAN® is outstanding based on the long tradition and experience producing Clad Materials – and especially for the DACC-application. For these quality reasons Wickeder Westfalenstahl has developed and installed a special numeric marking system for the original Wickeder Westfalenstahl FERAN® coils. Therefore since some months every single production lot is marked with an individual special numeric marking and not copy able parameters.

The cooling of power plants is a very critical factor and each component needs to perform perfectly. So also the raw material that is used is a very critical component. That is why so many customers count on the Clad Materials from Wickeder Westfalenstahl. For example in case of the DACC a delamination of the metallic composites could lead to costly bundle replacement work, reduced power generation/effiency and possible power plant shutdowns.

Therefore a really strong bonding – without delamination - between aluminum and steel is essential. No brittle regions in the diffusion zone between aluminum and steel before, during and after the sensitive brazing process are allowed as it is essential that the fins and the clad Al-layer have a close connection to the steel which is in contact with the vapour.

The most dangerous problem of a DACC system is a leakage caused by corrosion leading to a collapse of the vacuum inside the tube system. This will lead to a significant drop in the efficiency of the power plant system.

Another important thing during the brazing process is the thermal stability. Due to its inseperable bonding of the two metals and its thermal properties FERAN® fulfills these very important requirements.

For an optimum welding of the tubes the two metals are not bonded at the edges. The Al-free edges that are achieved by edge free cladding guarantees a highly efficient welding process of the steel tubes: tube manufacturers can weld steel to steel.

The consistency of production parameters – which is guaranteed by Wickeder Westfalenstahl due to the experience from several hundred thousands tons of material - is essential to fulfill the requirements of modern direct air cooled condenser tubes. The following factors play an important role: - Right material selection for the right combination of aluminum and steel - Optimization of the production parameters for heat treatment, rolling, surface preparation and edge free cladding.

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Feature - Air cooled condenser tubes Compared to other materials used in the power plant industry the FERAN®-tube consists out of an integral Al-layer of at minimum 50µm on the outer side. This avoids any corrosion of the air cooled condenser and guarantees a stable bonding and brazing connection for the aluminum fins – the heat transfer is and stays reliable. Furthermore Wickeder Westfalenstahl developed and installed a patented inner surface which shows a maximum of heat exchange by an increased inner surface area.

“Most people in rural Indonesia get their water from rivers and streams; and wells if they can afford it”.

The dry cooling of power plants – means the cooling with air - is – not only but especially – suitable for the cooling of power plants in areas where there is not enough water available for the cooling.

That´s why the dry cooling of power plants is really interesting for so many regions in India and Asia in general.

And - beyond that – due to its corrosion resistance - FERAN® is also the choice material for DACC in regions with humid rainfall periods.

Some of the recent projects where Wickeder Westfalenstahl´s material is involved are in Asia and have reached a significant MW-amount. To improve delivery times and to guarantee the immediate access for the DACC producing companies Wickeder Westfalenstahl has established a FERAN® stock for example in China. This enables customers to cover an uninterrupted production period of at least 8 weeks. A continuous delivery system in place saves the material volume needed at any time.

Nearly all leading producers of cooling systems count on the original FERAN® due to its benefits: - FERAN® has a minimum Al-layer of 50 µm to guarantee long lasting corrosion protection - The Al-free edges enable optimum welding - The increased inner surface area shows maximum of the heat exchange

If you are interested in the original FERAN® by Wickeder Westfalenstahl, the aluminum clad steel, don´t hesitate to contact us.

Your contact person, Mr. Hans-Jürgen Gauger, Tel: +49 2377/917 – 764, E-Mail: Hans-Juergen.Gauger@ wickeder.de is awaiting your questions.

For more information you can also visit the following website: www.wickeder.com

32 | POWER INSIDER VOLUME 4 ISSUE 5

FERAN® first choice for Direct Air Cooled Condenser-Tubes FERAN® - Aluminum Clad Steel: t .JOJNVN ˜N "M MBZFS t 'SFF FEHFT GPS PQUJNVN XFMEJOH PG UVCFT

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Maximum power plant efficiency over life time through: t $PSSPTJPO SFTJTUBODF PG JOUFHSBM "M MBZFS t 3FMJBCMF IFBU USBOTGFS CZ TUBCMF CPOEJOH BOE CSB[JOH DPOOFDUJPOT t "M GSFF JOOFS UVCF TVSGBDF t )JHIMZ TPQIJTUJDBUFE QSPEVDUJPO GBDJMJUZ JO (FSNBOZ FMFWBUFE NFDIBOJDBM QSPQFSUJFT FYDFMMFOU RVBMJUZ BOE SFMJBCMF EFMJWFSZ QFSGPSNBODF

Wickeder Westfalenstahl has established an unique traceability system based on special marking on the steel side.

Contact 8JDLFEFS 8FTUGBMFOTUBIM (NC) www.wickeder.com

Dry Cooling

Steel

Feature

Standby Power aSia..

I

n an age where emergency preparedness is increasingly subject to public scrutiny, standby and emergency power provision has become a necessity.

In addition, planning, emergency procedures and nonlinear load problems are important to the overall implementation and maintenance of an effective standby power system.

Asia has been one of the fastest growing economic regions in the world and continues to outpace other regions in terms of growth within the electricity sector. As Asia develops and expands so will the demand for additional infrastructure and reliable power. To experience continuous high growth patterns and economic development, significant infrastructure improvements and expansions are necessary. Based on the time frame and costs associated with the construction and implementation of permanent power plants, the global stand by power industry has been increasing at a rapid rate, particularly in Asia. Standby power throughout this region is growing due to the rapid increase in demand for electricity, inefficient grids contributing to power losses, massive population growth within countries such as India and China, expanded urban business activities throughout many of the smaller regional economies, un- foreseen natural disasters damaging large-scale permanent power structures, and the increased industrialization in most countries throughout Asia.

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Electricity Growth

Rapid and accelerating growth in electricity consumption is occurring in the developing countries of Asia at a higher rate than the world average and is likely to continue due to fact that the electricity consumption per capita is still far below that of the world average.

The International Energy Agency has forecasted that the energy consumption of developing Asia (excluding South Korea, which is an OECD country) will have doubled by 2030, while the world’s energy consumption will increase by 1.5 times over the same period. As a

“As a result, developing Asia’s share of global energy consumption will increase from 27.5% to 36.3% in 2030”.

result, developing Asia’s share of global energy consumption will increase from 27.5% to 36.3% in 2030. In conjunction with the massive growth of Asia’s global energy consumption, the temporary power market is expected to experience substantial growth in the near future.

Fast-Track Power

Emerging countries throughout Asia have seen tremendous activity within the standby power business over the past few years. The growth patterns cannot always be properly forecasted and can be driven by the failure of a power plant, natural disaster, weather phenomenon or some other unforeseen event.

In these circumstances, there is often a need for fast-track power to ensure an adequate power supply of electricity to industries, governments, and households.

Standby power is the most efficient

Standby Power Asia a local grid or limited access to the main transmission network may prohibit the delivery of electricity required for the customer to sustain production and operations. Industrial companies are dependent upon constant power to ensure that maximum operational capacity is achieved to avoid costly plant outages and maintain competitive effectiveness throughout world markets. Again, standby power applications can be the most effective short to medium term solution as temporary power providers offer not only power generation equipment but also the engineering, installation, operation and maintenance expertise necessary to turnkey the entire operation. This allows industrial operators to focus on the core of their operation driven by a reliable and efficient power solution.

Specifying standby power generators used to be mainly a technical process that evaluated electrical loads and electrical codes for maintaining essential life-safety systems. These codes ensured that in the event of a utility outage, there was enough power to provide minimal lighting, operate elevators in high-rise buildings, and keep alarm systems activated while employees or customers safely exited the building.

The solution then was a generator set that met these minimum requirements. But increasingly, sizing and specifying standby power generator sets is becoming a business decision, driven by economic risk assessment and a continually growing dependence on a perpetual source of electric power.

Today, that fundamental design question has expanded to include: how much a utility outage will cost per hour in terms of lost production, lost products, lost revenue, lost data or customer dissatisfaction; and how much a company should invest in a standby or on-site generator to reduce these risks to nearly zero.

Outages can be costly

In new business-model assessment’s, nearly all facility electrical loads are deemed essential because all are necessary for the normal continuation of the business.

For the average large business, the cost of an electrical outage can extend beyond $1 million per hour.

In industries such as manufacturing and telecommunications, losses may even exceed $2 million to $3 million per hour. In fact, in 2011, several Korean companies lost an estimated 100 billion won (approximately $89.4 million) resulting from a power outage that

solution for a fast-track capacity application because of the modular design that is custom engineered for rapid mobilization and start-up.

