Evaluation of Additives
As part of a program to optimize the combustion
process of heavy fuel oil in utility boilers and within a protocol that
has been established by the Comisión Federal de Electricidad (CFE),
which obliges to potential additive suppliers to conduct an experimental
evaluation at the Instituto de Investigaciones Eléctricas (IIE),
two additives from the USA and one from Germany were assessed in relation
to the emissions levels abatement and ash neutralization.
With these studies, CFE has precise technical elements that may contribute to make a decision to test these additives in oil- fired boilers.
Micrometeorology and Dispersion of Atmospheric Pollutants in the Oil Sector
In an effort to aid CFE in solving the environmental problems derived from air pollutants emissions, which are produced during the combustion of fossil fuels in power plants, IIE established a method to evaluate the atmospheric impact of power plant emissions in 1996. The results of this work motivated interest in the oil sector. At the end of 1996, Petroleos Mexicanos (PEMEX) asked IIE for support to install and startup a micrometeorological station and a complete computer aided system for continuos evaluation of atmospheric impact of the refinery emissions within a radius of 42 km at the General Lázaro Cárdenas refinery in Minatitlan, Veracruz. With this installation, the Minatitlan refinery becomes the first industrial complex in Latin America able to assess the dispersion of atmospheric pollutants by applying advanced techniques. Nevertheless, the project became more ambitious: after the formal presentation of the project results, the refinery authority decided to take advantage of their new capabilities and asked IIE investigators to establish during 1998 a Center of Environmental Management, to which a stack gas monitoring net, connecting the main chimneys shall be integrated. In the long term, the idea is to provide the rest of the refineries in the country with this kind of resource.
Engineering Studies for Rehabilitation of Process Heaters at PEMEX Refineries
During 1997, the IIE has assisted the PEMEX Refinement Division (Refinación) with its program for modernization of combustion systems and ancillary equipment at plant refineries all around the country. This has been done by implementing top technology in four projects to develop engineering studies for renovation of three fired heaters at the General Lazaro Cardenas Refinery located in Minatitlán, Veracruz and one for the modernization of a heater for nafta reforming process at the Antonio Dovalí Jaime Refinery located in Salina Cruz, Oaxaca.
It is expected that with new burners and the modernization of ancillary equipment and control instruments, the performance of the heaters will improve in terms of operational procedures and less emissions to the environment.
Sturdiness Tests of the Rotor Bore Inspection System
Turbine rotors may be difficult systems
for non-destructive evaluation due to its non-uniform external geometry;
fortunately, some of these rotors may be inspected internally through the
bore, whose geometry is simpler. The systems currently available for such
evaluation are stationary, so that on-site inspection is not possible, and
moving it to the inspection site would require a truck for transportation
of the rotors. Due to the advantages of portable systems for field inspections,
the Institute has built a portable mechanical device for ultrasonic transducer
positioning within the rotore bore. The mechanical device as well as the
ultrasonic head are controlled through a personal computer, which is additionally
used to acquire and store data whose processing will indicate the presence
of inhomogeneities in the rotor. The system was recently tested with success
during the inspection of the high and intermediate pressure sections of
the turbine of one of the units of the Valle de México power station.
The incorporation of visualization routines to enhance the automatization
of the system is planned.
Degradation and Protection of Materials for High Temperature
The degradation of boiler materials exposed to combustion flue gases has specific characteristics resulting from the high levels of sulfur, vanadium and asphaltenes in the Mexican fuel oil. Corrosion rates of alloys used in components operating at temperatures higher than 500°C in this environment are frequently higher than those expected by design. In order to contribute to the solution of this problem, the characteristics of the fuel-oil ash corrosion process of different types of alloys has been studied in depth for several years in the IIE. The experimental research on the performance of different alloys exposed at temperatures in the range of 500°C-900°C continued during 1997. This research involved low-alloy steels ferritic and austenitic stainless steels, Ni-base alloys and an alloy FeCrAl produced by mechanical alloying. These alloys were exposed to several fuel-oil ash deposits whose chemical composition covers a wide spectrum of corrosive potentials commonly found in Mexican boilers. The work in this area will continue in order to determine the factors involved in the corrosion process and to define alternative alloys. The results are useful in the selection of materials for specific corrosion problems and also for evaluating the corrosive potential of fuel-oil ash deposits.
Upgrading gas Turbine Controllers
In 1996, the IIE developed a control
system for the W191G model gas turbine. It includes a controller device
and a personal computer (PC). The first version was developed using an IIE-proprietary
microprocessor-based controller (SAC Sistema de Adquisición
y Control), and a PC to support the man-machine interface (MMI). Typical
functions were configured using a commercial software package. In 1997,
a commercial Programmable Logic Controller (PLC) substituted the SAC controller
and the MMI functions were configured with a different commercial software
package. The combinations of controllers and MMI options provide the clients
with six possible alternative solutions. Each one with a different price
associated to the upgrade of the control of the W191G model gas turbines.
The IIE continues the development of this type of control systems. The next
product will be a controller for the GE5001 gas turbine.
Upgrading Instrumentation and Control Systems at PEMEX Refineries
As part of an ambitious plan to have process plants upgraded by the year 2000, PEMEX Refinement Division (Refinación), asked the IIE to develop the specification for new instrumentation and control systems for 28 plants located in four refineries. The specifications contain: piping and instrumentation diagrams (PID's), field instrumentation, distributed control systems (DCS's), communication system, advanced control software and protections. Architecture and facilities to install, test, commission and startup are other aspects included in the specifications.
Gas Detection System for Oil and Gas Production Facilities
The office of environmental protection and industrial security management (GPASI) at PEMEX Refinement Division (Refinación), asked the IIE to specify, integrate and configure a gas detection system for the critical areas of the General Lázaro Cárdenas del Rio refinery in Minatitlán Veracruz. Later on, the IIE will also supervise the installation and commissioning of the system. Presently, the specifications and documents for bidding the equipment, sensors and software have been completed. The project will continue in 1998. The results obtained can be applied to other refineries.
