Diesel & GT Worldwide Jan-Feb 16

7/25/2019 Diesel & GT Worldwide Jan-Feb 16

1/44

the prime-mover magazine since 1969

January-February 2016

www.dieselgasturbine.com


2/44

Changing grid topologies are creating challenges for todays power generation

infrastructure. An increasing demand for grid stabilizing solutions calls for

highly precise excitation regulation algorithms, which fulfill the most stringent

grid codes. Special grid situations like island grids or large load variations may

require additional functionality to guarantee stable and reliable operation.

ABBs solution for all these requirements: The extended ser ies of excitat ionsystems UNITROL6000 for indirect and static excitation with three new types:

Light. Power. Nuclear. All excitation systems are compliant with global grid codes

and are tested for more than 20 year lifetime. Visit us now and learn more about

the new state-of-the-art series UNITROL6000:www.abb.com/unitrol

ABB Swit zer land Ltd

Excitation Systems

Phone: +41 58 589 24 86

E-Mail: [email protected]

New UNITROL6000. Fulfilling the most

stringent grid code requirements worldwide.


3/44

One Screw Compressor.Two Ways to Save.

Ask Kobelco! The Best Solution for Any Gas Compression.

Kobelco Compressors America, Inc.

Houston, Texas

+1-713-655-0015

[email protected]

Kobe Steel, Ltd.

Tokyo +81-3-5739-6771

Munich +49-89-242-1842

www.kobelcocompressors.com

No Standby RequiredStill thinking about recip or

centrifugal compressors for fuel

gas boosting? A Kobelco screw

compressor is so reliable, you wont

need to buy a spare. Whats more, the

screw design is inherently more economical

to maintain. Youll get around six years of

continuous operation between overhauls. Plus

youll have only one machine to maintain.

Save on PowerKobelco screw compressors

feature an innovative slide valve

that substantially reduces power

consumption without steps to

handle fluctuations in turbine load

(turndown range: 100% to 20%) and

suction pressures (up to 1,500 psig/100 barg).

So youll continue to conserve power and

reduce costs every day.

FUEL GAS BOOSTINGCOMPRESSORS FOR GAS TURBINES


4/44


5/44

Diesel & Gas Turbine Worldwideis the leading authority for

prime-mover products, technologies and news.

www.dieselgasturbine.com

MEMBER OF BPA WORLDWIDEDIESEL & GAS TURBINE WORLDWIDE (ISSN 0278-5994) Volume 48, Number 1. Published monthly except, Jan/Feb& July/Aug issues combined, by Diesel & Gas Turbine Publications, 20855 Watertown Road, Suite 220, Waukesha, WI 53186-1873 USA Subscription rates are $85.00 per year/$10.00 per copy worldwide. Periodicals postage paid at Waukesha, WI53186 and at additional mailing offices. Copyright 2016 Diesel & Gas Turbine Publications. All Rights Reserved. Materialsprotected by U.S. and international copyright laws and treaties. Unauthorized duplication and publication is expresslyprohibited. Canadian Publication Mail Agreement # 40035419. Return Undeliverable Canadian Addresses to: P.O. Box 456,Niagara Falls, ON L2E 6V2, Canada. Email: [email protected]. POSTMASTER: Send address changes to: CirculationManager, Diesel & Gas Turbine Worldwide, 20855 Watertown Road, Suite 220, Waukesha, WI 53186-1873 USA.PRINTED IN THE USA

Diesel & Gas Turbine Worldwide 3 January-February 2016

Gearboxes & Drivelines 6 Voith Turbo Creates Special Test Rig

For Journal Bearings

26 The Forgotten Essentials

Load Banks10 Loading Up Worldwide

Power Generation12 Island Power

22 First Enhanced Steam Path (ESP)

Upgrade For D-11 Steam Turbine

36 China Fights Back Against Pollution

2016 Power PlantsOf The World14 Power Plants Of The World

Rail Technology25 Train To Climate Change

31 Sensing And Diagnostics On Track

Prime-Mover Order Review32 Prime-Mover Order Review

CONTE

NTS

january

Follow @dgtww on:

In Every Issue 2 Haight Notes

4 PMO Report

8 Events & Meetings

24 Featured Products

28 Newsmakers

30 Industry Drivers

38 Index Of Advertisers

39 Marketplace

40 World Viewpoint6Voith Turbo CreatesSpecial Test Rig For

Journal Bearings

22First Enhanced

Steam Path (ESP)

Upgrade For D-11

Steam Turbine

14Power Plants

Of The World

-february

C

overDesign:AlyssaLoope


6/44


CAPSTONE Capstone will supply two C1000 microturbines to provide

power for an offshore oil company operating in the South

China Sea.

Capstone will supply Horizon Power Systems three C800 sys-

tems and two C1000 systems for a total of 4.6 MW for a large

flare gas energy project in North America.

Capstone will supply a C600 microturbine package to up-

grade a Colombian hotel.

GE GE will supply four advanced GE 7F.05 heavy-duty gas tur-

bines and a GE steam turbine for Saudi Electricity Co.s new

1390 MW Waad Al Shamal combined-cycle power plant.

GE will supply two high-efficiency 9HA gas turbines, one

steam turbine (engineered by Alstom and now incorporat-

ed into GEs portfolio) and associated equipment to Harbin

Electric International Co. Ltd. for its new 1.2 GW Balloki

combined-cycle power plant in Pakistan.

MAN DIESEL & TURBO MAN Diesel & Turbo will supply 12 MAN 8L51/60DF four-

stroke engines to Sembcorp Marine in Singapore for a new

semi-submersible crane vessel for Heerema Offshore Services.

MAN Diesel & Turbo will supply four 20V28/33D STC engines,each delivering 9100 kW, for the KatExpress 3, a high-speed

ferry newbuilding from the Australian shipyard Incat for

Mols-Linien, the Danish ferry operator.

MITSUBISHI HITACHI POWER SYSTEMS Mitsubishi Hitachi Power Systems Ltd. will supply a steam

turbine and a generator for the San Buenaventura Power

Plant, a 500 MW ultra-supercritical-pressure coal-fired power

generation plant to be built by San Buenaventura Power

Ltd., a special purpose company in the Philippines.

NIIGATA POWER SYSTEMS Niigata Power Systems will supply four NGT3B-T light oil-

powered emergency gas turbines for the Korean NHs Na-

tional Computing & Information Agency.

Niigata Power Systems will supply three 8L22AG-type gas

engines and three related auxiliary machines for a gas en-

gine power plant ordered by Japans Toho Earthtech Inc.

ReportPMOAdditional information on these

Prime-Mover Orders is available at

www.dieselgasturbine.com/pmo-report/

Prime Mover: A machine that transforms energy from a chemical, thermal, electrical or pressure

form into a mechanical form. Electric motors, engines and turbines are examples of prime movers.Perez, Robert. 2013.Illustrated Dictionary Of Essential Process Machinery Terms;

DGTP Inc., Waukesha, Wisconsin, USA

ROLLS-ROYCE Rolls-Royce Power Systems will supply 23 MTU Onsite En-

ergy standby gen-sets to the Al Farwaniya hospital in Ku-

wait City, Kuwait. The gen-sets are based on Series 4000

20-cylinder engines that deliver a maximum of 2750 kVA of

prime power each.

Rolls-Royce will supply ten 16-cylinder MTU Onsite Energy

Series 4000 diesel gen-sets and one eight-cylinder Series

1600 unit to the DIA Holding construction company for

standby power on new health campuses of the Turkish Min-

istry of Health in Mersin.

Rolls-Royce will supply 14 MTU Onsite Energy Series

16-cylinder and five 12-cylinder Series 4000 units to the DIA

Holding construction company for standby power on new

health campuses of the Turkish Ministry of Health in Bilkent.

SIEMENS Siemens will supply two SGT6-8000H gas turbines and two

SGen6-2000H generators for the 791 MW Empalme II

combined-cycle power plant in Sonora, Mexico.

WRTSIL Wrtsil will supply two heavy fuel oil Wrtsil 46 engines,

with a combined capacity of 34 MW, as part of an extensionto a 53 MW Flexicycle power plant under construction near

Dakar, Senegal.

Wrtsil will supply two 16-cylinder and two eight-cylinder

Wrtsil 32 engines and one six-cylinder Wrtsil 20 engine

for two new Aker Arctic-designed icebreakers under con-

struction at the PJSC Vyborg Shipyard in Russia.

Wrtsil will supply two five-cylinder Wrtsil RT-flex 50-D

main engines and six six-cylinder inline Wrtsil 20 generat-

ing sets propulsion systems for two new dry bulk carriers be-

ing built for Canadian operator Algoma Central Corp.

