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Energy in all we do
watt yOU NEED
wattyOU NEED
Index
SolutIonS to Watt You need Solutions from 1 to 50 MW
Benefits ofCogeneration
Watt Solutionswe Offer to Industries
Product Selection
Watt else: Options
Watts Insideour Package
Complete PowerPlants
Watt’S InSIde: ProductS12
Turbomach’s ServiceSupport
MaintenanceTechnology
Long Term ServiceAgreements
Global ServiceNetwork
Watt’S SuPPortIng You: ServIceS18
4
Our Company
Quality andCertifications
Facilities Worldwide
Contacts
21
Watt about uS24
Cogeneration is More Efficient
Gas Turbines Provide Cleaner Power
Watt about SuStaInabIlItY10
4
SolutIonS to Watt You need
energy in all we do
5
InduStrY SolutIonS
SolutIonS FroM 1 MW to 50 MW
You need energy to power your business. With our compre-hensive product range we can provide you with a complete solution, from 1 MW gas turbine packages to complete 50 MW power plants.
Working together with our customers we develop optimal solu-tions to meet their specific needs. We offer the most extensive line of industrial gas turbine models and we can supply any additional equipment required to construct a complete power plant.
Operating your own power plant gives your businness an im-portant competitive edge by:• lowering your total energy cost• giving you a reliable power source • protecting our environment through lower emissions.
Watt SolutIonS We oFFer to InduStrIeS
Whatever your application, Turbomach can help you meet the need for electrical and thermal energy based upon our expe-rience, engineering competence and extensive range of gas turbine products for:• steam or hot water production-for providing power and heat• tri-generation-for providing power, cooling and heat• drying with direct use of exhaust gases• chilled water generation – for air conditioning• combined cycle-for high efficiency electric power generation • peaking power-for rapid dispatch
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dIagraM 1 - SteaM and Hot Water generatIonThe exhaust heat of the gas turbine can be used to generate steam or hot water, for instance in the following industrial applications:• Pulp and Paper, Food, Chemical or Pharmaceutical Industry• District Heating
dIagraM 2 - tHerMal oIl and SteaM generatIonThe exhaust heat of the gas turbine can be used to generate steam or thermal oil, for instance in the following industrial applications:• Chemical or Pharmaceutical Industry• Textile Industry
1 PoWer, SteaM and Hot Water generatIon
2 PoWer generatIon, tHerMal oIl and SteaM generatIon
HOT WATER
FEED WATER
STEAM
FEED WATER
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dIagraM 3 - dIStrIct coolIngThe exhaust heat of the gas turbine can also be used to power chillers for cooling, which is needed for the following applications:• Air conditioning for Communications and Building Complexes• Turbine air inlet chilling, to improve performance at high ambient temperatures
dIagraM 4 and 5 - drYIng aPPlIcatIonSDirect drying applications use the exhaust gas heat of the gas tur-bine to directly dry products in these applications:• Ceramic Industry • Tissue Mill
5 PoWer generatIon and tISSue drYIng
4 PoWer generatIon and ceraMIc PoWder drYIng
3 PoWer generatIon and dIStrIct coolIng
DRY PRODUCT
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6 PoWer generatIon and drYIng oF bIo-MaSS
7 PoWer generatIon
DIAGRAM 6 – DRYING OF BIO-MASSThe exhaust gas heat of the gas turbine can be used to directly dry bio-mass.
DIAGRAM 7 – POWER GENERATIONPower generation applications combine the gas turbine with a steam turbine cycle to convert all thermal energy into electric power, or to extract a variable part of it for thermal use, for in-stance in district heating applications.This concept can be combined with bio-gas applications, using bio-gas as a fuel.