Portable Equipment to Test Electrical Energy Measurement Devices
In 1997, an improved version of this equipment was developed which adds the ability to automatically test device operation and calibration in the field. The equipment works with induction and electronic measurement devices. The previous version was tested in the field showing a 0.1% accuracy, human errors elimination (at reading and calculations) and operation that complies with practice and regulations.
Technical Support for the Integral Process Information System
Continuing with the technical support
for the integral process information system (SIIP, the Spanish acronym)
of the Laguna Verde nuclear power plant, the IIE implemented 12 software
modification packages and design engineering of the system. Moreover, some
discrepancies were solved and some additional displays requested by the
plant´s operators were developed, installed and tested.
In order to maintain its operativity and to improve the functionality of this important system, software and hardware platforms will be upgraded in the coming year.
Power Systems Automation
In 1996, the IIE began an interaction with the operation and control center of the Luz y Fuerza del Centro electric company to automate the supervision and control functions of substations and distribution centers. The project included the design of the architecture to install six master stations in an open platform of personal computers. In 1997, some methodologies were developed to automate three more master stations. The platform included modern operating systems, forefront data bases and vanguard software that facilitate the implementation, and remote connectivity RAS (Remote Access Service) of the master stations.
Modernization of Systems at the "Francisco Pérez Ríos" Fossil Power Plant
Started in 1996, the integral information system (SIIT, the Spanish acronym) has continued to be implemented at the "Francisco Pérez Ríos" fossil power plant in Tula, Hidalgo. The system allows the users to know the effect of the operation of the plant outside the design conditions, using real time information. In the second of five stages of the modernization process, the new fuel inventory system was installed. Furthermore, development of the heat rate monitoring system was started. At this time, the man machine interface, the design of deviation curves, the specification of instrumentation, and the data acquisition system for the heat rate monitoring system have been concluded.
Modernization of Fossil Power Plants
Technical specifications were developed for the
implementation of distributed control systems
for PEMEX refineries.
The IIE is collaborating with the Electricité de France company in order to develop an on-line assistance system for operation of fossil power plants (SACSO, the French acronym). Based on the French company´s experience, the system will improve the continuity of service, security, equipment lifetime, startup and scheduled download. The first version of the system´s knowledge base (SACBASE) has already been completed. In 1998, the system will be tested in a simulator at the "Ixtapantongo" Operator's Training Center (CAOI, the Spanish acronym) owned by the national electric utility, CFE.
Especification of Real Time and Predictive Control Techniques for Refineries of PEMEX
In order to improve the operation process in oil refineries, technical specifications were developed for the implementation of real time analysis and predictive control systems for the national oil industry (PEMEX). The specifications include the use of predictive models for regulation, constraint models for optimization and on line simulation for analysis in real time operation.
Quality Assurance
In 1996, the project coordination group for transmission and transformation (CPTT by its Spanish acronym) of CFE started the process of becoming certified under the ISO 9001 standard. The IIE was requested to support it in order to develop a quality system. The quality system consists of the quality manual and the job's procedures and instructions for the technical and construction management. Furthermore, training was provided on the topics such as: design control, acquisitions, documents control and quality register.
Consulting for Upgrading the CAPUFE Toll Collection System
Nowadays, the IIE is expanding its research services to users out of the electrical industry. As a consultant, the IIE collaborated with the national road company (CAPUFE, the Spanish acronym) to upgrade its toll collection system. The project included an international market analysis about toll collection products and services. The development of technical bases for the bidding process and the design of the methodology to evaluate the offers were also part of the project's scope.
Synchronous Machines Emulators
In 1996, the IIE developed two emulators
of synchronous machines for the Mexican utility CFE. A data acquisition
system has been implemented in the emulators. Data acquired from the generator´s
automatic voltage regulator (AVR) can be recorded and used as a reference
by the emulator to validate performance of the AVR. Testing of AVR´s
was carried out at two hydroelectric power plants (Chicoasén and
Infiernillo) and one thermoelectric power plant (Carbón II). Additionally,
more than 30 CFE engineers were trained in the use of the emulators.
Development of a New Platform for the Laguna Verde Nuclear Power Plant Training Simulator
In 1995, the IIE began a project to replace the Gould computers with modern workstations at the Laguna Verde nuclear power plant simulator. The project also included implementing software enhancements to the instructor console and to the software maintenance tools. The new versions of the real time executive, the instructor console, the databases, the global memory and the node for communications with the control boards and input-output data conditioning, were completed and implemented. The new instructor console includes interactive process diagrams, which allow the instructor to have on line monitoring and interaction with the mathematical models of the simulator by means of graphical instrumentation. The open architecture of the new platform provides the capacity of adding new computer nodes. Presently, the simulator remains operative with both platforms by means of a selector switch, until the acceptance test procedures of the new platform are completed.
Structural and dynamic numerical analysis of the algebraic-differential system of equations of the Laguna Verde nuclear power plant training simulator
In a full scope nuclear power plant simulator, the process and logical mathematical models are very complex. As a consequence, efficient coding of this complex system of equations is a difficult task. The IIE has developed numerical analysis techniques to support this task. The 47 models of the Laguna Verde nuclear power plant simulator were analyzed to obtain the optimal ordering of equations, so as to improve numerical stability, precision and robustness. Testing of the modified models is being carried out at the simulator.
Update of the Laguna Verde Nuclear Power Plant Simulator to the Fifth Fuel Re-load. Part1: Pre-analysis
The IIE developed the Laguna Verde nuclear power plant training simulator based on design data available in 1985 from the plant's unit 1. Because of regulatory requirements, the simulator has to be updated to reflect the changes in the reference plant.
The first updating of the simulator was developed based on the state of the plant at the time of the first nuclear fuel load. This work was accomplished in 1995.
The fifth nuclear fuel re-load of unit 1 was finished on July 1997, then CFE required the IIE to update their simulator. The IIE proposed to develop the update in three stages: (1) pre-analysis of the changes and definition of the impact on the simulator; (2) analysis and design of each change for the simulator and (3) developing, implementing and testing of the changes in the simulator.