Wrtsil will supply three Wrtsil 50DF dual-fuel engines

running primarily on natural gas, with light fuel oil as backup,

for a 50 MW Smart Power Generation power plant to Mar-

quette Board of Light and Power in Michigan, USA.A


7/44

Engine and Marine Systems Power Plants Turbomachinery After Sales

Go for GasFor exibility in an era of renewables

As we enter an age of renewables, the V35/44G is a great source of power, and a great source

of exibility. It is the rst fully electronic four-stroke gas engine from MAN Diesel & Turbo, and

combines exceptional efciency, proven reliability and excellent TCO. The V35/44G produces up to

10.6 MW, making it ideal for industrial applications and local electricity generation, including CHP.

Discover the power of MAN gas technology:

www.mandieselturbo.com


8/44

Voith Turbo Creates Special TestRig For Journal Bearings

Rig designed to test bearings under more realistic

operating conditions

by Dr. SteffenKmmerer


tandard test procedures for tur-bomachinery gearboxes work

for some gear units, but they are

inadequate for journal bearings.

Voith Turbo BHS solved this

problem by creating a special test rig

for journal bearings. The rig allows

bearings to be tested under more re-

alistic operating conditions, including

full speed and full load.

Under typical procedures, test runs for

bearings are not executed at full load

because many gear manufacturers andmaintenance providers dont have facili-

ties with sufficient braking power.

Most specialists resort to load-free test-

ing, a well-established method that, in

most cases, provides all the necessary

information, including gear characteris-

tics rotor dynamics and tooth contact

as well as most failure modes.

Load-free testing, however, has its lim-its when it comes to journal bearings.

The procedures do not reflect real-life

scenarios for journal bearings, especially

when those components turn at high

speed and high load in unfavorable

thermal conditions.

Existing design tools and load-free

tests cannot accurately forecast bearing

temperatures, affecting the accuracy of

the operating safety margin, especially

in challenging applications.

These factors are what drove Voith Tur-bo BHS to develop the test rig, which can

be used for steady-state and dynamic-

bearing tests, the company said.

The rig consists of a dummy shaft, two

support bearings and a test bearing

mounted in a support ring, which, in

turn, is connected to a system for ap-

plying and measuring radial loads. An

electric motor and gearbox drive thedummy shaft at the required circumfer-

ential velocity (up to 160 m/s).

Two pneumatic cylinders arranged at

90 create the static load. Each cylin-

der can provide a force of 165 kN, al-

lowing realistic loads for bearings up

to 200 mm in diameter. The load vec-

tor on the test bearing is adjusted by

varying the distribution of force be-

tween the two cylinders.

For steady-state testing, the test bear-

ing is run at various combinations ofspeed, load and oil flow. Measurements

reveal how bearing temperatures corre-

late with these three parameters.

Using this rig, Voith Turbo BHS tested

its BHS UltraCool bearings for an inter-

national OEM, reporting the results in

steady state. The journal bearings were

part of a parallel-shaft gearbox designed

S

On the test rig, the bearing is mounted on a dummy shaft driven by an electric motor.

Two pneumatic cylinders mounted at right angles supply the radial load.

Dr. Steffen Kmmereris head of R&D, technical calculations, Voith Turbo BHS Getriebe GmbH in Sonthofen, Germany. Visit

http://tinyurl.com/j5rbttd for more information.


9/44

GEARBOXES& drivelines


to transmit 30 MW between a gas turbine and a compressor.

The maximum continuous speed (MCS) of the high-speed shaft

is around 10 000 r/min.

The challenges facing hydrodynamic bearings under such

conditions are a high oil inlet temperature (up to 65C) as a

result of the hot environment within the plant, high loads

(more than 3 MPa), and high circumferential velocities (more

than 80 m/s).

The customer required Voith Turbo BHS to guarantee amaximum bearing temperature of 100C at full load and

rated MCS for both the high-speed (170 mm) and low-speed

(200 mm) shafts. The specified oil conditions were: ISO VG32

oil, an oil inlet temperature of 60C and an oil inlet pressure

of 1.7 bar.

The UltraCool type bearings used for this application are gen-

erally used at journal velocities up to 95 m/s and specific loads

up to 4 MPa. Design calculations indicated that in this applica-

tion the maximum bearing temperatures would be close to the

limit specified by the customer.

Voith Turbo BHS decided to use the test rig to confirm the

thermal performance of the bearings. The temperature probeswere positioned at 25 and 75% of the bearing width, in ac-

cordance with API 670. Voith Turbo BHS production bearings

are already drilled for temperature sensors at these positions.

For R&D purposes, however, it is possible to use extended test

setups with around 20 temperature probes. This gives a denser

map of the temperature distribution and a more complete pic-

ture of the thermal loading.

The bearing temperatures recorded from the test rig fell

within 2C of the corresponding measurements from the ful-

ly assembled gearbox, taken at both no-load and part-load

conditions. A

Voith Turbo BHS tested its UltraCool bearings

under full-load conditions on its test rig foran international OEM.

engineering for a better world

GEA Westfalia Separator Group GmbH

Werner-Habig-Strae 1, 59302 Oelde, Germany

Phone: +49 2522 77-0, Fax: +49 2522 77-1778

[email protected], www.gea.com

GEA Separation Technology protects the performan

safety and economy of your power generator systemworldwide.

Our separators shield your diesel engines and gas

turbines from all aggressive by-products in fuel oils,

reducing service downtimes and failures.

Diesel engines are safe from destructive cat fines

in low-sulphur residual oils. Gas turbines are

protected from corrosion caused by sodium

and potassium in untreated oils.

High-PerformanceSeparatorsSafeguarding your dieselengines and gas turbines

E N

0 1

0 0 4


10/44REGISTER WITH CODE DGTTO SAVE 15% OFF THE CURRENT RATE! BE THERE

EXPERIENCE THE POWER

THE RIGHT CONNECTIONS.Thousands of power industry

professionals will converge in New

Orleans to connect with peers andadvance their knowledge on pressing

issues impacting power generation.

THE RIGHT CONTENT.Over 60 educational sessions

programmed specifically for generating

companies, making ELECTRIC

POWER Where the Gencos Meet!

THE RIGHT SOLUTIONS.200+ knowledgeable suppliers in

power generation ready to discuss

the services and solutions they offerto meet the needs of your plant.

THE RIGHT SHOW.The 18th Annual ELECTRIC POWER

Conference + Exhibition returns to New

Orleans in 2016 to provide insight on

topics that matter and solutions to the

challenges that impact your plant.

www.electricpowerexpo.com

EXHIBITION: APRIL 1820, 2016

CONFERENCE: APRIL 1821, 2016

Morial Convention Center New Orleans, LA

REGISTER WITH CODE DGTTO SAVE 15% OFF THE CURRENT RATE! BE THERE

EXPERIENCE THE POWER

THE RIGHT CONNECTIONS.Thousands of power industry

professionals will converge in New

Orleans to connect with peers andadvance their knowledge on pressing

issues impacting power generation.

THE RIGHT CONTENT.Over 60 educational sessions

programmed specifically for generating

companies, making ELECTRIC

POWER Where the Gencos Meet!

THE RIGHT SOLUTIONS.200+ knowledgeable suppliers in

power generation ready to discuss

the services and solutions they offerto meet the needs of your plant.

THE RIGHT SHOW.The 18th Annual ELECTRIC POWER

Conference + Exhibition returns to New

Orleans in 2016 to provide insight on

topics that matter and solutions to the

challenges that impact your plant.


EXHIBITION: APRIL 1820, 2016

CONFERENCE: APRIL 1821, 2016

Morial Convention Center New Orleans, LA

9-10GlobalConBoston, Massachusetts, USA+1 (770) 279-4392

www.globalconevent.com

15-16Power & Electricity World AfricaJohannesburg, South Africa+27 11 516 4031www.terrapinn.com/exhibition/power-electricity-world-africa/index.stm

20-23Western Turbine UsersConferencePalm Springs, California, USA

+1 (513) 604-8018www.wtui.com

21-23Shipping 2016Stamford, Connecticut, USA+1 (203) 406-0109 x3717www.cmashipping2016.com

3-4Gas/Electric PartnershipConferenceHouston, Texas, USA+1 (713) 529-3216www.gaselectricpartnership.com

22-25Asia Turbomachinery &Pump SymposiumMarina Bay Sands, Singapore+1 (979) 845-7417http://atps.tamu.edu

1-3Middle East Electricity (M.E.E.)Dubai, United Arab Emirates+971 4 407 2472www.middleeastelectricity.com

6-10Corrosion 2016Vancouver, British Columbia,Canada+1 (281) 228-6200www.nacecorrosion.org

22-23Cogen Europe Annual ConferenceBrussels, Belgium+32 2 772 8290

www.cogeneurope.eu

29-31China International Offshore Oil& Gas ExhibitionBeijing, China+86 10 5823 6555www.ciooe.com.cn/2016/en

13-15Sea Japan

Tokyo, Japan

+81 3 5296 1020www.seajapan.ne.jp

18-21Electric Power

New Orleans, Louisiana, USA

+1 (832) 242-1969


m

ar

& MeetingsEVENTS

feb

apr


11/44

Wemovethe

world

FLENDERGRAFFENSTADEN

Through a long history of gear manufacturing,

we have acquired the know-how and the experience

to be a leader in the field of high speed gears.

Our industrial site has developed a tradition

in high performance gear units for over 60 years

and through more than 13000 references

for the Power Generation and the Oil & Gas industries.

FLENDER-GRAFFENSTADEN S.A.S.

