Solar Takes Off at India's Airports: March - April 2015

March - April 2015
Solar takes off at

India’s airports
CONDITION MONITORING TECHNOLOGIES GET SMARTER n CONVERTING A CHP PLANT FROM COAL TO BIOMASS n HOW
ENCLOSURES IMPACT COGENERATION’S EFFICIENCY n WILL EUROPE’S ENERGY UNION HELP DECENTRALISED ENERGY?
In Association With
WORLD ALLIANCE FOR DECENTRALIZED ENERGY
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Contents Volume 16 • Number 2
March - April 2015
Features
March - April 2015
Solar takes off at

India’s airports
18 On-site solar takes off at India’s airports
Projects are underway in India to install captive solar photovoltaic power systems at the
country’s airports, exploiting innovative funding models and long-term power purchase
agreements.
By Raghavendra Verma
18 Condition monitoring systems get smarter

Effective condition monitoring has always been key to plant reliability, but the advances of
the digital age are opening up new horizons and the possibility for feet-wide management
of gas turbines and balance of plant equipment.
CONDITION MONITORING TECHNOLOGIES GET SMARTER n CHP FUEL CONVERSION: FROM COAL TO BIOMASS n HOW
ENCLOSURES IMPACT COGENERATION’S EFFICIENCY n WILL EUROPE’S ENERGY UNION HELP DECENTRALISED ENERGY?
By David Appleyard
In Association With
WORLD ALLIANCE FOR DECENTRALIZED ENERGY
24
On the cover: On-site solar
photovoltaics are increasingly
Making the switch from coal to biomass
powering India’s airports. See With specifc modifcations, a bituminous coal-fring combined heat and power system can
feature article starting on page 8. be converted to operate with wood or other biomass pellets. We fnd out what’s involved in
COVER ART: Keith Hackett one such switch at Dong Energy Thermal Power’s Studstrupvaerket plant in Denmark.
By Thomas Krause and Yaqoub Al-Khasawneh
28 Enclosures and effciency

Most cogeneration installations are housed in an enclosure, which can be a container or a
special boiler house. Here we show how the setup of an installation’s enclosure can affect
its effciency.
By Dr Jacob Klimstra
2 Cogeneration & On–Site Power Production | March - April 2015 www.cospp.com
1503cospp_2 2 3/12/15 5:01 PM

www.cospp.com
ISSN 1469–0349
28 Chairman:
President/
Frank T. Lauinger
Chief Executive Offcer: Robert F. Biolchini

Chief Financial Offcer/
Senior Vice President: Mark C. Wilmoth
Group Publisher: Rich Baker
Publisher: Dr. Heather Johnstone
Managing Editor: Dr. Jacob Klimstra
Associate Editor: Tildy Bayar
Consulting Editor: David Sweet
Contributing Editor: Steve Hodgson
Design: Keith Hackett
Production Coordinator: Kimberlee Smith
Sales Managers: Tom Marler,
Natasha Cole
Advertising:
Tom Marler on +44 (0)1992 656 608
or tomm@pennwell.com
Natasha Cole on +1 713 621 9720
or natashac@pennwell.com
Editorial/News:
18
e-mail: cospp@pennwell.com
Published by PennWell International Ltd,

The Water Tower,
Gunpowder Mill, Powdermill Lane,
Waltham Abbey, Essex EN9 1BN, UK
Tel: +44 1992 656 600
Opinion Fax: +44 1992 656 700
Web: www.cospp.com
13 The case for LPG in the industrial sector

When it comes to industrial environments, which could be in rural or off-grid
locations, switching to liquefed petroleum gas (LPG) can deliver both fnancial and
Published in association with the
World Alliance for Decentralized Energy (WADE)
environmental benefts.
By Rob Shuttleworth
Executive Profle
© 2015 PennWell International Publications Ltd. All rights reserved.
14
No part of this publication may be reproduced in any form or
Cogenco’s Trevor Atkins by any means, whether electronic, mechanical or otherwise
including photocopying, recording or any information storage or
Trevor Atkins is Head of Operations at UK utility Veolia’s specialist packaged combined retrieval system without the prior written consent of the Publishers.
While every attempt is made to ensure the accuracy of the
heat and power subsidiary, Cogenco. We speak with him as he prepares for retirement information contained in this magazine, neither the Publishers,
after 20 years in the CHP sector. Editors nor the authors accept any liability for errors or omissions.
Opinions expressed in this publication are not necessarily those of
By Tildy Bayar the Publishers or Editor.
Subscriptions: Qualifed professionals may obtain free

subscriptions by visiting our website at www.cospp.com and
Regulars completing an online subscription form. Extra copies of these

forms may be obtained from the publisher. The magazine may
also be obtained on subscription; the price for one year (six
issues) is US$133 in Europe, US$153 elsewhere, including air
mail postage. Digital copies are available at US$60. To start a
4 Editor’s Letter 34 Genset Focus subscription call COSPP at +1 847 763 9540. Cogeneration and
On-Site Power Production is published six times a year by Pennwell
Corp., The Water Tower, Gunpowder Mill, Powdermill Lane, Waltham
Abbey, Essex EN9 1BN, UK, and distributed in the USA by SPP at 75
Aberdeen Road, Emigsville, PA 17318-0437. Periodicals postage
6 Insight 36 Diary paid at Emigsville, PA.

POSTMASTER: send address changes to
Cogeneration and On-Site Power Production, c/o P.O. Box 437,
Emigsville, PA 17318.
7 WADE Comment 36 Advertisers’ Index Reprints: If you would like to have a recent article reprinted for a
conference or for use as marketing tool, please contact Rae Lynn
Cooper. Email: raec@pennwell.com.
www.cospp.com Member, BPA Worldwide
1503cospp_3 3 3/12/15 5:01 PM

Editor’s Letter
Proven cogeneration
technology serving the
industry well
I
n early February this year, I had the privilege the match between electricity and steam
of attending a celebration of one million production on the one hand and demand
successful running hours accumulated on the other is close to perfect. One unit is
by four cogeneration units at a factory in equipped with supplementary fring to create
Roermond, The Netherlands. It was a very some extra fexibility in steam production. The
pleasant event with a happy customer and factory has received a number of awards for
a happy supplier. its environmental friendliness.
The cogeneration units have been in A rough calculation reveals that,
operation since 1983, and I well remember compared with separate generation, this
all the efforts we took in those days to cogeneration plant emits about 15 kilotonnes
Dr Jacob Klimstra
Managing Editor promote cogeneration. The monopolistic less CO2 per year. One might argue that
electricity companies initially tried to block 30 MW in wind turbine capacity can achieve
the connection of local generators to the grid. the same reduction in CO2 emissions.
They feared voltage and frequency instability, However, the output from wind turbines is
and were afraid that any generator not highly volatile, so the Roermond factory, with
controlled by them would create safety issues. its steady energy demand, could never run
Fortunately, we could convince the authorities on wind power alone. Yet the owners of wind
that increasing the number of generators on turbines receive substantial subsidies, while
the grid would improve the security of supply the economy of the cogeneration plant
as well as the frequency stability. currently suffers from artifcially low electricity
The big advantage of cogeneration, prices and artifcially high gas prices. Soon
of course, was and is the substantial fuel we will have a discussion with the responsible
savings compared with separate generation. ministry in The Netherlands about this unfair
Nowadays, grid connection for local situation. Hopefully the talks will result in more
generation is generally accepted. The factory favourable conditions for the country’s many
in Roermond expects many years of successful cogeneration plants.
operation to follow. Notwithstanding the low fnancial benefts
The four cogeneration units supply of cogeneration in the current climate, the
electricity and heat for a factory that management of the Roermond factory
processes an amazing 600,000 tonnes of is investing in upgrading the installation’s
recycled paper per year, turning it into useful control systems and counting on many more
products. The prime movers are modifed happy running hours. Being the energetic
aero-derivative gas turbines running at and environmental benchmark for the
14,250 rpm. According to the manufacturer, European paper industry is highly rewarding
many people initially doubted that such light in itself, and is seen as a positive asset by
machines would really show high reliability customers. The cogeneration installation is a
and durability. Some engineers might have prime example of a reliable technology that
thought that a single large industrial unit can provide its services for many years.
would prove a better solution. Cogeneration is still one of the better
However, all doubts have been removed. options to save primary energy and to
The overhaul interval is only once every reduce greenhouse gas emissions.
45,000 hours. If needed in case of a calamity,
PS: Visit www.cospp.com
a turbine can be exchanged in one day. to see regular news updates, the current issue of
The concept of having four units in parallel the magazine in full, and an archive of articles from
previous issues. It’s the same website address to
offers high supply reliability. At this factory, sign-up for our fortnightly e-newsletter too.
1503cospp_4 4 3/12/15 5:01 PM

1503cospp_5 5 3/12/15 5:01 PM

Insight
Stop wasting
Europe’s heat
T
here is much to encourage The amount of Europe’s heat supplied by
Europe’s cogeneration and district cogeneration would grow by half, and CO2
energy industries in the European emissions would be cut substantially.
Commission’s launch of a strategy to But market barriers to the wider uptake
achieve what it calls a ‘resilient Energy Union of cogeneration and district energy remain.
alongside a forward-looking climate change Apart from recent poor spark spreads, the
policy.’ main challenge for cogeneration remains
The EC’s vision of an Energy Union is overcoming energy market failures which
all about maximising fexibility of energy expose CHP operators to variability of both
Steve Hodgson
Contributing Editor systems across the continent in order to cut electricity and fuel markets. Achieving a
primary energy use and thus reduce imports. reasonable business proposition for CHP
This is to be achieved by new rules that developers and operators straddling these
ensure energy users having more choice of two energy markets is still the single biggest
suppliers; the phasing out of poorly designed challenge for the sector, concludes the
subsidies; and energy fowing freely across CODE 2 report.
national borders. But the EC also points to COGEN Europe’s new heat manifesto calls
a fundamental rethink of energy effciency for the EC to use an integrated approach
– seeing it as a resource in its own right; to the energy system, where heating and
and ensuring that locally-produced energy cooling are taken into account at the start
– including renewables – can be absorbed of any process towards new legislation. Any
into energy grids. new European heating and cooling strategy
Europe is the largest energy importer in the must interact genuinely with the power and
world, importing around 53% of its energy at fuel supply sectors in order to overcome the
an annual cost of €400 billion ($443 billion), main barriers to cogeneration.
so any way to reduce these imports is to be The manifesto also calls for the tracking of
welcomed. primary, not just fnal, energy consumption,
Trade association COGEN Europe has and in particular the massive losses
emphasised the obvious connection occurring in power systems, by EU member
between high-effciency cogeneration states. As COSPP readers will already know,
technology, heat, and the need to cut something approaching two-thirds of the
energy imports. Just a day after the EC primary energy supplied as fuel to coal-
announcement, the association issued its fred power plants is lost as waste heat or,
own manifesto calling for heat to be taken into put another way, more heat is discarded at
account thoroughly in the EC’s work towards power stations than is used to heat buildings
the union. Fundamentally, cogeneration in many countries.
works by recovering and putting to use what Integrate heat with power policies, and
would otherwise be enormous quantities of take proper note of energy system wastage
‘waste’ heat discarded at thermal power – if the EU takes note of this advice from
plants. the industry, its move towards a new Energy
COGEN Europe also refers the EC back to Union will also beneft the decentralised
the results of the recently-completed CODE 2 energy industry.
project, which estimated that cogeneration
could double in size to generate one-ffth
of the EU’s electricity by 2030, employing a
growing proportion of renewable fuels and
delivering substantial primary energy savings.
1503cospp_6 6 3/12/15 5:01 PM

