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electrical power

At the end of 2014 the company Industrias de Hule Galgo decided to undertake the installation project of an efficient CHP plant for its production plant, with the aim of bringing down energy costs and improving the company’s competitive position in the market. The new plant has already started its first operational phase. The project has comprised the installation of a single cycle with gas-powered gensets providing a total electrical capacity of 6.6 MW. This provides the necessary thermal oil for the production plant; covers 100% of the electrical power consumed by the industrial complex; and also generates cooling water, giving improved production capacity by supercooling the extrusion system.
To execute these works, Industrias de Hule Galgo contracted the services of engineering company AESA to provide the engineering, procurement and construction of the CHP plant.

Industrias de Hule Galgo S.A. de CV, based in Tula, Hildalgo, is a private company that has a plant dedicated to the production of tyre treads for the renovation of tyres and inner tubes. This project has meant that the purchase of grid electricity and natural gas for its thermal needs has been replaced by an efficient cogeneration system that guarantees the generation of electricity, thermal oil and cooling for the company’s factory.

The CHP plant has been designed in a single cycle configuration with gas-powered gensets and heat recovery boilers. Its cooling water production system works via the recovery of heat from the engine’s high temperature circuit to cool the product via an absorption chiller. The plant offers a production capacity of some 6.6 MW ISO. Read more…

Ricard Vila & Cristina Martí, AESA

Article published in: FuturENERGY January-February 2016

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Siemens has been awarded an order from Westar Energy, Inc. to supply, support installation and provide service for 122 wind turbines for the Western Plains Wind Farm project to be located near Spearville, Kansas, approximately 100 miles west of Hutchinson.  Installation of the wind turbines is scheduled to begin in early summer 2016, with the start of operations expected by early 2017.  The service and maintenance provided by Siemens will include the company’s advanced remote monitoring and diagnostics.

The blades for this project will be manufactured at the Siemens blade facility in Fort Madison, Iowa. The nacelles will be assembled at the Siemens facility in Hutchinson, Kansas.  Siemens’ 300,000 square-foot Hutchinson factory recently celebrated its five-year anniversary of nacelle production.  To date, workers at the facility have produced more than 2,640 G2 nacelles, supporting wind power generation across the United States.  Kansas is a national leader in wind power, with wind generating enough electricity to power nearly one million homes.

“We are proud that workers at our factories in Kansas and Iowa will produce the nacelles and blades for this project, supporting the development of reliable, sustainable and affordable power generation in Kansas.  We welcome the opportunity to work with Westar Energy on this project, as wind power becomes an increasingly important part of America’s energy mix,” said Jacob Andersen, CEO Onshore Americas, Siemens Wind Power and Renewables Division.

The 280-MW project is expected to create enough clean energy to power approximately 100,000 average U.S. homes annually.  The project will feature Siemens SWT-2.3-108 wind turbines, each with a power rating of 2.3 megawatts (MW) and 53 meter blades.

The Siemens SWT-2.3-108 wind turbines are part of the company’s G2 platform of onshore geared products – the workhorse of Siemens’-installed portfolio with rotor diameters optimized for all wind conditions. The G2 platform features highly-engineered, designed and manufactured components, exceptional reliability and low operational costs for an optimized return on investment.

With over 5,000 Siemens wind turbines installed in the U.S., capable of producing clean, renewable power for more than 2.5 million households every day, Siemens has made a significant commitment to wind energy in America.

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The multinational OPDE, who specialise in development, investment and maintenance of PV plants, has obtained a green light for the construction of two new 5 MW PV plants in England. Both projects will produce the electricity equivalent to the consumption of 2,750 homes.

The PV plants are located in the counties of Lancashire and Leicestershire. This success is a new milestone in OPDE’s commitment to strengthen and consolidate its presence in the photovoltaic market in the UK.

OPDE has now grown its development portfolio in the UK to 77 MWp, split between seven projects located mostly in southern England.

OPDE’s presence in the UK is part of the already consolidated internationalization strategy of the company. Consequently, OPDE accumulates the development and construction of 225 MW in solar photovoltaic farms located in Italy (48.8 MW), UK (77 MW) and Spain (105 MW).

