megawhat-h2o october 2012

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DecoDing Mars gcc’s approach to energy anD water conservation

HEAD LINES• GE strEnGthEns localisation commitmEnt in Ksa • abu Dhabi to host rEnEwablE EnErGy micro-GriD pilot

sustainability champion

ON THE RECORDKarl s FEssEnDEn, prEsiDEnt & cEo, powEr GEnEration sErvicEs, GE powEr & watEr. SHORT TAKEvincEnt GuillaumiE, EmEa watEr inDustry manaGEr,rocKwEll automation.

LED TRENDSJamEs chorlton, businEss DirEctor, honEywEll ElEctrical DEvicEs & systEms (ED&s)

OCTOBER 2012

MEGAWHAT/H2O | OCT 2012

CONTENTSOCTOBER 2012 NEWS8/ The meter10/ Round up14/ In the region

22/ INDUSTRY NOTES•Unique range•Global desalination capacity rises by 57%•GE strengthens localisation commitment in Saudi Arabia

25/ SHORT TAKEVincent Guillaumie, EMEA Water Industry Manager, Rockwell Automation.

ON THE RECORD26/ The service propositionKarl S Fessenden, President & CEO, Power Generation Services, GE Power & Water.

DEMAND SIDE28/ LED TrendsQ&A with James Chorlton, Business Direc-tor, Honeywell Electrical Devices & Systems (ED&S)28/ Lighting the futureWith DY Kim, President, LG Electronics Gulf.

PUMPS, COMPRESSORS, VALVES37/ Design for Energy EfficiencyBest practices can help reduce the large share of energy consumption of pumps and com-pressors in process industry.

41/ INSIGHT•MI Graduate presents biodiesel project at Rio+20 •Rough patches on the CSP road

SECTOR REPORT49/ Looming shortageA leaner global polysilicon industry is poised for rebound, says Bernreuter Research

FLIP SIDE49/ A slice of historyOil & Gas museum at ADIPEC2012

SPOTLIGHT6/ NYNASSpecification and maintenance guide for min-eral insulating oil

PLUS42/ Market Place43/Events44/ Tenders & Contracts

4/EDITOR’S LETTER

COVER STORY32/Sustainability ChampionDecoding Mars GCC’s approach to energy and water conservation

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EDITORS


PublisherDominic De Sousa

Associate PublisherLiam Williams • [email protected]

Chief Operations OfficerNadeem Hood

EditorAnoop K Menon • [email protected]

Business Development DirectorVedran Dedic • [email protected]+971 55 8644831

Business Development ManagerDeep Karani • [email protected]+971 50 8585905

Marketing & Team AdministratorLeila El Madalla • [email protected]+971 4 375 1506

DesignCris Malapitan • [email protected]

Digital Services Manager IT DepartmentTroy Maagma • [email protected]

Web DeveloperWaseem Shahzad • [email protected]

Production and CirculationJames P. TharianRajeesh M

USA and CanadaKanika SaxenaDirector - North America25 Kingsbridge Garden Cir. Suite 919Mississauga, ON. Canada L5R [email protected]/fax: + 1 905 890 5031

Published by

Head OfficePO Box 13700 Dubai, UAETel: +971 4 375 1500Fax: +971 4 365 9986www.megawhatme.com / www.h2ome.net

Printed by:Printwell Printing Press LLC

© Copyright 2012 CPI.All rights reserved.While the publishers have made every effort to ensure the accuracy of all information in this magazine, they will notbe held responsible for any errors therein.

MW/H2O combines the bi-monthly legacies of two power and water industry thought-leadership brands into a monthly edition thatprovides an unbeatable, 360 degree perspective of the Middle East& North Africa (MENA) region’s utility and energy sectors.

Anoop K [email protected]

note

The search for a role model

If you expected the ‘usual’ in this is-sue, I apologise. This time around, we took a path less trodden with regard

to the cover story and decided to profile an end-customer. These days, we often hear utilities talking about Demand Side Management (DSM) programmes that seek to help end-customers control their water and energy demand. But what if the end-customer turns out to be pro-active in reducing their water and energy demand, without waiting for the carrot or stick of a DSM programme or otherwise?

I first covered Mars GCC, the Dubai-headquartered Middle East business unit of the world’s second largest chocolate manufacturer in 2010, in the erstwhile H20 magazine, profiling their water con-servation efforts. Even then, Mars GCC was marching step in step with its parent company’s global agenda that called upon all sites to meet absolute targets – short term and long term - for reducing energy and water use and waste. While many com-panies in the region have adopted a wait and watch attitude when it comes to mak-ing their operations sustainable, a few like Mars GCC have ventured forth on their

own, recognising that their responsibility for the future of mankind and the planet we live in cannot wait.

What our story highlights is only a pro-verbial tip of the iceberg of the sustainabil-ity initiatives underway in Mars GCC, the objective being to provide a snapshot of the key projects being implemented by the Dubai site to align itself with the absolute targets set by the parent. I would recom-mend a visit to Mars’ global website to un-derstand the sound reasoning behind these targets and how the company proposes to achieve them. For regional utilities looking for role models at the demand-end to pub-licise the importance of sustainable water and power consumption, companies like Mars GCC could be great examples.

The other highlight in this issue is the expansion of the GE Manufacturing Tech-nology Centre in Dammam, which af-firms the trend of global power and water industry players establishing a manufac-turing footprint in the region to get closer to their customers and participate in the regional agenda of local value chain de-velopment and job creation. Read more on that inside.

Until the next issue, au revoir.....

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SPOTLIGHT ADVERTORIAL NYNAS

Mineral insulating oil is the most widely used insulating liquid for cooling and insulation in oil-filled electrical equipment.

Standard specifications and guidelines are regularly maintained and used for purchasing and supply of virgin unused oil and also for maintenance of in-service oil.

International standard IEC 60296 is used in the electrical industry for purchasing and supply of unused mineral insulat-ing oil. Globally it is the most widely used standard for supply of mineral oil in the electrical industry. Both users and producers realised some weakness in this standard; therefore during IEC TC10 general meeting in 2005, it was decided to revise this stand-ard. As of February 2012 the revised standard is now published. We urge all our customers to ask for these 2012 standards for all future requirements.

At Nynas, we’re passionate about everything to do with power.

Need to talk to a transformer oil supplier who

understands your business? One who’s local enough

to be near you, yet global enough to have the

expertise you need. Get in touch. www.nynas.com

AD_talker_SA_landscape_420x145.indd 1 2010-12-13 14.57

Specification and maintenance guide for mineral insulating oil

Among several improvements the revised standard address lower furfural content of the oil as well as clearer definitions of addi-tives. Demands on testing for sulfur induced copper corrosivity were also finally formalised.

For reliable operation of oil-filled electrical equipment, monitoring and maintenance of insulating liquid is essential. The characteristics of the oil, supplied as unused, may change during service life. Therefore, the oil quality should be monitored regu-larly during its service life.

In many countries, power companies and electrical power authorities have established codes of practice for this purpose. In general these cover monitoring guidelines and corrective actions depending on the oil status. If a certain amount of oil de-terioration is exceeded then the possibility and risk of premature failure should be considered.

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At Nynas, we’re passionate about everything to do with power.

Need to talk to a transformer oil supplier who

understands your business? One who’s local enough

to be near you, yet global enough to have the

expertise you need. Get in touch. www.nynas.com

AD_talker_SA_landscape_420x145.indd 1 2010-12-13 14.57

While the quantification of the risk can be very difficult, a first step involves the identification of potential effects of increased deterioration.

Physical contaminants such as water and particles can be removed from the oil restoring oil breakdown voltage, however, chemical contaminants cannot be removed by simple filtration/degassing of the oil and requires chemical treatment of the oil.

This is particularly important issue for repaired transform-ers and refilling of these repaired units would be best with new virgin oil. IEC 60422 is a guide for supervision and maintenance of mineral insulating oils. This standard is now under revi-sion to take into account development in oil and equipment technology and inclusion of the best practices currently in

use worldwide. Changes are also made to use current method-ology and comply with requirements and regulations affecting safety and environmental aspects.

Should you have any questions related to the above aspects, feel free to contact:

Hendrik Cosemans(General Manager Nynas Middle East) Emial: [email protected]. No. 00971 4 332 71 25

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The total number of energy storage projects deployed and announced (including inactive projects) during the first half of 2012, an increase of eight per cent from the start of the year. According to Pike Research’s ‘Energy Storage Tracker,’ the number of projects deployed on a global basis increased over those six months from 482 to 514. The region with the larg-est base of energy storage is Asia Pacific, which has just over 60 GW of cumulative installed capacity.

Stake acquired by ACWA Power, the Saudi water and power developer, owner and opera-tor in a solar photovoltaic (PV) plant located in Karadzhalovo, Bulgaria in partnership with an af-filiate of First Reserve Energy Infrastructure Fund and Clean Energy Transition Fund. The plant, rated at a capacity of 60MWp, is expected on aver-age to produce 81,000 MWh per annum and is in operation since March 2012, dispatching electric-ity to the Bulgarian power grid.

The capacity of the Waste-to-Energy facility which will be jointly developed by TAQA and the Centre of Waste Man-agement Abu Dhabi (CWM) by 2015/16. The facility will be capable of processing up to a million tonnes of municipal solid waste per annum, contrib-uting towards CWM's stated target of 80% diversion of waste from landfill, which falls within the Abu Dhabi Vision 2030 objectives.

100MW

The number of power projects – hydro and gas-based – proposed to be implemented by Kurdistan’s Ministry of Electricity. The ministry has plans to implement three hydropower plants in Deraluk-Rashawa Dam, Mandawa-Kopala and Taqtaq and two 200 MW gas power plants in Qaladze and Harir.

Saudi Arabia’s share of world oil re-serves, according to the latest report by the Kuwait-based Diplomatic Centre for Strategic Studies (DCSS).

NEWS IN NUMBERS

5

42%

649THE METER


Pumps ■ Valves ■ Systems

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Pumps ■ Valves ■ Systems

Comprehensively convincing.

Customers around the world rely on our intelligent solutions for water and waste water management, for process engineering applications and building services, and for the energy and mining sectors. Like Etanorm standardized pump for safe and reliable pumping jobs, Movitec high-pressure in-line pump or Isoria butterfly valve ensuring perfect shut-off. Benefit from our all-round advice and convince yourself just how comprehensive we are: www.ksb.ae

Etanorm Movitec Isoria


NEWS IN BRIEFROUND-UP

ACCIONA Agua bags first Saudi deal

Saudi Arabia’s Marafiq Power & Water Utility Company for Jubail & Yanbu has awarded the consortium of AC-

CIONA Agua and Saudi BinLaden Group the contract for the design, construction and commissioning of the Al Jubail de-salination plant which will service the city of Al Jubail and its associated industrial complex in the Eastern Province. This is ACCIONA’s first-ever contract in Saudi Arabia. The desalination plant is expected to come into operation at the end of 2014 and will have a capacity of 100,000m3/day. This is well over twice the combined capacity of the city’s existing five desalina-tion plants. Currently, Al Jubail industrial city has two Multistage Flash Desalination (MSF) plants, and three RO facilities with a combined capacity of 84,000 m3/day.

Germany installed roughly 320 MWp of solar power in August, according to initial reports. This

addition has bumped Germany past 30 GWp, the first country in the world to reach this level of photovoltaic capacity. Total German solar installations make up more than the rest of Europe combined. “Positive market developments and ongo-ing changes in the industry underscore Germany’s position as the global frontrun-ner in solar power,” said Tobias Rothacher, photovoltaic industry expert at Germany Trade & Invest in Berlin. As the industry matures, the market segment of homes and businesses that consume the energy they generate is expected to see the strongest growth. Leasing, power trading and plant management are up-and-coming service sector fields driven by the commercial rooftop market.

German solar installations surpass 30 GWp

Borouge and Borealis have launched Borlink, a technology platform that offers a complete global package of

power materials, experience, knowledge and support, in the Asian market. The launch took place during the Wire China 2012 exhibition held in Shanghai, China last month. Borlink offers a complete glob-al portfolio of cross-linkable polyethylene (XLPE) compounds, experience, knowl-edge and support targeted at high voltage direct current (HVDC) cable applications. The technology includes a tailor-made and unique pressure process for the production

Borouge and Borealis launch Borlink in Asia

The launch took place at Wire China 2012 in Shanghai

IFC, a member of the World Bank Group, has invested $12 million in Norway’s Aqualyng Holding to expand

the company’s seawater desalination pro-jects in China. The investment is part of Aqualyng’s recently completed $30 million fund-raising round, which also attracted investments from Clean Resources Asia Growth Fund, in which IFC is also an in-vestor, and Pareto Staur Energy. Aqualyng will use the funds to build new desalina-tion plants in China in areas experiencing

IFC invests in Aqualyng

Modern Water has announced the installation and commis-sioning of its 200 m3/day For-

ward Osmosis (FO) desalination plant at Al Najdah in the Al Wusta region of Oman. The company was awarded the contract, worth OMR250,000, to build and operate the plant in June 2011 by Oman’s Public Authority for Electricity and Water (PAEW). The plant is

Modern Water commissions FO plant in Oman

water scarcity and also other parts of Asia, producing up to 100,000 m3/day of fresh water. This is IFC’s first investment in Chi-na’s emerging seawater desalination indus-try. Aqualyng and its joint venture partner Beijing Enterprises Water Group recently commissioned the first stage of the Caofei-dian desalination plant in Hebei province, which can process 50,000 m3/day of fresh water. The plant is one of the first large-scale, commercial seawater reverse os-mosis plants in China and is considered a model desalination project in the country. Aqualyng’s equity investment in this pro-ject received a guarantee from the World Bank Group’s Multilateral Investment and Guarantee Agency (MIGA).

of high purity and super clean low density polyethylene base polymers with superior electrical properties. The whole process from the base polymer production via the cross-linking technology takes place in ei-ther a closed and/or controlled production loop (from monomer to final packaging). This enables to avoid any contaminations and delivers world class clean and homog-enous and high quality compounds.

the world’s first commercial forward osmo-sis desalination plant and the group’s sec-ond plant in Oman. The plant Al Najdah is now operating commercially at full capacity and the group has now entered into the 12 month operation and maintenance (O&M) phase. Al Najdah plant is vital to the area as it supplies the local community with a much needed source of clean drinking water.

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Untitled-2.indd 1 10/4/12 4:14 PM


ROUND-UP

CST Industries, a global leader in the manufacture and construction of factory coated metal storage

tanks, aluminium domes, specialty covers and reclaimer systems, has named Tony Thill as President of CST International, the division responsible for operations outside of North America.