Comment
Fifty Shades of CHP
T
he precipitous drop in Washington and who currently the country, we are excited by the
energy prices is having serves as Chairman of the Board strong opportunities that lie in the
repercussions throughout of the power company Dynegy. Gulf region and with industrial
the energy industry, In addition, neighbouring customers. We hope that you
and nowhere is this felt more Mexico is undergoing an energy can join us in Houston.
profoundly than in the energy renaissance as it opens up its
capital of Houston, Texas. In markets to foreign investment,
the US we have 50 states, each which is creating a range of
of which has a distinct market opportunities for energy projects
profle for CHP and distributed and infrastructure.
power generation. While the The US energy boom has
Texas economy has diversifed in created a remarkable industrial
recent years, it is still very much expansion in the Gulf Coast David Sweet
an energy town and when prices area. According to the American Executive Director
fall as far and as fast as they Chemistry Council (ACC), World Alliance for
have, there is going to be some the shale-related chemical Decentralized Energy
pain experienced. It is estimated investment has offcially topped dsweet@localpower.org
that there could be 130,000 job $100 billion which will create
losses in Texas by this summer 55,000 permanent jobs in the
as a result of the drop in energy chemical sector.
prices. While energy prices seem While the Obama
to be slightly rebounding, natural administration is giving out mixed
gas prices remained remarkably messages on energy policy, with
low throughout the winter in the the recent veto of a bill that
US, notwithstanding the record would have allowed the Keystone
low temperatures and snowfalls Pipeline project to move forward
that many parts of the country and announcement of methane
experienced. regulations that will impact the
The fip side of this price natural gas production and
slide is that interest in effciency delivery sectors, the Executive
measures, such as CHP, is Order that articulated a goal
escalating as companies look for to increase the use of CHP in
solutions to increase productivity the United States by 40 GW
and reduce costs. WADE is having by 2020 remains in effect. The
a conference this April that will Clean Power Plan announced
focus on CHP for the industrial by the EPA will also create new
sector and the many new and signifcant opportunities
opportunities for CHP in areas for CHP, as it can be used as a
such as oil and gas, chemicals, mechanism for compliance with
processing and others. We will the new emission targets.
hear from none other than Pat While the US is comprised
Wood, a Texan who served as of 50 unique states and there
Chairman of the Federal Energy are 50 shades of the market for
Regulatory Commission in decentralised energy throughout
www.cospp.com Cogeneration & On–Site Power Production | March - April 2015 7
1503cospp_7 7 3/12/15 5:01 PM

On-site renewables
On-site solar powering India’s airports
Cochin International Airport in Kochi plans to add 12 MW in additional solar power capacity Credit: Cochin International Ltd
Projects are underway in India to install captive solar photovoltaic (PV) power
systems at the country’s airports, exploiting innovative funding models and long-
term power purchase agreements. However, the country’s grid power operators
are refusing to purchase any excess power, fnds Raghavendra Verma
T
he Airports Authority eschew supplementary with solar power systems or
of India (AAI), which diesel generators. currently obtaining such power
is owned by the At least eight of India’s sources include Indore city’s
Indian government, 130 airports, including those Devi Ahilyabai Holkar Airport,
plans to generate 50 MW owned by private companies Raipur’s Swami Vivekananda
of electric power from solar such as the Indira Gandhi Airport, Bhubaneswar’s
plants at 30 airports by the International Airport in the Biju Patnaik International
end of 2015. A communiqué capital, New Delhi, already had Airport, Bhopal’s Raja Bhoj
issued in May 2014 noted functional solar power systems, Airport, Amritsar’s Sri Guru
that the plan was designed operating smoothly before Ram Dass Jee International
to reduce the sector’s the announcement of the Airport, Chandigarh
dependence on India’s solar expansion plan. Other Airport, Ahmedabad’s
unreliable grid power and Indian airports already ftted Sardar Vallabhbhai Patel
1503cospp_8 8 3/12/15 5:01 PM

On-site renewables
Devi Ahilyabai Holkar Airport in Indore has installed two 50 kW systems

2014. The plant includes Meanwhile, Devi Ahilyabai
Credit: Airports Authority of India
8736 PV modules of 245 W Holkar Airport, Indore, installed
each, which have an anti- two smaller, 50 kW systems in
refective coating to avoid October 2013 under the build-
distracting landing aircraft own-operate model, with a
crew. They are mounted on power purchase agreement
galvanised iron structures that for 25 years with Mumbai-
can be tilted in three positions based Chemtrols Solar Pvt
to adjust with the seasonal Ltd. It owns and maintains the
changes in the sun’s position. plant, charging $0.18/kWh,
Spread over 3.64 ha falling to $0.11 by the end of
and running parallel to the the agreement.
4.43 km runway ‘11/29’, the Such tariffs are fxed
solar modules are connected through a tender bidding
to 16 combiner boxes, which process as per AAI guidance
International Airport, power generating capacity use 630 kW inverters to and vary according to
Guwahati’s Lokpriya Gopinath requires 1.8 ha of land and convert direct current into location. According to India’s
Bordoloi International Airport, costs $1.3 million in investment, alternating current. Installed Central Electricity Regulatory
Hyderabad’s Rajiv Gandhi Rakesh Kalra, regional by the German company Commission, the desert state
International Airport and executive director of the AAI, Enerparc, the average energy of Rajasthan and the southern
Jaisalmer Airport. told COSPP. generation of the plant is state of Tamil Nadu have very
Of course, India’s move In most of the ongoing 10,000 kWh, peaking at high potentials for solar energy
towards airport solar power solar power projects, the AAI 13,050 kWh. After synchronising and hence quoted tariffs
is far from unprecedented, has not invested up front, but with the low tension voltage are low, while New Delhi, for
with other airport industries is making deals with solar received from the grid, the instance, has more cloud and
worldwide assessing its beneft. power companies to install solar power is fed into two less space and hence bids per
In November 2010, for instance, and maintain the plants. 1600 kVA transformers and kWh are higher.
the US Federal Aviation Kalra said it was possible that stepped up to 11 kV in In Indore, in the central
Administration (FAA) said that airports might invest their own the airport’s high tension Indian state of Madhya
‘airport interest in solar energy money, rather than under a distribution network. It is used Pradesh, peak power
is growing rapidly as a way build-own-operate basis, but for aeronautical ground generation occurs during
to reduce airport operating with a lifespan of 25 years, lighting systems installed at summer afternoons, when
costs and to demonstrate a either system should be the airport’s three runways, systems work at 85% capacity,
commitment to sustainable “cost-effective.” taxiways and parking stands. whereas this reaches only
development’, and issued a The cost of grid power The system includes a 10%–15% on a cloudy summer
technical guidance paper in India has been rising weather monitoring system morning, a senior Indore
promoting the idea. continuously. For example, to check that the energy airport manager told COSPP.
Generating on-site solar according to a note from produced follows actual solar Despite this useful power
power is a particularly an India’s recently replaced radiation, thereby assessing contribution, the Indore airport
attractive proposition in India, Planning Commission, power performance. It also features plant contributes only a
which receives signifcant tariffs for use in commercial SCADA systems, which small fraction of the airport’s
sunshine during most of the establishments rose by 19% raise alarms about poor average power requirement
year and suffers from chronic between 2008 and 2012. performance and generate of 1500 kWh and its electricity
power shortages, leading to According to Kalra it is reports. is mainly used within the
unreliable grid supplies. expected to continue to do
India’s new Bharatiya Janata so, while the cost of electricity
Party (BJP)-led government, from existing solar plants
elected in 2014, has plans for should either remain constant
expanding solar energy of all or even fall.
kinds. It has already approved
25 large (non-airport) solar Airports lead the way
energy projects, with a note Delhi’s Indira Gandhi
from its Ministry of New and International Airport – which
Renewable Energy (MNRE) is owned and operated by
saying it wants to develop Delhi International Airport
20,000 MW of solar power Private Limited (DIAL) – started
capacity nationwide by 2019. operations of its 2.14 MW
The cost of grid power in India has been rising continuously
Each megawatt of solar solar power plant in January Credit: Airports Authority of India
1503cospp_9 9 3/12/15 5:01 PM

On-site renewables
Many Indian airports have large amounts of unused land that could be used for power generation projects. ‘This kind of an issue
Credit: Delhi International Airport (P) Ltd should better not [be] micro-
managed,’ he said. There are
several pending proposals with
ground-based solar panels,
but now, without the subsidy,
many will remain unviable
or may not be optimised, he
argued.
Raju VR Palanisamy,
president of India’s Solar Energy
Association, said companies
bidding for ground-based
solar power plants have even
started to quote prices without
factoring in the subsidy. But
they are applying for subsidies
nonetheless.‘If the government
grants that, it would be their
terminal building. The plant the panels. Delhi airport has director of the Solar Energy windfall,’ he told COSPP.
draws power from 414 solar a pressurised water washing Corporation of India (SECI). Subsidies are distributed
panels of 240 W installed system for cleaning and Furthermore, according by SECI, which is a state-
over 1200 square metres, maintaining the entire plant to Kumar, airports now owned not-for-proft company
800 metres from the main area. Delhi airport authorities commissioning new solar responsible for implementing
runway. Made by Mumbai- have also planted slow- plants face a key disadvantage and facilitating solar
based PV Power Tech, the growing grass to ensure as the government has development. Since its launch
solar modules are placed at minimum grounds-keeping decided not to grant the in April 2013, all new Indian
an 18o incline facing south to maintenance and to reduce subsidy to projects (including airport projects have been
catch the maximum amount exposure and damage those at airports) which do routed through it. ‘We ensure
of sunlight. They can withstand caused by birds and reptiles. not install panels on rooftops. quality and remain engaged
wind speeds of up to 160 km The design requirement of ‘The Ministry says that rooftop for two years in the operation
per hour and are resistant to the Delhi project included a is rooftop and not the ground,’ of the system,’ said Kumar.
lightning. The system uses two guaranteed life of 25 years, he said. And while that might Instead of choosing vendors
50 kW inverters from German module effciency exceeding sound like fuzzy logic, there is for each project, SECI chooses
company KACO. 15% and plant load factor of a reason: solar panels on roofs them for each city on the basis
The plant is equipped with more than 20%. are more visible than those on of the best-priced tenders,
sensors for solar radiation, A spokesperson for DIAL the ground, and this helps the taking into account bidders’
ambient temperature, module told COSPP that the project government popularise solar technical and fnancial
temperature and wind speed. also received customs and energy, said Kumar. strengths. Furthermore, to
It can be monitored remotely excise duty exemptions on Explaining why AAI prefers create competition, it selects
through a KACO web portal buying materials used in the ground-based over rooftop at least two bidders in each
that shows various parameters plant. The company also plans solar projects, Kalra said: ‘The city to encourage a second-
in real time as well as archived to expand the airport’s solar [airport] rooftops are not placed bidder to match the
data. power plant capacity. big enough or are curved at price of the frst, said Kumar.
According to Kalra, AAI solar many places, and climbing SECI has already selected
power systems are designed Restricted subsidies for the maintenance on the 25 solar power vendors and
to constantly compare the Indian government policy top of these glass buildings is installers for 37 cities – mostly
energy generated by the provides for a potential 30% not user-friendly.’ On the other state capitals – and it will slowly
plants with airport power subsidy for any solar power hand, many Indian airports expand its approvals to smaller
requirements, drawing only project to encourage the have a vast amount of unused towns and cities for airport and
the required additional power generation of renewable land; for example, Hyderabad other solar energy projects.
from the grid. energy. However, subsidies Rajiv Gandhi International The chosen companies
These solar plants also have not been given to every Airport is spread over 2200 ha, themselves search for solar
can be protected by the solar power project and the while Chennai International power business in a city. In the
comprehensive security government is trying to restrict Airport has around 1500 ha. case of an airport project, SECI
already in place at airports. them to only those projects Kumar believes the shares the details of chosen
And there is little maintenance that would otherwise be government should continue vendors in the particular
required except for cleaning unviable, said Rakesh Kumar, to pay subsidies to land-based city with AAI and starts the
1503cospp_10 10 3/12/15 5:01 PM

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On-site renewables
bidding process between the

