Diesel & Gas Turbine Technology

January-February 2013

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Haight Notes

President & CEO..................... Michael J. Osenga Executive Vice President.... Michael J. Brezonick

Gas-Fired Power Generation On The Rise Increasing demand for electricity — coupled with new attitudes toward nuclear plants; increased emissions regulations affecting air, water and noise pollution; as well as increasing costs for wind and solar energy — bodes well for gas-fired power plants. While coal remains the dominant fuel for power plants around the world, its foothold as the fuel of choice for power generation is shrinking. In April 2012, the U.S. Energy Information Administration (EIA) published electric power data showing that, for the first time since the EIA began collecting the data, generation from natural gas-fired plants was virtually equal to generation from coal-fired plants, with each fuel providing 32% of total generation. Preliminary data showed net electric generation from natural gas at 95.9 million MWh, only slightly lower than generation from coal, which was 96 million MWh. Coal has been the main thermal electric fuel thanks to its cheap price, worldwide availability, easy transport and low-technology threshold. However, coal’s biggest drawback is the pollution emitted from its combustion. In January, the EIA released its Short-Term Energy Outlook. Despite projected declines in electric power consumption from 2012 levels, consumption of natural gas for electric power generation remains high by historical standards and reflects a structural shift toward using more natural gas for power generation. The EIA estimates that coal consumption in the electric power sector totalled 752 million tonnes in 2012, the lowest amount since 1992. Lower natural gas prices paid by electric generators led to a significant increase in the share of natural gasfired generation. The EIA expects that natural gas consumption will average 1.97 billion m3/d in 2013 and 1.96 billion m3/d in 2014.

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Editor & Publisher............................Brent Haight Managing Editor..............................Mike Rhodes Executive Editor....................................DJ Slater Regional Manager/Editor................Ian Cameron Regional Manager/Editor...........Roberto Chellini Regional Manager/Editor............ Roberta Prandi Field Editor/Business Manager......Bo Svensson Senior Editor...............................Joseph M. Kane Senior Editor.................................... Patrick Crow Associate Editor................................. Jack Burke Associate Editor..............................Chad Elmore Copy Editor.................................Jerry Karpowicz Digital Content Manager........... Catrina Boettner Advertising Manager.........................Sarah Yildiz Circulation Manager....................... Sheila Lizdas Production Manager.................Marisa J. Roberts Graphic Artist.........................Brenda L. Burbach Graphic Artist.............................. Carla D. Lemke Graphic Artist............................ Amanda J. Ryan Graphic Artist................................. Alyssa Loope

While total consumption is relatively unchanged from 2012, the makeup of that consumption is changing. Because of a warm winter last year, 2012 residential and commercial consumption was very low. However, the hot summer (as well as relatively low natural gas prices) led to record-high use of natural gas for power generation. Forecasts for closer-to-normal temperatures in 2013 and 2014 will lead to increases in the natural gas used for residential and commercial winter space heating. These increases are offset by declines in natural gas for power generation as summer temperatures are expected to be closer to normal, meaning cooler than they were in 2012. The EIA forecasts that natural gas will account for 27.5% of total generation in 2014 and coal will account for 39.6%, both relatively unchanged from the projected 2013 fuel shares. There is, however, a high degree of uncertainty in the generation fuel mix forecast. Lower than projected natural gas prices along with the industry’s response to future environmental regulations could cause the natural gas share of total generation to exceed this forecast. A

2 J a n u a r y - F e b r u a r y 2 0 1 3 Diesel & Gas Turbine Worldwide

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Brent Haight [email protected]

Reprints of all articles published in Diesel & Gas Turbine Worldwide are available. Please address inquiries to: [email protected] Tel: +1 262-754-4147 • Telefax: +1 262-754-4177

Contents January-February 2013

Cover designed by Brenda Burbach

January-February 2013

Features POWER GENERATION Centrax Ready For Russian Projects...........................................................4 Ansaldo Energia Wins €300 Million Contract..........................................18 Fast-Tracking Customized Power..............................................................22 Taking Over For OEM Control..................................................................26 Wärtsilä Helping To Power Jordan...........................................................48 OPRA Hits High Notes..............................................................................50 Alstom Adds 400 MW In Kuwait..............................................................58 LUBRICATION TECHNOLOGY Alignment On Cylinder Oils Concerns.......................................................6 Marine Lubricants With A “Green” Edge..................................................10 Lubes Key To Turbine Performance..........................................................20


WW JanFeb Cover.indd 1

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On The Cover: Our annual Power Plants Of The World feature examines power plants commissioned the previous year. Coverage of 2012’s power plants begins on page 32. Follow dgtww on:

Global Markets

VIBRATION DETECTION & ANALYSIS Partial Discharge Monitoring......................................................................8 Vibration Monitoring For Rotating Machinery..........................................12 EMISSIONS WORLDVIEW MAN’s EGR Achieves IMO Tier 3.............................................................14 Final Phase For Carbon Capture...............................................................52 INDUSTRY NEWS Mitsubishi To Acquire Pratt & Whitney Power Systems..........................16 New Marine Circuit Breaker Controllers..................................................30 Tackling The Threat Of Water..................................................................41 Now It’s Cummins’ Turn...........................................................................46


OIL & GAS Powering LNG-Fueled Drilling Rigs..........................................................28 Addition By Reduction..............................................................................44 Turkish Refinery Upgrade.........................................................................54

PRINTED IN THE U.S.A.

POWER PLANTS OF THE WORLD 2013 Power Plants Of The World 2013.............................................................32

Global Coverage

Departments ® MEMBER OF BPA WORLDWIDE DIESEL & GAS TURBINE WORLDWIDE (ISSN 02785994) Volume 45, No. 1 — Published monthly except, Jan/Feb & July/Aug issues combined, by Diesel & Gas Turbine Publications, 20855 Watertown Road, Waukesha, WI 53186-1873 U.S.A. Subscription rates are $85.00 per year/$10.00 per copy worldwide. Periodicals postage paid at Waukesha, WI 53186 and at additional mailing offices. Copyright 2013 Diesel & Gas Turbine Publications. Canadian Publication Mail Agreement # 40035419. Return Undeliverable Canadian Addresses to: P.O. Box 456, Niagara Falls, ON L2E 6V2, Canada. E-mail: [email protected]. POSTMASTER: Send address changes to: Circulation Manager, Diesel & Gas Turbine Worldwide, 20855 Watertown Road, Suite 220, Waukesha, WI 531861873 U.S.A.

Dateline.......................................................................................................9 Newsmakers..............................................................................................30 Featured Products.....................................................................................43 Industry Drivers........................................................................................45 Literature Library......................................................................................47 Advertisers’ Index.....................................................................................62 Marketplace...............................................................................................63 World Viewpoint.......................................................................................64 Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 3 3

Power Generation

by ian cameron

A Centrax installation in Siberia. Centrax technicians are preparing to install and commission 17 generating set packages.

Centrax Ready For Russian Projects Operational flexibility, ability to operate on associated gas with variable fuel quality key components of extreme regional operations

Despite the demanding environmental and competitive conditions in the Russian oil and gas industry, U.K.-based Centrax Gas Turbines is in the midst of one its busiest periods ever in the country. Centrax technicians are preparing to install and commission 17 generating set packages to aid the expansion of three oil fields. In the Tyumen region on the West Siberian Plain, 1600 km east of Moscow, 12 of the packages — each comprising a single 5.2 MW Rolls-Royce 501 unit — are being installed for the Ust Teguss field. The total generating capacity of 62.4 MW will meet the facility’s growing energy demands. Additionally, five Centrax CX501KB7 packages are set to equip the Verhnekolikieganskoe facility near Rostovskaya in southwest Russia, supplying 24 MW of power. As at Ust Teguss, a factor in the choice of Centrax packages was their operational flexibility and ability to operate on associated gas with variable fuel quality, the company said.

Both facilities are owned by TNKBP, for which Centrax has already supplied a fleet of 14 units operating at sites throughout Russia. Centrax, based in Newton Abbot, Devon, has also won a contract to supply two gas turbine packages to the South-Oshkoye oil field in Russia’s Komi Republic in northwestern Russia, 800 km northeast of Moscow. Centrax is working with St. Petersburg-based Zvezda Energetika. According to Centrax, its ability to deliver the first unit within four months was the prime factor for its success, helping the customer minimize its exposure to penalties incurred by flaring associated gas during 2013. The operational experience of Centrax units in harsh environments is another reason for the company’s current success in Russia, Centrax regional sales manager Nick Royal said. “In the Komi Republic, average mid-winter temperatures drop to around -20°C with an all-time low


recorded at -58.1°C,” Royal said. “In the Tyumen region, the average temperature over the whole year is only around 1.3°C, with continuous below-freezing conditions for much of the winter. “We have also developed a standardized design package for coldtemperature environments, incorporating special features such as additional space heaters and a temperature-regulated control panel shelter. These allow the equipment to be installed outdoors and to be maintained properly at these ambient conditions without the need for a special building, significantly reducing the overall project cost for our customers.” At less than 1 tonne, the 501KB7 gas turbine’s light weight means it can be delivered by road or helicopter to any land base. The company added it intends to use the experience it has gained in Russia and in its 20 million total operating hours worldwide to develop its business across other CIS countries. A

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Lubrication Technology

Castrol Marine agrees with MAN’s recommendation that shipowners use “cylinder lube oil with 70BN or higher” for latest generation superlong stroke engines using higher sulfur fuel (above 1.5 to 2%).

Alignment On Cylinder Oils Concerns Companies agree mid-range oils not blanket solution to all applications

Castrol Marine is supporting new recommendations to shipowners from MAN Diesel & Turbo that misapplication of mid-range Base Number (BN) cylinder oils can cause corrosion. The engine manufacturer recently issued service letters that recommend “cylinder lube oil with 70BN or higher” for latest generation super-long stroke engines using higher sulfur fuel (above 1.5 to 2%). MAN said it could not recommend cylinder oils with a BN level between 50 and 60 for these engines. The company said shipowners have been persuaded to try a host of new mid-range lubricants on the basis that they offer a solution across the range of sulfur content in fuel oil, including during slow steaming operations. For more than a year, Castrol Marine has advised owners that the use of mid-range BN cylinder oils when slow steaming could lead to cold corrosion. To combat this, Castrol Marine introduced Cyltech 80AW earlier this year, an 80BN oil addressing lubricant performance issues identi-

fied under slow steaming conditions when using HFO towards the top end of the permissible range. In a letter to customers on lubricant performance of 50 to 60 BN oils across its engine portfolio, MAN said, “Oil wear varies significantly between engine types and between operational conditions. Although mid-range lubricants were sometimes reliable, the test results from the mid-range cylinder oils cannot be transferred to general guidelines.” Another letter from MAN questions the “mid-range fits all” proposition. “At present, we cannot recommend these new type oils on our newest engine designs: the Mark 9, the S80MEC9, and all G-engines,” the company said. MAN said its B&W two-stroke design is based on optimization of the amount of a BN70 cylinder oil for fuel sulfur content above 1.5 to 2% and a BN 40 cylinder oil for lower sulfur content. Oils with a viscosity lower than SAE 50 are also not recommended for Mark 9 or G-type engines. “We welcome these recommendations from MAN,” said Paul Har-


rold, Castrol Technology manager, Marine & Energy Lubricants. “They support the exhaustive bench tests and shipboard trials that led to our own recommendations on cylinder oil selection in the slow steaming era. The recommendations we make to customers must always be based on sound science.” Some cylinder lube oil suppliers have suggested that a single midrange BN cylinder oil is sufficient for use with all marine fuels under all operating circumstances. Castrol said it believes customers faced with the prospect of only one grade of cylinder oil to cover all operating scenarios may be putting themselves at a disadvantage, especially if they regularly use fuel at the upper and lower ends of the permitted sulfur spectrum. MAN supports this assertion. “The design philosophy of two distinct lube oils is based on observations and tests showing that over-lubrication leads to over-additivation, with consequential risk of calcium deposit formation and total suppression of corrosion, thus decreasing the scuffing tolerance,” the company said. “Moreover, under-lubrication may lead to under-additivation, which will lead to corrosive wear in cylinder liners and piston rings.” Beyond 2015, MAN recommends BN 70 to 80 (-100) cylinder oils for fuels with up to 3.5% sulfur content and low BN oil in SOx-ECAs between 2015 to 2020. By 2020 and 2025, the engine manufacturer envisages fuels being used in combination with scrubber technology. “In case of scrubber solutions, high BN cylinder oil is to be used — ideally a BN 80 to 100,” MAN said. “In cases where very low sulfur content in fuel is anticipated, BN 10 to 20 cylinder oils are needed.” “Our technical arguments have been challenged by a series of competitor product launches of lubricants conceived before slow steaming was even adopted,” Harrold said. “This direct advice from MAN corroborates our own tests on the real issue.” A

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Vibration Detection & Analysis The new PD solution by Meggitt provides early detection of partial discharge pulses, utilizing coupling capacitors that can be installed extremely close to the windings for lower attenuation effects and more sensitivity.

Partial Discharge Monitoring Meggitt Sensing Systems launches new partial discharge (PD) monitoring system, adds to Vibro-Meter division

The hardware and software of the new Meggitt partial discharge (PD) system monitors, logs and reports partial discharge activity in the generators, motors and cabling systems used in industrial power generation. This new capability adds to the division’s Vibro-Meter power generation monitoring products, which already include machinery protection and condition monitoring systems and sensors for hydro, steam and gas turbines. Meggitt said the new PD monitoring system provides another level of protection for critical power generating machinery. In fact, the early detection of partial discharge enables condition-based maintenance to increase reliability and minimize repair costs, the company said. The manufacturer explained that a partial discharge is a localized electrical discharge in an insulation system that does not completely bridge electrodes, usually occurring in voids and gaps in high-voltage insulation. Partial discharges are a leading indicator of insulation breakdown that can lead to destruction of the generator. Meggitt Sensing Systems said its PD solution provides early detection of partial discharge pulses, utilizing coupling capacitors for direct measurements; an

interface to enable existing resistance temperature detectors embedded in the windings to be used as additional partial discharge sensors; and either a permanent or portable monitoring module, both of which come with Meggitt’s PDSight software for analysis and identification of trends. Meggitt said coupling capacitors (CC) are the hallmark of this technology sensor network because of their stable and reliable performance and robust design, which makes it possible to install them extremely close to the windings, thus minimizing attenuation effects and increasing system sensitivity. Once installed, the coupling capacitors monitor the current. If electricity starts to loop back instead of going out of the generator, reducing the efficiency of the system, the software highlights the situation to the operator, who can take action to remedy any problem long before there is a catastrophic failure. The CC 308, CC 316 and CC 328 from the Vibro-Meter product line represent Meggitt’s 8 kV, 16 kV and 28 kV options, respectively. Meggitt’s PD monitoring system offers coverage of critical stator windings areas by utilizing the VibroMeter RTD 600 interface module.


