Project Update

Aggreko to test Brazilian wind farms

Aggreko’s service centre in Namibia.
Credit: Aggreko

Aggreko has been chosen by one of the largest independent renewable power generation companies in Brazil to conduct performance tests at the Morro do Ventos wind farms in the northeast of the country.

Aggreko will supply load banks – a recreation of the load that a power source will generate – for commissioning tests of the 145 MW wind farms, which are operated by Dobreve Energia. Load bank testing ensures that the wind farm is ready for grid connection.

Diogenes Paoli Neto, managing director of Aggreko South America, said Aggreko’s load banks have been used for many years”in more traditional sectors such as manufacturing, oil and gas and shipping. Our equipment has been built to work with any power source, allowing us support test needs of all technologies, traditional or new.”

Meanwhile, Aggreko has opened its first service centre in Namibia. The facility is Aggreko’s sixth in its southern and east African network and the company’s regional managing director James Shepherd said the expansion into Namibia was”a major step in our strategy to build a local presence. As the region continues its strong growth, Aggreko is well placed to support this growth through the provision of the world leading temporary power and temperature control services.”

ABB clinches US and UK contracts

dual channel AVR
Eggborough power station: ABB will supply it with a dual channel AVR.
Credit: ABB

ABB has won an order worth around $260 million from US utility Bonneville Power Administration, part of the US Department of Energy, to upgrade the existing Celilo high-voltage direct current converter station in Oregon.

This station is an important part of the electricity link between the Pacific Northwest and southern California and was commissioned more than 40 years ago in 1970.

The Celilo converter station is located at the north end of the Pacific DC Intertie, also known as Path 65, which has a capacity of 3100 MW and originates near the Columbia River. This Intertie is 846 miles long and connects to the Sylmar converter station in the south.

Key components of the station upgrade include valves, controls, transformers as well as switchgear and cooling equipment. As well as modernising the converter station, the upgrade will also make it possible to boost capacity up to 3800 MW. ABB carried out a similar upgrade of the Sylmar converter station in 2004.

Brice Koch, head of ABB’s Power Systems division, said the upgrade”will enhance the reliability of this important HVDC link, thereby reducing the risk of blackouts and helping to secure power supply in the region”.

ABB has also won an order to supply a dual channel automatic voltage regulator (AVR) for Eggborough Power’s coal-fired power station in Goole, England.

Eggborough Power Station provides around 2000 MW for the UK’s National Grid. The plant went online in 1967 and became an independent business in 2010.

From the 1990s a number of upgrades have been undertaken to improve environmental performance and to replace major components with more efficient modern designs, the latest of which is the upgrading of the power station’s AVRs.

ABB is manufacturing a complete replacement for the existing AVR equipment, based on its UNITROL 6080 Automatic Voltage Regulators with dual auto channels and dual power converters replacing one of the existing single channel AVR units, while retaining the rotating exciters.

The UNITROL 6080 is based on the AC 800PEC high performance processor family, which is an extension of ABB’s 800xA control platform, developed to meet the fast control requirements of power electronics.

MHI and Marubeni to revamp GTCC plant

Mitsubishi Heavy Industries and Marubeni Corporation have jointly signed a contract with NTPC to rehabilitate a 663.36 MW gas turbine combined cycle (GTCC) power station in Auraiya, in India’s Uttar Pradesh state.

Under the turnkey contract, the two companies will revamp gas turbines, renew control equipment and supply and install equipment. The project is slated to be completed in April 2015. The Auraiya GTCC power station has been operating since 1990. The rehabilitation work is expected to boost its installed capacity by 55 MW and extend its service life by more than ten years.

Europe’s largest land wind park goes online

CEZ Group’s 600 MW Fantanele/Cogealac wind park, Europe’s largest onshore wind project, has entered full operation in Romania.

The project in Dobrogea, Constanta County, features 240 GE 2.5 MW wind turbines.

Ondrej Safar, CEZ project manager, said:”Thanks to the Fantanele/Cogealac wind farm, CEZ is making a major contribution to increasing Romania’s renewable energy generation. Before this project, Romania’s installed wind capacity was only 14 MW.”

The individual wind turbine components for the Fantanele/Cogealac wind farm were produced all over the world. The turbine nacelles were supplied from GE’s facility in Salzbergen, Germany. The rotor blades and towers came from Germany, Brazil, the Czech Republic, Denmark, Poland and China.

The size of the components – one rotor blade measures nearly 50 meters in length – and the number of units required comprehensive planning. Twelve modes of transport were needed to move the components for each turbine from the port of Constanta on the Black Sea to the project site. At peak times, 25 cranes were in action at once.

Metso recovery boiler fires up at pulp plant

The Metso-supplied evaporation plant and recovery boiler for Eldorado Celulose e Papel S.A. have been started up successfully at Eldorado’s Tràƒªs Lagoas mill in Brazil.

The mill, the largest single-line pulp mill in the world, counts on Metso’s cutting-edge equipment in its recovery line.

The evaporation plant, with a capacity of 1600 tonnes an hour of evaporated water, is the largest single line evaporation plant in the world with the purpose of concentrating black liquor up to 80 per cent dry solids content for efficient and low-emission combustion in the recovery boiler.

The recovery boiler is also among the largest in the world in operation and has a 6800 tonnes of dry solids/day black liquor burning capacity and steam generation of 1109 tonnes of steam/hour. The steam will be used in the pulp manufacturing process and in power generation to supply the entire mill and produce a significant amount of power surplus. Additionally, the recovery boiler has high chemical recovery efficiency making the mill economically and environmentally sustainable.

Sayano-Shushenskaya sees new unit online

A fourth new hydropower unit has been commissioned at Sayano-Shushenskaya hydropower plant, Russia’s largest hydroelectric plant.