Delhi Airport’s 8376 photovolatic modules have an anti-refective coating to avoid distracting aircraft landing crews
two chosen local competitors, Credit: Delhi International Airport (P) Ltd
Kumar explained.
After an initial agreement,
a solar power benefciary
and project installer/operator
bring a detailed project report
to SECI, which sanctions it
for a fee. Upon satisfactory
completion of a project,
two-thirds of the subsidy
amount is released by SECI
directly to the project installing
company. The remaining
subsidy is paid in two equal
instalments after the frst and
second year of successful and
satisfactory performance. ‘So
we remain engaged with them
from allotment to two years of so that surplus power can be with solar power. ‘Solar is going which any excess solar power
operations and ensure quality sold onto the grid. Indeed, to replace many things and supplied to the grid could only
and performance,’ said Kumar. the AAI’s April communiqué people will become self-reliant,’ be adjusted against future
However, he said subsidies noted that solar power plants he said. Indeed, solar power power bills. ‘We have given
will be harder to secure in are being set up on a site will continue to be attractive to in-principle approval’ for the
future even for rooftop projects, ‘to meet not only its own users with a poor grid supply, airport’s proposal, a senior
as the government has a requirements but also to feed as they have to run costly offcial of KSEB told COSPP.
limited budget. ‘30% subsidy is the surplus power generated diesel generators. ‘Even if you Cochin airport plans to add
going to be reduced to about to the local grid.’ Likewise, are able to reduce the running 12 MW in solar PV capacity on
15%,’ he added, although it is Kalra stressed that some of the of generators for a few hours 22 ha of land before the end
not yet known when. smaller Indian airports have in the week, you are making a of this year. It already has a
little power consumption and good saving,’ said Kumar. 1 MW system installed at three
Financing models big stretches of empty land to Solar power is also locations, including a 320 kW
SECI does not insist on any generate excess solar power. especially attractive to plant on a hangar roof.
particular fnancial model According to Kumar, one business customers, as Indian One potential way out of
for agreements between a possible approach is net power tariffs for commercial grid supply deals for Indian
solar power operator and the metering, where bills are settled units are higher than for the airports would be to install
land or rooftop owner. Kumar at the end of every month or residential sector. For instance, power storage systems – but
said the ‘build-own-operate’ year. ‘But [frst] we have to see the Indore airport pays such developments are
model, which is preferred by all this happening as it is a very $0.13/kWh to the grid supplier, unlikely in the short term.
AAI, is benefcial because new concept,’ he said. One while local residential tariffs are ‘Storage is a very costly affair
the installing company is potential problem with such $0.08/kWh. and not very environmentally
encouraged to demand better a system is pricing disparity, friendly,’ said Kalra. ‘The
quality products to avoid future with solar power being costlier Pressing ahead batteries have a limited
generation losses. But even than conventional power, These benefts are life; it takes lot of energy to
here he foresees potential leading grid operators to encouraging airports to manufacture them, and bulk
problems, which could even refuse to pay the higher price press ahead with their on-site power cannot be stored.’
generate court action. ‘If, in for excess solar electricity. solar power projects despite Meanwhile, diesel
the future, a rooftop owner ‘They do not have any interest the recent diffculties over generators will continue to
doesn’t make payments in in promoting solar energy and subsidies. Cochin International operate on standby mode at
time or starts fnding fault with want separate government Airport, in the southwestern India’s airports whether they
the service or decides that help if forced to purchase solar state of Kerala, is pushing have solar power systems or not.
he does not need the system power,’ he said.This is especially ahead with a plan to sell
and tells the vendor to take likely to be a problem if solar excess power from its solar units Raghavendra Verma is a
it away, it could lead to legal panel operators become net to the grid. It has negotiated New Delhi-based journalist.
complications,’ he warned. exporters onto the grid, he a power banking contract
Kumar said SECI suggested. with local power company This article is available
recommends installing grid- Kumar argued that India the Kerala State Electricity on-line.
connected solar power systems needs new regulation to deal Board Limited (KSEB), under Please visit www.cospp.com
1503cospp_12 12 3/12/15 5:01 PM

Opinion
The case for LPG

in the industrial sector
Switching to liquefed petroleum gas (LPG) can deliver both fnancial and
environmental benefts in industrial environments, argues Rob Shuttleworth
W
ith the energy also produced during the oil around 15%–20% per year and
Rob Shuttleworth landscape refning process. Its combustion reduce the associated CO2
c h a n g i n g emits 33% less CO2 than coal emissions by up to 29%. In just
so rapidly, and 17% less than heating oil. two months, fuel costs were
industrial organisations In addition, LPG emits almost lowered by £42,000 ($64,000).
could be forgiven for feeling no black carbon, which is the
bombarded with messages second largest contributor to The time is right for LPG
about the most effective global warming after CO2 and The industrial sector has a
power solution.Across much a signifcant contributor to large role to play in helping
of Europe, different markets poor air quality. LPG’s low levels Europe and the wider
are trialling a variety of of particle and NOx emissions developing world to meet
technologies to deliver also make it ideal for both ambitious carbon reduction
on their energy needs. indoor and outdoor use. and renewable deployment
Of course, concerns over The lowest-carbon fuel targets. However, as a
fossil fuels are directing available in non-mains gas complement to renewable
the energy spotlight onto areas,LPG has been used within energy and energy effciency
renewables; however, these commercial applications measures, it is apparent that
do not suit all environments. for the past 40 years. It is a certain conventional fuels like
Indeed, while governments particularly attractive option LPG still have a distinct area
are concerned with meeting for larger organisations that of responsibility as part of
global targets, for the majority have to report on their carbon the development of a more
of businesses and industrial emissions. And the fact that sustainable energy future.
units the challenge is on a more LPG will be in plentiful supply Indeed, market conditions
local level. Most organisations for many years to come adds are currently favourable for the
are focused towards delivering security for any commercial type of on-site gas-powered
cost savings, ensuring process building energy managers. cogeneration to which LPG is
effciencies and removing the particularly suited. With LPG
risk of unplanned downtime. Case study: UK site production forecast to increase
The benefts that LPG can bring over the coming decades,
The opportunity for LPG to a commercial property stability of supply is clearly a
When weighing up the options were highlighted recently with selling point. As technology
for powering the industrial an installation carried out at develops and the effciency of
sector, specifers should a packaging manufacturer engines and pumps increases,
not overlook the potential to reduce its carbon footprint the arguments for introducing
advantages of affordable and energy costs. LPG into the industrial sector
and available conventional One of the key company continue to stack up.
energies, such as liquefed sites is located in an off-mains
petroleum gas (LPG), a area and had previously relied Rob Shuttleworth is chief
low-carbon fuel that is portable, on an oil-powered fuel system, executive of the UK
widely available, easy to install which had not only begun Liquefed Petroleum Gas
and competitively priced. to prove expensive, but had Association (UKLPG)
A mixture of propane (C3H8) also heavily increased the
and butane (C4H10), LPG is CO2 output. By switching to This article is available
derived during the exploration LPG, the company was able on-line.
of natural gas felds and is to reduce its fuel costs by Please visit www.cospp.com
1503cospp_13 13 3/12/15 5:01 PM

Executive profle
Executive Profle
Trevor Atkins: a life in CHP

Trevor Atkins is Head of Operations at UK utility Veolia’s specialist packaged combined heat and power
subsidiary, Cogenco. After 20 years in the industry, he is set to retire this year.
with Nedalo. He managed was asked to stay on to wind

14 embedded generation up the frm’s 1999 contract with
sites, from 1 MW to 10 MW, Tangmere Nurseries. Then, set
plus a feet of maintenance to retire again, he was asked to
engineers, and was fnancially stay on as a general advisor to
responsible for the sites and management until Christmas,
their maintenance. when he was asked to set up
Both Eastern Electricity, now training programmes on new
known as TXU Europe, and technology, control systems,
Nedalo were owned by US frm air-to-fuel ratio controllers
Texas Utilities. Around the time on engines, software system
that energy and commodities controls and a bespoke
frm Enron declared remote monitoring and control
bankruptcy, the power market system.
price collapsed and Texas
I
n his 20 years of service Power Protection Ltd, where Utilities in Europe entered Change and challenge
in the combined heat he carried out service and administration. In 2003 part When asked about the
and power (CHP) commissioning on CHP and of the business was acquired biggest change he’s seen in
sector, Trevor Atkins rotary UPS systems. When Holec by npower, and some 12 the industry, Trevor said: ‘The
has acquired a wealth of split, forming a new company months post-administration biggest change is in engine
experience across control between Eastern Elecricity Nedalo was bought by its technology, with the contrast
engineering, EPS systems and newly-created Nedalo, management team, making between the very lean burn,
and CHP engines for a Trevor moved across to Nedalo Trevor a minority shareholder very high effciency engines
breadth of applications, where he worked as project in the business. which we have today and the
and a deep knowledge manager for fve years. He The four majority and old stoichiometric engines
of their operation and recalls installing CHP systems six minority shareholders which weren’t too clean for the
maintenance. During his for hotels, leisure centres and renamed the frm Cogenco environment.
long career Trevor has industrial and agricultural and proceeded to rebuild it ‘The biggest change
worked with almost every sites, and in the late 1990s to manufacture and produce engine-wise is effciency and
aspect of CHP. He spoke with he worked on the UK’s frst its own CHP systems. The increased demand for lean
COSPP as he was winding combined heat and power company grew quickly and burn/clean burn engines to
up his work at UK packaged system for greenhouses. further funding was required, come under the new emissions
CHP frm Cogenco. This was Nedalo’s frst so it was sold to Dalkia in 2007. standards,’ he added. As to the
After leaving school at 16, big project, at Tangmere It is now owned by Veolia. biggest overall technology
Trevor joined the Royal Navy Nurseries in Chichester. It was a At the time of the TXU Europe change, he cites how engine
where he served for 24 years £6.5 million ($9.9 million) administration, Nedalo sold off controls and electronics have
as a controls electrical artifcer, contract, which Trevor project all but one of its embedded shifted to digital controls.
maintaining weapons systems managed and helped design. generation sites. Trevor took ‘Now it’s impossible to set the
– missiles, gunnery systems, It featured nine Cat 3516 over as Operations Manager engine up without use of a
sonar systems and ship engines with heat recovery for the whole of Cogenco, laptop! A huge V20 engine is
electrics – as well as working and CO2 scrubbing systems, which involved managing controlled from a laptop; all
for 10 years in mine warfare. On feeding exhaust gases back some 35 service engineers, emissions, controls, closed-
his discharge he was awarded into the greenhouses to seven to eight commissioning loop air-fuel ratio controllers
a British Empire Medal by the enhance crop growth. The engineers/product specialists, are software-based.
Queen for services to the Navy. frm went on to install similar and a budget of £10–11 million ‘Before, you had a gas
Newly discharged in 1988, systems at another 13 sites. per year. This was his job until supply, you put the gas supply
he joined power solutions Around 2000,Trevor became May of last year, when he was in the engine, there was a
frm Holec, now called Hitec an embedded manager slated to retire. However, he butterfy valve and a mixer,
1503cospp_14 14 3/12/15 5:01 PM