In addition, the company is currently active in other markets such as Mexico, United States and Chile, with over 800 MW under development.

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Advanced steam turbines and a distributed tower solar field

Renewable sources of electrical energy need to be increasingly deployed to reduce fossil fuel consumption and CO2 emissions as much as possible. CSP represents a promising and currently rapidly evolving renewable energy segment. Both the solar field, forming the essential of CSP block, and steam turbine generator with its auxiliary components, traditionally seen as a standard part of any power block, require an innovative approach to make it competitive. Doosan Sˇkoda Power has designed dedicated steam turbine generators in the range of 20-300 MW for CSP applications based on a widely-applied turbine modular design. While power blocks are supplied to large-scale CSP projects, a long-term partnership with CSP start-up Vast Solar is being used to gain additional insight into the operational and planning aspects of medium-scale CSP projects.

Steam turbine manufacturers are investing heavily into the development of technologies for large ultra-super critical units, highly efficient and flexible turbines for combined cycles and in the design of compact high-speed turbines for special applications.

Through advances in materials, numerical optimisation methods, improved manufacturing techniques, advanced instrumentation and control, steam turbine technology is quickly maturing, boosting turbine performance mainly due to higher inlet steam parameters and superior internal aero-efficiency. Steam turbines for CSP applications need to intelligently combine all these aspects. Read more…

Lubos Prchlík
Director of Turbogenerator Product Doosan Skoda Power

Article published in: FuturENERGY November 2015

The Chilean wind power market has moved a step further towards the diversification and specialization of the Operation & Maintenance services. For the first time in the country, these services are to be provided by an independent company through Full-Service maintenance at the Monte Redondo Wind Farm, located in the region of Coquimbo in northern Chile. This strategic project will make it possible to develop and upgrade the NCRE (Non Conventional Renewable Energies) in Chile. It is to be directed by the Spanish multi-national Ingeteam, a global leader in the provision of operation & maintenance services and responsible for the services in 25% of the total installed power in the country. The provision of this Full-Service contract is the fruit of an agreement signed with Engie Group, the company owning the Monte Redondo Wind Farm and the leading electricity producer in northern Chile.

The Monte Redondo wind farm comprises twenty-four Vestas® V90 2MW wind turbines, which were installed in 2 stages. The first stage was completed in 2010, and the second stage just a year later. Now that the warranty period established by the manufacturer has ended, Ingeteam has won the contract for the provision of comprehensive maintenance services to the entire wind farm, becoming the first independent services company to undertake the comprehensive maintenance of a wind farm in Chile.

Positioning in Chile

Since Ingeteam first started operating in Chile, 3 years’ ago, the company has gone on to secure its position as a leader in the operation and maintenance of renewable energy generating plants. In Latin America, Ingeteam provides maintenance services to a total of 1.9 GW, of which 551 MW are in Chile, accounting for 25% of the country’s total installed renewable power.

Ingeteam is also a leader in the solar sector in Chile, where the company provides O&M services to a total of 330 MW and has supplied PV inverters delivering more than 280 MW of power. This record figure was achieved thanks to the presence of Ingeteam in the largest plant in Latin America, located in the Atacama desert, in northern Chile, being the driest place on earth. Considering the unbeatable solar radiation levels recorded in this region, the plant is expected to generate up to 270 GWh of energy per year, which will prevent the emission of 135,000 tons of CO2 into the atmosphere.

Furthermore, Ingeteam’s control, protection and metering systems are present in 17% of the substations responsible for transmitting the wind power generated in Chile.

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Abengoa the international company that applies innovative technology solutions for sustainability in the energy and environment sectors, has signed an extension to its operations and maintenance agreement with the Moroccan Power and Drinking Water Office (ONEE) for the 472 MW Ain Beni Mathar solar-gas power plant. It is the first plant to use integrated solar combined cycle technology (ISCC), which came into commercial operation in the world in 2010. The contract is worth approximately €63 million.

Covering a site of 160 hectares, Ain Beni Mathar was commissioned in 2010 as Africa’s first STE plant and generates 10% of the electricity consumed in Morocco. It has an installed capacity of 472 MW, which it generates from a combination of solar power and natural gas.