by roberta prandi

With a typical coverage of only the most critical 10 to 15%, coupling capacitors installed at the line terminals of a machine have a limited visibility into the machine windings. Meggitt said with its interface module, the existing RTD wiring in generators and motors essentially acts as an antenna for other signals in close proximity, allowing the monitoring system to see much more of the machine’s windings. Meggitt’s permanent, online solution is the PDM 150, a stand-alone monitoring system consisting of a power supply, main CPU and sensor inputs for up to 15 CCs, and the RTD 600. Additional inputs are available for temperature, ambient humidity, current, load and pressure, among others. The PDM 15P portable analyzer enables periodic recording of partial discharge activity and provides 15 input channels, with storage capacity to enable data from multiple devices to be stored and uploaded to a PC for further analysis. The PDSight software — supplied with the PDM 150 and PDM 15P — performs analysis and diagnostics, supports the configuration of the PDM 150 and 15P units, allows the analysis and display of all data generated, and simplifies downloading and storing of captured data. PDSight can measure or calculate multiple partial discharge pulse parameters including polarity, pulse count, magnitude, phase angle and partial discharge intensity in order to determine the type of PD problem and its severity. Meggitt said the PDSight software results in accurate partial discharge detection as a result of extremely low noise, achieved by noise cancellation and filtering techniques. As most of the discharge activity (and resulting released discharge energy) occurs below 30 MHz, all Meggitt systems are tuned to concentrate in this range. Meggitt said most competitive systems use only capacitive couplers as sensors, hence reducing the sensitivity of their systems. Thanks to their noise rejection capabilities, Meggitt said its systems monitor the frequency range of interest without being affected by interferences. A

Dateline

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September *Sept 24-March 22 - Diesel Progress Online Show XI, At www.dieselprogress.com and Diesel Progress Magazine; Diesel Progress, 20855 Watertown Road, Suite 220, Waukesha, Wisconsin, U.S.A. 53186 Tel: +1 (262) 754-4100 Fax: +1 (262) 754-4175 E-mail: [email protected]

february *Feb 4-6 - Power-Gen Middle East, Qatar National Convention Center, Doha, Qatar; PennWell Global Energy Corp., The Water Tower, Gunpowder Mill, Powdermill Lane, Waltham Abbey, Essex EN9 1BN, U.K. Tel: +44 1992 656 610 Fax: +44 1992 656 700 E-mail: [email protected] Web: www.power-gen-middleeast.com *Feb 6-7 - Gas/Electric Partnership Conference, Northwest Forest Convention Center, Cypress, Texas, U.S.A.; Gas/Electric Ventures, 5327 Mandell Boulevard, Houston, Texas, U.S.A. 77005 Tel: +1 (713) 529-3216

Fax: +1 (713) 529-3318 Web: www.gaselectricpartnership.com *Feb 17-19 - M.E.E. Middle East Electricity 2013, Dubai International Convention & Exhibition Centre, Dubai, United Arab Emirates; IIR Middle East, Office 301, Sultan Business Centre, P.O. Box 28493, Dubai, United Arab Emirates Tel: +971 4 3365161 Fax: +971 4 3353526 E-mail: [email protected] Web: www.middleeastelectricity.com

MARCH March 5-6 - Russia Power Conference, Expocentre, Moscow, Russia; PennWell Corp. Warlies Park House, Horseshoe Hill, Upshire, Esses EN9 3SR, United Kingdom Tel: +44 1992 656 617 Fax: +44 1992 656 700 Web: www.russia-power.org E-mail: [email protected] *March 6-7 - GlobalCon, Pennsylvania Convention Center, Philadelphia, Pennsylvania, U.S.A.; The Association of Energy Engineers,

4025 Pleasantdale Road, Suite 420, Atlanta, Georgia 30340, U.S.A. Tel: +1 (770) 279-4392 Fax: +1 (770) 381-9865 E-mail: [email protected] Web: www.globalconevent.com *March 10-13 - Western Turbine Users Group, San Diego Convention Center, San Diego, California, U.S.A.; Western Turbine Users, Inc., 6475 East Pacific Coast Highway, Suite 140, Long Beach, California 90803, U.S.A. Tel: +1 (513) 442-0986 Fax: +1 (532) 685-0662 E-mail: [email protected] Web: www.wtui.com *March 17-20 - Middle East Turbomachinery Symposium, Qatar National Convention Center, Doha, Qatar; The Turbomachinery Laboratory, Texas A&M University, College Station, Texas 77843, U.S.A. Tel: +1 (979) 845-7417 Fax: +1 (979) 845-1835 Web: http://middleeastturbo.tamu.edu E-mail: [email protected]

*Boldface indicates shows and conferences in which Diesel & Gas Turbine Worldwide is participating. A more complete listing of trade shows is available at www.dieselgasturbine.com

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In the event of a leakage, the newly developed range of Klüber Lubrication’s readily biodegradable speciality lubricants for ships and other marine applications reduce the threat to the environment.

Marine Lubricants With A “Green” Edge Specialty lubricants by Klüber Lubrication offer high-wear protection with low environmental impact

Under the motto, “Powerful, naturally,” Klüber Lubrication has presented a new range of readily biodegradable speciality lubricants for ships, offshore rigs and other marine applications. New additions to Klüber Lubrication’s portfolio are the hydraulic fluids of the Klüberbio LR 9 series, meeting the stringent environmental requirements of the European Eco Label. These synthetic oils are readily biodegradable and nontoxic, which makes a risk of leakage much less threatening to the environment. Klüberbio LR 9 oils are intended for use in mobile hydraulic systems in the marine and offshore sectors, but they are also indicated for landbased hydraulic applications in ecologically sensitive environments such

as in hydro-electric power plants or waterway locks. The new Klüberbio M 72-82 is readily biodegradable grease especially developed for rolling bearings. Thanks to its high resistance to water, the company said it protects components against corrosion, and its adhesion enables long relubrication intervals. This grease is also indicated for lowtemperature applications. “Both environmental authorities and ship operators increasingly call for biodegradable lubricants to be used in all lubrication points on a ship that can come in contact with water,” said Dirk Fabry, market manager, Marine & Offshore at Klüber Lubrication. “Consequently, the development of eco-compatible, highly efficient speciality lubri-


cants for the marine industry is a focal theme.” Synthetic gear oils for thrusters and rudder propellers are also within the company’s product range for marine applications, as are ecofriendly stern tube oils especially designed for the lubrication of bushes and shaft seals of fixed-pitch and controllable-pitch propellers. Klüber Lubrication is part of Freudenberg Chemical Specialities KG, a business unit of the Freudenberg Group, Weinheim, Germany. The company said that in developing new oils, there is a very close cooperation with its affiliated companies Simrit and Merkel Freudenberg Fluidtechnic, both manufacturers of shaft seals and profiled seals for the marine industry. A

Vibration Detection & Analysis

by roberta prandi

The Brüel & Kjær Vibro VDAU-6000 monitoring system for rotating machinery features a high-density, 16-channel parallel processing functionality and is Zone 2 ATEX certified.

Vibration Monitoring For Rotating Machinery VDAU-6000 scalar condition monitoring capability provides up to 16 configurable frequency band measurements per vibration input channel

Vibration specialist Brüel & Kjær Vibro has released a new condition monitoring system for rotating machinery. The VDAU-6000 — featuring highdensity, 16-channel parallel processing functionality — is capable of monitoring complex machine trains as well as balance of plant machinery. The Zone 2 ATEX certified VDAU6000 can be mounted directly next to the machines or placed in an instrument cabinet as a condition monitoring extension to an existing safety monitoring system. At the core of the VDAU-6000 lies a scalar condition monitoring capability that provides up to 16 configu-

rable frequency band measurements per vibration input channel, together with speed and process parameter measurements. These scalar measurements include, among others, running speed and harmonics, vectors, blade passing frequencies and bearing fault frequencies. Brüel & Kjær Vibro said these scalar values are easy to monitor and trend to provide early fault detection without false alarms, and do not require in-depth diagnostic expertise for interpretation. Moreover, each of these measurements can be monitored for specific operating conditions, thus providing even earlier reliable fault detection.


The VDAU-6000’s monitoring software and database platform, the Monitoring Workstation, is the same platform Brüel & Kjær Vibro uses on its flagship rack-based condition monitoring system, the Compass 6000. The optional Diagnostic Workstation software provides versatile online time waveform recording and analysis capabilities. The raw time signals for all channels are simultaneously recorded and can be stored and post-processed for analysis using FFT, Cepstra, enveloping or other systems. Brüel & Kjær Vibro provides a comprehensive product range, including rack-based, plant-wide monitoring solutions; vibration monitors; vibration sensors (acceleration, velocity and displacement sensors); and handheld instruments. Brüel & Kjær Vibro is part of U.K.based Spectris plc, a supplier of productivity enhancing instrumentation and controls. A

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Emissions Worldview

MAN’s EGR Achieves IMO Tier 3 Broad cooperation results in emissions compliance without significant engine performance compromise

A detailed illustration of the total EGR integration into the new MAN B&W engine type 6S80ME-C9.

MAN Diesel & Turbo, together with HHI-EMD, the engine and machinery division of Hyundai Heavy Industries, has presented the first IMO Tier 3-compliant diesel engine utilizing exhaust gas recirculation (EGR), the company said. The presentation of the engine took place at HHI-EMD production facilities in Ulsan, South Korea. The new engine type, a MAN B&W 6S80ME-C9 with integrated EGR, was presented to a group representing shipyard and ship owners. MAN Diesel & Turbo began testing exhaust gas recirculation (EGR) as applied to their two-stroke research engine in Copenhagen, Denmark, years ago. The EGR technique makes the marine diesel engine IMO Tier 3-compliant, the company said. “The testing achieved a low penalty,

equivalent to 1 to 3 g/kWh, which is even better than our most optimistic expectations,” said Søren H. Jensen, vice president and head of Research & Development, Marine Low-Speed, MAN Diesel & Turbo. “The EGR system represents a milestone in Tier 3 development, enabling the engine to meet IMO Tier 3 NOx regulations, which will be introduced in ECAs (Emission Controlled Areas) from 2016. The new development means that this strict emissions limit can be met without significantly compromising engine performance.” The EGR system was designed, produced and assembled in close cooperation with HHI-EMD, Alfa Laval, Siemens, GEA and Vestas Aircoil. The combined efforts have ultimately resulted in a reliable prototype engine configuration that MAN Diesel &


Turbo stated will form the basis for its future low-speed diesel program. “As a promising spin-off benefit, the engine can also run in a fuel-optimized Tier 2 mode that facilitates an approximate 4 g/kWh fuel-oil consumption reduction at part load,” Jensen said. The favorable result was accomplished through a combination of sequential turbocharging, turbocharger cutout and low EGR rates. This makes the engine even more efficient than today’s high-efficiency Tier 2 engines during transoceanic operation, MAN said. The engine will be installed in a Maersk Line C-class container vessel currently under construction at Hyundai’s shipyard. The ship is due for delivery during the first quarter of 2013 and is bound for service between Southeast Asia and West Africa.

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A view of the MAN B&W 6S80MEC9 engine with integrated EGR pictured at HHI-EMD, the engine and machinery division of Hyundai Heavy Industries.

The A.P. Møller-Maersk Group and MAN Diesel & Turbo have agreed to operate the engine 20% of the time in IMO Tier 3 mode, and to otherwise

favor the fuel-optimized Tier 2 mode with low EGR rate. “We intend to follow the engine’s performance closely over the next

three years in order to gain service experience and increase the EGR system’s reliability for future engines,” Jensen said. A

Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 3 15

(Image courtesy of Pratt & Whitney)

Industry News

Pratt & Whitney Power Systems’ (PWPS) aero-derivative gas turbine.

Mitsubishi To Acquire Pratt & Whitney Power Systems Mitsubishi Heavy Industries Ltd. to acquire industrial power generation company Pratt & Whitney Power Systems, agreement signed with United Technologies

Mitsubishi Heavy Industries Ltd. (MHI) has reached an agreement with United Technologies Corp. (UTC) under which MHI will acquire Pratt & Whitney Power Systems (PWPS), the small- and medium-size gas turbine business unit of aero-engine manufacturer Pratt & Whitney (P&W). MHI and UTC, P&W’s parent company, signed the agreement in early December. PWPS engages primarily in the engineering, assembly and sales of aeroderivative gas turbines and also provides gas turbine services and engineering, procurement and construction services of related power generation systems. The company has approximately 430 employees. PWPS owns a majority share of Turboden s.r.l. of Italy, a manufacturer of organic rankine

cycle (ORC) turbines, which will also be included as part of the acquisition. MHI, which has focused its gas turbine business principally on largecapacity, high-efficiency systems, will significantly diversify its power generation product portfolio with the acquisition of PWPS. PWPS’s aeroderivative gas turbines are known — especially in emergency power generation applications — for their compact design and rapid start-up time, with over 1700 units delivered to date worldwide. Going forward, significant growth is anticipated in applications requiring a flexible power source complementary to a renewable energy power source, the company said. Robust market demand is also expected for small power sources applications in emerging markets. PWPS’s


main products to date have been 30 MW class machines, but currently the company is developing new 60 MW class models, which are expected to boost PWPS’s market share significantly, the company said. PWPS U.S. operations will be aligned with Mitsubishi Power Systems Americas Inc. (MPSA), headquartered in Lake Mary, Florida, U.S.A. “The PWPS business offers tremendous synergy with our existing U.S. operations,” MPSA President Koji Hasegawa said. “It significantly diversifies our equipment offering and compliments the scope of our service business.” Turboden’s ORC turbines have the capability to generate power or supply hot water using a relatively lowtemperature heat source, e.g. biomass, factory waste heat or geothermal energy. To date, the company has sold more than 300 units in 20 countries, primarily in Europe. In Japan, increasing opportunities are emerging to use this technology in biomass and geothermal applications. In its gas turbine business, MHI is presently establishing a global structure to substantially increase annual manufacturing capacity of large high-temperature, high-output gas turbines. In addition to output from its Takasago Machinery Works in Japan, shipments have now also begun from MPSA’s Savannah Machinery Works, a new gas turbine manufacturing and service facility located in Pooler, Georgia, U.S.A. With the addition of flexible and reliable small and medium-size offerings to its product portfolio through the acquisition of PWPS, MPSA will now be able to meet broader customer needs through combinations of those units and high-efficiency machines, the company said. MHI intends to further strengthen its marketing activities for gas turbines, which the company said can offer clear benefits in terms of efficient energy usage and reduction of environmental burdens, leveraging the merits of both large-capacity and aeroderivative gas turbines as well as their synergy effects. A

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Power Generation

Three Ansaldo Energia AE943A4 gas turbines — manufactured in the company’s production facility in Genoa, Italy — will deliver a total rated output of over 660 MW to the new Hassi Messaoud power plant in Algeria.

Ansaldo Energia Wins €300 Million Contract With contract for Hassi Messaoud power plant, Ansaldo Energia passes 4000 MW total power output supplied for Sonelgaz power plants in Algeria

Ansaldo Energia has received a €300 million contract from Sociéte Algérienne de Production de l’Électricité (SPE), a Sonelgaz group company. Ansaldo Energia will supply the Hassi Messaoud (Wilya d’Ouargla) open-cycle power plant with a total rated output of more than 660 MW. The plant comprises three generating sets — three Ansaldo Energia gas turbines model AE 94.3A and alternators — all manufactured at the

company’s production facilities in Genoa, Italy. The company said this project further strengthens its cooperation with Sonelgaz as one of the main development partners in Algeria’s strategic electric power production plan. The first contract for Ansaldo Energia in Algeria dates back to the early 1970s, when the company handled a project for Sonelgaz regarding a 75 MW thermal power


station in Annaba This first project was followed by several other thermal power plants in the Oran area, at the time the biggest power plant complex ever built in Algeria. With the introduction of gas turbine technology in Algeria in 1999, Ansaldo Energia completed the Hamma opencycle power plant, which included two 225 MW turbines. Additional projects followed, including a station in Larbaa (four 140 MW turbines); a plant in Ain Djasser (two 130 MW turbines); a plant in M’Sila (two 215 MW turbines); a station in Labreg (two 140 MW turbines); and an extension to the Ain Djasser plant with two more 130 MW turbines. With this latest contract for the Hassi Messaoud power plant, Ansaldo Energia has contributed over 4000 MW total power output for Sonelgaz power plants. A

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Shell has 60 years of experience in developing oils for gas turbines and is currently redeveloping its top-tier Turbo GT for use in industrial light- and heavy-duty gas turbines and turbo compressors.

