MANUFACTURING Design and manufacturing challenges
in bespoke excitation control Across Europe, many generators nearing 40 or 50 years of service still have their original steelwork, cabling and thermal clearances. Retrofitting excitation systems into these environments requires engineering matched precisely to ageing infrastructure. Article by, Ryan Kavanagh, director at excitation design specialist EES.
P
ower plants, whether newly constructed or undergoing retrofits, face unique challenges that demand customised excitation system solutions. Infrastructure constraints, such as limited space and legacy cabling, often require compact and adaptable systems and components. For example, retrofitting excitation systems into existing plant layouts may require panels that fit in tight spaces and align with predetermined generator specifications. Grid codes such as NESO’s impose stringent requirements on excitation systems, including rapid response times and fault ride-through capabilities. These standards ensure that excitation systems can maintain stability during grid disturbances, which is crucial for the reliable operation of power plants and the wider power systems.
Moreover, operators increasingly demand real-time performance data for monitoring purposes. However, cyber security concerns often limit the feasibility of remote-control access. Therefore, secure, read-only SCADA data streams become essential for providing the necessary insights without compromising system security.
Budget constraints, particularly in industrial sectors like cement and oil and gas, further
influence system design. These industries often prioritise modular, serviceable systems over full redundancy, balancing cost and reliability to meet their specific operational needs.
Site realities shape the system Retrofit and new build projects begin with detailed site surveys. These often include thermal imaging and cabling inspections to identify any physical or electrical constraints. This ensures that the excitation system design fits the unique requirements of each site. Modular, scalable excitation systems are then designed to match the required redundancy level, balancing reliability and complexity.
To address cybersecurity concerns, secure live data feeds are provided to client SCADA systems without allowing remote control access. Designs are continuously updated to reflect evolving grid codes and operational feedback. For example, a recent refinery retrofit successfully integrated modular excitation with partial redundancy and live data streaming, supported by comprehensive testing and simulation. EES has supplied excitation systems for sites with significant spatial and environmental
constraints. At the Thames Barrier, the original 1970s cubicles housing the emergency diesel generator controls could not be removed due to the cramped underground installation. To meet the constraints, EES removed the existing internal components and installed new systems within the same steelwork, working to a footprint of just 400 x 1000 mm. This allowed the barrier’s generation systems to be modernised without requiring structural changes.
Every power plant and industrial facility operates within its own set of challenges, and addressing those challenges starts with a system designed specifically for them. Whether its adapting to legacy infrastructure, meeting evolving grid codes or maintaining resilience in harsh environments, excitation systems must be tailored from the ground up. Learn more at https://excitationengineering.
co.uk/design/
32 DECEMBER/JANUARY 2026 | ELECTRONICS FOR ENGINEERS
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