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Watt MoneY IS In It: beneFItS oF cogeneratIon
Cogeneration systems, also called combined heat and power systems, generate both heat and electrical power. The gas tur-bine drives an electrical generator to provide electrical power, and the exhaust heat of the gas turbine is further utilised to reach total plant efficiencies of up to 90%. Thus cogeneration is an efficient form of energy conversion, achieving primary energy savings of over 40% compared to separate power and heat generation. This form of energy generation directly bene-fits the environment, by burning less fuel while getting the same amount of usable energy.
Along with benefiting the environment, cogeneration can have a big benefit for your business by lowering your energy costs and providing reliable power.
ELECTRICPOWER10 MW
THERMALENERGY14.3 MW
Electricity
SteamSteam
Oil Fired BoilerEfficiency 85%
Coal Fired Central Power PlantEfficiency 40%COAL
25 MJ/s
NATURAL GAS28.6 MJ/s
OIL16.8 MJ/s
Cogeneration PlantEfficiency 85%
LOSSES 15 MWCO2 85’000 t’year
LOSSES 2.5 MWCO2 36’000 t’year
LOSSES4.3 MW
CO245’000 t’year
Electricityfrom Grid
COMPARING COGENERATION TO SEPARATE GENERATION OF ELECTRICITY AND HEAT
32% ENERGY SAVING76’000 TONS CO2 SAVINGS PER YEAR
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Watt about SuStaInabIlItY
energy in all we do
11
cogeneratIonIS More eFFIcIent
Cogeneration systems – also called combined heat and power systems – generate both, heat and electrical power. While the gas turbine drives an electrical generator to provide electrical power, the exhaust heat of the gas turbine is further utilised to reach total plant efficiencies of up to 90%. This efficient form of energy conversion achieves primary energy savings of over 40% by using a cogeneration system instead of separate power and heat generation.
Turbomach’s comprehensive product line, along with innovative engineering expertise, provides an optimised solution for your specific energy needs. The more closely your plant meets your energy requirements, the higher the overall efficiency. Better ef-ficiency means less fuel burned per megawatt-hour generated and less CO2 emissions.
by providing energy with a cogeneration plant, you can sub-stantially improve the total energy efficiency, and reduce dras-tically the co2 emissions of your operations.
gaS turbIneS ProvIde cleaner PoWer
Generating power with our highly flexible gas turbines contri-butes to sustainable development. this enables you to meet your growing needs for greater power, efficiency and avail-ability while helping to protect our environment. clean coMbuStIonSolar gas turbines equipped with SoLoNOx dry lean-premixed combustion systems achieve very low emissions of NOx and CO pollutants throughout a wide operating range. This advanced combustion technology, well proven with over 1’800 installed units, is available as an option for most of our gas turbine models.
clean FuelSnatural gasBurning natural gas reduces CO2 emissions by more than 30% compared to oil, and 50% compared to coal.
alternative FuelsBurning biogas or harmful waste gases, such as landfill gas, coke oven gas or coal-mine gas, advanced gas turbine technology ena-bles sustainable production by converting them into useful energy.
NOx EMISSIONSNORMALISED
TO SAME %-O2
StandardCombustion
Gas Turbinewith SoLoNOx
CO2 EMISSIONS PER UNITHEATING VALUE (LVH)
Coal Oil Natural Gas
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Watt’S InSIde: ProductS
energy in all we do
13
Watt do I cHooSe: Product SelectIon
tHe World’S leadIng InduStrIal gaS turbIne
Turbomach is a fully integrated part of Solar Turbines, a leading manufacturer of mid-range industrial gas turbines. With over 60 years of experience over 13’000 turbines are installed with a total operating experience of over 1.4 billion hours.
These gas turbine units are operating in over 95 countries and under varying conditions, including arctic, desert and tropical environments. Even under the harshest conditions, Solar gas turbines continue to provide safe and reliable power.
InduStrIal gaS turbIneS FroM 1 MW to 22 MW
With the most complete product range of the industry, we can provide you with a solution that fits any power need you have.