Typically, consumers need additional power quickly either for base load, continuous operation or for emergency standby in the event they are able to control the electricity requirements through load management.

Industrial companies operating independently from the grid often require a dedicated source of electricity. An unreliable supply from

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Feature - Standby Power Asia

lasted all of 16 minutes. The floods in Thailand a few years ago also caused continuous outages, greatly stalling industrial production.

What’s more, widespread outages are common in Asia. In Indonesia, businesses experience outages at least three times a week. Faced with such high-stake risks, businesses are seeing standby power as a critical lifeline and no longer just a luxury.

While standby power system reliability is a concern for any facility, it is especially important for mission-critical applications such as hospitals, data centers, telecoms, government, and water and wastewater treatment. In addition, there are numerous organizations that rely on standby power systems for business continuity and to reduce exposure to financial loss resulting from a utility outage.

To maximize reliability, facility managers need to understand and consider the critical factors that go into specifying, installing and maintaining a standby power system. Lets look at some of the considerations;

1. How has the generator set been designed and has it been manufactured to the highest quality 2. How big is the footprint for the system 3. Can it minimize downtime by ensuring its running in under 10 seconds 4. What will the maintenance schedule be and how often will it be tested

While no mechanical system can be expected to be 100% reliable 36 | POWER INSIDER VOLUME 4 ISSUE 5

over time, todays modern diesel and gas standby power systems come very, very close to the ideal, obviously as long as they are properly maintained. Looking at the past few years, the occurrence of mechanical failure has been rare; it’s most often down to human error and neglect.

A single, large diesel standby generator may have sufficient capacity to supply all your critical loads; however, it is often advisable to divide the load among smaller, multiple standby generators to maximize reliability and operational flexibility. In the unlikely event that one standby generator does not start when needed, the others will start and supply the load by drawing on their built-in reserve capacities.

Another factor in the general sizing of a standby power generator unit has to do with the amount of physical space that is available to house the system. Standby systems located inside buildings should have a dedicated room with sufficient airflow for cooling and sufficient space for proper maintenance activities.

Large standby power systems may also have their own separate building or they may be located outdoors in weather-tight and sound-attenuated enclosures or ISO style containers. Problems are often caused in shopping malls and data facilities where there simply isn’t enough room to ensure the correct unit. Suppliers need to look at the design of systems that can offer a much higher power output whilst reducing the overall footprint.

Many sites for todays generator sets are in very harsh environments, where the operators can ill afford any form of compromise to their equipment. Really, only generators that can operate efficiently under

extreme ambient temperatures, different altitudes and of course in the middle of the ocean can be considered for applications such as mining and oil and gas. Often, diesel units are used as they are proven equipment, cost effective and reliable. But this also forces operators to look at things like the cost of fuel, which is currently rising throughout Asia. These pieces of machinery run for extended periods of time, so fuel is an important consideration.

Today’s modern machines will need

Standby Power Asia

power generation products.

One thing is for certain, suppliers must be able to offer cost effective, locally packaged generator sets with well known branded engines to reduce price, increase sales and fight the Chinese invasion.

Technical know-how aside, it is of critical importance that the supplier is able to discuss and determine with you the economic risk associated with a utility outage and your desired level of response to that risk when planning for a standby power generator set.

This ensures that you receive a high performing and reliable product that is tailored to your specific needs from the very beginning. In addition, a supplier that provides a single point of contact simplifies the purchase, setup and long-term maintenance of the generator set.

Moving Forward

According to the International Monetary Fund, Asian countries face a major challenge as they seek to upgrade their infrastructures while their economies are growing rapidly.

Given the various constraints on government, primarily financial ones within the region, private participation in infrastructure is likely to increase sharply.

to ensure longer servicing schedules making downtime as minimal as possible.

Choosing the right supplier

While it is tempting to purchase a cheaper generator set or the first one that meets your immediate power requirements, it is of utmost importance to consider the quality of the product and the supplier as this will have a significant impact on the overall lifespan of the generator. Ideally you should approach a supplier that has the expertise and experience in offering

“For the average large business, the cost of an electrical outage can extend beyond $1 million per hour.

Most Asian governments have recognized the importance of changing their policies and creating an environment conducive to sustainable private sector involvement in their infrastructure sectors. But the reform of these sectors needs to be accelerated, and private developers should develop more flexible, innovative, and realistic project designs and concepts. Until this time, there will remain a constant requirement for temporary power throughout the region and the globe.

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Interview

In today’s ever changing economic environment maintaining business continuity is of utmost importance for all companies in order to compete effectively in a global market, whether they are from the commercial or industrial sectors. According to research by contingency planning organizations, the cost of an electrical outage can exceed $1 million per hour for the average large business. In certain industries such as semiconductor, energy production, data centers and telecommunications, losses may reach $2-$3 million per hour or higher. Given our 24/7 dependence on electric power, these high-stake risks and costs are forcing commercial and industrial facilities managers worldwide to evaluate new options to provide a continuous supply of power.

In the traditional model, facilities managers typically considered that in the event of a utility outage, the backup power sources can provide minimal lighting, operate elevators and keep alarm systems activated while employees or customers safely exited the building in accordance with the local safety and electrical codes and standards. The solution then was a generator set that met these minimum requirements. However more and more, sizing and specifying standby power systems is becoming a business decision, driven by the economic risk assessment and a continually growing dependence on a virtually perpetual source of electric power such that today, that fundamental design question has expanded to now include: how much will a utility outage cost per hour in terms of lost production, lost products, lost revenue, lost data or customer dissatisfaction? And, how much should a company be willing to invest in a standby or on-site power system to reduce these risks to nearly zero?

Given these economic factors behind the need and desire to maintain business continuity in the event of a utility power failure and the need to provide reliable standby power the new fundamental selection criteria’s importance now includes the use of high-horsepower generator sets that meet not only these basic safety and electrical code requirements, but are also able to provide a desired level of dependability and reliability whilst providing the optimal physical design.

Depending on the industry, customers have different requirements and demands. However, the fundamental requirement remains constant- a reliable back-up power solution to ensure uninterrupted operations as power failures can be very costly.

Power Insider Asia sat down with Mark Vanderkolk, Director – Asia Pacific Power Systems Business, Cummins Power Generation, to discuss more on the power generation landscape.

Q: We are seeing power demand increasing rapidly, particularly in Asia.

How do you see the power generation industry’s requirements evolving within the various market use segments?

Prime power applications

As a general statement - Applications that rely on off-grid, supplement power sources or where the generator sets are in fact the only source of power, then to achieve operational stability requires generator sets that perform well for extended-run scenarios.

These include mining, oil and gas or other projects in remote locations, operating in harsh and challenging environmental conditions. This calls for a robust prime power solution to support the facility and heavy machineries, as well as being resilient enough to function under harsh conditions – think blazing-hot at 50 degrees Celsius with a lot of dust.

In addition, for applications running as the prime power source, fuel efficiency is an important consideration because even a moderate improvement in fuel consumption will equate to considerable fuel savings. Furthermore, minimizing operational downtime is equally crucial to ensure continued mining operations, so longer intervals between servicing is preferable.

Power of More Critical and standby power applications

Again talking in general - For critical applications such as data centers, healthcare and water treatment plants, reliable standby power is of high priority to ensure uninterrupted power supply. In the event of a power outage, having the backup power system start up within a few seconds is essential, to minimize downtime. In applications such as data centers where floor space is an investment, a power system with a smaller footprint is also ideal.

Q: How is Cummins Power Generation (CPG) responding to the world’s growing – and changing – demand for power?

CPG is introducing a new series of high horsepower generator sets, which were developed in anticipation to the changing demands of the commercial and industrial sectors. The new QSK95 Series of generator sets are powered by the robust and compact high speed Cummins QSK95 95 Liter engine designed to deliver outstanding power capability.

Delivering more power, performance and reliability, the QSK95 series generator sets are optimized for a wide spectrum of applications ranging from prime power through to standby applications, thanks to their scalable output of up to 3,750 kVA (3.5 MW).

Best-in-class fuel efficiency for prime power application

In terms of prime power applications, the QSK95 Series generator sets are designed to operate reliably in the most challenging environments. A best-in-class fuel efficiency in the market also promises substantial cost savings for fuel.

For example over a course of 8,000 operational hours per year, this can amount to savings in excess of US$400,000 annually, dependent on delivered fuel costs in remote locations. Moreover, optimal uptime is guaranteed through many engineering and design improvements, achieving industry-leading hours to overhaul and doubled service intervals.

Optimal power/size ratio for stand-by power application

The new QSK95 Series generator sets offer the industry’s most favorable power output to its 20 cylinder competitors.

