September – October 2013www.gasturbineworld.com 300MW in 10 minutes with under 2ppm NOx page 12 Old Fr 9s given new life and better performance page 18 Marine gas turbine rated 5MW at 34.5% efficiency page 22 September – October 2013 Gas Turbine World • Vol. 43 No. 5 Editor-in-Chief Robert Farmer Managing Editor Bruno deBiasi European Editor Junior Isles Engineering Editor Harry Jaeger Field Editor Michael Asquino News Editor Margaret Cornett Fast response flexibility Combined cycle plant combines fast startup response for peaking with high efficiency operation for base load generation, page 12 Marketing Director James Janson Publisher Victor deBiasi On the Cover. Siemens 550MW El Segundo fast start 5000F combined cycle power plant Subscriptions Peggy Walker Facsimile (203) 254-3431 Email:
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[email protected] 2 Project development and company news $1.6 billion UK order for 8000H plants, $84 million 700MW Woodbridge Energy Center, 1,260MW NGCC Siberia project 12 El Segundo 550MW rapid response plant From 0 to 300MW in 10 minutes and full 550MW combined cycle power output in less than 1 hour with 2 ppm limit on NOx 18 Technology transplants for old 9F units Surpassing OEM design ratings to increase output by up to 8% efficiency by up to 2% and TBO intervals by up to 8,000 hours 22 High power density MT7 marine engine Compact marine gas turbine engine rated at 5MW shaft output and 34.5% efficiency designed to weigh less than 1,000 pounds 26 Dubal upgrading 2,350MW powerplant Aluminum producer is upgrading output, efficiency and durability of mixed gas turbine fleet to up productivity and cut costs 30 IGCC power and gasification technology © 2013 Pequot Publishing, Inc. All rights reserved. Reproduction without written permission strictly prohibited. Postmaster, please send Form 3579 to PO Box 447, Southport, CT 06890 Technology transplants New technology hardware and controls software can improve original OEM design rated output, efficiency and durability, page 18 China $4.2 billion coal-to-gas project, syngas production in Mongolia, Tepco and Mitsubishi planning to build 4,500MW of coal-based IGCC capacity More payload and range Smaller turboshaft engines with 25% more power will increase the payload capacity and double the range of new hovercraft in development, page 22 Gas Turbine World (USPS 9447600, ISSN 0746-4134) is published bimonthly in addition to the GTW Handbook annual by Pequot Publishing Inc. 654 Hillside Rd., Fairfield, CT 06824. Periodicals postage paid at Fairfield, CT 06824 and at additional mailing offices. Canada Post International Mail Product (Canadian Distribution) Sales Agreement No. 0747165. Printed in U.S.A. says InterGen. capable of operating at a combined cycle design efficiency of over 60%. according to the regional power market monitor’s report. the project debt that GE Capital Markets arranged is the first sizeable project financing of a greenfield.” said Alex Urquhart. reflecting the project’s strong fundamentals. New Jersey 700MW FlexEfficiency project has an estimated $842 million price tag Competitive Power Ventures (CPV) is building a natural gas-fired 700MW Energy Center in Woodbridge.603 million equipment and combined construction price. 1. The addition of duct firing raises output of the Woodbridge CPV plant to its nominal 700MW rating at slightly lower efficiency. the power production capacity of this state-of-the-art natural gas-fired station will be approximately 1.000MW of new gas-fired generation to come online this year. that works out to an installed cost of around $775 per kW for each plant – not counting the cost of financing. Turnkey installed cost of the two plants is estimated at around US$1. The equipment package includes two fast-start fast-ramping 216MW 7F 5-series gas turbine generators. Without supplementary duct firing. project development and related owner’s costs. 3. “By providing both capital and technology for the Woodbridge Energy Center.0% combined cycle efficiency. When completed. Presumably. In addition. Most likely Siemens’ SCC5-8000H 2x1 combined cycle plants which are nominally rated 1. Project development is being financed through GE Energy Financial Services and ArcLight Capital Partners who arranged to anchor $561 million in senior secured credit against an estimated $842 million total cost for the complete project. the two plants will be similar in design and rating. at 59°F and sea level site conditions on natural gas fuel. Reportedly. the last unit.100MW quoted by InterGen. New Jersey that will be powered by a 2x1 FlexEfficiency 60 combined cycle plant.260MW. GE’s 2x1 7F-5 standardized reference plant is design rated at 655MW net plant output and 59. As more wind and solar generation comes online to meet the state’s 33% renewable mandate by 2020. The power station that is being built in the town of Nyagan is designed around three 420MW combined cycle units. the grid agency is looking at the need for backup gas-fired generation to maintain grid reliability. and two duct-fired triplepressure reheat HRSGs in a 2x1 configuration. there is a 16-year contractual services agreement to support long-term plant reliability and availability. The debt syndication was oversubscribed.1GW of H-technology gas-fired combined cycle generation capacity at two sites in the UK: Spalding Energy in Lincolnshire and Gateway Energy Center in Essex. says GE. These will be the first 8000H-technology power plants in the UK and the most advanced. GE Power & Water has a $260 million order to provide a FlexEfficiency 60 com2 GAS TURBINE WORLD September – October 2013 bined-cycle engineered equipment package and engineering services for the 700MW plant. drawing on our financial strength. No further details have been released. 