Executive profle:
and you just set the engine up CHP units are being ftted to factor is either price or a bad put it all in, and 18 months later
like a car throttle, turned a few blocks of fats, district heating experience with the previous the Americans bought it and
screws, got the mixture right schemes, and things like that.’ supplier – we win others’ moved the whole database
and the engine would run,’ he And requirements are contracts too. But taking on back to the US. The rotary UPS
explains. ‘It’s like the difference changing. Like engine other people’s kit can be a system was very interesting
between running an old Morris manufacturers, Trevor says his challenge. We prefer to ft our because we couldn’t afford to
8 car and a new high-tech frm is now increasingly looking own bespoke monitoring and make mistakes.The UPS systems
car on the road today. It’s a into alternative fuels. Cogenco control systems.’ supported all their computer
constant battle adapting to deals primarily with natural Asked about his most networks: one mistake and you
new software – one of the gas, biogas from anaerobic challenging project, Trevor put the whole place down!
training programmes I’m digestion or sewage gas, as cites the Tangmere Nurseries ‘Systems today are very
setting up now is about this. well as red diesel and biodiesel. installation – Nedalo’s frst similar, they just use much
We’re trying to broaden the ‘It’s an up-and-down
experience of our service
engineers in the feld to give
market,’ Trevor says. ‘When I
frst came into the industry it
‘People are much more aware of
them, for example, a better wasn’t unusual to see a spark the bottom line now’
understanding of remapping gap of 6–1 or even 7–1, while
engine fuel maps.’ over recent years we’re lucky to contract, ‘so it was all new to larger engines now,’ he adds.
From a business get 3–1 or 4–1 because of the us. We had a sister company ‘They were moving from
perspective, Trevor said difference between gas and in Holland so I spent a fair 500 kVA MTU engines to
his biggest challenge has electricity prices. This makes amount of time there looking 2 MW Cummins engines when
been that consultants are savings not quite as good, but at how other projects were I left: from single-unit supply to
increasingly aware of CHP there are still savings to be had done and best practices,’ multiple-unit supply.’
and its capabilities, so tender for the end customer. he says. ‘Then I had to put When asked what advice
specifcations today are a package together in the he would give to new industry
much tighter than they used An evolving industry UK along with a horticultural entrants, Trevor says: ‘To be
to be. Additionally, the level of The basic principle behind engineer from Holland. We had a CHP engineer these days
effciency sought by today’s CHP systems is ‘the same as to build, from scratch, three you’ve got to be an electrician,
industry ‘wasn’t even dreamed it’s always been,’ Trevor says, big engine rooms with three a mechanical engineer, a
of 15 years ago,’ he said. ‘It’s although today’s margins 3516 Cats in each engine plumber and a gas engineer!
not unusual now to be asked are tighter and demands on room, and incorporate the You have to have a gas
for 94% availability on projects, suppliers are higher. mechanical, electrical and qualifcation to work on CHPs,
which is very high. In reality ‘When I frst joined Nedalo,’ HV connections which we had you have to know the ins and
this is too high an expectation, he says, ‘I helped project- to sort out, although we had outs of engines, you have to be
particularly when you consider manage and install 30 CHP consultants for the HV. competent and safe working
that service and overhauls units in Hilton hotels. Those ‘Then we had to go to the with electricity, and you have
have to be accounted for engines have now run their Continent and look at COdi to be open to training because
within the 6% allowed for course, many with over 120,000 NOx’s huge catalytic converters very few people who come into
downtime.’ operating hours on them.’ which scrub exhaust gases, the business are competent in
Cost is also a growing issue, Cogenco is currently in the as well as interface water all of those aspects.
he added: ‘People are much process of decommissioning systems, exhaust sytems and ‘That then applies to project
more aware of the bottom line old plant at Hilton and Marriot HV systems, and then deal managers as well,’ he adds.
now. In the past our customers sites as well as at a Land Rover with the grid connections with ’You need a good all-round
may have gone for, say, a Rolls manufacturing facility, and Southern Electric – so that general grounding in the
Royce CHP unit, while now they installing new plant, including project, over the course of 18 basic principles of engineering
and consultants are looking two new MTU CHP units. ‘We’ve months, involved £6.5 million and electricity. You need to
at price more than anything now run through a complete worth of kit.’ also be able to be fnancially
else, and the market is very cycle with those engines,’ On a previous project responsible.’
competitive price-wise.’ Trevor says. ‘Those contracts with Holec, undertaken right Trevor is uncertain about
Trevor believes this trend will have run their course and the after his retirement from the how well retirement will suit him
continue into the future. He customer is renewing. Navy, Trevor was service and – as we can perhaps tell from
says: ‘Looking at any major ‘We tend to fnd that commissioning engineer on the fact that he’s still working!
project now, any developer hospitals and universities are a data centre installation in But whatever he does in future,
now has got to put, within his now required by European the UK. ‘We were dealing with we wish him all the best.
remit, some sort of energy- law to have open tenders,’ he putting in a 500 kVA rotary UPS
saving technology, and CHP adds. ‘In the majority of cases system,’ he recalls.‘It was going This article is available
fts quite nicely with that. We’re we do tend to win our old to be a combined booking on-line.
fnding now that a lot more contracts back. The deciding centre for several airlines. We Please visit www.cospp.com
1503cospp_15 15 3/12/15 5:01 PM

DistribuGen 2015
Cogeneration
Discuss among yourselves
An upcoming conference will discuss new power market dynamics, new
technologies and new policies that are changing the game for the many
cogeneration systems that experts agree are on the horizon, writes Paul Cauduro
T
he market for CHP is systems altogether as part of
changing and many their investment.
now have a better But more deployment of
understanding about CHP won’t stop there. CHP
power generation. Aiding and waste heat-to-power
this understanding is the (WHP) technologies can and
constant drumbeat of news will play an increasing role in
suggesting that abundant the nation’s manufacturing
natural gas supplies are renaissance beyond just
expected to keep the price chemical processing and
of the fuel at multi-year refning. Industrial demand
lows for the foreseeable for electricity is growing in
future. As a result, the every region and all industries kept otherwise good energy where gas faring is occurring.
economics supporting are sure to examine, and projects from moving forward. In April, the World Alliance
CHP development are ultimately implement, CHP as This change was deemed for Decentralized Energy
becoming increasingly an economic, effcient and important in the ongoing (WADE) will bring together
attractive, thereby driving reliable on-site energy option. discussion about how Texas will business and energy leaders,
more adopters to seek CHP This also holds true for many power its industrial expansion engineering consultants,
for both its economic value other CHP end-user candidates and vibrant population growth project developers, policy
proposition and for power such as hotels, hospitals, data while, at the same time, reduce specialists and end users
reliability. centres, residential towers and the amount of water used by to Houston, Texas for the
This is evident in America’s even single-family homes. traditional power generation. DistribuGen Conference and
chemical processing and Additionally, policymakers Policy initiatives like these in Trade Show for Cogeneration/
refning industry. These concerned about grid many states, combined with CHP 2015. There attendees
operations need heat, lots inadequacies are beginning equipment and technology will explore new market
of heat, and where these to better understand the advances, innovative project drivers, discuss emerging
or other concentrations of emission benefts. Plus, fnancing mechanisms and technologies, examine policy
manufacturing facilities are many now know that more power price dynamics are changes and survey the
located are typically the same distributed energy using CHP all driving decisions to install growing demand for the
locations where CHP facilities saves vast quantities of water, new CHP and WHP systems. energy security and resiliency
can best provide heat and making water shortages in Currently, 82 GW of installed offered by CHP and WHP
power. Last year the American many regions an important CHP capacity (9% of US systems for the industrial,
Chemical Council gathered a driver for additional CHP. Just energy-generation capacity) commercial and institutional
list of 148 proposed chemical last year the Texas legislature are in use at more than 4100 sectors.
plant investments between changed the state’s utility sites across every state. But at This is the ffth year that this
now and 2023, and found code to allow CHP facilities least 50 GW, and up to almost important energy conference
that chemical companies to sell electricity to multiple 200 GW, of additional potential has been held, and more
are planning to spend customers in microgrid-type remains. The potential for WHP about the event can be found
$100.2 billion in the US. The vast arrangements. projects is equally impressive, at www.distribugen.org.
majority of new projects are Before the change, CHP with more than 11,000 MW
in the Gulf Coast area and facilities could only sell available at industrial sites Paul Cauduro is Director
will involve the expansion of electricity to one customer, as well as gas compressor of WADE’s Cogeneration
existing CHP systems or new and this restriction may have stations, landflls and locations Industries Council
1503cospp_16 16 3/12/15 5:02 PM

1503cospp_17 17 3/12/15 5:02 PM

Operations and maintenance
SKF’s Machine Condition Indicator is a vibration sensor and indicator for monitoring non-critcal machines Credit: SKF
Making condition
monitoring smarter
Effective condition monitoring has always been key to plant reliability, but
the advances of the digital age are opening up new horizons and the
possibility for feet-wide management of gas turbines and balance of plant
equipment, fnds David Appleyard.
C
o n d i t i o n A clear understanding of reduce both the frequency
monitoring these conditions thus allows and duration of shutdowns
allows operators systems to be maintained for maintenance, but also
to switch from more effectively, improving maximise the lifespan of
a preventive maintenance overall availability and such machinery whilst saving
programme – in which key reliability and reducing money on other associated
components are inspected unplanned outages. areas of the maintenance
and replaced on a regular Furthermore, by making programme, for instance
schedule – to one based on such a transition, owners and minimising inventory.
actual physical conditions. operators not only typically Principal parameters for
1503cospp_18 18 3/12/15 5:02 PM

1503cospp_19 19 3/12/15 5:02 PM

achieving economic viability, signed an agreement to

even for captive power plants acquire Piezotech LLC for
where the presence of on-site $41.2 million, bolstering its
renewables is increasingly access to high-performance
introducing an element of piezo-ceramic technology
greater variability. As Griffths for extreme temperature gas
notes: ‘The current market, turbine sensors.
where machines need to
operate under variable load Adopting new
conditions, increases the need approaches
for detailed information about Faced with growing
machine availability and operational complexities,
reliability. Therefore, the need asset owners and operators
for an online monitoring system are increasingly turning to
that provides plant operations more sophisticated condition
with a clear indication of monitoring techniques as
whether it is safe to operate they attempt to maintain a
the machine has never been competitive edge. As Griffths
greater’. says: ‘There is an increasing
Henry Reinmann, Vice acceptance of condition
President (Energy) for Strategy, monitoring in a range of
Sales & Marketing at Meggitt industries, with vibration
Meggitt Sensing Systems’ rack-mounted VibroMeter VM600 monitoring
system is designed for power plants where measurement data is accessed Sensing Systems, echoes monitoring being one of the
from a central area Credit: Meggitt Sensing Systems this theme of increasingly technologies used in these
demanding operational programmes’.
monitoring gas turbines in mechanical failure and the requirements, saying: Dr Geraint Jones, Technical
on-site and combined heat associated environmental ‘Operational costs have to Manager for SKF’s Traditional
and power (CHP) applications health and safety risk to be low, emissions have to be Energy business, picks up on
include temperature and plant personnel. Analysis of low for SOx and NOx; it’s now another change too. ‘Perhaps
pressure – both dynamic and the signals obtained from a also CO2. Effciency needs to what’s slightly different now,’
static – as well as vibration. correctly selected vibration be increased and availability he says, ‘is that the process
Other methods of investigation transducer can provide insight and fexibility of the machines data is incorporated within the
include oil analysis and into the machinery condition needs to be high, and vibration data, your analysis
thermography. Temperature and the possible cause of a these are all contradictory data and which instrument
and pressure readings, for malfunction. More importantly, requirements’. you’ve used to collect your
example, allow operators to continuous monitoring of Reinmann continues: ‘If you data. That allows you, with the
control combustion more machine vibration can provide want to increase effciency condition monitoring software
precisely, enabling advanced early detection of deterioration and lower emissions you have we have now, to incorporate
warning of potential failure of the machine condition to operate the machine in a the process parameters that
modes or unstable and and enable proactive very lean manner. You have tell you how the gas turbine
potentially hazardous management of the asset and to go close to the stall limits of is operating.’ However, Jones
combustion conditions. its maintenance.’ the machine, which is when, also notes: ‘These installations
Similarly, vibration monitoring And this is the crux of for example, a gas turbine are not just a gas turbine on
can reveal the vast majority condition monitoring, as starts pumping. That could their own. You might have
of machine faults which arise Griffths notes: ‘The operating potentially be dangerous something on a skid with oil
from shaft misalignment, condition of a gas turbine and you need to monitor it to pumps and other ancillary
imbalance or bearing and can only be assessed by see whether, if such an event equipment, and all those extra
gear wear. use of a comprehensive is coming up, you have to machines are important. The
Indeed, the importance of online monitoring system that move away from that critical task of condition monitoring
effective condition monitoring provides an indication of both stage with the machine. The is to treat the whole machine
in power generation and the mechanical integrity and chemical composition of the as a complete system, not just
CHP assets cannot be over- thermodynamic performance fuel affects the combustion focus on the gas turbine.’
emphasised. As Derek Griffths, of the machine’. dynamics, so a change in the Reinmann also notes an
Sales Director, Western Europe gas supply on the grid may increasingly holistic approach
for GE Measurement & Control’s New requirements, have a signifcant effect. You to condition monitoring, saying:
Bently Nevada product line, changing demands can only do that with active ‘We see a combination of
explains: ‘Excessive vibration The need for fexible and monitoring’. monitoring tasks, with vibration
can lead to catastrophic effcient operations is central to In late August 2013, Meggitt and combustion monitoring,
1503cospp_20 20 3/12/15 5:02 PM