Powered by a 16-cylinder engine, the QSK95 has a smaller footprint offering comparable power output to its competitors.

For our customers, this means overall lower installation costs. In addition, with 100 percent one step load acceptance capability and 10-second start up time, this translates into less downtime, which is very important for critical applications.

In addition, data center customers will be happy to know that Cummins has a complete line of QSK95 Series generator sets with a Data Centre Continuous (DCC) rating that is pre-approved for Uptime Institute’s Tier III and Tier IV certification.

With this rating, data centers get the most efficient use of their generator system with unlimited run-time and no restriction on hours of operation. Plus, the QSK95 Series generator sets will run closer to their optimum load level, which will increase the life and reliability of the generator sets.

Power of More Q: Can you tell us more about the development of this new series of generator sets?

Cummins has committed major resources to the new QSK95 Series generator sets with millions of dollars investments in research and development and new manufacturing build and facilities to establish production line and test cells.

Our generator sets have been extensively tested on our factory on-site production cells to evaluate the performance of the engine, alternator and other critical components. Additional testing at Cummins’ Acoustical Test Center facility measures the precise noise output, ensuring minimal acoustic emissions. Housing a sprawling 13,000-square foot anechoic test area, this is currently the world’s largest generator set-testing facility.

The QSK95 Series generator sets have also been designed to comply with major global standards and certifications, including CE, CSA, UL, U.S. EPA, NFPA 110, TA Luft and ISO 8528.

As part of Cummins Power Generation’s introduction of the new QSK95 series generator sets in Asia, the company will be hosting the launch via webcast in a virtual environment. This will take the form of an exhibition hall where you can visit our booth and find out more about the product. A resource center will allow you to view and download information on the QSK95 Series generator sets. There is also a networking lounge where you can chat with Cummins experts holding a live Q&A session.

There will also be a series of thought leadership discussions run by Cummins experts, featuring presentations by Rich Freeland, President and Chief Operating Officer Cummins Inc, and other Cummins leaders.

Register for The Power of MoreTM - QSK95 Series generator sets launch event: QSK95serieslaunch.com/virtual November 6th, 2014

Session 1: 11 am Hong Kong Time 8.30 am - Colombo/ Delhi/ Mumbai 9.00 am - Dhaka 10.00 am - Bangkok/ Ho Chi Minh/ Jakarta 11.00 am - Hong Kong/ Beijing/ Shanghai/ Kuala Lumpur/ Manila/ Singapore 12.00 pm - Seoul/ Tokyo 2.00 pm - Melbourne/ Sydney Session 2: 9 am GMT 2.30 pm - Colombo/Delhi/Mumbai 4.00 pm - Bangkok/Ho Chi Minh/Jakarta 5.00 pm - Hong Kong/ Beijing/ Shanghai/ Kuala Lumpur/ Manila/ Singapore

Four presentations from 6 Cummins leaders: Richard Freeland, President and Chief Operating Officer of Cummins Tony Satterthwaite, Vice President of Cummins and President of Cummins Power Generation John Wall, Vice President and Chief Technical Officer for Cummins, and Gary Johansen, Executive Director of Engineering for Cummins Power Generation Dennis Heathfield, Executive Director of Power Systems, and Ray Amlung, Vice President of Distribution Service Operations & Cummins Service - Functional Excellence

Interactive Networking Session - Live Q&A with Cummins experts at networking lounge - Virtual booth staffed by Cummins employees to answer any additional questions - Resource center to download information

More Reliability. Less Downtime.

Introducing the QSK95 Series of high-horsepower generator sets.

Mission critical applications demand a robust, reliable source of power to ensure uninterrupted operations. For operators who seek to maximize uptime, the QSK95 Series of generator sets exceeds industry standards by providing 100 percent, one-step load acceptance in less than 10 seconds. And with ratings at up to 3,500 kW (3,750 kVA), the QSK95 delivers high-horsepower output while achieving installation economies with an innovative small-footprint design.

Register to attend our virtual event on November 6 to learn about The Power of More.

QSK95serieslaunch.com/virtual Our energy working for you.

TM

© 2014 Cummins Power Generation Inc. All rights reserved. Cummins Power Generation and Cummins are registered trademarks of Cummins Inc. “Our energy working for you.” is a trademark of Cummins Power Generation Inc.

Feature

Ansaldo Energia AE64.3A gas turbine upgrade IN RESPONSE TO THE CHALLENGES OF THE Russian energy market INTRODUCTION

- Natural gas will be used more and more in high efficiency combined cycle power plants instead of in traditional steam plants; - For climatic reasons, gas-fired district heating generation plants have proved to be the best solution from both economic and environmental points of view thanks to the combined generation and sale of heat and electric power.

Added value other than efficiency is therefore represented by: an engine size that is a good fit for use in district heating applications< maximized availability and reliability< a low initial investment and the 42 | POWER INSIDER VOLUME 4 ISSUE 5

Figure 1: AE64.3A references

The global power generation market has been changing constantly over the last decade and continues to evolve. Gas turbine users working in todayâ&#x20AC;&#x2122;s energy market are also challenged by different market needs, which often depend on regional factors such as climate, energy demand over the day, grid features and requirements, generation resources and assets.

The key factors for competitiveness and sustainable growth are therefore the ability to provide the best match for regional market needs. Specifically, energy market trends in Russia can be summarized as follows:

opportunity to optimize it through a step-by-step construction strategy.

In this regard Ansaldo Energia offers a wide range of both F and E class technology gas turbines, all with proven reliability of over 99%.

The AE64.3A is the smallest engine in the family, with an output of 78 MW coupled with F-class efficiency. This gas turbine is especially appreciated in small to medium size applications such as grid support, co-generation and district heating due to its affordability, high efficiency and optimal size.

The references in Figure 1 demonstrate this worldwide appreciation. Reliability and availability of greater than 99% and 94% respectively have been proven over 2,100,000 Equivalent Operating Hours. Fifteen AE64.3A engines are running in Russia today, all of them in district heating applications. The rest of the fleet is located primarily in Western Europe.

The AE64.3A gas turbine has been improved continuously since the 1990s to deliver increased power and efficiency. Todayâ&#x20AC;&#x2122;s GT delivers an output of 78 MW and 36.1%

Gas Turbine Upgrade efficiency. This turbine is also available in a “Low BTU version”, which can burn unconventional gas with a low heating value.

The AE64.3A gas turbine is based on a single-shaft design. Today’s design includes a fifteen-stage axial compressor with variable inlet guide vanes and a four-stage axial turbine with a common rotor.

The single-shaft rotor runs at 5400 RPM and consists of a front shaft section, compressor blade disks, a central hollow shaft section, turbine blade disks and a rear shaft section, all held together by a single central tie bolt with a clamping nut at the turbine end. The rotor resulting from this construction is a self-supporting drum with low weight and high stiffness.

Each rotor disk has radial Hirth teeth

“Ansaldo Energia offers a wide range of both F and E class technology gas turbines, all with proven reliability of over 99%”. on both sides. The Hirth serrations provide radial alignment between the rotor sections, ensuring torque transmission and allowing free relative radial expansion and contraction. This construction is particularly significant in terms of the operating life of the rotor components in response to changes in operating conditions and temperature distribution in the rotor. This solution therefore enables short start-up times and a broad range of operating capabilities in all steady-state and non-steady-state rotor temperature conditions.

The rotor is supported by two bearings, one in the front shaft

section and one in the rear shaft section. The bearing at the compressor end is a combined journal and thrust bearing designed to balance the axial thrust of the rotor. The two bearings are located outside the pressurized region of the gas turbine, providing the basis for constant good alignment and excellent running qualities.

The generator is driven from the compressor cold end and is coupled via a gearbox to the gas turbine shaft. The gearbox reduces the 5400 RPM of the turbine rotor to the required grid frequency. Thanks to the specific gearbox mounted and the features of Ansaldo Energia’s WY18Z electrical generator, the AE64.3A gas turbine can generate electricity at 50 Hz or 60 Hz. While a single-shell casing design has been adopted for the first part of the compressor, a two-shell design (outer and inner casings) has been adopted from the tenth compressor stage downstream to

the turbine outlet and for the combustion chamber.

The major advantage of the two-shell design principle is that the mechanical and thermal loads are separated on the outer and the inner casings: mechanical loads due to internal pressure are borne by the outer casing on which the thermal loads are low, while thermal loads are borne by the inner casing on which the mechanical loads are low.

The inner casings also act as stator blade carriers.

All the turbine stator vanes and rotor blades are air-cooled, with the exception of the last stage, which is not cooled. Blade cooling air flow is provided directly by bleed lines from the compressor at specific pressure and temperature conditions to optimize cooling effectiveness and engine performance. The cooling air, after flowing through the blades and vanes, discharges into the hot gas stream.