2 currently undergoing final stages of testing should be commissioned by the end of 2013 and No. Western Siberia 1260MW combined cycle project nears completion Fortum’s nominally rated 1260MW gas-fired combined cycle power station in Western Siberia is almost two-thirds the way towards completion. Nyagan No. Construction is scheduled to begin in the last quarter of 2013 and commercial startup in the first quarter of 2016. The California power grid expects about 2. No. we are applying our skills as banker and builder. The plant expects to sell its capacity through 15-year standard offer capacity agreements with New Jersey utilities.14GW each and more than 60% efficiency at 59°F (15°C) sea level ISO conditions. This is attributed to the state’s effort to limit carbon emissions from old plants and to a reduction in hydro power.63 billion (£1 billion GBP). Calpine’s more efficient power plants in the western United States produced 17 percent more electricity in the second quarter this year compared to 2012. and estimated $1. president and CEO of GE Energy Financial Services. was commissioned in April 2013. England Turnkey order for 8000H 2x1 combined cycle plants InterGen says it has awarded Siemens a turnkey order to supply and build up to 2. partial- California Over 700MW of combined cycle peaking capacity Calpine reports that its 429MW Russell City Energy Center near Hayward and 309MW Los Esteros Critical Energy Facility near San Jose entered commercial service just ahead of this summer’s peak demand period. The full power output of both plants is going to Pacific Gas and Electric which is supplying natural gas fuel for both plants under 10-year power purchase sales agreements. is scheduled for commercial startup by the end of 2014. risk management and technical know-how.INDUSTRY NEWS merchant power project to be broadly syndicated in the traditional project finance bank market in many years. At the nominal capacity rating of 2. Financial details have not been disclosed. one D-11A steam turbine generator. The first. . mpshq.912°F) n First commercial J-Series unit..November 2013 Update J . 2 C/C Plant went commercial early.Series Gas Turbines www.600 MW n Global 60 Hz fleet. | 100 Colonial Center Parkway | Lake Mary.400 AOH and 136 starts to date n Eight M501J units now in commercial operation n First unit of the 2.600°C (2. and the second unit is in advanced stage of commissioning. n New turnkey order (6x501J) – Taiwan Power Company C/C power islands totaling 2. in operation since 2011. Inc. FL 32746 USA | 1-407-688-6100 .com Successful implementation of the M501J continues around the world.. now 24 units Mitsubishi Power Systems Americas. n Validated record breaking turbine inlet temperature of 1. with more than 12.919 MW Himeji No. Coal-fired boiler unit 3 rated at 150MW and oil-fired unit 4 rated at 440MW are to be permanently shut down by June 2014. The agreement to buy 430MW of power from NextEra Energy’s Duane Arnold Energy Center from 2014 through 2025 will lessen capacity needs of the new combined cycle plant and keep nuclear as a significant part of the utility’s energy mix. The gas turbines are to be equipped with dry low NOx combustion to limit emissions and with evaporative cooling to augment hot day power output. Earlier this year. Salem Harbor $200 million contract for 7F-5 FlexEfficiency CC gas turbines Footprint Power has awarded General Electric a contract valued at $200 million to supply FlexEfficiency 60 equipment for redeveloping the existing coal-fired Salem Harbor Station into a new natural gas combined cycle facility. the 3x1 design could be close to 990MW and 59. covering planned maintenance on the units for a fixed period of eight years.2% efficiency at 59°F sea level site conditions on natural gas fuel. were removed from service in 2011. Massachusetts 692MW duct fired 7F-5 NGCC plant Footprint Power Salem Harbor Development LP has been approved to construct and operate a nominal 630MW natural gas-fired quick start combined cycle facility at Salem Harbor Station.4% efficiency – at 59°F and sea level site conditions. the utility expects to begin construction in 2014 with an anticipated commercial startup date in 2017. 501D5A and W251 gas turbines as well as all Mitsubishi and Westinghouse technology steam turbines.The contract also includes two service agreements. PP13 in Dhurma and PP14 in Riyadh.0% rating for a 2x1 configuration. Trafos. 42 – 00198 Roma. Emerson’s expertise in control systems design for the power industry. US Emerson and Mitsubishi expand scope of turbine control retrofits Emerson Process Management and Mitsubishi Power Systems Americas have expanded their scope of control system retrofits to include steam turbines. GE says that the new facility will be powered by two 215. To supplement its power output. the number of gas and steam turbine units on order suggests that each project is being designed around two 3x1 combined cycle plant configurations (three 7F-5 gas turbines. Alliant says it will extend for 11 years an expiring agreement to buy power from the state’s only nuclear plant. The cost of the new 600MW Marshalltown plant is estimated at $700 million. Alliant expects to receive appropriate regulatory decisions by the end of this year to proceed. For more information visit the website http://globalprocurement. If approved. 4 GAS TURBINE WORLD September – October 2013 GE says that its advanced 7F-5 technology will provide significant fuel savings and lower emissions to meet the Kingdom’s growing energy needs with the ability to respond to dramatic daily changes in power demand. Design specifics and performance have not been disclosed.6MW 7F-5 gas turbines. Scope of supply includes 12xGE 295. Design ratings for a 3x1 7F-5 combined cycle plant are not readily available. The 7F 5-series 1x1 combined cycle reference plant design is nominally rated at 323MW gross and 58. Alliant Energy’s Iowa utility company plans to build a nominal 600MW natural gas-fired combined-cycle plant on the site of the Sutherland station in Marshalltown. Their alliance now supports overhaul and maintenance in the Americas for W501F. rated at 84MW and 81MW respectively. Main equipments on sale are Turbogas. based on the 665MW and 59. Proposed facility is to be powered by two FlexEfficiency 60 combined cycle plants design rated at 315MW each (346MW with duct firing). Recent projects include mechanical upgrades and installation of Ovation control systems at two power plants in Texas.com .com/en-GB/ Reference: Enel Servizi S.apgoem@enel. Saudi Arabia $700 million supply order for 7F-5 combined cycle projects Saudi Electricity Company has awarded General Electric a contract valued at nearly $700 million to supply 7F-5 technology gas turbines and associated equipment and services for two new combined-cycle power projects. WorleyParsons was awarded a contract valued in excess of $120 million to design and manage construction of the PP13 and 14 greenfield projects. one for each site. Coal-fired boiler units 1 and 2. Generators. the new facility will be capable of generating an additional 62MW for a total output of 692MW. teamed with Mitsubishi’s experience in gas and steam turbine technology and service. The existing Salem Harbor Station is comprised of four steam electric generator units.Industry News Iowa Alliant planning $700 million 600MW combined cycle plant In the wake of cancelled plans to build a large coal-fired generating station. Initial shipments are expected to start at the beginning of 2015. e-mail: pcc. 501B. Speculatively. – Italy Procurement – Generation Procurement – Via Arno.8MW 7F-5 series gas ENEL MACHINERIES AND SPARE PARTS FOR SALE Until February 15 th 2014 it is possible to qualify for the Enel machineries and spare parts sale process.enel. offer owneroperators a competitive alternative to OEMs for control systems maintenance and replacement. 