“Tony’s leadership experience in global business development makes him an ideal candidate to assume this role,” said De-clan McLaughlin, President and CEO of CST Industries. “His knowledge of CST’s

New president of CST International

Tony Thill

Jukka-Pekka Mäkinen, President and CEO of The Switch, called for the adoption of an industry-wide net-

worked model to overcome the rigidity of the vertical integration that still stifles the entire wind power industry. Industries that have embraced networking are better pre-pared for fluctuations in the market that can come from business cyclicality, market volatility or even geographical shifts.

“In the wind power industry, we have all witnessed the fallout from the global eco-nomic downturn and the significant geo-graphic shift from Europe and the US to-wards China and emerging markets. Now, we’re finally seeing signs of this industry opening up to the benefits of networking, with large turbine manufacturers selling off component manufacturing operations to other specialist players to better compete by concentrating on their core strengths,” said Mäkinen.

Networking within entire industries is not new. The automotive or telecommuni-cations industries have been operating in such a manner for years, leading to deeper specialist expertise, the ability to add scale where necessary and faster time to market.

Companies in the wind power industry now need to focus on being good at their chosen core competences, believes The Switch CEO. Through specialisation, they can tap into cumulative experience, which leads to significantly improved quality, en-suring a world-class solution with bigger and better wind turbines.

New business model

Jukka-Pekka Mäkinen, President and CEO of The Switch

The Dow Chemical Company and the Saline Water Conversion Cor-poration (SWCC) have signed a

commercial agreement for research col-laboration. The announcement follows a memorandum of understanding (MoU), in March 2012, between Dow and SWCC to conduct joint research in desalination technologies. Dow and SWCC will partner to test the desalination technologies devel-oped by Dow Water & Process Solutions (DW&PS), evaluating their performance in the Arabian Gulf ’s unique environment, including their ability to effectively han-dle factors such as high salinity and high temperatures. The tests will be conducted by the Saline Water Desalination Research Institute (SWDRI) in Al Jubail, Saudi Arabia, over a period of one year. SWCC is the largest desalinated water producer in the world with 32 desalination plants responsible for 18% of the world’s desali-

Dow, SWCC sign commercial research pact

Dr Ilham Kadri

NEWS IN BRIEF

products and his experience working with CST’s companies and divisions to develop aggressive growth strategies will be ex-tremely beneficial leading our Interna-tional group.”

Prior to joining CST Industries in 2006, Thill served in multiple executive roles with GE Energy and the former BHA Group, leading the dry filtration business unit, developing international markets, accelerating product development and im-plementing marketing, sales and corporate strategy worldwide.

nated water production. “We welcome this opportunity to further prove the effective-ness of DOW UltraFiltration and DOW FILMTEC Reverse Osmosis technologies in the challenging environmental condi-tions we see in the Arabian Gulf. We are proud to partner with SWCC and confident our innovations will deliver enhanced solu-tions for the unique needs of the Kingdom,” said Dr Ilham Kadri, General Manager, Dow Advanced Materials, Middle East and Africa, and Commercial Director, Dow Water & Process Solutions (DW&PS), Europe, Mid-dle East and Africa.

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IN THE REGION


Saudi Arabia aims to liberalise its power industry beginning with the privatisation of the electricity sector

by 2014. The privatisation moves aims to create a competitive market for electricity generation in Saudi Arabia, where current-ly the government-owned Saudi Electricity Company (SEC), produces, transfers and distributes electricity on a national basis.

“We are working at establishing four generation companies and one distribution company by 2014,” said Amer Al Swaha, head of SEC’s IPP programme while speak-ing at the Saudi Mega Infrastructure Pro-jects Summit held in Riyadh last month.

Saudi electricity sector to be privatised by 2014The largest electricity market in the Middle East will see demand rise to 120,000 MW in 2030

“The four generation companies will have similar capacity and technology and will not be based on geographic regions. They will all have the same starting point which will allow us to compare their relative per-formance.”

The restructuring will involve the divi-sion of SEC’s electricity generation business into similar companies that will compete with each other and SEC’s independent power providers (IPPs). The SEC will also set up a single buyer of electricity from the four electricity generation companies and the IPPs. A single separate transmission company has already been established and

has been in operation since January 2012.Al Swaha continued: “We will have a single

buyer model to buy the power from all those companies and pay a transmission fee to the transmission company and distribution fees to the distribution companies.”

A liberalised power sector is expected to help ease increasing electricity demand in the Kingdom, which rose by 8.9% to 51,000MW in 2011. “Demand is rising strongly and we expect it will be signifi-cantly higher than 120,000 MW in 2030,” added Al Swaha.

At the Saudi Mega Infrastructure Projects Summit, experts forecast over $300 billion worth of projects in various sectors to be awarded over the next three years. “The in-vestment in several ambitious projects will have a major impact on Saudi Arabia’s eco-nomic and social fabric; and will make it a truly regional financial, leisure and industrial hub of growing international importance,” said Edmund O’ Sullivan, chairman, MEED Events, organisers of the Saudi Mega Infra-structure Project Summit.

Passavant-Roediger, a wholly owned subsidiary of Drake & Scull Inter-national, has been selected by the

Iraqi Ministry of Municipalities as the turnkey contractor for a waste water treat-ment plant (WWTP) located in the city of Kerbala. The project was awarded by Al Hanan Contracting Company and the contract value of Passavant-Roediger is Dh86 million.

Under the terms of the contract, Passa-vant-Roediger will design and build the sludge treatment system of the WWTP based on anaerobic sludge digestion, in-cluding energy recovery and generation from biogas. It will install 12 sludge di-gesters each with a capacity of 3,400m³ all equipped with the propriety Passavant-Roe-diger Sequential Gas Lance Mixing System.

Passavant-Roediger’s patented anaerobic sludge digestion technology reduces sludge volumes and renders it harmless for safe

Passavant-Roediger bags sludge digestion deal in IraqDrake & Scull subsidiary continues Iraqi expansion with major waste water & water treatment ventures Dr Mazen Bachir

discharge. It also allows the recovery of en-ergy from the organic matter it treats. The process involved can generate up to 80% of the power requirements of a WWTP.

Commenting on the award, Dr Mazen Bachir, Managing Director of Passavant Roediger said, “Our global experience and patented technology will allow the imple-mentation of an optimal treatment process tailored to the sophisticated requirements of this high- scale project. Our modern digesters will guarantee energy saving op-erations and less consumption of chemi-cal substance required for the treatment process while ensuring efficiency and long term profitability for the client. We are currently gearing up to mobilise on site shortly and we expect the project to be delivered in 2013”.

DSI acquired Passavant-Roediger in 2009 to enhance its capabilities in the re-gion’s water and wastewater sector. Pas-

savant-Roediger is a leading global de-veloper of wastewater, water and sludge treatment technologies, with opera-tions across Europe, Africa, Asia and the Middle East and has portfolio of several ongoing and completed pro-jects in Iraq including Ramadi Sa’ad 21 Industrial Complex ETP, Arbil WWTP, Baquba WTP and Salahudin Refinery ETP as well as more than 20 other pro-jects in the water and wastewater treat-ment sectors ranging from full scale plants to package plants. The company delivers comprehensive in-house solu-tions for the design, supply, build, op-erations and maintenance, wastewater and water treatment facilities and is one of the leading Engineering, Pro-curement and Construction (EPC), Wastewater and Water Treatment (WWT) and Re-Use Design and Build Contractors Worldwide.

NEWS MENA

14

IN THE REGION

SS Lootah international has partnered with Germany based Arndt to of-fer solutions for fully-automated

biodiesel plants in the region. The locally manufactured plant with integrated auto-mation and remote control monitoring will optimise the conversion of used cooking oil into environmentally friendly biodiesel with minimum human intervention.

The partnership agreement was signed between Abdullah Bin Saeed Al Lootah, CEO of SS Lootah International, and Klaus Dieter Arndt, General Manager of Arndt, in Dubai. The agreement framework will

allow SS Lootah International to com-bine its local knowledge and engineer-ing talent with Arndt’s global expertise in setting up biodiesel plants with safe automation.

Commenting on the partnership, Ab-dullah Lootah said: “As we move towards a sustainable future, introducing techno-logical and infrastructural solutions to the region’s energy requirements is cru-cial. We are confident that this partner-ship will take Biodiesel production in the region to the next level.”Klaus Dieter added: “Having set up auto-

mated biodiesel plants across Europe, we are glad to cooperate with SS Lootah In-ternational to bring the knowhow to the Middle East and North African (MENA) region. Our high quality equipment and sensors together with automation and computer remote control help achieve highest plant safety and product quality in reduced time. With the increased demand for turning waste materials into commer-cially viable and environmentally friendly products, we hope that our partnership will open up a niche market for biofuel production and its application.”

Pact to bring biofuel production to the regionThe plants will convert used cooking oil into environmentally friendly biodiesel.

Abdullah Bin Saeed Al Lootah, CEO of SS Lootah International and Klaus Dieter Arndt, General Manager of Arndt GmbH after signing the MoU.

NEWS MENA

15


The construction boom and rising investments in real estate in the Kingdom of Saudi Arabia (KSA),

have resulted in phenomenal growth for building technologies such as heating ventilation and air-conditioning (HVAC), lighting, and mechanical-electrical-plumb-ing (MEP) systems in recent years. As all these systems operate on electricity, KSA’s energy consumption has inevitably surged rapidly over past few years. Additionally, economic growth across sectors such as petrochemicals and plastics, power, water and wastewater, infrastructure, and metals and mining, has contributed to increased energy consumption.

According to Frost & Sullivan, in 2011, the energy consumption pattern in KSA was dominated by its residential sector with 54% of total energy consumption, fol-lowed by commercial sector with 29%, and industrial sector with 17%.

KSA is projected to account for over 50% of the Gulf Cooperative Council’s (GCC) district cooling operating capacity and 33% of overall revenue by 2016, at a compound annual growth rate (CAGR) of 21.7%. KSA is highest waste generator in the GCC, which was recorded at approxi-mately 22 million tonnes in 2011. Avail-ability of cheap fossil fuel and low land-fill rates, however, have been hindering growth of waste-to-energy and recycling market in the country.

However, the rise in energy consump-tion must be addressed by developing new techniques for energy efficiency. Frost & Sullivan has recommended upgrading ex-isting systems including controls, sensors, building management systems, and per-formance contracting models, along with harnessing energy-efficient products and systems to help rationalise energy con-

Saudi Arabia puts energy efficiency on radarLack of awareness amongst end users poses a major challenge to the market, notes Frost & Sullivan.

KSA offers over $1.35 billion of energy-saving potential

sumption in the country. Some techniques that can support energy-efficiency measures are HVAC, lighting, integrated building management systems (IBMS), performance contract-ing, and recycling. Phasing out inefficient lighting systems with energy-efficient compact fluores-cent lamp (CFL) and light-emitting diode (LED) lights is further expected to reduce annual electricity consumption by 3.2 Twh and CO2 emissions by 2.4 Mt.

KSA is spearheading the region’s emerg-ing trend towards adoption of alternative and renewable sources of energy. With strong renewable energy resource base and constant technological developments, KSA has ambitious plans to improve energy efficiency by effectively using existing systems and encouraging use of energy-efficient products.

In 2010, the Government of KSA estab-lished the Saudi Energy Efficiency Board (SEEC), as energy efficiency was identi-fied as a national priority. Amongst others, one objective of the SEEC was to propose a national energy-efficiency plan in order to rationalise energy usage in the coun-try. Thus, KSA’s first grid connected solar power plant was inaugurated in 2011. KSA offers over $1.35 billion of energy-saving potential and out of this about one billion dollars is an immediate addressable market potential for energy efficiency. Currently, the KSA accounts for $1.44 billion of un-tapped energy-saving market, which trans-lates to about 37.1 bn kWh of energy saved.“Greener equipment should start mak-ing inroads into the KSA market. If Saudi Arabia implements energy-efficiency pro-grammes as proposed by the electricity advisor, demand for products such as pro-

grammable thermostats, energy-efficient HVAC equipment, and other associated services and solutions is expected to in-crease,” said Frost & Sullivan Environmen-tal and Building Technologies Industry Manager, Kumar Ramesh.

According to Frost & Sullivan’s study on ‘Energy Efficiency in KSA’, a critical chal-lenge to development of the Saudi Arabian energy-efficiency market is lack of aware-ness amongst end users. To address this, Frost & Sullivan recommends that KSA should implement mandatory regulations on energy management and incentives for energy-efficient investments in order to generate awareness. It is also essential to include efficiency standards for new air-conditioning appliances, along with ac-tions on replacing inefficient models and regulation on maintenance.

KSA needs to incentivise implementa-tion of new technology to reduce energy consumption, provide more autonomy to energy-related organisations to work to-wards efficiency, create awareness about the need to conserve energy, and educate end users with respect to increasing energy prices. As ongoing massive industrial de-velopment in the Kingdom is expected to raise the energy demand further, Frost & Sullivan recommends implementation of a transparent building model, showcasing periodic reduction in operational costs for new constructions as well as existing build-ings, ensuring energy-efficiency.

IN THE REGION NEWS MENA

16

BioAir Solutions, a leading US-based provider of biological odour and emission control solutions for

wastewater treatment plants, which had recently established a presence in the Middle East region, has reported en-couraging results from its odour control project in Qatar.

Operating more than 190 pumping sta-tions to handle sewage to the city’s waste-water treatment facilities, Ashghal, Qatar’s public works authority, was looking for a better way to handle odours at their Pump-ing Station 11, which services the Najma Al Mansoora region and is located beside the Holiday Villa hotel in Doha.

BioAir helped Ashghal assess the odour situation at the pumping station, estab-lish suitable design criteria, and develop

Successful odour controlBioAir claims that its odour control project for Ashgal continuously exceeded the 99% H2S removal guarantee.

BioAir’s EcoFilter technology uses bacteria to remove odours.

a solution using the company’s EcoFilter biotrickling filter technology. A high-per-formance EcoFilter EF52 biological odour control system, which is capable of han-dling H2S concentrations in excess of 750 ppmv while achieving removal efficiencies of greater than 99.5%, was installed at the station. The BioAir EcoFilter technology uses bacteria to remove odours without us-ing chemicals or activated carbon. The so-lution also functions continuously without the need to remove or replace the media.

Ashghal was interested to see how well the EcoFilter technology would operate in the peak summer heat, which reaches am-bient temperatures of up to 55°F (131°F). Upon delivery and installation, the EcoFil-ter unit eliminated the odours almost im-mediately and demonstrated its efficiency

regardless of the ambient air temperature. The company has further claimed that system performance has continuously ex-ceeded the 99% H2S removal guarantee that BioAir Solutions specified when the unit was installed.