Lubes Key To Turbine Performance Advancing technologies, firing temperatures increase as operators strive to produce higher MW; lubricants must keep pace with demanding conditions

It is widely known that the prevention of a gas turbine failure is crucial to operators and original equipment manufacturers. One of the key factors to a turbine’s reliability is also one of the least visible parts of the power generation process — lubricating oil. Theoretically, turbine oils should last for years, although exactly how long is subject to a variety of factors, especially as the fluid must have good thermal and oxidation resistance. “Modern lubricants need to keep pace with advances in turbine technology,” said Peter Smith, Shell’s technical manager for industrial specialties, Shell Lubricants, which focuses on turbine, electrical and process oils. “Gas turbine firing temperatures are increasing to up to 1450°C and, although the oil is not directly exposed to this temperature, this means that the whole gas turbine system is

under much more stress than ever before,” Smith said. “Therefore, lubricating oils have to be more resistant to such things as deposit formation due to oxidation and thermal degradation. Firing temperatures in gas turbines over the years have gone up by hundreds of degrees. The temperatures have increased so much because operators want to produce even greater MW of power. For example, a Siemens gas turbine can produce up to 375 MW; the lubricants have to be able to withstand the demands placed upon them in such conditions. “As OEMs and operators try to achieve higher and higher efficiencies from their gas turbines, we can provide a lubricant able to help them achieve that, especially as some operators want more than 50 000 operating hours from their lubricants before a service. Of course, OEMs


by ian cameron

want their gas turbines to last longer and provide maximized reliable service between extended maintenance intervals.” Shell said it is currently redeveloping its top-tier Turbo GT using its proprietary additives and Group 3 base oil. It is being designed for use in industrial light- and heavy-duty gas turbines and turbo compressors. According to Shell, Turbo GT has up to 50% better oxidation stability compared with the industry standard for gas turbines. Shell uses gas to liquid (GTL) technology, utilizing the Fischer-Tropsch process that converts gas and feedstocks to liquids. Shell’s Pearl GTL plant in Qatar makes synthetic oil products from natural gas, including cleaner-burning diesel and oils for advanced lubricants. “Another trend we are noticing during discussions with turbine manufacturers concerns the growing demand for smaller lubricant reservoirs for gas turbines,” Smith said. “Not only do OEMs want to optimize the power and efficiency of their machines, but they want to control the cost of manufacturing their gas turbines. They prefer smaller lubricant reservoirs as smaller amounts of lubricants can now be considered using the latest generation of top-tier oils. If the reservoirs are smaller, then the turbines can be downsized and the cost of components reduced. “Good surface properties of the oil, such as rapid air release, are essential. If these are poor, that can lead to foaming of the oil. Under changing load, entrained air can be released, causing bubbles and foaming. In highly loaded regions, this can cause the air and oil vapor bubbles to literally implode and burn, thus potentially causing cavitation damage to the turbine’s bearings.” Shell has 60 years of experience in developing oils for gas turbines and supplies fuel and lubes to more than 1500 power plants in more than 80 countries — some 100 people work in its power sector product area. The company has technology centers in the U.S.A., U.K., Germany, India, China, and a joint venture in Japan. A

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Power Generation

by mike rhodes

The existing 100 MW turnkey plant in Uruguay consists of four high-power density FT8 MOBILEPAC dual-fuel turbine generators.

Fast-Tracking Customized Power New contract will provide additional 200 MW capacity to Uruguayan national grid in conjunction with existing plant, offers example of temporary bridging solutions

APR Energy has signed a new 200 MW contract in Uruguay to supply its fast-track, temporary power solutions to the national grid to address the country’s anticipated power needs. The initial term of the contract will run into mid-2014. APR Energy also announced that it has signed an extension to its existing 100 MW contract with the customer. “This new deal, together with the contract extension, is representative of the strong demand we continue to see across the temporary power market, particularly in Latin America, Africa, the Middle East and Asia,” said John Campion, APR Energy chief executive officer. “As seen with the Uruguay contract, a key growth driver of the tem-

porary power market continues to be demand for mobile gas turbines.” The electricity sector of Uruguay is largely based on domestic hydropower, which leaves the country vulnerable to seasonal rainfall patterns. The Uruguayan state power company Usinas y Trasmisiones Eléctricas (UTE) needed a reliable, cost-effective temporary power solution to meet demand while new sources of power generation were financed and built. In the fall of 2012, APR Energy delivered, installed and commissioned a 100 MW turnkey plant consisting of four high-power density FT8 MOBILEPAC turbine generators able to run on both diesel and natural gas. The FT8 features a prime power out-


put of 24 MW at 3000 r/min (50 Hz) and 25 MW at 3600 r/min (60 Hz). APR Energy said that the units have been specifically designed for fast-track mobilization and installation and can be put into place often in less than a day. The company said this allows for the smallest footprint within the industry — an 8 x 18.5 m space — and requires very little advance site preparation, significantly decreasing the overall installation time. The current plant, including the required substation and interconnection works, was completed in 45 days. “Efficiency and emissions are the major compliances you have to face with every project,” said Mitchell continued on page 24

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Power Generation

Providing 24 MW of peak demand backup power to one of the Sultanate of Oman’s electricity distribution companies (MEDCO), APR Energy’s equipment was required to operate reliably under the extreme daytime temperatures.

Bridgeforth, director, Turbine Business Unit, APR Energy. “Those were the drivers for UTE in Uruguay. They were aware of what they needed, aware of the trends in emissions, and it matched what we were offering, the latest in mobile turbine technology.” Bridgeforth said that sometimes APR Energy moves into markets that are unsure of what solution will best meet their need. “We are a total turnkey company,” Bridgeforth said. “We are able to go in, determine what the customer’s exact needs are, design a customized solution to meet the those needs, get their feedback, maybe tweak it a bit, and come up with the best solution.” This theme of customizing solution to application runs through everything APR Energy does, the company said. APR Energy provided 24 MW of peak demand backup power to one of the Sultanate of Oman’s electricity distribution companies (MEDCO) in

the event the power grid got close to regulation capacity, particularly during the blistering summer months when heavy demand can cause intermittent power outages. APR Energy said it was able to deploy and commission the site in less than 20 days, and local specialized contractors were utilized to fabricate the fuel supply system and build the interconnection infrastructure. As a result of the devastating earthquake and tsunami that struck Japan in early 2011, the Tokyo Electric Power Company (TEPCO) lost nearly 21 GW of its capacity, leaving 4.4 million households without power. Power needs for rebuilding and disaster recovery were immediate, with no time for construction or setup; the country was without a unified power grid; radiation exposure heightened scrutiny of nuclear reactor use and lead to shut down of all nuclear power; oil refineries were set ablaze, complicating fossil-


fuel power delivery; and supplemental power was not sufficient to meet the demand, particularly in the cities of Hitachinaka and Yokosuka. “Japan was an, ‘All hands on deck’ project,” Bridgeforth said. “For everyone, there was no concern for how much it cost or how it got done. They needed power, right now.” APR Energy shipped and airfreighted 69 diesel and gas turbine power solutions and personnel from all over the world. Only days after the last delivery of equipment, both plants (Hitachinaka and Yokosuka) were fully operational, delivering 203 MW to the TEPCO grid. “We still have equipment there, but as they repair facilities and bring more of their own power online, they are phasing us out as they should,” Bridgeforth said. “That’s our job, that’s what we do. “That is an example of what you will see moving forward — bridging

Power Generation

The APR Energy FT8 MOBILEPAC features a prime power output of 24 MW at 3000 r/min (50 Hz) and 25 MW at 3600 r/min (60 Hz).

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solutions to permanent power that slowly evolve into longer and longer term deals. Cogeneration, nuclear or hydro facilities take a lot of time, money and effort to build, and until they can get them built, they need power. As part of that bridging solution, we have to work very closely with that utility to interconnect into their grid system and transition seamlessly to make sure there is no loss of power between the bridging solution and the permanent solution.” APR Energy’s primary market has been emerging markets, where loss or lack of power can be disastrous both economically and socially. “These countries are some of the neediest anywhere,” Bridgeforth said. “We don’t just produce temporary power and leave. We look at the bigger picture and the effect on the community.” APR Energy said it maintains a strong local hiring and training program — approximately 86% of employees are local. “They understand out projects are interim, but they are receiving training and certifications in their fields — mechanical, welding, fuel oil handling, accounting, computer skills — so after we move out they have job skills to move forward.” In places such as Ecuador, Costa Rica, Botswana and Haiti, APR Energy has worked closely with locals to install technology centers, build and improve schools, assist with disaster relief, improve food supplies, fix or construct water pumps and initiate health center programs. In Costa Rica, the abandoned site was transformed into a community soccer pitch, complete with bleachers and water fountains. In addition to making a meaningful impact on the regional economy, the setup and operation of APR Energy’s dual-fuel turbine solution has helped provide a temporary solution to Uruguay’s supply/demand constraints. “This new deal was driven by our ability to offer our customers fast-track solutions that meet their specific technology needs and emissions requirements,” Campion said. “It is further testament to the opportunities and success we are seeing in our strategy to offer gas turbines in the temporary power marketplace.” A

Power Generation

by mike rhodes

The immediate focus of this collaboration is the launch of a Rockwell Automation PlantPAx-based controls upgrade, which the company said is the only process automation system capable of managing the entire range of automation applications including motion, safety and drive systems.

Taking Over For OEM Control Wood Group GTS, Rockwell Automation collaborate to develop, deliver third-party control solutions

Wood Group GTS and Rockwell Automation have formed a strategic partnership to facilitate the joint development of a fully integrated, openarchitecture alternative to proprietary original equipment manufacturer (OEM) gas turbine control systems. The companies said this partnership brings together two of the industry’s leading service and technology providers with complementary capabilities. Cooperation initiatives include joint engineering, product development and packaging of solutions; global manufacturing and spares/technical support; comarketing and sales initiatives to grow market share; and optimization of technology integration. The immediate focus of this collaboration is the launch of a PlantPAxbased controls upgrade for operators of DLN equipped GE Frame 6B, 7E, and 9E gas turbines, with future expansion into F-class machines. The Rockwell Automation PlantPAx process automation system is built on standard-based architecture using components that enable multidisciplined control, the company

said. The distributed control system (DCS) can integrate skid-based equipment into the overall system and ensure easy incorporation into the existing plant control systems. Rockwell said that the PlantPAx is the only process automation system capable of managing the entire range of automation applications including motion, safety and drive systems. “We have an extensive history of working with Rockwell Automation’s proven hardware and software with hundreds of turbomachinery applications and thousands of batch, process and general automation systems installed,” said Frank Avery, president of Wood Group GTS’ Power Plant Services. “This partnership was formed to deliver a fully integrated, open architecture controls solution for both the heavy frame gas turbines and balance of plant applications.” When it comes to maintaining vital control systems for gas turbines, users are often at the mercy of proprietary OEM control systems, Wood Group said.


When optimizing performance and managing costs, managers and operators experience issues such as locked “black box” software, which can leave managers unable to access, control of make system changes to control logic; high cost or unavailability of site-specific customizations; long wait time for issue resolution; short life cycle and higher cost of spares and support; lack of capability of user modification, which triggers higher support and operating costs; and the inability to respond effectively to changing operating requirements. “Purpose Built” hardware platforms are often closed solutions manufactured, supported and priced by OEMs. Wood Group said that because of these issues, upgrades are budgeted due to premature hardware obsolescence dictated by the OEM rather than from a planned maintenance perspective. Both companies stressed that gas turbine owners and operators face mounting challenges in managing power generating assets effectively and profitably, all the while confronted by shifting operating profiles brought on by complex market dynamics. “Power generation companies are under pressure to drive operational flexibility and maximize performance while also driving down operating costs, minimizing risk of plant operations, meeting regulatory emissions levels and achieving high thermal efficiencies,” said John Nesi, vice president of Market Development for Rockwell Automation. “By combining our best-in-class process control technology with Wood Group’s industry knowledge and expertise, we’re able to offer our mutual customers proven, safe and field-tested turbine control system upgrades that maximize their return on investment by reducing operating costs, lowering total cost of ownership and improving availability.” Wood Group said its control systems solutions have been field tested and plant proven in over 500 retrofitted systems, 60 different turbine models and by 17 different turbine manufacturers. A

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Oil & Gas

Seneca used GE’s 1 MW Jenbacher J320 turbocharged natural gas engines to convert the power plants of two existing diesel-powered rigs to use cleaner-burning LNG.

Powering LNG-Fueled Drilling Rigs Seneca uses GE Jenbacher gas engines to replace diesel generators, reduce emissions in giant unconventional gas field

Energy developer Seneca Resources Corp. and drilling partner Ensign Drilling have installed two GE Jenbacher gas engines to power the first liquefied natural gas (LNG)-fueled drilling rigs of their kind in the Marcellus Shale region of Pennsylvania, U.S.A. The gas-rich Marcellus Shale formation is located in sections of Pennsylvania, New York, West Virginia, Ohio and Maryland. Seneca converted the power plants of two existing diesel-powered rigs to use cleaner-burning LNG in GE’s 1 MW Jenbacher J320 turbocharged natural gas engines. The Jenbacher units were combined with Ensign Drilling-designed rig packages to provide all the electricity needed by each drilling rig. The J320 represents GE’s first U.S. Environmental Protection Agency certified technology for mobile and stationary drilling applications, the company said. In October 2012, Seneca Resources and Ensign Drilling converted their first rig, which is operating in Lycoming County, Pennsylvania. The second rig was converted to LNG in Novem-

ber 2012 and was assigned to Seneca’s Marcellus Shale gas leases in Forest, Elk, Jefferson and McKean counties. Powering a drill rig with natural gas instead of diesel can result in up to 60% lower fuel costs. LNG also represents a cleaner alternative to diesel for the transportation industry and trucks, reducing overall combustion emissions up to 25%, the company said. Unconventional gas is quickly becoming the most abundant source of natural gas in the United States and accounts for about a quarter of U.S. natural gas production. By 2035, half of U.S. natural gas will come from unconventional sources, according to the U.S. Energy Information Administration (EIA). The boom in unconventional gas, up from just 2% of the total in 2000, has cut gas prices to record levels, reduced energy imports and set the country on a path to energy independence. Seneca Resources is a wholly owned exploration and production subsidiary of National Fuel Gas Company, while Ensign Drilling is a land-based driller and well servicing provider for


crude oil, natural gas and geothermal projects. Prometheus Energy Group, a North American industrial LNG supplier, is Seneca Resources’ turnkey supplier of the LNG and related equipment and services. “We are excited to work with our partner Seneca Resources to implement this innovative project,” said Robert Geddes, president and CEO of Ensign Drilling. “By using LNG in GE’s proven Jenbacher gas engines to reduce the environmental impacts of energy production, we are giving communities in Pennsylvania the opportunity to share in the economic benefits of developing the Marcellus Shale gas reserves.” Ensign Drilling operates 15 drilling rigs utilizing natural gas in the United States — 11 of them exclusively using GE’s Jenbacher gas engines. The latest project with Seneca Resources further underscores the oil and gas industry’s increased deployment of more efficient and cleaner on-site power solutions. “Our fuel-flexible Jenbacher gas engine technology offers customers lower-emission on-site power generating capabilities, making it ideally suited to support Seneca Resources and Ensign Drilling’s LNG initiative,” said Roger George, North America general manager – Gas Engines for GE Power & Water. “We think this will serve as a model for other operators in the Marcellus Shale region.” A

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Industry News

Newsmakers

The LS-5 and easYgen control systems may act as a link for all related engine and generator information.

