Automation for biomass power plant.

ABB has secured its ninth contract with TOYO Engineering Corporation in Japan to supply its distributed control system (DCS) ABB Ability™ Symphony Plus, to the Wakayama Gobo Biomass Power Plant, around 120 km south of Osaka.

When operational in 2025^[1] the 50 MW biomass power plant, which will use wood pellets and agricultural byproduct as a feedstock, will be capable of supplying enough power for up to 110,000 Japanese households a year. The plant is being developed in partnership by Enewill (formerly JAG Energy), Osaka Gas and SMFL MIRAI Partners who have employed engineering, procurement and construction (EPC) contractor TOYO to design and build the facility.

ABB’s DCS solution will deliver complete visibility of operations, enabling operators to make informed decisions in real time to help optimize production, improve processes, and drive efficiencies. ABB will also deploy its Adaptive Execution™ project management methodology which utilizes digitalization to speed up delivery schedules and achieve faster site start up.

The new order, booked earlier this year, follows ongoing collaboration between ABB and TOYO, with the company integrating its automation solutions at eight other biomass facilities being constructed across Japan.

With domestic supply of energy increasing over four percent year-on-year, Japan, previously seen as a carbon intensive country^[2], is investing in ways to match growth in demand with reducing its reliance on fossil fuels. In 2022 its renewable energy output increased by 11.7 percent, driven primarily by solar power and biomass generation^[3].

“In its sixth Basic Energy Plan^[4], Japan’s Ministry of Economy, Trade and Industry announced a target of 8 GW for installed biomass capacity in the country by 2030 which would cover five percent of its projected power demand,” said Brandon Spencer, President of ABB Energy Industries. “The nine projects that we are involved in will deliver a collective generation capacity of 500 MW, achieving over six percent of the Government’s target and providing energy to power more than one million households.”

Japan is currently the world’s fifth largest biomass market^[5] and is expected to grow by 5.4 percent a year until 2025 and 3.7 percent a year through the following decade^[6]. ABB is an established leader in the power generation market in Japan, with expertise when delivering process control systems. This, coupled with new initiatives that have been proven on other TOYO projects, made ABB the partner of choice.

---

[1] 50 MW biomass power plant
[2] Japan 2021 – Analysis - IEA
[3] FY2021 Energy Supply and Demand Report (Revised Report) (meti.go.jp)
[4] 6th_outline.pdf (meti.go.jp)
[5] Japan: biomass energy market size 2035 | Statista

@ABBgroupnews @ABBMeasurement @abb_automation @AdmiralPR #PAuto  #DCS #Japan

Transformer monitoring.

As part of an initiative to safeguard reliable power output and reduce risk, a biomass power plant in the north of the Netherlands has installed a continuous transformer monitor. The Vaisala MHT410 continuously measures three key parameters in transformer oil – moisture, hydrogen and temperature. Owned and operated by the energy company Eneco, the Bio Golden Raand plant produces steam for local industry as well as power, with a capacity of approximately 135 MW thermal and 49.9 MW electrical.

Background.
Transformer materials can deteriorate over time, resulting in the potential for costly faults, repairs and downtime. However, the development of transformer faults results in the accumulation of dissolved gases in the transformer oil, so this oil is routinely tested as part of a preventative maintenance program. Eneco’s transformer gas monitor was installed to provide continuous data and reduce the requirement for periodic oil sampling and laboratory analysis.

Eneco Transformer

“We discussed our requirement for the early detection of potential issues with our local service provider, Flux Transformer Services,” explains Laurens Freriksen, a project manager and maintenance specialist for Eneco. “They suggested that we should consider using one of Vaisala’s online monitors to support the planning and optimization of preventive maintenance; to extend the lifespan of our transformer, and reduce the risk of unexpected and costly outages.”

Vaisala’s Andreas Hilgers then visited the site to demonstrate two options; the MHT410 which monitors a single gas (hydrogen), and the OPT100 which is a multi-gas DGA (dissolved gas analysis) monitor. Subsequently, the MHT410 instrument was installed by Flux TS, and Laurens says: “We have benefited from online measurements for around one year now, and it has been very reassuring to see low hydrogen levels in the transformer oil, irrespective of the transformer load.”

Bio Golden Raand Power Station.
Biomass is used as a feedstock at the Bio Golden Raand plant (NL) to generate energy from wood waste. This form of power generation helps to reduce the consumption of fossil fuels. The plant uses non-hazardous Grade B waste wood. This type of waste may contain Grade A wood (mainly from packaging waste, scrap pallets, packing cases and cable drums, and process off-cuts) together with other waste wood sourced from construction and demolition activities, transfer stations, civic amenity sites and the manufacture of furniture from solid wood.

Every year, the plant processes approximately 300,000 tons of waste wood that arrives in Delfzijl (NL) by ship and truck from the Netherlands and surrounding countries. The wood is passed to a boiler fitted with a circulating fluidized bed furnace operating at 900°C. Flue gases from the furnace pass through three heat exchangers to a water steam circuit, where steam at 90 bar with a temperature of 520°C is produced. This steam can be delivered directly to local industry, or it can be used to drive a steam turbine, which in turn drives a generator that produces electricity.