IN THE REGIONNEWS MENA

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Global Green Growth Institute (Chairman, Lars Rasmussen, for-mer Prime Minister of Denmark),

an intergovernmental organisation com-mitted to promoting green growth in the developing world, is joining hands with Masdar Institute (MI) and the Research Institute for Industrial Science and Tech-nology (RIST) in Pohang of South Korea to design a robust and cost-efficient micro-grid operating on 100% renewable energy. The project is supported by approximately $1 million from GGGI and POSCO, the world’s fourth largest steel producer.

The announcement of this innovative collaborative UAE-South Korea research project, which is led by the UAE Ministry of Foreign Affairs’ Directorate for Energy & Climate Change and coordinated by the GGGI, was made in Abu Dhabi last month.

During the event, the joint Project Team between MI and RIST revealed a concep-tual design for an island-based renewable

The project will be implemented as a public private partnership (PPP) between GGI, MI and RIST

Abu Dhabi to host renewable energy micro-grid pilot

micro-grid. The conceptual design consists of a control system, energy storage, and a high efficiency DC distribution system. It is designed to incorporate renewable en-ergy sources such as solar PV, small wind power and biofuel production from waste and algae. The micro-grid system can be linked to local seawater desalination and electric powered boats for island access.

The Public Private Partnership project is coordinated by GGGI and will tap the expertise of Masdar Institute in the design and simulation of micro-grids with renew-able energy, and the RIST team’s estab-lished expertise in commercialising tech-nologies demonstrated by the project on Jeju Island, South Korea. The project island in the UAE will become a ‘sister’ island, featuring advanced micro-grid and ‘smart renewable’ technologies.

Dr Scott Kennedy, Dean for Research, Masdar Institute, said: “Micro-grids are gaining increasing popularity as a key

enabler of smart grid infrastructure and an important technology in expanding electricity access to areas with weak or non-existent power infrastructure. Such grids are essentially small, low to medium voltage power systems that can operate in isolation or connected to a larger trans-mission system. Featuring advanced con-trol systems that allow them to operate in grid-connected or isolated mode, they can also include up to 100% renewable energy, therefore providing zero-carbon power.”

The Joint team already conducted a pre-workshop in Pohang, Korea in July, 2012 and visited a potential demonstration site in Abu Dhabi, the UAE in August, 2012 to set up the conceptual design. The team will develop a UAE tailored micro-grid model and an action plan for a subsequent imple-mentation project until March, 2013. The developed micro-grid model will be high-lighted during the World Future Energy Forum in January 2013 in Abu Dhabi.

The project will tap the expertise of Masdar Institute in the design and simulation of micro-grids

Micro-grids are gaining increasing popularity as a key enabler of smart grid infrastructure

IN THE REGION NEWS MENA

18

MEGAWHAT/H2O | OCT 2012 19

The second edition

of Water Leakage Summit Middle East will once again bring

stakeholders from the region’s water sector to explore and discuss current issues,

best practices and regulations for leakage reduction.

Join us for a two-day summit packed with presentations, panel debates, and workshops to

discover practical approaches suited to the region’s specific requirements. Learn about innovative

financing models, while celebrating the sector’s achivements.

21-22 NovemberThe Address Dubai Marina

Dubai, UAE

SPONSORS

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White version.indd 1 10/10/12 7:25 PM

INDUSTRY NOTES


F ounded in 2010, Dubai-headquar-tered Orion Systems’ offering cen-tres on systems of its own invention

that leverage the unique properties of the 433MHz radio frequency together with other complementary sub-1GHz frequen-cies. In fact, the company claims a non-line-of-sight transmission range of up to seven kilometres without repeaters, which it asserts could greatly reduce the cost of sensing and monitoring pipeline installa-tions and refurbishments.

“Orion Systems is an unusual compa-ny – one that combines innovation with vast practical project experience, to de-velop truly cost-effective answers to long-standing problems,” says Martin Saville, Chief Executive of Orion Systems. “The technology and solutions that we develop meet important operational challenges that could not be addressed before – and do so

Unique rangeSub-1GHz wireless sensing, tracking and monitoring technology and solutions can deliver significant cost savings to the region’s power and water industry.

quickly, economically and with minimal disruption. Most importantly, they pose no threat to humans or animals.”

He continued: “Because we have the strongest possible focus on engineering and use only the very best componen-try, our solutions are more reliable, with greater compatibility and lower power consumption than others. Our Orion Radio-Control Application (ORCA) takes the real-time data from accurate, highly-secure longer-distance transmissions, even through concrete walls, and turns it into real-time information for the purposes of monitoring, alerting, remote control and management reporting.” Saville noted that his company’s solutions are ideally suited to the region’s power and water sectors: “The wireless delivery of encrypted real-time information from end-devices, with up to three levels of transmission redundancy,

which may previously not have been viable due to additional cabling requirements or the substantial limitations of higher-band mesh and multi-hop wireless networks, en-ables 100% dependable, earlier and more specific alerts than previously possible,” he said. “In addition, scalability and flexibility are built-in, so the fast implementation of additional monitoring and control systems to support the expansion of a desalination plant or a pipeline, for example, is easily catered for. Our technology has been for-mally tested in extreme conditions, so we know it stands up to the special environ-mental conditions prevalent in the Middle East, both onshore and offshore.”

Orion has on board experts of the like of radio technology innovator and VP of Research and Development Dr Jean-Louis Hygounet, technical consultancy, design and delivery principals John Greaves (an

20

INDUSTRY NOTES


international authority on wireless, radio and data capture technologies and stand-ards) and Grahame Edwards (a leading authority on control and security solutions for ports, airports and buildings) and the local market knowledge of Chairman Tony Durnford (founder of long-established UAE solutions company Cimac) and other key employees.

The company’s strategy is to lead with its technical consultancy to evaluate and ana-lyse big, complex and expensive operation-al challenges for organisations in major sectors, including utilities, airports, ports, buildings and facilities, security and the environment, and to deliver a comprehen-sive statement of requirements on which to base the development or adaptation of a solution to meet a client’s specific needs.

In addition to the considerable experi-ence and expertise of its key personnel, in-

terested parties are reassured by being able to view live updates of the development and test installations. Grahame Edwards said: “Our demonstration and services centre features our ORCA software driving a bank of monitors displaying data from a range of devices collected wirelessly in real time over long distances, and enabling the data to be manipulated on-screen. This provides our potential clients with invalu-able ‘hands-on’ experience of the power and flexibility of our systems.”Saville noted that Orion Systems is well aware of major challenges posed by exist-ing in-place systems: “Our modular sys-tems provide almost unlimited options but they have one thing in common: intelligent design. Their conformity to international standards means that they can integrate with and extend existing hard-wired or wireless infrastructures and SCADA or

other monitoring systems, including CCTV and audio installations, or can be standalone. They also enable the provision of accurate enhanced management infor-mation to rapidly identify problem areas and to support programmes of continuous improvement.”

By Max Tuttle

Orion Systems demonstration and services centre showing real time data collected wirelessly.

21


The past five years has seen a 57% increase in the capacity of desali-nation plants on-line according to

the latest data published by the Interna-tional Desalination Association (IDA) and Global Water Intelligence (GWI). The in-stalled base of desalination plants around the world now has a capacity of 78.4 mil-lion m3/day compared to 47.6 million m3/day at the end of 2008, according to the latest edition of the IDA/GWI Worldwide Desalting Plant Inventory.

The growth of the market for desalina-tion reflects the fact that coastal commu-nities are increasingly turning to the sea to meet their drinking water needs, while inland there is a tendency for groundwater to become increasingly brackish over time. Around 60% of desalination capacity treats seawater; the remainder treats brackish and less saline feed water.

Historically, large scale desalination has mainly been built in the Gulf region where there is no alternative for public water sup-ply. The combination of lower cost mem-brane desalination and growing water scar-city means that big desalination plants are

Global desalination capacity rises by 57%Desalination industry enjoys growth spurt as water scarcity starts to bite, notes IDA/GWI data

DEWA plant: An integrated desalination and power plant. Historically, large scale desalination has mainly been built in the Gulf region.

now being built outside the Gulf. The largest membrane desalination plant in the world – the 444,000 m3/ day Victoria Desalination Plant in Melbourne Australia – came on line last month, but it will be soon surpassed by the 500,000 m3/ day Magtaa plant in Algeria, and the 510,000 m3/day Soreq plant.

The largest thermal desalination plant in the world is the 880,000 m3/ day Shoaiba 3 desalination plant in Saudi Arabia, although this will be displaced in 2014 as the larg-est desalination plant in the world by the 1,025,000 m3/day Ras Al Khair project in Saudi Arabia, which uses both membrane and thermal technology.

Christopher Gasson, publisher of Global Water Intelligence said, “At the moment, around one per cent of the world’s popula-tion are dependent on desalinated water to meet their daily needs, but by 2025, the UN expects 14% of the world’s population to be encountering water scarcity. Unless people get radically better at water conservation, the desalination industry has a very strong future indeed. Seawater desalination is the only additional renewable source of freshwat er available on this planet.”

“In the short term, however, it is likely that there will be a lull in the market because it will take a bit of time for demand to catch up with the amazing build-out of desalination plants we have seen over the past five years,” he added.

“Growth in desalination is not linear, and it is tied to many other factors including the cost of oil, prices of certain commodities, and availability of financing. However, the un-derlying factors that have driven the growth of desalination remain in place, including population growth, industrial development, pollution of traditional water resources, and climate change. At the same time, the de-salination industry has done much to lower the cost of desalination by developing tech-nologies that lower energy requirements, implementing practices that achieve greater operational efficiency, and adopting meas-ures to enhance environmental stewardship,” said Patricia A Burke, Secretary General for the IDA.

Desalination is now practiced in 150 coun-tries, from Australia to China and Japan, the United States, Spain and other European countries, the Middle East and North Africa.

INDUSTRY NOTES

By 2025, the UN expects 14% of the world’s population to be encountering water scarcity.

22


INDUSTRY NOTES

Invests USD1 billion in innovation, healthcare and energy initiatives; announces expansion Manufacturing Technology Centre and launch of new Pressure Control Facility in Dammam.

Building on eight decades of part-nerships in Saudi Arabia, GE an-nounced a slew of measures aimed

at strengthening its manufacturing and localisation commitment in Saudi Arabia together with an investment plan focussing on three main areas central to the King-dom’s current developmental thrust - in-novation, healthcare and energy.

The USD1 billion (SR 3.75 billion) in-vestment plan announced by GE is in line with the Kingdom’s Vision 2020 and Ninth Development Plan to diversify the econo-my, strengthen manufacturing capabilities, and build human resources. Under this, GE will partner with public and private sector leaders to roll out path-breaking projects in innovation, healthcare and energy focusing on localisation and driving the growth of Saudi human capital.

GE’s Vice Chairman John Rice said: “With this investment, GE will promote in-novation and human capital development, which in turn strengthens the country’s manufacturing capability and supply chain in healthcare and energy. We are commit-ted to work in partnership with key min-istries and customers to support the Saudi Vision of boosting the country’s competi-tiveness and building a knowledge-based economy. Today, we live in a world where multi-way partnerships can better unlock potential; empower a strong local work-force and stimulate the SME sector to build local technologies and solutions that ad-dress pressing challenges.”The USD 1 billion investment focussing on innovation, healthcare and energy will help double GE’s workforce in the King-dom to over 2,000 by 2015.

Bringing innovation to marketThe new GE Innovation Centre, which will come up in Dhahran Techno-Valley in the Eastern Province, will focus on co-creating local solutions, with customers, universities and industry organisations, to address the Kingdom’s priorities in driving cleaner and more efficient en-ergy solutions, as well as sustainable and affordable healthcare solutions. The setting up of the Centre follows a strategic agreement signed by GE and King Fahd University of Petroleum & Minerals (KFUPM) in 2011 to build a full-fledged GE technology centre and office in Dhahran Techno-Val-ley. Planned for inauguration in early 2013, the Innovation Centre will seek

to cultivate a culture of home-grown in-novation and R&D led by Saudi talent. In addition, GE will work with strategic partners to bring its renowned global ecomagination Challenge to the region. The ecomagination Challenge is an inno-vation platform where businesses, entre-preneurs, innovators and students share their best ideas, and here, the focus is on how to create and build energy efficiency solutions for a desert environment.

GE also announced the first global roll-out of new energy efficient technol-ogy programme to enhance heavy fuel oil (HFO) conversion to meet Saudi’s grow-ing demand for electricity while localis-ing capabilities in the power generation and oil and gas sectors.

GE strengthens localisation commitment in Saudi Arabia

Signing of the agreement with Saudi Aramco’s Wa’ed to develop SMEs.

At the ground-breaking ceremony for the phase 2 expansion of GE Manufacturing Technology Centre, Dammam.

23

INDUSTRY NOTES

Boosting manufacturing GE also announced the ground-breaking of the second phase of the company’s Man-ufacturing Technology Centre and the in-auguration of a new and advanced Pressure Control Facility, both based in Dammam. These are expected to further contribute to localisation in the energy sector and boost domestic manufacturing capabilities.

Currently over 170,000 sq ft in area, the second phase expansion of GE Manufac-turing Technology Centre will more than double its area to about 390,000 sq ft. The facility recently completed its first year of operations, and serves more than 50 cus-tomers in the Kingdom, the Middle East, Africa and Europe. In the first year, the Centre extended service support to drive the efficiencies of over 450 gas turbines.

After the expansion, the technology centre will feature five key components: a modern manufacturing facility of high-end equipment for the power, water and oil and gas industries; a service and repair centre for advanced turbine equipment; a training centre that offers the latest technol-ogy and managerial courses for college stu-dents, field engineers and other power in-dustry professionals throughout the region; a Repair Development Centre; and a state-of-the-art high-speed balance facility.

Being the first company to manufac-ture oil and gas vibration systems in the Kingdom puts GE in a position to provide close product management and engineer-ing support to customers and also involve them in the design and assembly process. The direct benefits to the industry include the provision of local fabrication and ma-chine shops, and boosting the supply chain for feeder industries in addition to reduc-ing cycle time for customers. The new Repair Development Centre will

focus on core engineering to develop new repairs procedures by collaborating with international and regional partners. The Centre will be strategically aligned with the needs of the Kingdom and the wider Mid-dle East and North Africa region, focusing on power, water and oil and gas repair de-velopment processes.

The high speed balance facility is envis-aged to be the only facility of its kind in the Kingdom. With an installed fleet of more than 500 GE gas turbines supporting over half the power generation in the Kingdom, the facility will provide advanced repair ser-vices that extend the life of the equipment, and boost safety and reliability.

The construction of the high-speed bal-ance facility as well as office space expan-sion will be completed next year with the rest of the components slated to be com-pleted in phases by 2014.

