Articles - Power Generation

Revolutionising Power Control

EES’s insights into cost-effective retrofits

October 2024

Articles - Power Generation

Revolutionising Power Control

EES’s insights into cost-effective retrofits

October 2024

Technology is best when it brings people together, and there is no better example than when Tamworth-based power control specialist Excitation Engineering Services Ltd (EES) took centre stage in Doha, Qatar, in October 2023. Beyond the glamour, EES demystified the intricacies of excitation in power generation, dispelling the notion that excitation systems necessitate extensive overhauls. The focus was on the transformative potential of retrofitting in power control systems, a philosophy that could save the industry thousands.

Established in 2011, EES excels in excitation control systems/ Founded by two electrical engineers, it now boasts a team of twenty-one professionals. Key milestones include designing its first system for Shin Power Station in 2012, earning ISO9001 accreditation in 2015, and winning the Chamber of Commerce awards in 2020. EES, committed to excellence, delivers high-quality services tailored to customer needs, emphasising expertise in design, manufacturing, commissioning, and maintenance of excitation systems while adhering to international standards.

 

The presentation

The presentation took place on October 8, 2023, at the Radisson Blu in Doha, Qatar. The primary objective was to provide a comprehensive overview of Excitation Engineering Services Ltd and shed light on the intricate aspects of excitation control systems for synchronous machines.

During the presentation, key topics centred around displaying the capabilities of excitation control systems. The audience was taken through a detailed explanation of excitation, covering its role in synchronous machines and the broader spectrum of power generation.

Furthermore, the presentation highlighted practical examples of EES's work, with a specific focus on successful projects involving upgrades and replacement systems. This practical application aimed to illustrate how EES addresses challenges in the field, showcasing its ability to provide innovative solutions and improvements to existing power generation infrastructure. The audience received insights into the benefits of front-end retrofits, where control cubicle upgrades enable cost-effective replacements while retaining critical high-power components.

 

Technical aspects

The technical aspects covered in the presentation provided a deep dive in depth look, into excitation control systems.

The presentation outlined the two main types of excitation systems — brushless and static. Brushless excitation systems eliminate the need for brushes and slip rings, offering improved reliability and reduced maintenance. On the other hand, static excitation systems employ solid-state components, such as thyristors or insulated-gate bipolar transistors (IGBTs) to regulate the excitation current. Both systems are crucial for ensuring stable and efficient power generation in synchronous machines.

EES emphasised the versatility of synchronous machines, showcasing the applications across various industries, including compressors, pumps, fans and blowers, and motors all applications involving power generation. These machines play a pivotal role in frequency conversion and power generation, maintaining a constant speed and operating efficiently across a diverse range of power factors.

The presentation underscored the fundamental role of excitation in the power generation process. Excitation involves supplying DC current to the rotor of a synchronous machine, forming an electromagnet that induces a current in the stator coil. This induction process is essential for generating electricity as the rotor's magnetic field passes the stator poles.

The presentation delved into the two prevalent configurations of excitation systems — thyristor bridge and IGBT output stage arrangements. Thyristor bridges, a conventional setup, involve the controlled rectification of AC to DC through thyristor devices. Conversely, IGBT output, favoured in modern excitation systems, provide advantages in terms of efficiency and control.

Finally, EES tackled the challenges encountered by power generation plants, emphasising the role of excitation control systems in mitigating issues like system reliability, efficiency, and adaptability to aging infrastructure. The solution, as proposed by EES, is front-end retrofits, strategically enhancing system reliability and efficiency, leading to minimised costs and downtime. This approach ensures that power generation plants can overcome challenges and maintain optimal performance through advanced excitation control systems.

The primary focus was on EES's dedication to enhancing efficiency and reliability in power generation through advanced excitation control systems.

The presentation offered valuable insights into the strategic advantages of front-end retrofits for existing excitation systems, a key solution in power generation upgrades. EES highlighted the concept of front-end retrofits concentrating on enhancing the control cubicle while safeguarding crucial high-power components like the thyristor bridge, field switch, and transformer.

The key advantage lies in the cost-effectiveness of this approach. By focusing on enhancing the control cubicle, EES empowers power plants to achieve substantial system improvements without undertaking a complete overhaul of the high-power components. This not only delivers significant cost savings for clients, but also minimises downtime during the replacement process.

The retrofit strategy aligns with EES's dedication to delivering economical and efficient solutions, allowing clients to benefit from enhanced excitation control systems without incurring excessive expenses. This approach emphasises practical, sustainable, and economically viable solutions for power generation plants.

 

Past projects

EES has already undertaken a diverse array of projects, encompassing front-end retrofits, emergency installations, automatic voltage regulator (AVR) designs and more.

For example, EES designed a dual-channel excitation systems for a thermal power station undergoing a biomass upgrade. This retrofit featured a third AVR for the pilot exciter, establishing innovative redundancy for seamless supply transition. The bespoke design allowed a smooth changeover between supplies, demonstrating EES's adaptability in upgrading diverse power generation setups.

Similarly, EES installed a static excitation system at a power station facing an exciter failure. Executed and installed within a three-week timeframe, the system enabled continued operation while the rotating exciter was repaired. This rapid deployment underscored EES's ability and capacity to address critical issues promptly while ensuring uninterrupted power generation.

EES also received a commission from a major European utility to design an excitation system suitable for installation across multiple hydroelectric assets. With twelve units installed and commissioned since 2012, EES's solutions have demonstrated reliability, compliance with the UK national grid code, and a positive contribution to efficient power generation at hydroelectric facilities.

In 2018, EES secured a contract from Parsons Peebles to design and produce control systems for three rotary frequency converters at an Australian military facility. The rotary frequency convertors comprised of a 60Hz synchronous generator mounted on the same shaft as a 50Hz synchronous motor. EES provided three complete control cubicle suites; each comprising of a PLC to handle startup and shutdown sequences, an IGBT based AVR for the motor and a static excitation system for the generator.

EES’s presentation in Qatar delved into the intricacies of power generation, challenging the conventional approach of complete system overhauls. The commitment to practical and sustainable solutions, highlighted through front-end retrofits, signifies a paradigm shift.

By prioritising cost-effectiveness and efficiency, EES actively contributes to the evolution of power control systems, aligning with industry demands. Embracing a future where advancements are strategic, economical, and focused on lasting efficiency.

To find out more about how EES can bolster your power control and generation needs, visit the excitationengineering.co.uk website or call at 01827 286100.

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