for example. A trend we distance. These signals from OEM specifcations and is bringing together all of
are seeing is that the large piezoelectric transducers are control systems.’ these limits that live in many
machines usually monitor the quite critical, but you cannot Carrigan continues: different data sources,’ he
traditional rack-mount systems, easily transport them over ‘An original equipment says. ‘Consolidating and
and we now see combinations large distances.’ manufacturer, for instance, normalising this data ensures
with balance of plant and Mark Carrigan, Senior Vice- will have established reliability that the operational limits
the smaller machines with President of Global Operations limits. The plant will have stay in sync. It also provides
modular distributed systems. for PAS Inc, also highlights optimisation limits that it wants additional capabilities such
With distributed monitoring the growing complexity to keep within the reliability as varying the alarm in the
there is certainly an advantage of condition monitoring limits of the equipment. In distributed control system
of reducing cabling and systems in process plants. this case, a plant that pushes (DCS) so that the alarm always
installation cost and increasing He says: ‘For many in the oil production must understand enunciates at the right time,
fexibility.’ He adds: ‘Many and gas community and the resulting long-term impact allowing the operator to take
machine manufacturers want petrochemical industry, there on equipment performance. the proper action.’
to have monitoring systems on has been a focus over the This requires a co-ordinating In February of this year, PAS
the smaller machines so they last couple of years on better element that is best handled announced a new multi-year
can swap out the machine, managing operating windows. through automation.’ contract with BP Downstream
including all the monitoring The issue that processing Explaining how such a to help manage critical
around it. They take it out and industries have is managing system works, Carrigan points operational limits in refneries
put a new machine in and across the literally thousands to a hierarchy of operability and petrochemicals assets.
everything is on there already.’ of measurements and their limits, such as an optimisation The product, PlantState Suite
Such modular ancillaries associated operating limits. limit, which should be lower inBound, captures, analyses
are connected to the control The problem is exacerbated than an alarm limit, and and alerts operators on
and monitoring system via an by the fact that the storage correspondingly should boundary data within plant
ethernet cable. As Rienmann of all those different operating be lower than the value at operations. Boundary data
notes, ‘You don’t have to windows is typically scattered which long-term reliability of includes process alarms, safety
worry about transporting across various locations, the equipment is affected. instruments and environmental
pico coulomb signals a long including documentation, ‘The main value PAS provides trip points, mechanical design
1503cospp_21 21 3/12/15 5:02 PM

limits, normal operating zones,

Metso’s wireless Maintenance Pad is a portable data
and safe operating envelopes. collection and analysis tool that includes the Metso
Carrigan says: ‘Companies Machine Analyzer vibration analysis software
Credit: Metso
have realised the diffculty in
managing all these systems
they’ve put in place. No one
plant has one control system
vendor that does it all, so
it’s hard to try and get these
systems working together.’
He concludes: ‘Automating
boundary management
with software within a plant is
considered an industry best
practice today. Most of the
majors have an initiative in
place to get a handle on their
operating windows.’ More recently, in January ‘Integrating SKF’s condition OEMs at an earlier stage
PAS is not alone in adopting Meggitt released its VibroSight monitoring technologies into and do condition monitoring
a more holistic approach to software for turbines, critical mobile devices supports the at the point at which the
condition monitoring, covering machinery and balance- group’s focus on asset lifecycle equipment is commissioned
not just the gas turbine but also of-plant equipment. The management. By providing and tested. The way we would
critical ancillary equipment company says its software access to real-time machine see that working would be
and balance of system. suite fags critical events performance data in a user- to encourage our clients to
For example, in July 2014, and monitors machinery friendly format, customers specify this to their OEM as a
GE’s Measurement & Control health, enabling the use of and maintenance engineers pre-requisite when ordering
business invested in asset predictive methodologies are better able to take new equipment.’
performance management which help operators make informed decisions regarding Jones also calls for turbine
(APM) software company informed decisions about maintenance activities and manufacturers to work
Meridium, Inc to integrate asset management and increase machine effciency,’ a with such companies to
Meridium’s suite of enterprise maintenance. statement says. design condition monitoring
performance management A further focus of machines into the equipment
and asset strategy software development in condition Building relationships at the outset, as well as earlier
with GE’s System 1 condition monitoring has seen with the OEMs engagement with their clients
monitoring and diagnostic considerable energies While condition monitoring on condition monitoring.
solution. The new integrated expended on improving the equipment is growing in He notes that owners and
solution, Production Asset interface between the various sophistication, there are operators will often provide
Reliability (PAR), aggregates monitoring systems and the nonetheless signifcant detailed specifcations for
data from System 1 and other decision-making user. opportunities for further the turbine, but the issue of
plant maintenance systems to As Carrigan explains: ‘The improvement. Some sensor condition monitoring will only
provide plant engineers with a frst thing you want to do is make and diagnostics companies be raised at the shipping
dashboard of reliability metrics, it available to the operator, already work with turbine and point, when customers may
the company says. According visualise it and see real-time balance-of-system original belatedly realise that there
to a statement, this new data against these limits and equipment manufacturers in is no condition monitoring
industrial internet offering can make sure we’re operating order to more effectively place equipment included in the
result in an estimated 10%–30% within them. The second is that or embed sensor equipment package as specifed.
reduction in maintenance you want to provide a score within machines during the ‘One development we
costs. card to management.’ For manufacturing process, as are really interested in at the
‘The way we do business example, in mid-December SKF well as enable condition moment, in terms of our varying
is being dramatically altered announced further investment monitoring systems to establish research, is embedding the
in the era of the industrial in ‘smartifying’ its maintenance a clear performance baseline. accelerometer in the bearing
internet. We are realising the service offering, production However, Jones argues itself. If we could do that,
increased productivity and and sales processes. As that more could be achieved, we would save a lot more
effciency gains from big data part of the investment, feld saying: ‘Normally, in that bearings than we currently
and analytics delivered in real maintenance engineers situation, we would want do. The condition monitoring
time,’ says Art Eunson, General and others are equipped to work in partnership with becomes more robust,’ says
Manager of GE’s Bently with smart devices using the client, but we would like Jones. He adds: ‘Advanced
Nevada product line. tailor-made software apps. to really get in touch with processing techniques
1503cospp_22 22 3/12/15 5:02 PM

give you a better understanding of the continue to improve the effciency of their understanding of what the machine
rolling element bearing. Although those operations, which will require some form of is doing, and also to be able to plan
techniques are not new, they are still very condition monitoring to provide them with changes, upgrades etc. I think there is a
useful. Simply embedding the sensor in the an indication of where they need to focus long way to go for condition monitoring.’
bearing makes them even more effective.’ their maintenance efforts and improve
There is also a continued push the overall availability of their plant, whilst David Appleyard is a freelance
towards simplifed modular systems. keeping control of their operational costs. journalist specialising in the energy,
For example, SKF has launched remote Think of this as enabling condition-based technology and process sectors.
wireless technology sensor systems – maintenance.’
machine condition indicators – which And, as Reinmann says: ‘Thus, it will This article is available
include a traffc light system that require more condition monitoring, data on-line.
activates depending on the vibration management, more knowledge and Please visit www.cospp.com
limit programmed into it. ‘This can remove
some of the burden for data collection,’
says Jones.
The future of condition

monitoring
A natural consequence of a more holistic
and online approach to condition
monitoring is the potential beneft for feet-
wide operations. As Griffths says: ‘Remote
condition monitoring via the internet
allows entire feets of gas turbines to be
managed from a central location. This
allows feet data to be gathered, common
faults to be identifed, and engineered
solutions developed to improve the overall
reliability of the feet.’
This is a theme also picked up by
Reinmann: ‘In the early days you had
machine specialists in every power plant,
and that is just not economical anymore.
Large utilities concentrate resources, they
have remote monitoring centres, and
some of the large OEMs do that also. They
want to get a central location where the
specialists sit, and it can then act or react Stator Protection That
remotely, if they have a feet of machines
of the same type. If there’s an event Stands on Its Own
happening on a machine, they look at the
The SEL-2664S Stator Ground Protection Relay is the
data to see if there are other machines of
only relay on the market that offers standalone stator
the same type showing similar indications
winding protection with built-in I/O contacts and multiple
- a feet-wide approach.’
communications protocols. Combined with state-of-the-
Jones also points out the development
art technology that uses four individual low-frequency
of remote diagnostic centres, saying:
injections, the SEL-2664S will ensure your generator is
‘As a condition monitoring tool, you can
protected all the time, even during startup.
actually monitor your machines online
and you don’t need someone walking Choose the SEL-2664S for complete stator ground
around. As you move to an online system, protection in a single, powerful relay. Learn more at
you can possibly move towards remote selinc.com/2664S-cospp3.
diagnostic centres; those have been
developed in the past decade.’ However,
he also sounds a warning: ‘The other side
of the coin is that cybersecurity is an issue.
That has to be considered.’
Looking ahead, Griffths says: ‘I
believe power generation operators will
1503cospp_23 23 3/12/15 5:02 PM

Biomass case study
Making the switch

from coal to biomass
With specifc modifcations, a bituminous coal-fring CHP system can be
converted to operate with wood or other biomass pellets, write
Thomas Krause and Yaqoub Al-Khasawneh
T
he Studstrupvaerket In summer 2013 one of the type MPS 190. Inside the mill
power station in upper mills (mill No 40) and (see Figure 1) the grinding
Studstrup, Denmark the respective burners were process of the fed raw coal
features two units, 3 upgraded at SSV3 to allow is initialised by rolling off
and 4, which are designed wood pellet operation as well stationary, rotating grinding
for combined heat and as coal combustion. After the rollers upon a turning grinding
power (CHP) production. modifcations, the transition bowl.
The maximum net power from coal to biomass operation The fuel is fed via a coal-
output is 350 MW and the (and reverse) should be chute centrally into the mill
maximum district heating possible within a period of to the rotating grinding bowl,
output is 455 MJ/s per unit. 30 minutes or less for each mill and afterwards is transported
Dong Energy Thermal Power while the unit keeps running by centrifugal force to the
is planning a fuel conversion continuously. grinding rollers. The grinding
at unit 3 (SSV3) to 100 per Four different trial runs were rollers are pressed on the
cent wood pellet fring, while conducted from October grinding bowl due to their
as far as possible keeping 2013 to February 2014 using own weight and an additional
the maximum thermal heat bituminous coal and different external force, generated by
output at 930 MWth with the kinds of wood pellets for testing a spring-loaded rope pull
option of using the present under different load conditions, system.
fuel qualities (coal, straw and variable load ramps and The fuel gets crushed
oil) alternatively to the pellets. fuel switching between coal through pressure and shearing
The complete conversion and biomass at the modifed inside the milling gap between
of unit 3 comprises mainly mill. From December 2013 to grinding rollers and grinding
new unloading and feeding March 2014, a total of about bowl. The primary air required
systems, wood pellet storage, 70,000 tonnes of wood pellets for drying and pneumatic
feeders and modifcation of were ground and burned with transport of the ground fuel is
existing mills and burners. The the upgraded combustion provided by a separate fan.
existing coal feeding system equipment. The required primary air fow
remains ready-to-operate to depends on the inserted mass
allow a fuel switch between Mill modifcations fow rate of the fuel. The desired
hard coal fring and wood The boiler at SSV3 is equipped primary air temperature is
pellet fring. with four bowl and roller mills achieved by mixing hot and
1503cospp_24 24 3/12/15 5:02 PM

Biomass case study
Raw coal
Coal dust outlet
cold primary air. The primary
air is fowing into the grinding Coal down pipe Louver blades adjustment
chamber through a nozzle ring,
Dynamic classifer
with a defned temperature,
velocity and fow direction. Rotating cage
Return hopper
The mills at Studstrup unit
Louver blades
3 are equipped with dynamic Loading frame
Spring Sealing air circle line
classifers of type HEP 33H6.
This classifer uses adjustable, Guide frame Grinding rollers
stationary blades and a speed- Rod
Inner housing
controlled rotor for fneness (Double wall) Dam ring
adjustment. Increasing the
Nozzle ring
rotor speed leads to an Hot air inlet duct Hot air
improvement in the grinding
fneness. The dynamic classifer Grinding track
Motor
is designed for coal operation
Hot air annular channel
with a grinding fneness of R_90
µm = 5%–25% (about 10%–30% Mill gearbox
residue on a sieve 75 µm).
Because of the differences
in grinding, drying, pneumatic
transport and the fneness Figure 1. MPS mill for coal and biomass operation
requirements for combustion fan at the classifer motor; pulverised bituminous coal. consists of the following main
of pulverised coal and wood • Double wall installation Six burners are arranged in components:
pellets, it is not possible to grind (cylindrical airfow defector) four elevations, located on • Ignition device;
both fuels simultaneously. inside the grinding chamber the boiler front and rear walls. • Core air tube;
The parameters of the and upstream classifer. Each burner is connected to • Primary air tube with
grinding system regarding the These mechanical the combustion air supply integrated fuel nozzle,
requirements of pulverised modifcations allow mill system by a secondary air primary air swirl device and
fuel drying, as well as fre and operation with both fuels. The duct, including the necessary inlet elbow linked to the
explosion protection, are set classifer, for example, can damper and fow measuring pulverized fuel line;
either for coal or for wood be controlled by the angle devices for individual • Secondary air pipe with
pellets. After the correct setting, adjustment of the louver combustion air control. swirl blades and tertiary air
the mill operates economically blades and by adjusting the The target for the defecting cone;
and reliably with the chosen classifer’s rotational speed modifcation was to operate • Tertiary air nozzle with swirl
material. to fulfl the different fneness the swirl burners either in blades;
Necessary changes for requirements for bituminous 100 per cent bituminous coal • Burner wind-box.
adjusting the grinding system coal and biomass combustion. mode or 100 per cent biomass The prerequisites for the
to the new fuel, besides the The grinding system is mode on a wood pellet process are created through
adapted control technology, equipped with additional basis. the interaction between swirl
are mechanical modifcations temperature measuring points For the realisation of coal/ devices and fuel nozzle, as well
to the mill and classifer and an explosion suppression biomass combustion the six as the resulting heat transfer
regarding grinding, pneumatic system. burners of the upper level in the nearby burner zone.
transport of the pulverised Besides mechanical 40 were upgraded with the Early oxidation of the pyrolysis
fuel, and classifcation. The modifcations, some essential DS Burner elements. products with a defned oxygen
following modifcations were adaptations to the control Concentric setup and volume is the precondition for
made to adapt the grinding system had to be arranged. swirling of all burner fows are stable low-NOx combustion in
system: Mill operation with bituminous essential features of this burner the core fame.
• Grinding bowl rotational coal or wood pellets is realised type. The DS Burner design is The core fame is surrounded
speed increase; individually by an independent determined by the ignition, the by spatially staged fows of
• Dam ring installation at the operation programme fame start and the subsequent secondary and tertiary air,
grinding table edge; which contains the required low-oxygen primary reaction while the combustion process
• Coal-downpipe extension; parameters and limit values for phase. Further, the burner has is supplied with the necessary
• Modifcation of the classifer: mill operation. been designed to handle the oxygen by a continuous
installation of variable drive fuel particles in the pyrolysis delayed supply from the
for louver blade angle Burner modifcations process as well as their peripheral burner fow.
adjustment, return hopper The 24 burners were originally subsequent oxidation. For the burner modifcation,
modifcation, change of the designed for the use of In general, the DS Burner new primary air tubes with
1503cospp_25 25 3/12/15 5:02 PM