Steve Bolze, President & CEO, GE Power & Water, added: “One of the significant ad-vantages offered by our new investment is our ability to offer localised design, engi-neering and repair services for all sectors of the energy industry through active col-laboration with our partners. This is of crit-ical value in driving the overall operational efficiencies, and now our partners can benefit from significant time-savings with local cutting edge repair and technical ex-pertise. Additionally, by investing in talent, GE will play a key role in developing a pool of skilled technologists who can partner in meeting the energy sector growth require-ments of the Kingdom.” The Manufacturing Technology Centre currently employs over 350 technologists and is training more than 100 others un-der an agreement with the Technical & Vocational Training Centre (TVTC). The participants are being trained in key areas

of maintenance and repair of gas turbines, electrical motors and generators that are critical to the efficient generation of elec-tricity in the Kingdom. Over 50% Saudisa-tion has been achieved to date at the Centre.

The new Pressure Control Facility, lo-cated in second Industrial City, will manu-facture key equipment such as wellheads, and valves that support the upstream oil and gas sector. The facility, which is API and ISO certified, employs over 75 Saudi professionals in addition to offering train-ing programmes for young Saudis.

Another key aspect of GE’s investment is a focus on developing a Saudi-based supply chain that promotes the manufac-turing sector of the Kingdom, which has been ranked as the 17th most competitive nation by the World Economic Forum Global Competitiveness Report 2011-12. GE has signed an agreement with Saudi Aramco’s Wa’ed to develop and identify opportunities in the Kingdom for small and medium enterprises. With access to funding and training, Wa’ed and GE will provide new growth opportunities for young Saudis and establish a supply chain for manufacturing in energy and oil and gas in the Kingdom. This part-nership could also potentially lead to stronger international collaborations and knowledge transfer that will benefit the Saudi entrepreneurs.

GE Chairman & CEO Jeffrey Immelt said: “The expansion of the landmark GE Manufacturing Technology Centre in Dammam will contribute significantly to enhancing manufacturing and localisa-tion in the power sector of Saudi Arabia. Through the second phase investment and the opening of the Pressure Control Facility, we are delivering on our prom-ise to strengthen our investment and partnership commitment to our valued customers in the Kingdom. It will also create jobs for young Saudi profession-als and promote the Kingdom’s human capital through advanced training on cutting edge technologies. We are de-lighted to join hands with our long-term partner Saudi Aramco to further develop a Saudi-based supply chain in the manu-facturing sector that will promote entre-preneurship among young Saudis.”

GE Chairman & CEO Jeffrey Immelt with the first group of technologists trained at the Manufacturing Technology Centre under a joint programme with the Technical & Vocational Training Centre (TVTC).

Encouraging SMEs in the energy sector


SHORT TAKE


At Rockwell Automation, our value proposition is quite straightfor-ward– first, we want to help cus-

tomers reduce their project lifecycle cost – in other words, help them implement projects at the right price, at the right time and deliver to expectations. Delivering a project at the right time is critical. For ex-ample, if your oil field is ready for produc-tion in February, but if your water desali-nation plant will be ready only in May, then you are in trouble.

Second, we want to help customer im-prove the operational performance of their assets. In the water sector, the plant lifecycle tends to be very long. Apart from treatment plants, operators have to man-age huge networks whether it is for water distribution or sewage collection. The key challenge in the region, in the case of wa-ter networks, seem to be leakage which is range of 15-40% depending on the coun-try followed by energy efficiency. So we work with our customers to help them reduce leakage, improve energy efficiency and manage their assets more efficiently and in a sustainable manner.

The third part of the value proposition is about regulatory compliance by giving people the right data or the right level of

EMEA Water Industry Manager, Rockwell Automation

management at the right time. Increasing-ly, the water sector is being subject to great-er regulation and water quality norms are becoming stricter. The people who manage the water infrastructure need to be able to know how their plants and networks are performing. Even if the existing infrastruc-ture doesn’t have our products, we can still pull data from all the points into a dash-board for them to take decisions, whether it is about plant efficiency or process con-sistency or plant security. At Rockwell Auto-mation, we believe that we provide the best integration of every asset in a global archi-tecture. Unlike some of our competitors, we don’t believe that everything has to be sup-plied by us. Rather, we believe in partner-ships. There are companies like Cisco and Endress + Hauser out there, who possess state of the art technologies and equipment. We believe we can add value by co-operat-ing with them so that we can integrate their products into our architecture and propose best in class solutions to customers. Our selling point is easy integration, which is easy for the project people, easy for the op-eration and maintenance people.

Our consultants work with partners to advise customers during the early stages of the project about the best architecture,

Unlike some of our competitors, we don’t believe that everything has to be supplied by us. Rather, we believe in partnerships.

Vincent Guillaumie

best in class solutions and best practices. The emphasis is on helping the customer address issues like operational efficien-cy, optimising plant design and the like than on selling specific Rockwell equip-ment. We also educate the customer on the need to drive specifications so that he doesn’t end up with a jigsaw of differ-ent suppliers. Without that, project costs could go up and operations may turn out to be a nightmare.

The fact that we are an approved supplier worldwide for global water companies like Veolia Water, in this case for control and power solutions, has helped established us as a serious player in the water industry. In the Middle East, we also have partnerships with local distributors and system integra-tors for supplying, installing and commis-sioning our solutions because that’s how market prefers to work. Our partners have been qualified and trained by us, have ref-erences in the specific industries and can deliver all the value of Rockwell Automa-tion solutions in the specific local market, equipped as they are with knowledge of local rules, language and environment. We believe that we have to bring best in class partners to define the best in class solutions for the customer.

25


ON THE RECORD

Could you give us a brief overview of your business and your role in the context of setting up the Manufactur-ing Technology Centre in Dammam?

We operate the service business around the world in terms of part fulfilment, field ser-vice, craftwork as well as major service and repair activities. Power Generation Servic-es provides full support to GE’s global in-stalled base of gas turbines, steam turbines and generators. I spend my first 10 years in GE with the aviation business in a variety of roles including General Manager of Avi-ation Parts, and Managing Director of the engine overhaul facility in Wales. In 2005, I joined GE Energy as General Manager of Parts & Repair Services. Around this time, we began to develop new Centres of Excellence (CoE) around parts and repair services globally. Given the technological advancements, we felt that it made sense

Karl S Fessenden, President & CEO, Power Generation Services, GE Power & Water is responsible for developing and delivering a global services strategy that offers electric utility customers the technology, knowledge and insight they need to manage the entire lifecycle of their power plants. Power Generation Services is a USD7-billion business with about 7,600 employees in more than 100 countries globally. Karl, who joined GE Energy in 2005, has more than 27 years of engineering, operations and leadership experience. He also played a key role in establishing the GE Manufacturing Technology Centre in Dammam, Saudi Arabia, the most advanced technology centre of its kind in the region and also the largest such GE facility in the world today. At the sidelines of an event launching the Centre’s phase two expansion, Karl spoke to Anoop K Menon on the role it will play in advancing GE’s localisation commitment in the Kingdom, and the benefits the centre brings to customers in the region and at large.

The service proposition

to put major CoEs around the world where we could invest in the latest technologies, more plant and equipment and reap the benefits of mass and scale. In Saudi Arabia, the service side was looked after for a long time by the Middle East Engineering Ltd Saudi Arabia (MEELSA) facility, set up in partnership with Ali A Tamimi & Sons. Four years ago, we started the journey of investment in the GE Manufacturing Tech-nology Centre. In that sense, it is my baby.

How did you put your aviation busi-ness experience to use in the power generation services business? How critical is your business to GE Power & Water’s overall growth?

The aviation side, because of the nature of the industry, has a lot of structure and fo-cus on quality and execution. Growing up in that industry, I learned a lot about the

importance of quality, timeliness and using advanced technologies to push the enve-lope for the customers. This background proved really useful when I moved into the energy business. GE’s leadership develop-ment is often the case where they move people across different industries. The con-cept of scale, investment in technology and best practice sharing was something I lev-eraged from what we did in the repair and overhaul side of aviation business.

Of course, the service business is a critical aspect of GE’s industrial business portfolio, be it aviation, energy or trans-portation. It’s a key reason why a lot of our customers buy our products in the first place; they expect us to assist them in ensuring that their assets are operat-ing at highest reliability, availability and efficiency. Typically, the thermal business will sell and install the turbine unit with our projects team. We would be a partner through that process and thereafter, carry on with a long term service contract with the customer.

Most of our multi-year agreements are contractual service agreements (CSA) where we manage the interval, the main-tenance and the overhaul of the turbine through its life. We also introduce new technologies, like technologies to do repair development (like we did in Dammam), so that we can refurbish parts and save the customer the cost of investing in new parts. Thus, we are a partner, right from installa-tion all the way through to the product life-

26

ON THE RECORD


cycle – it could be a traditional plant where we would come in at different intervals, do combustion inspection, hot gas path or other major inspections. In many cases, we refresh the technology and bring in new technology that extends the life of the plant.

Thus, my business not only manages, operates and maintains on behalf of our customers and partners with them, we also infuse new technologies in the plant. For example, we have Dry Low NOx (DLN) combustion systems for gas turbines that lower emissions and increase flexibility. The DLN systems extend the interval life of our inspections, which means more uptime for customers and significantly lower NOx emissions. That’s a big ad-vantage we provide to our customers who have to do it for regulatory reasons or even do it because it is the right thing to do as it gives the plant more flexibility and extends the interval.

You seem to operate in a business environment where you have a lot of independent players offering similar services at competitive rates. So how do you differentiate your business?

Obviously, as the OEM, we have scale, breadth and knowledge of our technology. As GE, we have invested over $10 billion over the past few years in developing new technologies, not only for turbines but also for repair development, inspection capa-bilities. No one else has the level of technol-ogy, understanding of the whole system, of the turbine and the power plant and a 125 year legacy as we do. That’s what we bring to the table when a utility partners with us.

How did GE Power and Water arrive the a decision to set up its largest ever service centre in the Kingdom?

The idea of this centre literally started with a phone call to my desk at 7.00 am in At-lanta from John Krenicki, the vice chair-man and CEO of (erstwhile)GE Energy. John said that we really need to invest in the Kingdom and bring in our repair and service capabilities. GE has 500 gas tur-bines in the Kingdom and 50% of the pow-er generated in this country is provided by GE technologies.

Our decision to invest in service and repair CoEs globally is guided by several factors. We look at our installed base in the coun-try and the region, our ability to do busi-ness and partner with customers, and the competitive nature of the workforce, the level of their capabilities. We have been very happy partnering with the Saudi gov-ernment through TVTC and KFUPM, and these partnerships helped us get great Sau-di talent that we put through local train-ing as well as our own technical, leadership and management training. I was thrilled to see some of the students we hired three years ago presenting to the GE Chairman and doing a fantastic job at that. Also, we have been partnering with Saudi Electricity Company (SEC) and Saudi Ara-mco for many years, and they were vocal on the need to develop local capabilities as well as the capabilities of the country. For instance, SEC had been talking to us for a high speed bunker for a long time, and the one that we have here in Dammam will provide capabilities to cover 90% of our installed generation base in the Kingdom. We are very happy with the support extended by the Saudi authorities and getting clear di-rections on what their expectations are.

GE had announced earlier that the Dammam facility will have a global service footprint. How would you ex-plain this level of confidence?

We have been doing business for eight dec-ades in the Kingdom, so we understand the issues, the challenges and the opportu-nities. As we refreshed our service centre network over the past five years, we looked at developing major global centres of excel-lence that provided advanced technology repair, shorter cycle times, more cost com-petitiveness and better quality. When we invest in CoEs, we look at the investment for the installed base – country, region and globe. The Dammam centre, because of modern logistics, can and does support Europe, the Middle East and Africa.

We had a dialogue with our customers, especially with the ones in Europe, over our investment plans. We also brought people to Dammam as we developed the centre.

I think it is really about working out how to maintain the quality, technology,

turnaround times and cost competitive-ness of the repairs that we do here. And as you succeed in that, stand behind your work, and get very high quality levels, and as customers come here and see a centre that rivals any service centre of any OEM or capability in the world, they become convinced. In fact, what matters is meet-ing their Critical to Quality (CTQ) param-eters. The Fulfilment Five - Safety, On-time Delivery, Productivity, Quality, Cost - are the key five metrics we drive our teams to. These customer-facing metrics helps ensure we meet all the customer require-ments and earn their business again.

When we invest in Centres of Excellence we look at the investment for the installed base – country, region and globe.

27


What is Honeywell’s positioning in the LED Lighting segment?Honeywell has a 40-year heritage in devel-oping LED lighting technology and its aim is to be the best supplier of LED solutions, where the customer is fully aware of the to-tal cost of ownership.

Even before any product is evaluated, Honeywell ED&S can offer advice on the feasibility of implementing LED lighting and on how to get the best from the solu-tion. The additional investments made by the Honeywell ED&S business into skilled people, internal resources and services means the customer will receive exempla-ry service from start to finish. Our global consulting service includes site surveys, devising bespoke lighting schemes, pro-ducing detailed energy and cost saving cal-culations to arm facilities managers with proof that an investment in LED lighting will reap a good return on investment; this is important when trying to get buy-in from Board members.

LEDTRENDS

How would you classify or categorise the market (users) for LED lighting today? Where do you see the biggest opportunities in LED lighting appli-cations?LED lighting is now drawing huge inter-est because of its tangible energy-saving benefits, in light of new, enforced energy efficiency targets.

Some key areas where we’re seeing the fastest uptake include infrastructure pro-jects – such as tunnels – and public utility spaces such as airports. LED technology is also being used in architectural lighting for residential, commercial, hospitality and mixed-use developments. Commercial ap-plications are also increasing in areas such as warehouses, cold storages, with a focus on high-bay and panel lighting for these applications.

What are the benefits of embracing LED Lighting? Do you believe that LED technology will replace tradi-tional lighting in general lighting ap-plications?Fifty per cent energy savings provides a concise business case! There are many benefits that LED can provide, with envi-ronmentally friendliness, lower mainte-nance costs and longer lamp life being the key ones. With a Honeywell ED&S LED

lamp, for example, we have a unique exter-nal driver design that allows us to offer a 60,000 hours warranty – that equates to 10 years of normal usage. We are also seeing customers report better quality of light-ing, especially in retail environments and commercial offices, where colour repre-sentation and contrast is important.

LED technology will replace tradition-al lighting once price parity and the ROI are recognised by users. The question is when. Honeywell ED&S believe the an-swer is now.

LED is perceived as costing 10 times more than incandescent and fluores-cent lighting. Why this cost differ-ence? Has this affected LED’s market potential?In the residential lighting market this maybe the perception, but in the com-mercial market the initial costs are much closer and over time can be much, much cheaper.