Abengoa has more than 15 years of experience operating and maintaining renewable energy and conventional power plants as well as water and waste treatment plants. The renewal of this agreement reflects Abengoa’s experience of operating and maintaining electrical power plants, while further consolidating its position in the international market with the development, operation and maintenance of hybrid solar-gas plants, cogeneration plants and water treatment plants.

Duro Felguera (DF), in a 50/50 consortium with Elecnor, has won the tender called by the Comisión Federal de Electricidad (the Federal Electricity Commission or CFE in Spanish) in Mexico to build the Empalme II combined cycle power plant in the State of Sonora. The project is for 397 million dollars, equivalent to 349.3 million Euros. The deadline for delivery is estimated at 30 months.

According to the contract terms, signed at the close of business on Friday 23 October in Mexico City, the capacity of the Empalme II plant will be roughly 790 MW, and it will be gas-fired. There will be two gas turbogenerator units, two heat recovery boilers with three pressure levels and a steam turbine. The cooling system will be simple and will employ seawater. The plant will be connected to a 400 kW substation.

According to CFE, the purpose of the facility is to meet the growing demand for electricity in the north-west of the country.

Mexico is the country where DF has delivered most projects in Latin America, mainly in the field of energy. The power installed is almost 4,500 MW. Since 1998 the company has collaborated in the delivery of combined cycle, open cycle and cogeneration power plants with technologists such as Westinghouse, Siemens and Alstom Power.

DF’s first steps in Mexico in the field of energy were taken in 1998 in projects that the group had contracted by means of its subsidiaries Felguera Montajes y Mantenimiento and Mompresa, for the installation of turbomachinery. Both companies had previous experience in Colombia and started work in Mexico with the electromechanical assembly at the 150MW open cycle power plants of El Sauz, Hermosillo and Huinalá.

These projects were delivered to Westinghouse and followed by the full electromechanical assembly of recovery boilers at the combined cycle plants of Monterrey I, II and III, and Hermosillo, and for the full electromechanical assembly of the Rosarito plant, this time for the multinational ABB Alstom Power, and in larger facilities. In the first decade of the 21st century, the company was contracted by Siemens-Westinghouse to deliver the majority of the work at the open cycle plants of El Sauz II and El Encino: preparing the land, civil works, supplying the balance of plant equipment, the complete electromechanical assembly and commissioning.

These experiences enabled DF to keep on working in the country, with practically the whole assembly of the power plants of Valle de México, Naco Nogales, San Lorenzo and Tuxpan, in some cases almost 350 MW. In addition to the work on all these gas-fired power plants, in 2003 and 2004 the company delivered an EPC turnkey project for a cogeneration plant within the Pemex petrochemical Pajaritos plant, located in Veracruz. In this case DF took on the whole project, from the engineering to commissioning: 39 MW and 180 tons of steam per hour. Almost ten years later, Mompresa built further cogeneration plants in Mexico: one for the paper manufacturer Biopappel in Veracruz, and another for the textile company Kaltex Fibers in Altamira.

Apart from the energy field, DF has also worked on projects on Mexico for the petrochemical, iron and steel, cement and bulk handling sectors, for clients as important as Pemex, Cemex and Altos Hornos de México.

To understand just how far along the energy efficiency road Spain has travelled, the key concept is undoubtedly the “energy audit”. From an objective standpoint, the audit can be seen as the tool via which energy saving potential is identified in the object of the study (building, process, etc.) using the energy flows analysis created. However a more ad hoc definition that is designed for those responsible for investing in the service can be obtained by substituting the word ‘energy’ for ‘economy’. This may seem simplistic, but it could be the answer. We do not know if technological development will simplify the procedures for obtaining electrical power, but one thing is clear: the international community will one way or another end up paying for its wastage.

Many measures have been adopted in recent years to incentivise the Spanish business owner and in particular, everything that is related to the hotel sector, to take advantage of this tool. Undoubtedly, the most resounding commitment to promoting this measure will be the implementation of Directive 2012/27/ EU that will require every large company to undertake an energy audit of its activities or to introduce an Energy Management System, such as the well-known ISO 50001. Implementation is still pending and it is hoped that its arrival will be imminent, as it requires these audits to be undertaken by October this year, something that is already an uphill task.