The plant run by RusHydro was closed in 2009 following an accident which resulted in the deaths of 75 people, damage to all 10 turbines and the collapse of the turbine hall roof.

Since then, new units have been manufactured and installed by Power Machines.

Prior to the commissioning of unit No. 9, a series of start-up tests were performed, including testing of individual equipment and systems of the unit, idle running of the turbine, as well as reliability run of the unit equipment and systems during 72 hours.

Unit No. 9 has the same functions as units 1, 7 and 8 which were commissioned in 2011 and last year.

UK firm in bid to build longest turbine blade

Blade Dynamics
Thinking big: bid for largest blades.
Credit: Blade Dynamics

A UK firm is building what it believes will be the longest ever wind turbine blades.

In a à‚£15.5m ($24.8m) project, Blade Dynamics – which is based in the Isle of Wight off the south coast of England – will construct blades of between 80 to 100 metres in length, incorporating carbon fibre rather than conventional fibre glass. Blades currently deployed offshore are between 60 to 75 metres in length.

The blades are expected to be put into production by late 2014, with structural trials to be carried out at a UK test facility.

Blade Dynamics claims the blades will weigh up to 40 per cent less than their conventional glass-fibre counterparts, which would enable significant cost savings throughout the rest of the turbine system.

The blades are expected to be utilised on the next generation of large offshore wind turbines currently under development with a capacity of 8 to10 MW.

The project is being backed by the UK’s Energy Technologies Institute, which will become an equity investor in Blade Dynamics.

Blade Dynamics’ senior technical manager David Cripps said:”Financial backing from the ETI for this project allows deployment on ultra-large turbines far sooner than would otherwise have been possible and as a result of this project we will be hiring new engineers and technologists to make this possible.”

He added that longer, low weight blades were”a key part of the solution to making the generation of electricity through offshore wind both more reliable and more economical”.

The ETI’s offshore wind project manager Paul Trinick said:”Offshore wind has the potential to be a much larger contributor to the UK energy system if today’s costs can be significantly reduced. Investing in this project is a key step for the whole industry in paving the way for more efficient turbines, which will in turn help bring the costs of generating electricity down.”


Alstom installs 1 MW tidal turbine for testing

High tide
High tide: Alstom’s 1MW turbine.
Credit: Alstom

Alstom has installed a 1 MW tidal turbine at the European Marine Energy Centre’s full-scale test site in Orkney, Scotland.

The 1MW tidal turbine is fitted on the same tripod support structure used to deploy a previously tested 500kW device.

It will now be tested in different operational conditions off Orkney over an 18 month period.

Jacques Jamart, senior vice-president of Alstom New Energies, said:”This new milestone installation is a step further towards the commercialisation of this new power solution. The aim of this project is also to demonstrate a new, efficient and reliable turbine design.”

The turbine has a rotor diameter of 18 metres, a 22 m-long nacelle and a weight of 150 tonnes. It has three pitchable blades and operates, fully submerged, at a depth of 40 meters, by rotating to face the incoming tide.

Cummins unveils new mobile gensets

Cummins Power Generation has launched four new mobile generator sets specifically designed for rental applications.

Ranging from 150-300 kVA, the new models include the Cummins QSL9 and QSB7 diesel engines. Supplied as pre-integrated systems, Cummins says the new models are ideal for construction, industrial and events applications.

Available in 150, 200, 250 and 300 kVA configurations, the generator sets have been designed by Cummins’ new team of specialist rental engineers. All four new models benefit from Cummins made key components supplied as a pre-integrated system, which the company says increases maintenance efficiency as any potential issues for the engine, alternator or control system can be resolved by a single engineer.

GE targets turbine degradation with filter

GE's ClearCurrent PRO
GE’s ClearCurrent PRO
Credit: GE

GE has introduced ClearCurrent PRO, a gas turbine inlet filter cartridge that has been field tested and shown to positively affect gas turbine performance while helping to reduce the effects of turbine degradation.

The filtration portfolio expansion supports GE’s growing focus on the use of natural gas for power generation. GE’s ClearCurrent PRO cartridge filters are compatible with GE’s FlexEfficiency portfolio.

Over the next five years, GE plans to invest nearly $11 million to improve its facilities that produce the ClearCurrent PRO cartridges.

Keith White, general manager of GE’s Air Filtration business, said ClearCurrent PRO’s inlet filter”offers enhanced output and lower fuel costs for turbine operators”.

“Degradation-based maintenance is very important to turbine operators,” added Paul Sennett, product line leader for gas turbine inlet systems at GE.”Our PRO technology can help reduce that degradation and make it so that the choice of inlet filters has a direct correlation to turbine performance.”

Martin Engineering’s brush with conveyors

Martin Engineering
Clean sweep: Martin’s brush cleaner.
Credit: Martin Engineering

A new powered brush cleaner for conveyor belt applications has been introduced by Martin Engineering.

The rotating design removes material accumulation and dust in difficult applications, even in conditions involving sticky materials or stringy fibers such as coal and biomass.

Martin states that the 230/460-volt, 3-phase electric motor provides successful cleaning with minimal power consumption. A 1 HP motor powers the units for 18-42 inch belts, and a 2 HP motor drives the cleaners for 48-96 inch belts. The motor can be operated in either direction, and the unit can be installed on the left or right side of the cleaner, depending on the plant’s requirements.

Parker to overhaul Danfoss water pumps

Motion and control technology company Parker Aerospace, part of Parker Hannifin Corp, is to overhaul and recertify the Danfoss series of high-pressure water pumps for power generation industry applications.

Danfoss provides high-pressure water pumps to industry leaders such as General Electric, Rolls-Royce, and Siemens. The initial overhaul and recertification work will be performed at Parker’s gas turbine fuel systems division facility in Massachusetts.

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