4xGE steam turbines and 16xGE generators. With duct firing under summer conditions. However. three unspecified HRSGs and one steam turbine generator).l. Construction is scheduled to begin in June 2014 and continue for a period of approximately 23 months before the start of commercial operation in June 2016. spare parts and components of different types.r. repair and manufacturing services currently provided by TurboCare (Siemens business unit). the new company will have greater capability to operate in an expanded global market.3A gas turbine already incorporates dry low NOx combustion to limit emissions. The plant will also use air-cooled condensers. risk management and life-cycle optimization as well as power plant construction services worldwide. including the long-term service agreement. Order value for Siemens.000 tons per year. After more than 100 years. TurboCare. it is projected that regional NOx emissions will be reduced by 10 percent. SO2 emissions will be reduced by 8 percent. Provisions were made when installed in 2007 to facilitate its eventual conversion to combined cycle operation. According to ISO New England. completely eliminating the use of hundreds of millions of gallons of water per day from Salem Harbor for once-through cooling. The resulting ownership is to be Wood Group 51% and Siemens 49%. while maintaining an efficiency level that rivals any fossil fuel unit in New England. is widely known and respected for its aftermarket gas turbine. The existing coal and oil-fired Salem Harbor Station will shut down at the end of May 2014. the duct-fired HRSG design will include an oxidation catalyst to control CO and volatile organic compound emissions. the three most senior generators at Riverton. the proposed organization sees itself as a global rotating equipment service provider to the power generation. It will also have the ability to turn down during off-peak hours. Basically. the plants will be among the most environmentally advanced in the country. the new combined cycle CHP facility will produce 95% less sulfur dioxide. say company executives. A name for the new company will be announced upon conclusion of negotiations expected in the first quarter of 2014 subject to a range of conditions including merger approvals. this transition brought to a close the coal generation era at Riverton.3A peaker to combined cycle mode Empire District Electric Company is converting its nominally rated 150MW gas turbine peaking plant (Riverton unit 12) into a combined cycle plant to increase power output and efficiency while reducing emissions. meeting or exceeding the environmental performance of every other fossil fuel power-generating facility in New England. To reduce emissions even further. The project will receive a five-year capacity payment incentive to construct the facility and fill the power gap in the Northeastern Massachusetts/Boston zone. will be retired.turbines. the new Salem Harbor combined cycle facility is needed to maintain the reliability of electricity supply in the greater Boston area beginning on June 1. but were transitioned to natural gas operation in 2012. the new facility will reduce regional carbon emissions by an average of approximately 450. it has a strong presence in the oil & gas and process industries. It is expected that the combined cycle conversion will be upgraded to around 250MW output and 56% combined cycle efficiency for base load duty. International Wood Group GTS and TurboCare joint venture Wood Group and Siemens have entered into an agreement to form a joint venture that will integrate the maintenance and power solutions businesses of Wood Group GTS with the international aftermarket gas turbine. In combined heat and power mode of operation. oil & gas and industrial sectors to build on the complementary strengths of Wood Group and Siemens in these sectors to grow the business. one SST-400 steam turbine. Commercial operation of the new facility is planned for June 2016. over 30% less NOx and over 95% less particulate emissions. In February 2013. says GE. steam turbine and generator design. 8 and 9. Plus. With the new plant in service. the CHP plant is rated at 84% fuel efficiency. According to GE. TransCanada Turbines and Sulzer Wood companies which are not part of the planned joint venure. making it the first “rapid response” power plant to be deployed in New England with capability to add 300 MW of power to the grid within 10 minutes. Compared to the old coal-fired power plant it replaces. maintenance. Together. Empire has awarded Burns & McDonnell the EPC contract to complete the project in the spring of 2016 to replace capacity provided by steam boiler units 7 and 8 which will be retired in conjunction with its commissioning. and GE’s equipment will ship in late 2014/early 2015.6MW and 53. In effect. What the Wood Group brings to the party is in-depth experience in asset operations. Missouri $170 million to convert V84. and HRSG design which will house an oxidation catalyst to limit CO followed by ammonia injection and SCR catalyst to further limit NOx. which primarily operates in the power generation segment. steam turbine and generator design.3A(2) natural gas-fired plant was nominally rated at 150MW output and 38% simple cycle efficiency. Footprint cleared the ISO-NE “Forward Capacity Auction” to supply electric generating capacity beginning in 2016. These reductions result from the efficiency and flexibility of the 7F-5 gas turbine equipment in the new facility. 