1, rue du vieux moulin - BP 10063

F - 67402 Illkirch Cedex - France

Phone : +33 (0)3 88 67 60 00

www.flender-graff.com

HIGH PERFORMANCE TRANSMISSION FOR ENERG

Boldfaceindicates shows and conferences in whichDiesel & Gas Turbine Worldwideis participating.

A more complete listing of trade shows is availabl e at www.dieselgasturbine.com/events/

19-207thAVL Large Engines TechDays

Graz, Austria

+43 316 787 1195

www.avl.com/large-engines-techdays

25-27Gulf South Rotating MachinerySymposiumBaton Rouge, Louisiana, USA+1 (225) 578-4853www.gsrms.org

25-29Hannover Messe

Hanover, Germany

+49 511 89-0

www.hannovermesse.de

2-5Offshore Technology ConferenceHouston, Texas, USA+1 (972) 952-9494www.otcnet.org

10-12Sensor+Test 2016Nuremberg, Germany+49 5033 9639-0www.sensor-test.de

11-13China International Marine,Port & Shipbuilding FairNanjing, China+86 25 8452 1101http://china-ship.com

17-18Offshore ArabiaDubai, United Arab Emirates+971 4362 4717 x617www.offshorearabia.ae

18-20Power-Gen India & Central AsiaNew Delhi, India+44 1992 656 610www.power-genindia.com

24-26G-Power 2016Shanghai, China

+86 21 2352 1028www.powerchinashow.com

24-26Eastern Gas Compression

RoundtablePittsburgh, Pennsylvania, USA+1 (412) 372-4301www.egcr.org

31-June 3Energy LebanonBeirut, Lebanon+961 5 959 111www.energy-lebanon.com

6-10CIMAC World Congress

Helsinki, Finland+49 69 6603 1567www.cimaccongress.com

6-10Posidonia 2016Athens, Greece+30 210 428 3608www.posidonia-events.com

Follow @ dgtww on:

may ju

n


12/44

Loading Up WorldwideDemand growing steadily for load banks; data

center and oil-and-gas sectors lead the way

by IanCameron


here is increasing demand for load

banks, especially in regions where the

oil and gas industry is growing.

Load banks enable companies and

organizations to test and confirm that

electrical power systems will meet the demands

placed on them.

According to load bank supplier Aggreko, akey challenge is raising cross-industry aware-

ness of the value of load bank testing and the

need for ensuring a reliable, efficient and con-

sistent power source.

Routine testing of an existing power supply

helps to identify performance issues and ensure

it is in optimum condition. Regular tests check

that it continues to perform efficiently and to its

manufactured rating.

This is perhaps more crucial to an operation

in locations where extreme temperatures, alti-

tude and humidity contribute to significant de-rating, reducing reliability and

efficiency. Load bank testing can be a key component of an effective energy

strategy, particularly for vulnerable companies and sectors.

Aggreko said that whilst little has changed within the load bank industry, cus-

tomer needs and demands continue to evolve. With the digital revolution, and

with more and more companies relying on a constant power supply, and with

grid capacity challenges a constant threat, all power and emergency power

sources should be considered.Certain industry regulations, such as the National Health Service in the U.K.,

for example, call for routine testing of emergency power provisions, and some

critical applications have longer durations of testing in some cases up to 24

hours of continuous load testing is required, said James Smith, Aggreko area

service manager (United Arab Emirates).

This is also true for life-safety systems in tall buildings, such as fire lifts, sprinkler

systems and smoke-extract systems, and is often an insurance requirement.

We are seeing an increase in demand for load banks as the global data-

center industry continues to grow, particularly in North America, the U.K.

and Central Europe. This rising demand comes hand-in-hand with the rising

expectations of constant power quality. An inability to keep data safe and ac-

T

Aggreko said there is a rise in

demand for load banks in regions

where the oil and gas industry

is witnessing continued growth,

such as the Persian Gulf and

throughout Africa.


13/44


14/44

Island Power

MAN diesel engines power new 210 MW plant in the Caribbean

by RobertaPrandi

Diesel & Gas Turbine Worldwide 12January-February 2016

AN Diesel & Turbo inau-

gurated the Pointe Jarry

diesel engine power plant

on the French territory

island of Guadeloupe in

June. Construction began in September

2012 on this fourth island power plant

for EDF Production Energtique Insulaire

(EDF PEI), the subsidiary of lectricit de

France responsible for Corsica and over-seas departments.

The plant is composed of 12 MAN

18V48/60 engines with a total capacity

of around 210 MW, and is the last of four

island power plants MAN Diesel & Turbo

completed for the EDF PEI since 2008.

Pointe Jarry concludes a long-

standing and successful partnership

for which we would like to thank MAN,

said Jean-Michel Lebeau, president of

EDF PEI. The people on Guadeloupe

are getting a ... power plant that cuts

fuel consumption by 15% and nitrogen

oxide emissions by 85%.

The new power plant replaces the

30-year-old Jarry Nord, which was pow-

ered by eight MAN Pielstick diesel en-

gines with 19 MW power output each.

In operation since 1983, the old plant

was decommissioned and replaced with

the new facility that is intended to coveraround 45% of the islands energy needs.

Dr. Hermann Krger, senior vice presi-

dent at MAN Diesel & Turbo and head of

the Power Plants business unit, said the

rest of Guadeloupes power needs are

covered by a steam turbine plant fired

by sugarcane residue, another MAN die-

sel power plant with four engines and

some windmills.

The new plant achieves a technical and

environmental standard that is seldom

seen in the field of diesel power stations,

Krger said. SCR catalytic converter tech-

nology and urea injection deliver signifi-

cantly reduced emissions, while the dedi-

cated seawater desalination plant allows

for 700 000 tonnes of valuable drinking

water to be saved every year.

The seawater desalination plant was

also within MANs scope of supply and

was built together with the new powerplant. It supplies industrial water for the

power plant use via reverse osmosis.

The new power plant established a re-

cord performance in May, the company

said. It produced 85.9 GWh, more elec-

tricity in one month than any of the cus-

tomers other island power plants.

Prior to Pointe Jarry, MAN Diesel & Tur-

bo commissioned plants on La Runion

(Port-Est), Corsica (Haute Corse) and

Martinique (Bellefontaine). All base-load

M

The new Pointe Jarry diesel engine power plant on the Caribbean island of Guadeloupe

is the latest of four island power plants that MAN Diesel & Turbo completed for the

French energy provider EDF PEI.


15/44

POWERgeneration


power plants, the four are equipped with

MAN 18V48/60 engines, each engine

supplying 18.5 MW of electric power.

The island of Guadeloupe is a do-

main autre mer (DOM, that is an over-

seas department of France, thereforeit is subjected to emissions standards

in the European Union), said Dieter

Kunkel, senior project manager, power

plants at MAN Diesel & Turbo. Like the

other three EDF plants, Pointe Jarry is

equipped with the latest technology

in SCR exhaust aftertreatment and flue

gas cleaning.

MAN Diesel & Turbo headed the

project as consortium leader and was

responsible for the plant mechanical

construction and for commissioning,including all studies and documenta-

tion for building permit by the authori-

ties to the customer.

Kunkel said the project was logistically

challenging. Guadaloupe has an almost

tropical climate, and the island lacks in

infrastructure with infrequent ship and

flight connections, he said. Our engines

do not need special features to cope

with the tropical weather, but the loca-

tion itself had very demanding speci-

fications. We profited from the lessonslearned with the previous projects and

capitalized on the advantage of using

the same suppliers and the same com-

missioning teams.

For example, the very narrow build-

ing site posed challenges in the lay-

out, in the storage of materials, and

made civil, mechanical and electrical

working in parallel quite demanding.

At its busiest peak, in April 2014, the

building site accommodated 800 peo-

ple working together.Kunkel said that the narrowness of

the site required that the large tanks

for fuel and firefighting water be built

in Europe and shipped to the island by

sea. The biggest tank for 1200 tonnes of

fuel is 18 m high and 12 m in diameter.

Diesel and heavy fuel oil is shipped

from refineries in Europe or other plac-

es to Guadaloupe by ship and needs

adequate storing capacity.

Guadeloupe required also a lot of re-

dundancies to cope with EUs Health,

Safety and Environmental requirements,

Kunkel said. Safety standards for hurri-

canes and earthquakes are very high here.

The fact that all four island power

plants have the same configuration

with different layouts was a significant

advantage in the construction and com-

missioning phase, Kunkel said. All aux-

iliary systems are the same, too, and we

used the same systems suppliers, he said.

Krger said EDF PEI initially chose the

18V48/60 engine for its efficiency and

reliability. MAN Diesel & Turbo said it

would provide complete maintenance

services for the Guadeloupe plant from

Europe. The company said there are

plans to provide local support to cus-

tomers, which means setting up a serv-

ice hub in the Caribbean.A

The powerhouse of the new Pointe Jarry power plant features 12 MAN

18-cylinder 48/60 engines with a total capacity of around 210 MW. The

plant is expected to cover about 45% of Guadeloupes energy needs.