There is also Law 8/2013 on urban refurbishment, regeneration and renovation. This requires every collective or similar residential building (citing hotels as an example) to have a Building Assessment Report (IEE) available prior to applying for any public funding. This document, valid for 10 years, includes the Energy Certificate, the Technical Inspection of the Building and the Accessibility Report. Read more…

Letter Ingenieros

Article published in: FuturENERGY September 2015

La Laguna combined cycle plant (Mexico)

Iberdrola se ha adjudicado un nuevo gran proyecto de generación de energía en México, la central de ciclo combinado de Noreste, que tendrá una potencia de 850 MW y va a requerir una inversión de unos 400 M$. El ciclo combinado de Noreste, ubicado en el municipio de Escobedo, estado de Nuevo León, dará suministro de energía eléctrica a dos millones de mexicanos. La empresa tiene previsto que la central entre en funcionamiento en julio de 2018.

Según la adjudicación, que ha sido otorgada por el Gobierno mexicano, Iberdrola será la encargada de la construcción, operación y mantenimiento de esta planta de generación, además de ser su propietaria. Iberdrola venderá toda la energía que se produzca desde esta instalación a la CFE mexicana, mediante un contrato a 25 años con cargos fijos de capacidad. Este contrato con la CFE aporta una gran certeza a la inversión realizada, alineando el proyecto con la estrategia de Iberdrola de crecer en actividades reguladas y predecibles.

Las obras de Noreste se iniciarán a principios del año 2016 y, junto a la construcción de la planta, se pondrán en marcha todas las instalaciones asociadas necesarias para su conexión al sistema eléctrico nacional, como son las líneas eléctricas o la subestación transformadora. La planta contará con dos turbinas gas de última generación y una de vapor del fabricante japonés Mitsubishi Hitachi Power Systems, y tendrá como suministrador de las calderas a la empresa estadounidense Foster Wheeler.

Iberdrola dispone en estos momentos en México de proyectos de generación de energía que suman más de 1.000 millones de dólares de inversión, una de las apuestas internacionales más importantes realizadas por la compañía en su historia. En concreto, construye dos nuevas plantas de ciclo combinado (Baja California III y Dulces Nombres V), tres cogeneraciones (Ramos Arizpe, San Juan del Río y Altamira) y los parques eólicos de Pier 2, en el Estado de Puebla, y Dos Arbolitos, en Oaxaca

Iberdrola está presente en México desde hace más de 15 años. A partir de entonces, y de forma ininterrumpida, ha ido incrementando sus inversiones y sus actividades hasta consolidarse como el mayor productor de electricidad privado del país. En la actualidad, dispone en el país de una capacidad instalada de 5.000 MW en centrales de ciclo combinado y 230 MW en parques eólicos, cuya producción es capaz de dar servicio a una población de alrededor de 20 millones de mexicanos. La compañía prevé invertir hasta 5.000 M$ en el país durante los próximos cinco años.

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Rolls-Royce suministrará ocho grupos electrógenos a gas que generarán 50 MW de energía eléctrica para satisfacer la demanda de diferentes fábricas de de acero del grupo Abul Khair en Bangladesh, que está en plena expansión. Esta será la mayor fábrica de fundición de acero del país, una vez que se complete la expansión. Los grupos electrógenos se basan en el motor de gas de velocidad media de 20 cilindros B35 40V20AG2 de Bergen Engines, que forma parte de Rolls-Royce Power Systems dentro de la División Land & Sea de Rolls-Royce.

Con base en Chittagong, en el sureste de Bangladesh, Abul Khair va a ampliar sus instalaciones de fabricación de laminados de chapa de acero bobinados en frío y bobinas galvanizadas. La potencia eléctrica producida por la planta de energía en el sitio con motores Rolls-Royce se requiere para su uso interno funcionando en sincronización con la red. Grupo Abul Khair también planea utilizar en el futuro los gases de escape para la producción de vapor.

Aparte del contrato de suministro de equipos, Rolls-Royce y Abul Khair Steel & Power, una filial de grupo Abul Khair, también han firmado un acuerdo de servicio de supervisión de la operación de dos años de duración, que incluye el suministro de piezas de repuesto. Los motores están programados para ser puestos en marcha en el primer semestre de 2016.