Figure 2: Internal view of the annular combustion chamber and the coated metallic heat shields originally used in place of the current ceramic tiles

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Feature - Ansaldo Energia

Figure 3: Insights on the AE64.3A on offer today

product portfolio.

Figure 3 provides insights on the AE64. Along with the performance enhancement to 78 MW and 36.1% efficiency, this engine has been designed with a special focus on operating flexibility associated with the grid requirements for spinning reserve or frequency control, and on competitiveness when generating during variable and discontinuous electricity demand. 15 MW/min fast load ramps have recently been tested on site. Full-speed no-load is reached in 5 minutes from ignition, and base load can be reached in less than 10 minutes.

The upgraded AE64.3A gas turbine INTRODUCTION is equipped with an annular market The global power generation combustion chamber and 24 dry has been changing constantly over low NOX burners for both fuel to the last decade and continues gas andGas fuelturbine oil operation.

In the in evolve. users working two-shell design, the combustion today’s energy market are also chamber is mounted inside the challenged by different market central section of the outer casing. needs, which often depend on The combustion chamber inner regional factors such as climate, shells are surrounded by the energy demand over the day, grid compressor air. The inner features anddischarge requirements, shell surfaces exposed to the hot gas generation resources and assets. are lined with heat shields.

These The key factors for competitiveness heat shields weregrowth originally and sustainable are made of metallic tiles with a ceramic therefore the ability to provideoxide the layer on their asmarket shown in best match forsurface, regional Figure 2, whereas today’s needs. Specifically, energydesign market uses ceramic tiles.

The trends in Russia can beAE64.3A summarized burner is a dual-fuel hybrid as follows: (diffusion-premix) design which -enables Naturalstable gas will bereliable used more and and more in high efficiency combined combustion with fuel-gas and cycle power plants instead of inCO fuel-oil and very low NOX and traditional steam plants; emissions. The burner aerodynamics are by two concentric, - Forgiven climatic reasons, gas-fired co-rotating swirlers (axial and district heating generation plants diagonal).

Thetopremix have proved be the fuel-gas best solution distribution pipes areand integrated from both economic in the diagonal swirl generating environmental points of view thanks blades, which improves the mix to the combined generation andof the fuel with the air flowing through sale of heat and electric power. the diagonal swirler.

Added value other than AE64.3A features represented efficiencykey is therefore Mid-sized gas turbine by: an engine size thatapplications, is a good fit such as grid support, co-generafor use in district heating tion and district heating in Russia, applications< maximized require the gas turbine to maximize availability and reliability< a low the performance and reliability initial investment and the of compact low initial investment

44 | POWER INSIDER VOLUME 4 ISSUE 5

plants and enable phased plant capacity expansion programs.

For this purpose, high efficiency and power must be provided within a compact, robust and affordable engine design, while keeping the initial investment low. Ansaldo Energia has been continuously improving the AE64.3A with this goal in mind, by coupling the well proven affordability and compactness of the AE64.3A engine family with the latest technology design features of the well proven AE94.3A gas turbine, which is Ansaldo Energia’s high-efficiency, large-sized, F-class gas turbine.

As a result, the F-class AE64.3A is one of the most advanced gas turbines in Ansaldo Energia’s

Moreover, engine maintenance intervals will soon be extended to 33,000 Equivalent Operating Hours and NOx emissions reduced below 15 ppm.

“Ansaldo Energia offers a wide range of both F and E class technology gas turbines, all with proven reliability of over 99%”.

Figure 4: Two-step Secondary Air reduction strategy aimed at increasing engine performance

Proud to be here

ansaldoenergia.com

Feature - Ansaldo Energia and vanes, enhanced blade cooling systems, the optimization of the secondary air flows and low-loss aerodynamic profiles. With regard to the blades and vanes in the first three stages, enhanced hot-flow resistance has been progressively implemented by means of an advanced Metallic Bond

stresses are low and the engine maintenance intervals can be extended from 25,000 to 33,000 Equivalent Operating Hours.

Coat. These three air-cooled stages have also been improved to achieve significant cooling air reduction of about 6% of the total amount of blade cooling air. To achieve this goal, each blade and vane has been upgraded by optimizing the internal blade cooling system and enhancing the thermal barrier coating. With the exception of the last stage, in fact, the turbine vanes and blades are cooled by internal convective systems and external film coverage (the latter for the 1st and 2nd stages, see Figure 5).

translates into rapid delivery of upgraded components.

Moreover, no changes were made to the blade castings and the necessary modifications involve only machining processes, which

Figure 5: Film-cooled first stationary vane row

This engine performance has been made possible by adopting a continuous improvement approach over the years to implement the latest F-class technology in the AE64.3A gas turbine: along with compressor enhancement and the low-loss profiles used for the fourth turbine stage and the exhaust-gas duct struts, the other major improvement relies on the reduction of the Secondary Air System requirements in the hot section of the turbine and in the combustion chamber.

The secondary air mass flow obtained in this way is added at the burners inlet to support combustion stability and allow the turbine inlet ISO temperature to be increased (Figure 4). The specific key features of the gas turbineâ&#x20AC;&#x2122;s major subsystems are summarized below.

Compressor

The high performance compressor has been down-scaled directly from the well proven design of the F-class AE94.3A gas turbine. The number of compressor stages has been reduced from the early 17 to 15 stages and the number of compressor rotor disks has therefore been reduced by the same amount.

The current compressor design yields: 212 kg/s air mass flow, equivalent to 10% more mass flow with almost identical inlet and outlet cross sections; higher pressure ratio from 16 to 18; higher aerodynamic efficiency; greater than 20% improved margin against surge.

The journal and thrust bearing at the compressor end now has enhanced features to balance the higher axial thrust of the rotor.

Hot-section turbine

The 4-stage hot-section turbine has been improved continuously with solutions once again derived directly from the AE94.3A engine design. There have been modifications to all four turbine stages: advanced coatings on blades 46 | POWER INSIDER VOLUME 4 ISSUE 5

The implementation of improved thermal barrier coating on all these three stages raises overall cooling efficiency and enables a concomitant reduction of cooling air mass flow.

The average temperatures of the hot components therefore remain below or equal to the previous values despite the concurrent increase of the hot-gas inlet temperature. As a result, the thermo-mechanical

With regard to the fourth and last turbine stage, the rotating and stationary blades have been down-scaled from the AE94.3A engine with new aerodynamic profiles which ensure increased aerodynamic efficiency with the higher flow rate delivered by the compressor. This improvement involves: new profiles and shapes, enhanced materials experience deriving from the AE94.3A engine, rotor blade cored cast to reduce thermo-mechanical stress, a reduced number of blades and vanes per shroud, and metallic bond coat deposition to improve oxidation and hot corrosion resistance.

Finally, the turbine hot-end exhaust-gas duct has been redesigned. Profiled struts (in place of the early straight ones) yield further aerodynamic loss reduction.

Gas Turbine Upgrade Figure 6: View of the annular combustion chamber equipped with ceramic tiles and metallic tile-holders (view of inner shells)

Combustion chamber

For the combustion chamber too, the strategy was to continuously implement the high-performance design features of the well proven AE94.3A gas turbine, in which the internal surfaces of the annular combustion chamber are lined with ceramic tiles that act as heat shields. As stated above, the original AE64.3A design used air-cooled metallic heat shields to protect the annular combustion chamber shells from the hot gas. Todayâ&#x20AC;&#x2122;s design uses ceramic tiles, which do not require cooling, instead of the early metallic tiles, which do. Air-cooling is required only for the metallic tile-holders, but thanks to their compact design the exposed surfaces are small and cooling requirements are low (see Figure 6). Overall, the upgraded system requires less air-cooling than with metallic tiles. The entire operation will reduce combustion chamber cooling air by about 40%.

The system presented has been designed to make maintenance operations easier: both the tile and the holder are disassembled frontally (not laterally) and the bolt

connections to the shell have been provided with a specific patented system that ensures the best reliability and ease of disassembly during field service interventions by avoiding blockage due to oxidation and thermo-mechanical fatigue.

Burners

The burners have been optimized to match the increased mass flow delivered by the compressor.

Moreover, the air mass flow made available by the reduction in secondary air is added at the burners inlet to support combustion stability and allow the Turbine Inlet ISO Temperature to be increased.

Improvements include the redesign of the pilot burners and diagonal swirlers, while maintaining dualfuel capability. Specifically, the axial flows in the pilot burners have been improved through new axial-swirler blading and optimized fuel injection streams in order to increase combustion stability in the new operating conditions. The new burners will also be able to achieve NOx emissions below 15 ppm.