16/44


Ansaldo EnergiaDedisa Peaking Power Plant

Port Elizabeth, Republic Of South Africa

Dedisa Peaking Power Ltd., the project company led by ENGIE

Group, officially started commercial operation of Dedisa Peak-

ing Power Plant (DPPP) on Sept. 30.

ENGIE Group is the new name of GDF Suez group, a global en-

ergy player with operations in three sectors: electricity, natural

gas and energy services.

DPPP is an open-cycle gas turbine plant rated 340 MWe, lo-

cated in Port Elizabeth, in the Eastern Cape province of the Re-

public of South Africa.

The plant was built on an EPC contract basis by a consortium

between Ansaldo Energia (as leader) and Fata. Ansaldo Ener-

gias scope of work included the supply of two model AE94.2Agas turbine generator sets fueled with diesel oil, the plants dis-

tributed control system, civil works and the relevant mechani-

cal and electrical works.

The construction of DPPP began in September 2013 and was

completed in advance of the contract deadline. The facility is

the first large-scale independent power project in South Af-

rica to be originated by the countrys Department of Energy,

Ansaldo Energia said.

The power generated will be sold by Dedisa Peaking Power to

South Africas state-owned utility, Eskom Holdings, under the

terms of a 15-year power purchase agreement.

Ansaldo Energia will maintain the full efficiency of all rotat-

ing equipment and relative auxiliaries, guaranteeing maximumavailability for a minimum duration of 15 years or at least until

October 2030.

Caterpillar Power SolutionsBeckton And Crossness Sewage Treatment Works

London, U.K.

Beckton and Crossness Sewage Treatment Works are two of

Europes largest waste treatment plants. Located just a few ki-

lometers apart, on either side of the River Thames in London,

U.K., the neighboring plants have undergone major upgrades

continuedonpage16

With 340 MWe output, the Dedisa Peaking Power

Plant will sell the generated power to South Africas

state-owned utility Eskom Holdings.

Editors Note: Each year, Diesel & Gas Turbine

Worldwide invites prime-mover original equip-

ment manufacturers to submit one specific

power generation project it feels merits special

attention due to advances in one or more of the

following: efficiency increase, environmental

aesthetics, operation characteristics, emissions

improvements and construction principles. The

coverage is limited to plants commissioned

during the 2015 calendar year.

This longstanding tradition has become apopular feature. This years edition once again

highlights several noteworthy projects. Enjoy.


17/44

KOHLER large gas generators are custom-made to meet

your needs. Unlike one size fits all generators, we offer gas

generators designed and rated specifically for continuous,

prime or standby applications giving you the cost-efficient,

targeted solution for non-pipeline and natural gas. Explore a

range of options from 25 to 1300 kW at KohlerPower.com.

Power Systems

LARGE GAS GENERATORS400 TO 1300 kW | PURPOSE-BUILT FOR EVERY APPLICATION | EPA-CERTIFIED


18/44


as part of Thames Waters development strategy to maintain

and improve services.Thames Water appointed Tamesis (a joint venture of Imtech

Process and Laing ORourke) with a 300 million contract to co-

ordinate projects at both sites.

Thames Waters aim was to expand the sewage treatment

works in anticipation of increased population and to treat the

waste to a higher standard, while also preventing sewage over-

flow into the River Thames.

Beckton Sewage Treatment Works serves 3.5 million people.

The improvements will enable the site to treat 60% more flow

than it does now and allows for a 10% population increase until

2021. The increase will enable it to fully treat increased flows

during heavy rainfall, and treat additional storm flows from theLee Tunnel.

Currently serving 2 million Londoners, the improvements

made at Crossness Sewage Treatment Works will enable the

site to treat 44% more sewage than it does now, significantly

reducing the amount of storm sewage that overflows into the

River Thames during heavy rainfall when the site becomes

overloaded.

The project includes the installation of improved anaerobic

digestion of sewage sludge on site that will include a thermal

hydrolysis plant (THP).

The THP, an industrial-scale pressure cooker, heats sewage

sludge to around 160C to improve the organic material break-down. After the THP, the sludge is digested where it can produce

up to 50% more biogas, which is used to generate renewable

power in the combined heat and power (CHP) generators sup-

plied by Edina Group, U.K.s power generation specialist.

With an output of 2 MWe, the MWM TCG 2020 V20 gen-set by

Caterpillar Energy Solutions was chosen for its high electrical ef-

ficiency, which, when combined with an inclusive maintenance

contract provides the client with a low life-cycle operating cost.

The scope of supply included the installation of three MWM en-

gines at both sites, totaling 12 MWe of power generation. The

plant was delivered and commissioned in January 2015.

The MWM CHP units, fed with the biogas produced at the THP,

were each containerized at Edinas manufacturing facility based

in Lisburn, Northern Ireland. A specific requirement of the sites

due to electrical fault levels was to have high impedance HV

alternators. The packaged plant gen-sets were accompanied

with standardized peripheral equipment and a containerizedset with the lowest whole life cost of ownership, Caterpillar

Power Solutions said.

Dresser-RandPil Andina S.A. Dairy Farm

Santa Cruz, Bolivia

The Dresser-Rand business, part of Siemens Power and Gas

Division, delivered some waste-to-power solutions to Bolivian

dairy farms.

The company explained that dairy production in the tropics

is difficult, as most productive dairy breeds do not tolerate theheat. Those breeds that are well adapted to the tropics do not

produce much milk. However, the climate in the Santa Cruz

region, where Bolivian dairy farms are highly concentrated, is

suited to the highest producing dairy breeds.

Pil Andina S.A. is a leader in the Bolivian dairy food market,

with three production facilities for various dairy products. As

with all dairies, Pil Andina uses a lot of electricity in the pro-

duction process for its milking machinery, refrigeration, storage

and intensive milk processing procedures.

Dresser-Rand said that energy efficiency, reduced energy

costs and minimal greenhouse emissions are important to the

Bolivian dairy industry and dairy firms have begun to embracerenewable energy technologies.

Pil Andina turned to the Dresser-Rand business through its lo-

cal distributor, Gas & Electricidad, to deliver the essential power

equipment needed to cover the entire power needs of its Santa

Containerized MWM TCG 2020 V20 gen-set by

Caterpillar Energy Solutions is delivered to the

Beckton and Crossness Sewage Treatment Works,

in London, U.K.

The 6.3 MW power plant of the dairy farm

by Pil Andina in Santa Cruz, Bolivia, is based

on Guascor gen-sets burning biogas.


19/44


POWER PLANTSof the world

Cruz dairy. The project, spearheaded by the local gas and elec-

tric company, consisted of two stages.

First, the company installed five Guascor SFGM560 gen-

sets, with a total output of 5 MW. In stage two, three Guascor

FGLD180 gen-sets and a Guascor SFGL240 gen-set were in-

stalled, bringing the total output to 6.3 MW. This output meetsall of the power requirements of the Santa Cruz dairy plant.

The gen-sets can work in continuous duty of approximately

8000 hours per year, with scheduled interventions to replace

some parts and change the oil, Dresser-Rand said. The com-

pany said that it has optimized these operations during down-

time, making it easy to maintain the equipment.

By producing energy and heat using its own raw material (cow

manure) and not having to purchase electricity for the manufac-

turing process, Pil Andina was able to lower its operating costs.

When manure decomposes without oxygen in anaerobic con-

ditions, such as in many farms, methane and nitrous oxide (bio-

gas) is produced and released into the atmosphere. However,when this biogas is burned, it reacts to the oxygen, uses up the

gases and prevents them from rising into the atmosphere.

GEs Distributed Power BusinessHamburg Metropolitan Region CHP Plant

Stapelfeld, Germany

In November, Hamburgs Senator for Environment and Ener-

gy, Jens Kerstan, inaugurated a nearly 10 MW combined heat

and power plant in the northern Germany town of Stapelfeld,

making it the largest such project in the multistate Hamburg

metropolitan region, according to GE. Owned by HanseWerkNatur GmbH, the facility is producing power for 21 500 house-

holds and heat for 6000 average single-family homes.

The new gas-fueled CHP plant is helping HanseWerk Natur sup-

port the environmental priorities of the countrys Energiewende

energy transition program and to stabilize the regional

grid. HanseWerk Natur GmbH, a wholly owned subsidiary

of HanseWerk AG, invested 6.8 million in the facility, which is

powered by one of GEs Jenbacher J920 FleXtra gas engines.

The facility can generate over 76 million kWh of electricity as

well as up to 80 million kWh of heat annually. The centerpieceof the plant is the J920 FleXtra gas engine. Using a design in

which the waste heat of the engine is fed back into the heat

circulation for efficient use, the plants overall efficiency can be

increased to over 95%, the company said. This allows CO2emis-

sions to be cut by approximately 60% compared to generating

power and heat separately. This amounts to an annual reduc-

tion of more than 9979 tonnes of CO2.

MAN Diesel & TurboMoa Power Plant

Moa, Cuba

The 184 MW power plant in Moa, Cuba, was inaugurated in

the spring. This is one of the largest projects designed and

commissioned by MAN Diesel & Turbo in the Caribbean region,

the company said.

Located at about 600 m from the sea coast near Moa city,

about 900 km southeast of Havana, the plant will supply ap-

proximately 270 000 Cuban households with electricity. Moa is

an industrial city with many open nickel mines.