The first part was developed during 1997. A total of 1919 logical diagrams, 112 process and instrumentation diagrams, and 452 modification documents were revised, pre-analyzed and classified. This information is the basis to analyze, define and implement the changes in the simulator.
Feasibility Study For The Installation Of A Fossil-Fuel Power Plant In Central America
In 1996 the IIE began a feasibility study for the installation of a fossil-fuel power plant to cover a fraction of the foreseen increase demand for electric energy in Central America. The information about the electrical systems of the six countries involved in the project was integrated in a data base in 1996. In coordination with the Central American Electrification Council (CEAC) and the Nicaraguan Energy Institute (INE), during 1977 the final model of the integrated electrical system was developed to establish the generation and transmission expansion program. From the results of the model, and as the best option for Central America, the installation of a coal-fueled power station with two 250 MWe groups was recommended. The anticipated characteristics of the combustion gases were evaluated from the point of view of their potential pollution effects, in order to establish the needs of gas- treatment systems. In the power plant siting process, three possible locations were identified: El Salvador, Guatemala and Nicaragua.
At present, the IIE is working on the definition of the power station scheme, so that the CEAC can promote their construction by private and public investment organizations.
Cooling Towers Retrofitting
In the framework of the support that the IIE offers to the CFE, PEMEX and other process companies on cooling towers retrofitting, and taking into account that the IIE has developed computational programs to predict the behavior of the different fills used in such equipment, PEMEX Refinery Division (Refinación) requested the review of the specifications for the modernization of their towers. The work done comprised the incorporation of the tower's design analysis to the technical proposals request bases developed by the public company to rehabilitate and modernize the towers of the Salina Cruz, Cadereyta, and Salamanca refineries, and the evaluation of the technical aspects of the bids for the projects.
Modeling of Power Plant Reliability
The utilization of generic failure rates (from other plants) and the hypothesis that components perform under normal conditions are some common assumptions in reliability assessments. The IIE has proposed to remove these limitations using specific field data and expert analysis, based on a Bayesian network technique. Such a technique manages uncertainty and represents dependencies between failures. Following the above fundamental principles, during 1997 a computational system was developed in order to automatically obtain a Bayesian network from a reliability block diagram, its usage allows users to model any power plant system including historical field data and knowledge of maintenance or operation personnel. This approach might include deterministic information, and in that case its application could be extended to decision processes. To improve the information for the Bayesian network and in order to accomplish the optimal assignments of maintenance tasks and equipment replacement, the addition of labor and spare parts costs are expected to be included in short time.
Surface Equipment Design for Geothermal Fields in Costa Rica
Considering the IIE geothermal surface equipment design experience, the company Ingeniería Comercial Latinoamericana (ICLA) signed a contract with the IIE to make the surface equipment design for the Miravalles project in Costa Rica. The IIE developed the design (according to ASME code) and drawings for 90 and 110 t/h cyclonic steam-water separators as well as the water tanks.
The equipment will be installed in the 55 MW Miravalles II geothermal power plant, which will increase the Costa Rican electric generation capacity by 9%.
Evaluation of Remaining Life of Turbines
It is very important to evaluate the remaining life of turbogenerators which have been in operation for more than twenty years of service, in order to guarantee their structural integrity and reliable operation. The analysis implies a non-destructive evaluation (ultrasonic testing) of the surface of the rotor bore; a study of the turbine operational historical data; the knowledge of the rotor geometry; and an analysis of the thermomechanical stresses and of fracture mechanics. The Institute carried out this type of studies in the project Technical Audit, exhaust flow analysis, remaining life estimation and diagnosis for recovering the efficiency of the steam turbine units 1, 2, and 4 of the Valle de México thermoelectric power plant and unit 2 of the Salamanca power plant. The achievements of this project, based on the actual operational conditions of the units, were to characterize the structural behavior of the rotor on the high and intermediate pressure sections. Furthermore, the analysis of the remaining life was made, considering for the first time the results of the rotor boresonic inspection, where two minor inclusions were detected; it was concluded that the inspected rotors did not show significant anomalies. To have the capacity for evaluating the remaining life of equipment allows for making the best decisions regarding continuing the operation, making repairs, or stoping the operation; enabling the optimization of human and material resources and great economic savings for the electric sector.
Diagnosis of Blade Turbine Failures in Central America
The diagnoses for recovering the efficiency
of units 1, 2 of the Valle de México and
the unit 2 of Salamanca thermoelectric
powe plants were made.
On three gas turbine units of the Acajutla power plant, in the Republic of El Salvador, problems related to repetitive failures of the moving blades were occurring. The purchase of new blades represented a great expenditure, that did not resolve the problem. In 1997 the Institute was invited to diagnose the causes of the failures, and a complete set of tests were made to the blades: a visual inspection, a metallographic analysis, and a stress analysis which led to the diagnosis of the failure. Based on the analysis made, recommendations were developed to eliminate the cause of failure and to prevent its occurrence. As a result of this work, the more complicated details of the metallurgical/manufacturing processes for the gas turbines blades were explored and new relations were established for widening the participation of the IIE in the central american market.
Refurbishment of Gas Turbine Transition Pieces
The Comisión Federal de Electricidad requested the IIE to refurbish the gas turbine transition pieces of the El Sauz combined cycle power plant, in Querétaro. These components showed heavy damages: deformations, hair cracks, metallurgical degradation of the base material, and failures of the sealing system on the joint with the inner turbine case. The refurbishment of the transition pieces involved the development of the technology for welding, straightening, heat treating, and reassembling procedures; as well as a quality control program. The developed technologies were used for the first time in our country and resulted in great savings of foreign currency and in reduced time to solve these problems by attending them locally, with a quality comparable to that of service providers from other countries. In the near future, these technologies will be applied to other units of El Sauz and Valladolid power plants in Yucatán.