Generator step-up transformers provide the critical link between a power station and the transmission network. These transformers step up the voltage from generator level to the transmission voltage level, which steps down the current and thereby reduces the loss of energy as heat and ensures efficient power transmission over long distances. Typically, generator transformers operate continuously 24/7 so they need to be extremely reliable.

Transformer oil.
Generator transformers are generally oil-filled to provide insulation and cooling. The transformer at Bio Golden Raand, for example, contains around 20 tonnes of oil. A special mineral oil is used for its chemical properties and dielectric strength, and this is routinely tested as part of an effective preventative maintenance program for the transformer.

Oil degradation occurs when its molecules break down under the influence of thermal and electrical stresses due to transformer faults such as discharges or hot spots, for example. This degradation raises the levels of hydrogen, carbon oxides and hydrocarbon gases in the oil. Hydrogen concentration increases with all fault types, but the ratio of hydrocarbons depends on the fault type.

Testing and monitoring transformer oil.
Traditionally, transformer oil samples are collected once or twice per year and sent for laboratory analysis to determine the level of gases. This spot sampling method provides an indication of dissolved gases and oil quality at one moment in time. The main advantages of continuous monitors therefore, are that they are able to reveal trends so that users can correlate gas levels with transformer load, for example. Importantly, by measuring continuously, DGA monitors can provide early warnings of faults.

The levels and trends of dissolved gases can be used for fault identification, and this is the subject of a Cigré Technical Brochure (Ref.783) on DGA Monitoring Systems. This document describes the different types of DGA monitors, and includes an impressive performance evaluation of monitors including Vaisala’s OPT100.

In addition to hydrogen, the MHT410 also measures temperature, which is a key indicator of faults. Moisture in oil is also measured by the device because moisture decreases the dielectric strength, accelerates cellulose (insulation) decomposition, and increases the risk of bubble formation at high temperatures.

DGA monitoring at the plant.
Explaining the reasoning behind the installation of the Vaisala MHT410, Laurens Freriksen says: “A power plant transformer is one of the most valuable assets in a power network - ours is around 10 years old and operates continuously. However, there is no redundancy so it is important for us to be able to monitor its condition and performance closely.

“We chose the MHT410 because it offered an opportunity for the early identification of potential problems, which is an important risk reduction measure. Early fault identification enables timely corrective measures such as transformer service, oil change, repairs and possibly transformer load management through customer engagement. If the transformer indicates a fault through increased hydrogen levels, it may also be necessary to deploy a multigas monitor such as the OPT100, in order to obtain a full fault diagnosis.”

Laurens Freriksen

Data from the MHT410 continuously feeds into the Eneco digital control system, which Laurens is able to access from his laptop. This means, for example, that he is able to track transformer load on the same screen as the MHT410 measurements. “The digitization of assets is an important issue for our industry, and this is a good example,” Laurens adds. “Remote access to live data informs decision making, lowers risk and was an enormous benefit during the Covid lockdown, because it meant that we could check the transformer at any time, from anywhere.”

The MHT410 has been set to raise a high level alarm at 100ppm hydrogen and a very high level alarm at 150ppm. In addition, an alarm will be issued if there is a sudden increase in the readings for hydrogen, moisture or temperature. However, Laurens is pleased to confirm that during the first year of operation there have been no alarms, with hydrogen readings typically ranging between 2 and 15ppm, with no significant effects during periods of high load.

Robust power transformer monitor.
Designed for quick and easy installation with almost no maintenance requirement, the MHT410 has a low cost of ownership. “This is important,” explains Andreas Hilgers. “However, the cost of DGA monitors is negligible in comparison with the value of the assets that they help protect, or in comparison with the cost of outages.

MHT410 Installation

“One of the main advantages of digitization is a reduction in the need for unnecessary site visits, so it makes sense to install a Vaisala monitor that does not incur an extra service requirement." Frans van Hofwegen from Flux TS agrees. He says: “This is a good example of cooperation between Vaisala, Flux and the end-user; combining knowledge and experience to achieve the desired goals. As the first MHT410 that we have installed in the Netherlands, the device at Bio Golden Raand represents a great start to our relationship.”

The MHT410 takes measurements with an in-situ probe, so there is no requirement for pumps or membranes. With no consumables or moving parts that could fail, the instrument is encased in an IP66-rated metal housing equipped with a weather shield. Every unit is individually tested for a pressure of at least 10 bar and also withstands vacuum conditions. Special attention has been given to EMC tolerance; for example, all electrical connections are isolated. In addition, the MHT410 has been designed to tolerate short-term power outages.

In brief.
For Eneco, the installation of the Vaisala monitor is essentially a risk reduction measure, but as Laurens explains: “It is very reassuring to have constant visibility of the transformer’s condition. However, the key advantage is that it buys us time – time to plan an effective strategy if oil conditions deteriorate - to optimize the performance of the transformer and to extend its working life.