Biomass case study
integrated fuel nozzles and inlet higher compared to pulverised R_0.09 = 20% (residue on a scanners and checked by
elbows, linked to the pulverised- bituminous coal. screen 90 µm) related to the video recordings of the wing
fuel tubes, were installed. The Special attention was paid to coal parameters HGI = 55°H, burners from the side wall
fuel nozzles, fabricated as a suffcient distance between moisture = 9% and ash content inspection holes.
single component of spun- carrier gas temperature and = 13.5%. Later the mill was The dynamic behaviour of
casting heat-resistant alloy, are self-ignition temperature of the equipped with a dynamic the modifed mill had already
welded to the pulverised-fuel pulverised biomass in a hot air classifer of type HEP 33H6 for been tested in January 2014.
tubes. With exception of the atmosphere, and to preventing fneness improvement. Today, Load change behaviour of
fuel nozzles, the pulverised- biomass ignition at hot surfaces the average grinding fneness the modifed mill has not
fuel tubes are fabricated of in the grinding system. is about R_0.09 = 14% Related deteriorated compared with
composite material, including During coal operation to the design fuel and the unmodifed mills. The required
an inside erosion-protective the required primary air higher fneness degree, the grid code parameters have
lining on a chromium-carbide temperature and, partly, coal mass fow for the same been achieved.
base. the grinding system surface mill load is 11.65 kg/s. A deterioration of part load
On the circumference of temperature during coal The pulverised coal mass behaviour appears while in
the core air tube, primary swirl operation could lead to wood fow, the accessible grinding coal operation mode. The
blades with angle position of pellet ignition. Before switching fneness and the dynamic modifcations have led to an
35° to the fow direction are from biomass to coal operation behaviour of the mill should increased grinding capacity,
welded at a certain distance the grinding system must not be limited by the mill while also increasing the
to the burner tip. In addition, be emptied of biomass – in modifcations. These are achievable minimum load.
the existing core air nozzle was particular, the hot air annular the requirements given by The aim of a minimum load of
replaced by a new one made channel below the mill’s EnergiNet DK Grid Code: load 5.2 kg/s leads to a disturbed
of heat-resistant material, with nozzle ring, and the reject box. changes at 50%–90% plant smoothness, so that the
length of about 650 mm. The primary air temperature load not less than 4% per obtainable minimum load
Due to the new design of may only be increased to the minute; below and above this was increased to 6–6.5 kg/s.
the pulverised-fuel tubes, new required values after this step. range plant load changes The desirable minimum load
secondary air swirl inserts Before switching from coal not less than 2% per minute. could be realised through
must be installed. With the to biomass operation it must Furthermore, the functionality adjustment of the grinding
exception of the SA nozzle with be ensured that the hot zones of the modifed burner must force during operation (state-
TA defector, all burner parts inside the mill are cooled down be demonstrated. The burners of-the-art, but not implanted
on the combustion air side suffciently to prevent self- should have a stable ignition in SSV3) or by a moderate
remained unchanged. ignition of the fuel during any and fully satisfying coal decrease of the modifed mill’s
operating mode or shutdown combustion behaviour. grinding capacity.
Process parameter and procedure. Therefore, The performance of the With the exception of
safety considerations additional temperature modifed mill 40 and the the temporary limitation of
Coal and wood pellets have measuring points inside the function of the dedicated minimum load behaviour
a clearly different grinding mill housing were installed. burners were proven in a trial during coal operation, the
and combustion behaviour While switching fuel types, run in February 2014. The mill performance of the modifed
than coal. Thus the operating dust samples were taken from was operated safely with a grinding system as well as
parameters of the fring system the PF lines at certain times to coal mass fow of 12.5 kg/s the burners turned out to be
have to be adjusted to the determine the duration of the and measurements were comparable to the capacity
individual fuel properties to fuel discharge. taken at the mill, as well as coal of the unmodifed units. Thus,
comply with the following Figure 3 shows parameters sampling at the pulverised high expectations for biomass
tasks: grinding and classifying, and temperatures of the fuel lines. Burner functionality operation could be fulflled
drying, pneumatic transport primary air upstream mill and was monitored by the fame and even exceeded.
and distribution of the fuel dust of the carrier gas at mill outlet
into the individual pulverised as well as fuel parameters to Secondary Air Swirler
Fuel Nozzle
fuel lines. Furthermore, stable reach the boiler peak load
ignition at the burners and of 930 MWth in four-mills
the combustion process in the operating mode.
furnace has to be ensured. Mill
operation with coal or wood Operational results
pellets is realised individually In delivery state, the mill MPS
by an independent operation 190 was equipped with a
programme. static classifer of type SLK,
Due to the highly volatile and designed for grinding
PF Tube Primary Air Swirler
content, the reactivity of a coal fow of 12.78 kg/s Core Air Tube TA Defector
pulverised biomass is much with a grinding fneness of Figure 2. DS Burner components
1503cospp_26 26 3/12/15 5:02 PM

Biomass case study
Pulverizer operating data for 930 MWth (boiler peak load) the primary air temperature
for coal operating mode.
In addition, cleaning of the
reject box is required prior
to an increase in primary air
temperature. After that the
classifer rotational speed
can be increased continually
towards coal operating mode
requirements. This must be
done carefully as the coarse
wood pellet particles have to
leave the mill frst.
Dr Thomas Krause is Head

of Process Engineering
Pulverizing Systems at
Mitsubishi Hitachi Power
Systems Europe. Dr Yaqoub
Figure 3. Gas and fuel parameter per mill for 930 MWth (boiler peak load) with guarantee fuels
Al-Khasawneh is Process
Switching modes mode. Complete clean-out the particles of the pulverised Engineer for Pulverizing, Coal
The target was 30 minutes of the mill is ensured with coal leaving the classifer must and Ash Handling Systems
to shut down each mill and a special purge sequence. be fne enough to ignite safely. at MH Power Systems Europe
restart it with the other fuel The mill reject box has to be Before starting with Service.
– and the same process in cleaned completely as well. coal operation, it must be
reverse – or two hours for all Good dynamic behaviour ensured that biomass can This article is available
four mills.Furthermore, it should of the grinding systems be discharged from the mill on-line.
be checked if a direct switch opened the possibility for a completely before setting Please visit www.cospp.com
between operating modes direct switch between fuel
without stopping the mill is modes. Direct switching
possible. without any infuence on
A switch between the fuels fame stability at the burner
in a period of 30 minutes with was tested in a separate trial
a shutdown and restart of run, and comprehensive
the mill was possible from the safety assessments were
beginning onward. conducted. As a result of these
It is important to note that, assessments, the operation
during the switch from coal programmes were modifed
to biomass operation, the mill accordingly. The previously
is cooled down suffciently mentioned safety parameters
prior to the biomass feeder must be fulflled, and the
start in order to decrease experience gained from prior
the material temperature at operating modes must be
the nozzle ring and the hot incorporated.
air inlet channel below the During coal operation, the
self-ignition temperature of
biomass in particular. During
material temperatures of the
complete mill must be lower
GAS ENGINES
the cooling-down process with than 150°C prior to biomass Reliable heart for your unit
the operational programme, feeder start. To ensure this,
the temperatures inside the additional temperature Power range: 80 - 210 kW
mill were measured. measuring points have been
When switching from installed. After switching
Fuels: NG, Biogas, LPG,
biomass to coal, it must be to biomass feeding, the Wellhead gas, CBM gas
ensured that no biomass classifer’s rotational speed and others
remains inside the mill, as has to be continually lowered
self-ignition could occur due to the wood pellet classifer info@tedomengines.com, +420 483 363 642
to the increased primary air speed to protect the mill from www.tedomengines.com
temperature in coal operation overflling. At the same time,
1503cospp_27 27 3/12/15 5:02 PM

Cogeneration optimisation
Enclosures and effciency

In the ffth of a series of articles on optimising cogeneration plant, Dr Jacob Klimstra
explains how the setup of an installation’s enclosure can affect its effciency.
A properly designed enclosure can improve installation effciency and stability

Credit: Emerson Process Management
M
o s t temperature and the way cylinder block is normally
cogeneration the ventilation system works. thermostatically controlled.
installations are If no enclosure is present, the Here we will use a series of
housed in an intake air of the reciprocating examples to illustrate the effect
enclosure, which can be engine or gas turbine equals of enclosures on the effciency
a container or a special the ambient temperature. of a cogeneration installation.
boiler house. An enclosure In that case, for an exhaust
is generally needed to temperature controlled at a Cogeneration effciency
avoid noise radiating to the fxed value, a lower ambient with no enclosure
environment and to shield temperature results in higher The fuel effciency of a
sensitive equipment from losses in sensible heat with the cogeneration installation
the weather. An enclosure intake air. is 100% where the exhaust
can also prevent unqualifed In addition, the temperature equals the
people from tampering with temperature difference intake temperature and
the installation. between the engine and its the insulation ensures that
The effciency of a surroundings will then vary no heat escapes from the
cogeneration plant is also with the ambient temperature, machine to the environment.
affected by its enclosure, affecting the convection Complete combustion should
depending on the ambient loss. The temperature of the also be present, and the heat
1503cospp_28 28 3/12/15 5:02 PM

Heat required for raising the intake air temperature to 25°C on an enclosure’s effect on higher. Modern reciprocating
percentage of lower calorifc value
6 total energy effciency is very gas engines operate at a λ

