Diesel y Gas Turbyne Marzo 2014

Also In This Issue: Clean Air Technology

Overhaul, Service & Repair

Marine Propulsion

DEDICATED TO ENGINE ROOM PRODUCTS, TECHNOLOGIES & NEWS

March 2014www.dieselgasturbine.com

45thANNIVERSARY1969 2014DIESEL & GAS TURBINEWORLDWIDE MAGAZINE

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DIESEL & GAS TURBINE PUBLICATIONSPresident & CEO .................... Michael J. OsengaExecutive Vice President ... Michael J. Brezonick

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2 March 2014 Diesel & Gas Turbine Worldwide

The governor of California, U.S.A., declared a state of emergency on Janu-ary 17th due to the ongoing drought conditions plaguing the state. How bad is it? Forecasts for the water sup-ply at nearly every major water gauge in the state were less than half of av-erage seasonal norms as of February 5. Snowpack in the northern Sierra Nevada range, an indication of how much water will be available to fill res-ervoirs and power hydroelectric gen-erators throughout the year, is about one-fifth of normal.

The driest December on record has resulted in nearly 60% of the state clas-sified as being in a condition of extreme drought, the second-worst category in the U.S. drought monitor index.

In fact, the drought is Californias worst on record, and there is evidence that it may be the worst drought in the last 500 years. There are at least 17 ru-ral California communities that are in danger of running out of water within the next two to four months.

Drought is posing a serious chal-lenge to the state, not just for drink-ing and agriculture needs, but also for electricity generation.

According to the Energy Informa-tion Administration (EIA), almost 14% of the nations hydroelectric generat-ing capacity is concentrated in Cali-fornia. Since 1989, hydroelectric dams have accounted for varying portions of electricity generated within California, from 11% in 1992 (reflecting a low water year) to a high of 28% in 1995 (a high water year).

Absent output from in-state hydro-electric resources, the California Inde-pendent System Operator (CAISO), the electric grid operator for most of the state, imports more power from neighboring regions. Much of the im-ported power comes from hydroelec-tric dams located in the Pacific North-west. This has been an acceptable alternative in the past, but this year,

the Pacific Northwest is also experi-encing low water supply.

The Northwest River Forecast Cen-ter released its 2014 water supply projection for the Pacific Northwest in January. The drought is also affecting Washington, Oregon and Idaho, where precipitation in many areas is about half the normal level, which will drasti-cally limit hydroelectric production.

Natural gas to the rescue.In 2011, California generated about

42 million MWh of electricity from hy-dropower, and about 89 million MWh of electricity from natural gas. The fol-lowing year, the beginning of the re-gions current drought, hydroelectric generation plummeted to less than 26 million MWh, while gas-fired genera-tion soared to 121 million MWh.

Some analysts predict an additional 40% decrease in Californias hydro-electricity generation in 2014, further increasing its reliance on natural gas.

As summer approaches, Califor-nians are questioning the states ability to handle the looming peak demand, citing the 2000-2001 energy crisis that resulted in rolling blackouts and na-tional headlines. While state officials try to ease concerns, showcasing the 2052 MW of capacity added within the last year (mostly in gas-fired plants), energy watchdogs are skeptical.

In 2012, California mothballed two nuclear reactors in Southern Califor-nia that provided electricity to power 1.4 million homes. Part of the plan to bridge the power gap left by the plant closure was heavy investment in pow-er transmission lines to import power from neighboring states. Unfortunate-ly for that plan, the drought knows no boundaries. Hydroelectric power from neighbors in the Northwest may not be there. A

HaigHt Notes

Water Woes Wreak Havoc On Western U.S.

Brent [email protected]

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DIESEL & GAS TURBINE WORLD WIDE (ISSN 0278-5994) Volume 46, No. 2 Published monthly except, Jan/Feb & July/Aug issues combined, by Diesel & Gas Turbine Pub lications, 20855 Water town 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 2014 Diesel & Gas Turbine Publications. All Rights Reserved. Materials protected by U.S. and interna-tional copyright laws and treaties. Unauthorized duplication and publication is expressly prohibited. 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 Man ager, Diesel & Gas Turbine Worldwide, 20855 Watertown Road, Suite 220, Waukesha, WI 53186-1873 U.S.A.

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Diesel & Gas Turbine Worldwide March 2014 3

BRICS

Thirst For Power Lingers On .....................................................................8

Strong CHP Market In Russia ..................................................................12

Cummins Invests In Local Content .........................................................14

CLEAN AIR TECHNOLOGY

Keeping Watch On Emissions .................................................................16

Low Emissions For Heat And Power .......................................................36

Replacing Coal .........................................................................................38

RENEWABLE ENERGY

Biogas Powers Up For Growth ................................................................18

OVERHAUL, SERVICE & REPAIR

Always On The Lookout ..........................................................................20

Stitching An Engine .................................................................................42

POWER GENERATION

South Korea CCPP Exceeds 60% Efficiency ............................................22

Power On Demand ..................................................................................28

Expanding Proven Solution .....................................................................34

INDUSTRY NEWS

Cummins Boosts Turbo Range ................................................................24

Double Debut From Motortech ...............................................................40

MARINE PROPULSION

Ready For Hybrid ....................................................................................26

LNG-Powered Escort Tugs ......................................................................30

Wrtsil Targets Future Fuel ..................................................................32

Saying Aloha To Green Ship ...................................................................44

Features

Contents

Haight Notes ..............................................................................................2

PMO Report ...............................................................................................4

Dateline .....................................................................................................6

Featured Products ...................................................................................31

Literature Library ....................................................................................37

Newsmakers .............................................................................................42

Industry Drivers ......................................................................................43

Advertisers Index ....................................................................................46

Marketplace .............................................................................................47

World Viewpoint .....................................................................................48

Departments

Cov

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by A

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marCh2014

On The Cover: D&GTW explores the myriad large- horsepower prime-mover developments in BRICS countries. Coverage begins on page 8.

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CENTRAX Centrax will supply 12 gas turbine packages, each

comprising a single 5.2 MW Rolls-Royce 501-KB7 gas turbine, for service at the UstTeguss field in the West Siberian plain, some 1600 km east of Moscow, Russia.

GE GE will supply six megamodules, each housing a

turbogenerator train powered by a 43 MW GE 6B gas turbine and electric generator, to ZADCO (Zakum De-velopment Co.) for the Upper Zakum UZ750 field in Abu Dhabi, UAE.

MAN DIESEL & TURBO MAN will supply Jacksonville, Florida, U.S.A.-based

Crowley Maritime Corp. with two MAN B&W 8S70ME-GI8.2 main engines and six MAN 9L28/32DF auxiliary engines to power two new LNG-powered ConRo ships.

MAN will supply twelve 18V32/40 engines to the Bangladeshi Maisha Group for a 108 MW power plant that will provide additional peak load power to the state capital, Dhaka.

MAN will supply four 18V48/60TS engines to the

PMO RePORt Additional information on these Prime Mover Orders is available at www.dieselgasturbine.com

the Republic of Nigers Ministry of Energy and Petro-leum for a new 80 MW power plant in Niamey, Niger.

MITSUBISHI POWER SYSTEMS AMERICAS Mitsubishi Power Systems Americas (MPSA) will

supply a natural gas-powered M501J gas turbine, an SRT-50 steam turbine and associated electric generators for a new Unit #3 at the Grand River Dam Authoritys (GRDA) existing power generation facility in Chouteau, Oklahoma, U.S.A.

SIEMENS ENERGY Siemens will supply Enerjisa, a joint venture of

Sabanci Holding and E.ON, with an SGT5-8000H gas turbine, a model SST5-5000 steam turbine and other components of a turnkey construction for the Bandirma II combined-cycle power plant (CCPP) in Turkey.