2016. Siemens is contributing the TurboCare global business and Wood Group contributing a large portion of its Gad Turbine Services (GTS) portfolio. Units 7. three 11 kV generators. Commissioning is planned for early 2016. Siemens contract scope of supply includes turnkey construction. This will require the addition of a supplementary fired HRSG. Wood Group’s gas turbine activities are to be limited to joint ventures including Rolls Wood Group. Units 7 and 8 historically operated on coal fuel. and mercury emissions will be reduced by 6 percent. two HRSGs and a 12-year maintenance agreement for the gas turbines. two 50. Operationally. followed by selective catalytic reduction to limit NOx emissions. The total cost of the combined cycle conversion is unofficially estimated at $170 million. The natural gas-fired Gorzów facility will be powered by two Siemens SCC-800 1x1 combined cycle plants ISO rated at 66. condensing steam turbine generator and cooling tower for the bottoming steam cycle. Upon completion of the combined cycle project in 2016.5MW SGT-800 gas turbines. The senior leadership team will comprise Mark Dobler from Wood Group GTS GAS TURBINE WORLD September – October 2013 5 . The original Siemens Westinghouse V84. with 90MW of thermal output in the form of steam extraction for district heating. eliminating the consumption of extra fuel and emissions output associated with a plant startup. this will support the continued deployment of wind and other renewable energy sources. repair and manufacturing services. The original V84.8% combined cycle efficiency each for electric power generation. is valued at around Euro 160 million (US $220 million). For example. Poland Turnkey order for 133MW combined cycle CHP plant Polish energy utility PGE has awarded Siemens Energy a turnkey contract to supply and build a nominally rated combined heat and power plant in Gorzów Wielkopolski. depending on choice of operation. On a fast-track schedule. which are capable of peaking as well as intermediate power generation due to their fast startup. which offers increased performance. Neil Sigmund from TurboCare as Deputy CEO. Driven by GE’s 7F-class gas turbine upgrade portfolio. Duke filed the application in partnership with the North Carolina Electric Membership Corp. Currently. According to the state permit. steam turbines. Guadalupe will pick either a GE or Siemens high efficiency gas turbine model for its proposed peaking plant.200MW of combined cycle generation in ERCOT. construction could begin after the company receives regulatory approval. South Carolina Duke seeking approval for a 750MW combined cycle plant Duke Energy has filed an application with South Carolina regulators seeking approval to build a 750MW natural gas-fired combined cycle power plant to be sited at the existing Lee Steam Station in Anderson County. According to Duke. which . Today’s aeroderivative and small industrial gas turbines are designed to reach full output within less than 10 minutes of a cold start which is fast enough to qualify for nonspinning reserve capacity. And operate as an independent aftermarket service provider across a broad range of OEM equipment (including GE and Solar Turbines) including parts. The plant is being built around two SGT800 2x1 combined cycle power blocks with bypass capability to operate in simple cycle 6 GAS TURBINE WORLD September – October 2013 mode. with the first block available in late 2013 and the second block available in the first half of 2014. says Alstom.000 a year in fuel savings GE and TransCanada are working together to help recast the energy generation landscape to the benefit of both the power provider and its customers. supported by management drawn from both parent companies. The Guadalupe project is reported to be one of about 10 similar generation projects totaling 4. and Claus-Maasbracht in the Netherlands). cycling and very low part-load operation. Total cost of the project is estimated at around AU $500 million (US $455 million). 2 x steam turbines and the 4 x HRSGs. Australia 242MW SGT-800 combined cycle nearing initial startup Diamantina Power Station Ltd. Panda Power Funds. Siemens scope of equipment supply includes 4 x gas turbines. Canada. The MXL2 upgrade offers GT26 owneroperators two key benefits. component lifetime is extended to allow up to an additional 8. are delivering more power while reducing operational costs and emissions. high ramp rate. one inlet chiller (for summer operation) two NEM twin pressure HRSGs and one SST-400 steam turbines with associated balance of plant equipment for the steam bottoming cycle. South Carolina. components and associated overhaul and repair services for the generally more mature Fiat and Westinghouse turbines (up to W501D4) and. It will operate as an authorized service provider of maintenance. Calpine Corp.” If Duke does decide to build the facility. Pratt & Whitney FT4 and GG4 gas turbines. overhaul and repair services. It also will provide overhaul & maintenance and engineering.800 MW of additional gas-fired generation in ERCOT. gains of 13-23MW in power output are possible for combined cycle. construction (EPC) services for cogeneration. Texas Developer proposing 470MW multi-unit simple cycle plant The Texas Commission on Environmental Quality has issued an air permit to Guadalupe Power Partners for a proposed 470MW peaking plant to be built outside San Antonio that will be powered by multiple simple cycle units. The five GT26 gas turbines at Pembroke and four at Staythorpe will each be retrofitted with the multi-mode MXL2 upgrade. with the plant beginning commercial operation as early as June 2017. Each block consists of two SGT-800 gas turbines.200MW Pembroke and 1.000 operating hours before the next Type C hot gas path inspection which increases availability and reduces maintenance costs. FlexEfficiency upgrade options. along with a possible 0. The project developers are also working to obtain a greenhouse gas permit from the Environmental Protection Agency. They are also fast ramping up and down for intermittent renewable power backup. are said to be waiting for the Public Utility Commission to show support before committing to build new projects.650MW Staythorpe facilities – Britain’s two biggest gas-fired combined cycle power plants. Siemens is responsible for the overall plant design and is providing technical advisory services during the construction and commissioning phases of project development. the peaking plant could be installed and commissioned for commercial service by mid-2015. with financing and permitting in place. overall plant output is expected to increase by 4-12MW and 0. substantial improvements to operational efficiency and enhances availability through increased maintenance intervals. procurement. according to Reuters data. and the Lower Colorado River Authority are constructing 2.200 MW under development in Texas’ primary grid that is overseen by the Electric Reliability Council of Texas (ERCOT). and Chris Watson from Wood Group GTS as CFO. components. In addition.5% point increase in efficiency.8% point increase in efficiency. The still-to-be-named JV company will be the OEM provider of parts. through Wood Group Pratt & Whitney.7 to 0. In the XL mode. Diamantina is on schedule to be fully operational next year. the company has not made a final decision to build a facility at the Lee Steam Plant.Industry News as CEO. Other developers have obtained or are seeking permits