In 2013, the fuel flexibility of the HR3-type burner was extended to

include Low BTU gas capability.

A specific burner has been designed for unconventional gas with LHV down to 19 MJ/kg, which is around half the value of natural gas.

Experimental tests demonstrated that this burner can light using low BTU gas only, without needing any conventional natural gas as a backup for ignition even in extreme winter conditions. It has also been demonstrated that combustion is very stable in the entire load-range up to base load conditions.

Conclusions

Ansaldo Energiaâ&#x20AC;&#x2122;s AE64.3A gas turbine has been illustrated with a specific focus on the key success factors for small to medium size gas turbines operating in the Russian energy market: the AE64.3A design concept has been described in detail, along with its technical features and performance capabilities. The evolution pathway described contributes to demonstrating Ansaldo Energiaâ&#x20AC;&#x2122;s capability to implement the latest F-class technology improvements on the AE64.3A, making this gas turbine a top-class performance engine.

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Feature

Stuxnet:

Coming to a town near you?

Author: Leigh Warren Leigh Warren – Vice President of Field Operations, Blue Coat Leigh Warren is the vice president of field operations at Blue Coat and is at the forefront of the latest developments and innovations in the IT and security sector. He has more than 25 years’ technology experience across Europe, Africa, Latin America and the Asia Pacific regions.

In his role, Mr. Warren is responsible for growing the company, as well as strengthening and building its already robust distribution and channel model. He will oversee the development of projects and growth initiatives in line with the company’s continuous expansions in the APAC region.

Prior to joining Blue Coat, Mr. Warren held President and Chief Executive roles at Unisys, Tandem Computers, Oracle in South Africa and ANZ and more recently Ventyx in EMEA. He has also held executive consultancy roles and interim roles at global technology firms such as Blue Chip Consulting, SAP and Mincom.

Warren also serves on the board of ANZ based Gentrack Ltd and ASX listed Objective Corporation.

F

our years ago, news broke about the discovery of a 500kilobyte computer worm that had infected the control systems of at least 14 industrial sites in Iran, including the nation’s top uranium-enrichment plant.

The scale and capabilities of the worm, known as Stuxnet, was like nothing that had preceded it. Not only did it impair the operations of key manufacturing and infrastructure assets nationwide, it reportedly wiped out one-fifth of Iran’s nuclear centrifugesi – core components of any atomic energy programme.

The attack took place in multiple phases. First, the worm entered Windows-operated computers by means of the Internet. It then spread to networks not connected to the web via use of USB sticks, where

48 | POWER INSIDER VOLUME 4 ISSUE 5

users remained unaware of the worm’s presence. Once inside a private network, the virus exerted control over the systems and processes that manage assets like the Bushehr nuclear power plant in southwestern Iran.

The purpose of the attack was multifold, but notably it sabotaged Iran’s atomic energy programme.

The extent of the damage caused

by Stuxnet remains unknown, yet commentators have valued this anywhere from US$100 million upwards. Of more significance, however, are the perpetrators of the worm, who are widely believed to be an inter-government alliance between Israel and the US (although neither have admitted responsibility for the attack).

An added bonus – if we can indeed call it as such – is that the worm caused zero fatalities. However, had

Stuxnet they wanted to, the attackers could have wreaked harm to hundreds of thousands of people from across the region.

While the majority of the general public view Stuxnet as an extremely rare and isolated incident, the alarming fact is that it is not.

Daily, other critical infrastructure assets located in all corners of the world are compromised by cyber-attacks. These include facilities like oil refineries, chemical plants, defense systems and transportation networks. Moreover, those found the West are often equally as vulnerable to those operating in developing nations.

The susceptibilities of such facilities are multiple in number. A large percentage of the systems that control critical infrastructure are more than 30 years’ old and are thus largely incompatible with present-day IT architecture.

Furthermore, they are unintentionally connected to the Internet, which exposes them to malware and other online threats,

and bear scant cyber-security features. Newer facilities are equally as vulnerable, however, as IT protection continues to be an afterthought during a facility’s development. Ownership gaps exist between IT teams and the operators responsible for the daily monitoring of these assets. There is also a global shortage of qualified personnel who can competently operate these systems.

Perpetrators of such cyber-attacks are likewise diverse. These include criminal gangs, terrorist cells, national governments and even disgruntled employees, among many other groups. All of the above makes uncomfortable reading for owners and operators of critical infrastructure, as well as national

“First and foremost, infrastructure operators must roll out robust policies that tackle each of the above issues individually”.

leaders that depend on these assets to keep their economies afloat.

What therefore can be done to prevent another Stuxnet – or worse, a similar event that causes widespread fatalities?

First and foremost, infrastructure operators must roll out robust policies that tackle each of the above issues individually. This begins with making IT security a boardroom issue, where C-suite executives are regularly informed about the risks cyber-threats pose to their operations.

In support of this, asset operators must implement cutting-edge IT security features within their networks, conduct frequent drills and tests, and ensure that ownership of cyber-security issues are shared among IT heads, system controllers and risk managers.

Asset operators must also employ the best engineers available in the talent market.

In the event that infrastructure operators fail to act, Stuxnet will likely be seen as the forerunner to an event far larger in terms of scope, scale and casualty numbers.

Alarmingly, this could happen in a town near you.

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Interview

Pankaj Sharma Vice President, Asia Pacific Schneider Electric, IT Business Pankaj Sharma is the IT Business Vice President for Schneider Electric Asia Pacific. He oversees the business strategy across East Asia, India and the Pacific, 17 countries in all, ensuring that businesses across the region remain focused on customers and partners. He leads the team in developing customer-oriented processes, delivering innovative energy efficient solutions in data centres, and builds successful relationships with Schneider Electric’s stakeholders.

Based in Singapore, Pankaj’s achievements include leading his team to grow the APW President’s rack business in India, a company Schneider Electric acquired in 2011 and other Mergers and Acquisitions performed for Schneider Electric IT Business.

Pankaj first joined APC in 2000 as Country Service Manager, then Country General Manager and President for Schneider Electric IT, for the Greater India region. Pankaj has also held Vice President roles for S.Korea and Japan with the goal to help rebuild the business in that region and driving the overall P&L for the IT Business. As well Pankaj was previously responsible for the Strategy function, HBN (Home and Business Networks) and Marketing for Asia Pacific and Japan, supporting the channel operations and increasing the company’s client base.

Pankaj has a broad range of experience in IT across the region, including India, Asia Pacific and Japan.

He is a six sigma green belt and ISO 9000 certified auditor.

Q1. What can be done to improve Transmission & Distribution in Asia?

A1. Over the past 5-10 years, Asia’s IT space has shifted. Countries like Indonesia, the Philippines, Malaysia and Thailand are now facing considerable IT growth fuelled by the development of connected devices, a growing and increasingly IT-savvy population, and complementary government support and initiatives.

This increase in reliance on new information networks means we must ensure effective transmission and distribution. Smart grids are the answer to smarter and more effective transmission and distribution and Asia is taking heed, as seen in the growing smart grid market in the region which is expected to generate $15.83 billion in revenue in 2018, up from just $5.4 billion in 20121.

Smart grids offer reliable and sustainable power delivery by strengthening the electricity network to meet the increasing power demand. This in turn enhances operational efficiencies.

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Pankaj Sharma Schneider Electric’s open-ended solutions make grids more efficient, more flexible and more secure. We achieve this by: Improving service continuity while absorbing increasing demand and peak loads Connecting and managing more green and volatile energy by up to 30% Delivering better quality power while drastically reducing network losses Operating the grid safely and securely Delivering greater visibility and decision-making tools at enterprise level allowing to improve CAPEX and OPEX

Q2. What do you feel are the current challenges in Asia?

A2. One of the main challenges is addressing the demand for fast, reliable storage of power or data.

The trend of the Internet of Things (IoT) holds the promise of more effective business models and improved processes. But if the data centre can’t accommodate the increase in data complexity brought on by IoT, the data’s value is lost.

We urge organisations to implement solutions that will enable their IT facilities to process, analyse and compute information so they can make informed decisions to meet their business and service goals. For example, Data Centre Infrastructure Management (DCIM) is a technology offering that optimises enterprise energy by collecting and managing data on a facility’s assets, resource use and operation status throughout its lifecycle, so facility owners and operators can have greater control over their data environment. We recommend this solution because it not only enables customers to identify hot spots, overloaded servers, and adjust them accordingly; it also empowers them with financial insight and visibility into business performance, assisting them with enhancing their facility’s energy efficiency via sustainability planning.

Evolving enterprises and SMEs can also look at prefabricated data centre solutions. These fast-to-deploy systems enable new, established and growing companies to adapt and align their infrastructure to the speed of business growth in order to meet their changing business, needs now and in the future.