WRTSIL Wrtsil will supply twelve 50DF dual-fuel engines

to PT Indonesia Power, a subsidiary of the state util-ity PT Perusahaan Listrik Negara (PLN), for the turnkey construction of the Pesanggaran power plant in Bali. A

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Worldwide Aftersales

MANdiesel_Mar14_WW.indd 1 2/13/14 9:24 AM


Dateline follow dgtww on

* 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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MARCHMarch 4-6 Russia Power Conference, Expocentre, Moscow, RussiaTel: +44 1992 656 617Web: www.russia-power.org

March 11-12 Power & Electricity World Africa, Johannesburg, South AfricaTel: +27 11 516 4015Web: www.terrapinn.com/exhibition/power-electricity-world-africa/index.stm

*March 17-19 Shipping 2014, Stamford, Connecticut, U.S.A.Tel: +1 (203) 406-0109 x 3717Web: www.shipping2014.com

*March 19-21 China International Offshore Oil & Gas Exhibition, Beijing, ChinaTel: +86-10-5823 6555Web: www.ciooe.com.cn/2014/en

March 19-21 Power Plant Flexibility 2014, Berlin, GermanyTel: +44 20 36 27 13 60Web: www.eventfulpower.com

*March 23-26 Western Turbine Users Group, Palm Springs Convention Center, Palm Springs, California, U.S.A.Tel: +1 (513) 604-8018Web: www.wtui.com

APRIL*April 1-3 Electric Power, New Orleans, Louisiana, U.S.A.Tel: +1 (832) 242-1969Web: www.electricpowerexpo.com

April 3-4 Cogen Europe Annual Conference, Brussels, BelgiumTel: +32 2 772 8290Web: www.cogeneurope.eu

April 7-11 Hannover Messe, Hannover, GermanyTel: +49 511 89-0Web: www.hannovermesse.de

April 8-10 Power 2014, Shanghai, ChinaTel: +86 21 51978782Web: www.powerchinashow.com

*April 9-10 GlobalCon, Atlantic City, New Jersey, U.S.A.Tel: +1 (770) 279-4392Web: www.globalconevent.com

April 9-11 China International Marine, Port & Shipbuilding Fair (CIMPS), Nanjing, China

Dateline

Tel: +86-25-8452 1101-869Web: www.china-ship.com

MAYMay 5-7 Power-Gen India & Central New Delhi, IndiaTel: +44 1992 656 610Web: www.power-genindia.com

*May 5-8 Offshore Technology Conference, Houston, Texas, U.S.A.Tel: +1 (972) 952-9494Web: www.otcnet.org

*May 6-7 6th AVL Large Engines Techdays, Graz, AustriaTel: +43 316 787 927Web: www.avl.com

June*June 2-6 Posidonia 2014, Athens, GreeceTel: +30 210 4283608Web: www.posidonia-events.com

*June 3-5 Sensor+Test 2014, Nuremberg, GermanyTel: +49 5033 9639-0Web: www.sensor-test.de

*June 3-5 Power-Gen Europe 2014, Cologne, GermanyTel: +44 1992 656 617Web: www.powergeneurope.com

June 3-6 Energy Lebanon, Beirut, LebanonTel: +961 5 959111Web: www.energy-lebanon.com

*June 16-20 ASME Turbo Expo 2014, Dusseldorf, GermanyTel: +1 (404) 847-0072Web: www.asmeconferences.org/TE2014

June 25-26 Energy Management Congress West, Washington State Convention Center, Seattle, WA, U.S.A. Tel: +1 (770) 279-4392Website: www.energyevent.com

SePTeMBeR*Sept. 9-12 SMM Hamburg, Hamburg, GermanyWeb: smm-hamburg.com

*Sept. 10-12 Power-Gen Asia, Kuala Lumpur, Malaysia Tel: +44 1992 656 634Web: www.powergenasia.com

*Sept. 22-25 Turbomachinery Symposium, Houston, Texas, U.S.A. Tel: +1 (979) 845-7417Web: www.turbolab.tamu.edu

*Sept. 23-26 InnoTrans 2014, Messe Berlin, Berlin, GermanyTel: +49 30 30 38 2376Web: www.innotrans.de

oCToBeROct. 1-3 World Energy Engineering Congress, Washington Convention Center, Washington, D.C., U.S.A.Tel: +1 (770) 271-7869Website: www.energycongress.com Oct. 6-10 11th International Rotor Dynamics Seminar, Leonardo Hotel, Cologne, GermanyTel: +49 2267 6585-0Website: www.arla-online.com Oct. 12-14 Power-Gen Middle East, Abu Dhabi National Exhibition CentreAbu Dhabi, United Arab EmiratesTel: +44 1992 656 610Web: www.power-gen-middleeast.com Oct. 21-23 Power-Gen Brasil, Transamerica Expo Center, So Paulo, BrazilTel: +1 918-832-9305Website: www.powergenbrasil.com Oct. 21-24 Shiptec China 2014, Dalian World Expo Center, Dalian, ChinaTel: + 86 411-3991-6904Web: www.shiptec.com.cn Oct. 22-24 EP Shanghai 2014, Shanghai World Expo Exhibition & Convention CenterShanghai, China Tel: +86 10 5129 3366Web: www.epchinashow.com Oct. 22-24 SNAME, Hyatt Regency Houston, Houston, Texas, U.S.A.Tel: +1 (703) 997-6701Web: www.sname.org

noveMBeRNov. 24-25 Plant Maintenance in the Middle East, Millenium Hotel, Abu Dhabi, United Arab EmiratesTel: +44 207 384 7983Web: www.wraconferences.com

WW_March_Dateline.indd 1 2/14/14 8:14 AM

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by ian cameron

With the global thirst for energy continuing to grow over coming years, the problems and opportuni-ties it presents are most evident in the BRICS economies Brazil, Russia, India, China and South Africa.

It is in India and China especially where the transformation in energy demand poses huge challenges for their governments, power generation companies and populations.

As recently as the middle of 2013, the U.S. Energy Information Admin-istration (EIA) projected that over the next three decades world energy con-sumption would rise by 56%, driven by growth in the developing world.

Rising prosperity in China and In-dia is a major factor in the outlook for global energy demand, EIA admin-istrator Adam Sieminski said. Com-bined, these two countries account

million tonnes the previous year. The country produced 628 million tonnes in 2012 compared with 580 million tonnes the previous year.

Natural gas is used in part for elec-trical generation in India, but there is more and more reliance on imports despite the fact that the country does have its own significant natural gas reserves, estimated to be 1.24 trillion m3 at the end of 2012 compared with 1.15 trillion m3 in the previous year.

However, some progress toward developing natural gas opportunities was recently made by Oil and Natural Gas Corp. Ltd. (ONGC), one of the biggest Indian oil companies. In late January, ONGC signed a memoran-dum of understanding with Japans Mitsui to cooperate in the explora-tion and production of conventional and unconventional petroleum and

Rolls-Royce gas compression equipment installed on the WEPP project in China.

for half the worlds total increase in energy use through 2040. This will have a profound effect on the devel-opment of world energy markets.

The EIAs research and projections merit further detail, and arguably it is in India where the challenges of supplying reliable and sufficient energy are most demanding. India is the fourth-largest energy consumer in the world, follow-ing the U.S., China and Russia. Yet a 2012 report by the EIA estimated that almost one-quarter of the Indian popu-lation lacks basic access to electricity, while electrified areas suffer from roll-ing electricity blackouts.

Indias largest and most readily available source of energy is coal it has the fifth-largest coal reserves in the world. According to the EIA, in 2012 India consumed 726 million tonnes of coal compared with 654


Thirst For Power Lingers OnBRICS energy markets having major impact on worldwide industry

BRAZIL RUSSIA I N D I ACHINA SOUTH AFRICA

BRICS

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natural gas opportunities in India and other countries.

Last year, ONGC, Mitsui, Bharat Petroleum Corp. Ltd. and the New Mangalore Port Trust also revealed plans for a feasibility study of a liq-uefied natural gas (LNG) terminal at Mangalore in the state of Karnataka.

Because of the high dependency on imports of crude oil and gas into In-dia, nationalized oil companies have made overseas purchases to try to partly redress the situation. ONGC Videsh Ltd. (OVL), a subsidiary of ONGC and Oil India Ltd., acquired 10% in the Rovuma Area 1 offshore block. The block covers approxi-mately 1.05 million hectares in the deepwater Rovuma Basin offshore Mozambique and represents one of the largest gas discoveries in offshore East Africa, with estimated recover-able reserves of 1 to 1.8 trillion m3.

OVL said the move marked the companys entry into this offshore gas basin with significant future upside potential. Area 1 has the potential to become one of the worlds largest LNG producing hubs and is strategically lo-cated to supply LNG to the growing Indian gas market, the company said. OVL is also involved in 32 projects in 16 countries including Russia, Brazil, Azerbaijan, Colombia, Iraq, Kazakh-stan, Libya, Myanmar, South Sudan, Sudan, Syria, Venezuela and Vietnam.

In China, initiatives by the govern-ment to relieve problems with air pol-lution will lead to the largest growth in natural gas demand, according to the EIA.

It added that from 2010 to 2020, natural gas consumption will rise at an annual average rate of 7.5%, with pro-duction growing by an average of 2.4% per year with a greater use of shale gas and coalbed methane from 2020.

Expanding natural gas-fired and renewable plants and boosting trans-missions are a government priority in China, the worlds largest energy con-sumer and the largest coal producer and consumer. Due to the significant rise in demand for electric power in China, the countrys government de-cided to introduce distributed gas en-

gine power generation systems with a total output of 50 GW by 2020.