to build another 8. This agreement also includes a comprehensive maintenance program for the RWE Generation GT26 fleet across Europe (including Staythorpe and Pembroke in the UK. but “it is prudent to continue with the regulatory actions necessary to keep the project moving forward. is developing a site rated 242MW natural gas-fired combined cycle project near Mount Isa in the state of Queensland site rated at 242MW plant output and 51% combined cycle efficiency. Many developers. however. supply chain and construction services to OEMs (including Siemens) for gas turbines. TransCanada’s Ravenswood power plant in New York and 167MW Mackay River cogeneration facility in Alberta.4 to 0. England RWE contract award for GT26 performance and life upgrade Alstom has agreed plans for a major upgrade with RWE Generation to implement its high performance MXL2 upgrade package on all nine gas turbines at the 2. Guadalupe Power Partners is owned by Minnesota-based Wayzata Investment Partners and managed by Navasota Energy which in the past built and operated two 550MW gas turbine plants in Texas. combined cycle and simple cycle gas turbine configurations. In the M mode. which will own 100MW of the project if constructed. generators and other rotating equipment. Canada 7F-3 efficiency upgrade worth $900. it .1853-2013 Branded energy for 160 years ansaldoenergia. the unit still generates power. existing energy within Kentucky and building new generation. Additionally. As part of this turnkey project Emerson also installed eight natural gas-fuel modulation valves. Green River and Tyrone stations) and building a 640MW NGCC unit at Cane Run. Additionally. Maryland. The companies plan to file a certificate of public convenience and necessity for the new NGCC plant and solar facility before the end of this year. TransCanada says it expects these efficiencies to result in a total of approximately $900. 40% natural gas-fired and 1% renewable.com/gas_turbine_world 8 GAS TURBINE WORLD September – October 2013 2013 Online GTW Handbook Unlimited Online Access List Price $170 Online and Print 2013 Edition Online access plus Hard Copy List Price $250 Searchable Handbook Database Access to historic Handbook ratings (from 1976) and prices (from 1982) List Price $495 Add to Cart Add to Cart Add to Cart . The Ravenswood combined-cycle unit has experienced an output increase of nearly 5% from the upgrade. If approved. says GE. as well as new revenue opportunities for Ravenswood in bidding into the area’s power market.000 in annual fuel cost savings for the company. Details are being finalized. LG&E and KU’s generation capacity will be 59% coal-fired.industrialinfo. Building a second NGCC at the existing Green River site proved to be the best long-term solution for base load generation. 16 gas-fuel stop valves and eight gas-fuel vent valves. The utilities intend to have the NGCC plant online in 2018 and the solar facility online in 2016. as the remaining turbines blend operation to maintain load on the generator. The Mackay site has also experienced a reduction in emissions of approximately 160 tonnes of NOx per year.Industry News couple advanced gas path hardware with performance-enhancing software. but the plant is expected to have about 700MW of capacity and cost approximately $700 million to construct. Maryland Control system upgrade to improve starting reliability Emerson Process Management has replaced aging turbine and balance-of-plant controls with its Ovation expert control system at Exelon Generation’s Westport unit 5 station in Baltimore. Kentucky 640MW NGCC planned to replace retired 800MW of coal-fired units Louisville Gas and Electric and Kentucky Utilities have announced plans to apply for permission to construct a second natural gas combined-cycle generating station (in Muhlenberg County) and a solar generating facility. Competitive bids that were submitted included renewable energy. A request for proposals was issued in September 2012 to address the amount of lost generating capacity in light of long-term load growth. If any pair of turbines is taken offline. Gas Turbine World Handbooks Globally-Aware & Dedicated to Covering Emerging Technology View and order online at: www. were installed on one natural gas-fired 7F 3-series gas turbine at each plant. The two companies had previously announced retiring 800MW of old coal-fired generation (at Cane Run. they want to construct a nominal 10MW solar facility costing approximately $25 million at one of its existing generating stations. while Mackay River plant output saw a 10% increase in output. Several sites are under consideration. Ravenswood and Mackay River have experienced fuel efficiency increases of more than 1% and 2% respectively. This 116MW simple cycle peaking unit has a unique configuration consisting of eight Pratt & Whitney aeroderivative GG47 gas generators that are coupled with four Worthington Model ER-224 double-flow expander turbines. mining and metals. GAS & CHEMICALS POWER Building Confidence Bechtel is among the most respected engineering. . partners and suppliers on diverse projects in nearly 50 countries. project management. gas and chemicals. We stand apart for our ability to get the job done right—no matter how big. Since its founding in 1898. Bechtel has worked on more than 22. Today. civil infrastructure. our 53. or how remote.000 projects in 140 countries on all seven continents. Bechtel operates through five global business units that specialize in power generation. and construction companies in the world.000 employees team with customers. and government services. oil. how complex.CIVIL GOVERNMENT SERVICES MINING & METALS OIL. Siemens scope of supply included two 292MW SGT5-4000F gas turbines. Scope of the SARB project includes the construction of facilities to transfer oil that will be produced by eighty-six wells tapping the offshore field located about 120 km northwest of Abu Dhabi. This timeframe was necessary in order for the unit to be available to meet peak summer demand. which are sited at Inter RAO’s Dzhubginskaya thermal power plant. The two complete turbo compressor systems also will be string tested in Italy. upgrades and repair service as well as field service engineers and training. three SGen52000H generators. Equipment related to collection and transport of that oil will be constructed on two artificial islands. GE will supply six Frame 7E gas turbines (86MW each).000 barrels of oil and 35 million cubic feet of gas. They will be installed to power four compressor stations along the 1. They also feature DLE 2. According to project plans. Abu Dhabi Marine is 60% owned by the Abu Dhabi National Oil Company. 