Energoimport, the Cuban agency responsible for the procure-

ment and importation of all electricity-related components

and services, owns the power plant.

MAN Diesel & Turbo supplied basic and detail engineering,

procurement of all equipment, and supervision of instal-

lation and commissioning for the construction of the new

Powered by GEs Jenbacher J920 FleXtra gas en-

gine, the 10 MW combined heat and power plant in

Stapelfeld is the largest such project in Germanys

multistate Hamburg metropolitan region.

The Moa power plant in Cuba uses 10 gen-sets

powered by MAN 18V 48/60B engines rated at

18.4 MW each, which run parallel to the grid in

base-load mode.

continuedonpage18


20/44


generating station. It uses 10 gen-sets powered by MAN 18V

48/60B engines rated at 18.4 MW each and will run parallel

to the grid in base-load mode under normal operation. MAN

Diesel & Turbo also supplied the fire detection and firefighting

as well as the air conditioning system, electrical equipment

and control system.The Moa plant runs on heavy fuel oils (HFO) supplied through

barges to two bulk tanks located at the citys port, which is 12 km

from the power plant. HFO is then transferred through a pipeline

to the power plant tank farm. In this plant, two cooling towers

per engine and heat exchangers are used for engine cooling.

Rolls-Royce Power Systems Bergen EnginesCombined Heat And Power Plant

Tabor/Sezimovo st, Czech Republic

In the Czech Republic, a combined heat and power (CHP)

plant designed to provide grid support officially went into op-eration at the beginning of January.

Based on four 20-cylinder Rolls-Royce engines, the plant

generates a total of 37 MW of heat and power for the town

of Tabor/Sezimovo st, roughly 100 km southeast of Prague,

the capital. The medium-speed type B35:40 gas engines were

supplied by Bergen Engines, which is part of Rolls-Royce

Power Systems (RRPS).RRPS said that this is the first natural gas power plant based

on medium-speed gas engines in the region to go into opera-

tion supplying heat and power to the local grid. Until now, coal-

fired plants predominantly generated electricity and heat in

the region. The new plant was designed and built by the Czech

prime contractor PSG International.

The CHP plants medium-speed engines are flexibly designed for

different operating modes. They can be used to generate base-

load or peak power or can operate in combined cycle. The heat

from the engines can be used to generate steam in the heat re-

covery steam generators. The steam is supplied to industrial cus-

tomers for their technological needs. The power plant can also be

used for district heating by utilizing hot water from the engines.

RRPS said that its medium-speed engines enable C-Energy to

operate the plant efficiently, both in terms of cost and time. The

engines quick-start capability means the engines can ramp up to

a rated speed of 750 r/min within five minutes, giving the plantaccess to the amount of power and heat needed within a short

time. The plant has also been certified to provide grid-balancing

services, due to the stable operation of the engines and their abil-

ity to quickly respond to changes in grid parameters.

Additionally C-Energy and Bergen Engines signed a two-year

service agreement that covers scheduled maintenance, spare

parts and technical support. The four gas engines were hand-

ed over to PSG in November 2014, and a series of certification

procedures was completed before the plant officially went into

operation at the beginning of January.

Rolls-Royce Power Systems MTU Onsite EnergyEmergency Gen-Set For Water Supplierberlingen (Lake Constance), Germany

In June, the Lake Constance Water Supply Authority started up

the new emergency standby gen-set from MTU Onsite Energy,

which extends the capacity of the existing emergency power

supply system and ensures that the supply of drinking water to

4 million people in Baden-Wrttemberg is safeguarded, even in

the event of a power outage.

With around 1700 km of pipeline and a water delivery of

125 million m3 to consumers each year, the Lake Constance

Water Supply Authority is the largest in Germany.

With a mechanical output of 6500 kW, the new generator is

the most powerful MTU emergency backup gen-set Rolls-

The engine room of the 37-MW CHP plant in

Tabor/Sezimovo st, Czech Republic.

With a 6500 kW mechanical output, the newTB34 gen-set by MTU Onsite Energy is the most

powerful MTU emergency backup gen-set

ever built. It went into operation at the Lake

Constance Water Supply Authority.


21/44



Royce has ever built, the company said. The MTU and MTU On-

site Energy brands are part of RRPS.

The new TB34 emergency backup gen-set purchased by the

Lake Constance Water Supply Authority is based on a high-

speed, 20-cylinder Series 956 diesel engine from MTU. The pow-

er output of this new TB34 type gen-set, which has gone intoservice with the Lake Constance Water Supply Authority for the

first time, is almost 5% higher than that of the preceding TB33

generation, RRPS said. The engine has a mechanical output of

6500 kW at 1500 r/min (50 Hz), which is converted by the gen-

erator into a rated output of 7800 kVA.

MTU is scheduled to deliver the next 10 gen-sets of this type

in 2016 and 2017 to Ostrovets 1 and 2 the Belarusian nuclear

power plant for the emergency power supply system there.

Besides the engine and the generator, MTU has also supplied

numerous components for the emergency power supply sys-

tem, which fills three stories of a new building at the Lake Con-

stance Water Supply Authority and includes the ventilation andflue gas system, air intake system, fuel supply, engine cooling

system, compressed air chamber and switchgear. The charge

air and engine of the new gen-set are cooled using water taken

from Lake Constance. The water is pumped from a depth of 60 m

and has a maximum temperature of 8C, which is ideal for

cooling purposes.

To provide a reliable supply of drinking water to the 320 towns

and villages throughout Baden-Wrttemberg in the event of a

power outage, the Lake Constance Water Supply Authority has

operated an emergency power supply system consisting of

two MTU gen-sets since 1986. The new gen-set will increase the

power output from 8.8 to 15.3 MW. When all of the three gen-sets are in operation, it will be possible to increase the delivery

volume of untreated water to 3000 L/sec.

Siemens Power and GasPanda Temple 2 CCPP At The Synergy Industrial Park

Temple, Texas, USA

For the Panda Temple 2 Power Project in Texas, Siemens sup-

plied the power island equipment, including two SGT6-5000F

gas turbines, one SST6-5000 steam turbine, two SGen6-1000A

generators, one SGen6-2000H generator, the SPPA-T3000 in-

strumentation and control system as well as two Benson heavyduct-fired heat recovery steam generators manufactured by

NEM. A long-term service agreement has also been signed for

the main generation components.

This is the third order designated to Siemens by Panda Power

Funds, following the Temple 1 and Sherman Power Projects.

Bechtel, a partner of Siemens, was responsible for the engi-

neering and procurement for the balance of the plant, and

the installation, construction and commissioning of the fa-

cility. Commissioning of the power plant was three months

ahead of schedule.

Located adjacent to Panda Temple 1 at the Synergy Industrial

Park, the natural-gas-fired power plant will have a gross in-

stalled electrical capacity of 758 MW. Together with the Panda

Temple 1 and Sherman combined-cycle power plants in Texas

all three plants can continuously supply the power needs of up

to 2.25 million homes in one of the fastest growing regions of

the United States.The multishaft Temple 2 combined-cycle plant is equipped

with Siemens Flex-Plant 30 technology that can begin power

generation within 10 minutes of startup, and full base-load

power production in less than one hour, the company said.

The adjacent Panda Temple Power 1 plant was the first natu-

ral gas-fired, multishaft Flex-Plant in commercial operation in

Texas. Together, the two power stations deliver 1516 MW power

and share common facilities, laterals and operations. The two

facilities are supplied with natural gas from Texas suppliers.

The Temple site is strategically located to meet electricity de-

mand in the Texas Triangle, a 155 399 km2area bordered by

Dallas, Austin, San Antonio and Houston four of the fastest-

growing metropolitan areas in the US and home to 75% of

the states population.

Ural Turbine WorksCombined Heat And Power Plant CHPP-4

Ulaanbaatar, Mongolia

Ural Turbine Works, part of ROTEC Holding, put a new 123 MW

combined heat and power plant, CCHP-4, into operation in

March at Ulaanbaatar, Mongolia.

Ural Turbine Works said this was the largest project in the

post-Soviet period implemented by Russian contractors for the

power industry of Mongolia.

Ural Turbine Works acted as a supplier and general contrac-

tor for construction of the new power unit. Several Russian and

Mongolian companies took part in the construction.

The new power unit in Ulaanbaatar was equipped with a

continuedonpage20

The 758-MW Panda Temple 2 combined-cycle

power plant in Texas, USA, features two SiemensSGT6-5000F gas turbines and one Siemens

SST6-5000 steam turbine.


22/44



steam turbine -120/130-130-8, the newest developmentof Ural Turbine Works, designed on the platform of model

-100. This turbine embodies the whole range of advanced

design and technological solutions available, said Ural Turbine

Works. Following the results of computer modeling of the wet

steam flow, the decision was made to modify the guiding ribs

system in the exhaust casing. Modification of the guiding ribs

allowed reducing losses for working medium exhaust velocity

and obtaining the growth of the exhaust casing operating ef-

ficiency in a wide range of operating modes.

In addition, the -120/130-130-8 steam turbine is equipped

with a control and protection system that uses microprocessor-

based control technology. The company said the service life ofthe turbine is designed to be 40 years.