Q3. In light of this, where do you think Asia is heading in particular?

A3. The reality is, we’re living in a world that requires us to do more with less. IT departments are stretched to maximum capacity, putting a strain on resources that is not sustainable in the long term.

In fact, Southeast Asia’s energy demand is projected to be 80 per cent higher by 2035, fuelled by an economy that is expected to triple and a population that will increase by nearly 25 per cent. Compounding the situation is the reality that CO2 emissions are set to double by 2050, driven by the rising energy demand1.

For organisations to remain sustainable and successful in this environment, they need to re-evaluate their strategy and account for energy management solutions. In fact by implementing integrated energy management solutions in industrial, commercial and residential buildings today, we can save up to 30% of three quarters of the world’s final energy consumption.

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Interview - Schneider Electric Q4. What projects are you most proud of in Asia?

A4. We are most proud of our Data Centre Lifecycle Services (DCLS) Bureau which was developed in anticipation of the market’s evolving needs. Based in India, the Services Bureau provides services to keep our customers’ data facilities running optimally and effectively on an ongoing basis, achieved via a five-step DCLS process.

The first four-steps set the foundation for the facility by assessing, planning, designing, and ultimately building the data centre. Once built, step five – maintain, operate, monitor and optimise – begins its ongoing process of assessment. During this phase, our data scientists at the Services Bureau monitor and make sense of what is happening with our customers’ data centres as well as offer predictive modelling on what is required in the future, so these facilities can adapt to change.

For organisations that manage their own internal data centre operations, DCLS brings more precision and predictive power to the way the data centre physical infrastructure is managed. This in turn drives down costs and boosts operational efficiencies.

For enterprises offering data centres as a service offering to customers – including those in wholesale, retail and managed services, and cloud providers – DCLS manages expenditure and enhances operational efficiencies, which enables a more efficient service to their customers. With more effective practices in place, it consequently drives the organisation’s profit margins and enables better monetisation of the business’ products and services.

“Southeast Asia’s energy demand is projected to be 80 per cent higher by 2035”.

Q5. Tell us about some of the challenges you face and how you overcome them?

A5. Our main challenge is ensuring the consistent development of innovative solutions for varying business models.

For example, our enterprise customers are looking for: A data centre that keeps up with the explosive pace of cloud based business and big data. Their facility needs to be reliable, efficient and scalable, while keeping data secure.

Automated and integrated data centre management to drive business performance.

An increasingly simplified and rapid process of planning, designing and building their data centre.

Schneider Electric has addressed these challenges by simplifying the data centre lifecycle from concept through to commissioning. We also offer our clients a full portfolio of reference designs and the largest collection of data centre components.

Comparatively, our SME customers need a solution that: Eliminates hot spots through predictable cooling paths Enables quick, easy deployment of new equipment Gains optimal efficiency from a right-sized environment Allows room for growth without changes to the installation We help these clients by anticipating changes they are facing and adapting accordingly. Our modular architecture means we can provide a quickly deployed, correctly-sized data centre throughout an SME’s business growth, eliminating the costly risk of over-sizing.

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Pankaj Sharma Q6. How do you feel local governments can help the situation in Asia?

A6. We are gradually seeing governments play a greater role in the creation of more efficient data centres in more developed markets. For example, the Singapore government uses a positive reinforcement approach with the SS564 Green Data Centre Standard. This scheme presents a rebate to companies with data centres that meet the nationâ&#x20AC;&#x2122;s standards for environmentally-friendly buildings, the Green Mark standard.

In developing markets, some businesses are still operating with the conservative mind-set of building and operating their IT entirely in-house. Convincing them about the merits of cloud computing will generate a groundswell of demand for data centres. It is great that the governments in Asia recognise this steady uptake of cloud-based technologies, and to address it, have launched initiatives to encourage content and application providers, as well as SME businesses to embrace the cloud.

Bourgeoning markets like Thailand are also witnessing IT growth following Board of Investment approved initiatives for data centres aimed to help strengthen the countryâ&#x20AC;&#x2122;s IT infrastructure and encourage more investment in high-level IT business.

Investments like these create an attractive environment for investments and growth of the market and economies.

Q7. What makes Schneider competitive in the region?

A7. We are competitive because we offer more than point solutions: we deliver efficient end-to-end, holistic solutions and services. Our solutions enable people to experience and transform efficiency together at home, in the enterprise, across the grid, in towns and cities, and in energy-poor countries. Most importantly, our solutions improve business, operational and financial performance while conserving resources for a more sustainable world. In fact, by implementing our offerings, we can save up to 30% of three quarters of the worldâ&#x20AC;&#x2122;s final energy consumption.

Q8. From a development perspective, what are your plans for 2015?

A8. 2015 is looking to be an exciting year for Schneider Electric. Our DCLS, Services Bureau and prefabricated and DCIM offerings will continue to play a significant role in our customer solutions strategy. We constantly strive to simplify the entire data centre life cycle from concept to commissioning. It is this desire, and our commitment to sustainable IT practices that will continue to drive our innovative offerings.

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Feature

ENERGISING ELECTRICAL GRIdS WITH LEAdING HVdC TECHNOLOGIES Alston need’s no introduction when it comes to the power market. A global leader in the world of power generation, power transmission and rail infrastructure, it often is seen as the benchmark for innovative and environmentally friendly technologies. Everywhere you look in the power markets, you will see Alstom has a presence. At the current time, the worlds utility markets are looking at more efficient ways of generating renewable and sustainable power technology, but one of the main issues is ensuring that the power actually reaches the end user. We have taken some time to speak with Alstom on how their solutions actual reach the end user and some of the challenges the market faces.

According to the International Energy Agency (IEA), global electricity demand is set to rise by 50-70% by 2030, representing an average annual growth of approximately 2.2%. CO2 emissions will increase at 3.2%, outpacing energy demand. By 2050, renewables (wind, solar and hydroelectric) are expected to represent 25% of the energy mix on average.

Electricity is on the verge of a global revolution, one whose impacts will be felt in the energy sector, across industry as a whole and even on the global economy. The predicted increases in demand bring the need for innovative solutions to ensure a stable, reliable power supply while enabling a cleaner, more sustainable energy mix at affordable prices. A growing number of electricity providers are now looking to Supergrids as a means of linking resources and optimising the performance of their high voltage networks.

However, the sites producing renewable energy are often a long way from the places in which energy is needed.

As a result, the challenge lies not only in producing electricity on a large scale, but also—and perhaps more importantly—in carrying that power over long distances without prohibitive loss.

New advances in Direct Current (DC) power transmission—along with innovative solutions in power electronics— have now made it possible to transmit bulk amounts of electricity. Buoyed by the latest advances in HVDC technology, these trailblazing systems are the first steps to interconnecting new Supergrids, linking electrical networks to provide the transnational “power highway”.

HVDC: a technology that has made its mark AC transmission solutions have been widely used around the world since the end of the 19th century.

High-voltage direct current (HVDC) systems were previously seen as niche but following major developments in the central technology, they are now making their mark through some of the most ambitious power-transmission projects. This surge is largely attributable to fast-growing countries such as China, Brazil and India, which are seeking ways to meet the need to transmit more and more electricity over increasingly long distances. This is also true for countries such as Canada and the United States, where most of the electrical system was built in the 1960s and 70s, and there are not enough lines today to meet the exponential growth in electricity demand. North America strives to complete and reinforce its aging grids at an optimised cost while improving grid capacity, reliability, stability and resiliency to prevent blackouts.

Many HVDC transmission systems still operate at ±500 kV, with a capacity of 3,000 MW. The newest generation of HVDC technology operates at ±800 kV and can carry up to 7,200 MW (equivalent to a medium-sized nuclear plant).

China and India were the first countries to introduce ±800 kV technology as the most optimal means of transmitting electricity to major cities from power plants built in remote areas.

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HDVC Technologies

Transmitting huge amounts of electricity over very long distances The majority of renewable energy sources such as hydro, wind and solar power are often far removed from the places in which the power is used.

The issue of distance is even more critical for subsea connections, which require insulated power cables in contrast to the exposed lines used in overhead systems. AC transmission over 60-80 km or more becomes impossible without the use of major and expensive installations for compensation. Therefore, for long-distance transmission added to sub-water junctions, HVDC systems may be less expensive. As a result, distance is not an issue when it comes to crossing large expanses of water with HVDC submarine cables, which have been widely used for subsea connections since the 1980s. That makes HVDC an ideal solution for offshore wind farms built far from the coast or crossing sea channels and straits.

Lower electrical losses HVDC provides an effective means of tackling a tangible problem.