18 centrifugal compressors. six variable speed drive (24MW each) and six waste heat recovery units. . the order also covers installation supervision and technical support at the commissioning stage. GE Oil & Gas Global Services will support the new equipment sold to Statoil and also provide aftermarket components and equipment for Statoil’s installed fleet of GE 10 GAS TURBINE WORLD September – October 2013 turbomachinery equipment. That oil and gas processing facility will have a daily capacity of 200. Each train to consist of two main refrigeration units for converting natural gas into LNG for transportation. Consortium made up of Technip in France and JGC in Japan have been awarded the EPC contract for three production trains. Hyundai will build a facility in Zirku Island to separate gas from crude oil collected in the SARB and Umm Al Lulu oil fields. When it reaches full operating capacity in 2016. each with the capacity to produce about 5.115km Line C gas pipeline section of the vast 1.5 million tons of LNG a year. including potential to supply gas domestically to the Republic of Kazakhstan.5GW of electrical generating capacity. Total and JODCO.3% simple cycle efficiency at 15°C sea level on natural gas fuel. The service agreement includes spare parts. respectively.com. electrical equipment and the SPPA-T3000 instrumentation and controls system. Gas Turbine World reserves the right to edit printed submissions for clarity and context. GE is scheduled to deliver the equipment to Russia in the second half of 2015. Oman 1. the first gas liquefaction train is to reach its full capacity in 2017 followed by the second and third trains in 2018 and 2019. Each Trent 60 gas turbine is capable of producing up to 66MW of power and will feature low emissions technology to minimize environmental impact. the plants will add 1. Rolls-Royce will supply five Trent 60 gas turbine generator sets to power offshore production platforms and oil and gas processing facilities on Zirku Island. Russia Huge gas turbine compressor order for LNG megaproject GE has received an order to provide key turbomachinery equipment for the Yamal liquefied natural gas (LNG) megaproject being developed on the Yamal Peninsula in Russia’s northern Siberia region. UAE Offshore oil platform order for five Trent 60 generators Rolls-Royce has a contract to supply Abu Dhabi Marine Operating Company with power generation equipment and related services to help boost oil and gas processing at an offshore project in the United Arab Emirates. The units. GE Power Conversion facilities in France will test the variable speed drives prior to shipment. procurement and construction firm. Quebec and Mount Vernon. with the remaining 40% shareholding divided between BP. one SST5-5000 steam turbine.5GW combined cycle capacity on schedule Siemens Energy and its consortium partner GS E&C have commissioned Sohar 2 and Barka 3 combined cycle plants in the Sultanate of Oman on schedule.Industry News Emerson says that they managed to complete the project within a compressed schedule of roughly six months. In all. GS E&C supplied the HRSGs and was responsible for the civil construction work. In addition to equipment supplies. Norway First offshore application for LM6000 gas turbine power Norway Statoil Petroleum has entered into two 5-year agreements for GE Oil & Gas to supply equipment as well as services to support Statoil’s installed fleet of GE turbomachinery. which eliminates the need for water injection to reduce NOx emissions. The gas turbines are to be manufactured in Greenville. The contract for the Satah Al-Razboot (SARB) offshore project was awarded to R-R by the Korean engineering. the Central Asia-China network will transport up to 55 billion cubic meters of gas each year from Turkmenistan and Uzbekistan to China through Uzbekistan and Kazakhstan. Generating 750MW each. GE’s first equipment order (under the agreement) is to supply LM6000 mechanical drive gas turbines for operation in the Aasta Hansteen field and LM2500 gensets for SeaSmart offshore packaging. Submit News Articles & Images Email news articles. can start up to reach full power output in less than 10 minutes. raising the Sultanate’s current existing capacity to approximately 6GW. and the compressors in Florence.0 dry low emissions technology. Italy. Please accompany image files with copyright/credit information and written permissions for use. electrical transformers and ancillary systems as well as equipment installation. Ohio. The 50Hz LMS100-PBA is ISO rated at 99MW and 44. Meanwhile.833km long Central Asia-China gas pipeline network. Rolls-Royce will manufacture and package the equipment at its energy facilities in Montreal. In addition. Russia LMS100s to provide peaking power for the Olympic games GE announced that two of its LMS100-PB gas turbines that will supply power for the Krasnodar region and peaking backup during the 2014 Winter Olympic Games are close to being commissioned. Hyundai Engineering and Construction. The Line C pipeline in Kazakhstan will contribute up to 25 bcm per year of the total capacity. contact information and high-resolution image files to gtwnews@gmail. Kazakhstan-China RB211 compressor units to power Asia-China pipeline Rolls-Royce announced a $175 million contract to supply Asia Gas Pipeline with twelve RB211 gas turbine powered pipeline compressor units. South Carolina. PWPS.pwps. always moving forward.com or call 1.PowerALL (1.3725) to learn more.866.769. PW Power Systems continues to bring you advances in products and capabilities for the energy and power markets. Now an MHI group company.866. It’s the same trusted technology you know. Visit www. with over 50 years of experience. is driven to provide the high-quality products and support you’ve always depended on.Same power. New owner. Same products. . which equates to a little over 5400 hours a year. Entire combined cycle block can ramp up and down at 3035MW per minute while maintaining 2 ppm NOx stack emissions and virtually no CO. California. represents what is a growing trend among US operators to install plants that have the operating flexibility to back up the growing amount of renewable generation on the grid in markets like California. says: “When you look at the plant. the new plant will enable the site to reduce the consumption of potable water by nearly 90%. o Emissions. More specifically: o Rating. Commenting on the new plant. but the unique thing is that it’s actually a peaker. When you hit “start” each block delivers 150MW in 10 minutes. for a total of 300MW. while the 335MW Unit 4 is still operating. inaugurated what is only the second combined cycle