Mitsubishi Heavy Industries (MHI) and Hitachi have formed a joint ven-ture company that will be headquar-tered in Shenzen, China. MHI said the new company would strategical-ly evaluate the market for distributed gas engine power generation systems, which is anticipated to expand rap-idly in China going forward. Looking


BRICS

ahead, the two companies will join forces to penetrate a full-scale entry into the distributed gas engine power generation systems business in Chi-na with the aim of expanding their market share.

The willingness to try to embrace greener alternatives to fossil fuels in China is not just restricted to the government. China Huaneng Group,

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WW787.indd 2 2/14/14 8:16 AM

a state-owned organization focused heavily on the production and sale of power, and Italian energy company Enel Group, have linked up to co-operate in environmentally friendly power technologies.

In a similar vein, the need for Chi-nese companies to reduce emissions and comply with upcoming NOx regulations is more prevalent than ever. An example of this is the work scheduled to have begun early this year by Wood Group GTS, which was awarded a Dry Low NOx (DLN) combustion system conversion con-tract by ZhongshanYongan Electric-ity Co. based in Zhongshan City, Guangdong Province.

The work involves upgrading the combustion system from standard diffusion to DLN on a GE Frame 9E combined-cycle gas turbine, and the modification of the existing control system and DLN monitoring and tun-ing services.

As part of a bid by the China Na-tional Petroleum Corp. to promote economic growth in western China, the HuaQi Ansai LNG project in the city of Ansai, Shanxi Province, was inaugurated in 2012 and is today re-garded as a key asset in the area. It features the first application of GEs 24 MW convertor in China and sup-

plies an estimated 2 million m3/d of LNG and 436 446 tonnes/yr.

GEs Power Conversion Business supplied the compressor drive set in-cluding the convertor, rotating ma-chine and transformer. Rolls-Royce has also announced a US$28 million con-tract to supply PetroChina with equip-ment and services to expand the flow of natural gas through the Lunnan-Tulu-fan branch of the second West to East Pipeline Project (WEPP II).

The Lunnan-Tulufan pipeline branch transports 17 billion m3/yr of gas and connects Lines I and II of WEPP, which links Chinas western Xinjiang region to Fujian province in the southeast. In total, WEPP transports up to 47 billion m3/yr of gas. Rolls-Royce will supply PetroChina with an additional two RB211 gas turbine driven pipeline compressor units, bringing the total number of RB211 units sold for instal-lation on China and Central Asias nat-ural gas pipeline network to 70.

The EIA estimates that South Afri-cas total electricity consumption has grown by over 20% in the last decade, but only 55% of the rural population and 88% in urban areas have access to electricity, leaving approximately 12.5 million people without power.

Energy consumption grew by 20% from 2000 to 2010, while installed ca-

pacity grew at only 7%, straining the available supply infrastructure to the point where the country suffered roll-ing blackouts and a major power crisis in 2008, threatening power supply to many businesses including the coun-trys vital mining industry.

The National Energy Regulator of South Africa (NERSA), which is re-sponsible for implementing South Africas energy plan, and Eskom, the state electricity company respon-sible for electricity transmission and generation of 95% of South Africas electricity, are focused on diversify-ing energy sources, securing energy supplies and pushing forward new energy projects across sectors.

In 2010, almost 70% of South Af-ricas energy supply came from coal, followed by oil (19%), solid biomass and waste (10%), natural gas (2%), nuclear (2%) and hydro (less than 1%), according to EIA estimates. The EIA said that South Africa has the worlds ninth-largest recoverable coal reserves, holds 95% of Africas total coal reserves, and is the fifth-largest coal exporter in the world.

Unfortunately, because of its de-pendence on hydrocarbons, particu-larly coal, South Africa has become Africas leading CO2 emitter and the 12th largest in the world. Despite en-vironmental pressures and a focus on energy diversity, coal use is expected to rise to meet demand. This includes the return to service and construction of coal-fired plants. The EIA said that there is a considerable amount of in-vestment in new power projects with targeted capacity additions of over 40 000 MW by 2030, which will include mostly coal but also renewable and nuclear generating capacity.

A recent EIA analysis stated that South Africa has 13.6 trillion m3 of technically recoverable shale gas re-sources, most of which are located in the Karoo Basin. After previously enacting and then lifting a morato-rium on shale gas exploration, the Pe-troleum Agency South Africa (PASA) issued technical cooperation permits (TCPs) to authorize research into shale gas potential to several inter-


Rosnefts Angarsk refinery, one of the largest Russian oil processing plants.

BRICS

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Diesel & Gas Turbine Worldwide Month 2014 XX

national companies including Royal Dutch Shell, Falcon Oil and Gas Ltd. and Bundu Gas & Oil. However, some companies are awaiting approv-al to convert their TCPs to explora-tion licenses, the EIA said.

With the largest natural gas re-serves in the world, Russia is one of the leading producers and consumers of electric power globally and a major exporter of both oil and natural gas. According to EIA figures, the country achieved 996 billion kWh of electric power generation in 2011, with con-sumption totaling 861 billion kWh.

While Russia has substantial coal re-serves, production is relatively light at 351 million tonnes/yr with consump-tion of 249 million tonnes/yr, and this has led to strong export figures for the resource.

In 2012, Russia was behind just the U.S. and Saudi Arabia as the worlds largest producer of liquid fuels, with pipeline exports accounting for the ma-jority of the countrys crude oil exports.

The pipeline network is dominat-

BRICS

ed by Transneft, which operates ap-proximately 70 000 km of pipelines and more than 500 pumping sta-tions. The company also transports 93% of Russian oil.

Another key player in the Russian energy business is oil and gas com-pany, Rosneft, which is engaged in exploration and production of hy-drocarbons, and production of petro-leum products and petrochemicals. The company has an annual output of natural and associated gas of about 12 billion m3.

Rosneft is also expanding and up-grading its refineries, including one of its key facilities at the Ust Teguss oil field in Siberia, where U.K. company Centrax has started the largest installa-tion of gas turbine packages produced by the company on a single site world-wide. Twelve of the packages, each comprising a single 5.2 MW Rolls-Royce 501-KB7 gas turbine, are being prepared for service at the facility.

Russia is estimated to have the larg-est deposits of recoverable shale oil

around 75 billion barrels although work towards production has not been hasty. However, in a key move Rosneft and Statoil of Norway have agreed on a joint venture to assess the feasibility of commercial production from the Domanik shale formation in the coun-trys Samara region. Rosneft president Igor Sechin said the move would help the company accelerate the launch of hard to recover reserves development. Rosneft and Statoil will set up a joint venture company to run a three-year pilot program to assess the potential for commercial production.

If successful, we believe this could be a world class shale oil as-set, said Helge Lund, Statoil chief executive officer.

The energy scenario in the BRICS countries is dynamic and challeng-ing. It is beyond doubt that the power production and consumption strate-gies being played out there will have an everlasting impact across all seg-ments of the energy industry and on the environment. A

Crestchic_Mar14_WW.indd 1 2/4/14 10:12 AMWW787.indd 4 2/14/14 8:16 AM

by bo svensson

Wrtsil has been contracted to supply two combined heat and power (CHP) plants to Russias Chelyabinsk region in the South Urals. The plants are a part of the local administrations program to upgrade the district heat-ing system by replacing outdated boiler plants with modern power gen-eration technology.

The two power plants, located in the towns of Kasli and Karabash, will be built for Perspektiva LLC, a pri-vate investment company. Each of the plants will be equipped with two Wrtsil 20-cylinder, V-type 34SG gas engines, producing a combined 20 MW of electric power and approx-imately 9.6 MW of heat. The engine operates at 750 r/min for 50 Hz appli-cations, and will run on natural gas.

Wrtsils scope of supply includes

autumn in time for the winter heating season, the company said.

We were looking for a solution that would ensure a reliable heat sup-ply during the extremely long and cold winters in this region, said Andrey Ry-abenko, director of Perspektiva LLC. We believe that Wrtsils technology will provide the outstanding reliability and high efficiency that is needed.

Wrtsil said that replacement of the old boilers by cogeneration plants would significantly improve the fuel utilization rate by producing extra electric power. The local administra-tions program to upgrade and renew the district heating system is high on its agenda due to the positive impact for the local communities.

Both the economy and environmen-tal performance of the combined sys-

The Wrtsil 20-cylinder 34SG gas engine will be used for two combined heat and power (CHP) plants in the

South Urals region of Russia.

the generating sets and all mechanical and electrical systems, including heat recovery equipment and systems like pumps. In Kasli, the equipment will be installed in a separate building, also part of the supply. In Karabash, the equipment will be fitted into an existing boiler house. The plants have been engineered to accommodate a high degree of modularity, which will enable repetitive use of the solution in similar projects throughout the coun-try, the company said.

