IPA June Issue 09

7/27/2019 IPA June Issue 09

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P R O M O T I N G O N - S I T E P O W E R A N D C O G E N E R A T I O N

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JUNE 2009

Looking to Asia forsolutions

I N D E P E N D E N T P O W E R A S I A



Invitation to Participate...

Neb Saric or Richard Teasdale at Global Media Publishing LimitedGlobal House, 13 Market Square, Horsham, West Sussex, RH12 1EU, UK

Tel: +44 (0) 1403 220750 Fax: +44 (0) 1403 220764

E-mail: [email protected]

Sales Agents:

For Further Details, please contact:



CHP/GAS TURBINES 9Steve Dunlop outlines the temporary power and loadbank

services provides for the 323m-long FPSO Peng Lai, the largestoilfield ship ever built in China.

GEN-SETS 12

John Dorman reflects on a range of generators aimed the Asian

markets which have been designed to provide reliable powerin high ambient temperatures while also keeping down noise

and emissions.

STEAM TURBINES 13

The Makuhari New City's District Heating and Cooling Centre,by EnergyAdvance, relies on steam and Wärtsila engines with a

power generation efficiency of 45.6%.

BOILERS 14

Korea South East Power runs an eco-friendly power plant withthe latest DeSOx & DeNOx System - but a new fluidised bed

boiler is key to the operation.

SWITCHGEAR 16

The market for gas-insulated high-voltage switchgear has neverbeen more buoyant when you consider three recent contracts

involving India, Korea and China, reports IPA.

TURNKEY 17

IPA takes a look at the 565 MW Bugok II CCGT Power Plant inSouth Korea which has just been handed over by Siemens

Energy.

EMISSIONS 18

Singapore's power generation industry has made significantreductions in its carbon emission intensity. One of its reduction

leaders is Senoko Power.

Editor:

Aidan Turnbull

[email protected]

Sales Director:

Neb Saric

[email protected]

Publisher:

Richard Teasdale

[email protected]

Journal Assistant:Zoë Taylor

[email protected]

Accounts Division:

Sally Gasson

[email protected]

Far East Sales:

C H Park,

Far East Marketing Inc

[email protected]

German/Danish/Swedish Sales:

Mario Dobresko

[email protected]

Russia Sales:

Sergy Stanovkin

[email protected]

US Sales & Subscriptions:

Alex Carter

[email protected]

Asia-Pacific Correspondent:

John Goss

[email protected]

Contributors

Aggreko; Cummins; Wartsila; Doosan,Korea South East Power;

EnergyAdvance; AREVA; Siemens

Energy; Senoko Power; Daio Paper

Corporation; JFES; GE Energy; BWE;

Alstom.

Published by:

Global Media Publishing Ltd

Global House, 13 Market Square,

Horsham, West Sussex, RH12 1EU,

UK. Tel: +44 (0)1403 220750

Fax: +44 (0)1403 220751

Website: www.gmp.uk.com

© Worldwide Independent Power

(ISSN 1468-7100).

Subscription price £120 (UK),

£180 (overseas) per year.

Please send address changes to

Worldwide Independent Power,

Global House, 13 Market Square,

Horsham, RH12 1EU, UK.

Printed by Manor Creative, UK

Auditors: ABC applicationapproved October 2006

In the next issue• CHP/Cogeneration

• Diesel/Gas Engines

• Gas Turbines/Gears• Heat Exchangers

• Gen-Sets/Loadbanks

• Filtration/Test/Measurement

• Design/Software/Simulation

Power news from around the world 6

C O N T E N T S

R E G U L A R S

Our power portfolio includes:

Makuhari District Heating and Cooling Centre (MDHCC), Page 13.

J u n e 2 0 0 9

P R O M O T I N G O N - S I T E P O W E R A N D C O G E N E R A T I O N

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JUNE 2009

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I N D E P E N D E N T P O W E R A S I A

New

Technology

for Asia

The Peng Lai (above) is the largest floating, production, storage and offloading (FPSO) vessel ever built inChina. Key to the project was theinstallation of a power package from Aggreko. See page 9 for the story.

8-10 June - NEC - Birmingham

IP&EE2010Independent Power & Energy Europe

The 565 MW Bugok II CCGT PowerPlant in South Korea, Page 17.

GMP




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W O R L D W I D E I N D E P E N D E N T P O W E R • J U N E 2 0 0 9

5

EDITOR’S LETTER

EUROPE ASIA-PACIFIC MIDDLE EAST

AFRICA AMERICAS

WELCOME

A warm welcome to this month’sissue of Worldwide Independent

Power - as always bringing youcloser to the stories and issuesaffecting on-site power andcogeneration around the world.For editorial comments, please donot hesitate to contact the editor.

BIENVENUESoyez le bienvenu à cette issue deWorldwide Independent Power.

Comme d'habitude, nous vousapportons toujours plus près dessujets qui affectent l'énergie et laco-generation sur place autour dumonde.N'hésitez pas contacter lerédacteur pour des commentaireséditoriaux.

WILLKOMMEN

Herzlich Willkommen zur Ausgabedieses Monates von Worldwide

Independent Power. Wie immerbringen wir Sie näher heran an dieEreignisse und Geschichten derStromerzeugungsindustrie rund umdie Welt.Für redaktionelle Kommentare undAnregungen wenden Sie sich bittean den Autor.

BIENVENIDO

Bienvenido a esta edición deWorldwide Independent Power.Como siempre, acercándolo a lostemas que afectan a la energía y a

la cogeneración in-situ. No dudeen contactar con nuestro editorpara cualquier cuestión editorial.

BENVENUTI

Benvenuti a questa nuova edizionedi Worldwide Independent Power.Come sempre cercheremo dioffrirvi storie e questioniriguardanti on-site power ecogeneration a livello globale. Percommenti editoriali, si prega dicontattare l'editore.

Is the cheap energy dream over?