5 small. between 1.8 and 2.1.
lambda = 1 Stoichiometric combustion The cylinder block of a
4
lambda = 2 of methane requires reciprocating engine is often
3
lambda = 3
17.36 kg of air per kg of controlled at a temperature
2 gas. Most prime movers in close to 85°C. This warrants a
1 cogeneration installations use proper temperature distribution
0 a fuel-lean mixture for better of the engine’s inner parts,
-1 performance and lower NOx while the coolant provides
emissions. For an air-to-fuel a suitable temperature for
-2
ratio λ of 2 with respect to a heating systems. For a modern
-40 -20 0 20 40
intake temperature °C
stoichiometric mixture, one turbocharged engine with a
needs 34.72 kg of air per kg of brake mean effective pressure
Figure 1. A low intake temperature requires much energy to heat up the methane. at full load of about 20 bar,
intake air to 25°C
The specifc sensible heat the heat loss from the engine
coming from the electricity in which cp = specifc heat in kJ/ to be added to the intake air block to its surroundings
generator should not be lost kg; Tref = reference temperature is (eq. 2): is about 1.5% to 2% of the
to the environment. Such in °C; Hi = lower calorifc value in E (air)= λ • 17.36c (air)(T _T ) fuel energy where the room
specifc p ref in
stringent boundary conditions MJ/kg. temperature is 30°C.The actual
Hi
are diffcult to implement in a For methane, cp is about value depends on the size and
practical installation. 2.2 kJ/kg and Hi is 50 MJ/kg The cp of air at ambient construction of the engine.
A reference temperature of for a reference temperature of conditions is about 1 kJ/kg. Since, in a normal situation, the
25°C is a suitable value for the 25°C. The cp of nitrogen (N2) is We now know how to heat transfer from the engine
sensible heat of the intake air about 1.04 kJ/kg and that of determine the sensible heat block to its surroundings is
and exhaust gas, since it is, in carbon dioxide (CO2) about required to bring the intake air via convection, the heat
practice, the lowest possible 0.84 kJ/kg. Some natural and fuel gas to the reference loss to the surroundings is
temperature used in heating gases contain considerable temperature of 25°C. This directly proportional to the
systems. At 25°C, heat can be amounts of nitrogen. Biogas amount of heat, as a temperature difference. This
used for soil heating systems in can contain much CO2. percentage of the fuel energy heat loss can be written as
horticulture and for under-foor It is generally presumed that required to raise the intake (eq. 3):
heating systems in buildings. natural gas from underground air temperature, is shown in Econvection= 85 – Tsurroundings·0.015·Hi
When determining the heat pipelines has a temperature Figure 1.
85 – 30
balance of a cogeneration of 15°C. The specifc sensible Figure 1 reveals that a
installation, we need to heat needed to raise the cogeneration system which Figure 2 shows the
calculate how much the fuel gas temperature from 15°C draws its combustion air dependence of the convection
gas and intake air must be to 25°C is 2.2 · (25–15)/50 = directly from outside can need loss on the temperature of
heated or cooled to reach 0.44 kJ/MJ, equalling 0.044% up to 6% of the fuel energy to the surroundings, in a case
the reference temperature. The of the fuel energy, meaning bring the intake temperature where no forced air fow is
same applies for the exhaust that it is close to negligible. from -30°C to the reference present around the machine.
gas. A cogeneration installation’s temperature of 25°C. Most Some packagers design the
Here, as we are focused enclosure has no effect on the gas turbines operate at an ventilation system in such a
on the enclosure’s effect on gas temperature, and therefore air-to-fuel ratio λ of 3 and way that blowers create high
the energy balance, heat we will ignore the small effect
loss resulting from an exhaust of the gas temperature on Convection loss reciprocating engine
temperature higher than the effciency. 3.5
percentage convection
reference temperature of 25°C The composition of natural 3

loss of fuel energy
will not be discussed. (This was gas depends on its source, 2.5
the subject of an article in the but methane is always by 2
November–December 2014 far the main constituent. The 1.5
issue of COSPP, now available properties of natural gas,
1
on-line at www.cospp.com.) such as calorifc value and
0.5
The sensible heat per unit of stoichiometric air requirement,
0
calorifc value Especifc of the fuel depend on its composition. For
-40 -20 0 20 40
gas equals (eq. 1): simplifcation purposes, we will
temperature surroundings (°C)
here use pure methane as our
Especifc(gas)= cp(gas)(Tref_Tin)
fuel gas example.The infuence Figure 2. The convection loss of a reciprocating engine is directly proportional
Hi
of the actual gas composition to the temperature difference between the engine block and its surroundings
1503cospp_29 29 3/12/15 5:02 PM

air fows against the engine examples exist where no

block. This can substantially ventilation takes place in the
increase the engine block’s enclosure. This has, e.g., been
heat loss. the case with the FIAT TOTEM,
Figures 1 and 2 show that a 15 kW cogeneration unit
a cogeneration installation with a water-cooled generator.
exposed to ambient air can All larger installations use
easily lose 6% of its fuel energy ventilation within the enclosure.
if the ambient temperature In the example of Figure
is very low. Unfortunately, 3, the inner temperature of
heat demand generally the enclosure is controlled
increases with a lower ambient at 30°C. This means that
temperature. the temperature difference
between the engine block and
Figure 3. A cogeneration installation in an enclosure with forced ventilation to
An enclosure with a its surroundings is constant, keep the inner temperature at 30°C.
controlled internal resulting in a convection loss
temperature at full load of some 1.5% of Losses due to intake air heating +
ventilation (intake air from outside)
percentage of lower calorifc value

As mentioned earlier, the lower calorifc value of
7
cogeneration installations are the fuel (equation 3). The
normally inside an enclosure. generator loss of about 1.5% of 6
lambda = 1
This includes the electricity the fuel energy is also added 5
generator. At full load, the to the ventilation air, so that lambda = 2
generator loss is some 1.5% in total 3% of the fuel energy 4
of the fuel energy. Generators leaves the enclosure with the 3
have to be cooled in order ventilation air.
2
to avoid overheating of their The air for the engine
windings. Sometimes ambient process is drawn from outside, 1
air will be used to cool the which means that the energy 0
generator, but in many cases required to heat the intake air -40 -20 0 20 40
the air inside the installation’s to the reference temperature Figure 4. The heat loss for the intake air and ventilation air of a reciprocating
enclosure is cold enough to of 25°C is dependent on the engine-driven cogeneration installation running at full load in a temperature-
controlled enclosure, expressed as a percentage of the lower heating value of
cool the generator. ambient temperature. Figure
the fuel
4 gives the resulting fraction
INTAKE AIR FROM OUTSIDE THE of the fuel energy that is lost
ENCLOSURE due to intake air heating and
Figure 3 is a schematic enclosure ventilation.
representation of a Actually, the energy required
cogeneration system in an to heat the intake air is exactly
enclosure. The temperature the same as in Figure 1. No
inside the enclosure is line for λ = 3 has been given
controlled by a variable-speed in Figure 4, since the data on
ventilator. If ventilation was not the convection loss apply for
present, the enclosure would reciprocating engines only
reach a temperature of over and these engines do not
85°C, which means that the operate at such high lambda
air inside the enclosure would values as the turbines. In this
have the same temperature solution, the convection loss Figure 5: A cogeneration installation that draws its combustion air from inside
as the engine block. Therefore, will never exceed 1.5% at full its enclosure
convection from the engine load. This is in contrast with a
block to its surroundings would no-enclosure situation, where very low. Therefore, this solution engine from the enclosure
stop. the convection loss can reach with intake air taken from itself. Figure 5 illustrates this
However, there is still heat 3% of the fuel energy in the outside the enclosure is not concept. The air infow into
input from the generator case of very low ambient ideal. the enclosure is now the sum
and from radiation of the temperatures. of the intake air for the engine
turbocharger, and ultimately Again, the heat from a INTAKE AIR FROM INSIDE THE and the ventilation air. If the
the engine block will even cogeneration installation is ENCLOSURE average temperature inside
start to receive heat from generally most needed when A better solution is to draw the enclosure is below 30°C,
its surroundings. Only a few the ambient temperature is the required intake air for the the ventilator will stop, and the
1503cospp_30 30 3/12/15 5:02 PM

NUCLEAR POWER
FUELS
LITY
FOSSIL
RID
OBI
S
ER
EG
E-M
UM
TH
NS
ES
ES
CO
TI
L
LI
AB
TI
U
EW R
RE
N WE
E PO
N SIT
O
OPE
EUR
THE ENERGY
E
YS TORAG
ENERG
TRANSITION
WASTE TO ENERGY
MUNICI
PALITIE
IS CHANGING...
S
9 - 11 JUNE 2015 AMSTERDAM RAI, AMSTERDAM, THE NETHERLANDS
THE ENERGY TRANSITION IS CHANGING ONSITE POWER

Europe’s energy transition has opened the door to fexible, onsite power solutions that are being adopted in more and more countries across
the continent, involving both cogeneration and tri-generation technologies.
All this and more will be discussed at POWER-GEN Europe and Renewable Energy World Europe 2015. Join us in Amsterdam for Europe’s
largest gathering of power professionals. To learn more about these exciting events and information on your sales representative please
visit www.powergeneurope.com or www.renewableenergyworld-europe.com or contact:
Sales and Sponsorship

Gilbert Weir Jnr. Amanda Kevan
POWER-GEN Europe Renewable Energy World Europe
T: +44 1992 656 617 T: +44 (0) 1992 656 645
E: exhibitpge@pennwell.com M: +44 (0) 7866 382 462
E: amandak@pennwell.com
Owned and Produced by: Presented by:
www.powergeneurope.com
Æ www.renewableenergyworld-europe.com
1503cospp_31 31 3/12/15 5:02 PM

Set value enclosure T = 30°C

enclosure temperature (°C)
35
30
25
20
15
10
5
0
-40 -20 0 20 40
ambient temperature °C
Figure 6. The enclosure temperature as a function of the ambient temperature

where the engine intake air is drawn from the enclosure
heat from the generator and had to be ventilated away. In Cogeneration plant in Lubmin, Germany Credit: Siemens
engine block will only heat the case of drawing the intake
the infow of air which exactly air from inside the enclosure, much heat has to be ventilated designs, ventilators push
equals the intake air of the for the same low temperature away when the intake air for ambient air into the enclosure
engine. of -30°C, only about 0.5% of the engine is drawn from inside instead of drawing the air
The question now is which the fuel energy is needed the enclosure at ambient out. In such situations, the
average temperature will to raise the intake air to the temperatures from -12.5°C. engine’s intake air can have
be present in the enclosure, reference temperature of If the ambient temperature a temperature close to the
depending on the ambient 25°C. Therefore, for ambient exceeds 30°C, the ventilation ambient temperature. The
temperature. If the air fow into temperatures below -12°C, system is no longer able to convection heat and the
the enclosure equals the intake the energy effciency of a keep the temperature in the generator loss are then not
air fow, the energy needed to cogeneration plant is about enclosure at 30°C. For ambient used to heat the intake air,
heat the infow of air to the three percentage points better temperatures exceeding 30°C, resulting in less-than-optimum
enclosure temperature equals, when the air for the engine the convection loss from the fuel effciency. High convection
for a λ of 2: is drawn from inside the engine block will begin to losses also occur when cold
enclosure. decrease. ambient air is blown against
Einfow=34.72·(Tenclosure–Tambient)/500%
A positive side effect of The output of turbocharged the engine block. Sometimes
The heat provided from the taking the intake air from reciprocating engines does incoming air jets from the
engine block (see equation inside the enclosure is that its not depend on the intake air ventilators are the cause of a
3) and the generator (= 1.5%) temperature varies only slightly temperature as long as this heavily fuctuating intake-air
equals: with the ambient temperature. temperature remains below temperature, which creates
85–Tenclosure This makes the task of the 30°C. This is in contrast with unsteady engine operation. It
Eprovided= ·1.5% +1.5%
lambda control system much gas turbines, where the power is recommended here to keep
55
easier, since the temperature capacity is proportional to the the atmosphere inside an
Therefore, as long as of the intake air considerably intake air temperature. enclosure as quiet as possible,
the temperature inside the affects the air-to-fuel ratio In practice, the temperature with ventilators drawing the
enclosure is lower than 30°C: prepared by carburettors. inside an enclosure is not air from the enclosure. A
Tenclosure = 39.69 + 0.717 Tambient Finally, fgure 7 shows how always uniform. In some slight underpressure inside
the enclosure also prevents
The result of this relationship foul gases escaping when
fuel energy ventilated away (%)
3.5
is shown in Figure 6. the doors are opened during
Figure 6 immediately 3 running.
shows the huge advantage 2.5 A properly designed
of drawing the intake air from enclosure can clearly improve
2
inside the enclosure, instead a cogeneration installation’s
of directly from the ambient 1.5 energy effciency and stability,
air. In the previous case, with 1 especially on cold days.
intake air drawn from outside
0.5
the enclosure, almost 4% of Dr Jacob Klimstra is
the fuel energy is needed to 0 Managing Editor of COSPP
heat the intake air from -30°C -20 -10 0 10 20 30
ambient temperature (°C)
to + 25°C, while 3% of the fuel This article is available
Figure 7. The fraction of fuel energy ventilated away as heat from a
energy resulting from engine cogeneration installation, where the intake air is taken from inside the
on-line.
block and generator losses enclosure and the set point for the enclosure temperature is 30°C Please visit www.cospp.com
1503cospp_32 32 3/12/15 5:02 PM