Along with emergency boilers, the power plants will feed electricity to the local grid and will be the sole suppli-ers of heat to the two towns, each with approximately 17 000 inhabitants. The deliveries are scheduled to be complet-ed by June 2014, and the two plants are scheduled to be in operation this


Strong CHP Market In RussiaReplacement of old boilers by cogeneration plants improving fuel utilization rate, producing extra electric power


BRICS

WW781.indd 1 2/14/14 8:18 AM


BRICS

INNOVATIVE SOLUTIONS. PROVEN PERFORMANCE.

Harco_Sept12_WW.indd 1 8/10/12 2:54 PM

tem will be improved compared to the previous installations, said Igor Petryk, sales director, Wrtsil Power Plants. Proven technology and a reliable sup-plier were important requirements im-posed by the local authorities.

For each plant, two exhaust gas heat exchangers have been manu-factured by Aprovis Energy Systems, Weidenbach, Germany. Aprovis said it has succeeded in building up a thriving export business that now accounts for more than 60% of the companys turnover.

To improve the flexibility of the plant, the heat exchangers locat-ed inside the power buildings are equipped with exhaust bypass valves, allowing the gas engines to operate in pure simple-cycle mode, if required. The exhaust bypass valves are sup-plied by German based Fackert Spe-zialarmaturen GmbH.

Each of the two waste heat recovery units for the Kasli and Karabash plants produces a thermal output of 4790 kW. The exhaust gas temperature entering the heat exchanger is 392C and the temperature of the gas exiting the ex-changer is 113C; water enters the heat exchanger at 84C and exits at 100C.

The existing district heating sys-tems are being modernized in many parts of Russia. The short delivery and construction time made possi-ble by the modular design and the high electrical efficiency and trans-parent operating costs have made our concept attractive for private in-vestors, said Alf Doktar, regional di-rector, Europe East, Wrtsil Power Plants. The availability of Wrtsils service network in Russia and strong references in the region were also key factors in securing this contract.

Igor Petryk, sales director, Wartsila Power Plants, said, Wartsila has de-livered more than 50 power plants to Russia. Last year, we received an or-der for a 110 MW power plant in the town of Tikhvin, near St. Petersburg, that will be the largest reciprocating engine power plant in Russia. These two new plants are further examples of the relevance of our flexible power generation concept. A

A rendering of the plant in

Kasli, Russia, that will pro-

vide heat and power to the

towns 17 000 inhabitants.

WW781.indd 2 2/17/14 2:50 PM

by mauro belo schneider

Cummins Brazil will supply seven units of emergency generators to work in the Brazil pre-salt layers, fo-cusing its 2014 strategy on offering packages with local content to fulfill requests of the Petroleum National Agency (ANP).

The first unit will be delivered to GE, which is responsible for supplying power modules for the Atlntico Sul shipyard, located in Recife in Pernam-buco state. The modules will be used as emergency generators in seven drill ships by Petrobras and might also be used in the Brazilian coastal areas.

According to Rodrigo Teixeira, Cum-mins Maritime Business manager in Brazil, the delivery of local content will grow gradually, with product na-tionalization eventually increasing to 40 to 50%.

The package generators will be equipped with a Cummins QSK 60 engine and a WEG alternator with a unit power of 1800 KWe. The pack-age also utilizes a modern panel

In 2013, the domestic market repre-sented 81%, the company said.

In 2013, we saw an effective, stra-tegic growth in our business in Bra-zil, said Kip Schwimmer, Cummins Power Generation director in South America. We invested in infrastruc-ture projects that might demand more energy equipment, such as air-ports, but also in agribusiness and in the construction segment.

Cummins said it intends to build a new power generator plant and a new distribution center in Itatiba city, So Paulo state. Operations at this facility are expected to begin in early 2015. The company also announced that Cummins Power Generation has a new operational structure in Brazil that focuses on four product lines: Power Products (up to 1000 kW); Power Systems (1000 kW and higher); Power Solu-tions (gas and biogas solutions); and Cummins Generator Technologies (CGT) for alternators. A

Cummins Power Generation will continue to expand its operational structure in Brazil, focusing on four

product lines.

C-Command Elite Plus, which Cum-mins said works not only in a preven-tative role such as managing opera-tional costs but also allows vessel monitoring via satellite.

The propulsion engines range var-ies from 19 to 60 L and 368 to 1986 kW. Generator groups have potency between 250 to 1825 kW, while auxiliary engines will be available from 5.9 to 60 L and 75 to 1900 kW. Cummins said these products com-ply with IMO Tier 2 and EPA Tier 2 emissions standards.

Cummins also said that it has fur-ther expansion plans in Brazil, which currently leads the companys activi-ties in South America and represents 56% of Cummins earning in the re-gion. In 2012, Cummins Power Gen-eration was responsible for 13% of Cummins earnings in South Amer-ica. Of the generators manufactured in its Guarulhos plant in So Paulo state, 63% were destined to the do-mestic market and 37% for exports.


Cummins Invests In Local ContentDelivering key propulsion units; Brazil market major share of companys South America business


BRICS

WW785.indd 1 2/14/14 8:20 AM

PetroCanada_Mar14_WW.indd 1 2/11/14 11:45 AM

Continental Controls Corp. (CCC) has created the FM50, a gas flowme-ter that can be sized to measure flow and fuel consumption for nearly any reciprocating gas engine or small to medium-sized gas turbines.

The new product comes just af-ter the U.S. Environmental Protec-tion Agency (EPA)-proposed Clean Air Act standards cut carbon diox-ide emissions from new and existing power plants. The announcement from the government agency came on Sept. 20, 2013.

According to the proposal, new large natural gas-fired turbines


The FM50 flowmeter from Continental Controls Corp. is designed to

measure flow and fuel consumption for gas engine and turbines.

Keeping Watch On Emissions True mass calculation corrects for temperature, pressure inconsistencies; designed for engine, turbine range from 75 to 7457 kW

The FM50 flowmeter installed on a gas engine application.

Clean air TeChnology

WW761.indd 1 2/14/14 8:22 AM

Clean air TeChnology


would need to meet a limit of 454 kg of CO2 per MWh, while new small natural gas-fired turbines would need to meet a limit of 499 kg of CO2 per MWh. New coal-fired units would need to meet a limit of 499 kg of CO2 per MWh, and operators would have the option to meet a tighter lim-it if they choose to average emissions over multiple years.

The EPA is also developing stan-dards, regulations or guidelines to address carbon emissions from exist-ing power plants. According to the June 25 Presidential Memorandum, the EPA will issue proposed stan-dards for existing power plants by June 1, 2014.

The FM50 provides near instant flow momentary measurements, as well as measurements either aver-aged or totalled over a period of hours, days or months, the com-pany said. The venturi-based FM50 provides a true mass flow calcula-tion that corrects for temperature or pressure inconsistencies, result-ing in an accuracy of 3% of read-ing or 0.5% of full scale, whichever is greater.

Specifically designed for single en-gines, the FM50 works with engines and gas turbines from 75 to 7457 kW. The basic design of the FM50 remains the same, no matter what size engine or turbine it is installed on, and the unit is sized to match the needs of a particular engine, the company said.

Features of the new flowmeter in-clude a pressure drop of 0.14 bar, a response time under 10 ms, and a turndown ratio up to 20:1. CCC also calibrates the meter, which automati-cally makes adjustments to re-zero the transducers each time the meter is powered down.

The 20.3 cm device can be dropped into a 5 cm inlet pipe rather than hav-ing to re-pipe the inlet and find a way to fit a larger meter in around existing equipment, CCC said.

The FM50 comes with a heated, backlit display built into the body, allowing the device to operate in ex-treme sub-zero temperatures. Data

can be stored locally on a USB por-table drive or can be communicated via CAN J-1939, Modbus, Ether-net, satellite or cellular modem, or through the included 2.6 GHz wire-less radio.

In addition to environmental compliance, the FM50 is useful for applications where a drilling rig or compressor is using a bi-fuel gas

substitution system (GSS), the com-pany said. In such a case, the FM50 provides measurements of the fuel flow and cost-saving estimates. For a gas turbine with a low NOx com-bustor, CCC said the FM50 could measure the flow to each part of the combustor and provide that data to the turbine control system for deter-mining efficiency. A

Just as a racing driver needs to have the best possible technology to avoid devastating pit stops - Camfil filters will provide gas turbine operators maximum uptime to avoid unnecessary maintenance. The CamGT 3V-600 takes the lead in gas turbine filter performance - no filter has ever provided lower pressure drop at (H)EPA grade efficiency.