Economic reports suggest that global energy consumption will increase by 44% between 2006

and 2030, driven by strong long-term economic growth in the developing nations of the world.This is the conclusion of a study from the ‘International Energy Outlook 2009"’(IEO2009)

released by the Energy Information Administration (EIA). While world energy demand in the near

term has slumped slightly as a result of the global economic downturn, most countries already

anticipate that energy consumption growth rates will return to pre-recession levels within a very

few years. China isn’t even waiting for this to happen - it appears to be forging ahead to meet

future demand by building at least one new power plant every week.

If you are into big numbers, here are some for you. Total world energy use is predicted to rise

from 472 quadrillion British thermal units (Btu) in 2006 to 552 quadrillion Btu in 2015 - and then to

678 quadrillion Btu in 2030. As a consequence of this the costs behind energy production have to

come down. What this means is that over the next few years as prices rise, it is the relatively

cheap, unconventional resources - such as extra-heavy oil, coal-to-liquids, and gas-to-liquids, oil

sands and biofuels such as rapeseed oil and fats derived from animals - which could be fuelling

more of the power stations of the future.

Certainly, from examples on the Continent, tallow made from rendered-down cow carcases

appears to be working out as a renewable and ‘green’ energy resource. See page 25 for our full

report on the Mouscron Biomass co-gen plant example in Belgium. Currently producing 18MW of

‘green energy’ - enough to meet the needs of 44,000 families and offer further profit from

recoverable ‘waste’ heat. Its operators suggest that a plant like this can reduce CO2 emissions by

66,000 tonnes a year. The EIA believes that world production of unconventional resources - which

totalled 3.1 million barrels per day in 2006 - will expand to an amazing 13.4 million barrels per day

in 2030 - which represents 13% of total world liquids supply in 2030.

EU Commissioner for Energy, Andris Piebalgs, believes that research and development into

alternative power generation systems along these lines is crucial and reflects the energy and

climate change policies set by the EU. Clearly, the EU has a sort of 20:20 vision.

By 2020 - Piebalgs says - the EU will seek to reduce energy usage across Europe by 20% while - atthe same time - boosting renewable energy to 20% of the EU’s overall final energy consumption.

Greenhouse gas emissions in Europe are also projected to be cut by 20%.

“Making energy systems more sustainable and secure is one of the greatest challenges for Europe.

The potential is definitely there. It is now essential to unlock it and find appropriate ways to work

for industry, research and government to work together to achieve our common targets,” he says.

This kind of approach would appear to be the way forward to achieving EU Energy and Climate

Change Policy objectives as well as reducing the costs involved with producing energy at affordable

prices. But will it actually happen by 2020? Watch this space.

Aidan Turnbull

Editor



N E W S

6

Two team up for

contractsAREVA, teaming up withKorean contractor, DAELIMIndustrial Co., Ltd., hasbeen awarded a contractby Korea Hydro & NuclearPower Co., Ltd. (KHNP),South Korean nuclearpower plants operator toreplace the 6 steamgenerators on the Ulchin 1& 2 NPPs during outagesplanned for 2011 and2012. For the purposes ofthis project, a consortiumhas been set up, jointlyby AREVA and DAELIM.AREVA as Original

Equipment Manufacturerwill lead the consortiumand perform the primarysystem and licensingoperations in co-operationwith KHNP and KoreaPower Engineering Co.,Inc. (KOPEC). DAELIM willimplement all the second-ary and local activitiesassociated with thisproject.

Toshiba & TENEXThe Toshiba Corporationhas announced a memo-randum of understanding(MOU) on discussionstoward co-operation inthe nuclear fuel businesswith Joint Stock CompanyTechsnabexport (TENEX),a group company of JSCAtomenergoprom ofRussia, which supervisesRussia's civilian nuclearpower generationbusinesses. TENEX is saidto have long-standingexperience and expertisein providing uranium

enrichment services andproducts.

China contract for

Canadian SolarFounded in 2001,Canadian Solar Inc.(Canadian Solar) is avertically integratedmanufacturer of solarcell, solar module andcustom-designed solarapplication productsserving customers world-wide. Canadian Solar hasbeen chosen to supply

solar panels for 80,000rural households inSichuan province.

JFE Environmental Solutions has received its thirdcontract for an advanced biomass gasification plantbased on its updraft gasification technology. The

new plant is owned by Daio Paper Corporation and islocated at Daio's Kani-Works facility in Shikokuchuo-shi, Ehime-ken Prefecture, Japan.

The Daio gasification plant generates a syngasderived from wood for the existing production

facilities. The syngas replaces heavy oilconsumption and consequently reduces the site'sdependency on fossil fuel for paper production. Thisis a completely new application involving a gasifierin Japan, says DPC.

Peter Laursen, License & Partner Manager forBabcock & Wilcox Vølund A/S told IPA: "The VølundSystems™ biomass gasification facility was originallydeveloped as a power generation plant.

“This new application, with energy conversion,will be the model of an epoch-making solution thatwill help industries reduce green house gasemissions and energy costs,” he concludes.

Daio seeks biomass gasification approachIn brief...

Anniversary for GE Energy's Jenbacher

engines in Yamagata wood-to-gas plantGE Energy's Jenbacher gas engineshave completed their first year ofservice in a wood gas-to-energyplant in the Yamagata Prefectureof Japan. Two Jenbacher gasengines capable of generating2MW of electricity were installedat the plant in 2008 and are cur-rently being fuelled by gasifiedwood chips from a nearby forest.

The plant is seen as an importantspecialty gas-to-energy technologymodel which supports theJapanese government's initiativesto expand renewable energy pro-duction to help meet its emissionsreduction goals under the Kyoto

Protocol.The wood gas-fuelled power

plant was installed by Kanagawa-based JFE EnvironmentalSolutions. The plant is owned andoperated by Yamagata GreenPower, an electricity distributioncompany and subsidiary of renew-able energy development firmJapan Biomass DevelopmentCompany.