“We are proud to be leading the way in the Netherlands with this form of digitization, and since the MHT410 was installed, we have received a great deal of interest from our colleagues in other sectors, such as wind power.”

@VaisalaGroup @_Enviro_News #Eneco #Power #PAuto

Control for biomass plant in Brazil!

Yokogawa America do Sul, has received an order from AREVA Renewables Brazil, a subsidiary of the French firm AREVA SA, to supply a control system for a biomass power plant that will be the largest facility of its type in Brazil. The plant is being constructed by Bolt Energias in São Desidério, Bahia, in the northeastern part of the country.

This biomass plant will have three power units with a total capacity of 150 MW, and will burn eucalyptus as its fuel. For this facility, Yokogawa will supply a CENTUM(R) VP integrated production control system, ProSafe(R)-RS safety instrumentation system, and other products. Yokogawa will also be responsible for engineering, and providing installation support and commissioning for these products. The plant will be connected to the power grid in mid-2017.

Although Brazil and many other countries in South America have relied largely on hydroelectric power, this power source has been less reliable in recent years because of severe water shortages. There is thus an urgent need in such countries for the construction of power plants that utilise alternative energy sources. As Brazil is the world’s largest producer of eucalyptus pulp and sugar cane, biomass power plants that can utilise this energy source are a promising solution.

Yasuharu Shoda, President & CEO of Yokogawa America do Sul, commented, “Yokogawa has a solid track record in Brazil, having installed more than 500 of its control systems at a wide variety of industrial facilities. Yokogawa’s solutions help our customers operate their facilities safely and with a high degree of efficiency. Encouraged by this order, Yokogawa will continue to focus on the electric power and renewable energy fields in Brazil and other countries in South America, and will help to provide a stable energy supply”.

Yokogawa will continue to expand its business in the promising electric power market.

Biomass to low-cost energy

New offering helps create renewable energy, reduce greenhouse gas emissions

Emerson Process Management is expanding its energy management portfolio with new technologies and services that help companies and municipalities convert low-cost waste and biomass into renewable energy more efficiently and reliably, with lower carbon emissions.

As regulatory agencies increase renewable fuels standards and governments consider renewable energy and carbon management legislation, Emerson’s technology and plant automation and control solutions are helping customers convert biomass or waste fuel – whether waste gases from a petroleum refinery, hydrogen from a chemical plant, biogas from potato waste at a food processing plant, or wood waste from a pulp mill – into steam and electrical power.

In the United States, for example, the industrial sector accounts for nearly 30 per cent of the energy used nationwide and 27 per cent of the country’s carbon emissions.

“Biomass-to-energy conversion is the fastest-growing segment of the energy business,” said Steve Sonnenberg, president of Emerson Process Management. “Faced with high energy costs and environmental goals, our customers recognise they can retrofit decades-old plants to convert their own waste streams into environmentally friendly and low-cost sources of power, which is a plus to both the environment and their bottom line.”

Emerson’s new combustion optimisation technology uses Model Predictive Control (MPC) and other algorithms to determine the heat release of biomass and waste fuels. With this capability, the combustion can be optimised to the highest potential efficiency and the waste fuel can be maximised to minimise the cost of energy and reduce emissions. This provides the most affordable and environmentally friendly operation available in the industrial energy market.
“With this technology, many of our customers are operating on renewable energy up to 95 per cent of the time,” Sonnenberg said.

Seattle Steam, a district heating facility that provides heat in the form of steam to 200 buildings and hospitals in Downtown, the central business district of Seattle, USA, turned to Emerson’s new combustion optimisation technology when it decided to rely on low-cost urban wood waste to provide energy for the Downtown area.

“We have reduced our annual carbon emissions by 60 per cent since turning on the new biomass facility that uses wood instead of natural gas,” says Stan Gent, president and chief executive officer of Seattle Steam. “We are looking at upgrading the control systems at all of our existing facilities to achieve additional efficiency gains.”
Emerson’s energy solution includes biomass and waste fuel combustion optimisation technology, that provides automatic, real-time process adjustments based on changing quality and availability of alternative fuels, costs of alternate and fossil fuels, emissions, and process constraints. Emerson also provides energy monitoring and controls to spot unusual energy usage, identify opportunities to improve energy efficiency, and manage operations based on real-time energy costs.

They also takes advantage of its wireless measurement technologies in its energy management programmes to reduce the installed cost of monitoring instruments and to allow more measurements in tougher places. In fact, wireless measurements are being installed at approximately a third of the cost of traditional hardwired implementations.

Biomass currently provides more than 3 per cent of the total energy consumption in the United States, with U.S. government studies (Report) predicting biomass could supply up to 15 per cent of U.S. energy demand by 2030.

Emerson Process Management is a leader in renewable energy, working with hundreds of biomass-to-energy industrial customers, advanced biofuel companies converting cellulosic feedstocks into premium fuels, and commercial power generators converting wind, solar, and hydro power and biomass into electricity. Emerson has a dedicated staff of experienced energy consultants who assist customers with identifying opportunities, developing alternate fuel solutions, and implementing overall sustainable energy programmes.