Visit www.nonstop-performance.com and learn more about the benefits of a properly designed Inlet Air System or contact your local Camfil representative.

CLEAN A IR SOLUT IONS

www.camfil.com/ps

CAMGT 3V-600

NONSTOPPERFORMANCE

Camfil_halfpisland_DGTWW_Jan.indd 1 1/15/14 10:07 AMWW761.indd 2 2/14/14 8:22 AM

As more governments worldwide are aiming to encourage the use of renew-able energy, interest in biogas plants re-mains strong. Two new biogas projects in the U.K. are due to come on-stream shortly as the move towards these facili-ties seemingly gathers momentum.

In such systems, organic matter is broken down by bacteria to produce biogas a mixture of methane (CH4) and carbon dioxide (CO2) which is used as a fuel to generate electricity. According to German biogas special-ist company, Weltec Biopower, 1 m3 of biogas with a methane content of 60% has an energy content of 6 kWh. The company said this is equivalent to approximately 0.6 L of heating oil.

To generate biogas, a large variety of organic materials including cow and pig manure, poultry droppings, dung, corn, whole crop silage, grass, grains, beets and harvest residues, is broken down in digesters. Other sources are food remnants, fryer grease, slop/silage and animal wastes such as fat,

Hajo Schierhold, the worldwide mar-ket for renewable energies depends on varying governmental policies.

The main focus markets are current-ly France and Great Britain because the governments have set priorities around achieving more renewables by 2020, Schierhold said. However, for several years we have noted growing demand and increased interest, especially from Asian countries, Russia and the U.S.

The biogas market has huge advan-tages, especially as biogas can be pro-duced from many different substrates: therefore, a biogas plant can also be very attractive without any subsidies. One example is our project in Uru-guay. The operators plant is complete-ly self-sufficient because it uses the slurry and maize silage from its own farm. The heat and some of the power produced are used for dairy and milk powder production.

The company said it has recently completed major contracts in France, where, along with its partner Domaix Energie, it has developed four agri-cultural biogas plant projects. The plants use sludge and food leftovers, and Weltec said the units are a reflec-tion of the trend that French biogas plants are increasingly fermenting in-dustrial leftovers.

Since the introduction of the sepa-ration and utilization of kitchen waste from large catering establishments in France at the end of 2011, organic waste from schools and company caf-eterias must be used for the produc-tion of energy, Weltec said.

Two 600 kW plants use MWM en-gines and CHP systems that are sup-plied by Germanys Dreyer & Bosse the plant in Charente uses a 3000 m3 stainless steel digester, while the Bur-gundy plant has two digesters with a capacity of 2000 m3 each.

The two other plants have an elec-trical output of 190 and 255 kW, re-spectively. The smaller Weltec biogas plant in Lorraine comprises a 1500 m3 stainless-steel digester and is loaded with cattle manure from the operators farm as well as whole plant silage and food leftovers. The 255 kW plant also uses agro-industrial waste. A

An interior view of a digester.

blood, gastro-intestinal contents and slaughter waste.

Two Weltec plants will soon begin operations in the U.K. In Londonderry, Northern Ireland, a Foyle Food Group-owned 500 kW plant will commence operations using a Liebherr engine.

The industrial meat processing com-pany will feed the 3000 m3 stainless steel digesters with waste from its abat-toirs, primarily with stomach contents and flotation fat. Onsite, Weltec has in-tegrated a hygienisation unit, a 530 m3 digestate storage unit and the compa-nys MULTIMix input system.

The other Weltec project is a 500 kW agricultural plant in Leicester, England, a biogas facility using a mix of renew-able raw materials that also utilizes a Liebherr engine. The operator, an agri-cultural contractor with its own crop-ping farm, mainly uses maize silage as substrate. Both plants use a 500 kW combined heat and power (CHP) sys-tem supplied by 2G Energy AG.

According to Weltecs head of sales,


Renewable eneRgy by ian cameron

Biogas Powers Up For GrowthWorldwide market depends on governmental policies; two Weltec plants poised to begin U.K. operations

WW783.indd 1 2/14/14 8:25 AM

www.nidec-asi .com

Fernanda owns a bar on the beach in Carnarupim. Her dream is to build a hotel one day.

The use of an FPSO means that her beach will remain clean and pollution free.

Nidec, turning dreams into results.

Nidec ASI

FPSO Project, Brazil

Our customers dream was to build one of the largest, most efficient and reliable

converted FPSOs in the world.

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Nidec ASIs explosion proof motors provide maximum reliability, performance and safety with

a high level of efficiency.

Explosion proof motors - ET series.

Nidec_May13_WW.indd 1 3/26/13 1:10 PM

MAN Diesel & Turbo has intro-duced EcoCam, a retrofit solution offered for low-speed, mechanical en-gines with a single turbocharger. The MAN EcoCam is a flexible cam pro-file called a virtual cam. The profile is controlled hydraulically by adjust-ing the amount of actuator oil in the hydraulic pushrod. As a result, the exhaust valve can start closing earlier and the Pmax cylinder pressure can be increased at low-load for engines that were originally optimized for high-load performance.

MAN said that until now, flexible exhaust-valve timing has only been available for electronically controlled engines and not possible for mechani-cal engines.

The EcoCam offers significant fuel savings with short payback times, the company said, and MAN will initially roll out the EcoCam to a number of its MAN B&W S50MC-C engine us-ers. The EcoCam will be released for

retrofit solution includes a junction box for the various engine cylinders and a tachometer system. Both these units are located adjacent to the en-gine. A system control unit will be in connection with the operating panel and, besides the hardware compo-nents, NOx emissions documentation and a torsional vibration solution are provided, MAN said.

When a low-load tuning method is installed on an engine, it will impact torsional vibration and NOx emis-sions, MAN said. Operators must take this into account and ensure the vibrations impact is not harming the engine and that the NOx levels remain in compliance with IMO regulations.

The EcoCams effect on fuel re-duction and NOx impact has been verified by two independent test bed installations and aboard a test vessel in service, Ludwig said.

One of the tests of the EcoCam con-cept was carried out with a 6S50MC-C8.1 engine at the Mitsui test bed. The tests aim was to compare and register the lifting curves of a reference non-modified engine with the engine mod-ified with the EcoCam system.

MAN said the results of the test clearly showed that the controlled drainage of the hydraulic oil from the top of the actuator reduced the specific fuel consumption by 7 to 19 L/kWh in the 20 to 60% range of specific maximum continuous rat-ing (SCMR). Another challenge was to find the solution for the torsional vibration impact within a specific en-gine speed range the solution was an automatic on/off switch within the critical speed range.

We have estimated the time re-quired for installation and commis-sioning of the EcoCam system on a 6S50MC-C engine to be two to three days with a staff of three fitters and a superintendent, Ludwig said. De-pending on an engines load profile, a savings in the 7 to 19 L/kWh range for smaller engines could result in a payback period of as little as 1.5 years. For example, this could be the case with a 6S50MC-C engine with 6000 annual running hours. A

its mid- and large-bore engine pro-gram, beginning with a number of S60MC-C engines, during the first quarter of 2014.

Slow-steaming is now an estab-lished industry standard across all segments including the tanker and bulker markets and we are always seeking to refine our technology and improve efficiencies, said Christian Ludwig, head of Retrofit & Upgrade, MAN Diesel & Turbo. The EcoCam adjusts the exhaust-valve timing in the range from 20 to 60% load, giv-ing a 7 to 19 L/kWh fuel savings with minimal to no interruption to a ves-sels schedule during installation.

The Eco-Cam modification includes a new valve actuator block, which has a controlled drain line from the top of the pushrod. This drain line allows the valve to close earlier, achieving a higher Pmax cylinder pressure.

Besides the new and modified valve actuator, the scope of the EcoCam


Overhaul, Service & repair by bo svensson

Always On The LookoutVirtual cam reduces specific fuel oil consumption (SFOC); now available for mechanical engines

The EcoCam modification in-

cludes a new valve actuator

block with a controlled drain

line (the thinnest of the three

pipes), which allows the valve

to close earlier and achieve a

higher Pmax cylinder pressure.

WW788.indd 1 2/14/14 8:27 AM

Dictionary_OnSale.indd 1 10/29/13 2:24 PM

The latest commissioning by Sie-mens in South Korea, in cooperation with consortium partner GS E&C, is the Dangjin 3 combined-cycle power plant (CCPP) in Bugok, about 120 km south of the capital city, Seoul.