GE Energy said that a key designfeature of the plant is its woodgasification system. JFE has

licensed the updraft gasificationboiler technology from Babcock &Wilcox Volund of Denmark.

GE Energy noted that Asia's woodgas segment represents a newgrowth opportunity for itsJenbacher gas engine business,which has previously installed sim-ilar units in wood gas plants inEurope and North America. GEEnergy - a unit of General ElectricCo. (GE) - expects its Asia-Pacificbusiness to continue growing rap-idly this year, supported by gov-ernments' carbon reduction effortsand stimulus packages.

[Right]The 6021 from GE Energy.

Chiyoda licenses flue gas process to BWE

The Chiyoda Corporation, Japan's leading engineering and constructioncompany, has it has reached an agreement with Burmeister & WainEnergy (BWE) to license its CT-121flue gas desulphurisation processtechnology for use at Asnaes Power Station, which is owned by themajor European energy provider Dong Energy.

The Asnaes coal-fired power station in Kalundborg is Denmark'slargest generating facility, with total capacity of 1,057MW. Under theagreement, Chiyoda will license the CT-121 process to BWE, and BWEwill be responsible for engineering, procurement and construction Thisis the first contract acquired since Chiyoda executed a technologylicense agreement for Europe with major Danish energy provider BWEand Italian company Salvatore Trifone & Figli S.p.A., the parentcompany of BWE, in 2004. The CT-121 process already has a 22% share

of the US market, where environmental regulations are becomingincreasingly stringent.

I N D E P E N D E N T P O W E R A S I A • J U N E 2 0 0 9

Typical papermaking process at DPC.



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8

N E W S

In brief...

India buys in

transformersThe Power Grid

Corporation of India hasordered two 500 MVA trans-formers from Areva T&DIndia. The 400 kV, three-phase units will be used toaugment capacities at 400kV substations atMalerkotla and Patiala inPunjab.

Kyrgyzstan opts for

hydro schemesKyrgyzstan intends to buildtwo hydropower plants,Kambarata 1 andKambarata 2, even though

Uzbekistan and Kazakhstanhave objected over sharedwater rights. Experts inKyrgyzstan claim that theplants will improve energyand water security in theregion.

Sri Lanka gets energy

development moneyThe Asian DevelopmentBank has approved loans ofUS$160m for the CleanEnergy AccessImprovement project in Sri

Lanka. The loans will beused to develop renewableenergy, energy efficiency,and increase access torural homes.

Geotherm plant

project begins in

Java2010 marks the inaugura-tion of a 30MW geothermalpower plant project atKaraha Bodas in Garut,West Java, costing in theregion of US$50m. The

plan is to complete it by2013.President Director PTPertamina GeothermalEnergy, Abadi Poernomotold IPA that Pertaminawas ready to fund theproject. "It will be fundedby a corporate loan, fromPertamina to its subsidiary,Pertamina GeothermalEnergy - PGE," Abadi said.The power plant will havea 30 megawatts capacity,but have the capacity forexpansion if needed.Thiswas originally a joint

project betweenPertamina, PLN and theUS-based Karaha Bodas.

OKI & HEH agree China dealIt's been just 16 weeks sinceHongkong Electric Holdings Ltd

bought the entire issued sharecapital (HK$5,680 million) ofOutram Limited from Cheung KongInfrastructure Holdings Ltd. (CKI).Outram is a company formed byCKI to hold 45% equity interests inthree joint ventures owning powerplants in mainland China.

Through Outram, HEH now holds45% equity interests in three powerplants, namely Zhuhai Power Plantin Zhuhai city, the neighbouringJinwan Power Plant and SipingCogen Power Plant in Jilin

Province.Group Managing Director of HEH,Tso Kai-sum, said this is anexcellent transaction for HEH,allowing HEH to take a strategicstake in the electricity generationbusiness in the mainland.

"We have been looking forsometime for an opportunity toinvest in the China power marketand this transaction will allow usto acquire very high qualitygenerating assets, most of whichare strategically located inGuangdong Province adjacent toHong Kong. I believe ourshareholders will find this

transaction highly-attractive whichshould be positive for our share

price," Mr. Tso added.The Zhuhai and Jinwan power

plants are strategically located inthe load centres in the westernpart of Pearl River Delta, anindustrial centre that is in need ofpower supply and with growthopportunities.They accounted forabout 7% of Guangdong Province'sthermal electricity output in2007.

The generating capacity of thethree power plants located atZhuhai, Jinwan and Siping are

1,400MW, 1,200MW and 200MWrespectively. Both Zhuhai andJinwan power plants are equippedwith flue gas desulphurisationplants, while Siping is currentlypartially equipped and in theprocess of full upgrade. With thistransaction, HEH will haveinterests in 8,457MW of totalgenerating capacity.

The Sihanoukville Special

Economic Zone (SEZ) in Cambodiais constructing a 90MW coal-firedpower plant which will enterservice in 2010 as part of thegovernment's 2013-18 CambodiaPower Development System plan.The proposed national grid will becontrolled by the state-runElectricite du Cambodge.Special Purpose Transmission

Licences will be available toprivate companies to operatesections of the grid, he said.It is expected that these willmostly be used to supply largeindividual consumers as well asrural areas off the main grid.

Electricity cost from18 US centsper kilowatt-hour in Cambodiacompared to only around 5.4cents per kilowatt in Vietnam.The high cost of electricity was

due to the country's almost total

reliance on fuel imports. Majorindustries and Special EconomicZones within 10 kilometres ofsubstations will be able to sourceelectricity on a direct feed.

This will give them acomparatively lower grid tariff byexempting them from networktransmission charges.

Phnom Penh, which accounts for85% of Cambodia's electricityconsumption, will be the centralpoint of the proposed grid.Substations will be built in thecapital, Kampong Speu, Takeo,Kampot and Sihanoukville by2011.

The grid will be connected towestern Cambodia by 2012 tosupply electricity to Siem Reap,Battambang and BanteayMeanchey.