Pow
er o
utpu
t ISO
[MW
]
STEAM PRODUCTION AND POWER RANGE
00
2
4
6
12
8
10
14
18
16
20
22
5 10 15 20 25 30
TITAN 250
TITAN 130
MARS 100
SATURN 20
CENTAUR 40CENTAUR 50
TAURUS 60TAURUS 65
TAURUS 70
MARS 90
MERCURY 50
Steam Production @ 10 bar(a) saturated [t/h]
With supplementary firing, steam production to over 100 t/h is possible.
14
7 . aIr FIlter SYSteM For generator coolIng and ventIlatIon aIr
8 . gaS turbIne Solar industrial gas turbines combine ease of maintenance with highest reliabil-ity, durability and efficiency. This guaran-tees you the best payback throughout the lifetime of the plant.
9 . reductIon gear Matches gas turbine rotational speed to speed of generator rotor.
10 . generator Transforms mechanical energy into electrical power.
11 . SubSYSteMSAir, Fuel, Oil and Start Subsystems are fully integrated and tested before ship-ment. This safes time and cost on site.
12 . StartIng SYSteM
13 . Fuel SYSteM
14 . lube-oIl SYSteMwith integrated lube-oil cooler
15 . connectIonSThe simple interfaces guarantee an easy and fast installation and integration. This saves time and cost on site.
16 . InterFace connectIonS• fuel• instrument air• 400V auxiliary power• medium voltage power• connection to compressor washing system
Watt’S InSIde our PacKage
Turbomach gas turbine packages offer unmatched advantages: easy installation and integration, maximum reliability, and maintenance convenience. Each package is functionally complete with all main and auxiliary systems fully assembled. The whole package is tested in our factory to guarantee outstanding quality, saving you time and money.
All components of the package are proven and standardised to guarantee the highest possible availability.
1 . encloSure The enclosure protects the package from weather, and reduces operational noise, allowing an outdoor installation. This eliminates the need for a building and saves investment cost. Modular panels allow the entire enclosure to be disas-sembled in sections.
2 . encloSure doorSDoors allow full access to every side of the package making inspection and maintenance operations fast, safe and easy.
3 . baSe FraMe The base frame integrates all subsys-tem components with gas turbine and generator and allows an easy and fast single-lift installation or relocation
4 . SPrIng daMPerS The spring dampers absorb operational vibrations and minimise the require-ments for the foundation, allowing an installation practically anywhere.
5 . MaIntenance ProvISIonSThe package is designed for ease of maintenance, with built-in maintenance devices. Provisions to remove the genera-tor and gas turbine are integrated in the package design. This safes time and cost during maintenance.
6 . FIlter Structure For coMbuStIon aIrCan be configured to local conditions and allows for installation of inlet air cooling.
control SYSteMThe advanced control system can ope-rate the package completely automati-cally, and allows easy communication with other systems. This provides equip-ment safety, operator convenience and low operating cost.
control rooM The control and electrical systems are housed in a tightly sealed and air-condi-tioned control room, which is integrated on the package. This eliminates the need for a separate control room and associated construction costs.
2
7
15
cablIng The interconnecting cabling is installed and tested before shipment. This guaran-tees highest quality and reliability.
auxIlIarY PoWer SWItcHgear
batterY SYSteM
HuMan MacHIne InterFace (HMI)The user-friendly interface can be oper-ated locally or via the remote operator station. This guarantees an optimum operation of your equipment.
910 8
12
13
11
15
3
4
5
1
6
16
14
oPtIonS avaIlablesome of the available options are:• alternative fuel capability (gas, liquid, low BTU)• water injection or SoLoNOx combustion system for lowest emissions is available for most turbines• packaging designed for a wide variety of environmental conditions • combustion air inlet chilling• generator voltages of 6.3 or 11 kV
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Watt elSe: oPtIonS
coMbuStIon tecHnologY Solonox tecHnologYSoLoNOx combustion technology is available as an option on most Solar turbines. SoLoNOx was introduced in 1992 as a low emissions combustion system. Gas turbines with SoLoNOx use dry lean-premixed combustion technology to ensure uniform air/fuel mixture for a clean combustion.