Dangjin 3 is a turnkey project by Siemens and GS E&C for one of the two independent power producers in South Korea, GS EPS, which invested US$460 million in the project. The 415 MW single-shaft, combined-cycle follows two other installations at the same Bugok site, all fueled by LNG: Dangjin 1 is a 538 MW combined-cy-cle plant in 2+1 multishaft configura-tion that was the first in Korea to use SGT6-4000F gas turbines and was, at the time of commissioning in 2000, the most efficient plant in the country; and Dangjin 2, another 2+1 multishaft combined-cycle facility using Siemens F-class technology and delivering 550 MW of power with an efficiency of 58.6% (LHV basis net).

Ki Hwan Cho, team leader and Phase 3 team project manager of GS EPS, said that the company decided to move to

eration thanks to the gas turbine and steam turbine working on the same generator, and features a synchronous self-shifting (SSS) clutch between the steam turbine and generator.

The SSS clutch is disengaged when the gas turbine is in operation, for example, during start-up, to run in-dependently from the steam turbine. When the steam turbine is accelerat-ed and overtakes the generator speed, the clutch is engaged and transfers the torque of the steam turbine to the generator.

The company said this configura-tion together with the condenser being positioned laterally to the low-pressure steam turbine allowed for all the major components in the pow-ertrain to be installed on a low-bay foundation without basement. The result is a simpler plant layout one turbine building and one service crane compared to a multishaft installa-tion. Also, the lubrication system, with only one lube tank, is the same for all components and related systems.

The generator is a standard two-pole, hydrogen-cooled SGen6-2000H type with direct radial hydrogen cool-ing for the rotor winding and indirect hydrogen cooling for the stator wind-ing. The generator casing is pressure-resistant, gas-tight and is equipped with two end shields.

Assembled in the same turbine

building on a low-bay founda-

tion, the Siemens powertrain

of the Dangjin 3 single-shaft,

combined-cycle power plant

features a much simpler layout

than multishaft installations.

higher efficiency Siemens H-class tur-bines to achieve even lower fuel con-sumption and reduced emissions.

The plant achieves a limit of 15/16 ppm in NOX emissions without after-treatment, thanks to the Siemens low NOX combustor technology, Cho said. This plant has broken more than one record it is not only the first 60 Hz combined-cycle plant in Asia to achieve over 60% net effi-ciency, but this is also the first time Siemens has installed a single-shaft, combined-cycle configuration with an H-class 60 Hz unit.

Thomas Hagedorn, vice president, Gas Turbine Power Plant Solutions APAC at Siemens Energy, said that Dangjin 3 features an SGT6-8000H ful-ly air-cooled gas turbine in single-shaft configuration with a Siemens SST6-5000 steam turbine, the same used in the Dangjin 1 and 2 CCPP units.

The absence of a cooling media for the gas turbine allows for very quick starts, Hagedorn said. The single-shaft powertrain, a first for an LNG plant in Korea, provides flexible op-


Power Generation by roberta prandi

South Korea CCPP Exceeds 60% EfficiencySiemens confirms South Korea as key market for LNG-powered electricity production, opening regional headquarters

WW786.indd 1 2/14/14 8:28 AM


Power Generation

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The hydrogen is circulated in the generator interior in a closed circuit by axial-flow fans arranged on the rotor shaft journals. A start-up frequency converter is used for starting the turbine generator unit, and the generator thus acts as a motor in converter mode to start the gas turbine set.

The heat recovery steam generator (HRSG) is a triple-pressure reheat system with HP once-through Benson-type boiler and natural circulation LP/IP boiler design housed in a boiler room. The Benson boiler dispenses of the use of a big drum in the HP circuit, which makes the start-up of the HRSG quicker, the company said.

Benson technology has been already used in our H-Class benchmark CCPP Ulrich Hartmann (former-ly Irsching 4) in Germany, Hagedorn said. There, the steam reaches 600C in the SH and RH sections. That is the only boiler in operation worldwide reach-ing that temperature. In the Dangjin 3 CCPP, the live steam temperature reaches 585C with 150 bar in the SH and RH sections.

Dangjin 3 is equipped with an integrated SPPA-T3000 control system that monitors the powertrain with a con-tinuous flow of information to the plants control room.

The plant features more than 3% natural gas savings per kWh compared to Dangjin 2, a savings of up to 20 000 m3/yr of natural gas in base-load, Hagedorn said. Siemens has also been committed to the health and safety aspect during project execution. The lost time accident frequency rate (LTIFR) at Dangjin 3 registered a mere factor of 0.07 in approximately 1470 million man hours.

Siemens and GS E&C involved many local companies as suppliers for components, equipment and services, which the company said makes the plant a real Korean product.

South Korea has become a key market for Siemens En-ergy. The company said it has 4 GW of projects valued at over 4 billion lined up for the next two years, including four combined-cycle power plants with H-class technology scheduled for commissioning between 2014 and 2015. A total of seven high-efficiency SGT6-8000H gas turbines are being installed.

This market growth is emphasized by the foundation of a new regional headquarters in Seoul for the companys Ener-gy Solutions Business. The new entity, Siemens Energy Solu-tions Ltd., will be responsible for the Energy Solutions Busi-ness in Asia-Pacific and the Middle East and will be headed by Rochus Bergmann, who has been with Siemens over 20 years. The Seoul facility is expected to employ up to 500 people by the end of the first investment phase in 2017. A

The Dangjin 3 power plant (formerly Bugok 3) in

South Korea is equipped with a Siemens SGT6-

8000H gas turbine reaching a gross efficiency of

nearly 61%. The adjacent Bugok 1 and 2 plants

are in the background.

WW786.indd 2 2/14/14 8:29 AM

Cummins Turbo Technologies has unveiled a new addition to its range of large turbochargers for 16 L-plus engines, the Series 900.

Full-scale production of the single- or two-stage turbocharger will begin in 2015 at the companys factory in Charleston, South Carolina, U.S.A. The company said the Series 900 has a string of technical advances and can improve overall turbocharger ef-ficiency for a typical application by up to 10%. The large turbochargers provide robust flexible solutions for


Industry news by ian cameron

Cummins Boosts Turbo RangeCompany to offer improved turbocharger efficiency; continued testing, development on waste heat turbine expander prototype

The Cummins Series 900 turbocharger is designed for a variety of industries including power generation, rail, marine and off-highway.

a variety of industries such as power generation, rail, marine and off-high-way, Cummins said.

The new Series 900 is a signifi-cant addition to our 800 and 1000 models and represents a big step up in efficiency, performance and reliability, said Mark Firth, execu-tive director for product line man-agement and marketing, Cummins Turbo Technologies.

Cummins range of large turbo-chargers Series 800, 900 and 1000 are suitable for a wide variety of 16

to 120 L high-speed engines running at 1000 to 2000 r/min, and for power outputs up to 5 MW.

Technical advances include a high- efficiency turbine design, which im-proves fuel economy, and lead-free and special corrosion-resistant bearing systems that can help the turbocharger combat damage when it is used with aggressive fuels such as landfill gas. The shift in focus to prioritize fuel economy highlights Cummins Turbo Technologies belief that global engine and equipment manufacturers are de-

WW771.indd 1 2/14/14 8:30 AM

Industry news

veloping products designed to insulate customers from ris-ing fuel prices.

Other advances include an inverse impeller design in which the designer specifies the desired flow conditions and computer software develops the blade shape using an optimized process. Aluminum or titanium wheels are available for fatigue resistance for operating/ambient con-ditions needing high compressor-discharge temperatures, the company said.

Vaned and vaneless compressor stages, which enable the tailoring of performance for different applications and allow optimization of efficiency for either single- or two-stage operation, are available.

Cummins said the risk of oil leaks is reduced because of improved sealing, and a modular design provides common engine connection points for all performance variants within the Series 900 frame size. Both hose bead and bolted flange compressor housing outlet designs are being developed to meet different customer needs, the company said.

V-band connections allow a high degree of housing ori-entation flexibility and ease of service in the field. There is also a water-cooled bearing housing, which provides a lon-ger life for the bearing system, and an integral speed sensor providing extra engine protection and diagnostic control schemes, Cummins said.

Testing and development work is also continuing on the

prototype of the companys waste heat turbine expander (WHTE) prototype, which captures in the form of heat what would otherwise be lost ener-gy from a number of sources onboard the vehicle and turns it into extra me-chanical (25 kW) or electrical (5 kWe) power capable of reducing vehicle fuel consumption. The company also an-nounced that work is progressing well on its waste heat recovery turbine ex-pander that could provide 6% annual fuel savings worth around US$4000 for heavy-duty trucks.