New Marine Circuit Breaker Controllers LS-5 manages complex power generation and distribution systems, synchronizes up to 32 different bus segments

PG&D, a business unit of Woodward Inc., announced the release of the LS-511/521 Marine circuit breaker controllers. The LS-5 controller series is approved by major marine certification societies in conjunction with Woodward’s easYgen-3000 series gen-set controllers, enabling the full management of complex electrical power systems in the most demanding marine applications, the company said. The new LS-5 series circuit breaker controllers include expanded CAN communication to the easYgen-3000 series gen-set controllers for managing complex power generation and distribution systems with multiple tie and feeder breakers. This functionality can now be extended to offshore applications with marine versions having DNV, Lloyd’s Register and ABS approvals. Available in door mounted and back-panel mounted variants, the

LS-5 series controllers and the easYgen-3000 series controllers are designed to accommodate tight space requirements, said Woodward. A remote panel RP-3000 can be used with either of the variants for remote control. Up to 16 LS-5’s can communicate with up to 32 easYgen systems over a single CAN communication line, greatly reducing point-topoint wiring. The LS-5 and easYgen control systems provide isochronous load sharing, soft loading/unloading, and active synchronization on up to 32 different bus segments. This system may act as one communication link between a vessel’s power management system and gen-sets for all engine and generator related information, leading to fewer components for the power plant. Woodward said the system helps meet precise dynamic positioning requirements, a crucial requirement for mobile offshore drilling units. A


VOITH TURBO: Voith Turbo has named Christian Strahberger its executive vice president of Voith Turbo Schneider Propulsion GmbH & Co. KG. He is responsible for Voith Schneider Propeller, as well as the products for Voith Inline Thruster, Radial Propeller, SteamTrac, and Voith Turbo Fin. Strahberger succeeds the previous division head, Martin Füllenbach. Prior to joining Voith AG, Strahberger worked for seven years at Siemens Management Consulting in Munich as a consultant and project manager of international industrial projects of Siemens AG. At Voith, Strahberger started out at Voith Paper in 2009 as vice president – Strategy. From 2010, he was in charge of rebuilds, spare and wearing parts, as well as services for stock preparation and recycling machinery as senior vice president – Products & Services, and was a member of Voith Paper Fiber & Environmental Solutions management board. McCROMETER: McCrometer has hired Carl Kull as its regional sales manager for the oil & gas and C. Kull industrial markets for Southeast Asia. Kull, who reports to David Splatt, director of Sales, joins McCrometer following 18 years at ABB’s K-TEK division as the regional sales manager for Asia and Asia Pacific, where he developed international managers and representative sales networks in the industrial process measurement industry. Early in his career, Kull served in the U.S. Navy, where he held electronics technician certification, nuclear power certification and nuclear operator and nuclear ET certifications. EGSA: The Electrical Generating Systems Association (EGSA) has named Robert (Bob) Breese as the association’s new director of Education. Breese has more than 30 years of experience, most recently working as the lead service trainer and technical writer for Generac Power Systems. In that position, he developed the course curricula for Generac’s factory and field service training programs. He has also

Newsmakers served as an EGSA Advanced and Basic School instructor for the past three years. Breese’s responsibilities will include directing the association’s educational programs such as the Basic and Advanced Power Schools, the EGSA Technician Certification Program, as well as the David I. Coren Scholarship Program. Breese will also have full responsibility for the eLearning Program as it is developed and implemented. R. Breese

MIRATECH: Miratech has named Jessica M. Hotier as its marketing director. She is responsible for managing external marketing communications, print and web-based vendors, as well as handling sales management, sales support and CRM supervision. Hotier, who will be based at the company’s Tulsa, Oklahoma, U.S.A., headquarters, has a background that includes

positions in military intelligence and international planning and strategy for the U.S. Air Force, the Department of Defense and NATO in locations including Honduras, Ecuador, Japan, Germany, Italy and Washington D.C., U.S.A. More recently, Hotier served as a NATO Strategic Planner for the U.S. European Command in Stuttgart, Germany, and held management positions in global corporations Lafarge and Saint-Gobain. She has directed multinational planning, sales support and business development projects throughout Western and Eastern Europe. TOGNUM: Jörg Schwitalla has been named the new executive board member for Personnel and Integrity at Tognum AG. The position has been newly created to meet the group’s future requirements, such as the planned integration of Bergen Engines AS and the group’s growth targets. With this appointment, Schwitalla assumes responsibility for Personnel, Legal Affairs, Patent Management, Data Protection and Information Security, in addition to Business Practice and Compliance.

He will also perform the duties of industrial director within the group. Schwitalla was the chief human resources officer on the executive board of MAN until July 2012 and has since acted in an advisory capacity for the Volkswagen Group. During the six years he spent at MAN, he was responsible for, among other things, all the traditional functions in the field of human resources. He was also involved in activities and projects including group security, auditing and purchasing, and had a leading role in the investigation of compliance issues at MAN. After completing his studies in business administration, Schwitalla began his career in the personnel department of Michelin. He later spent several years with automotive components supplier Valeo in various personnel management positions in Germany and France before transferring to MAN in 2006. J. Schwitalla

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Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 3 31 Universal_De12_WW.indd 1

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Power Plants Of The World

2013

Editor’s note: Each year, Diesel & Gas Turbine Worldwide invites engine manufacturers to submit one specific power generation project they feel merits special attention as the result of advances in one or more of the following: efficiency increase, environmental aesthetics, operational characteristics, emissions improvements and construction principles. The coverage is limited to plants commissioned during the 2012 calendar year. This longstanding tradition has become a popular feature and this year’s edition once again highlights several noteworthy projects around the globe. Enjoy.

Alstom Power

Claus C Repower Project, The Netherlands The Claus C repower project demonstrated Alstom’s ability to repower an existing steam power plant into a combined-cycle power plant with double the power using a 35% increase in fuel, as well as a 40% reduction in CO2 emissions. The Claus power plant consists of two identical gas-fired, steam-generating units, that came on-stream in 1977 and 1978, respectively. Alstom received the order to repower Essent’s 640 MW Claus B unit in 2008. The conversion increased the capacity to 1309 MW through the addition of three Alstom GT26 gas turbines, three heat recovery steam generators (HRSGs) and a retrofitted steam turbine. The Claus C repowering project was inaugurated in June 2012 and now reaches an efficiency of 59%, compared to 39% of the replaced Claus B unit.

The Claus C repower project involved turning an existing steam power plant into a combined-cycle power plant with double the power using a 35% increase in fuel, as well as a 40% reduction in CO2 emissions.

Alstom’s proposal dealt with reusing and refurbishing most of the existing infrastructure, such as a section of the existing steam turbine building and electrical building, the direct cooling facilities — the main cooling water pumps — and the cooling tower. According to the customer, reusing the steam turbine building and its facilities provided a 15 to 20% savings compared to a new combinedcycle power plant building. It is also the first time Alstom has provided a three-on-one configuration for a KA26 combined-cycle power plant. The three GT26 gas turbines provided the flexibility that is required in today’s electricity market, the com-


pany said. In this setup, three gas turbines each exhaust into its own heat recovery steam generator (HRSG) to generate steam that is then fed to a single steam turbine. Alstom’s gas turbines, the GT26 and the GT24, made a difference in the Claus C project’s efficiency. The two turbine models use the sequential combustion principle as a way of increasing efficiency and operational flexibility, Alstom said. The GT24/ GT26 combustion system is based on an Alstom combustion concept using the EnVironmental (EV) burner in an annular combustor, followed by the Sequential EnVironmental (SEV) burner in the second, annular combustion stage. Integrating the concept of dry-low NOx EV burner and sequential combustion into a single shaft gas turbine resulted in the GT24/GT26 — a machine with highpower density, a small footprint, and high-exhaust temperature in order to maximize the efficiency in combinedcycle, the company said. www.alstom.com

Ansaldo Energia

Open-Cycle “6th October” Plant, Cairo, Egypt The open-cycle power plant known as “6th October” is located on the outskirts of Cairo, Egypt, where the highway to Alexandria begins. The 600 MW plant was a turnkey project worth €245 million that Ansaldo Energia carried out for the Cairo Electricity Production Co. and commissioned in June 2012. continued on page 34

Power Plants Of The World 2013 The contract for the new plant was signed in March 2011 and included the delivery of four Ansaldo AE94.2 gas turbines with relative alternators and auxiliary systems. The power plant can be fired both by gas and fuel oil. The project was one result of the Egyptian Energy Ministry’s decision to urgently commission additional power plants to remedy the electric power deficit that caused a crisis in the country’s electric power distribution system in summer 2010.

The construction of the 600 MW “6th October” power plant was a fast-track turnkey project Ansaldo Energia carried out for the Cairo Electricity Production Co.

The construction of the “6th October” power plant was a fast-track project, scheduled for completion within a very demanding 14.5-month period. Ansaldo Energia said that engineering, supply orders and subsequent delivery represented the critical points for project start-up and rapid development. The work site was opened early in April 2011 and Egyptian contractor Orascom performed the civil works for the various buildings, making it possible for mechanical and electrical assembly workers to access the site at predefined deadlines under the close supervision of the Ansaldo Energia work site team. Work site activities during the busiest period from October to December 2011 required a peak of about 2000 people, and were carried out on-site in such a way as to guarantee the utmost worker safety possible under the close supervision of the various safety entities involved. In fact, in May 2012 the customer presented Ansaldo Energia with a certificate recognizing 7 million hours of work without an accident. In April 2012 — one year after the

start of the project — the four gas turbines were synchronized with the grid for the first time. This was followed in May by successful performance tests on the new 600 MW power plant. By early June, all units were available to feed the national grid. Worth mentioning is the recognition by the authorities and the customer of the effort made by Ansaldo Energia to complete the start-up of all units according to the contract schedule, contributing 600 MW during the summer to satisfy increasing demand — particularly during a period of profound change for the country, which at the time had already elected a new Parliament and was on the way to naming a new President. www.ansaldoenergia.com

Caterpillar

Jhulda 100 MW Power Plant, Bangladesh The Jhulda 100 MW heavy-fuel oil power plant became operational in March. The plant was sold to Acorn Infrastructure Services Ltd. (AISL), an affiliate of Caterpillar’s Bangladesh Dealer, BanglaCat. It sits on 8 hectares of land on the south bank of the Karnafuli River.

worse. Because electricity is crucial to economic growth and improved quality of living, increasing generation capacity is a high priority for the BPDB. Since January 2009, several contracts have been approved to increase capacity by 4500 MW. The Jhulda plant utilizes eight Caterpillar 16CM43 generator sets that produce 14.4 MW of power each. In 2012, the first 16CM43 generator set — the largest that Caterpillar manufactures — was commissioned for operation. As the natural gas infrastructure in Bangladesh becomes more robust, a shift in fuel source may become necessary or beneficial. When gas becomes readily available, the 16CM43 can be easily retrofit to operate in a dual-fuel capacity on both liquid and natural gas sources, the company said. Caterpillar and local dealer, BanglaCat, have provided operational support, training, maintenance and repair services and tools, the supply of related equipment and emergency services. AISL signed a five-year rental power agreement to sell power to the BPDB and will also supply power capacity to the national grid. The plant is expected to be operational for 25 to 30 years. www.caterpillar.com

Centrax

The Jhulda plant utilizes eight Caterpillar 16CM43 generator sets in support of the Bangladesh Power Development Board.

The additional 100 MW of capacity supports the Bangladesh Power Development Board’s (BPDB) national target of, “Electricity For All” by 2021. Just 49% of the people in Bangladesh have access to electricity. The unstable grid causes frequent power outages, while a shortage of natural gas and load shedding during peak hours make the situation


12 MW CHP Plant, Versailles, France Centrax, a U.K. gas turbine power generation packaging specialist, has completed one of its highest-profile installations in recent years with the commissioning of its first Siemens CX400 package. This 12 MW unit is now meeting 40% of the hot water demand of the French city of Versailles, on the outskirts of Paris, while also producing electricity for sale to French power utility EDF. Customers for its heat and power include the Palace of Versailles and surrounding residential areas, and the new power plant re-uses the existing building and replaces an older gas turbine. continued on page 36

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Power Plants Of The World 2013 The Versailles combined heat and power (CHP) installation is the first Siemens gas turbine to be packaged by Centrax since the two companies forged an agreement that enables Centrax to market the SGT-300 and 400 gas turbines in the U.K., France, Italy, the Netherlands and Belgium. Besides its technical benefits, the CX400 also gives Centrax the commercial advantage of providing the greatest power output and energy efficiency below the 12 MW cap imposed on cogeneration projects in France, the company said.

The 12 MW Siemens CX400 package allows Centrax to provide the greatest power output and energy efficiency below the 12 MW cap imposed on cogeneration projects in France.

This allows French energy producer COFELY, parent company of Versailles operator Verséo, to maximize its revenue by exporting 12 MW of power across the ambient temperature range during a contracted operating time of 3600 h/yr. The Versailles sale also further enhances the Centrax track record with power company COFELY, which now operates 23 Centrax units at installations in France and the U.K. Crucially, Centrax completed the installation and commissioning well within a tight schedule to meet the start of the winter heating season in France. The contract brings the number of generator sets packaged by Centrax for the European market to more than 320. The company said that Siemens gas turbines complement the current product range by giving customers one of the widest choices of power output in Europe, with a range of between 2.5 and 64 MW. With customer service bases in

France, Italy, the Netherlands, Germany, Spain, Portugal, Ireland and Russia, 95% of the Centrax output is exported. www.centraxind.com

GE Power & Water

J624 Two-Stage Plant, Houweling’s Tomatoes, Camarillo, California, U.S.A. A combined heat and power (CHP) greenhouse project that captures carbon dioxide (CO2) for use in plant fertilization has been installed at Houweling’s Tomatoes, a 505 857 m2 tomato greenhouse in Camarillo, California, U.S.A. Unveiled on Aug. 22, the project uses two of GE’s 4.36 MW J624 two-stage turbocharged natural gas engines and a GE-designed CO2 fertilization system. Boasting both lower carbon dioxide (CO2) emissions and increased overall efficiency, the system provides 8.7 MW of electrical power — enough to power nearly 8800 homes — and 10.6 MW of thermal power (hot water) for heating the glass greenhouses on-site. The project represents the U.S. launch of GE’s J624 two-stage turbocharged gas engines for the 60 Hz segment. Introduced by GE in 2007, the J624 is a 24-cylinder gas engine, which features double turbocharging for commercial power generation. Greenhouse CHP combines the production of heat and power to enrich the greenhouse atmosphere with CO2, keep the temperature on a constant level, and provide dispatchable power for lighting so that harvest yield can be significantly increased, GE said. The CHP plant at Houweling’s Tomatoes enables flexible generation and contributes electric power during peak daytime demand periods. With a five-minute start-up capability, this high-efficiency plant also provides power to the electric utility to augment the power grid. Additionally, the thermal energy produced from the engine during power generation can be transferred to


the greenhouse immediately during cooler periods or retained in existing thermal storage tanks for use at other times of the day. The system offers a total thermal efficiency of almost 90%, GE said. The concept of a power plant being able to generate heat and power at nearly 100% overall efficiency is made possible by condensing out water vapor created in the combustion process, GE said. Thermal energy is recovered in exhaust gas heat exchangers for use in the greenhouse, which uses very low water temperatures in its heating system to cool down exhaust temperatures below the dew point. The engine exhaust gases are purified by a COdiNOx flue gas cleaning system in such a way that the present CO2 can be piped into the greenhouse to fertilize the plants during the daylight photosynthesis process. In addition, Houweling’s uses the water condensed out of the exhaust gas in its operations, saving 35 961 L/d of usage from local water sources.