Predictive and Preventive Maintenance for Rotating Machinery of PEMEX
The Dos Bocas pumping inshore plant, at Tabasco, pumps 76% of the national crude oil production and for this reason PEMEX carries out actions to increase the reliability of its installations and equipment through a modernization program which takes into consideration a stepped implementation of a maintenance system. According to this objective, the Institute developed and implemented a predictive and preventive maintenance system to organize, document and manage the maintenance activities; customized in such a way that the operational indicators could be maintained and improved. At the end of the project, the mechanical maintenance personnel at Dos Bocas could know the facility´s condition and recommendations for improvement; program efficiently all the preventive maintenance activities; reduce costs and increase reliability through the implementation of a mechanical maintenance system; have a customized computer program for the maintenance management; have the specialized technical training to do the mechanical maintenance and to use the computer program; and to increase the efficiency when performing mechanical maintenance activities on the equipment.
Generators Overhaul
The Institute continued working successfully
on the overhaul of electric generators. In 1997 the windings of the stator
of unit 3 at the hydroelectric plant Ingeniero Carlos Ramírez Ulloa,
"El Caracol", were reconditioned, the packaging system of the
bars in the slots and the connection between stator bars were modified.
The generator reliability was greatly improved and significant savings in
maintenance expenses were achieved.
Three Phase Induction Motor Testing
By request of the Fideicomiso de Ahorro de Energía, FIDE (Electric Energy Saving Trust), IIE Salazar Laboratory started a project to test repaired motors, according to the standard NOM-074-SCFI-1994, as part of a leading program for the optimization of the techniques for rewinding of failed electric motors. First, the efficiency of new motors was experimentally determined, and then artificial failures were induced. Afterwards the motors were repaired by workshops specified by Fide and once repaired, the test procedure was carried out to determine their new efficiencies. As a result the shops and the techniques that they use were identified.
Diagnostic Testing of Electrical Generators
The IIE capability on electrical generators diagnostic was applied in the diagnosis of the Chixoy Hydroelectric Power Plant, in Guatemala, of the Instituto Nacional de Electricidad (Guatemalan National Electric Bureau, INDE). The results were used to formulate the epecifications for the overhaul of the generators through an international bidding. Also, a Mexican company - with technological support from an important Japanese manufacturer - engaged the IIE in the diagnostics of two generators of the Comisión Hidroeléctrica del Río Lempa (El Salvador National Electric Bureau, CEL) in El Salvador.
Predictive Maintenance of Electrical Equipment
As part of the renovation and quality improvement program of the oil seaport terminal Dos Bocas of PEMEX, IIE developed a computerized maintenance system for crude oil pumping medium voltage induction motors, based on modern practices. The system includes programs, manuals and maintenance criteria to automatically produce working orders. Also, it records the status of the main electrical power equipment and allows the elaboration of preventive and predictive maintenance procedures.
Resonant Transformer for Generator Testing
The Institute designed and built a new resonant transformer for generators windings, distribution and submarine power cable testing. The resonance of the fixed coil transformers is adjusted with an electronic variable frequency supply from 45 to 120 Hz. The transformer can provide an output voltage of 20 kV. The equipment is compact and easy to transport.
Isotopic Study of Production and Reinjection Wells
In 1992 the IIE started the development
of new methodologies which would allow to determine stable isotopes in geothermal
fluids. Since then isotopic studies have been carried out in most of the
exploration areas as well as in all the exploitation fields in the country.
In 1997, a program of sampling of geothermal fluids and their isotopic characterization
was carried out in the main Mexican geothermal fields. The program included
138 wells from Cerro Prieto, Baja California; 30 wells from Los Azufres,
Michoacán and, 2 wells and 20 springs from Las Tres Vírgenes,
Baja California Sur.
The interpretation of the isotopic data gives information about processes occurring in the reservoir as response to the exploitation of geothermal fluids. The isotopic data provided the CFE with a useful tool which was helpful in decisionmaking regarding rational politics of extraction and reinjection of fluids from the above mentioned geothermal fields; allowing the anticipation of changes in the fluids exploitation and reinjection strategies and to infer reinjection effects in the surrounding wells.
Evaluation and Administration of Geothermal Fields
Since 1990 the IIE has developed tools to evaluate geothermal reservoirs, among these are data bases. During this year several modules from a user friendly intelligent system were developed. The modules, Núcleo, Visual, Geoquim and Simflu, were implemented in a computer network and are used to evaluate and administer geothermal reservoirs. The Núcleo module is the base of the system. It consists of a powerful, flexible and tested relational data base. It includes all the information usually required by the user in order to evaluate and administer geothermal fields. Visual is a visualization system integrated to the data base which automatically integrates pre-defined standard graphics. Geoquim incorporates all the commonly used geochemical records in the evaluation and administration of geothermal fields and automatically recovers the necessary data from Núcleo. Simflu allows the simulation of energy and mass flow in geothermal wells and like the other options, automatically recovers the necessary data from Núcleo. This intelligent system maintains only one consistent data base for the users in the geothermal department. It facilitates the interdisciplinary cooperation and generates important man-hour savings. During 1998 new options will be incorporated for the intelligent analysis of pressure tests and for the analysis of well production.
Petrophysics and Rock Mechanics
After several years of work, the IIE has been consolidated as the performer of specialized studies (never done before in Mexico). It has been recognized by PEMEX and the Instituto Mexicano del Petróleo (Mexican Oil Institute), in petrophysics and rock mechanics, petrography and petrology. During 1997 several studies were carried out for PEMEX Exploration and Production Division (Exploración y Producción) it is worth mentioning the petrophysical characterization, mechanics of rocks, petrography and geology of drilling well cores from the oil fields of Ku-Maloob-Zaap and Cantarell in the marine region of the sounding line of Campeche; Muspac, Iride and Samaria, in Tabasco and, Abkatún in the northwest sounding line. To support a project on the stability of wells on hydrophillic formations, studies on the characterization of mechanical behavior of cores from well SEN-143 were done for the Instituto Mexicano del Petróleo (IMP).