Test work on the expander is on-going at the companys purpose-built laboratories in Huddersfield, England, with the product expected to be com-mercially available from 2018.

Cummins Turbo Technologies is part of the Cummins Components Group, with technical centers in Huddersfield (the companys European Technical Centre); Columbus, Indiana, U.S.A.; Pune, India; and Wuxi, China. A

E960

DamaliniEasyLaser_Mar14_WW.indd 1 2/10/14 10:56 AM


Cummins is developing and testing the prototype for its waste heat

turbine expander (WHTE), which will turn lost energy into mechanical

or electrical power.

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ZF Marine has introduced a number of hybrid-ready transmissions to ad-dress the needs of hybrid propulsion solutions in the market of fast crafts typically large motor yachts. This is especially true for hybrid gearboxes se-lected for the high demands on reduc-tion of noise vibration, similar to what happens with commercial applications.

The latest addition to the product portfolio is in the ZF 5000 transmis-sion family, the ZF 5300 PTI model. Already available in the hybrid-ready version are the ZF transmissions in the 9000 family, with other families to follow soon, the company said.

Andr Krner, head of product line commercial and fast craft at ZF Marine in Friedrichshafen, Germany, said that the new hybrid solutions could be in-stalled in most marine applications.

ZF Marine said it has already regis-tered interest for its 5300 PTI hybrid-ready transmission, which has been chosen and installed in some vessels by the Italian coast guard. We also have some contracts for yacht appli-cations that have not yet been com-missioned, Krner said.

The advantages of hybrid-ready transmissions are that the vessel can be operated in electric mode at low speed, which has obvious benefits in fuel efficiency and exhaust emis-sions, Krner said. With the diesel engine kicking in only for full pow-er, there is also the advantage of less maintenance for the diesel unit.

The ZF 5300 PTI model is used with engines with power output up to 1700 kW and a maximum of 2600 r/min. The unit has a gear ratio of up to 5.5:1 and is available with an array of different configurations for ex-ample, nonreversible (NR) versions. Krner pointed out that the transmis-sion is a full modular concept that al-lows a great degree of design freedom.

The hybrid-ready solution can be retrofitted to ZF transmissions, even to units already in operation, Krner said. This is a fairly simple operation and usually takes approx-imately two days.

According to Krner, the big-gest demand for hybrid-ready solu-tions today comes from the market of large yachts and coast guard ves-sels. Although Krner said he pre-dicts hybrid solutions will probably never be a mass market, he expects the demand to increase for megay-achts, commercial vessels and some offshore patrol-type of crafts. From a geographical point of view, the de-mand now comes mostly from Eu-rope, Krner said. The North Amer-ican market does not seem to be very interested yet.

ZF Marine said it expects to in-crease the number of transmissions fitted for the hybrid-ready add-on. By the end of 2014, we plan to ex-tend our offering in the higher power range, providing solutions to cover from 800 to 2000 kW engine power output, Krner said. A

They are ideal for crafts that spend a lot of time idling or at low speeds with occasional bursts of high speed, including yachts, ferries and offshore patrol vessels, Korner said.

Hybrid-ready transmissions essen-tially consist of an auxiliary power take-in (PTI), where a second power input can be connected (in this case, an electric motor).

The transmission can work with the input from the diesel engine or from the electric motor, Krner said. Both power inputs can also be select-ed together for a boost mode.

Krner explained that the power input selection is done manually from the deck, but it would be easy to inte-grate the selection function in an au-tomatic electronic control should the demand ever arise.


Marine ProPulsion by roberta prandi

Ready For HybridZF Marine added to hybrid-ready transmission portfolio

The new ZF 5300 PTI transmission is a hybrid-ready unit featuring an auxiliary power take-in

for the electric motor.

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Caterpillar is providing 12 of its G20CM34 generator sets for Mid-Kansas Electric Co.s newly con-structed power plant, Rubart Station. When fully operational in mid-2014, the facility will have the capacity to produce 110 MW of nominal power to 200 000 customers in central and western Kansas, U.S.A.

Mid-Kansas said the stations con-struction has moved at a swift pace the company broke ground in March 2013 and was to have all the engines in place by January. Derek Seacat, Mid-Kansas project manager for Rubart Station, said that the utility has the ability if needed to mir-ror its current facility and add anoth-er 12 G20CM34 gen-sets to the west, bringing the total engine count to 24.

At the heart of the project are Cat-erpillars 20-cylinder, four-stroke turbocharged G20CM34 natural gas reciprocating engines, which feature a bore and stroke of 340 x

makes this so exciting for us is that we have a customer located in the middle of a wind corridor where this technol-ogy can demonstrate how flexible and efficient it really is.

After a long-term analysis study, Mid-Kansas determined that con-struction of Rubart Station was warranted due to a shortfall of ca-pacity resources.

We knew that there was a deficit coming at us well before we really needed to formally launch anything, said Kyle Nelson, Mid-Kansas senior vice president and chief operating of-ficer. As it got closer, we understood that we needed to reach out to our technical partners at Burns & Mc-Donnell to select the proper technol-ogy as well as the site.

The timing worked to everyones advantage, Powell said. We became aware of Mid-Kansas preference for gen-sets in the 10 MW range and they embraced our technology and

The Cat G20CM34 gen-set

features a natural gas re-

ciprocating engine capable

of producing 500 kW for

each of its 20 cylinders.

420 mm, and a 38.1 L per cylinder displacement.

The gen-set has a 500 kW per cylin-der output, a mean piston speed of 10.1 m/s and a mean effective pressure of 21.9 bar. For ratings, the engine can be manufactured with 16 or 20 cylinders, and produce between 8 and 10 MW of mechanical power at 720 r/min. The G20CM34 has a rating between 7800 to 9750 kW, the company said, and measures 2.9 m wide, 13 m long and 3.3 m high, and weighs 130 000 kg.

The G20CM34 engine drives a Leroy-Somer generator. The pack-age also includes a GEA radiator, an Eaton MV switchgear, Cat electronic controls, an H+H Umwelt- und In-dustrietechnik GmbH SCR system and a Cat-designed Rotas base frame.

This is Caterpillars newest engine platform, said Dean Powell, direc-tor of global sales and marketing for Caterpillar power plants. Its also our largest natural gas engine. What


Power Generation by dj slater

Power On DemandCat natural gas reciprocating engines provide flexibility to Kansas power plant

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the need for our medium-speed, natural gas reciprocating internal combustion engines.

Nelson said that internal combustion engines could peak well while maintaining high efficiencies when power is needed to supplement unpredictable renewable power such as wind. While both gas turbines and reciprocating engines can create power by burning natural gas, reciprocating en-gines operate more efficiently at any load, Nelson said.

We favor recip engines because of their flexible nature. Turbines have an efficiency curve that tends to be relatively low when the unit is at low load, and then that curve climbs fairly steeply. Reciprocating engines have an efficiency curve thats shaped very much like the torque curve on a diesel engine, so it has a steep line that climbs very quickly from essentially no load up to its maximum efficiency, and it stays very flat over its entire load range, Nelson said.

An advantage of a recip engine configuration is that the power is produced by multiple engines. Instead of one 100 MW gas turbine, were getting up to 110 MW with 12 units. We operate only the engines we need, and those that are on can be operated at low loads without compromising efficiency.

Powell added that reciprocating engines dont de-rate like turbines do at high temperatures and elevations. Re-ciprocating engines also use closed-circuit cooling, thus eliminating the water consumption common with turbines.

Before passing through Rubart Stations 32.6 m exhaust stacks, NOx, CO and air pollutants will be controlled us-ing selective catalytic reduction (SCR) as well as oxidation catalysts, Mid-Kansas said. Sulfur dioxide (SO2) and par-ticulate emissions (PE) wont be an issue due to the qual-ity of the natural gas from the pipeline, the company said. Additionally, the facilitys noise emissions comply with the U.S. EPA guidelines.

As crew members work to meet the June 2014 commis-sioning deadline, Powell reflected on the potential for a new trend in power generation.

The benefits of reciprocating engines are encouraging companies to embrace this technology, Powell said. In the past five years or so, weve seen more and more of these in-stallations being added to the system. A

Power Generation

The 12 Cat G20CM34 gen-sets ordered by Mid-Kansas were manu-

factured in Rostock, Germany, and sent to Rubart Station via freight

and later rail.

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GEA_Westfalia_Mar14_WW.indd 1 2/12/14 9:43 AM

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Norwegian shipping company Buk-sr og Berging said its escort tug M/T Borgy is the worlds first tug to be fu-eled by liquid natural gas (LNG). The tug was designed by the companys in-house team, assisted by Marine Design AS in Norway, and will be operated by Gassco for Statoil at the Krst terminal.