RE
G
2 IS
EA 01 TE
RL 5 T R B
1 VENUE, 2 EVENTS, 3 DAYS Y O EF
BI C O
RD LA RE
D IM 17
IS Y A
Featuring: C O P
O U RI
U R L
N
T
14 - 16 May 2015, Pragati Maidan, New Delhi, India
RE-ENERGISING INDIAíS POWER SECTOR

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1503cospp_33 33 3/12/15 5:02 PM

Genset Focus
Trigeneration powers Russian hospital
Genset supplier FG Wilson power plant based on four FG natural gas consumption,
has delivered a vital power Wilson PG750B gas generator the power solution operates
solution for a major new sets. The units work in base in trigeneration mode,
medical centre in Russia. load operating mode in producing not only heat but
FG Wilson’s Russian parallel with the local mains also cooling – the CHP systems
dealer Technoserv has grid at full load. For water supply exhaust gas-heated
commissioned and installed heating, a combined heat water to the chemical
gas gensets and combined and power system was used absorption chiller for cold
gas heat exchanger systems in conjunction with a local water produce, meaning the
for a power station that runs Russian manufacturer, CTM. total electric power plant
Hospital VIT in Nizhny Tagil City, FG Wilson said that capacity is 2.4 MW and
in the Ural district. in order to ensure the around 2 MW thermal or cold
Technoserv designed the maximum effciency of water power.
Aggreko commissions diesel plant in Mozambique

A new power plant has been increasing as the country’s ‘Nacala is experiencing until longer-term sustainable
commissioned in Mozambique annual GDP grows by more rapidly growing commercial solutions can be deployed.’
by Aggreko and state power than 7 per cent and its industrial and industrial activity based
utility Electricidade de sector rapidly expands. around its role as a logistics
Moçambique (EDM). However, electricity supplies in hub of northern Mozambique.
The diesel plant in the port the north have been strained By adding additional
city of Nacala comprises 22 due to seasonal fooding generation capacity close to
diesel generator sets and has that has caused disruption to areas of high energy demand,
a maximum output of 18 MW. networks in several provinces. EDM is addressing increased
Power demands across EDM executive board power requirements with
Mozambique are rapidly member Carlos Yum said: fast-track power provision
Finning offers new gensets for CHP and continuous power applications
Finning Power Systems has a high effciency turbo, and with power ratings of up to total electrical effciency,
launched its Cat G3520H gas a high effciency generator 2500 ekW, with three while the HR and HA turbo
generator set for combined design. The company confgurations available: High trim confgurations provide
heat and power and claims that time and costs Effciency (HE), High Response optimisation for altitude
continuous electric power associated with maintenance (HR), and High Altitude (HA). and ambient performance
applications. are reduced due to to the With the HE option turbo trim capability and dynamic load
The G3520H gas generator G3520H’s optimised piston, ring is optimised for maximum response, Finning said.
is ideal for use in industrial and and liner designs, which help
commercial facilities, as well to minimise oil consumption.
as in distributed generation The G3520H is the second
power plants, Finning said, genset to be introduced as
adding that it features the part of the G3500 H-series,
lowest total lifecycle cost in its following the G3516H, which
class. Finning launched in January
It has a long stroke design, 2013.
high compression-ratio pistons, The gensets are offered
1503cospp_34 34 3/12/15 5:02 PM

Genset Focus
Cummins ships European Grid Code-compliant gensets

Cummins Power Generation generator sets have been the grid code requirements of determine the stresses and
has announced that its delivered successfully to a Germany, France and Italy. optimise designs for the
certifed Grid Code Compliant customer in Germany. Cummins said its team products’ expected lifetime.
Compliance for grid- studied variations in grid code The gensets then underwent
connected power plants is requirements across network testing in parallel with the
already a legal requirement operators and countries with live UK National Grid, using a
in Germany, with many other the aim of designing genset simulation device to create a
countries expected to follow components that could meet localised fault. Real test results
suit. DNV GL has validated the electrical and mechanical were then used to validate a
the Cummins 60-litre and stresses encountered during model which could predict the
91-litre lean-burn gas genset grid faults. Computer-aided gensets’ performance in the
range as fully compliant with design tools were used to event of a low-voltage grid fault.
Himoinsa gensets used in Egyptian water treatment plants

Himoinsa has supplied said Leopoldo Lainz, Asia of over 300,000 people, is equipped with a 400 kVA
Acciona Agua with fve Pacifc Development Manager Himoinsa said. The sewage generator set, the HMW- 350 T5
gensets for operation in four for Acciona Agua. plants of Sodfa-El Ghanayem model.
water treatment plants in Egypt. The largest plant, with a and El Ayat, which have
The project aims to purify fow of 82,000 m3/day, is the similar characteristics, have
150,000 m3/day of urban Abnoub-El Fath plant where been equipped with HTW-920
wastewater, and re-use it for two open gensets were T5 gensets. Both emergency
irrigation. The gensets activate installed, the HMW-1135 T5 and gensets will help maintain
the water purifcation system HTW-2030 T5 models. The two activity at the plants, which will
whenever a power cut occurs, gensets, with outputs of 1200 supply over 200,000 people.
‘something that happens kVA and 2250 kVA, will allow The plant in Abu Simbel, a
quite frequently in this area,’ supply to reach a population popular tourist destination,
POWER-GEN CONFIDENCE INDEX

A PennWell Event
HAVE YOUR SAY: BAROMETER OF POWER SECTOR CONFIDENCE LAUNCHES IN APRIL

This month sees the launch of a poll of power industry professionals To ensure that the POWER-GEN Confdence Index for Europe
which will provide a comprehensive guide to confdence in the represents the views and opinions of all aspects of the industry,
European sector. COSPP invites you to participate in the study.
The European energy industry is undergoing widespread changes Why contribute to the POWER-GEN Confdence Index?
in the way it produces and delivers electric power to industry and 1. An opportunity to contribute to a ground-breaking initiative in
consumers. the power sector – the inaugural POWER-GEN Confdence Index
This energy transition is shifting the sands under the baseload 2. An opportunity to contribute to an authoritative and
providers in the coal, gas and nuclear sectors, so that distributed comprehensive report providing key market information and
generation, renewables, smart energy systems and consumers insights
are playing an increasingly important part in the electricity value
3. An opportunity to have your say on the key issues facing the
chain.
power sector
As power industry companies contemplate their next important
4. An opportunity for your voice to be heard and for you to
step, it is crucial that they have an understanding of the current
infuence and help shape strategic thinking in the power sector
state of the industry and a vision of where it is going. Thus research
and reports are essential to support their strategic thinking. 5. Respondents completing the Confdence Index questionnaire
will receive the full Confdence Index report free of charge
Building on its expertise and the audience generated by its
global POWER-GEN events, PennWell International is launching a 6. Respondents to the Confdence Index questionnaire will be
POWER-GEN Confdence Index. invited to join a dedicated Social Media Group designed to
elicit further discussion
A comprehensive pan-European report for the power industry, the
POWER-GEN Confdence Index will provide key market information, As a power industry professional, your opinion has never been
insights and trends to aid strategic decision making. Compiled more important. Please contribute to the POWER-GEN Confdence
on an annual basis to facilitate year-on-year trend analysis and Index to help shape the power industry of the future.
comparison, this authoritative industry study will deliver insight, For further information please visit www.powergeneurope.com/
perspective and direction. index/power-gen-confdence-index

1503cospp_35 35 3/12/15 5:02 PM

Diary
Send details of your event to Cogeneration and On-Site Power Production:

Diary of events
DistribuGen Conference and COGEN Europe Annual ASME Turbo Expo POWER-GEN Asia Financial
Trade Show 2015 Conference Montreal, Canada Forum
7 – 9 April 19 – 20 May 15 – 19 June 1 – 3 September
Houston, Texas, USA Brussels, Belgium www.asmeconferences.org Bangkok, Thailand
www.distribugen.org www.cogeneurope.eu www.powergenasiafnance.com
POWER-GEN Africa
Energy Cities 2015 POWER-GEN Europe 15 – 17 July 44th Turbomachinery, 31st
22 – 24 April 9 – 11 June Cape Town, Pump Symposia
Aberdeen, Scotland Amsterdam, The Netherlands Republic of South Africa 14 – 17 September
http://aberdeen2015.energy-cities. www.powergeneurope.com www.powergenafrica.com Houston, Texas, USA
eu/ www.pumpturbo.tamu.edu
Renewable Energy World Asia-Pacifc District Cooling
37th Euroheat & Power Europe Conference POWER-GEN Middle East
Conference 9 – 11 June 25 – 27 August 4 – 6 October
27 – 28 April Amsterdam, The Netherlands Bangkok, Thailand Abu Dhabi, UAE
Tallinn, Estonia www.renewableenergyworld- http://energy.feminggulf.com/ www.power-gen-middleeast.com
www.ehpcongress.org europe.com asia-pacifc-distric-cooling-
conference POWER-GEN International
POWER-GEN India 5th China International 8 – 10 December
& Central Asia Distributed Energy Expo POWER-GEN Asia Las Vegas, Nevada, USA
7 – 9 May Beijing, China 1 – 3 September www.power-gen.com
New Delhi, India 15 – 17 June Bangkok, Thailand
www.indiapowerevents.com www.cdee-expo.com/en/ www.powergenasia.com
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1503cospp_C4 4 3/12/15 5:07 PM

Solar Takes Off at India's Airports: March - April 2015

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March - April 2015

Solar takes off at

WORLD ALLIANCE FOR DECENTRALIZED ENERGY

1503cospp_C1 1 3/12/15 5:07 PM

1503cospp_C2 2 3/12/15 5:07 PM

Engine and Marine Systems Power Plants Turbomachinery After Sales

Discover the power of MAN gas technology:

For more information, enter 2 at COSPP.hotims.com

1503cospp_1 1 3/12/15 5:01 PM

Solar takes off at

18 Condition monitoring systems get smarter

WORLD ALLIANCE FOR DECENTRALIZED ENERGY

28 Enclosures and effciency

2 Cogeneration & On–Site Power Production | March - April 2015 www.cospp.com

1503cospp_2 2 3/12/15 5:01 PM

Chief Executive Offcer: Robert F. Biolchini

Published by PennWell International Ltd,

13 The case for LPG in the industrial sector

Subscriptions: Qualifed professionals may obtain free

Regulars completing an online subscription form. Extra copies of these

6 Insight 36 Diary paid at Emigsville, PA.

www.cospp.com Member, BPA Worldwide

1503cospp_3 3 3/12/15 5:01 PM

4 Cogeneration & On–Site Power Production | March - April 2015 www.cospp.com

1503cospp_4 4 3/12/15 5:01 PM

1503cospp_5 5 3/12/15 5:01 PM

6 Cogeneration & On–Site Power Production | March - April 2015 www.cospp.com

1503cospp_6 6 3/12/15 5:01 PM

Fifty Shades of CHP

www.cospp.com Cogeneration & On–Site Power Production | March - April 2015 7

1503cospp_7 7 3/12/15 5:01 PM

On-site solar powering India’s airports

8 Cogeneration & On–Site Power Production | March - April 2015 www.cospp.com

1503cospp_8 8 3/12/15 5:01 PM

Devi Ahilyabai Holkar Airport in Indore has installed two 50 kW systems

www.cospp.com Cogeneration & On–Site Power Production | March - April 2015 9

1503cospp_9 9 3/12/15 5:01 PM

10 Cogeneration & On–Site Power Production | March - April 2015 www.cospp.com

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STAY AHEAD. STAY SIPOS

For more information, enter 4 at COSPP.hotims.com

1503cospp_11 11 3/12/15 5:01 PM

bidding process between the

12 Cogeneration & On–Site Power Production | March - April 2015 www.cospp.com

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The case for LPG

www.cospp.com Cogeneration & On–Site Power Production | March - April 2015 13

1503cospp_13 13 3/12/15 5:01 PM

Trevor Atkins: a life in CHP

with Nedalo. He managed was asked to stay on to wind

14 Cogeneration & On–Site Power Production | March - April 2015 www.cospp.com

1503cospp_14 14 3/12/15 5:01 PM

www.cospp.com Cogeneration & On–Site Power Production | March - April 2015 15

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16 Cogeneration & On–Site Power Production | March - April 2015 www.cospp.com

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18 Cogeneration & On–Site Power Production | March - April 2015 www.cospp.com

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achieving economic viability, signed an agreement to

20 Cogeneration & On–Site Power Production | March - April 2015 www.cospp.com

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