Ulaanbaatar CHPP-4 is the largest energy generating plant

in Mongolia, Ural Turbine Works said. After commissioning of

the new turbine unit, the installed electric power of the plant

(with steam extraction for central heating) has been increased

by 20%, from 570 to 703 MW (the maximum capacity from 660

to 790 MW). Installed heat energy generation for consumers of

Ulaanbaatar has also been significantly increased.

Ural Turbine Works said the new plant increases Mongolias

total power system capacity by 13.2%, enough to meet grow-

ing power demands until 2018, according to an assessment by

Dashzeveg Zorigt, Ministry of Energy of Mongolia.

WrtsilIPP3 Power Plant

Jordan

IPP3 in Jordan is the largest internal combustion engine pow-

er plant in the world, said Wrtsil, with a capacity of 573 MW

(632 MW in ISO conditions).

The Smart Power Generation plant supplied by Wrtsil was

inaugurated in April. The plant, recognized by Guinness World

Records for its size, comprises 38 fast-starting Wrtsil 50DF

multifuel engines. It is mainly used for peaking operation. In

Jordan, the daily electricity demand peaks of up to 2 GW are a

challenge to the stability of the power system.

Wrtsil reported that, according to the data by the Jordanian

grid operator NEPCO, the impact of IPP3 and its sister plant

IPP4 a 250 MW engine plant also supplied by Wrtsil is remarkable. Since starting operation, the plants have cap-

tured the daily demand peaks. While doing so, they have re-

leased the large gas turbine power plants in the grid from this

load-following task. As a result, the gas turbines now produce

steady base-load, instead of ramping output up and down,

and operate much more efficiently.

This system-optimizing effect is possible due to the inherent

operational flexibility of the internal combustion engines. The

engines can be operated independently, and they are capable

of following the load very precisely by starting to full load very

fast, and ramping power up and down continuously without

impact on maintenance.According to Amman Asia Electric Power Co. (AAEPC), the

owner of IPP3, the plant can start from zero to full 573 MW

power in seven minutes. Typically, for peaking operation, the

engines stop in the night and start in the morning.

As fuel supply is unstable in Jordan, fuel flexibility was crucial

in planning the IPP3 project. As a result, IPP3 can run on three

different fuels: heavy fuel oil, light fuel oil and natural gas. Fuels

can be changed on the fly without downtime.

By design, output is the same regardless of the fuel. AAEPC

plans to switch from liquid fuels to natural gas in 2016 when

liquefied natural gas (LNG) becomes available. This will reduce

various emissions significantly. The environmental benefits ofIPP3 include close-to-zero water consumption, which is highly

appreciated in the extremely dry region.

Wrtsil supplied the plant in full turnkey delivery, on fast-

track basis. The first 16 engines were installed in just 16

months and the whole 38-engine plant was up and running

in 24 months.

The latest development of Ural Turbine Works, the

-120/130-130-8 steam turbine, was installed

in the Ulaanbaatar, Mongolia, combined heat and

power plant CHPP-4.

The IPP3 combustion engine power

plant in Jordan has a capacity of 573

MW with 38 fast-starting Wrtsil

50DF multifuel engines.


23/44


24/44

POWERgeneration

First Enhanced Steam Path (ESP)Upgrade For D-11 Steam Turbine

Upgrade enabled a 26 MW output improvement


n December, GE completed its first enhanced steam path

(ESP) upgrade on a D-11 steam turbine at the Rhode Island

State Energy Center (RISE) in Johnson, Rhode Island, USA.

The move increased the turbines efficiency by 1% (project-

ed) and created the potential to improve the sites average

electrical revenue by more than US$4 million a year over the

next five years. The station was acquired by The Carlyle Groupfrom Entergy Corp. in 2015.

The upgrade at the natural gas-powered, combined-cycle

plant enabled a 26 MW output improvement, increasing the

plants capacity to 609 MW, up from the sites original 583 MW.

An ongoing vibration issue with a steam turbine led RISE to

consult with GE for a solution. Initially, RISE noted the issue,

which limited the turbines load under certain conditions,

through GE Mark V control screens. The planning process be-

gan nearly two years prior to a major inspection in 2015.

With a turbine rotor replacement being one of the options,

GEs design engineers developed an ESP solution with en-

hanced performance to help offset the cost to the operator. Forthe project, GE performed a complete steam path replacement

of the HP/IP section of the turbine.

According to GE, RISE reduced risk and improved reliability by

choosing the new ESP turbine rotor. Having a new major com-

ponent also will improve efficiency, capacity and revenue due

to the parts output capability, the company said.

The performance improvements also support regional grid op-

erator ISO New Englands short-term need for additional power

at a pivotal time, with several plant retirements forthcoming.

The equipment for the rotor replacement was manufactured

at GEs facility in Bangor, Maine, USA. RISEs D-11 unit with the

ESP upgrade is part of the global fleet of D-11 steam turbinesmonitored by GEs remote Monitoring & Diagnostics (M&D)

Center in Atlanta, Georgia, USA.

In March, GE is scheduled to perform a similar ESP upgrade on

the D-11 steam turbine at a cogeneration facility in Tupman,

California, USA, operated by Elk Hills Power LLC.

According to GE, the payback period for both sites is estimat-

ed between two to three years.

These two projects are great examples of how GEs advanced

upgrades for steam turbines are cost-effective and increase

efficiency, said Paul McElhinney, president and CEO of GEs

Power Services business. GE has a fleet of approximately 200

D-11 steam turbines throughout the world, and our current ESP

offering can be applied to 60 Hz units to help our customers

improve long-term reliability, availability and performance in

the competitive markets that exist globally.A

I

GE completed its first enhanced steam path (ESP)

upgrade on a D-11 steam turbine at the Rhode

Island State Energy Center in Johnson, Rhode

Island, USA.


25/44

CONGRESSHELSINKI | JUNE 610, 2016

TECHNICAL PROGRAMME

Over 200 lectures and papers

EXHIBITION

Presentation of new technologies

and products

NETWORKING

More than 1,000 international experts

TECHNICAL TOURS

Visits to local industry

SOCIAL EVENTS

Official Reception and Gala Dinner

Meeting the future of combustion engines28th CIMAC WORLD CONGRESS

Combustion Engine Technology forShip Propulsion | Power Generation | Rail Traction

HIGHLIGHTS

Learn more about the 28th CIMAC World Congress!

www.cimaccongress.com

REGISTER

NOW!


26/44

FEATURED PRODUCTS

a common male O-ring SAE-8 port

threads, the company said.

www.alliancesensors.com

Flowmeters by KRAL are used for

lubricating liquids, especially in the

field of precision metering for in-

dustrial applications. The company

explained that in these products,sensors limit the maximum operat-

ing temperature while the flow vol-

ume and direction are registered by

means of spindle rotation.

Within its Volumeter range of flow-

meters, the company has launched

the OMP series with high temperature

sensors for up to 200C, as an eco-

nomically attractive solution together

with the standard flowmeter model

for temperatures of up to 125C.

For applications requiring up to250C, the company offers its OMG

series. KRAL Volumeter delivers preci-

sion of 0.1% of the measuring value.

www.kral.at

ESCO Tool has introduced a battery-

powered tube-beveling tool. The

FLOWMETERS

TUBEBEVELER

ESCO Mongoose Millhog Battery

Powered Beveling Tool is a self-

centering I.D. clamping right angle

drive tool that can bevel, face and

bore simultaneously. It can also be

supplied with a cutter head for mem-

brane and overlay removal. It is of-fered with a 6.2 Ah, 18 V recharge-

able battery, allowing up to one hour

of operation.

Providing chatter-free operation with-

out cutting oils, this portable tool uses

TiN coated cutter blades with a radical

chip breaker to direct heat away from

the tube surface.

www.escotool.com

Watlow, which designs and manu-

factures complete thermal systems,

has introduced its new ECO-HEATexhaust gas heating system that

functions as an internal load bank in

medium stationary and mobile diesel

generator applications. Incorporating

ECO-HEAT into a diesel generators af-

tertreatment system helps eliminate

problems encountered under low

generator load conditions.

ECO-HEAT is designed to be installed

in the exhaust pipe and provides heat

directly where it is needed within the

aftertreatment system. Using elec-tricity from the generator, it has the

dual effect of increasing exhaust gas

temperatures by both increasing load

on the diesel engine and heating the

exhaust directly. If generator load de-

mand increases, the ECO-HEAT sys-

tem gradually reduces its load and

thermal output, and shuts off as soon

as exhaust gas temperatures reach ac-

ceptable levels.

www.watlow.com

EXHAUSTGASHEATINGSYST

EM


FEATURED PRODUCTSFEATURED PRODUCTS

GE is set to enter the cloud ser vices

market with Predix Cloud, a plat-

form designed for industrial data

and analytics. This platform-as-a-

service will capture and analyze the

volume, velocity and variety of ma-

chine data within a cloud environ-ment, the company said.

Predix Cloud will deliver tools like

asset connectivity, machine data

support and industrial-grade secu-

rity and compliance, GE said.