Unrivaled Experience: Customers worldwide have ordered and installed over 1700 gas turbines equipped with SoLoNOx for a number of reasons: SoLoNOx technology has more than 35’000’000 operating hours and has saved over 1’200’000 tons of NOx emissions since introduction.Fuel options: Both natural gas and liquid fuel (diesel #2/distil-late or LPG) options are available.low emissions: Solar gas turbines with SoLoNOx are designed to meet most exhaust emission regulations throughout the world and cover a wide operating range of load and ambient temperatures.cost effectiveness: Dry, lean-premixed combustion technol-ogy means gas turbines with SoLoNOx generally do not require downstream cleaning devices to meet emission requirements.High Performance: Gas turbines equipped with SoLoNOx pro-vide the same power and heat rate as equivalent engine mod-els with conventional combustion technology.
AIR FLOW
AIR FLOW
FUEL
FUEL
3600 °F
2900 °F
SAME TURBINEINLET TEMP
70%
50%
30%
CONVENTIONAL
COMBUSTION
LEAN-PREMIXED
17
coMPlete PoWer PlantS You need energy to power your business. We provide you with complete and customised solutions.
In addition to our wide selection of gas turbines, we can also supply all equipment required for complete cogeneration systems and power plants, up to 50 MW.
Working closely with our customers, we engineer the optimum concept and scope for an energy solution, taking full respon-sibility for what we provide. Working closely with strategic partners, our project team closely controls the manufacturing, supply and construction of the power plant.
Leveraging our experience and engineering competence, we provide complete solutions that you can trust in: during planning, construction and throughout the entire lifecycle of your plant.
Fuel FlexIbIlItYOur gas turbines can burn a wide range of fuel types to convert them into energy. Turbomach adapts the gas turbine’s fuel system according to the specific gas composition, and can also provide filters for the right upstream treatment of the fuel, if needed.
Coal and Coke Oven Gas
Btu/scf
(MJ/Nm3)
0
0 20 40 60 80 100
500 1000 1500 2000 2500
WOBBE INDEX, WI = LHVSG
Associated Gas
Conventional SoLoNOx Combustion Technology
Pipeline and LNG LPG
Natural Gas LiquidsRaw Natural Gas
Landfill and Digester Refinery
GasifiedBiomass
and Waste
gaSeouS Fuel range
18
Watt’S SuPPortIng You: ServIceS
energy in all we do
19
MaIntenance tecHnologY
turboMacH’S ServIce SuPPort
Around-the-clock, anywhere in the world, highly trained tech-nicians provide assistance from the service location closest to you. This keeps your equipment running with maximum uptime.
global coverage
With our advanced maintenance technology and world-class processes, we go beyond just keeping your turbine running smoothly. We optimise its lifetime value, to help you get the most from it.
Turbomach’s extensive and international maintenance network of Customer Service representatives are always close to you. We provide prompt and reliable services based on many years of experience servicing gas turbine power generation and co-generation installations. You want to maximise your investment throughout its entire lifecycle – we make it happen. We keep your turbine running, with customised support for the mainte-nance and operation of your equipment, based on advanced maintenance technology.
24h
on SIte WItH InSIgHt SYSteM InSight System is the most comprehensive approach to equipment health management ever developed. Utilising advanced technology the system provides status on turbomachinery equipment condition and enables web-based remote troubleshooting capability, deliver-ing high value Machinery Management Solutions.
Leveraging the experience accumulated over 1.4 billion oper-ating hours, InSight System enables a transition from reactive time-based maintenance programs to one that is pro-active and condition-based. Using web-based technologies problems are detected and corrected before they result in costly downtime.