Norwegian-operated SN Power

Invest is bidding for the Angathydropower plant in thePhilippines and for otherstate-contracted independentpower producers' capacities. Inthe Philippines SN Power hasalready entered into a jointventure with Aboitiz PowerCorporation to invest in thecountry's hydropower sector.

In 2006, the joint venturecompany SN Aboitiz Powerbought the 360 MW Magathydropower plant as part of

the government's privatisationprocess of the power sector.The Magat plant is the largesthydropower plant in thePhilippines. It draws waterfrom the Magat Dam andoperates as a peaking plantwhich sells energy through thederegulated electricitymarket. The dam is also amajor source for irrigation,serving approximately 85,000hectares of rice land. The damis owned by the irrigation

authorities who areresponsible for regulating thedam.

SNPI seeks Angat

hydropower plant

Cambodia’s coal-fired plantdestined for Sihanoukville

Alstom to provide wind farms for TokyoAlstom has been appointed byThe Tokyo Electric PowerCompany (TEPCO) as theexclusive supplier for the new

Higashi Izu wind farm inShizuoka Prefecture, Japan.This represents Alstom's firstcontract in the Japanese windpower market since acquiringEcotècnia in October 2007.This is Japan’s fifth wind farmusing Alstom's technology.Under the terms of thecontract, Alstom will supply,install and commission thewind farm's eleven Eco 74 windturbines.The wind farm will have a

total approximate electricaloutput of 18 MW and will becommissioned in October 2011.Alstom has customised itsdesign to conform to the strictJapanese Building StandardsLaw.


China’s Shandong wind farm.



9

CHP & GAS TURBINES

T

he result of a multi-million pound

deal between ConocoPhilips China

Inc (COPC) and the China National

Offshore Oil Company (CNOOC), the one

thing which really impresses observers is

this vessel’s sheer size.

The Peng Lai FPSO is three times the

size of New York’s Statue of Liberty, piled

one top of the other.

It has an overall length of 323 metres, a

breadth of 63 metres and a depth of 33

meters. It has an onboard storage

capacity of 2 million barrels of crude oil.

The FPSO vessel's processing capability

amounts to 190,000 barrels of crude oil

per day with 510,000 barrels of fluids

coming from the wellhead platforms perday.

The sides and bottom of the vessel's hull

are double skinned with 24 ballast tanks

built into the double skin, with 17 oil

cargo tanks and two crude tanks taking up

the bulk of the volume.

What are FPSOs for?There are in fact two main types of

FPSO vessels in operation today; firstly

there is the converted oil tanker FPSO and

secondly there is the purpose built option.

The vessel's design type will depend on its

proposed area of operation.

These specialist vessels are particularly

effective in remote or deepwater

locations where long lengths of expensive

seabed pipelines are not cost effective or

practical. The FPSO eliminates the need

to lay these long distance pipelines from

the deep sea or remote oil well to an

offshore terminal. FPSOs can also be used

in smaller offshore oil fields which may be

exhausted in a few years and do not

justify the expense of installing a fixed

offshore oil platform and the pipelines.

With all of the sophisticated technologyand oil production equipment onboard -

plus the crew's living requirements - the

CHP & gas turbines in offshore oil

extraction

FPSO needs to have a reliable power plant

onboard to supply all of the vital energy

needed.These large purpose-built power plants

are the key to all of the FPSO's

operational functions and to its overall

success. The power plants are specifically

designed for the task ahead and carefully

installed during the build-up period in the

shipyard when the topsides of the vessel

are being completed.

Before the FPSO is moved to its location

the power plant, together with all of its

support and distribution systems, must be

thoroughly tested to ensure the reliability

of this key component.

The testing of the power system is

carried out by highly trained and

competent technicians using loadbanks

that will simulate the full load required

by the FPSO onto the power plant.

On this project the arduous testing wascarried out by Aggreko which has been

supplying temporary power and loadbank

services during the construction,

commissioning and critical periods on

FPSOs since 1998.

Not only has the company fully tested

many power plants and electrical systems

on FPSOs they have also supplied large

amounts of temporary power to specialist

offshore construction yards as the new

vessels are being built.

Additionally, in some cases Aggreko has

been asked to supply power to the FPSO

during the critical tow period when all of

the vessels electrical systems are tested

and then the power plant will be

.

The Peng Lai has the distinction of being the largest floating, production, storage and offloading (FPSO) vessel ever built in China. Key to the project was the installation of a

power package providing the commissioning power for the topside installation during the critical run-up and test phase, reports Steve Dunlop.

The Peng Lai FPSO relies on Aggreko power packages to run its systems.




CHP & GAS TURBINES

commissioned when the FPSO is at its

location over the wellhead. Many records

were broken during the Peng Lai’s con-

sturction phase. In a unique cross-corpo-

ration deal in March 2005 ConocoPhilips

China Inc (COPC) and its partner, the

China National Offshore Oil Company

(CNOOC), awarded the contract to

Shanghai Waigaoqiao Shipbuilding (SWS), a

subsidiary of the China State Shipbuilding

Corporation (CSCC).

This company was tasked with the

construction and delivery of the FPSO

hull. At that time, the 281,000 DWD (Dead

Weight Tonne) Hai Yang Shi You 117 FPSO

vessel was to be the largest ever to be

constructed in China.

Topside integrationOnce the FPSO's hull had been construct-

ed in the SWS shipyard in China it was

towed down to the Sembewang Marine

Offshore Engineering (SMOE) shipyard in

Singapore for its topside integration to

commence prior to the commissioning

process. The FPSO's 20 specialist topside

modules were fabricated in Singapore;

they were designed to have an operating

weight of 40,000t, which is one of the

largest FPSO topsides in the industry.

When completed, the vessel consisted of

20 topside modules plus one flare tower

and seven pipe rack modules.