The cloud platform is purpose-built

from the ground up, but it will also

run on other cloud fabrics if required

by a customer. Predix Cloud uses Piv-

otals Cloud Foundry to help with ap-

plication development, deployment

and operations.www.gesoftware.com/predix

Alliance Sensors Group has introduc-tion the SS-7 series LVIT (linear vari-

able inductive transducer) designed

for subsea environments and the

demands of oil and gas exploration.

The SS-7 series can be submerged to

a depth of 3000 m or installed in a

pressure-balanced, oil-filled chamber

to provide position feedback on blow-

out preventers, ROVs and relief valves.

SS-7 sensors are based on contact-

less LVIT inductive sensing technol-

ogy that employs a solid probe con-struction style, which requires only a

simple conductive tubular target or

a small-diameter, gun-drilled hole in

the cylinder rod for operation rather

than needing a permanent magnet ring

or some other type of special target.

The SS-7 series can withstand intense

shock and vibration, and operating

temperatures up to 105C with the

extended-range option. The 25.4 mm

diameter sensor head mounts with

CLO

UDPLATFORM

INDUCTIVELINEARSENSORS


27/44

RAILtechnology

Train To Climate ChangeKnorr-Bremse presented climate-friendly technology for railway applications


norr-Bremse, a German manufacturer of braking

systems for rail and commercial vehicles, show-

cased several products for climate-compatible rail

technology at the United Nations Climate Change

Conference in Paris.

The products include the driver-assistance system iCOM

Assist that helps drivers operate trains efficiently. The driver-

assistance system computes an energy-optimized run andmakes appropriate recommendations to the driver based on its

knowledge of the track topography, the composition of the train

and its scheduling, Knorr-Bremse said. This enables the absolute

energy consumption to be reduced substantially.

The companys energy-saving portfolio also includes mod-

ern heating, ventilation and air conditioning (HVAC) systems

from Merak and Sigma, subsidiaries of Knorr-Bremse. Thanks

to control engineering, these systems constantly adapt the

intake of fresh air to the actual number of passengers. Knorr-

Bremse explained that if there are not many passengers on

board, the system cuts its fresh-air intake, thereby reducing

the volume of air to be heated or cooled. As a result, the en-ergy consumption of the HVAC system is reduced without any

loss of comfort for the passengers.

Ideal energy distribution within the train is handled by auxil-

iary power converters from Knorr-Bremse, which, owing to the

use of innovative materials, are highly efficient, light and com-

pact, the company said.

Finally, the energy-metering system iCOM Meter registers and

records the actual energy consumption of the train in real time.

On the one hand, this enables the railway operators to precisely

check their electricity bills. And on the other hand, operators can

use this data to identify further potential for saving energy.A

K

Among the HVAC systems for rail applications

by Knorr-Bremse are models that can constantly

adapt the intake of fresh air to the actual

number of passengers onboard.


28/44

The ForgottenEssentials

Renk-Maags turbo gearboxes, clutches,couplings, play key role in high-torque,

high-speed applications

by RobertaPrandi


ore often than admitted, the primary prod-

ucts of Renk-Maag turbo gearboxes,

clutches and couplings are the ones that

are easily forgotten.Thats not a surprise to Michael Hartung,

the companys head of sales, marketing and commercial

project management. These products rarely see the spot-

light, but they are essential to keeping their respective

machines running.

The robustness and longevity of our products is very well

known among our customers, who see the reliability of our

units as a key asset, Hartung said. It is crucial, though, to

maintain the units correctly and to follow some basic rec-

ommendations. To this extent, Renk-Maag offers a capillary

maintenance and support service worldwide.

Based in Winterthur, Switzerland, Renk-Maags portfolioincludes a number of turbo gearbox families, such as the

parallel shaft gearbox variants, all of which fall under the

G-type name G, GD, GX, GS/GN and GB. The parallel shaft

gearbox is designed for applications in generator, compressor

and pump drive markets, with a power range up to 180 MW

and speeds up to 63 000 r/min, Hartung said.

Among the range of parallel shaft gearboxes, the G fami-

lies stand for single-helical toothing (G), double-helical

toothing (GD), single-helical gear with thrust collar (GX) and

for integrally geared compressors (multicom type GMX).

According to Renk-Maag, these gearboxes feature an

optimized distance between shafts and optimized toothwidth with adjustable bearing for an ideal tooth-contact

pattern. The gear teeth are subjected to longitudinal and

profile grinding, following Renk-Maag grinding proce-

dures to ensure the compensation of deformation. The

company said this allows the tooth-contact pattern to be

optimized under load.

Renk-Maag has also established itself as a designer and

manufacturer of vacuum gearboxes in the 15 to 120 MW

range since 1996, starting with the Maag brand.

The high-efficiency turbogear (HET) is the worlds most ef-

ficient gear in its class, the company said.

M

Within the range of parallel shaft turbo gearboxes,

the G family types are designed for generator,

compressor and pump drive applications.


29/44


GEARBOXES& drivelines

On a large, high-speed gearbox, the

efficiency can be pushed up to 99.4%,

Hartung said. Without the vacuum

technology, the same Renk-Maag gear

operates at 98.8% while most com-

petitors turbogear efficiency is signifi-

cantly lower.

Renk-Maag gearboxes can be supplied

with proprietary integrated synchro-nous clutches (freewheeling clutches),

which consist of a full line of products

available for power generation and ma-

rine applications, as well as for energy

recovery projects.

The range of the Renk-Maag synchro-

nous clutch coupling is composed of

the following models: the MS, HS and

the shift-capable ZD, all with integrated

gear coupling.

The MS type allows for automatic

clutch engagement at any synchronousspeed and disengages automatically if

the speed of the driven machine over-

runs that of the driver or the torque be-

comes negative.

The HS clutch type has a similar syn-

chronizing mechanism as the MS type,

but with a hydraulic system for engage-

ment. Instead of main helical toothing,

the HS has spur gear toothing, with the

synchronizing mechanism looking for a

clean tooth-to-gap position.

At that point, the clutch starts a screw-

like motion and a small front-face tooth-

ing engages. The hydraulic system then

kicks in and completes the engagement

with two hydraulic cylinders pushing in

a pure axial shifting.

Once the clutch is engaged, the hydrau-

lic system is unloaded and the clutch

works as a gear coupling able to transmitfull positive and negative torque without

disengaging. Disengagement is also car-

ried out by the hydraulic system and can

be done at partial loads up to 10%.

The ZD clutch type has a similar hydrau-

lic mechanism to the HS, but can only be

engaged at a standstill or disengaged at

low load. The complete disengagement

results in zero drag for the disconnected

running machines, the company said.

Bearing technology also plays an im-

portant role in the quality and durabilityof components, Hartung said.

Renk-Maag turbo gearboxes usu-

ally utilize hydrodynamic slide bearings,

as those are the only type of bearing

that can withstand the high loads and

speeds our components are employed

with, he said.

In turbo gearboxes, a driving ma-

chines torque output is transmitted

by the gearbox to the driven machine.

This primarily generates tangential and

axial forces in the gear teeth, which are

known as tooth forces.

When a turbo generator train ramps

up, the gearbox bearings are constantly

exposed to loads that vary according

to the torque. The radial bearing at the

gear pinion is dimensioned according

to the maximum tooth forces prevailing

at full load. These tooth forces are up to50 times greater than the weight of the

pinion, depending on the actual torque.

Materials and metallurgy also are im-

portant to ensure component quality.

In most high-performance gearboxes,

gear teeth are hardened and ground,

Hartung said. This process gives the

teeth the necessary surface hardness,

core hardness and precision in the

contact pitch.

Hartung added that case hardening

has two major advantages over nitro-gen hardening, which produces simi-

lar surface hardness. One advantage

is case hardening can produce a layer

thicknesses of more than a millimeter,

while nitrogen hardening produces

less than 0.6 mm. Additionally, the use

of case hardening generates residual

compressive stresses in the tooth root,

which go towards compensating the

load in the root caused by tooth force

or tensile stresses.A

Double-helical toothing is a

characteristic of the GD type of

parallel-shaft gearboxes.


30/44

NEWS MAKERS


operating waste heat to power and

combined heat and power plants at

their manufacturing locations.

Klefeker most recently served as

president and CEO of Denver, Colo-

rado, USA-based Southwest Gen-

eration, which operates natural gas-fired generating facilities in California,

New Mexico and Colorado, USA. Kle-

feker has worked in the independent

power and utility industry his entire

career, including 14 years with the

utility that serves Northwest Indiana,

where Primary Energy Recyclings

projects are located.

Scottish-headquartered gas turbine

service company Score Energy Ltd.,

has appointed two new sales manag-

ers in Kuala Lumpur. Ammai Nathan

and Mohd Firdaus Omarwill take on

the roles of regional sales manager

APAC based out of the companys

Kuala Lumpur office. The pair will be

responsible for the sales, services

and support of its customers acrossAsia Pacific.

M. F. Omar

Nathan started his career working in

the Royal Malaysian air force as an air-

frame/plant power technician before

carrying out courses at the Royal Aus-

tralian AirForce in Air-Craft Structure.He has also worked for firms such as

Malaysian Airlines/Pelangi Airways,

Sapura WoodGroup Synergy and

Kawasaki Gas Turbines.