LED lighting technology from Honey-well ED&S can offer a 50% energy sav-ing when compared to traditional light-ing. Capex costs for new technology will command a premium, but these can be alleviated by looking at the payback period. LED is so efficient that payback can occur within two years, so while the

Q&A: James Chorlton, Business Director, Honeywell Electrical Devices & Systems (ED&S)

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initial investment is not low, the overall long-term benefits and savings are sig-nificant. As more and more businesses are educated in these benefits, adoption is rising with increasing speed.

What do you consider most impor-tant and exciting projects/products for this year for your company?Our LED offering is designed to meet the needs of any facilities or energy manager looking to reduce energy consumption and meet energy reduction targets, in all build-ings and facilities. Energy consumption is a worldwide problem and Honeywell ED&S recognise that we need to align products to

suit our customers, to address this problem. Our target audiences are varied and include health-care, education,

retail and com-mercial. However, one of

our main focuses is on high-bay lighting for

warehouse applications and panel lighting for commercial ap-

plications. Both these areas consume a large amount of energy, and the business case is typically easy to demonstrate.

Could you share with us your growth plans? For the Middle East, we are actively pur-suing opportunities in warehouse and cold storages, car parks and shopping malls. The region presents strong potential for growth in all these areas, and LED light-ing alone can bring substantial savings. We have found that when we combine LED lighting with good sensor control, savings can exceed previous expectations, which leads to best practices adopted even in non-LED environments.

What do you consider the major challenges in the LED lighting indus-try in the years ahead? It is important for us to make sure that we are helping customers with their business cases and not taking the short-term view. According to McKinsey & Company, LED lighting has the potential to be the domi-nant technology in domestic and commer-cial lighting by 2015 so choosing the right supplier and ensuring it is implemented correctly is the key in this adoption pro-cess. Honeywell ED&S has a vested interest in delivering top-rate solutions, which is why a dedicated consulting team will work with the customer to prove the benefits, not just present them. For example, we of-fer pilot installations so that our customers can experience these benefits first hand.

What is the role of the government in driving LED adoption? Sustainability is a topic of growing inter-est both in the Middle East region and worldwide. Governments are increasingly turning their attention to the ‘green build-ings’ concept – and LED is a key building block of such important initiatives. There is also growing awareness among corpora-tions and customers themselves to look at LED as a positive step towards corporate responsibility. This awareness continues to grow with the sustained educational efforts that Honeywell ED&S and others are pro-moting throughout the industry.

According to McKinsey & Company, LED lighting has the potential to be the dominant technology in do-

mestic and commercial lighting by 2015. Key trends that we are seeing in the LED lighting market as the technology develops include a move towards

higher output LED chips (lumens per watt), enhanced IP ratings, a choice of form fac-

tor and application and greater lighting system intelligence.

What are the technology trends

you see in LED lighting?

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Recently, LED lighting has been placed in the spotlight – no pun intended – as more and more peo-

ple have become aware of the advantages LEDs offer. Already, LEDs have witnessed dramatic market growth. This growth isn’t temporary either. The global LED market is expected to grow another 13.4% (or $10.1 billion) in 2012 and about 40% with-in a few years.

The impressive rise of LEDs is being driven by the technology’s superior energy efficiency. Increasingly sophisticated de-signs are hitting the market, and consum-ers are lining up to buy lights that use less electricity, cut down on utility bills and ultimately help pave the way toward more eco-friendly buildings.

In terms of technology, Asian LED lighting manufacturers in particular have jumped out in front. This is large part due to the booming demand in Asia for lighting solutions as well as the massive investments on the part of manufacturers to better meet that demand. Recent research on the LED market and predicted that companies in South Korea, Japan and Taiwan would take more than 60% of the global LED market in 2012. To reduce the constant increase in energy consumption, their respective gov-ernments have enacted several regulations

regarding energy consumption to support companies and individuals who purchase high priced energy efficient products such as LED lighting.

With that in mind, it is worth taking a closer look at these Asian manufacturers to gain insight into how the industry has transformed itself and what might be ex-pected in the years to come. One South Korean company in particular is demon-strating an uncanny knack for coming up with lighting solutions to meet an array of architectural needs.

LED lamps have long garnered attention as eco-friendly alternatives to conventional lamps due to their remarkable energy ef-ficiency. They have also earned praise for having longer lifespans. Less frequent replacements translate to less waste and less expenditure.

Lifespans aside, energy efficiency is a key priority for consumers, particularly in large scale projects. Conventional fluores-cents use a lot of energy and contribute to burdensome electricity bills at the end of the month. LEDs use solid-state technol-ogy, which requires less energy to operate.

LEDs make eco-conscious consumers happy in other ways, too. Conventional lamps contain mercury and an inert gas. The mercury in particular constitutes an

With DY Kim President, LG Electronics Gulf

environmental hazard when the lamps are being disposed of, and they need to be disposed of more frequently than LEDs. LED lamps, on the other hand, don’t use mercury.

With respect to the latter advantage, LEDs are truly eyeball-friendly. In tech-nical terms, the PAR16 and MR16 de-liver a high light output and a high color rendering index (CRI) providing better presentation for exhibits without flick-ering or hazardous wavelengths that deteriorate valuable items. In non-tech-nical terms, they produce just the right amount of light, and the right quality of light, to help the human eye pick up the colors of various objects more naturally and with less eye fatigue. In other words, the PAR16 casts light that is as natural as sunlight, while the MR16 provides clean and bright light, creating a stylish atmos-phere. Both are ideal for a variety of in-terior spaces where people are more re-liant on accurate eyesight – department stores, art galleries, cafés, photography studios, offices and so on. Specifically, as for LED Lights, LG’s Flat Light is an easy to install option that is roughly the same size as ceiling textiles, while LG’s Down-light has the same dimensions as conven-tional down-light.

LIGHTING

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The third edition of the H2O Water Awards will be presented to outstanding nominations in the following categories:

PROJECT CATEGORY• Best Water Project• Best Wastewater Project• Innovative Use/Application of Technology• Water Efficiency Leader• Water Communications & Marketing

PRODUCT CATEGORY• Best Water Product• Best Wastewater product• Water-Efficient Product of the Year• Most Innovative Product/Technology of the Year (Industrial & Commercial)

Celebrating the oustanding achievements of the MENA Water Sector.

2012

To submit your nominations, please visit: www.h2ome.net/awards

21-November 7:30 pm onwards

The Address Dubai Marina Dubai, UAE

SPONSORS

Vedran DedicBusiness Development Director Email: [email protected]

Tel:+971 4 440 9154 / M +971 55 864 4831

Deep KaraniBusiness Development Manager

Email: [email protected]:+971 4 440 9158 / M+971 50 858 5905

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GOLD SILVER

Organised by:

Sustainability Champion

COVERSTORY


Year of implementation: 2008•Solarpanels:117•Storagetanks:3•Expansiontanks:5

Benefits•Savingondieselcosts:AED230,000/Year•Savingondieselconsumption:100,000litres/year•ReductionofCO2emissions:200tonnes/year

Solar panels:97(Integratedtotheoldsystemtomaximiseenergyusage)

Expected benefits•Savingsondieselconsumption:85,000litres/year•ReductionofCO2emissions:180tonnes/year

The targets are bold notwithstanding the muscle and fire-power of the world’s second largest chocolate company behind them - zero fossil-fuel energy use and zero green-

house gas emissions (GHG) by 2040, with similar commitments hinted for water and waste reduction as well; the short term targets that Mars Inc has set for itself on that road are no less daunting - reduce direct fossil-fuel energy use and GHG emissions, and also water use by 25% each by 2015; achieve zero waste to landfill by 2015. More important, these targets are applicable to Mars sites all over the world including the Dubai site, which serves as the chocolate major’s Middle East headquarters. Mars GCC, based in the Jebel Ali Free Zone (JAFZA) in Dubai, was established in 1993 with the chocolate factory starting operations in 1997. The latter has a capacity of 45,000 tonnes of chocolate per annum.

Mars’ approach to business, as the company’s website notes, is guided by the five principles of Quality, Responsibility, Mutuality, Efficiency and Freedom. Thus, from a sustainability standpoint, the company aims to create lasting, mutual benefits for all those involved in its business success by creating positive social impacts, minimising environmental impacts and creating economic value. In fact, the message from Mars’ CEO Paul Michaels (which kicked off the presentation that supplied the basis for this article) lays to rest any doubts on that front: ‘We will make a difference in the lives of people and the future of our planet because this company has decided to make sustainability a core value in how we run our plants, design our processes, support our supply chains, in fact, in every way we do business.’

“Sustainability has become an integral part of our operations be-cause the more we grow, the more we are able reduce our impact on the environment” says Christine Greaves, Corporate Affairs Manager, Mars GCC.

Globally, Mars has identified its operations (factories and of-fices) as the second-greatest area of impact on the environment, after its supply chain. To improve operational performance and mitigate environmental impact, Mars has developed Sustainable in a Generation (SiG) programme comprising long-term commit-ments and short term set targets for fossil fuel energy use, GHG emissions, water use and waste reduction. Except for waste, the baseline for all areas is 2007 across all Mars sites worldwide.

The responsibility for meeting these commitments at the Dubai site lies with Mansoor Mohammed, Safety, Environment and Secu-rity Manager, Mars GCC. The 2040 goal of zero fossil-fuel energy use, he said, will be realised by reducing the site’s energy consump-tion by three per cent every year and replacing fossil energy with renewable energy, which he feels will be easier for the Dubai site due to ample sunshine.

Decoding Mars GCC’s approach to energy and water conservation

PHASE 1

PHASE 2

Solar Garden

By Anoop K Menon

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•Numberoflightsreplaced:628•Energysavings:544MWh/year•CO2emissionreduction:290tonnes/year•Savingsonenergycosts:AED208,000K/year

COVERSTORY

Though the short term target for water use reduction is 25% by 2015, the long term commitment is still being defined. “In the area of water use, our target is to reduce consumption by three per cent every year. We haven’t set a long term target as chocolate produc-tion consumes a lot of water; we also have to meet food safety re-quirements, clean our machines on a regular basis and all of this require water.” However, Mars’ long-term objective is to achieve zero degradation of water quality. In other words, the quality of water entering and leaving any of its sites should be the same.

Mansoor claimed that Mars GCC is on track to achieve its 2015 energy and water saving goals. However, with zero waste to landfill turning out to be a “bit of a challenge”, the company is striving to achieve this goal by 2014 with internal efforts geared towards achieving it by 2013.

Projects in parallelTo cut down on its carbon footprint, Mars GCC has replaced diesel powered boilers with solar panel arrays to heat the water used in the chocolate manufacturing process. “Chocolate needs to made at a certain temperature, otherwise it will not flow through the pipe,” explained Mansoor. The factory has managed to progressively re-duce dependence on diesel-fired boilers, except during the night, but even here, insulated storage tanks are being used to keep the water warm for a longer period, helping cut down diesel usage. (See BOX SOLAR GARDEN). Today, solar energy supplies four per cent of the Dubai site’s energy consumption. “While the first two phases of the solar garden catered to the moulding line, phase three, which was launched this year, will cater to the fill-bar line,” said Mansoor.

Also, a flash steam recovery system implemented last year has helped the factory to reduce the energy needed to heat the water in its boilers. “We used a flash recovery system to collect the return steam from the boiler and send it into the boiler’s feed water tank. Normally, the return steam escapes into the atmosphere. Since the steam is already heated, less energy was required to heat the water,” explained Mansoor.

To reduce electricity consumption, the company equipped its factory with energy efficient induction lighting. “Halide lighting emits more heat, which drives up air-conditioning requirements. So we switched to energy efficient induction lighting last year as they are brighter and emit less heat,” said Mansoor, adding that induction lighting was found to be better suited to the factory en-vironment than LED. Mars GCC has also installed solar parking lights in its car parking area.

In recognition of the fact that the bulk of region’s power con-sumption is driven by cooling needs, Mars GCC has installed wind ventilators and ammonia chillers to save electricity. “In 2007, En-vironment, Health and Safety (EHS), which is the environmen-tal regulatory body for Jebel Ali Free Zone Authority (JAFZA) advised to replace our Freon chillers as Freon is a Green House Gas (GHG). Ammonia chillers are environment-friendly and consume 40% less energy compared to Freon. Also, the protec-tion systems for ammonia chillers have improved a lot. So we put in 1,839 tonnes of ammonia refrigeration in two phases between 2010 and 2011. Though ammonia chillers consume more water,

Years of Implementation: 2010 & 2011 Benefits•30%reductionincarbonemissions•1,839tonnesofrefrigeration•50%savingonelectricalpower•Ammoniachillerdrainwaterisusedforflushing oftoilets

Induction Lighting

Switching to Amonia Chillers

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•Numberoffans:10•Energysavings:182MWh/year

COVERSTORY

we have achieved net saving of 30% in water and energy consump-tion.” This year, the company has embarked on a pilot project for solar air-conditioning.

While sustainability projects initially target low hanging fruits or small initiatives before upping the ante, Mars GCC doesn’t make such distinctions. Thus, apart from the big ticket initiatives like so-lar arrays and ammonia chillers, the Dubai site has also implement-ed smaller initiatives like solar tubes and also waterless urinals and sensor taps on all faucets that have reduced water consumption by 600,000 litres/year and 200,000 litres/year respectively.

Mansoor continued: “Our capex and opex sustainability projects have always been implemented in parallel. Capex projects calls for investment while opex projects are mainly team driven. We have a budget allocated for sustainability projects every year by the global team. In addition to that, we also have local budgets.”

“At the end of the day, it is not only about how much it costs, it is also about reducing our impact on the environment,” added Greaves. “We get best practice recommendations from the global team but it is our call to take up what is relevant for our site.”Ongoing capex projects include wastewater treatment process up-grade to enable treated water to be re-used for irrigation and a Re-verse Osmosis (RO) system to polish the treated effluent for re-use in ammonia chillers. “We plan to reuse 100% of the wastewater,” said Mansoor.

Mars GCC is also putting in around 50-60 water meters in the steam lines and other areas. These will supplement the bulk con-sumption readings from the utility meters to help understand con-sumption patterns and pinpoint problems.

Zero waste?To tackle the goal of achieving zero waste to landfill by 2015,

Mars GCC has set up team-driven initiative called G-transformers. “By 2040, we want to eliminate waste completely from upstream and downstream activities,” said Greaves. “Our strategy is to re-duce scrap waste, packaging waste and waste from indirect pro-cesses, reuse waste from direct and indirect processes and increase waste recycling in that order.” The core team of G-transformers meets once a week to chalk out strategies. While each team owns the work streams in their areas of expertise, much of the effort is centre around changing mindsets, noted Greaves.