As a result of these studies useful information has been obtained in order to promote the development and exploitation of oil resources in the country. Moreover, technological independence has been achieved in addition to reliability, confidentiality in the results and considerable economic savings.
Wettability and Permeability in Drilling Core Samples
The national oil industry requires a great number of routine measurements and specific laboratory studies to generate information which will contribute to understand and to characterize multiphase flow phenomena between oil, brine and gas occurring in oil fields. The study of flow mechanisms is essentially based on the experimental determination of wettability and absolute permeabilities, effective and relative. Measurements are carried out directly on cores extracted from the drilled wells. In the country there is a very limited technical capacity to attend to these service requests. Due to this fact, and in order to support PEMEX and IMP, in 1997 an experimental functional leading system was built at the IIE. Nowadays absolute permeabilities, effective and relative, measurements under overloaded pressure and temperature reservoir conditions are carried out on core samples of up to 4 inches in diameter. Also, experimental capacity to carry out measurements on the water-oil preferential wettability index in drilling cores from oil wells was developed. These technologies included apart from learning and implementing new design methodologies, the design and development of original equipment.
Analysis of Advanced Boiling Water Reactors
The purpose of this development line is to obtain international competitiveness through participation in multinational programs. Collaboration projects with General Electric focused on the application of best-estimate methodologies for the design of the Simplified Boiling Water Reactor (SBWR). For this project, the impact of some model uncertainties was evaluated on the medium and long-term behavior of the SBWR containment during postulated loss of coolant accidents (LOCA). The results permit the application of these advanced methodologies to the safety analysis of other nuclear power plants.
Computing Program Development to Generate RAMA's Input Data from Nuclear Codes
With the acquired experience in the use and application of nuclear fuel management codes, the RACOID computing program, which generates the necessary nuclear information for the RAMA code (Radiation Analysis Modeling Application), was developed this year from the plant's operational information obtained from the lattice physics codes as well as from static three-dimensional nodal simulators. It was validated with the information from the Laguna Verde nuclear power plant. This project is part of a program being developed to evaluate the impact of the radiation over the internal structures and the reactor vessel and the way to mitigate the damage caused by this process. It is coordinated by the Electrical Power Research Institute (EPRI) with the participation of several other electricity generating companies like CFE.
Risk Analysis for PEMEX Facilities
A group of specialists from IIE performed
a risk analysis for the gas-crude oil separation and gas compression facility,
Poza Rica-X. This facility belongs to PEMEX North Region and is located
in the state of Veracruz. For this study, IIE used and integrated three
of the most advanced techniques for safety analysis: HAZOP (Hazard in Operations),
fault tree analysis and event tree analysis. From this study several recommendations
were proposed in order to improve installation's safety. Also, as part of
this project, PEMEX personnel were trained in the use of the mentioned risk
analysis techniques. It is worth mentioning that PEMEX also contracted with
IIE the risk analysis for the natural gas compression stations Sierrita
and Cuervito in Reynosa, Tamaulipas, as well as the risk analysis for the
crude oil storage and pumping facility in Poza Rica, Veracruz.
Probabilistic safety analysis (PSA)
IIE, under contract with CFE, migrated the Level I Probabilistic Safety Analysis of the Laguna Verde nuclear power plant to EPRI's CAFTA workstation platform. With the Level 1 PSA model installed in the new platform, the Laguna Verde Plant will be able to apply its probabilistic model in a very flexible manner to a wide range of day to day operational problems.
Projects with the Secretaría de Energía
Electrolytic cell coupled to a photovoltaic
panel to disinfect water.
Three projects have been assigned to IIE by the Secretaría de Energía (Energy Secretariat of the Mexican Government), in the areas of wind-electric and solar thermal concentrating power plants plus small photovoltaic systems interconnected to the electrical grid. The aim is to build a reference technical framework to facilitate decision making to foster and support electricity generation by means of non conventional energy sources. All projects will last for three years, along which technical and economical indicators for each technology will be derived; niches for applications as well as the technical and non-technical barriers for the introduction of these technologies will be identified; elements of strategy to foster and support the implementation of these technologies, as well as the methodologies, analytical tools and basic information for its performance analysis and evaluation will be developed. All three projects are being carried out within the framework of Mexico's participation in the Implementating Agreements of the International Energy Agency, which makes research more meaningful, enhances the country's presence at international fora and opens the possiblity to develop joint implementation projects with technologically advanced countries.
Solar Electricity for Water Disinfection
The problem of supplying good quality water to remote communities in Mexico, and in the world, is closely linked to the lack of electricity supply. In the project Clean water with clean energy, financed by the European Union, IIE is jointly working with other European and Latin American institutions in search of ways to disinfect water by means of electricity produced from local energy resources. One of the first results has been the electrical characterization of an electrolityc cell coupled to a photovoltaic panel, which produces a mixture of oxidant gases capable of killing all microorganisms which typically pollute water, including cholera. The only raw material needed for this process, besides electricity, is common table salt, which makes the technology very attractive for application in rural communities. The electrolytic cell was originally developed at the Centro de Adaptación de Tecnología (Cedat) of the Health Secretariat of Mexico, and is being optimized at IIE. Partners in this project include the Fraunhofer Institute for Solar Energy Systems of Germany; the Polytechnic University of Madrid, Spain; the National Institute for Agricultural Technology of Argentina; The Interamerican Center for Water Resources based in Toluca, Mexico; and the Iberoamerican Network for Rural Electrification with Renewable Energy (RIER) of the Program Science and Technology for Development (CYTED).
Energy from Sanitary Landfills
Biogas is a fuel which is naturally produced in sanitary landfills and is mainly composed of methane gas. It can be used to generate electricity, which offers a large potential for the mitigation of environmental pollution typical of these places. In 1997, IIE developed analytical tools to evaluate the technical and economic feasibility of using biogas from sanitary landfills to produce electricity. The tools developed can be applied to generate the technical and economic indicators that could help make decisions about the application and widespread use of the technology. Making use of biogas produced in all sanitary landfills across the nation to generate electricity, could mean saving around six million barrels of oil per year. Studies indicate that, under favorable conditions, the cost of electricity generation using this energy source could be competitive with that of conventional generation. The economical and environmental benefits offered by this technology can help promote eletricity self-generation by municipalities.