While renewable energy is now easier to produce, the distance between energy sources and the places in which the energy is used can be up to thousands of kilometres. Therefore energy loss during transmission has to be minimised. Using HVDC systems this transmission loss can be reduced by 30% compared to AC systems.

Interconnection for AC grids with different frequencies (asynchronous) For historical reasons, the frequency of national power grids can differ from one country to the next (50 Hz or 60 Hz). HVDC provides frequency conversion solutions for countries that use different frequencies but wish to connect their grids to share energy resources. In this case, the two conversion substations are directly connected in a back-to-back arrangement on the same site. HVDC can stabilise a network against disturbances due to the rapid changes in power.

Reducing infrastructure costs and footprints The latest HVDC systems can transmit up to three times more electricity than conventional AC systems using the same infrastructure (same number of pylons and type of conductors). As a result, the technology is an attractive option in the bid to reduce costs, limit the footprint of necessary overhead lines and provide a more compact flow of electricity in urban areas and underwater.

“By 2050, renewables (wind, solar and hydroelectric) are expected to represent 25% of the energy mix on average”.

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Feature - Energising Electrical Grids Technological challenges The latest HVDC technology has increased voltage from ±500 kV to ±800 kV, with the prospect of going up to ±1,000 kV. Handling such high voltage has required a number of new developments, some of which can rightly be called electro-technical revolutions.

Converter transformer: a key component in HVDC transmission Converter transformers are an essential part of HVDC transmission systems. They act as an interface between AC systems and DC systems. They provide the connection between the AC system from the generation source and the DC system used as the transmission line. On the other side of the transmission line, the converter transformer changes the voltage back to AC, to be distributed to end-users.

The reliability of these converter transformers is critical in meeting safety requirements for HVDC lines as they have limited overload capacity. Controlling power flow in a DC system requires good communication between all the terminals; power flow must be actively regulated by the converter control system.

Back-to-back for asynchronous connections and to change frequency

Point-to-point to transport bulk power in overhead lines

Point-to-point with a submarine portion

A significant contribution from power electronics: LCC and VSC solutions for HVDC Line Commuted Converter Most of the HVDC systems in operation today are based on line-commutated converters (LCC). HVDC LCC technology is based on large power semiconductors known as thyristors, a controllable switch which can be turned on but requires zero current to turn off naturally. In a line-commutated converter, the DC power can flow in both 58 | POWER INSIDER VOLUME 4 ISSUE 5

HDVC Technologies directions, thus enabling energy trading capabilities. LCC technology is the best suitable for high-power transmission (up to 7,600 MW) with voltages of up to ±800 kV for lines spanning extremely long distances of 2,500 km or more.

Voltage-Source Converter Today, there is rapid growth of another technology: voltage-source converter (VSC), which uses insulated gate bipolar transistors (IGBT) - large power semiconductors controllable switches - which have some advantages over the LCC thyristor switches because those can be switched both on and off. With regard to the technological challenge, VSC configurations offer advances over conventional LCC solutions, including a wide range of active and reactive power management and adjustment options, modular valves, the unprecedented ability to recover from total loss of local power HVDC lines (for intermittent wind farms), compact converters, no harmonic distortion, standard converter transformers and high-voltage cables. Alstom has developed and is testing and manufacturing its own power electronics solutions (MaxSineTM valve modules and submodules for VSC applications) along with embedded electronic control systems in each submodule.

“Alstom, with about 40 projects worldwide, has been a key player in the HVDC market for the past 50 years. It has provided over 35,000 MW of connection capacity worldwide”.

VSC connection of an off-shore wind farm

VSC can be a preferred alternative for projects involving significant environmental considerations on land or integrating massive offshore renewable energy sources. This type of technology is more flexible and more compact, enabling growth in offshore clusters that are a long way from the coast. Another advantage is the technology’s compatibility with the intermittent nature of renewable energy sources. A VSC converter can automatically re-establish the connection after a complete wind turbine shutdown due to lack of wind, which is difficult— and in some cases impossible—to achieve with a LCC converter.

However, the two technologies are not mutually exclusive, as LCC solutions are undeniably superior to VSC in terms of bulk power transmission. LCC HVDC transmission is still the preferred option across the globe due to its lower transmission losses, asynchronous interconnection and the capability to deliver energy over long distances.

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Feature - Energising Electrical Grids Control and protection of the DC grid In the case of a cable-connected HVDC system, a ground fault can occur, either by failed cable isolation or cable damage by an outside source. As more of these systems are installed into the bulk power system, control and protection of the HVDC systems must be a priority.

Smart control systems Management and control systems for this HVDC VSC technology require extremely sophisticated smart solutions.

The technology demands considerably faster computers to coordinate the hundreds of power electronics equipment found in a single valve. Based on experience gained from the protection and control systems used on their multiple projects around the world, Alstom teams have developed and are testing the full range of hardware, firmware and software needed to achieve the ground-breaking performance and applications of solutions that use HVDC configurations.

Besides a comprehensive array of engineering and simulation tools developed by Alstom for this new range of HVDC solutions, protection and control systems are fully tested in conjunction with customers as part of the acceptance process, involving all electrical cabinets (control cubicles) covered by the contract connected to Alstom’s real-time digital simulators (RTDS).

Fault protection As HVDC networks develop, it is clear that the management of faults on the DC side of the converters, and the protection co-ordination within any Grid is critical. Alstom is developing a clear protection strategy that encompasses the latest technologies – including converter blocking techniques and DC circuit breakers to be applied within a protection zone. Firstly there is the classic differential protection method called “discrimination” to determine where the fault lies, trigger the protection and isolate the fault zone. However, a second method is the Alstom ‘Open Grid’ approach. Each breaker has local monitoring and upon detection of a fault, this breaker opens.

There is no requirement to communicate any measurements to other breaker locations or a central control point.

This minimises the delay times associated with fault detection and breaker tripping. Once the breaker is open, the residual voltage at each DC circuit breaker is then assessed to identify healthy cables and/or lines, and those breakers not associated with the faulted section can be reclosed and the power flow can be re-established.

DC grid protection The circuit breaker is a new element of power network protection in the event of a short circuit. Circuit breakers are not necessary for direct current transmission line connections between two points. However, having a circuit breaker is vital for protecting complex so-called ‘meshed’ grids that will, in the near future, require the interconnection of several points. The challenge is to avoid failures and blackouts, by cutting the current in the malfunctioning element as fast as possible, isolating the fault from the rest of the grid. Alstom Grid’s new circuit breaker paves the way to multiple possibilities for future direct current grids.

In January 2014, Alstom successfully completed testing of its prototype HVDC circuit breaker. These latest tests ended with a project headed by RTE1 on operating and protecting DC power grids as part of the Twenties Project European research initiative. This innovation represents a huge improvement over technology currently on the market.

The “Supergrid”, a large network of power highways connecting countries and continents Today, the majority of systems are point-to-point LCC lines running from A to B. However, the increasing number of inter-regional connections and decentralised production sources requires the use of interlinked systems that comprise interconnecting nodes with a number of converter stations along each line. HVDC provides the technology needed to achieve this goal, making it possible to share asynchronous grid resources that otherwise could not be interconnected. HVDC makes multipoint systems a real possibility.

A number of studies have also highlighted the potential benefits of very wide area Supergrids based on HVDC since they can mitigate the effects of intermittency by averaging and smoothing the outputs of large numbers of geographically dispersed wind farms or solar farms.

The new energy model now emerging sees the concept of the Supergrid, with the switch from a one-way, centralised, passive system to an open, interconnected, interactive system.

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HDVC Technologies

Alstom, a worldwide leader in the HVDC market Alstom, with about 40 projects worldwide, has been a key player in the HVDC market for the past 50 years. It has provided over 35,000 MW of connection capacity worldwide.

Latest HVDC LCC examples In Brazil, Alstom is working on the Rio-Madeira project (3,150 MW), which features the world’s longest point-to-point HVDC LCC line (2,375 km). This project is to be commissioned this year, 2014.

Alstom used a back-to-back approach on the Gulf Cooperation Council International Authority (GCCIA) project to build three substations comprising two convertors each connected back-to-back to transmit 1,800 MW of power between Saudi Arabia (60 Hz) and the AC interconnection network (50 Hz) for the other five countries in the Persian Gulf, allowing them to share electricity with their neighbours. The project has been up and running since 2009 In Europe, Alstom headed in 2012 the benchmark IFA 2000 project to provide a 2,000 MW subsea line between France and the UK. In 2006, in Scandinavia, Alstom is the supplier for the Konti-Skan HVDC subsea transmission system (380 MW). Both projects are using point-to-point with a submarine portion HVDC links.