Some of the steps implemented to reduce waste include removal of trash cans from the desks, installing separate bins for plastics, paper and landfill, replacing all plastic cups with re-usable ceramic glasses, giving every employee a personal water bottle and setting up of a recycling area within the site, where employees are encour-aged to bring in waste from homes. Within the offices, the compa-ny has implemented a pooled printing system which has reduced paper use by 50%. Under this system, print jobs sent from the computer are triggered in the printer only after personal identifica-tion. Moreover, all the printers have double side printing option.To deal with plastic waste, Mars GCC recently signed a contract with Dubai-based Ecoplastic Industries which converts plastic into a wood substitute. “Before this, we were stuck with our plastic waste. With Ecoplastic, we have solved the problem,” said Mansoor.To deal with food waste, the company has implemented a Bokashi system on trial basis. The system uses microorganisms to ferment

Year of Implementation: 2010•Solargardenlights:11•Totalnumberofsolarpanels:11•Totalnumberoflightsconnected:33•Numberofenergyefficientexternalfloodlights:35Benefits•Energysavings:162GJ/year•CO2emissionreduction:25tonnes/year

Solar Parking& Garden Lights

Natural WindVentilator

34


COVERSTORY

the organic waste in a special Bokashi bin. The end- product, which looks similar to the waste originally put into the bin, is di-rectly buried in the ground near the trees inside the premises to serve as their fertiliser.

Change challenges “In Europe, environmental focus is embedded in people’s lives,”

said Greaves. “It is a different story here. A lot of the work is around changing people’s mindset. For example, to tackle the challenge of waste, we rely on mass communication as well as one-to-one meet-ings through volunteers”

Messages regarding new sustainability initiatives go out from the top management at Mars GCC. “Before we implement any change, our management communicates to the employees why it is being carried out,” explained Greaves. “Additionally, we have ex-ternal partners and internal experts from the global team visiting us every year to talk about sustainability.”

The company also organises ‘Lean and Green’ workshops to identify and eliminate waste, whether it is water, energy or office management. “We had a workshop for reducing water coming into the wastewater treatment plant,” said Manoor. “We have held simi-lar workshops to identify areas where energy is being wasted.”

“This is not just about fixing a problem, but also addressing it at source. We want to look at front end as well as back end,” added Greaves.

Beyond employees, the company is also roping in its suppliers to participate in its sustainability initiatives.

From a 2007 base line, Mars GCC has managed to reduce energy use by 28% and water use by 17% compared to 2010. In terms of in-ternal benchmarking, the Dubai site is ranked among the top Mars sites in the world for energy and water usage reduction.

“The Dubai site is serving as the role model for Mars’ new fac-tory coming up in Saudi Arabia, which is being built to Gold LEED standard,” revealed Greaves. “Also, EHS uses us as a role model for their sustainability forums and workshops as we were one of the first companies in JAFZA to embrace sustainability in our operations.

Waterlessurinalsinthefactorypremisesareexpectedtoreducewaterconsumptionby600,000litres/year.

“The Dubai site is serving as the role model for Mars’ new factory coming up in Saudi Arabia”

WaterlessUrinal

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TRENDS

We have now gotten used to hearing that many things have ‘intelligence.’ We have

intelligent pumps and controls and even smart materials. The meaning of the term ‘energy intelligence’ is far more coherent, and also, it takes a considerable amount of human intelligence to achieve it. So how do we identify opportunities to save energy?

One approach for achieving quick results is to scrutinise and optimise individual components (pumps, valves, heat transfer media and compressors) or specific subsys-tems (compressed air supply, chilled water supply). A study conducted by the Fraun-hofer Institute for Systems and Innovation Research shows that this is undoubtedly an important first step for many users. Fluid flow machinery such as pumps, fans and air compressors are particularly ‘energy hungry.’ It is considerably more difficult to take a holistic approach and perform opti-

misation at the system level. This approach results in the largest energy savings. Users also benefit from enhanced process stabil-ity and improved product quality.

Energy intelligence on pumpsRealistic estimates (Motor Challenge Pro-gramme, Hydraulic Institute) indicate that pumps consume 20% to 25% of the electricity which is produced worldwide, and the process industry accounts for a quarter of that total. An estimated 490,000 pumps are installed in the German chem-ical industry alone. The majority of all pump systems currently in operation are equipped with centrifugal pumps. The fig-ure worldwide is estimated to be around 73% and can be as high as 85-90% in spe-cific industries like the chemical industry.

Very well engineered pumps and opti-mal configuration of the hydraulic system appears to offer the best route to maximum energy efficiency. Ongoing maintenance

can also reduce energy consumption, be-cause wear and aging reduce the efficiency of all types of equipment. Corrosion and deposits increase flow resistance in pipe networks. Leakage in valves and fittings causes pressure losses in the system. A study conducted by the FfE Research Cen-tre for Energy Economics indicates that the energy efficiency of poorly maintained pumps can decrease by as much as 15%.

In practical application, diaphragm pumps are often twice as efficient as cen-trifugal pumps. However, the efficiency levels which are theoretically possible with displacement pumps are not always achievable, with friction losses being a particular problem.

Friction losses can be broken down as follows: gear unit (5% to 40%), plunger packing (1% to 20%), bearings (up to 3% depending on the oil level), churning loss-es (up to 3%) and hydraulics (2% to X%). Possible solutions are:

Design for Energy EfficiencyPumps and compressors account for a large share of energy consumption in the process industry. Best practices can help reduce consumption by this type of equipment.

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• Higher efficiency gear units (toothed gearing, belt transmissions)•Improved bearing efficiency (no gaskets, lean lubrication, optimal viscosity)•Lean lubrication with the lowest possible viscosity to minimise churning losses•Selection of the shortest possible seals with small seal facesEffective pulsation management on dis-placement pumps reduces losses by more than one per cent. Under normal condi-tions, pulsating flow increases pressure losses. Continuous flow saves energy and reduces stress on all system components.

ErP guideline sets minimum efficiency standardsThe European Ecological Design Directive (ErP) requires manufacturers to improve the energy efficiency of their equipment over the entire lifecycle and reduce the en-vironmental impact. Pumps are of course no exception.

The motor regulation (EC640/2009) ap-plies to nearly all motors rated between 0.75 kW and 375 kW as follows:• Stage 1: as of June 16th 2011 all motors must be IE2-compliant.• Stage 2: from January 1st 2015 all electric motors rated between 7.5 kW and 375 kW must either be IE3-compliant or IE2-com-pliant with a frequency converter.• Stage 3: from 2017 all electric motors rated between 0.75 kW and 375 kW must either be IE3-compliant or IE2-compliant with a frequency converter.

Minimum efficiency standards have been in effect in the US for years and the proportion of high-efficiency motors (IE2) is significantly higher than in Ger-many/Europe.

The ErP Directive is based on the simple realisation that not using energy is the best solution from both the ecological and eco-nomic point of view. A study carried out by the German DENEFF energy-efficient business initiative indicates that energy savings by businesses and households could eliminate the need for electric-ity generation equivalent to 10 nuclear power stations.

The standard principles of good pump design (working point close to the optimal pump operating point, hydraulically cor-rect pipe dimensioning) and the technolo-gies which are currently available to reduce energy consumption (efficient motors,

frequency converters for speed control, hy-draulics designed for optimum efficiency, reduction of losses in the coils and bear-ings) must be exploited to the fullest ex-tent possible.

FfE Research Centre for Energy Eco-nomics has provided some figures for 2009. The investment costs are comprised of the cost of the frequency converter (€100 to €200/kW pump rated power) and installa-tion costs of around €2000 per pump unit (these are guideline figures only).

Impeller modification is another meth-od which can be used to adapt centrifugal pumps to the specific application and re-duce pump energy consumption. Reduc-tion of pump and motor power ratings can cut energy consumption by between 10% and 40%. Modification can cost up to €1,000 depending on impeller size.

Interactive-enabled e-pumpsVariable speed drives not only save energy and money, they also provide interactive capability. Pumps with sensors and micro-electronics become actuators which can ‘intervene’ and affect the process flow.

Communication-enabled pumps with parameterisation features can ensure that a desired pressure level and volume flow are available in the reactor at a certain point in time or that exactly the right mixture of two substances is added at precisely the right moment.Compared to mechanical control with butterfly valves, etc., flow rates can be controlled far more accurately and reac-tion times are shorter when variable speed drives are used. E-pumps adjust the flow rate to match actual demand much faster and with greater precision in response to demand fluctuations. Variable speed pumps are more energy efficient, and they also help stabilise the process.

Overcoming obstaclesWhy have users not taken advantage of all optimisation options? There are a number of possible explanations:•Decisions are based on payback time: At many companies, the maximum payback period is two to three years. The payback pe-riod however is basically a risk management tool, but says nothing about ROI. NPV is the

TRENDS



TRENDS

method to use for that purpose.• Lack of a basic technical understanding: The people responsible for energy manage-ment cannot present the information in a way that managers without engineering expertise can understand.•Spending constraints: Approval is not given for any investment that is not ab-solutely necessary.•Lack of human resources: Opportunities to save energy are understood, but no one has time to take the appropriate action.•Investment only when faults occur: Re-investment is often only considered when systems actually fail. In such situations, the new system must be available quickly and cost as little as possible. No thought is given to lifecycle costs.•Failure to allocate costs: Many compa-nies only know what their overall energy consumption is. No consumption data is available for individual equipment. In many cases, personnel costs for maintain-ing old equipment is not allocated to the specific items. Without information on energy consumption and labour costs for the existing equipment, there is no way to

identify inefficient equipment, and a finan-cial evaluation of equipment optimisation is not possible.

Energy efficiency on compressorsIndustry uses compressed air similar to the way it uses electricity from a power socket. Compressed air is a very important source of energy in many production applications. Because compressed air is safe, reliable and easy to use, cost is a secondary considera-tion for many users. In some cases, a lot of money literally leaks off into thin air. Loss rates of 15% are the rule rather than the exception, and losses can be as high as 70%. All major manufacturers now offer a compressed air audit service to identify leaks, poorly dimensioned compressed air lines and mismatches between supply and demand.

Maximising the energy efficiency of every single compressed air component is necessary, but even more is needed to op-timise the overall system. With the excep-tion of continuous flow production in the process industry, analysis reveals fluctua-tions in the demand profile. If that is the

case, it can make sense to invest in variable speed compressors. A higher-level control-ler is recommended on larger systems, so that multiple compressors at a station can be operated in a coordinated fashion. For example, splitting the load between differ-ent size compressors can increase load re-sponse efficiency.

A central compressed air station has ad-vantages, but extremely long compressed air lines can make distributed supply the better option. Service and maintenance are easier if the compressors are consolidated in one place. Compression generates heat, and a heat recovery system can further re-duce energy costs. As much as 96% of the energy which is supplied to a compressor can be reused as waste heat (for example, for heating purposes).

Compressed air contracting on the increaseMore and more companies are choosing the contracting option which allows them to install a new, energy-efficient com-pressed air system without tying up capi-tal. A compressed air profile (maximum,

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average and minimum consumption) should be created before the compressed air contracting model is agreed with the customer. It is important to understand the consumption dynamics, in other words the magnitude of the fluctuations in volume flow and pressure which oc-cur in a minute/hour/day. What are the compressed air quality requirements? Does the customer operate one shift or multiple shifts?

In essence, customers who decide to purchase compressed air have better cost transparency. High-precision metering ensures that customers are only charged for the amount of compressed air that they actually use. Besides cost trans-parency, ongoing optimisation of com-pressed air costs is the main advantage of the contracting system.

Identifying leakageUsers know that compressed air is an ex-pensive energy source and leakage should be prevented. Compressed air that is “lost” has to be regenerated using energy-inten-sive compressors. Nevertheless, sufficient attention is not always paid to this aspect in practical application.

There are many reasons why leakage can occur in very long compressed air lines that have many branches. High-sensitivity ther-mal flow sensors (turn down ratios as high as 1:1.000) can be used to detect leaks. Us-ing this approach, electricity consumption by a battery manufacturer was reduced by 563 MWh/yr, a 21% savings (roughly 327 MT of CO2) according to ZVEI (German association for the electrical and electron-ics industry).

Energy efficiency on valves and fittingsFollowing the explosion on the oil platform in the Gulf of Mexico, there has been enor-mous pressure to come up with innovative solutions in the oil and gas sector. A num-ber of manufacturers have unveiled LDAR (Leak Detection and Repair) systems.

Pilot-operated safety valves (POSV) have a long, proven track record in the US and the Middle East. These valves have only been approved in Europe since the introduction of harmonised standard DIN EN ISO 4126-4. These valves have the ad-vantage that the sealing pressure increases

up to the set pressure, and as a result the user can operate the valve near the set pres-sure. Also, the backpressure can be higher with POSVs compared to spring-loaded safety valves. Rather than spring force, the system pressure holds POSVs closed. These valves are used in the chemical, re-finery and offshore industries.

Automation reduces operating costsIt is important to distinguish between two different requirements profiles for valve automation. One is open/close control, where the valve merely needs to be moved to the end stop. The other scenario is con-trol mode, where a valve is adjusted to control the flow based on a set value. Valve automation costs depend not only on the actual valves that you select, but also on the mode of activation (manual, electrical, pneumatic or hydraulic). Different com-binations result in different capital invest-ment, operating and energy costs.

There is also another aspect to con-sider. Lower activation force is needed for 90°-valves (flap, stopcock) compared to linear valves (butterfly, gate). The drives are smaller and less expensive.

A number of partners offer the stand-ardised Opos Interface which supports re-liable, efficient solutions that combine in-telligent positioners with pneumatic thrust or swivel drives. The attractive features of this interface include low-cost installation, lower spare part inventory costs, increased reliability and stability and safe positioner replacement during ongoing operation due to built-in shutoff. The advantages are par-ticularly evident in safety-related applica-tions. The non-proprietary interface gives users a wider choice of products.

Inadequate maintenance on control valves can have a very negative impact on process reliability. Complex analysis and the manufacturer’s expertise are required to assess the actual condition of a control valve in the production process. FDT/DTM can be used to provide connectiv-ity to a monitoring console or plant asset management system. The production team can keep valves and positioners under constant surveillance. The goal of suppli-ers is to provide predictive, preventive di-agnostics rather than drawing attention to symptoms. The emphasis is on the condi-


TRENDS

tion of the valve and not on alarm mes-sages. The root cause of the problem is identified and recommendations are is-sued concerning what action to take to extend the functionality of the valve and the entire production process.

Can automated valves contribute to improved energy efficiency? ZVEI has determined that this is indeed the case. Valves with electro-pneumatic position-ers can be used to optimise flow control. Control systems can react much more quickly in high-speed process applica-tions in the chemical and petrochemical industries. Less primary energy is needed to produce larger volumes of product. Product yields increased three per cent simply by installing an intelligent elec-tro-pneumatic positioner and a suitable pneumatic circuit in an OLEX process to separate butane and butene.