A combined heat and power project at Houweling’s Tomatoes uses two of GE’s 4.36 MW J624 two-stage turbocharged natural gas engines and a GE-designed CO2 fertilization system.

Besides the reduction of carbon monoxide, hydrocarbons and nitrogen oxides of the standard COdiNOx installation, Houweling’s selective catalytic reduction part of the system helps decrease even more nitrogen oxides contaminants than a standard SCR system. The local air pollution control district in Ventura County required the installation of the best available control technology for the CHP plant, and the NOx continued on page 38

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MTU Onsite Energy

24 MW Peak-Load Plant, Fulda, Germany The Überlandwerk Fulda Aktiengesellschaft (ÜWAG) power plant in the German city of Fulda was originally built 100 years ago to supply electricity to the city. Now, with a €10 million modernization in recent years, it is a modern power plant that supplies peakload power when demand is so high that there is insufficient capacity available in the combined European grid. To be able to balance the demand peaks more effectively in the future, two old diesel engines were retired and replaced by six smaller generator sets supplied by MTU Onsite Energy, featuring a 20-cylinder MTU Series 4000 engine. The first three of six gen-sets went into operation in the power plant in December 2011 and the facility was officially inaugurated in September 2012. Up to now, ÜWAG has mainly supplied what is called tertiary, or shortterm, operating reserve energy that has to be available within 15 minutes of being called upon. However, with the new MTU Onsite Energy gen-sets, ÜWAG will now also be able to supply the substantially more lucrative secondary reserve power. To do so, a provider is required to be capable of supplying 100% of the registered capacity within five minutes. Generating and delivering electricity that quickly is a major challenge because not only do the generators have to start up from standstill, they also have to synchronize their frequency, voltage and phases with the combined European grid system within a matter of seconds. ÜWAG said it believed the diesel power station is the most modern in the world and that the engines are indeed able to meet those grid start-up and synchronization requirements.

In addition to feeding the national grid, ÜWAG also supplies electricity to the city of Fulda. If the national grid suffered a failure, the generators at ÜWAG would make sure the city retained its necessary power. In that event, a “blackout start-up” gen-set, which requires no external electric pumps or auxiliary equipment to fire up, automatically starts and supplies the energy for the other five gen-sets to be started. Together, they can supply 24.8 MW of electricity. ÜWAG said that with the new engines the plant, when measured against the previous level per kWh generated, has reduced its particulate emissions to a sixth of what they were, and nitrogen oxides and carbon monoxide have been lowered by 25 and 50%, respectively, while concurrently lowering fuel consumption by 10%.

At the Fulda ÜWAG plant, MTU Onsite Energy has replaced two old diesel engines with six smaller generator sets, featuring a 20-cylinder MTU Series 4000 engine.

With the power plant located within the town of Fulda, ÜWAG also paid particular attention to reducing noise emissions. Special soundproof walls allow almost no sound to escape to the outside when the engines are starting up and running, the company said. ÜWAG has also had a special remote diagnosis system installed, allowing the specialists at MTU Onsite Energy in Friedrichshafen to access the gen-sets and other components of the plant remotely and give advice on how to prevent or rectify faults. www.mtu-online.com

MWM GmbH

26 MWe Station, Bilecik, Turkey Germany-based MWM GmbH has


supplied six TCG 2032 V16 gas generator sets to Tekno Energy’s Bilecik power plant. Bilecik is a city in northwestern Turkey that lies along the Karasu River. The region is renowned for its silk and ceramics industry and is home to 230 000 inhabitants. Tekno Energy is an independent power producer (IPP) and provides electricity to both the grid operator and to end users. The station is powered by six TCG 2032 V16 engines by MWM and can produce a total output of 26 MWe, operating as a peak plant assisting the grid operators in balancing the electricity market. The plant can be synchronized to the grid within 15 minutes and is capable of reaching full power output 20 minutes after the start button has been pressed. Tekno Energy is now expanding the plant up to 40 MWe and upgrading it into a combined-cycle with an additional steam turbine using the exhaust gas heat recovery and an ORC system for the cooling water heat recovery. This will increase the output and achive even higher efficiency. While Tekno Energy’s consulting engineering firm Güncan Energy designed the entire power plant, helped choose the right equipment and coordinate the construction phase, the local supplier Iltekno provided and installed the gas engines with all necessary auxiliaries.

Tekno Energy’s Bilecik power station can produce a total output of 26 MWe using six TCG 2032 V16 engines by MWM.

The new version of the TCG 2032 was launched by MWM in January 2012. Optimized spark plugs and improved turbocharger technology have made it possible to reach an electrical efficiency of up to 44.2% with a power output from 3333 to 4300 kWe. MWM said the two exhaust turbo-

Power Plants Of The World 2013 chargers installed as a standard in the TCG 2032 were fitted with a new exhaust turbine. Improved efficiency on the exhaust side automatically increases the boost pressure on the compressor side of the turbocharger. The higher boost pressure has a particularly positive effect on the part-load range when the load is adjusted. The most comprehensive change in the new engine version is the introduction of a new controller that combines and connects the previously separate controllers. Due to the operational experience gained from the predecessor versions, the operating time before major overhaul has been significantly increased from 64 000 to 80 000 hours. Because after-sales services such as maintenance and repair are crucial for the operation of the plant, Tekno Energy has chosen to work with Iltekno, which has proven to be capable and punctual in the design, delivery and maintenance, the company said. The group offers an inventory of spare parts and a local maintenance team. www.mwm.net

electricity in November 2011 after a 450-day construction and commissioning phase. The plant is powered by 16 Rolls-Royce B32:40 diesel engines ordered by Energypac Power Generation Ltd. of Bangladesh in June 2010 and is owned by the Bangladesh Power Development Board. An additional eight B32:40 units, ordered at the

same time, now equip the nearby 54 MW Faridpur power station. The engines run on heavy-fuel oil. The B32:40 engines provide a range of outputs between 2.6 and 7.2 MW, and are available in six-, eight- and nine-cylinder inline configurations and in 12- and 16-cylinder V-format. The Gopalganj plant, formally continued on page 40

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Power Plants Of The World 2013 opened by the prime minister of Bangladesh, Sheikh Hasina, has already been recognized as the best power project by the South Asian Association for Regional Cooperation. Its 2012 Enertia Award marks the plant’s potential to address power shortfalls and boost socioeconomic growth throughout the Gopalganj district, Rolls-Royce said. www.rolls-royce.com

Siemens Energy

Natural Gas-Fired, Combined-Cycle Plant, Lodi, California, U.S.A. The Northern California Power Agency (NCPA) officially dedicated its Lodi Energy Center (LEC) in August 2012. For the new natural gas-fired plant with an installed capacity of 300 MW, Siemens supplied the SCC65000F 1x1 Flex-Plant power island, which enables the NCPA to bring the plant to full load in a very short time. With an efficiency of over 57% and low start-up emissions, the LEC is one of the cleanest fossil power plants in the U.S.A., Siemens said. The LEC is the first operating Siemens Flex-Plant combined-cycle plant in the U.S.A. This fast ramping gasfired plant was specifically designed by Siemens as a solution to balance fluctuations on diverse power grids managing both renewable and traditional energy sources. The Siemens SCC6-5000F and SCC68000H Flex-Plants have continued to evolve and are designed — using the Siemens SGT6-5000F and the SGT68000H as the prime movers — for intermediate to continuous duty and are also capable of daily cycling. This facilitates a stable, reliable power generation grid while integrated renewables ramp up and down to respond to changing power demands, said Siemens. Flex-Plants are available with efficiencies from over 57% with the SCC65000F engine to more than 60% with the SCC6-8000H engine. Siemens’ Clean-Ramp integrated control logic maintains low start-up NOx and CO emissions while ramping. The Siemens Flex-Plant power island

at the LEC consists of a 200 MW Siemens SGT6-5000F gas turbine-generator operating in combined-cycle mode with a 100 MW Siemens SST-900RH steam turbine-generator. To power the steam turbine, gas turbine waste heat is captured by a Benson-style fastramping heat-recovery steam generator (HRSG) provided by Nooter/Erikson. The plants also include high-capacity steam attemperation and full capacity steam bypass systems; piping warmup strategies; and the Siemens steam turbine stress controller (TSC).

The Siemens Flex-Plant combined-cycle power island at the Lodi Energy Center.

The LEC uses reclaimed water from the adjacent Lodi’s White Slough Water Pollution Control Facility. The tertiary treated water is further processed by the LEC’s water quality facilities before use in the steam generation process and power plant cooling system. The LEC utilizes a seven-cell cooling tower provide by SPX Cooling Technologies Inc. The unrestricted full ramp rate gas turbine start reduces plant start-up time by up to 50%, providing 200 MW to the grid in 30 minutes or less and allowing a high level of operating flexibility to react to market opportunities. Resulting carbon monoxide reductions of over 181 tonnes/yr can be achieved when compared to traditional F-class combined-cycle plants. Comparatively, overall greenhouse gas emissions are being cut by 30%. Siemens said that the SPPA-T3000 integrated control system provides a control platform for the entire combined-cycle power plant, which has a total operational capacity of 2.4 million Wh/yr. Long-term service programs will


help to ensure the reliability and performance of the main components. www.siemens.com

Wärtsilä

180 MW Power Plant, Sasolburg, South Africa In December, a 180 MW power plant was commissioned in Sasolburg in the Republic of South Africa. Sasol New Energy (SNE) Holdings, a business division of Sasol, ordered the plant, which generates electricity for the company’s own use, with the excess energy going to the national grid. The Sasolburg plant was built on a turnkey basis by Wärtsilä, which supplied the generating equipment, engineering, civil works and construction. Wärtsilä also received a three-year operations and maintenance (O&M) agreement with SNE Holdings to ensure that the plant delivers the design output with maximum efficiency. Local SNE employees will also be trained as part of this agreement. The plant, situated 1500 m above sea level, runs on 18 Wärtsilä 34SG gas engines. The closed loop radiator cooling system employed in these engines offers significant benefits in locations where water resources are limited. Sasol also opted for combustion engines for the plant, which is designed for base-load generation, because of their ability to respond rapidly to changes in demand. In this plant, heat from the exhaust gases can be recovered and used to produce steam for Sasol’s industrial processes. Wärtsilä also handled the design and installation of the heat recovery boilers. Space is available for installing additional gen-sets. South Africa’s generating capacity has traditionally been dominated by coal-fired power plants, Wärtsilä said. Sasol’s gas power plant uses technology that reduces its carbon footprint by more than 40%. According to calculations, Sasolburg’s annual carbon emissions will be cut by 907 185 tonnes. A www.wartsila.com

Industry News

by ian cameron

Tackling The Threat Of Water Cases of water ingress leading to engine failure increasingly common, Gems sensor can prevent mechanical damage

parts solution for use with fuel filters and in compressor crankcases to determine if water is present in the lubricating oil, the company said. The WIF-1250 contains integral, high-temperature rated electronics that generate an alternating voltage to a probe tip. The probe tip is electrically isolated from the housing via a fused glass seal, providing a hermetic, high-pressure capability suitable for fuel system use, the company said. The presence of water completes the circuit, which, in turn, changes the condition of the transistor output. “In general, contamination from the ingress of water is often more problematic in diesel engines than in petrol engines because the subsequent corrosion can cause serious damage to the injection pump and injectors,” Dockendorff said. “Diesel engines require fine fuel filters and water traps to alert operators when there is too much water in the trap so that it can be 11/11/09 drained before theAMengine is damaged.” Ellwood.qxp 8:43 Page 1 Founded in 1955, Gems makes liquid level, flow and continued on page 42

A WIF-1250 sensor contains integral, hightemperature-rated electronics that generate an alternating voltage to a probe tip.

Fuel is subject to the relentless and unceasing hazard of contamination, with moisture as one of the most common dangers. Water in fuel that reaches the fuel system can affect the operational performance and life of engine parts or, worse, lead to early and possibly catastrophic failure. Controlling the ingress of moisture in fuel systems is therefore of vital importance. According to Jim Dockendorff, chief engineer, Level Products, Gems Sensors and Controls, cases of water ingress leading to engine failure are increasingly common. “There is a particular urgency to protect high-efficiency engines, especially modern ones, where moisture in the form of condensation is a common problem,” Dockendorff said. Gems has developed a conductivity-based sensor that can detect the level of water in fuel and lubricating oil and prevent mechanical damage as a result of lubricant property degradation. The WIF-1250 is a no-moving-

We Manufacture and Remanufacture the World’s Largest Engine Crankshafts Ellwood Crankshaft Group Irvine, PA, USA 16329 Hermitage, PA, USA 16148 1-800-247-1326 or 724-347-0250 [email protected] www.ellwoodcrankshaftgroup.com Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 3 41

Industry News pressure sensors, solid-state relays and barriers, liquid and pneumatic miniature solenoid valves, and preassembled fluidic systems. It has facilities in the United Kingdom, United States, China, Germany and Japan. The company points to the fact that conductivity based sensors are available to detect the presence of water in fuel and lubricating oil. “Conductive level measurement is achieved via the electrical conductance of the process material, typically a liquid with a lowvoltage source,” Dockendorff said. “In a tank of liquid, simple conductive sensors can be positioned at high and low points in the tank to detect maximum and minimum levels. When the level of process material rises to reach the upper probe, a switch closes to activate a discharge pump; when the process material makes contact with the lower probe, the switch opens to stop the pump. “However, there are now more sophisticated components available

that can detect the presence of water in fuel. Because water is electrically conductive and fuel is not, conductivity sensors such as those produced by Gems Sensors and Controls can be mounted in any position and withstand extreme temperatures. “Their output can be used to actuate relays, indicator lights or LEDs, as well as to interface with CMOS/ TTL logic, PLCs or microprocessors. Also, since water is heavier than oil, it tends to sink to the bottom of fuel tanks. These sensors can be positioned strategically in the tank bottom for water detection.” Dockendorff said for detecting water in fuel, conductivity based sensors have proved very successful in applications such as off-highway vehicles, locomotives and generator sets. “However, the marketplace is expanding as the sensors become more resilient,” Dockendorff said. “For example, in a conventional conductivity probe where a single

potential DC voltage is applied to a probe submerged in conductive liquid, metal from that probe will be lost over time via electrolysis. However, the WIF-1250 contains extra circuitry to produce an alternating potential. By using this technique, no electrolysis occurs, resulting in virtually zero probe material loss. “The WIF-1250 is a new solution for detecting the presence of water in fuel, but customer feedback is also telling us that this is proving to be an ideal solution for fuel filters, compressor crank cases, lubricating oil tanks and diesel fuel storage tanks because it has high reliability and long-term stability in oil.” Looking at future trends, Dockendorff said increasing legislation across the industry is setting stiff requirements for reliability and sustainability. “The newest level measurement technologies are powerful tools in helping plant engineers to meet these goals,” he said. A

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Contact Mary Graesing for pricing and details Phone: 262-754-4100

E-mail: [email protected]

Featured Products

Transfer, Isolation Switches

Russelectric has released its mediumvoltage (5 to 15 kV) circuit breaker-type transfer and bypass/isolation switches, which are suitable for use in legally required emergency power systems. The switches transfer electrical loads between normal and emergency power sources via controlled opening and closing of circuit breakers and may be configured for open- or closed-transition transfer, the company said. All switch functions are controlled by Russelectric’s RPTCS programmable microprocessor-based control system. Though designed for unattended op-

eration, the switches include controls for manual operation. The bypass/isolation switches provide all the functions of an automatic transfer switch plus the ability to bypass power from live source to load in the event the transfer switch becomes disabled. In addition, they are designed to allow isolation and de-energization of the automatic transfer breakers for maintenance, testing and repair. www.russelectric.com

Surge Protection

Joslyn AC surge protection devices (SPDs) from Thomas & Betts, which in-

clude more than 1300 standard configurations, are available with stainless-steel enclosures for corrosive applications such as wastewater treatment facilities. Other applications include oil and gas processing, civil construction, utilities and mining. Available through Thomas & Betts’ network of distributors, Joslyn SPDs protect operations from the damaging effects of electrical power surges, transients and noise from the service entrance to the equipment level. Suitable for protecting single-, split- and three-phase applications ranging from 120 to 600 V Delta, the SPDs are capable of handling high-surge energy from 20 to 400 kA per phase. The stainless-steel enclosures are standard in Type 304 stainless steel, an alloy of iron, chromium and nickel. Enclosures in marine-grade Type 316 stainless steel, which contains molybdenum in addition to the metals contained in the Type 304 stainless steel alloy, are available through special order, the company said. www.tnbpowersolutions.com continued on page 60

Turn your data into information and your information into power

Unprecedented ability to measure, manage, and control your ships and your future iShip is a unique set of applications built on an information management infrastructure which integrates existing vessel instrumentation and automation data into useful information. iShip provides real-time operational and event data so vessel operators and engineers can visualize, analyze, distribute, collaborate and act. Visit www.WOiship.com or contact us at [email protected]

Oil & Gas

Flare gas is used as fuel for the gas gen-sets, producing the 1.5 MW of electricity needed to power the oil pumps for the Rami oilfied production wells.