plant in the US to use Siemens “Flex-Plant” technology. Richard Loose. Meeting demand The repowering project has long been in the making. The El Segundo Energy Center features two Siemens Flex-Plant 10 fast-start SCC6-5000F 1x1 combined cycle power blocks. for a combined cycle that’s gamechanging technology. The new facility. Also. Siemens’ Director of Marketing Energy Solutions. Each SGT6-5000F gas turbine can deliver 150MW of nonspinning reserve peaking power within 10 minutes of startup. o Fast start.El Segundo combined cycle offers 300 MW of peaking in 10 minutes By Junior Isles 550MW Flex-Plant 10 combined cycle project represents a growing trend in the use of combined cycle technology that has the ability to provide peaking and base load power to complement intermittent renewables. The original plant at the El Segundo facility comprised four natural gas fired steam units – Units 1 and 2 which began operating in the 1950s and Units 3 and 4. Regional resources have not kept pace with this growth and the recent closure of the SONGS nuclear plant has resulted in the need to produce even more electricity than was previously thought. Units 1 and 2 were retired in 2002 and demolished in 2010 to make way for the two new units. 12 GAS TURBINE WORLD September – October 2013 The El Segundo Energy Center is the latest move in NRG’s ongoing drive to lower emissions from its thermal generating fleet while at the same time allowing greater use of renewables and the gradual replacement of aging steam units at the site. the plant must be available 24/7. The California Public Utilities Commission has determined that about 2000MW of locally produced power will be required to meet the region’s energy demand by 2016.9% combined cycle efficiency. Performance highlights include the ability to deliver 300MW in 10 minutes and limit transient NOx emissions during operation to 2 ppm.” . NRG Energy Inc. each of the 1x1 combined cycle units is permitted to start 200 times per year to meet both California’s base load and peak load demand. allow NRG to meet or exceed the State and South Coast’s strict air quality standards. In addition to helping the integration of renewables. In terms of operation. The repowering project is therefore essential for local energy reliability. Americas. Population continues to expand to the eastern parts of the Los Angeles basin. the removal of two large oil tanks at the south end of the property will lower the site’s profile and reduce the overall visual impact. in El Segundo. where summer hot spells make air conditioning a necessity. and require 30% less natural gas per MW produced than the original steam boilers. Each power block is rated at 275MW net output (at 85°F design point) for a total plant output of 550MW at 48. NRG first proposed the project in response to identified demand by California’s Independent System Operator (ISO). which had been running since the 1960s. you might think it looks like any other 1x1 combined cycle. O n September 12th. Unit 3 has also since been retired as part of the permitting of El Segundo Energy Center. Although NRG has committed to a capacity factor of about 60%. the company moved to an air-cooled configuration as explained by George Piantka. increasing the amount of electricity generated by renewables from 17 percent to 20 percent by 2010. the new plant is connected to the city’s sanitary discharge. extend maintenance intervals and enhance operating flexibility. Design features According to Siemens. The latest version of the turbine uses an Renewables driving combined cycle flexibility California is among the strictest states in the US with regards to power plant emissions. The engine is offered with an option of two combustion systems. as part of the infrastructure improvements. it adopted a Renewable Portfolio Standard. In the US. The plant is also designed to ramp up or down at 30MW per minute between 100% and 55% gas turbine load. which remove the energy and condense the steam. In August last year. So. who has been part of the permitting effort since 2000. ST valves wide open) in less than 60 minutes. The SGT6-5000F at the heart of the plant is capable of reaching 150MW in 10 minutes. with improvements made to increase efficiency and power output. the Northern California Power Agency inaugurated the Lodi Energy Center – the first operating Siemens FlexPlant 30 combined cycle gas turbine power plant in the USA. NRG was issued a licence in 2005 by the California Energy Commission for a 630MW ocean-cooled base load plant. full gas turbine output in less than 15 minutes and full plant output (GT at base load. Also. but with much higher electrical efficiency than peaking plants. a second Flex-Plant owned by NRG Energy has started up in California. In 2007. the rotor uses upgraded steel discs in the turbine section with a rotor air cooler to allow for greater flexibility in turbine blade cooling air temperature. Since first introduced in 1993. Accordingly. while maintaining emissions at the stack to less than air permit levels. It features a 13-stage compressor with four rows of variable compressor guide vanes enabling high efficiency at part load as well as at base load. an SGen6-100A-2P generator. Instead. In addition to featuring Siemens Flex Plant technology.Change of plan Originally. Each unit comprises an SGT6-5000F gas turbine. The facility is also designed for zero liquid discharge. The burgeoning amount of renewables on the grid requires additional peaking capacity to compensate for the variability of renewable generation such as wind and solar. one year later. Cooling is provided by low profile. He recalls that the decision to switch to a configuration that used air cooling allowed the retirement of around 400 million gallons per day of ocean water cooling. air-cooled heat exchangers (ACHEs). an SST-800 steam turbine. Director of Environmental Business for NRG West Region. however. are also working to improve the flexibility of combined cycle gas turbine (CCGT) plants that are also capable of backing up intermittent renewables. Adopting this air cooling design allowed water usage to be reduced by about 90 percent. however. this time in El Segundo. Siemens also supplied the complete electrical equipment and the SPPA-T3000 power plant instrumentation and control system. requiring that the amount of electricity supplied by renewables reaches 33 percent of total generation by 2020. the plant’s fast start capability to deliver 200MW in 30 minutes or less can result in a 30% reduction in greenhouse gas emissions when compared to traditional F-class combined cycle plants. gas-fired simple cycle peaking power plants have