Acoustic sensors can be used to detect leaking valves and prevent creeping prod-uct loss. If wear on a flare valve with a DN 150 nominal diameter and an upstream pressure of 20 bar results in three per cent leakage (which equates to a leakage loss of 800 kg/h), product losses can be as high as €10,000/day. Compared to conventional equipment, state-of-the-art positioners consume only a 1/10th as much instru-ment air, significantly reducing consump-tion of auxiliary energy. Conventional positioners consume around €200 to €250 of instrument air per year and device. At a medium-size plant with say 100 position-ers, the savings can be as high as €20,000. Compressed air consumption in the sys-tem can be managed more efficiently.

Manufacturers of pumps, compressors and valves often have to compete on price rather than on the operating cost of their equipment. Everyone involved should reach a consensus that NPV provides a better basis for decision-making than the payback period only.

(Source: DECHEMA - www.achema.de. Disclaimer: The trend reports are compiled by specialised international journalists. DECHEMA is not liable for incomplete or inaccurate information)

40


THE HUB

Rough patches on the CSP road

MI Graduate presents biodiesel project at Rio+20

In the wake of Chinese export restric-tions on rare earth metals, the depend-ence of some renewable technologies

on scarce materials has gained attention. Several players in the wind and PV indus-try are struggling to get away from exces-sive use of restricted elements, such as indium or rare earth metals. Meanwhile, there has been a shared notion amongst solar scientists and industry that Concen-trating Solar Power (CSP) would ‘probably’ be less exposed, since the plants are built using commonly available commodities like steel and glass.

According to a study by Chalmers Uni-versity of Technology, CSP does indeed seem to be largely unrestricted, viewing the material requirements compared to the global reserves. In theory, enough solar plants could be built to cover – at the very least – five times the current global elec-tricity demand.

However, the report also highlights some issues that are likely to pose chal-lenges to the industry. The main point of concern is that silver, today extensively used for reflecting surfaces, will most likely be in short supply in the coming decades even without demand from a booming CSP industry. CSP mirror manufactur-ers might have to look at other reflective surface materials, such as aluminium, to secure cost competitiveness.

“The prospects for strong growth for CSP over the next few decades seem good, but would cause a stir on the global com-modity markets,” said Dr Erik Pihl, lead author of the scientific article.

Following a Greenpeace/IEA Solar-PACES/ESTELA growth scenario where CSP reaches 8000 TWh/year in 2050, the solar plants would consume up to 50-120% of today’s yearly nitrate salt production, and 5-15% of several common materials such as

glass, nickel, magnesium and molybdenum.The report has used data directly from

plant manufacturers Cobra and eSolar for trough and tower plants. These plants have somewhat different characteristics when it comes to material use.

“Parabolic trough plants tend to use a lot of concrete and iron, while the concept of small heliostat tower plants involves higher use of aluminium and stainless steel,” said Pihl. “The common design of a parabolic trough plant also requires more molten salt per MW than a salt-receiver tower plant, even when the former has fewer storage hours. So trough plants appear slightly more sensitive than tower plants to pos-sible salt production bottlenecks, unless other storage techniques can be employed.”

Pihl expects material demands decreasing as plants aim for higher steam temperatures and increased efficiency. He continued: “We see that clearly when comparing a mature design to a novel concept. That does not automatically mean that all material restriction problems will be solved. We might trade a large use of com-mon materials for small quantities of scarce el-ements. It comes down to what alloys we use in pipes, receivers and turbines.”

Higher temperatures means more use of high quality steels, but alloy materials such as molybdenum and niobium have restrictions in both stock and production.

“There might be enough for CSP alone, but there are many other uses,” said Pihl. “That could be a problem in the more distant future. In the short term, substituting silver and in-creasing nitrate salt production should be the first priority.”

Rasha Abd Rabu, Master’s graduate Mechanical Engineering and a Re-search Assistant at Waste to Energy

Laboratory, Masdar Institute, showcased her project titled ‘Dual Chamber Tubular Reactor for Continuous Transesterification of Waste Cooking Oil’ at the Rio+20 Sum-

mit. Her study showed that biodiesel pro-duced from waste cooking oil (WCO) can provide a platform for sustainable resource consumption and bring down the five-to-six million tons of waste oil produced an-nually in Abu Dhabi. Providing details on her research, Rasha Abd Rabu said: “En-vironmental protection and conservation depend on reducing emissions and waste. Biodiesel, which has comparable physical and chemical properties to petroleum die-sel, can reduce the presence of GHG and

bring down harmful emissions. Through this process, I have discovered at the Mas-dar Institute laboratory that it is possible to minimise the negative impact on envi-ronment, while establishing world class waste management systems.” Rasha, who is the winner of the best thesis award in the Mechanical Engineering program at Masdar Institute, also participated in the Women Leaders’ Forum on ‘Gender Equality, Women’s Empowerment and Sustainable Development.’

41

MARKET PLACE


According to standards such as IEC 62271-203, a voltage with-stand test is necessary during the

commissioning of gas insulated high-volt-age switchgear (GIS). To date, the test was performed by connecting a high-voltage test transformer and a heavy control unit to the GIS.

OMICRON has combined its multi-functional primary test system CPC 100 with a newly developed CP RC package, consisting of the components CP TR8 and CP CR4 resp. CP CR6 – depending on the required inductivity - for testing GIS, which the company claims, eliminates the efforts associated with transport and han-dling of high-voltage test transformer and heavy control units required for traditional way of testing.

According to the press release issued by the company, the package is connected to a voltage transformer, which is specially designed for this purpose and already in-stalled in the GIS. Together, they form a

OmicronNew GIS testing package

CST Covers, a division of CST In-dustries, launched its new dome design called OptiDome at WEFT-

EC 2012 in New Orleans. An innovative flush batten aluminium geodesic dome design, OptiDome features a Double Web I-Beam and an optimised patent pending batten seal technology, which the company press release claims, eliminates environ-mental exposure and UV degradation. The new hub cover technology, the release continued, removes the need for exterior sealant at the nodes, eliminating routine maintenance and inspection requirements.

“OptiDome builds on the premium fea-tures of CST Covers’ present aluminum domes and the heritage of the Temcor

New Flush batten aluminium dome

CST Covers

Xylem has launched the Bell & Gossett Snap Zone Valve for residential and light commercial

HVAC applications. The Snap Zone Valve is a compact four-wire thermoelectrically operated on/off zone valve designed heat-ing and cooling systems. According to a press release issued by the company, the new snap zone valve features a compact design and adapter ring that allows for the actuators to be installed in any 360-degree position enabling the snap zone valve to fit under baseboards or in other tight spaces. The press release further notes that a push-button actuator facilitates one-hand-ed installation and permits wiring in any direction, while a visual indicator provides quick and easy recognition of which valves are energised. A replaceable plunger as-sembly allows for internal removal without removing the valve from the system.

Bell & Gossett Snap Zone Valve

Xylem

Other features of the Snap Zone Valve include:• Soft close technology suppresses water hammer•Silentactuatoroperation•360-degreeactuatorinstallation•One-handedactuatorinstallation•Valvein-pipeserviceable•Suitablefor50/50glycolmixandretrofitinstallations•Solarheatingapplication•Unionconnectionsenhancequickinstallation

The Snap Zone Valve is made with a forged brass body for high tempera-ture and high-pressure applications.

Operating specifications of the Snap Zone Valve are:• Operatingtemperaturerangeforfluidsof0°C–100°C•Ambienttemperaturerangeof0°C–50°C•Maximumoperatingpressureof240PSI•Maximumdifferentialclose-offof60PSI•Shutoffspeedof3min.•Openingspeedof3min.•Electricalratingof24V60Hz•Powerconsumptionof1.8W

and Conservatek brands to deliver a new benchmark in cover technology,” said John Delaney, Vice President of CST Covers In-dustries. “We are extremely excited because OptiDome immediately sets a new standard in design and aesthetics that provides cus-tomers in all the markets we serve with the high quality and reliability they have come to expect from CST Covers.”

OptiDome features an enclosed gasket de-sign that protects from UV and sealant deg-radation, reduces sealant use and eliminates ponding, the press release noted. The new OptiDome design from CST Covers is com-pliant to Euro-Code, Aluminum Associa-tion Design Manual 2010 and International Building Code 2012.

resonant circuit. As a result, the release claimed, no additional test transformer needs to be transported, and the space pre-viously required for the test transformer is no longer necessary. Also, for conven-tional external voltage withstand tests, the SF6 gas has to be drained and re-filled. By testing with the CP RC package, this time consuming task is redundant, claimed the press release.

The combination between CPC 100 and CP RC package provides the user with voltage withstand testing with a maximum test voltage of 200 kV for GIS which are rated up to 123 kV. Each unit of the pack-age weighs less than 30 kg.

42


EVENTS

Power + Water Middle East 2012, held in partnership with Abu Dhabi Water & Electricity Authority (ADWEA), co-located with INTERMAT Middle East 2012 and with ADCCI as a strategic partner, is a premier event for showcasing power and water re-lated products and services. It provides a platform for profession-als from these industries to interact with a number of the world’s leading companies and organisations. Sectors represented in the exhibition include Power Generation, Transmission & Distribu-tion, Automation & Controls, Research & Technology, Energy Efficiency, Water & Waste Water Treatment, Water Management & Distribution, Instrumentation & Process Control and Water Conservation. Highlights from 2011 include over 3,500 registered visitors, 52 visitor countries, 121 exhibiting companies and 26 ex-hibiting countries.

Contact:LathaRaviTel:97144072611Fax:97143353526E-mail:[email protected]:www.powerandwaterme.com/

8-10 OCTOBER ABU DHABI

Under the Patronage of the Municipality of Abu Dhabi city, the conference has turned out to be the leading event on geosynthetics throughout the Middle East and marked Abu Dhabi on the world map as an excellent meeting place for geotechnical and environment spe-cialists to exchange knowledge, conduct business and build strategic partnerships. Organized by SKZ the German Plastics Centre, the con-ference is taking place in November 2012 in Abu Dhabi at the Rocco Forte Hotel.

With a main focus on the region’s Transportation Infrastructure as well as Greening Solutions, this event will provide a platform for international geotechnical and environmental specialists to exchange their knowledge and experience. Key industry experts will present ap-plications & case studies on geosynthetics used in: Railways, Roads, Airports, Seaports, Bridges, Tunnels, Landfills, Environmental Pro-tection and other related topics.

The conference will be associated with a technical exhibition, where national and international companies are showcasing their products and services in: Geosynthetics, Geotextiles, Geomembranes, Water-proofing Membranes, Geosynthetic Clay Liners (GCL), Geogrids, Geonets, Geocomposites, Geofoam, Geocells, Geopipes, Water Man-agement Systems, Leachate Collection Systems, Irrigation Solutions,Erosion Controls and many more.

Contact:FabianBeermannTel:97148845001Fax:97148845002E-mail:[email protected]:www.geosyntheticsme.com

NOVEMBER 19- 20, 2012, ABU DHABI

Saudi Water & Power Forum 2012 (SWPF) is a premier power and water event in the Kingdom, connecting stakeholders and helping set the agenda for sustainable growth. Focus areas for this year include Sustainable Energy-Water Nexus, changing policies and strategies de-termining the future of power and water in the Kingdom, solutions to a sustainable energy-water nexus and opportunities for partnerships.The SWPF Award for Innovation and the Marafiq Award for Sustain-ability will be presented at the Forum Inauguration Ceremony. The event will be held at Hilton Jeddah.

Contact:ChrisHugallTel:+442079780084E-mail:[email protected]:www.ksawpf.com

MEED’s annual wastewater conference is recognised as being the best event of the year for all those involved in water, sewage treatment and wastewater reuse. Speakers from across the GCC and the wider MENA region will be supported by experts drawn from the water industry of the wider Middle East region and the world beyond. Key speakers include Abu Dhabi Sewerage Services Company (ADSCC), BESIX Concessions, Corodex, Drake & Scull, Kharafi National, and Regulation and Supervision Bureau (RSB)A new feature for 2012 will the pre-event focus day designed to explore the growing opportunities across the project supply chain for those who service the industrial wastewater sector. Contact:JubidaKulangarathTel:++97143900699E-mail:[email protected]:www.meedconferences.com/wastewater/

November 26-28, 2012, Abu Dhabi

DECEMBER 2-4, 2012, JEDDAH

Power + Water Middle East 2012Geosynthetics Middle East

Saudi Water & Power Forum (SWPF)

Middle East Water & Waste water Conference

43

TENDERS PROCUREMENT UPDATES


PROJECT NAME TRANSACTION ADVISORY SERVICES-1 Provision of transaction advisory services for the Al-Abdaliyah Integrated Solar Combined Cycle (ISCC) Project. October 7, 2012 July 12, 2012 Tender Service Kuwait Company Name: Partnerships Technical Bureau (Kuwait)Address: Touristic Enterprises Co. Bldg., 2nd Floor, Al-Jahra StreetPin: City: ShuwaikhCountry: KuwaitPhone: (+965) 2496 5901Fax: Email: [email protected]: http://www.ptb.gov.kwNew Tender July 12, 2012 Power Plants & Alternative EnergyRequest for Proposal (RFP)This tender service is at Al-Abdaliyah in Kuwait. The scope of the work involves development of an ISCC plant to generate power with a capacity of 280MW of which solar contribution will be equivalent to 60MW. The transaction advisor must have successful and variable experi-ence in doing similar transac-tions regionally and globally. The advisors are expected to have, as a minimum, expertise in the following:• Technical aspects and require-ments comprising site plan and general layout arrangements, plant capacity and equipment configurations for ISCC facilities• Project EIAs (environmental Impact Assessments including full mitigation plans and final approvals from the appropriate authority).• Review of feasibility studies and financial analysis.• Evaluation of project viability analysis including detailed risk analysis• Preparation of project technical documentation including tender

specifications, drawings, etc.,• Design of competitive procure-ment processes and preparation of tender documents.• Preparation of all required legal documentation (including con-tracting agreement) and negotia-tion of contractual frameworks• Negotiation support and trans-actions closing• Project Management.Tender documents can be ob-tained from:Partnerships Technical BureauSafat, Kuwait.Tel No: (+965) 2496 5900Prior to receiving the RFP, a letter of intent shall be submitted not later than 12:00 pm on July 29, 2012 identifying members of the consortium (if any) interested in purchasing the RFP. Compa-nies intending to purchase the RFP should provide a certified cheque from a local bank with a value of KD 1,500. Letter of intent and bankers checks are to be submitted in hard copy of the attention of:Partnership Technical BureauTouristic Enterprises Company Building2nd Floor, Shuwaikh, Adminis-trative Area,Al Jahra Street, Kuwait.And in soft copy toE-mail: [email protected] RFPs are expected to be is-sued on August 05, 2012.