Addition By Reduction Dresser-Rand provides two gas gen-sets to replace 30 diesel gen-sets in Egyptian oilfield

Equipment from Dresser-Rand is making production life easier for Agiba Petroleum, which produces 57 000 barrels of oil per day from six oilfields across Egypt. Dresser-Rand engineered and installed two Guascor SFGLD series gas generator sets, which use an electronic carburetion system to accommodate the inherent fuel fluctuations in the Raml oilfield, as well as run on a low methane number gas with a low heat value (LHV) of less than 40 MJ/Nm3. The gen-sets also remove water and heavy hydrocarbons from the gas during the liquid phase to ensure it is dry when entering the engine. As a result, the flare gas is now used as the fuel that produces the 1.5 MW of electricity needed to power the oil pumps for the production wells, Dresser-Rand said. Founded in 1981 as an operating company of the Egyptian General Petroleum Corp., Agiba previously used diesel generators to produce power for the Raml oilfield’s wells. The Raml oilfield is located 250 km from Al-Alamayn in the Egyptian Western Desert. Historically, the field produced poor economic returns because of its high gas-to-oil ratio and insufficient sepa-

ration of oil and gas, according to the company. Since it was not economically feasible to store and pump these low quantities of gas (70 792 m3/d), Agiba flared the gas to the atmosphere. Agiba’s operations, however, turned out to be expensive — to the tune of US$1/L for diesel fuel — to keep its generators running. The company soon turned to Dresser-Rand for equipment that would improve the oil and gas separation ratio while reducing fuel and maintenance costs. By converting the flare gas into fuel for the gas engines, Agiba reduced its


emissions from the Raml gas wells by 50% and lowered the amount of flare gas previously released into the air by 60%. The new generator sets save Agiba US$2.5 million a year, Dresser-Rand said. Prior to the installation, Agiba operated 30 diesel generators but now uses the two Guascor SFGLD gen-sets to power 30 wells. Gas generators also have longer intervals between planned maintenance compared with diesel generators, according to Dresser-Rand. Because of this power addition, Agiba will be able to run a much more sustainable and efficient operation, maximize its oil production, reduce emissions, lower maintenance costs and repair time, and drill and produce more crude oil. A

Dresser-Rand engineered and installed two Guascor SFGLD series gas generator sets, which use an electronic carburetion system and can also run with a low methane number gas.

Industry Drivers

GE

P

GE will upgrade TransCanada Energy Ltd.’s MacKay River 165 MW cogeneration plant with technology designed to deliver more power capacity with low emissions. GE will supply its Advanced Gas Path (AGP) product to its natural gas-fired 7FA turbine. AGP technology enables power providers to operate more efficiently and reliably by upgrading hot gas path, bucket, nozzle and shroud components with design and material innovations, the company said. This installation will be complemented by the controls capabilities of several GE OpFlex products, such as a Cold Day Performance app. Altogether, the improvements are expected to increase the plant’s output up to 4.5%, with the potential to increase steam and electricity production further in the future. The upgrades are part of a GE contractual service agreement, which will provide maintenance services to the plant through 2024. The plant, located northwest of Fort McMurray, Alberta, Canada, runs nearly 24 hours a day.

gines. The Cummins global distribution network will handle upfit, commissioning and warranty on dual-fuel engines.

LANGLEE WAVE POWER

P

Norwegian company Langlee Wave Power and Repnaval Shipyard (Zamakona Yards) have signed an agreement for the development of wave power in the Canary Islands. The two companies will file a common application to the EEA grants for

development of renewable energy in Spain. Langlee Wave Power AS has developed technology designed to convert ocean waves into electricity. According to the company, the Canary Islands are the best place for wave power in Europe because of its stable wave climate. With the company’s technology, electricity can be produced with lower cost by a renewable energy source, Langlee said. continued on page 56

CUMMINS

O

Cummins Inc. will produce dualfuel engines for land-based oil and gas drilling applications. The first engine for land-based drilling applications is the Tier 2 QSK50, rated 103.6 kW at 1200 r/min. Other QSK Series engines will follow, including engines capable of meeting upcoming U.S. Environmental Protection Agency (EPA) Tier 4 Final emissions regulations, the company said. The Cummins Dual-Fuel QSK50 engine will incorporate integrated controls designed to optimize the substitution rate based on operating conditions, and automatically transition between diesel-fuel and dual-fuel modes. Cummins said its dual-fuel technology enables drilling equipment to operate on 100% diesel fuel or in dual-fuel mode. In dual-fuel mode, the substitution rate — the percentage of natural gas relative to total fuel flow — can be as high as 70% in traditional operating conditions, Cummins said. The Cummins dual-fuel product will be applicable to both new QSK50 engines and as a retrofit on existing QSK50 en-

INNOVATIVE SOLUTIONS. PROVEN PERFORMANCE®. Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 3 45

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8/10/12 2:54 PM

Industry News

by dj slater

Monico’s Custom Protocol Converter (CPC Gateway) is programmed to monitor Cummins equipment through the ModLon gateway and output on several different protocols.

Now It’s Cummins’ Turn Four years after CDL Gateway, Monico launches CPC Gateway for monitoring Cummins equipment

Monico Inc. has released the Monico Custom Protocol Converter (CPC Gateway), which is programmed to monitor Cummins equipment through the ModLon gateway and output on several different protocols. With the device, Cummins users will have the ability to predict and prevent downtime, according to Monico. Four years ago, Monico introduced the Cat Data Link Gateway (CDL Gateway), which gave dealers, OEMs and end users direct access to engine monitoring parameters via Modbus TCP/ IP, Modbus RTU, BACnet and other protocols and memory map formats. Monico said during the CDL Gateway’s release it had plans to expand its product capabilities to accommodate other engines, and that time has come. A CPC Gateway is attached to the ModLon gateway or native Modbus. A template created by Monico programmers is used to extract data from Cummins equipment such as engines and generator sets. The collected data

can be translated into one of multiple protocols for use with PLC control systems, building automation systems, or through a web interface. Recently, the CPC Gateway was used to translate engine data into BACnet, Modbus and Allen-Bradley PLC. However, it has the ability to communicate over many other available protocols. Because a ModLon gateway supports up to five engines, the CPC Gateway can collect and translate the data from all attached engines and communicate it to one or multiple targets, Monico said. “All of these programming languages and protocols are what engine manufacturers use, and it’s necessary to get this data into a format they can use to communicate with their own network,” said Allen Walker, Monico’s vice president of sales. “The engines don’t speak the same languages as the operating systems that these companies have. The CPC Gateway allows these devices to communicate with each other.”


The CPC Gateway collects information over the ModLon gateway for older Cummins gen-sets or through Modbus RTU on newer Cummins gen-sets. The collected information is placed in a common, preconfigured data map, which can be used to convert data into Modbus TCP, BACnet, Allen Bradley PLC, GE Fanuc PLC, Siemens PLC, Omron PLC and other common protocols. Additionally, the added ports built into the gateway can collect data from switchgear and additional ancillary equipment. “What a lot of dealers are up against is they have a certain type of PLC and they need to get the engine and generator data,” said Bruce Eckley, a Monico engineer. “The CPC Gateway allows you to take one protocol and put it out to another. “We take all that data and map it out nicely, with complete registers, and we give that map to customers and dealers. They say it’s great,” Eckley said. The device also features four to six physical ports that can communicate in up to nine protocols simultaneously and support about 100 protocols. It runs on and includes a 24 Vdc power supply, din-rail mounting elements, user configurable port settings and addresses, UL-508 listed with C-UL, and modular jacks to prevent wiring errors. Monico said all its Gateways are capable of having I/O expansion modules added for additional flexibility, with available modules including thermocouple units with eight inputs, six RTD inputs, four analog outputs and eight analog inputs. A CP Gateway PLUS model also exists, which features upgrades such as a virtual HMI web server; SMTP support for sending e-mail and text messaging alerts; real-time data logging; an ftp server to retrieve data log files; and a sync server to automatically sync log files with an IP-connected computer. All of the CPC Gateway’s capabilities come preconfigured for simple setup and can be customized using Monico’s software, MonicoView II, which comes standard on every Gateway, the company said. A

Literature Library

Marine Gearboxes

WTZ�Roßlau

Bearing Products

Wissenschaftlich-Technisches�Zentrum�für Motoren-�und�Maschinenforschung�Roßlau�gGmbH

8 th Dessau Gas�Engine�Conference March�21-22,�2013�in�Dessau-Roßlau, Germany

A brochure from Siemens provides details on the company’s Flender Navilus gear units for marine vessels. Siemens offers marine gearboxes for singlemotor ships, two-motor ships, generators and dredgers. The gearboxes, available in twin-, multiple-drive, and singledrive, deliver power outputs up to 40 MW. www.siemens.com

Marine Lubricants

Miba Bearing Group has released information on its capabilities. The company offers slide bearings for several applications, such as stationary diesel and gas engines, locomotives, marine engines and compressors. Other products include half shells, flange bearings, thrust washers, bushings and tribological coatings. www.miba.com

Turbochargers

On March 21 and 22, 2013 the WTZ Roßlau will hold the 8th Dessau Gas Engine Conference. For the first time the conference will take place in the conference room of the Federal Environmental Agency. The participants will get the chance to learn something about technological developments and discuss the possibilities of further developments for gas engines. Well-know companies and institutions from private business, research and education will actively shape the lecture program in the sessions:

1. New Engine Concepts, Special Gases Chairman: Professor H. Tschöke Otto-von-Guericke-University Magdeburg

2. Experiences during Application Chairman: Professor A. Wimmer Graz University of Technology

3. Theoretical Basics Chairman: Professor G. Wachtmeister University of Technology München

4. Gas Engine Accessories Chairman: Professor H. Harndorf University Rostock.

During the conference you will have the opportunity to present your company, products and services. The complete conference program and registration procedures are available online at www.wtz.de For more information please contact the following address.

WTZ�Roßlau�gGmbH Total Lubmarine has pro- A guide on its range of turduced literature on its prod- bochargers is available from uct. The company offers ABB. Each turbocharger has a lubricants for marine appli- page that includes a descripcations. The product guide tion of the product, its charconsists of main lubricants, acteristics and a compressor auxiliary mineral lubricants, pressure ratio chart. A secauxiliary synthetic lubricants, tion on the company’s earlier eco-friendly lubricants, greas- generation of turbochargers es and eco-friendly greases. is also included. www.lubmarine.com www.abb.com/turbocharging

Ms�Constanze�Jackowski Mühlenreihe�2a D-06862�Dessau-Roßlau E-Mail: [email protected] Phone: +49�34901�883-124 Fax: +49�34901�883-120

Deutscher Akkreditierungs Rat

DGA-PL-2755.00

continued on page 49 Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 3 47

Power Generation

Supplying electricity to Jordan’s national grid, 16 Wärtsilä 50DF dual-fuel engines will power the new IPP4 Al-Manakher power plant.

Wärtsilä Helping To Power Jordan €184 million order placed by AES Corp., tri-fuel plant to be installed adjacent to existing plant

Wärtsilä has been contracted to engineer, supply and install a major power plant in Jordan. The order has been placed by AES Corp., a U.S.based independent power producer that owns and operates a diverse portfolio of electricity generation and distribution businesses around the world, the company said. The value of the contract is €184 million. The IPP4 Al-Manakher power plant is to be installed next to the existing AES power plant in Amman, Jordan, on a fast-track, turnkey basis, and is scheduled to be fully operational by July 2014. The power plant will supply electricity to the country’s national grid. The power plant will be running on 16 Wärtsilä 50DF dual-fuel engines and will be capable of using heavy fuel oil (HFO), distillate (DFO) or natural gas as

fuel. Wärtsilä said it expects that initially the plant will operate using HFO, but the fuel flexibility of its engine technology will enable a transfer to environmentally sustainable natural gas operation once the infrastructure for a natural gas supply is in place. This power plant order is the latest that Wärtsilä has received from Jordan within a short period of time. The government of Jordan is currently restructuring and upgrading its national electricity grid to ensure that a reliable power supply is available throughout the country. This will be the third power plant that Wärtsilä has delivered to the country. A 50 MW plant is already in use and is being operated and maintained by Wärtsilä personnel under an Operations and Maintenance agreement.


An additional 573 MW power plant project is under construction and is expected to be operational in 2014. “There are a number of reasons why Wärtsilä was successful in winning this valuable contract,” said Vesa Riihimäki, president, Wärtsilä Power Plants. “The prime reason, however, is our tri-fuel technology, which provides the customer with operational and fuel flexibility, high output efficiency and proven reliability. Furthermore, our ability to deliver this large turnkey project within a 17 month time frame was a major reason for Wärtsilä being awarded this contract.” AES has a number of projects with Wärtsilä power plant solutions, with three other power plants either already installed or in the process of being installed in Africa. A

Literature Library

Conversion Systems

Insulation

Huegli Tech published a brochure on its dual-fuel conversion systems. The system allows high-speed diesel engines to operate on 25% diesel fuel and 75% natural gas. It automatically compensates for variations in gas quality and availability and functions as a pure diesel engine if the gas supply is interrupted. www.huegli-tech.com

A brochure from Thermamax details the company’s capabilities as an insulation specialist for marine propulsion and power generation applications. The company’s products are designed to ensure that engines will operate smoothly for extended periods of time at maximum output without any heat-induced damage. www.thermamax.com

Diagnostics, Monitoring

Crankshafts

LOOKING FOR A HIGH-QUALITY FILTER?