InSight System monitors, gathers and analyzes information to help customers make decisions in their best economic interest, based on its capabilities for:
• Remote Monitoring and Diagnostics • Preventive Maintenance• Condition Assessments• Troubleshooting• Collaborative Communication• Information Management• Maintenance Management
InSight System, aimed at ensuring higher availability and reliability, is an important and unique feature of our extended warranty contracts.
20
Strategically located warehouses worldwide enable prompt de-livery of any part when required making certain your gas turbine operates with maximum up-time.
District project engineers plan scheduled maintenance ac-tivities with customers. Parts requirements are included in this planning to ensure that all components and parts arrive at the site on time.
When required Turbomach can also provide lease or exchange turbines in emergency situations.
eQuIPMent overHaul
gaS turbIneexcHange PrograM
Overhaul involves the inspection, testing and repair or replace-ment of gas turbine components.During a major overhaul the gas turbine is completely disassem-bled, inspected, reassembled and tested at full load, to ensure that original performance is restored . At the time of gas turbine overhaul, any package components that require attention can also be refurbished.
Each overhauled, zero-hour gas turbine, incorporates the latest in technology improvements to maximise safety and reliability.
Designed to maximise availability, our gas turbine exchange program delivers to you a completely overhauled gas turbine configured to your needs and guaranteed to meet our latest product specifications.
SuPPlY oF certIFIed ServIce PartS
21
Conducted by dedicated teams of specialists, our gas turbine field repair program provides on-site troubleshooting repair in less time and at less cost that returns your engine to service.
uPgradeS, retroFItS and Plant ModIFIcatIonS
Turbomach provides technological enhancements to improve the flexibility, performance and reliability of existing generator packages and associated plant equipment. Experienced teams of engineers work with customers to evaluate changing require-ments and help manage enhancement projects. These teams coordinate all aspects of the project from feasibility study, through design, engineering and installation, and handover of operations back to the customer.
Modifications or retrofits range from simple component modifi-cations to a complete upgrade of the gas turbine engine or en-tire plant and can include:• SoLoNOx combustion system upgrades for reducing emissions.• control system upgrades for improved operator convenience.• fuel system upgrades from single-fuel to dual-fuel or low-BTU fuel to increase fuel flexibility.• power turbine upgrades for improved performance.• turbine uprates• import/export power regulation
gaS turbIne FIeld rePaIr
22
long-terM ServIce agreeMentS
Turbomach provides you with fast, flexible and effective main-tenance service around the clock tailored to your needs. From on-call repairs to the most comprehensive long term service agreement, Turbomach is available 24 hours per day, 7 days per week to ensure safe, efficient and reliable operation of your gas turbine package.
The level and extent of these maintenance agreements can be individually tailored to meet your requirements. Contracts are generally grouped under the following contractual models:
PMc: Preventive Maintenance Contract buoa: Beneficial Use Overhaul AgreementeMc: Extended Maintenance ContractFMc: Full Maintenance Contract (or Long Term Service Agreement)o&M: Operation and Maintenance
operation or operation Supervision
Service parts
troubleshooting & repair on Package or Plant
turbine unscheduled overhaul and repair
turbine scheduled overhaul or Pro rata Warranty
annual boroscope Inspection of gt & rgb
annual maintenance on Package or Plant
PMc buoa eMc FMc o&M
23
Your lInK WItH uS: tHe Fleet Manager
For our customers with long term service agreements, the Fleet Manager is the primary service contact for customers techni-cal, commercial or logistical needs throughout the lifetime of the plant.
Working closely with customer representatives, fleet managers identify possible performance or equipment issues that can be solved with upgrades, retrofits or repairs.
They also manage and coordinate all aspects of logistics, plan-ning, including overhauls, maintenance and all individual trans-actions that affect equipment availability.
24h
Customer
Turbine Fleet
Service Engineer
Fleet Manager
Turbomach Team
global ServIce netWorK - cloSe to You
Wherever we deliver and install gas turbines packages, we have field service engineers located close by, that understand and can respond to local needs through:• a global service network operating in over 95 countries• product and operating knowledge gained from experience with more than 13’000 units worldwide• reliable worldwide field service support with around-the- clock response• Qualified factory repair and overhaul
FIeld ServIce Globally we have over 900 service engineers in the field, ready to support you when needed.