Wind Power Systems
In collaboration with other institutions like CFE, government bodies and private companies, IIE has actively participated for a number of years in the assessment and evaluation of the wind energy resources of Mexico. This activity has led to the identification of several areas with good potential for both, electricity generation on a large scale by means of wind power plants interconnected to the national electric system, and the supply of small quantities of electricity to remote regions without access to the conventional service. This year, IIE advanced the characterization of wind energy resources at several sites in the states of Baja California Sur, Quintana Roo, Oaxaca and Hidalgo. A good knowledge of the wind resource allows the development of other projects. The pre-feasibility study for a 150 MW wind power plant at La Venta, Oaxaca, was concluded this year. Work was performed with the economic support from The Commission for Environmental Cooperation of North America.
Flexible AC Transmission Systems
Analytical methods have been implemented to help utility planners to evaluate whether a transmission system can handle an increment in bulk power flow. A power system analysis package currently being used to identify possible bottlenecks on the transmission grid for power transfer. Evaluation of feasibility application of FACTS controllers in three areas of the Mexican power grid have been analyzed in order to alleviate power flow bottlenecks, enhance stability and increase overall network throughput. As a result it was found that thyristor-controller series capacitor and static vars compensators solutions increase power transfer in interconnections between two areas, one in the southeast and another in the northwest.
Static compensators to alleviate voltage stability under steady-state and dynamic conditions, for the Mexico City Area were sized and located in the transmission network. The commissioning of the static compensators will allow the reduction of load shedding practices, followed today under critical conditions in transmission and generations for the Mexico City Area.
Design of Dedicated Systems for Non-Linear Loads
The use of non linear loads connected to electric power systems is nowadays widely applied in industry, for a variety of applications such as electrochemical power supplies, adjustable speed drives, and uninterruptible power supplies. Since 1996, IIE has been working in the design and implementation of an offshore power system for Electrical Submersible Pump (ESP), an artificial lift system used by PEMEX in offshore oil fields where speed drives are used to control the operation of ESP. The work done by IIE included design, specifications, and commissioning of a generation platform and a submarine cable to power nine ESP systems. During the design and specifications of the system, special attention was given to harmonics control using phase multiplication and passive filters in order to keep total harmonic distortion at generating bus below 5% in voltage and 8% in current.
Powering and Grounding of Sensitive Electric Equipment
IIE put out information regarding recommended practices for surge protection of electric and electronic sensitive equipment, including wiring and grounding. These practices establish a basis for better surge protection, for reduction of losses, and for lessening surge-related damages to their electric and electronic equipment. Moreover, the recommended practices were applied to telecommunications stations and computer centers of the Mexican oil industry in the southeast part of the country, where lightning activity is one of the highest in Mexico.
Advanced operator's training simulators for Mexicali and Guadalajara area control centers
The IIE continued working on the
installation of simulators for operator´s
training of Electric Power Systems.
The installation of advanced simulators for operator's training of electric power systems (SENOP), which began in 1996, has continued for Mexicali and Guadalajara area control centers. Concerning Mexicali, the advanced simulator has been finished and its installation completed; whereas the computer hardware in which the simulator will reside has been installed in Guadalajara. The Guadalajara simulator is expected to be delivered during the first months of 1998.
It is important to mention that with the simulators assistance, the average period of time to fully train an operator has been reduced from almost two years to six months, period in which the trainees confront situations rarely encountered in reality in such a short period of time.
CENACE's Operation Planning Software modernization considering natural gas supply aspects
CENACE´s operation planning software
has been modernized through the development
of a mathematical optimization algorithm
for short term Operation planning, wich considers
new aspects in modeling natural gas supply restrictions.
The Energy Control National Center (CENACE), requested the IIE to modernize its Operation Planning Software through the development of a mathematical optimization algorithm for short term operation planning. This algorithm features new aspects in modeling natural gas supply constraints and pricing definitions. The new software integrates hydrothermal coordination and unit commitment functions. As part of this project, new versions of monthly and weekly hydrothermal coordination have been developed and integrated in workstations.
A System for Generator´s Retribution Evaluation of CFE Inner Energy Market
As a CENACE request, and based on a CFE's Technical Division proposal, the IIE developed a software system which calculates the hourly energy cost and estimates the retributions to CFE's generators for the energy and power dispatched.
The estimation system, which was installed in a CENACE's workstation, strengthens the adoption of the government owned utility inner energy market. This scheme looks for the sector's modernization, promotes optimum generation and allows the operative and financial performance evaluation of the conforming areas.
Substation Automation
Since 1995 IIE has been working together
with the CFE in the development of specifications and acceptance procedures
for a substation automation system known as SICLE. This system includes
SCADA functions, integrates information from intelligent electronic devices
(IED), such as multifunction meters and digital relays, on line and off
line maintenance functions of substation equipment, recording of variables
for incipient fault detection and general engineering analysis. IIE developed
a thermal monitoring system for power transformers using this platform.
Diagnostic Tools for Transformers
Transformer diagnostic services started
in 1994 at IIE. Although, with only few years of experience, a solid and
continuos advance has been achieved in this area. A set of high sensitive
testing techniques, such as partial discharges measurements, recovering
voltage techniques and low voltage impulse techniques were implemented to
evaluate the transformer insulation systems. Continuous technical support
was given to a national transformer manufacturer and a partial discharge
laboratory was installed in its factory.
Advanced techniques used on power transformers maintenance
IIE, on CFE request, participated in the diagnostic testing of power transformers (230 and 400 kV) using non-invasive techniques. A total of 18 power transformers from CFE were analyzed. The techniques were used to detect and locate electrical arcing and partial discharges occurring inside the power transformer.