HERE’S YOUR

SOLID CHOICE To meet industry‘s increasing demands for performance and power output, Camfil Farr has developed the CamGT 4V-300 gas turbine filter with a solid, airtight frame and a new technique for fixing the media, the double-sealing design. The result is a high-performing filter that eliminates bypass air, extends turbine life, and reduces maintenance costs. Furthermore, each filter grade is individually optimized in order to provide lowest possible pressure drop. Read more at

Windrock has released a brochure that provides an overview of its products and services, including online monitoring systems, portable analyzers, machinery health monitoring and asset management systems, emissions testing services, diagnostic and analysis services, and training programs. www.windrock.com

A brochure on crankshafts for ships, generators, machines and special-purpose vehicles is available from Maschinenfabrik Alfing Kessler GmbH. The brochure provides a history of the company, a breakdown of its crankshaft divisions, its crankshafts and other capabilities. www.alfing.de

www.premium-engine-protection.com

www.camfilfarr.com

Power Generation

by ian cameron

OPRA has installed an OP16-3B gen-set with dry-low emissions technology for Respell & Deiters GmbH in Germany.

OPRA Hits High Notes Healthy 2012 order book powering future plans, aiming for new gas turbine power range, expanding to Southeast Asia and Americas

Hengelo, Netherlands-based gas turbine maker OPRA Turbines rounded off 2012 with its highest-ever order book, entered into new markets in Germany, Romania, Estonia and Indonesia, and set expansion plans for this upcoming year. A key market for OPRA has been in Russia, where it sold 12 of its OP16 turbines in 2012. OPRA also opened a new office in Moscow to strengthen its sales activities in the country and to increase local service support to existing and future customers. OPRA said an added reason for a presence in Moscow was to meet the need for gas turbines in the 2 MW range to run on flare gas in remote oil fields. To date, OPRA has almost 50 allradial 2 MW OP16 gen-sets operating in Russia. The first OP16 gas turbines were delivered to Russia in 2005 and have achieved more than 50 000 running hours on associated gasses at the Tedinskoe oil field, which is operated by Lukoil Sever. Single or multiple OP16 units can

provide installations with an electrical power demand from 1.5 to 10 MW and, according to the company, are well suited for a variety of applications including combined heat and power (CHP) and oil and gas applications. “We achieved an all-time high order book in 2012 and are expanding to meet our need for more production space, testing and office requirements,” said Fredrik Mowill, OPRA Turbines’ chief executive officer. Four major installations — in Indonesia, Estonia, Romania and Germany — were completed in 2012. The recent installation of two OP16-3A dual-fuel turbines to PT Amerta Indahin Sukabumi in Indonesia represented OPRA’s first sale in Asia. Due to the unpredictable local supply of electricity, the client needed a reliable source of continuous power — 3 MW of power and almost 11 T/hr of steam for the production of its isotonic drink. OPRA supplied two OP16-3A turbines, each delivering up to 1.5 MWe and 4.3 MW of heating power. Ex-


haust gas heat produces just less than 11 T/hr of steam, exactly what PT Amerta Indahin needed to sterilize the water bottles and prepare the drinks. The gas turbines have dualfuel capability and can operate on liquid and gaseous fuels and switch under full load. The CHP system has a waste heat recovery steam boiler, and OPRA arranged for the supply of a gas boost compressor for the project. A Romanian government decision to add 5% of ethanol into gasoline was beneficial to alcoholic drink-maker S.C Murex S.A., which can produce 10 million L of bio-ethanol by using corn as their main raw material. The company, based in Braila, set up a CHP plant and chose a single OP16-3A gas turbine to provide steam and electricity to the factory 24 hours per day in local ambient temperatures down to -30°C. The OP 16-3A turbine produces 1.8 MWe and is connected to a cofired waste heat recovery steam boiler to generate almost 11 T/hr of steam. Murex has also signed a long-term service agreement with OPRA. OPRA has also recently installed an OP16-3B gen-set with dry-low emissions technology to Respell & Dieters GmbH, which makes adhesives for the corrugated board and paper industries

Power Generation

OP16s are installed on this FPSO facility off the coast of Brazil.

at its factory in Ibbenbüren, Germany. The company uses wheat starch for its products. The OP16 supplied its 1.8 MWe of power at the factory and the exhaust heat is used for direct drying of the starch production and for other production processes. The new

unit replaces an existing gas turbine that did not meet air emissions regulations. An added key feature, OPRA said, is that because the OP16’s bearings are in the gas turbine’s cold section, the lubrication is prevented from being exposed to the hot section.

This means the turbine has nearzero lubrication oil consumption and it is impossible for oil to enter the exhaust. Turbine exhaust gases that are oil free are vital for manufacturing food and paper products. Excess electricity produced at Ibbenbüren is exported into the grid. In Estonia, OPRA has supplied an OP-16 gas turbine for CHP application for the Sorbes Group in Switzerland, Estonia and the Ukraine. Sorbets Estonia needed 2 MW of power and 4 MW of heat to produce wooden boards. The heat is used to heat the thermal oil through a heat exchanger and the rest is used in the drying process. Mowill said OPRA is working on the development of a new gas turbine aimed more at applications in power ranges below 1 MW. Mowill added that the company is expanding its sales office network with particular emphasis on Southeast Asia and the Americas, and is also looking to carry out packaging work in in the United States. A

Which innovations could boost your business?

ENgINEER SuccESS New technologies New solutions New networks

For more information please contact: Tel. +49 511 89-0, [email protected]

At HANNOVER MESSE you’ll benefit from 11 leading trade fairs which span the entire value adding chain and offer insights into cutting-edge technology from all over the world See cutting-edge technology which spans the entire industrial value adding chain Access the latest know-how in the core sectors of industrial automation and IT, energy and green technology, power transmission and control technology, industrial supply, production technology and services, including research and development. Don’t miss the world’s most important technology event. You can find out more at hannovermesse.com

ember: A date to rem 13 8 –12 April 20 NEW TECHNOLOGY FIRST 8–12 April 2013 · Hannover · germany

Emissions Worldview

A view of the absorber and desorber columns at the Staudinger CO2 capture pilot power plant in Hanau, Germany. The post-combustion capture process developed by Siemens uses a scrubbing process to remove some 90% of CO2 from the flue gas of coal-fired power plants.

Final Phase For Carbon Capture Siemens PostCap process selected for third phase in technology qualification program at Norway refinery

After the successful completion of Phase One and the awarding of a contract for Phase Two, Siemens has been selected by Statoil to participate in the third phase of the technology qualification program. This phase will measure qualification for a full-scale CO2 capture plant at the combinedheat and power plant of a refinery in Mongstad, Norway. In Phase One, Siemens successfully demonstrated the applicability of the PostCap process for the Mongstad carbon capture plant by proving that PostCap can be dialed to full scale, has the required operational regularity, and that high capture ratios can be achieved with limited life cycle costs. Phase Two is already partially completed. Siemens explained that the subtasks of conducting stress tests on the solvent and documenting emis-

sions data on an automated laboratory test rig had been performed within the time frame agreed. The remaining task of a 3000-hour performance test at an approved verification pilot plant with flue gas from a gas-fired boiler is ongoing. The third and final phase, which has now been awarded to Siemens, is the concept phase for the design of full scale CO2 capture at Mongstad. Successful results in the technology qualification program will allow for the potential selection of Siemens’ PostCap technology in later project stages. This last phase started in late September 2012 and will be finished in April 2013. “The phased approach for the CCM project is very smart because Statoil and Gassnova can get a deeper understanding of the carbon capture


technologies and gain trust in the cooperation with the potential plant supplier,” Nicolas Vortmeyer, head of Technology Innovation of Fossil Power Generation at Siemens Energy. “Thus, it contributes to eliminating risks in the implementation of firstof-its-kind demonstration projects.” Siemens’ proprietary CO2 capture technology uses an amino-acid salt solution as a solvent. According to Siemens, this technology has proven to have several advantages compared to other post-combustion carbon capture processes: low energy consumption, low investment costs, as well as nearly zero emissions. Furthermore, the PostCap unit can be operated within the common safety standards of a power plant. It is suitable for retrofitting existing plants and new power plants, the company said. A

MARCH 6-7, 2013

pennsylvAniA Convention CenteR

•

pHilAdelpHiA, pA

Solutions to Secure an Affordable Energy Supply The GLOBALCON Expo and Conference is where decision makers from business, industry and government must now seek integrated energy solutions, which assure both a secure and affordable energy supply to meet today’s and tomorrow’s needs, and effective management of energy and overall operational costs. The multi-track conference covers a broad range of currently relevant topics, and gives you the opportunity to hear first-hand from some of the major players in the energy field. The Globalcon Expo will emphasize four critical areas of leading edge technology and related services: • • • •

Energy Management, HVAC and Smart Building Systems Renewables, Alternative Energy & Onsite Generation Lighting Efficiency & Integrated Energy Solutions Plant Engineering and Facilities Management

The 24 th Annual GLOB ALCON EVENT

Join your colleagues for the industr y event that brings you up to speed on the ver y latest developments shaping the energy field...

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Oil & Gas

The Izmit Tüpras refinery, located on the Gulf of Izmit in Turkey, is among the most advanced oil refineries in the Mediterranean region.

Turkish Refinery Upgrade Tüpras refinery to meet Turkey’s emissions requirements; GE gas turbines, steam turbines, generators to provide steam and energy

GE will provide a wide range of equipment and services for a major plant upgrade of the Izmit Tüpras refinery, located on the Gulf of Izmit in Turkey. GE technology will power the cogeneration site, producing a reliable supply of energy and steam to meet the growing needs of the Tüpras facility, which is among the most advanced oil refineries in the Mediterranean region. GE will supply two Frame 6B gas turbines, one steam turbine and three generators to Técnicas Reunidas of Spain, the engineering, procurement and construction contractor for the Izmit

Tüpras upgrade project. The equipment contract also includes performance testing, services, spare parts and technical advisors, the company said. GE has also signed a contractual service agreement (CSA) to provide maintenance services to Tüpras for 12 years. GE’s CSAs provide predictable maintenance costs while ensuring high availability and a steady flow of revenue from plant operations, the company said. GE has long-term agreements in place at more than 700 sites worldwide. “With its locally available resources


and broad base of technology and services, GE is an excellent partner for a project as challenging and complex as the Tüpras refinery upgrade,” said Juan Lladó, CEO of Técnicas Reunidas. “This project builds upon the already successful relationship that has been established between our two companies.” GE has been working with Técnicas Reunidas for 30 years, supplying nearly 4.5 GW of power generation equipment and oil and gas equipment — including turbines, compressors, pumps and reactors — for projects worldwide. continued on page 56

KEEPING EUROPE’S POWER

FLOWING Conference & Exhibition 4 – 6 June 2013 Messe Wien, Vienna, Austria

PRELIMINARY CONFERENCE PROGRAMME NOW AVAILABLE POWER-GEN Europe, the region’s largest event dedicated to power generation, is pleased to announce the availability of the preliminary conference programme for 2013.

For further information on exhibiting and sponsorship opportunities please visit www.powergeneurope.com Alternatively, please contact:

Taking Keeping Europe’s Power Flowing as the theme POWER-GEN Europe’s insightful and thought-provoking multi track conference sessions will cover strategic and technical topics chosen and presented by leading practitioners from the power industry itself and comprise the following: Track 1: Track 2: Track 3: Track 4: Track 5: Track 6: Track 7

Strategies for the European Power Sector Road to Decarbonization - CCS, Energy Efficiency & CHP Gas Fired Power Technology Thermal & Nuclear Power Plants Electrical & Automation for Power Generation Operation, Maintenance, Refurbishment & Optimization Joint Integration session with co-located Renewable Energy World Europe

Russia & CIS: Natalia Gaisenok T: +7 499 271 93 39 E: [email protected]

For full details of the conference programme, please visit the event website, www.powergeneurope.com and select the conference tab on the top navigation bar. Alternatively, if you have a smart phone with a scanning app , please use the QR code below to access the conference programme on your mobile device.

For further information please contact: Emily Pryor

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Industry Drivers

Oil & Gas

SIEMENS

P

GE will supply two Frame 6B gas turbines, one steam turbine and three generators to Técnicas Reunidas of Spain, the engineering, procurement and construction contractor for the Izmit Tüpras upgrade project.

“Refineries have very stringent reliability and safety requirements. GE’s proven 6B gas turbine technology will bring added security and robust availability to the already high standards of Tüpras’ petrochemical operations,” said Paul Browning, president and CEO — Thermal Products for GE Power & Water. “The upgrade project underscores GE’s commitment to supply the latest technology and services to meet the reliability demands of the petrochemical industry worldwide. Our ability to deliver the wide range of products and services needed for the Tüpras project highlights the strength of the synergies that exist among many of the business units across the company.” GE said its Frame 6B gas turbine has a strong record of performance in refinery and petrochemical applications worldwide. The models to be installed for the Tüpras project will be equipped with GE’s latest dry low NOx (DLN) combustion technology to reduce emissions, extend maintenance intervals and enable the site to operate more flexibly. GE’s DLN emissions-reducing technology is installed on more than 1900 heavyduty gas turbines worldwide.

Tüpras selected GE’s combustion technology to enable the refinery to meet Turkey’s new and more stringent emissions requirements. The new laws call for natural gas plants to limit emissions to 50 mg/Nm3. The GE (SANC1-6 model) 109K250 VHP steam turbine package for the Tüpras upgrade features heavyduty reaction technology that makes it an ideal equipment package for the oil and gas industry, GE said, allowing the client to operate the plant across varying conditions while still having a high efficiency of power production. The cogeneration plant for the Izmit Tüpras refinery expansion will begin commercial operation in the first quarter of 2014. Tüpras, Turkey’s leading oil company, operates four oil refineries including the Izmit site. The four facilities total more than 25.4 million tonnes of annual crude oil processing capacity. Tüpras is owned by the KOÇ Group, the largest business group in Turkey with participation in industrial, commercial and financial sectors. Técnicas Reunidas is among the leading international engineering and construction companies in oil and gas production, refining, and petrochemicals and power generation projects. A


Siemens received a US$220 million order for the supply of the power island for the UTE Mauá 3 combinedcycle power plant that will be located in Manaus, Brazil. The plant, which will have an installed capacity of 580 MW, will be built for Amazonas Distribuidora de Energia S.A., a subsidiary of Eletrobrás, the National Brazilian Electrical Co. Siemens will deliver the engineered power island, including two SGT6-5000F gas turbines, one SST6-5000 steam turbine, three SGen6-1000A generators, and the SPPAT3000 instrumentation and control system. The gas turbines, steam turbines and generators will be manufactured in the Siemens factory in Charlotte, North Carolina, U.S.A. With the construction lead by Construtora Andrade Gutierrez S.A., Siemens and Andrade will supply the natural gas-fired, combined-cycle plant in two phases. The first phase will be the construction of the simple-cycle plant scheduled to be online in 2014, thus supporting further growth in the region and the increased electricity demand during the 2014 FIFA World Cup Soccer games, Siemens said. The combined-cycle conversion will follow as phase two of the plant construction.

KRAL

M

Kral has supplied its fuel consumption measurement system to Denmark-based DFDS Seaways for three of its RO-PAX ships: Dover Seaways, Delft Seaways and Dunkerque Seaways. On each ship, the measuring systems monitor the fuel consumption of all four main motors, the power generation units and the two burners, and feature a local Kral BEM 500 electronic indication unit for each measurement system. The information of all nine consumption measuring systems is transferred to the bridge and displayed by the Kral BEM 800 on one display. Kral supplied 27 fuel consumption measuring systems to DFDS Seaways. The fuel consumption systems facilitate the comparison between the ships and thus optimization of the fleet consumption, Kral said. During the transition phase from heavy oil to distillates, the system helps observe the specified temperature gradient of the engine manufacturers.