It took approximately 26 months to

construct and complete the enormous hull

in China prior to towing it down to the

SMOE specialist offshore construction

shipyard in Singapore where the modules

were built. The tow was made by two

new ocean-going tugs which at five knots

took 16 days to reach the SMOE yard.

Once commissioned, the newly named

Peng Lai FPSO was towed into the South

China Sea where it formed part of the

Phase II at the PL 19-3 oil field. This

phase also included the wellhead plat-

forms and a central processing facility.

ConocoPhillips Asia had previously

worked with Aggreko on the Belanak FPSO

project and based on that performance

awarded a contract to the power company

for a 4MW temporary power supply at avoltage of 3.3kVat 50Hz.

The power contract included supplying

the power package with a complete fire

and gas detection and suppression system,

a bulk fuel system, a fuel transfer pack-

age, earthing transformers, a control

room plus full operation and maintenance

services. As in the previous project, space

was limited on the deck of the FPSO

which meant a stacking system in which

the generators were placed on top of the

HV transformer, spares container, control

room and bulk fuel tank.

The functions of this temporary power

package were to provide the

commissioning power for the topsides

installation during the critical run-up and

test phase for the numerous electric

motors, this process included the 350HP

sea water booster injection pumps and

the slurry injection system which are

crucial once the FPSO is fully operational.

The many circuits and distributionboards were fully tested and energised to

ensure that once the FPSO's main power

plant was commissioned that these sys-

tems will work. Additionally, the FPSO's

lighting and auxiliary power circuits are

energised to supply temporary power for

lighting, HVAC and other essential services

onboard right up to the sail-away.

The second phase of the project for

Aggreko and one that comes close to the

final phase of the commissioning process

on the FPSO is the run-up and testing of

the onboard permanent power generation

system.The 56MW power plant for the FPSO

Peng Lai consisted of two 28MW, 35MVA

Nuovo Pignone Frame 5 gas turbines.

In order to fulfil and to satisfy all of the

testing parameters of the FPSO

classification society and after discussion

with ConocoPhillips, Aggreko was asked to

provide a Resistive Reactive loadbank

testing package equivalent to 45MW at

10.5V, 50Hz.

The space challengeA challenging feature of this particular

loadbank package for the Peng Lai FPSO

was that storage space for any equipment

on the quayside was extremely limited.

This severe lack of available space for the

package resulted in Aggreko being asked

to minimise the space required by

stacking the loadbank package.

This stacking process significantly

reduced the overall footprint of the spe-

cialist testing equipment thus enabling

the yard and ConocoPhillips to make best

use of the remaining space.

The testing of a main power generationpackage was crucial to the success of the

entire FPSO project. Without reliable

power supplies offshore the Peng Lai

vessel would be a lifeless ship and a very

expensive one at that.

Of vital importance was the fact that

the Aggreko testing package enabled the

ConocoPhillips commissioning team to

fully load test the two essential 28MW gas

turbines to ensure that they would indeed

load share and operate efficiently when

synchronised together.

The Peng Lai FPSO broke many records for size and capacity in its

construction.

www.aggreko.com

Internet linkInternet link




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12

GEN-SETS

Anew series of generators in the

range of 175 - 220kVA is currently

being launched on the Asian

market. Designed to work quietly andefficiently in tropical temperatures the

new generator models are powered by the

latest QSB7 engine which is said to offer

improved noise reduction as well as the

'best in class' in relation to performance,

due to its higher power density capability.

In high ambient temperature

environments the generator sets are

capable of providing in some cases up to

20% more power when compared with

previous models.

The generator sets also boasts advanced

SIIIA emission compliance almost two

years ahead of the scheduled regulatory

requirements which will come into force

for 2011-2017.

In addition, the compact format (all

thanks to the reduced size of the engine

and optimised arrangement) of the QSB7

series generators is destined to appeal to

applications where space is a key consid-

eration, says the manufacturer.

Further benefits include a new

PowerCommand® 3.3/motorised circuit

breaker option, ideal for sensitive envi-

ronments where synchronising with other

generators or the mains is required to

ensure an immediate seamless and

consistent flow of power (all units feature

PowerCommand 1.2 control as standard).

The compact design also encourages

improved access to the generator sets,

whilst the patented recessed 2-point

lifting feature on the enclosed application

provides a further ease of handling

advantage.

Commenting on the new range of eightQSB7 platform based generators John

Dorman, General Manager of Cummins

More power to your generators

John Dorman reflects on a range of generators aimed the Asian markets which have

been designed to provide reliable power in high ambient temperatures while also

keeping down noise and emissions.

Power Generation Middle East and Africa

told IPA: "This launch demonstrates our

commitment to leading the market in

relation to the development of

generators. These boast optimum

performance coupled with advantageous

convenience benefits, whilst also setting

the standard in terms of emissions and

low noise compliance.

He said: "The fact that the new QSB7

generators fulfil the EU NRMM (Nonroad

Mobile Machinery) Regulations emissions

requirements a whole two years ahead of

schedule provides a perfect example of

the company's continued support of this

important industry issue."

Features to look for in the new unit

include:

* Compact/robust design for the base

frame;

* Manual, automatic and paralleling

options available;

* High base tank capacity: standard skid

offers 470L capacity/containment skidwhich offers 980L capacity (available

as optional on stationary application,

standard on rental). The enclosed set also

features two point lifting - lowered for

easier access, while the compact product

allows 6 units to be fitted in a shipping

container (represents twice as many units

as could previously be fitted into a 40 ft

container). The unit also offer control

panel viewing with a lockable access door.

Rental unit benefits include a noise

compliant enclosure (EC-2000-14), a heavy

duty base frame, a 25-hours fuel tank

and containment capability and a spark

arrestor feature integrated within the

silencer to enable unit to be used in

sensitive locations where sparks would

represent a threat to safety e.g. in oil

drilling/refining locations.

Finally, there is a panel of added

features and options to increase mobility,

access and serviceability.

What more could one ask for?