Also, CFE asked the Institute for the development of a tool to keep the power transformer inventory, their location, manufacturer, commissioning and maintenance test data. As a result the information system named Simatrap was developed, where all the transformer data, including maintenance test records have been digitally stored.
Counter Measures Against Suspension Insulator Pin Corrosion
In the last three years, as a measure
for preventing the risk of failure resulting from a reduction in the mechanical
strength of the insulating strings, CFE carried out an extensive maintenance
program aimed at replacing a great quantity of suspension insulators suffering
from metal fittings corrosion (mainly pin corrosion). During 1996, the IIE
developed a research project whose findings allowed the experimental reproduction
of the corrosion process in the laboratory, as well as the selection of
a number of anti-corrosion coatings to be tested in the field. The experimental
field testing program was started in 1997, and monitoring of the performance
of the recommended coatings will continue until early 1999. The use of anti-corrosion
coatings will be helpful in increasing the life-time expectancy of insulators
already installed in the field, thus reducing the need of further extensive
replacement of damaged units. In addition, the reliability of those transmission
lines operating under highly polluted environments will be also increased.
Operative Performance of Insulators
The project to follow up the performance of ceramic and polymeric insulators installed in transmission lines continued. Leakage current monitoring systems were installed in several high voltage lines to diagnose the performance of insulators operating under high pollution environments. The monitors detect electric surface discharges caused by the pollution accumulated on the insulator surface under different ambient conditions. The analysis of the data helped to established efficient predictive maintenance and therefore to increase the reliability of the monitored lines. The excellent results obtained in this project permit recommending the leakage current monitoring methodology as a diagnostic tool for both conventional and polymeric insulators.
In order to reduce the high maintenance cost (live washing) of the conventional porcelain insulation installed in a 230 kV transmission line located in an industrial and saline pollution area, the insulators of 22 structures were substituted by polymeric insulators. During the first year of operation a reduction in the washings from 15 to one was obtained. During the next 6 months, laboratory tests were carried out (clean and saline fog) in order to obtain the flashover performance of these insulators naturally contaminated. Even at very high pollution levels, the flashover voltage of the insulators remained above the nominal voltage line, however, inspections of the surface condition of insulators, located in the most critical industrial area, showed erosion patterns. This methodology has allowed the appropriate documentation of the information of polymeric insulators performance in highly polluted areas (marine and industrial) and to recommend these insulators as an alternative for the solution to line outages due to ambient contamination.
Lightning Over-Voltages Suppressor
Due to the fact that lightning caused faults represent more than 45% of the total faults of the 230 kV CFE transmission lines, last year, IIE began the development, installation and monitoring of a lightning over-voltages suppressor for these lines. This suppressor is similar to commercial external-series-gap, but 65% cheaper. With the installation of the suppressor, a 40% reduction in the numbers of lightning faults in the lines is expected, where the improvement of shielding and earth connection are not enough.
Polymer Concrete Surge Arresters R&D
During 1996 the Institute designed and manufactured a pilot lot of 1500 polymer concrete surge arresters for 13 kV power distribution lines. These prototypes were installed at various Divisions of the CFE. This resulted in an important reduction in the number of interruptions due to lightning discharges in the period 1996-1997. The country wide use of these arresters to improve the continuity and quality of the electrical energy supply is expected in the coming years.
The Institute designed and manufacturing
a pilot lot of 1500 polymer concrete surge
arresters for 13 kV powe distribution lines.
Mobile Capacitors Bank
IIE designed and built a prototype of a mobile capacitor bank for CFE with the following characteristics: 20-30 MVAR for the 115 kV level. This equipment will permit CFE to respond to emergency situations in order to maintain voltage level in specific bus-bars. The prototype is under construction. Field evaluation will start on September 1998.
System for the Management of Information of Big Dams and Special Structures
In 1997 the IIE started the development of the Graphical Information System (GIS) that is a component of the Structure Safety System (SSS). The general aim of the SSS is to support the Civil Engineering Division (Gerencia de Estudios de Ingeniería Civil) of CFE in the task of recording and verifying the behavior of important civil works (like the big dams). The specific objective of the GIS is to facilitate the management of the graphical information related to the power plants. This information includes the construction and the operation stages. The GIS will also be of great help by supporting maintenance programs that are carried out in these structures. The system will be implemented under a client-server philosophy. The data base will be located in a RISC IBM/6000 computer, and will be consulted by 1 to 16 personal computers.
Elaboration of a Catalogue of Transmission Towers
As part of a project aimed to standardize and minimize the number of different designs of transmission towers, the IIE is working in the elaboration of a catalogue of transmission towers. The goal is to have a catalogue with a minimum of towers (around 30) with the following characteristics: (i) cover all the technical requirements in a safe and economical way, (ii) include 115, 230 and 400 kV lines, (iii) be located in any zone of Mexico, and (iv) consider the different climatic and topographic conditions of our country. The development of this catalogue is based on the diagrams of the mechanical use of each proposed tower.
The IIE is working in the elaboration
of a catalogue of transmission towers.
Each of these diagrams is a graphic that represents all the possible conditions under which all the structural elements of a tower are working below their maximum resistance capacity. These diagrams enable one to know, at once, the maximum mechanical usage that can be given to any of the towers within the catalogue, for the particular conditions of a project. Thanks to this development, CFE will have important savings in concepts like: engineering design, testing, inventory control, storage control, construction and maintenance. At this moment, the structural design of 17 towers that will be part of this catalogue has been carried out. The drawings for the construction of 12 of these towers are ready. During 1998 the IIE will continue the design of the rest of the towers of the catalogue, and will supervise the testing of the towers that are ready for that.