Industry Drivers

ROLLS-ROYCE

M

Rolls-Royce has received a contract to power the U.S. Navy’s future fleet of hovercrafts, known as the Ship-toShore Connector (SSC). Each SSC will use multiple Rolls-Royce MT7 gas turbines, derived from the AE1107 engine that powers the U.S. Marine Corps’ V-22 Osprey tilt-rotor aircraft. The company will work with Textron Marine & Land Systems, which has been selected to build the initial development craft in a program that could extend to 73 craft. The SSC will replace the Navy’s current fleet of Landing Craft Air Cushion (LCAC) hovercraft over the next 20 years. The new hovercraft will be used to rapidly deploy personnel and vehicles between U.S. Navy ships and the shore. On each hovercraft, the MT7 gas turbines will be connected to a gearbox system providing both propulsion and lift. Rolls-Royce will also design and manufacture the air intake and exhaust systems. The MT7 is the latest Rolls-Royce gas turbine to be selected to power a ma-

jor U.S. Navy program and follows the MT30, which is already powering the Freedom class Littoral Combat Ships and will provide electrical power for the DDG1000 Zumwalt class destroyers.

PENTAIR THERMAL MANAGEMENT

I

Tyco Thermal Controls, a global provider of electrical heat-tracing products for refineries, power plants, oil rigs and chemical processing plants, is now called Pentair Thermal Management. As a new global business unit with Pentair Ltd., Pentair Thermal Management will continue to offer heat tracing, floor heating, snow melting and deicing products; temperature measurement; and firerated, wiring and leak detection systems to customers worldwide.

CLEAR ENERGY SYSTEMS

P

Clear Energy Systems Inc. (CES), which specializes in mobile and distributed power generation systems, announced that it has signed a master dis-

tribution agreement with Toronto-based GasGen Canada Ltd. Under terms of the agreement, GasGen will market, distribute and service CES power generation products throughout Canada. The agreement represents the second master distributor relationship CES has concluded within the last 30 days. Through this strategic alliance, Clear Energy Systems will launch its premier product — the Genesis 1000 — into Canadian distributed energy markets in early 2013, the company said. The Genesis 1000 is a compact, lightweight 1 MW power generation system, uniquely positioned in Canada’s burgeoning resource industry. At only 5.7 m long and 7348 kg, the fully enclosed Genesis unit is substantially smaller and lighter than typical 1 MW power systems, CES said. GasGen Canada supplies natural gas generator sets to Canadian energy markets through its network of sub-distributors. The fuel-flexible Genesis 1000 operates on natural gas, LP gas, biomethane from landfills and biodigesters, and flare gas from oil drilling and processing.

Power Generation

by mike rhodes

Alstom is adding two STF15C steam turbines and five horizontal dual-pressure heat recovery steam generators to convert the existing Az Zour power plant in Kuwait from simple-cycle to combined-cycle operations.

Alstom Adds 400 MW In Kuwait Plant conversion to combined-cycle to help country meet high summer power needs

Alstom is in the process of adding a steam tail (add-on) to the Kuwaiti Az Zour gas-fired power plant, converting it from a simple-cycle to a combined-cycle plant. The power plant is located approximately 90 km south of Kuwait City. Kuwait has experienced steady economic growth over the past few years, driven by rising oil prices. This growth has resulted in an increased power demand at an average of 8% per year. Meeting this demand has become a critical issue for Kuwait, especially during the hot summer months when airconditioning requirements battle with temperatures that can reach up

to 50°C. Consumption often reaches and exceeds the country’s maximum production capacity — the Ministry of Electricity and Water (MEW) has taken parts of Kuwait City off the grid in the past, causing blackouts in some parts of the country. The MEW is looking to add capacity to its currently installed 12.6 GW to meet these summer energy needs. The first stage of the project, consisting of five GT13E2 gas turbines operating in open-cycle, went online in 2008. The steam tail will add 400 MW to the existing 800 MW simplecycle power plant capacity, use the same amount of fuel, increase its efficiency from approximately 30% to


over 45%, and cut emissions per MW produced, Alstom said. Having built phase one and carried out several such conversions in the region — for example, the GTX project in Dubai — Alstom recieved a US$170 million contract for the combinedcycle extension by Alghanim International in March 2011. Alghanim International, a Kuwaitbased multinational conglomerate spanning a wide range of industrial sectors, is the project’s main contractor for engineering, procurement and construction (EPC). The company, which is building the plant for the MEW, will operate the plant for the continued on page 60

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Power Generation first seven years and then transfer operation to the Ministry. “The original simple-cycle power plant was designed from day one to allow for the eventual addition of the combined-cycle unit, given that the first installing and operating of gas turbines in simple-cycle mode allows power to be supplied to the grid very quickly,” said Marcel Streit, project director, Az Zour, Alstom. “The two STF15C steam turbines and five horizontal dualpressure heat recovery steam generators are then installed at a later date to convert to combined-cycle, thereby boosting power output and increasing efficiency significantly.” Apart from the usual challenges of working in the desert and adhering to the strict compliance standards required by the MEW, Streit said one of the main obstacles has proven to be the limited working space. “The add-on is being constructed on a very small plot of land that already has equipment in operation. With vari-

ous cables, cable trenches, cooling water pipes, treated water pipes, etc. passing through the site, it is difficult to establish a plot layout that fits the existing site layout.” Speed of engineering, manufacturing of equipment, and delivery all factored into the project. Because of insufficient cooling water, Alghanim International had to build a huge cooling tower, which has to be interfaced with the new generators and condensers. “Another complexity was the customer’s decision to opt for a common header for steam coming from the HRSGs to the steam turbines,” Streit said. For improved operating flexibility, the plant is designed so that steam from the five HRSGs flows into a single header and is then split between the two steam turbines. This configuration will allow the owner to operate any combination of HRSGs and steam turbines. “This means that each steam turbine has to be designed for the admission of steam from two and a half HRSGs,”

Streit said. “Although this may appear straightforward in theory, in practice it presents a huge design challenge and there are very few references of such a configuration in the industry.” The common header requires a very large structure measuring 100 m in length, 8 m in width, and 50 m in height. This structure houses and supports all the piping and equipment valves as well as everything else required to feed the common header connecting the HRSGs to the steam turbines. “Overcoming these challenges calls for good communication and careful project management,” Streit said. “As the major supplier, Alstom had to work with Alghanim International wherever possible to analyze what is critical to the contract schedule and accelerate the components on the critical path.” Alstom has signed an eight-year long-term service agreement (LTSA) contract that includes the provision of spare parts, reconditioning services and technical field advisory services. A

data into existing legacy vibration systems and plant monitoring controllers, all made possible through the Modbus interface. Battery life of the sensor typically exceeds five years when transmitting data three times a day, and a 24 Vdc source can power the EchoPlus box without battery life limitations, the company said. www.imi-sensors.com

On nonshielded gas engines, an inductive clamp is attached to the spark plug wire. The spark voltage is monitored in 1 kV increments up to 40 kV by a column of LEDs. The LED color ranges (green, yellow, red) provide operators with an indication about a spark plug’s condition. For engines equipped with special Motortech coils that have the inductive voltage measurement circuits built in, no extra high voltage clamp is required. www.motortechamericas.com

Featured Products

Vibration Monitoring System

Spark Plug Monitoring IMI-Sensors, a division of PCB Piezotronics Inc., has debuted the Echo wireless vibration monitoring system, designed to monitor the overall health of critical machinery and provide immediate notification when warning or critical levels are reached. The system can be applied to several industrial applications in the power, steel and chemical industries. The system uses the Echo wireless vibration sensor and the EchoPlus wireless junction box to transmit vibration data to a single, central receiver. The system allows for the integration of wirelessly transmitted

Marine Diesel Engines

Motortech has launched a new hand held device to support gas engine mechanics trouble shooting engine problems or going through preventive maintenance procedures. SparkView monitors the high voltage required by the spark plug when firing.


Dresser-Rand presented its Guascor SF240TA-SP family of marine diesel engines, suitable for several marine applications, including trawlers, seiners, long-line fishing vessels, ferries and tug boats. The Guascor SF240TA-SP family of engines improves performance and reduces fuel consumption by up to 20% compared to previous models, depending on the type of engine and use, DresserRand said. The product line has been redesigned,

Featured Products

featuring a new camshaft and a new cooling system complete with a double fresh water circuit. The new family includes six- and eight-cylinder inline engines and 12- and 16-cylinder vee configuration with power outputs spanning from 294 to 1155 kW at 1500/1800 r/min for continuous duty auxiliary engines, and from 331 to 1324 kW at 1600/1800 r/min for propulsion engines. All engines are certified for IMO Tier 2 emissions regulations. www.dresser-rand.com

Thermometers Ashcroft bimetal thermometers are designed to eliminate use of mercury to measure temperature. Available in dial diameters from 50.8 to 127 mm and ranges

from -62.2° to 538°C, these instruments are available in standard stem lengths from 63.5 to 609.6 mm and special order stems up to 152.4 cm. Ashcroft Maxivision thermometers provide a fixed rear or bottom stem while the Everyangle design allows the stem angle to be adjusted. Hermetically sealed for easy wash down or liquid filled to counter high vibration, Ashcroft stainless-steel bimetal thermometers are suited for difficult installations the company said. www.ashcroft.com

Sensor System Ludeca Inc. has launched sensALIGN, a sensor system for machinery alignment. sensALIGN combines Prueftechnik’s intelligent sensor technology into the ROTALIGN Ultra iS platform, which provides instant data acquisition and displays

real-time results with 100% accuracy, the company said.

The sensALIGN system automatically considers the effects of ambient vibration, acceleration of rotation, backlash, speed of rotation and other factors in determining the Quality Factor (QF) of alignment readings. This makes the system ideal for long-term, stand-alone monitoring of machine positional change (Live Trend) as well as routine everyday shaft alignment, Ludeca said. An improved user-friendly interface makes the ROTALIGN Ultra iS fast, while still collecting thousands of measurement points with its Continuous IntelliSWEEP method, the company said. www.ludeca.com

ADVERTISERS’ INDEX

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* Ansaldo Energia.........................................2 7 www.ansaldoenergia.it

Hannover Messe.........................................51 hannovermesse.com

* OPRA Turbines............................ Third Cover www.opraturbines.com

Camfil Farr Power Systems AB..................49 www.camfilfarr.com/ps

HARCO ........................................................45 harcolabs.com

China International Boat Show.................59 www.chinaboatshow.com

Hotstart, Inc. ..............................................39 www.hotstart.com

Petro-Canada..............................................29 lubricants.petro-canada.ca

13th China International Petroleum & Petrochemical Technology & Equipment Exhibition (CIPPE).................57 www.cippe.com.cn

Hytorc..........................................................15 www.hytorc.com

* Cummins Generator Technologies............19 www.stamford-avk.com/applications

Kobelco/Kobe Steel Ltd. ...........................13 www.kobelcocompressors.com

DCL International Inc. ..................................7 dcl-inc.com

* MAN Diesel & Turbo SE................................5 www.man-bluefire.com

* ECG, Ellwood Crankshaft Group...............41 www.ellwoodcrankshaftgroup.com

* MTU Friedrichshafen GmbH, Onsite Energy Diesel ..............................11 www.mtuonsiteenergy.com

Europort Istanbul.......................................61 www.europort-istanbul.com

Ipsen............................................................21 www.IpsenUSA.com

* MWM GmbH...............................................33 www.mwm.net

Power China................................................63 www.powerchinashow.com Power-Gen Europe.....................................55 www.powergeneurope.com Pratt & Whitney..........................................35 www.pw.utc.com/Power_Systems * Rolls-Royce Energy..................Second Cover www.rolls-royce.com * Thermal Structures, Inc. ..............................1 www.thermalstructures.com Thermamax Hochtemperaturdämmungen GmbH.....37 www.thermamax.com Universal LLC..............................................31 www.Universalaet.com

* GE Oil & Gas..............................Fourth Cover www.geoilandgas.com

MIRATECH Corporation................................9 miratechcorp.com

* GEA Westfalia Separator Group................25 www.gea.com

Murphy........................................................23 www.fwmurphy.com/dgturbine_ad/

WTZ Roßlau gGmbH...................................47 www.wtz.de

Globalcon 2013...........................................53 www.globalconevent.com

Nidec ASI S.p.A. .........................................17 www.nidec-asi.com

W&O Supply...............................................43 www.WOiship.com

* Further information on this company’s products can be found in the 2012 Edition of the Global Sourcing Guide (at GSGnet.net) and/or the 2012 Compression Technology Sourcing Supplement (at CTSSnet.net).

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by ian cameron, ashbourne, england

Into Africa Africa continues to attract growing attention — particularly in the oil and gas and power generation sectors — from companies and investors eager to tap into what some believe is “the next big thing.” Yet opinion is very sharply divided about whether the continent is ready to emulate China’s economic transformation over the past 30 years. To say that opinion is divided is an understatement. Opinions are poles apart. On the one hand, observers suggest that because the economies of some African nations are improving, this is evidence that a huge wave of economic prosperity is ready to wash over the continent. This wave will supposedly lift millions from the despair of poverty, raise the educational standards and propel nations onto the world stage. Others argue that the dream of an African economic paradise is an illusion, arguing that growth remains sluggish at best (even negative), that there is little manufacturing and that the continent is still too heavily dependent on natural resources. Leaving behind the endless debate on Africa’s pros and cons, there is at least evidence of growth, development, expansion and investment in both the power generation and oil and gas exploration and production sectors, all of which create opportunities for suppliers of equipment, technology and investment. A recent report by professional services company Ernst & Young,

one of the world’s largest accounting firms, said natural gas development “holds tremendous opportunity for Africa. It can be a primary driver of economic growth and broader social development, as well a major spur for local employment growth and infrastructure development.” On the subject of power generation, the company added, “The associated development or expansion of a domestic gas demand sector could also bring substantial commercial opportunities in the power generation, industrial and even transportation sectors. Indeed, many of the gas flaring reduction efforts are tied to domestic gas use projects.” Ernst & Young pointed out that while Algeria, Nigeria, Egypt and Libya have large natural gas reserves, production is “considerably lower,” adding that recently the sector’s growth has been in West Africa, principally in Nigeria and Angola. The report added, “While the West African gas growth will continue as flaring is reduced and local gas infrastructure is developed, the big future for African gas lies with the massive offshore gas discoveries in East Africa, particularly in Mozambique and Tanzania.” Naturally, such potential growth in power generation and oil and gas production bodes well not just for indigenous suppliers of services and equipment, but also for non-African companies that already have access to funds to capitalize on emerging opportunities. Many non-African gas exploration


companies are active there and have been for some time: companies such as oil and gas exploration and production company Tullow. In Africa, it has 58 licenses in 15 countries. It says Africa is a major part of its portfolio and cites Uganda and Ghana as key areas. One African company carrying out major investments in its infrastructure is Eskom, which generates some 95% of the electricity used in South Africa and approximately 45% of the electricity used in Africa. By its own admission, Eskom says its power stations are aging. “Sustained high levels of maintenance over the next three years are needed for reliable performance,” Chief Executive Brian Dames recently said. “Power station performance has been volatile and must be improved.” The company said its maintenance backlog is down from 26 units to 20, although lower imports and volatile plant performance reduced the space for planned maintenance. On average, the company’s power stations are 30 years old (one at 49), and Eskom said some of the aged plants would require refurbishment to extend their life cycle and improve their performance. “We need to sustain planned maintenance levels at 10% for three years to turn around and then sustain stable generation performance,” the company said. While the debate on whether Africa can match Asia’s transformation will no doubt rumble on for some time, there is proof that, within some sectors such as natural gas and power generation, the opportunities are there to be seized now. A

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