Other examples include: the Melo project in 2011 allowing Uruguay (50Hz) to share energy resources with Brazil (60Hz) via a 500 MW back-to-back connection, the dual subsea connection between South Korea and Cheju Island finished in 2011, and the first point-to-point ±800 kV HVDC link Champa-Kurukshetra in India (3,000 MW), one of the biggest contracts in the history of Alstom Grid, currently under construction.

Alstom also introduced its HVDC MaxSineTM as the ideal HVDC-VSC solution Alstom is applying its new VSC technology in the DolWin3 project in Germany, building the offshore HVDC VSC converter station connecting the wind farm in the North Sea to the converter station on the main land. This new HVDC line will be carrying the clean energy all the way to the country’s southern and western regions which are home to its most energy intensive major industries. The Dolwin3 Wind Farm Cluster will generate 900 MW at ±320kV. Alstom is also building the South-West Link in Sweden, providing an HVDC-VSC grid with a capacity of 1,400 MW covering the southwest of the country, which will be the world’s first multi-point HVDC connection.

In addition, Alstom Grid has successfully energised the second High Voltage Direct Current (HVDC) turnkey project on Jeju island in South Korea. The newly energised project which was awarded in 2009, establishes a 400 MW HVDC bi-directional transmission line between Jindo and the island of Jeju.

With 50 million people, South Korea is an energy-intensive nation, ranked eleventh worldwide in total energy consumption. Yet, it imports around 82% of the total energy that it consumes. Since 2006, the Korean government has developed new energy policies to become more energy dependent, meet growing demand and increase energy efficiency.

Jeju Island is located 100km south of the peninsular mainland at 73km wide and 41km long. Known as the countries honeymoon and holiday destination, the island previously operated on an independent electric network; it faced frequent blackouts and unstable power supply due to the network’s lack of efficiency and low power capacity.

Alstom’s HVDC technology is well aligned with Korea’s ambition for a low carbon economy, and is essential to carrying large amounts of power across long distances, with minimal losses.

The new HVDC link is designed to be bi-directional, where power flow goes in both directions between the main land and Jeju Island. This ensures that increasing renewable power on Jeju Island will be integrated for mainland use.

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Interview

Morten Miller, Ph.D. and co-founder of Mycometer, talks to PI magazine about Mycometers rapid method to detect bacterial loads in water samples.

Introduction Early detection of bacteria in drinking water and industrial process water is of utmost importance. Bacterial contamination is a serious potential health hazard. In the industry early warning can reduce water system downtime and reduce costs. With standard lab analysis, it can take up to 2 or even 7 days to grow bacteria cultures in order to determine if the water, e.g. in urban water supply, is contaminated. The Bactiquant®-water test reduces the time required from days into minutes. The concentration of bacteria in a filtered sample of water can be determined in less than half an hour, and potential problems can be identified before they become critical.

Comprehensive and quick results ”The conventional methods used for detection of microbial contamination of water are

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labour-intensive, time-consuming, and sensitive to errors during the performance of the tests”, says Morten Miller, co-founder of Mycometer. ”The problem is that you do not get timely results - our method is rapid and simple to perform”.

Even if the concentration of bacteria is low, the test can be completed in less than half an hour. It strengthens the ability to respond quickly and appropriately”. The Bactiquant®-water has been extensively documented by customers worldwide and has recently Received ETV Technology Verification by the United States Environmental Protection Agency (US-EPA).

The technology – Info Box Elcogen has analyzed closely the Bactiquant®-water targets a naturally occurring enzyme activity in bacteria.

The enzyme activity is present in a broad spectrum of bacteria, representing all major taxonomic

groups, including gram negative and gram positive bacteria as well as aerobic and anaerobic bacteria.

The enzyme belongs to a class of enzymes called hydrolases.

Bactiquant®-water is very sensitive to the presence of bacteria in water samples including suspended as well as bacteria immobilized on particles or in aggregates. The method follows the following steps. First bacteria in the water sample is concentrated on a filter. Then an enzyme substrate is added directly to the filter.

The substrate contains enzyme specific moieties combined with a fluorophore. The enzyme specific moieties are molecules that are especially inclined to combine with certain microbial enzymes. When they do so, the bond to the fluorophore is broken. The fluorophore is a fluorescent chemical compound.

When illuminated with light at a wavelength of 365 nanometres (barely visible ultraviolet light) it

Detecting Bacterial Loads emits light that can be measured at 445 nanometres (blue light).

The intensity of the fluorescence is proportional to the concentration of bacteria. The entire procedure takes 10 – 30 minutes, and it can be undertaken on-site.

The need for greater water efficiency The industries are major consumers of water and are under growing pressure from politicians and other groups to reduce their water usage. Today we have a situation where the water will soon not be available in the quality and quantity required for food processing and cleaning processes.

“The challenge today is to increase water efficiency in the industry by recycling

for response actions. On this basis, statistical changes can be detected at an early stage (ISO 11642-1).

It is therefore possible to prevent problems from occurring, rather than using many more resources to correct them after they have occurred.

The software is tailored to the requirements of the individual customer. “We have a great collaboration with Grontmij, an international consulting company based in The Netherlands, which allow us to provide a tailored software solution for our utility and industrial customers” says Morten Miller and continues “For our customers verification of water system hygiene is an indispensable requirement that requires rapid results and good data handling capabilities”

evaporative cooling products and a customer of Mycometer since 2006, has developed a comprehensive hygiene control system (HACCP) under ISO 22000. The system is based on firm hygiene instructions and procedures for the sale manufacture, installation and service of humidification systems.

Condair service engineers carry mobile Bactiquant®-water equipment for rapid evaluation of water hygiene quality.

The field equipment allows for on-site evaluation of feed water quality, post-treatment verification of cleaning and disinfection as well as rapid bacteriological trouble shooting.

“Instead of waiting days for results, Condair can act immediately and make sure that their systems are safe, when they leave the customer” says Morten Miller.

BQW-value indicate level of total bacterial load in water samples BQW-value

Total CFU/ml equvalent

10

10 - 100

100

100 - 1000

1000

1000 - 10000

10000

10000 - 100000+

The CFU equivalent is based on total bacterial counts using R2A agar, 35oC, 48 hours.

water without compromising water quality – this is where our technology provides a valuable tool to monitor microbial loads in water samples in near real time” says Morten Miller and continues “Our method is particularly suited to document and evaluate different water treatment methods. If, for example, a method for the removal of bacteria does not work as it should, you can quickly detect it, respond to it and regain control”.

Action on critical thresholds The full advantage of the technology can be reaped by frequent and regular monitoring of the water quality.

Mycometer provides a data handling software (FDA-21 CFR part 11 compatible) to help customers establish baselines for normal operation and to define thresholds

Verification of water hygiene in professional quality systems ISO 22000/HACCP HACCP is a systematic approach to reduce the risk of biological, chemical and physical hazards in production processes. The HACCP approach has been successfully applied to water quality management in the past two decades. The HACCP approach is based on the identification of critical control points, establishing critical limits, corrective actions and procedures for ensuring the HACCP system is working as intended. ISO 22000 specifies the requirements for a quality management system based on the HACCP principles.

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Interview - Mycometer

Applications in complex water samples Oil and Gas industry use billions of gallons of water in drilling, hydraulic fracturing and developing wells. The quality of the water is critical to the efficiency of the production, the quality of the production and the preservation of the well. A substantial cost in the management of this water is for biocides used to eliminate the bacterial load. “The technology can be used on a wide range of water types and is not affected by biocides, pH or hardness” says Morten Miller, co-founder of Mycometer “this makes it applicable to complex water samples even under rugged conditions”.

Bacteria, both aerobic and anaerobic, are significant risk factors in production. Bacterial contamination can cause corrosion of the equipment and the well casing and it can deteriorate additives that are necessary in the production process and can sour a well before production 64 | POWER INSIDER VOLUME 4 ISSUE 5

“The conventional methods used for detection of microbial contamination of water are labour-intensive, time-consuming, and sensitive to errors during the performance of the tests”.

even has a chance to begin.

“Monitoring the bacterial contamination is an essential part of the development and production of a well” says Morten Miller, “We have customers in the Oil and Gas segment who benefit from our technology by getting rapid answers – the incubation time for traditional anaerobic counts can be up to 28 days”.

Robust technology in use world wide Industrial customers, water utilities and consultancy companies, worldwide use Bactiquant®-water. “The method is relevant for suppliers of water and industries throughout the world”, says Morten Miller. “They get a robust technology that has proven its applicability in practice”.

Outstanding efficiency, economy and reliability.

The MWM Series TCG 2020.

Maximum efficiency, impressive economy and high overall availability through extended maintenance intervals. When you want one of the best energy solutions. www.mwm.net

TCG 2020

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