Omar has worked with several en-

ergy companies in his career, includ-

ing Advanced Power Solutions, Sime

Darby Industrial and Kawasaki Gas

Turbine Asia, starting his career as a

consultant electrical engineer and

taking on various roles, from project

A. Nathan

J. Herzog

IMI Critical Engineering, a global

specialist in critical flow products, hasappointed Jrgen Herzogas manag-

ing director of its IMI Bopp & Reuther

business, which handles safety, con-

trol and shutoff valve technology.

Herzog, a nearly 30-year industry vet-

eran, is tasked with further establish-

ing the companys position in the pro-

cess sector as well as in conventional

and nuclear power plants worldwide.

Herzog began his career as a design

engineer with Bopp & Reuther in 1987.

He then progressed to head of salesfor control valves in 2001. Since 2007,

he has been head of the power plant

business unit.

IMI acquired Bopp & Reuther at the

start of 2015 as part of the develop-

ment of its valve offering.

Wrtsil has appointed Javier

Cavada Caminoas president of Ener-

gy Solutions, executive vice president

and member of the board of manage-

ment of Wrtsil Corp. In this position,he is responsible for Wrtsils Energy

Solutions business globally, and will

report to President and CEO Jaak-

ko Eskola. Camino joined Wrtsil in

2002 and has since held several key

management positions in production,

research and development, quality, op-

erational development and business

operations. Until now, Camino has

the dual role of leading the services

business in South Europe and Africa,

as well as propulsion services globally.The current head of Energy Solutions,

Rakesh Sarin, retires, having reached

his statutory retirement age earlier

this year, the company said.

Fortistar has appointed Mo Klefeker

as chief executive officer of its portfolio

company, Primary Energy Recycling.

Primary Energy Recycling helps in-

dustrial companies create value from

waste energy by building, owning and

IMICri

tical

Eng

ineering

W

rtsi

l

Fort

istar

engineer to assistant sales manager.

Firdaus will deliver gas turbine solu-

tions to the Asia Pacific region along-

side Ammai.

Score Energy Ltd. is an aeroderiva-

tive and light industrial gas turbine

support company. The firm specializ-es in the inspection, overhaul, repair,

upgrade, modification, testing, supply

and leasing of gas turbines, fuel sys-

tems, accessories and auxiliaries.

Edward P. Kelleherhas been named

Global Business Development Manag-er Diesel at Windrock Inc. Kelleher

will be leading the effort in developing

a global distribution network, growing

the Windrock business in the marine

industry and other diesel-related appli-

cations as well as continuing the

growth of the Windrock customer base

in nuclear, military, mining and power

generation. Kelleher has 29 years of ex-

perience in field engineering in naval,

nuclear and power generation indus-

tries, with 20 years of condition moni-toring experience related to recipro-

cating engines and compressors in

various industries as well as more than

10 years in international sales and busi-

ness development.

Chromalloy has named Brian Sar-

tainas its vice president, Commercial

Aero & Military Strategic Business Unit

(SBU). Sartain, an aerospace executive

for more than 25 years, has held ex-

ecutive assignments in all aspects ofglobal business.

He previously worked at United Tech-

nologies Aerospace Systems (UTAS)

and Goodrich Aerospace, which were

acquired by United Technologies

Corp., where he worked for more than

20 years.

His most recent assignment was as

vice president, Business Develop-

ment Sensors & Integrated Systems,

where he led strategic planning,

Windroc

k

E. Kelleher

Ch

roma

lloy

Score

En

ergy


31/44


in the U.K., with plans to recruit up to 20

people over the next 12 months.

The U.K.-based team will be an exten-

sion of the BETA organization, which

operates under Wood Group Kenny and

is focused on the U.S., Canada, China

and Southeast Asia. Wood Group aimsto grow its vibration, dynamics and

noise specialist service line in other key

global locations.

vibration team, Jonathon Bakerjoins as

sales and business development man-

ager and Rob Swindell takes on the role

of R&D and technical authority.

These appointments bolster Wood

Groups integrity management capa-

bility by adding subsea vibration andfatigue experience to its onshore exper-

tise. This is the first step towards build-

ing a comprehensive vibration service

mergers and acquisitions, and prod-

uct line management.

Aeroderivative Gas Turbine Support

Inc. (AGTSI) has hired Miguel Mike

Trejoin a sales and customer support

role. Trejo is based in Arizona and willassist with AGTSIs customers located

west of the corporate headquarters

in Florida.

Trejo previously worked 20 years

with a fuel nozzle manufacturer and

repair facility.

Rick Butler, AGTSIs quality director,

announced his retirement. He spent

nearly 10 years with the company.

Cogen Europe appointed Roberto

Francia as managing director. Fran-cia takes over from Fiona Riddoch,

who led Cogen Europe from 2006 to

2015. Francia has been active in advo-

cacy with European Union institutions

since 2004, working across energy

and climate topics and particularly on

electricity policy.

Himoinsa named Daniel Crossan

project manager for Himoinsa Middle

East. His focus will be working on spe-

cial projects being undertaken in theMiddle East and east Africa. In recent

years, the large projects undertaken

by Himoinsa Middle East have been

carried out mainly in Saudi Arabia

and the United Arab Emirates. Oman

is another emerging region and Qatar

is planning for the construction of sig-

nificant infrastructures in time for the

World Cup in 2022

Wood Group has appointed three se-

nior engineering specialists who willlead a new team of up to 20 in the U.K.

to further build Wood Groups capabil-

ity in vibration, dynamics and noise.

This follows the acquisition of BETA

Machinery Analysis, a Calgary, Alberta,

Canada-based engineering consultan-

cy specializing in advanced vibration

analysis, and includes the opening of

a Southampton office in January 2016.

Mark Hutchinsonhas been named op-

erations manager of Wood Groups U.K.

A

GTSI

CogenEurope

Himoinsa

WoodGrou

pChristmas Tree & Dove Tail Form BroachesCreates highly accurate forms on turbine rotor

disks and blades of aircraft, ships and generators.

Visit Our NewProduction Facilities ~

717 Pushville Rd., Greenwood, IN 46143

317-530-1043

[email protected]

www.nachiamerica.com

Products for the

Aircraft &

Power Industry

Plan to visit us at

Booth - W-2245

Drills,

Endmills& Taps


32/44

INDUSTRY DRIVERS


INDUSTRY DRIVERS

ENERG RUDOX

Ener-G Rudox has purchased a new

facility in East Rutherford, New Jersey,

USA, to expand its production capaci-

ty and showcase its product line.

The facility will house the companys

new headquarters, as well as its man-ufacturing operations, test bays and

rental equipment fleet. It will also

provide space for the companys parts

and service departments and equip-

ment remote monitoring operations.

The facility is expected to be fully op-

erational by mid-2016.

The building will consolidate Ener-G

Rudoxs office space and provide ad-

ditional space for manufacturing low

carbon and renewable technologies,

combined heat and power systems

(CHP, CCHP) and standby generator

sets locally in northern New Jersey.

KELVION

A new standalone company has been

created out of the former Heat Ex-

changer division of the GEA GroupAG. Due to a change of ownership, the

German company is called Kelvion.

The other segments of the Heat Ex-

changer division will operate under

different names such as DencoHappel

(formerly Air Treatment), while the

Power Cooling Solutions business, as

of press time, had not been renamed.

MAN DIESEL & TURBO

Doosan Engine said that the initial

start of an MAN B&W 11G95ME-C9.5two-stroke engine took place during

October 2015 at its works in Korea; a

successful shop-test subsequently

followed. Rated at 76.8 MW, the en-

gine is the largest and most powerful

engine from the MAN Diesel & Turbo

portfolio ever designed and built, the

company said.

The engine is the first in a series of

six, bound for six 19,160 teu container

ships ordered by Mediterranean Ship-

pP

owerG

eneration

iI

ndustry

News

mM

arine

ping Company S.A., one of the worlds

largest shipping lines.

MAN Diesel & Turbo reports that it cur-

rently has orders for 28 11G95ME-C9.5

units, all for vessels serving the interna-

tional container trade.

The introduction of the G95ME-C9was an important addition to MAN

Diesel & Turbos G-engine program.

The G95ME-C9 engine, with a bore

of 950 mm and a stroke of 3460 mm,

provides 6870 kW/cylinder at 80 r/min

and 21 bar MEP (in L1) and supple-

ments the successful S90ME-C9/10

engine types by allowing the engine

to be further de-rated thanks to the

larger cylinder bore and/or fewer cyl-

inders to be installed.

PAS TECHNOLOGIES

PAS Technologies Inc., a provider

of OEM and maintenance, repair,

and overhaul products and services

for the industrial gas turbine and oil

and gas markets, has acquired

Bolton Aerospace.

Based in Manchester, Connecticut,

USA, Bolton Aerospace is a subtier

supplier of precision machined prod-

ucts. The company has more than 30

years of experience in manufacturingaerospace engine parts.

PAS Technologies operates

Documents

Diesel & GT Worldwide Jan-Feb 16