It is the first of two tugs developed by Sanmars shipyard in Istanbul for the Norwegian shipping company the M/T Borgy completed its sea tri-als successfully and began its maiden voyage in January; and the second Buksr og Berging tug is planned to sail in mid-April.

The gas engines, propulsion package and LNG system have been delivered by Rolls-Royce. Two Rolls-Royce Ber-gen C26:33L6PG main engines each supply 1705 kW of power at 1000 r/min. Rolls-Royce said this engine

ter (PM) emissions down to almost zero, the company said. The dis-charge of CO2 and NOx is reduced by 26% and 80 to 90%, respectively. The new hull and propulsion system of the tug will achieve up to 20% higher thrust efficiency compared to standard designs, Rolls-Royce said. The vessel offers a bollard pull of 68 tonnes with a maximum service speed of 13.5 knots.

Rolls-Royce said an increased avail-ability of LNG and growing public awareness of the gas fuel is driving its use for a variety of vessels, particu-larly gas driven tug boats.

Rolls-Royce has closed contracts with the Turkish Sanmar Shipyard for the supply of azimuth thrusters for another 12 new tug boats for various shipping companies. To date, the Sanmar Ship-yard has built 50 tugs equipped with Rolls-Royce thrusters. A

type is the only engine in the market built for operation on 100% gas fuel only. The engines are equipped with exhaust silencers with spark arrestors, and cooling is achieved by plate-type heat exchangers.

Rolls-Royce also provided two US35 CP azimuth thrusters with four-blade controllable pitch propellers, each with a diameter of 3000 mm and made from cunial, a high-strength, corro-sion-resistant alloy of copper, nickel and aluminium. The bow thrusters are Schottel SPJ 82 all-direction thrusters capable of providing 333 kW.

Additionally, two diesel fuel gen-eration sets per vessel have been de-livered by the Danish company Nor-dhavn. The engines are Scania Desel GASI 12-07-10-60G engines, each producing 240 kW at 400 V, 50 Hz.

The use of LNG eliminates sulfur emissions, bringing particulate mat-


Marine ProPulsion by bo svensson

LNG-Powered Escort TugsNorway continues to be playground for gas-fueled offshore support vessel; sister vessel to begin service in spring

The Norwegian escort tug M/T Borgy is powered by two Rolls-Royce

Bergen C26:33L6PG engines operating on gas fuel only.

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Super-, ultrafine powderSSolvay Specialty Polymers has intro

duced its new superfine powder (SFP) and ultrafine powder (UFP) grades of Keta Spire polyetheretherketone (PEEK) for waterborne coatings, powder coatings and resin preimpregnation of continuous fiber composites.

These new KetaSpire PEEK powders provide strength, durability and chemical resistance for applications including chemical processing, oil and gas, semiconductor, transportation and other industrial uses, the company said.

Solvays superfine PEEK powder offering includes KetaSpire KT880 SFP, a highflow grade, and KetaSpire KT820 SFP, a lowflow version. The ultrafine PEEK powder line includes KetaSpire KT880 UFP, a highflow grade, and KetaSpire KT820 UFP, a lowflow material. All four grades are unreinforced and supplied in a natural color.

www.solvay.com

GaS detector

The TS4000H intelligent toxic gas detector from General Monitors is IECEx approved, meaning that it is in compliance with international safety standards for explosive environments. The TS4000H offers protection against a wide range of hazardous industrial gases and is able to safeguard against oxygen deficiency, the company said.

The TS4000H offers many features including event logging, a visible LED and an indicator for remaining sensor life, according to General Monitors.

The TS4000H is compatible with the HART communications protocol for uniform and consistent communication without disturbing the integrity of the 4 to 20 mA analog signal, and is also available in a Modbus configuration and with three 8 A relays. All of the electronics are contained within an explosionproof housing so that sensor information can be processed at the sensor site.

www.generalmonitors.com

GauGe probeSAlliance Sensors Group, a division of

HG Schaevitz LLC, has released a line of springextend ACLVDTbased dimensional gauging probes (pencil probes) for QC metrology, XY tables and test stands. These dimensional gauging probes are regularly used with Gage R&R and CpK data collection to insure quality and for use with sixsigma QA programs, the company said.

With three ranges available, the DGP

LVDT probes are manufactured with precision ground bearings and come standard with an 8 mm diameter plain outer body with an optional sleeve available to increase the OD to 9.5 mm either plain or partly threaded. The 2m long axial shielded cable is strain relieved and can be quickly converted to a radial cable outlet with a right angle cable adapter that is included with a probe.

www.alliancesensors.com


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continued on page 39

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Superbolt_Mar14_WW.indd 1 2/13/14 12:58 PMFeaturedProducts.indd 1 2/14/14 8:37 AM

Wrtsil has successfully conducted full-scale testing of gas on its low-speed, two-stroke, dual-fuel engine and is introducing a full range of engines based on its established low-pressure technology.

The company said the first en-gine utilizing this technology would be available for delivery in the third quarter of 2014. Other engines from the companys Generation X series will follow and will be available for delivery during 2015 and 2016.

The RT-flex50DF engine operates according to the Otto process and in a premixed, lean-burn mode. The low-pressure gas is admitted at mid-stroke of the cylinder and ignited by a pilot fuel burner in a prechamber. There is also an option to use heavy fuel oil (HFO) for pilot fuel.

two-stroke engines will be available as low pressure dual-fuel (DF) ver-sions. The benefits of this technology are significant, said Ingemar Nylund, technology director, Wrtsil. Com-pared to other technologies, studies show that Wrtsils low pressure DF engines offer capital expenditure (CAPEX) reductions of 15 to 20%.

This is achieved through a sub-stantially simpler and lower-cost LNG and gas handling system op-erating at low pressures, and by the fact that no exhaust gas cleaning systems are needed to meet future emissions regulations.

On the operating expenditure (OPEX) side, the company said sig-nificant gains will be achieved with its technology there is no need to operate a high-pressure gas compres-sion system external to the engine on-board the vessel and NOx abatement systems are not required.

Wrtsil also said that the maxi-mum rating of an Otto engine is lower than for a diesel technology engine due to limitations caused by knocking/preignition. This limitation would in some cases require an ad-ditional cylinder for an Otto engine in order to reach a specified output.

The new engines are IMO Tier 3 emissions-compliant in gas mode, and the minimum Tier 2 level is achieved with liquid fuel. The com-pany said that due to the low pressure DF technology, NOx levels are below IMO Tier 3 without any exhaust gas aftertreatment. CO2, SOx and particu-lates emissions are also reduced while operating on a gas fuel.

The methane slip is higher for an Otto engine than for a diesel tech-nology engine, and Wrtsil said that direct methane slip could be avoided by correct gas admission valve tim-ing and by a complete combustion

An electronically controlled fuel injection system is fed from a com-mon rail gas fuel system, with two gas admission valves serving each cyl-inder. These valves are hydraulically actuated and powered by the oil servo system of the exhaust valves.

The engine has a cylinder bore of 500 mm with a stroke of 2050 mm. The speed of the engine will be in the 99 to 124 r/min range and the mean effective pressure is 17.3 bar. The en-gine will be offered in five- to eight-cylinder versions.

The engine control and automation system is based on the Wrtsil UNIC system, while control of combustion related parameters is individual for each cylinder in order to provide an optimized engine performance.

The entire portfolio of Wrtsil


Marine ProPulsion by bo svensson

Wrtsil has successfully conducted full scale testing of its low-speed two-stroke, dual-fuel

engine, establishing its basic performance and technological advantages.

Wrtsil Targets Future FuelBy 2020, company envisages more than 25% of ordered vessels could be designed to run on gas fuel

WW768_1.5pg.indd 1 2/14/14 8:39 AM

process resulting from the precham-ber technology. An optimized com-bustion volume is important to avoid dead volumes.

Our technology allows stable op-eration on gas across the entire load range, meaning that at low loads, there is no need to switch to diesel fuel as is

the case with other technologies, Nyl-und said. Moreover, the consumption of pilot fuel is approximately just 1% of the total fuel amount, much lower than with other technologies.

The DF engine provides for a grad-ual, speed-controlled transfer from liquid to gas fuel within a load range of 5 to 85%. The switch from gas to liquid fuel is instant on any load up to 100%, while engine speed and load remain stable during a transfer, the company said.

The engine is started on liquid fuel and transferred to gas fuel when idling and at low load. During a voyage, the engine continues to operate on gas fuel, including manoeuvring and slow speed operation. Transferring to liquid is always done before stops.

The benefits of the d

Documents

Diesel y Gas Turbyne Marzo 2014