The QSB7 enclosed gen-set is designed for areas where space is tight,

www.cumminspower.comInternet linkInternet link

IPA





STEAM & TRIGENERATION

Halfway between the centre of Tokyo

and Narita Airport is Makuhari New

City, the centre of Japan’s latest

and blodest trigeneration experiment.

The city's Makuhari District Heating and

Cooling Centre (MDHCC) owned and

operated by EnergyAdvance is

contributing positively to the city which isenergy-rich and environmentally-friendly.

Heat for the district heating and district

cooling system is supplied to the 61.6

hectares of the international business

area of the city.

Two years ago the MDHCC brought in a

new high-efficiency gas engine tri-genera-

tion plant . The results have been

significant in the high energy savings and

reduction of CO2 emissions.

Since the installation of the new system,

MDHCC has raised COP by 0.5 points and

has achieved a 24% reduction of fuelconsumption and cut CO2 emissions by

24,000t/a.

This saving of energy and reduction of

CO2 emissions results from the best mix

of optimum layout and design of high

efficiency equipment such as gas engines

which generate power using clean natural

gas as fuel and optimum operational

technology.

Two high-efficiency Wärtsilä engines

with a power generation efficiency of

45.6% have been introduced for the first

time into Japan. Electrical power

produced by the gas engines runs theelectric turbochiller to produce chilled

water. The surplus electrical power is

used to power the plant and is also sold

to generate cost benefits.

The Wärtsilä gas engines not only

produce high levels of efficiency but they

also provide low costs of operation as

natural gas costs less than fuel oil and the

consumption of lubricating oil is at a mini-

mum level.

A heat recovery system uses the gas

engine's waste heat to produce steam to

power the engine's waste heat boilers toproduce large amounts of steam which

drives absorption chillers that produce

chilled water. Additionally, no steam is

Steam operations in Japan

Clever utilisation of steam is at the heart of the Makuhari District Heating and Cooling

Centre located just outside Tokyo. Many consider it the perfect model of trigeneration.

wasted as it is actively used as a heat

source in all kinds of situations at the

operator's facilities.

The beneficial aspectsSteam created by the furnace flue boiler

becomes the heat source for customer's

heating and is also used as a heat source

for the steam absorption chiller.

Water tube boiler is operated primarily

to drive the steam turbine turbo chiller.

Heat generated during cooling of the gas

engine is sent to the hot water absorptionchiller to be used as a heat source for the

air conditioning.

In addition, high temperature heat

generated by the gas engine is used to

create steam at the heat recovery boiler,

which is used as the heat source to

produce chilled water for air conditioning

at the steam absorption chiller.

The cooling towers are installed on the

upper portion of the pyramid and serve to

radiate heat generated to the chillers.

The district heating and chilling pipelines

are installed in purpose-built culverts

which run throughout the city

The tri-generation power plant

contributes to the local environment by

significantly reducing CO2 emissions and

preventing air pollution by reducing both

NOx and SOx emissions.

The heating and cooling of buildings is,

in many cases, installed by independent

air conditioning systems. The buildings

must each provide everything from

installation of various heating and cooling

sources to management, operation and

maintenance.

On the other hand, district heating and

cooling generates 'heat' such as chilled

water and steam collectively at a single

energy plant.This is a centralised system that supplies

this through pipes to multiple buildings

located within a fixed area. By entrusting

such matters to energy professionals, cus-

tomers are able to use 'heat' that is safe,

secure and environmentally-friendly.

A spokesman for the MDHCC told IPA:

“The concept of tri-generation is now a

proven, cost effective alternative for a

continuous supply of electricity, heating

and cooling needed all year round.”

www.wartsila.com


IPA

Face of the future? Makuhari District Heating and Cooling Centre (MDHCC), Tokyo.[Inset] A Wärtsilä engine at the heart of the system.



14

Korea's latest and largest coal-fired,

eco-friendly, high-efficiency power

facility - officially titled the

Yonghung Thermal Power Plant Units 3

and 4 - has been operating at optimal

levels recently. This is all thanks to the

new core facilities and boiler equipment.

Run by Korea South East Power, the unitsare now part of an 870MW-class coal-fired

power plantwhich uses ultra super critical

technology. Moreover, the facility is an

eco-friendly power plant armed with

state-of-the-art, high- efficiency environ-

mental facilities (including desulfurisa-

tion, DeSOx & DeNOx System, and electri-

cal dust collectors).

A company spokesman told IPA: “The

completion of the Yonghung Thermal

Power Plant Units 1 and 2 has contributed

to easing the imbalance between power

supply and demand in the Seoulmetropolitan region, and has helped

stabilise the nation's electricity supply

network. Generators 3 and 4 at the plant

make a significant contribution to

stabilising the power supply during the

peak power demand season in summer.”

Power outputThe Yonghung Thermal Power Plant Units

3 and 4 generate 13.6 billion kWh of elec-

tricity per year, enough to supply 4 million

households. In 2004 Doosan an initial con-

tract for the supply of boilers for the sitein an international bid hosted by Korea

South-East Power in 2004, beating out

Japanese rivals.

Hard on the heels of this successful proj-

ect, Doosna was recently contracted to

supply equipment worth 100 billion won

(£50m) for a project involving the supply

of Korea's largest 340MW- class Fluidised-

Bed Boiler for Yeosu Thermal Power Plant

No. 2 operated by Korea South East

Power.

Doosan President & CEO Geewon Park

commented: "The contract involved thesupply of a 340 MW-class Circulating

Fluidised-Bed Boiler and supplementary

facilities. Unlike a Pulverized Coal Boiler,

which is used in most conventional power

plants, the Circulating Fluidised-Bed

Boiler is an eco-friendly boiler product

which significantly reduces the emission

of pollutants such as nitrogen oxide and

sulphur oxide. Another advantage is that

it can use low-grade coal as fuel, effec-

tively cutting fuel costs.”