Seismic Safety of Substations
Due to the high intensity of earthquakes, porcelain fracture and collapse of substation equipment have ocurred, causing the interruption of service. To assist in the solution of these problems, the Institute continued the mechanical testing of equipment, to obtain natural frequencies and damping of base-equipment systems. These properties are essential to predict the seismic behavior of substation equipment on strong earthquake zones. The testing was carried out on equipment at the following substations: Lázaro Cárdenas-Potencia in Guerrero, Cerro Prieto III and Mexicali II in Baja California and Mazatlán in Sinaloa. These results aided the calibration of analytical models for the prediction of seismic response. Practical solutions for improving earthquake response of equipment were derived. A new general procedure for seismic qualification of equipment in zones with high seismic activity was proposed.
Refinery Seismic Safety
The institute revised the structure of the F-100 and F-800 heaters as part of a modernization project. After analysing three reinforcement options, it was found that the structure was unable to resist the design loading requirements, including the changes required by modernization, considering the required safety for this kind of structure. It was proposed to try other options to improve the efficiency.
Expansion and Rehabilitation of Substations
PEMEX Refinement Division (Refinación) has embarked in a modernization program for energy distribution systems. This implies adapting all civil works to the new needs of space and safety. The Institute carried out the detailed engineering of the modernization of six substations, using the most recent advances in analysis and seismic design. This project´s objective is to ensure the safety of the structures housing substation equipment and complementary installations.
Daylight Saving Time Analysis
Technical support was offered by
IIE to CFE and FIDE (Electric Energy Saving Trust) during the daylight saving
time (DST) program implementation in its second year of application, including
its impact analysis for 1996 and 1997. According to the study, which considered
more than 600 residential, commercial, and industrial customers, and information
supplied by the National Electric Energy Control Center from its different
control areas, 943 million kWh were saved, which represent 0.83% of the
national annual electric energy consumption. That is to say, residential
customers paid as a whole, 500 million pesos less than before DST implementation.
In regard to the demand, the maximum value was displaced from summer to
winter. The maximum demand decreased 529 MW, which is a 2.6% reduction that
represents a differed investment of almost 4 200 million pesos. The above
results confirm the expected savings for the program.
Potential Electric Energy Savings Determination
Electric energy opportunity areas were identified within the oil field facilities located in Aguadulce, Veracruz, Comalcalco, Ocosingo and Reforma, Tabasco, as part of the activities developed with PEMEX Exploración y Producción in the South Region, where electric energy audits were carried out in more than 100 buildings. It was determined through this study, that it is possible to reduce the electric consumption by 30%.
Electrical Studies
As part of the activities carried out for PEMEX, the IIE undertook the project: Short-circuit, Protective Devices Coordination, and Electric Grounding System Analyses for Tuzandépetl and Cuichapa Facilities. Recommendations for the modification of these systems were given. As a result, it is expected to have a reduction in physical risks and in electric outage rate.
Energy Efficiency Study in Air Conditioning Equipment
In conjunction with the Energy Savings National Commission (CONAE) and other entities devoted to a better use of electric energy, the IIE has developed several official energy efficiency standards for electric equipment and appliances in the last five years. On this basis, the revision of the NOM 073-energy efficiency standard for air conditioning equipment, which was published in 1994, was initiated.
Pilot Development of a Corporate Data Storage for CFE
The increasing amount of information, geographical dispersion and data diversity in CFE operative information systems may produce data duplicity and lack of precision in data recovering activities. To overcome these circumstances, IIE specialists created a solution via a corporate data storage. This pilot data storage embraces CFE operational databases (Sistermo, Sishidro and Energéticos) installed in an IBM server at Gerencia de Informática y Telecomunicaciones. In addition, the IIE trained CFE's personnel to conclude the data storage using additional utility processes. Using this data storage CFE will be able to carry out automatic analysis using intelligent algorithms to search for tendencies and patterns, which is impossible with the present processes.
Requirement Specifications for the Information System for Technology Administration
To assist the technology administration process at PEMEX Exploration and Production Division (Exploración y Producción), IIE proposed to develop a computational system to store and retrieve technological information in order to evaluate and make precise decisions. The first step was to create a detailed system specification showing an organized requirements analysis. Centralized database architecture, concurrent multi-user operation and flexible mechanisms to restrict access and confirm data are the principal characteristics considered in the specification. The Information System for Technology Administration SIAT (after its initials in Spanish) is projected to be in operation in 1998.
Requirement Specifications of an Operational System for Service Quotation
The CFE's Office of Informatics Systems Development (Oficina de Desarrollos Informáticos), belonging to the Laboratory for Equipment and Materials Tests (LAPEM), requires an operational system to speed up and standardize the quotation of its technological services. The IIE developed a project to specify the requirements of an information system capable to store, modify and consult LAPEM's standard rates, integrating artificial intelligence and distributed database concepts. The IIE will compete in bidding for the development of this service quotation system, COSEL (after its initials in Spanish).
In the coming few years, the most common practice to build corporate databases will involve Internet technologies, since they offer new answers to communication challenges and interface problems. Work was started at IIE to maintain its leadership in this field by creating a system to access construction standards of CFE's distribution air networks through the Internet. This friendly system allows browsing text, tables and graphics that integrate the standards, in a simple way. The current development will be used as a prototype to create and commercialize similar systems.
Local Area Communications Network for PEMEX
The IIE worked in the integration, setting in service and operation of a local area communication network for the Technology and Professional Development Subdirection (STDP) of PEMEX Exploración y Producción (PEP). The goal of this network is to communicate the oil specialists groups located across México City and Villahermosa, Tabasco. The network began operation using the most modern and efficient communication equipment and software to integrate the STDP-PEP Intranet. It allows the oil specialists to share information and to collaborate through discussion groups by means of desktop videoconference services.
Tele-measurement System for Analog Signals
A system named "Telemóvil" was developed by the IIE for the electronic office of the Laboratory for Equipment and Materials Tests (LAPEM) of the CFE. It is constituted by optical links that are used to carry measurement signals (bandwidth of 60 Hz) and telecontrol signals from the test area. User friendly software (virtual instrumentation) controls the instrumentation, sequencing, testing, starting, switching and capturing information. The system is very versatile and it can be used in any electric noise environment, making it very useful in a great number of applications.
| Líneas de desarrollo | Publicaciones | Página principal |