24
Watt about uS
energy in all we do
25
our coMPanY Turbomach is a fully integrated part of Solar Turbines, the lead-ing manufacturer of mid-range industrial gas turbines with over 60 years of experience. The Solar Turbines family has over 6000 employees worldwide, of which around 400 are located at Tur-bomach in Switzerland.
Turbomach is fully dedicated to its power generation markets, which are served through our people around the world.
We are part of Caterpillar Inc., the world’s leading manufac-turer of construction and mining equipment, diesel and natural gas reciprocating engines and industrial gas turbines.
Customers value Turbomach’s lean and flexible approach, and they have confidence in the association with the strength, re-sources, and competence of Solar Turbines and Caterpillar.
QualItY and certIFIcatIonS
The quality of our products and services is the foundation of our success. Our vast experience in the field combined with the competence of our people drives us to continuously improve the quality and reliability of our products and services.
InternatIonal StandardSTurbomach packages and power plants are constructed in ac-cordance with international or European standards applicable in the power generation industry. We are certified as per the following international standards:• ISO 9000 / ISO 9001: 2000 – Systems for the management of Quality• OHSAS 18001: 1999 – Occupational Health and Safety Assessment Series• GOST-RWe continuously improve the quality, velocity and efficiency of our processes using 6 Sigma methodology.
26
FacIlItIeS WorldWIde
Manufacturing, administrative and Engineering FacilityRepair and Overhaul Facilityspare-parts warehouseField Office
CONtaCts
Netherlands2171 AL SassenheimTel: +31 71 408 09 [email protected]
Pakistan54000 LahoreTel: +92 42 35 87 [email protected]
Russia114400 MoscowTel: +7 495 755 81 [email protected]
singaporeSingapore 627973Tel: +65 6828 [email protected]
spain08290 Cerdanyola - BarcelonaTel: +34 93 586 41 [email protected]
thailandBangkok 10250 Tel: +66 2 366 [email protected]
turkey34330 IstanbulTel: +90 212 284 [email protected]
United arab EmiratesDubaiP.O. BOX 17779Jazfa, United Arab EmiratesTel: +971 [email protected]
OR OUR NEaREst FIElD OFFICE.
BrazilSao PauloTel: +55 11 2109 2015 orTel: +34 93 586 41 [email protected]
ColombiaCartagena de IndiasTel: +57 5 664 72 16 orTel: +34 93 586 41 [email protected]
EgyptCairoTel: +20 10 00 36 76 [email protected]
France91280 St-Pierre-Du-PerrayTel: +33 1 6989 00 [email protected]
Germany64347 GriesheimTel: +49 6155 [email protected]
IndiaMumbai 400 076Tel: +91 22 4042 54 [email protected]
Italy43122 ParmaTel: +39 0521 275 [email protected]
FOR FURtHER INFORMa-tION, PlEasE vIsIt www.tURBOMaCH.COM OR CONtaCt Us at:
tURBOMaCHswitzerlandVia Campagna 15 6595 RiazzinoTel: +41 91 851 15 11Fax: +41 91 851 15 55 [email protected]
sOlaR tURBINEs UsaSolar Turbines IncorporatedSan Diego, CaliforniaTel: +1 (619) 544 [email protected]
watts INsIDE & watts aROUND
Energy in all we do
www.turbomach.com
©2012 Turbomach. All rights reserved. BWYNTBM/512
CAT and CATERPILLAR are trademarks of Caterpillar Inc. Solar, Insight System, Titan, Mars, Taurus, Centaur, Saturn, Mercury, SoLoNOx are trademarks of Solar Turbines Inc. Turbomach is the trademark of Turbomach S.A.