Cutting fuel costsWith a Circulating Fluidised-Bed Boiler

at Yeosu replacing the use of heavy oil,

the plant will not only cut down fuel cost

significantly, but also reduce pollutant

emissions. Hence the utility facilities,

once revamped, will transform into an

economical, eco-friendly power plant.

Under the contract, Doosan plans to

design and produce the Circulating

Fluidised- Bed Boiler and supplementary

equipment at its Changwon Plant, anddeliver them by December 2011. Doosan

has also signed a licensing agreement with

Foster Wheeler, a global market leader in

Circulating Fluidised-Bed Boiler

technology, in 2006.

Executive Vice President Dongsoo Suh

said, "With the acquisition of the new

project, Doosan has set a precedent in

the supply of a 340 MW-class Circulating

Fluidised-Bed boiler, the largest scale of

its kind in Korea and among the largest in

the world."

He added: "As the use of low-grade coal

is steadily increasing, Doosan willcontinue to win more orders for

Circulating Fluidised- Bed Boilers not only

in Korea but also in overseas markets in

the future." Doosan also won projects for

the construction of coal-powered thermal

power plants adopting Circulating

Fluidised-Bed Boilers in Thailand and the

Philippines in 2007.

On June 14th, 2009, Doosan Heavy

Industries and Construction signed a

contract worth 74 million euros (US$102

million) with MAPNA Boiler of Iran for the

overall supply of eight heat recovery

steam generators (HRSGs) for four

combined cycle thermal power plants in

the Middle Eastern country. "The project

entails the supply of two HRSGs to each of

the four combined cycle thermal power

plants located in Kahnooj, Iran. Doosan

plans to begin designing the equipment

based on its own technology in June, and

is scheduled to supply them in phases

from April to December of 2010," a

spokesman told IPA.

Doosan Heavy Industries and

Construction secured the top spot in

terms of global market share in 2003

thanks to the acquisition of HRSG orders

worth 240 million euros(US$ 331 million)for the MFPNA combined cycle thermal

power plant, the world's largest single

such project. The company also won

successive orders in the Middle East in

2007 and 2008.

Dong Kyu Lee, head of the HRSG BU at

Doosan Heavy Industries and Construction,

told IPA: "Doosan was able to win the

project thanks to the strong engineering

capacity we have demonstrated during

the execution of our other projects in

Iran.” IPA


BOILERS

Boilers - a power plant’s heart

Fluidised -bed boiler installation.

www.doosanheavy.com


Korea South East Power runs an eco-friendly power plant armed with state-of-the-art,high- efficiency environmental facilities - including a DeSOx & DeNOx System, and electrical dust collectors- but a new fluidised bed boiler is key to the operation.



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16

SWITCHGEAR

Over a month ago AREVA's

Transmission and Distribution

division won an order worth over

€80 million from KEPCO, the South Korean

utility, to supply the converter stations for

a 400MW High Voltage Direct Current

(HVDC) bipole scheme linking South

Korea's Jeju Island with the mainland.The converter stations will transform

alternating current into direct current,

connecting the island to the mainland.

AREVA will provide the overall system

design, network studies and detailed

engineering solution for the HVDC

scheme. This will work in conjunction

with the existing 300 MW HVDC bipole link

installed by AREVA in 1997. The new HVDC

scheme will be operational in 2012.

"Through this contract, AREVA reinforces

its HVDC systems expertise and its com-

mitment to working closely withcustomers to develop cost-effective solu-

tions for all their energy needs," Michel

Augonnet, Executive Vice-President for

AREVA's Transmission and Distribution

Systems Business Unit told IPA.

Switchgear from SiemensSiemens Energy is constructing a high

voltage gas-insulated transmission line

(GIL) for Xiluodu China's second largest

hydropower plant "Xiluodu", currently

under construction in the southwest of

the country on the Jinsha Jiang river.

The total tube length for this line is12.5 kilometers. The project involves

seven three-phase systems, each with a

length of approximately 600 metres.

For Siemens, this is the most compre-

hensive GIL installation to date. The gas-

insulated transmission lines provide the

vertical connection between the gas-

insulated high voltage switchgear (GIS) in

the power plant cavern at the foot of the

dam and the overhead line at the edge of

the dam wall.

The gas-insulated high voltage

transmission line is designed for a power

capacity of 3900 megavolt ampere (MVA)

at a voltage of 550 Kilovolt (kV) and a

rated current of 4500 ampere (A). The

Switchgear for Asia The market for gas-insulated high-voltage switchgear has never been more buoyant

when you consider three recent contracts involving India, Korea and China, reports IPA.

order, which was placed by China Three

Gorges Project Corporation, Yichang, has

a value of about €30 million.

Commissioning of the GIL link is projected

for June 2013.

In a hydropower plant such as the one at

the Xiluodu dam, which has a rating of

12,600 megawatts (MW), large amounts of energy need to be transferred from the

foot of the dam to the overhead power

transmission line at the upper end of the

dam wall.

Gas-insulated transmission lines are

particularly well-suited for this purpose

thanks to their high load capacity.

Using a GIL instead of a high-voltage

cable has the added advantage of its

special design which eliminates any risk of

fire. Transmission losses from a GIL line

are also lower than with conventional

high-voltage cables or overhead lines,

says the company.

The virtually maintenance-free design

enables a long service life because the

gas-type insulation system effectively

does not age. Moreover, the GIL tubes are

welded over their entire length.

This not only increases operational

reliability but also gives the GIL a certain

flexibility, so it can adapt to any changes

in the tunnel wall that occur over time.

"With our GIL technology, high power out-

puts can be transmitted very efficiently

even in the very confined spaces that are

common, for example, in this hydropowerstation. With this project, we are helping

to build sustainable energy systems in

China with our solutions," Udo Niehage,

CEO of the Power Transmission Division in

the Siemens Energy Sector told IPA.