DESCRIPTION

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MPP2655-ESUEZ POWER PLANT CONSTRUCTION PROJECTEgyptName : Power Generation En-gineering & Services Company - PGESCo (Egypt)Address : 41 El-Salam Avenue, Central DistrictCity : Cairo Country : EgyptPhone : (+20-2) 2617 6497Fax : (+20-2) 2617 6519eMail : [email protected] Persons /Website: http://www.pgesco.com

PROJECT NUMBERPROJECT NAME

TERRITORYCLIENT

44

TENDERS


Construction of Suez power plant with capacity of 650MW.New TenderThis project is in Egypt. It will re-place an ageing plant of a smaller size. Client, a joint venture between Electricity & Energy Ministry, US’ Bechtel and Egypt’s Commercial International Bank is procuring equipment for the scheme. it is in talks with France’s Alstom and Italy’s Ansaldo Ener-gia for the main components of the project. Power Plants & Alternative EnergyPower Generation Plants

DESCRIPTION

TENDERREMARKS

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CLIENT

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TENDER PRODUCTS

MIRFA IWPP PROJECT Build-Own-Operate (BOO) con-tract for the design and execution of an independent water and power plant (IWPP) in Mirfa. December 6, 2009 2015 Project Abu Dhabi Company Name: Abu Dhabi Water & Electricity Authority (ADWEA)Address: ADWEA Building, Al-Falah StreetPin: 6120City: Abu DhabiCountry: United Arab EmiratesPhone: (+971-2) 627 1300 / 694 3333Fax: (+971-2) 626 7725 / 626 6089Email: Website: http://www.adwea.gov.ae Financial Consultant Company Name: HSBC Bank Middle East Limited (Abu Dhabi)New Tender July 8, 2012 Power Plants & Alternative EnergyUpdated On : July 8, 2012 Client has issued an Expressions of Interest (EoIs) to provide a developer partner on this scheme. A developer or devel-oper consortium is sought 40 per cent of a special purpose vehicle

to be incorporated for the IWPP, the remaining equity will be held by the client. The project will comprise:1. Purchase, ownership, opera-tion and maintenance (O&M) and financing of certain existing assets of Mirfa Power Company2. Ownership, development, financing, construction, opera-tion and maintenance (O&M) of a 1,000MW Greenfield power generation plant and a 30-mil-lion gallon-a-day reverse osmosis desalination plant3. Installation of four 100MW open cycle gas turbines and inte-gration of certain existing assets (3X7.5 million g/d desalination units) into the new plant.Last date to submit Expression of Interest will be on July 15, 2012. After Eols has been received, a request for qualification will be provided, with additional details regarding the project and the bidding process. Deadline for statements of qualification will be on September 10, 2012.

ZPR754-OTIBAT POWER PLANT CON-STRUCTION PROJECTOmanName : Oman Power & Water Procurement Company S.A.O.CAddress : Muscat International Centre, 2nd Floor, Suite 504City : Ruwi PC 112 Postal/Zip Code : 1388Country : OmanPhone : (+968) 2482 3028 / 2482 3000eMail : [email protected] Persons /Website: http://www.omanpwp.co.omConstruction of a gas fired power plant with capacity of 125-180MW in Tibat.2014 New TenderThis project will be located at Musandam in Oman. Purpose of the project is to meet the increas-ing national demand for electric-ity. It is currently under planning stage. Schedule of the project has

PROCUREMENT UPDATES

46


TENDERS not yet been determined. Power Plants & Alternative EnergyPower Generation Plants

SHAGAYA RENEWABLE EN-ERGY COMPLEX PROJECT Engineering, procurement and construction (EPC) contract to build a 70MW renewable energy complex at Shagaya. November 3, 2011 Project Kuwait Company Name: Ministry of Electricity & Water (Kuwait)Address: Ministry of Electricity & Water Bldg., South Al Surra Street, Ministries AreaPin: 12City: Safat - 13001Country: KuwaitPhone: (+965) 2537 1000Fax: (+965) 2537 1420 / 1421 / 1422Email: [email protected]: http://www.energy.gov.kw Financial Consultant Company Name: Fichtner Gmbh & Co. KG (Germany)Main Consultant Company Name: Lahmeyer In-ternational GmbH (Germany)New Tender July 4, 2012 Power Plants & Alternative EnergyThis complex will be developed in north of Kuwait, near the Iraqi border and comprise a 10MW photovoltaic solar plant, a 10MW wind farm and a 50MW concen-trated solar power facility using trough technology. The project is being implemented in joint venture with Kuwait Institute for Scientific Research (KISR). A tender for the EPC contract will be launched by the end of 2011 or early 2012. Contracts may be awarded for separate compo-nents of the scheme or as a single contract for the 70MW project in its entirety. The 10 million square metre site at Abdeli has potential to be expanded to 500-1,000MW of renewable energy capacity at a

later date. Germany’s Lahmeyer is advising on the project.Updated On : July 4, 2012 It is understood that client has moved the location of the scheme from Abdeli to Shagaya. Accord-ing to client, the Shagaya site is deemed preferable because it has less dust exposure. Scope of the project will remain same, which comprise a 10MW photovoltaic solar plant, a 10MW wind farm and a 50MW concentrated solar power facility. Each of the facili-ties will be tendered separately. Tender process is expected to be launched in October 2012, which was originally planned in September 2012 delayed due to Ramadan and Eid holidays.

TENDER CATEGORIES

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MPP1965-SASHUQAIQ THERMAL POWER PLANT PROJECTSaudi ArabiaName : Saudi Electricity Com-pany - Western Region (Saudi Arabia)City : Jeddah 21430 Postal/Zip Code : 9299Country : Saudi ArabiaPhone : (+966-2) 650 0005Fax : (+966-2) 653 4139Contact Persons /Website: http://www.se.com.saEngineering, procurement and construction (EPC) contract to build a thermal power plant in Shuqaiq with capacity of 2,400 MW.New Tender Updated On : June 20, 2012 Client has invited bids for the EPC contract on this scheme. Contractors have until October 2012 to submit technical bids. Technical bids will be assessed before financial offers are invited. This project is in Saudi Arabia. Client is planning to invite ex-pression of interest (EoI) by the end of May 2012. Bids will then be invited for EPC contract. Power Plants & Alternative EnergyPower Generation Plants

PROCUREMENT UPDATES

47

TENDERS


PROJECT NAME

DESCRIPTION

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CLIENT

STATUSLAST UPDATED

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CONSULTANTS

ABQAIQ, HAWIYAH & RAS TANURA ELECTRICITY & STEAM PLANTS PROJECT Build-own-operate-transfer (BOOT) contract for the con-struction of three greenfield gas-fired steam plants with capacity of 770 MW of power and 2.95-million pounds an hour in Abqaiq, Hawiyah and Ras Tanura. March 4, 2012 2016 Project Saudi Arabia Company Name: Saudi Arabian Oil Company (Saudi Aramco)Address: Saeed Tower, Dam-mam-Khobar HighwayPin: 151City: Al Khobar 31952Country: Saudi ArabiaPhone: (+966-3) 872 0115 / 810 6999Fax: (+966-3) 873 8190Email: Website: http://www.saudiara-mco.com Financial Consultant Company Name: Fichtner Gmbh & Co. KG (Germany)Financial Consultant-1 Company Name: HSBC Ltd. (Saudi Arabia)Legal Consultant Company Name: White & Case LLP (USA)New Tender July 23, 2012 Power Plants & Alternative EnergyThis project is at Eastern Prov-ince in Saudi Arabia. The facili-ties are likely to have following capacities: Abqaiq – 320MW and 1,2000 thousand pounds an hour,Hawiyah - 130MW and 550 thousand pounds an hour, andRas Tanura - 320MW and thou-sand pounds an hour.Each of the projects will convert fuel gas and feed water provided by client into electricity and steam for sale under an energy conversion agreement. Client has issued a request for qualification (RFQ) to developers to build

the plants. Developers have to respond to the RFQ by March 11, 2012. Each of the consortium members will be required to hold at least 20 per cent of the voting and economic rights held by the applicant in the project company upon its formation. Selection of qualified applicants is expected by April 22, 2012 followed by issue of request for proposals (RFP) on April 23, 2012. Bids are expected to be submitted by September 01, 2012 and award for three projects expected by December 31, 2012. The selected developer will be required to construct the projects to meet the following commercial operation dates: Hawiyah in November 2015, Abqaiq in January 2016 and Ras Tanura in March 2016.Companies have been responded to the Statements of Qualifica-tions (SOQs) on this scheme. They include: Saudi Arabia’s Acwa Power; UK/France’s IP-GDF; South Korea’s Kepco and Samsung C&T; Japan’s Marubeni, Sumitomo, JGC Corporation, Itochu and Sojitz Corporation; Saudi Arabia’s Saudi Oger and Powertek Berhad; Qatar’s Qatar Electricity & Water Company, India’s Tata Power; Malay-sia’s Tenaga Nasional Berhad; Singapore Sembcorp; Kuwait’s Kharafi National; UAE’s Taqa and Saudi Arabia’s National Power Company. Updated On : July 23, 2012 Client is now planning to issue a Request for Proposals (RFP) to qualified bidders on July 25, 2012, due to the slight delay. The revised RFP is expected to be submitted on November 13, 2012.

PROCUREMENT UPDATES

48


SECTOR REPORT

After a shakeout of nearly 40 manu-facturers, the polysilicon industry will slowly recover from oversup-

ply by 2014, while 2015 could be the har-binger of a new polysilicon shortage. This is one of the conclusions of the new mar-ket research report The 2012 Who’s Who of Solar Silicon Production, presented by Bernreuter Research during the 27th Eu-ropean Photovoltaic Solar Energy Confer-ence in Frankfurt/Main, Germany. Polysil-icon, the feedstock for the semiconductor and photovoltaic (PV) industries, glutted the market in 2011 when the annual pro-duction volume of 255,000 metric tonnes

Looming shortageA leaner polysilicon industry is poised for rebound, says Bernreuter Research

Bernreuter Research

(MT) exceeded demand by 25,000 MT. The manufacturers, most of them small and medium enterprises in China, suspended or abandoned production.

The scenario of future demand which Bernreuter Research has developed is more aggressive than forecasts of other analysts. “Several indicators we investigated point to new PV system installations of up to 37.5 GW in 2012,” said Johannes Bernreuter, head of Bernreuter Research and author of the new report. The market researcher examined 72 analyst forecasts made about global PV installations from 2008 through 2011. He found that the forecast average

remained more than 30% below the actual results. In the Basic Edition of ‘The Who’s Who of Solar Silicon Production (2010),’ Bernreuter Research thoroughly assessed the progress of 10 polysilicon production meth-ods including the standard Siemens process. While most of the new approaches will not make it into commercial production, mon-osilane-based technologies show promise as serious rivals to the established Siemens pro-cess. Another alternative is upgraded metal-lurgical-grade (UMG) silicon, but this tech-nology is yet to prove its value proposition. “The sweet spot of sufficient silicon quality at low cost is very small,” said Bernreuter.

49


The 15th edition of the Abu Dhabi International Petroleum Exhibi-tion and Conference (ADIPEC)

this year includes a unique feature: a UAE oil and gas museum. The ADIPEC mu-seum, which will remain open during the exhibition from November 11-14, is set to provide visitors with an interactive jour-ney exploring the discovery, extraction and production of oil in the UAE.

Comprising exhibits loaned by local and multinational energy companies, plus personal contributions, the museum will be a chronological study of the UAE’s oil and gas industry, and will in-clude an interactive timeline from 1928 to the 2000s.

The ADIPEC Oil and Gas Museum will comprise a wide variety of exhibits, many of them on public display for the first time, including archive photography, film, plans, engineering components and machinery, as well as the testimonies of former and present-day oil executives. In addition, the museum will feature a tribute to the vision of the UAE’s found-er, His Highness Sheikh Zayed bin Sul-tan Al Nahyan.

A number of exhibits have already been received with the support of contributors and sponsors (which include Partex Oil

A slice of history at ADIPEC2012

FLIPSide

& Gas, ExxonMobil, TOTAL and Shell). To date, the organisers have received in-teresting exhibits which include a copy of the original Abu Dhbai concession agreement dating back to 1939 as well as a geological map of the hinterland of Abu Dhabi drawn in 1935.

Among the images received for inclu-sion in the museum include that of the late ruler of Abu Dhabi, Sheikh Shakhbut bin Sultan, pictured with Dr Macpher-son of BP and N Barnonty of Khanaqin Oil Company, dating back to 1953, and a photo of a water distillation plant for fresh drinking water dated 1963. The equipment section will have some of the original tools and paraphernalia used to aid the extraction of oil, such as hydraulic power tongs, monitoring sys-tems used for ADCO and ADMA-OPCO

fields, and crude oil loading pumps dat-ing back to 1966.Three cars which were used during the oil boom in the UAE, and have been in the Emirates for more than 60 years, will also be on display at the ADIPEC museum. These include a Chevrolet 3100 pick-up, a Land Rover and a Dodge Power Wagon.

The ADIPEC Museum will also fea-ture a running documentary about the history of oil and gas in the UAE. In the video, industry professionals who have served in the sector for many years will recall their experiences. Contributors to the documentary to date include David Heard, H.E. Mohammed A.J. Al Fahim, Peter Hellyer, H.E. Ahmad Rahma Al Masaood, Ahmed Tamim, Murshed Al Romaithi, Saqar Muharibi and Martin Calouste Gulbenkian.

Production UnitDas Island 1969 Total Archives

Inauguration of ABK 1 July 1974 in the presence of Sheikh Zayed René of Lilliac Granier and president of the French Petroleum Company (PSC), Total Archives

50

Using the combination of MPD 600

and UHF 620 products, Dad can easily

perform partial discharge (PD)

measurements on gas-insulated

switchgear (GIS). These unique

products help him determine the

condition of insulation in a greatly

simplified way. The UHF 620 provides

different, freely selectable, bandwidths

for PD measurement enabling quick

configuration possibilities or, for

example, easy filtering of interferences.

As Dad can now also measure in the

ultra-high frequency range, the system

is sufficiently sensitive that it gives

brilliant results – perfect for on-site and

commissioning tests.

Now that‘s exciting!

and he likes the fast and easy process provided by MPD 600 and UHF 620!

www.omicron.at | [email protected]

World Leader in Innovative Power System Testing Solutions

MPD600-UHF620_ad_210x297_bleed5mm_enu.indd 1 2012-09-26 16:55:03

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megawhat-h2o october 2012

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