Last year, as part of the Jinping I dam

project in China's Sichuan province,

Siemens was awarded the order to

construct a similar GIL link with a total

tube length of 3.2km

Switchgear plants open in India Siemens Energy officially opened a

production faculty for gas-insulated

switchgear (GIS) in Aurangabad, India on

June 5th, 2009, at a total investment cost

of approximately €4 million. Aurangabad

now becomes the centre of manufacture

for 100 series 8DN8 2 switchgear panels

with a rated voltage of up to 145 kilovolts

(kV).

By the year 2013, it is planned to

increase annual production to

approximately 300 switchgear panels and

to expand manufacturing to include

switchgear with a rated voltage of 245 kV.The gas-insulated series 8DN8 2

switchgear - with a rated voltage range up

to 145 kV and a rated operating current of

up to 3150 - will be produced in a facility

covering a surface area of approximately

4200 square metres.

This type of switchgear is among the

most compact in this voltage range. The

design basis for annual production

capacity is 200 switchgear panels in

single-shift operation and 400 panels

in two-shift operation.

This year Siemens provided theswitchgear for the GIL project in

Xiluoda in China.

IPA


www.siemens.com/energy

www.areva.com

Internet linksInternet links



17

TURNKEY

South Korea's economy has been

developing steadily for some time

and as a consequence its demands

for power are increasing at an annual rateof approximately 5 - 6%. In recent years a

series of Combined Cycle Gas Turbine

(CCGT) power plants from have provided

significant amounts of reliable power to

South Korea with their high availability,

high electrical efficiencies, low environ-

mental impacts and excellent safety

records.

The latest in this series of award

winning plants is the 565 MW Bugok II

CCGT Power Plant located in South Korea's

Danjin Province, 100kms south of Seoul.

Siemens Energy officially handed over the

new Bugok II CCGT Power Plant to its

customer, GS Electric Power and Services

Co. Ltd., (GS EPS) Seoul and it has been

in full production for 16 months now.

The plant has an efficiency of 58.6 %

and since it started generating

electricity Bugok II has been operating

more as a base load unit instead of a part

load/middle range unit. The plant also

serves under 'Frequency Control Mode'.

Environmentally, the two SGT6-4000F gas

turbines are considered an improvement

on those installed in a sister plant, Bugok

I, located close by.

In principle they are the same heavy

duty type gas turbines that feature in the

Bugok I plant. However, their difference is

in their improved burner and combustion

system which allows operation with high

fuel gas preheating, combined with higher

mass flow from the improved compressor.

Consequently a much more stable

combustion with higher output, higher

efficiency enabling them to operate at

much lower NOX emissions (between 30

and 20 ppm).

The steam turbines also offer great

advantages in cost reduction. They can be

housed in a smaller type of building than

many other steam turbines. This is

because the SST6-5000 turbine is a typical

solution for combined cycle powerproduction where the HP/IP turbine is in

one common cylinder and the LP turbine

is designed for low bay arrangement with

two halves of the condenser on both sides

of the LP turbine. This compact design

means a smaller size without the high

pedestals for the ST foundation that are

normally required.

The control system of Bugok II features

the new Siemens SPPA-T3000 Power Plant

Control System which links together with

the control system of the Bugok I plant

which uses the former TELEPERM XP DCS

system.

This is the first time ever that both

systems were arranged in a manner that

the common systems for both power

plants can be controlled by both DCS

systems.

This parallel linking of the control

systems provides vastly improved control

capabilities for the operators which

advances the efficiencies of the two

plants.

IPA


South Korea’s Bugok II project

South Korea’s success with Combined Cycle Gas Turbine (CCGT) power plants is

epitomised by the Bugok II project near Seoul, reports IPA's John Goss.

The 565 MW Bugok II CCGT Power Plant is sited in South Korea's Danjin Province

A SPPA-T3000 Power Plant Control

System links the Bugok plants

www.siemens.com




EMISSIONS

According to the recent global

emissions analysis undertaken by

CARMA.org Singapore's power

generation industry was highlighted as one

of the few countries in the world which

had made significant reductions in its

carbon-emission intensity.Between 2000 and 2007, the emissions

were reduced by 30%, making it the best

reduction rate within the ASEAN region.

This reduction was attributable in large

measure, say the experts, to Senoko

Power's earlier Stage 1 Repowering pro-

gramme which occurred in 2008.

Through this Stage 2 Repowering

project, the company has been seeking

emission reduction credits, also known as

Certified Emissions Reductions (CERs),

from the United Nations Framework

Convention on Climate Change (UNFCCC)

Executive Board. One CER is equivalent to

one tonne of carbon-dioxide abated. The

CDM allows companies and countries to

mitigate global warming by implementing

projects that result in measurable and

long-term reductions in greenhouse gas

emissions. Roy Adair, President & CEO of

Senoko Power, tells IPA. "In Singapore's

competitive electricity market Senoko has

won many awards, including the SGP

(Singapore Green Plan) 2012 award and

Asian Power's Environmental Power Plant

of the Year (twice) while still competingeffectively in the Singapore Electricity

Market."

The new plants are scheduled for full

commercial operation by the end of 2011.

Just under a year ago Senoko Power

signed a S$750 million Stage 2 repowering

programme to convert its three 30-year-

old Stage 2 oil-fired 250MW steam plants

into two technologically modern and

environmentally-friendly gas-fired 430MW

combined cycle plants (CCPs).

The company has selected a consortium

comprising Mitsubishi Corporation,

Mitsubishi Heavy Industries and Hitachi

Asia as the contractors for the engineer-

ing, procurement and construction of the

new plants. Mitsubishi's latest gas turbines

will be used in this project. Experts say

their efficiency is at least 2 % higher than

the company’s existing CCPs,

representing a low-cost base to provide

competitively-priced electricity to

consumers.

C02 testing of emissions at theGeorgia Institute of Technology, USA

www.senokopower.com/power


IPA

Emissions impossible

Senoko Power's major repowering programme which have cut back on emissions is a

reflection of Singapore's desire to be eco-friendly across the board, reports IPA.



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IPA June Issue 09