become the preferred technology for providing this renewable support. the proposed plant was to be a 2x1 combined cycle plant designed to use ocean water for cooling. lawmakers passed the California Global Warming Solutions Act – a bill that requires the Air Resources Board to adopt a state-wide greenhouse gas emissions limit equivalent to the state-wide greenhouse gas emissions levels in 1990 to be achieved by 2020. Manufacturers. a heat recovery steam generator and an air-cooled heat exchanger. the engine is now designed for high reliability and frequent ramping without any service or increased maintenance penalty for fast startup and fast ramping. The compressor is connected to the 4-stage turbine by a single tie-bolt. the old plant did not have its own sanitary discharge system. There are no nickel-based alloys used in the rotor construction. Fast start technology The new plant features two power islands delivered by Siemens. first as a consultant and then as an employee of NRG. the 5000F engine has evolved over time. feeding condensate down a condensate receiver back into the cycle. ultimately approved in 2010. According to Siemens. This was expanded in 2011. Now. the site-rated 550MW facility is notably the first to incorporate NEM’s new DrumPlus heat recovery steam generator design. GAS TURBINE WORLD September – October 2013 13 . At the same time. This was in compliance with the objectives of the State Water Resources Control Board. In 2006. which is a Flex-Plant 30 design that incorporates a triple pressure boiler. The pilot and the main pre-mixers (on the combustor support housing) employ swirler fuel injection.9% efficiency powered by two gas-fired SCC6-5000F Flex-Plant 10 combined cycle blocks. CO emissions are kept below 10 ppm down to at least 40% load. 550MW El Segundo plant. Reduced low load CO emissions are achieved by operational modifications and bypassing supplemental cooling air around the combustor. where the fuel is injected off the swirler vanes. the single pressure version was used at El Segundo due to space constraints at the site. which leads to reduced CO production. First-of-a-kind Exhaust gas leaving the gas turbines at a temperature of about 582°C (1079°F) is fed into an HRSG used to generate steam to drive the steam turbine. these combined cycle units feature first-of-akind HRSG technology developed by NEM. according to NEM. 14 GAS TURBINE WORLD September – October 2013 . Unlike Lodi. The ULN system uses five fuel stages to mix the natural gas with combustion air.6 bar. Each plant is designed around a 5000F gas turbine-generator (which can generate 150MW in less than 10 minutes and reach full load in 12 minutes). HRSG with standard SCR/CO catalytic reactor. In this version. In addition to reducing NOx.ultra low NOx (ULN) combustion system that employs 16 can-annular combustors to reduce NOx levels to less than 9 ppm. without alteration to the internal architecture of the combustion system. the Flex-Plant 10 at El Segundo has a single pressure boiler. This is around 9-10 percentage points higher than a traditional simple cycle gas turbine peaking plant. Although double and triple pressure versions of the boiler are available. This provides more injection points and better mixing than the previous dry low NOx combustor. is the most economically competitive solution for peak-to-intermediate duty cycles. Rated at 550MW and 48. volatile organic compounds (VOC) and particulate emissions. producing 78. Interestingly. Steam from the HRSG is fed to the backpressure non-reheat steam turbine for an additional 70MW per train and resulting in an overall plant electrical efficiency of about 49 per cent. single-pressure non-reheat bottoming cycle with an air-cooled heat exchanger for backpressure steam condensing. The innovative heat recovery steam generator design allows the Flex-Plant 10 to not only meet the challenging emission regulations in California but also. This allows greater flexibility during cyclic operation.3 kg/s of steam at a tem- perature of 502°C and a pressure of 99. the ULN combustion system controls CO. Bypassing air around the combus- tor increases combustor flame temperature. . and air cooled heat exchangers (condensers) 21 days early. There will be virtually no CO emissions from the new units. So. Texas by the end of 2014. The drum also uses a thinwalled design to minimize stresses across the drums. Normally. The result is a plant that can operate like a peaker. It has been tested at several locations but this is the first time it is being fully implemented. where natural gas fuel is cheap. the new plant was completed in time 90 120 150 to meet the growing demand in the region. but with a conventional SCR at the back end. we have to meet our limit over that hour period. start-up CO emissions are reduced by 90% compared to conventional combined cycle gas turbine plants as a result of the shorter startup time. According to Siemens. Piantka noted: “In this district.HRSG design NEM worked with Siemens on the boiler design for the El Segundo units. Whereas conventional drum-type HRSGs run a high risk of severely reduced lifetime due to cycling stresses. Siemens believes this will be a growing trend in the US. Texas. with unrestricted startup. Instead of having a large high-pressure steam drum. the key consideration in its design was that it should not restrict any operation of the gas turbine. Ramping operation Another unique aspect of El Segundo is the use of what Siemens calls ‘Clean Ramp’ technology. and especially in regions where there is an increasing amount of renewables. According to project engineers. El Segundo has the operating profile of a peaker but the emission footprint of a combined cycle. Full GT power in under 15 minutes Load – 100% Less than 1 hour to fully open steam valves – – 80 – – 60 Flex-Plant combined cycle – – 40 Conventional combined cycle – – 20 – –0 Time (minutes) 0 30 60 during ramping.” The plant has successfully demonstrated this during commissioning and operation. The boiler design also allows the use of a conventional selective catalytic reduction (SCR) and CO catalyst. when ramping up or down. The technology allows the entire plant to ramp up and down at 30 to 35MW per minute while maintaining 2 ppm NOx out of the stack. sensors in the stack detect a NOx excursion and send a signal to input more ammonia to reduce NOx. for Best Available Technology. Effective implementation of the plan resulted in all equipment delivered ahead of schedule: steam turbines were delivered 63 days early.8% efficiency in less than 60 minutes. gas turbines three days early. being built for Panda Power Funds. Each 5000F 1x1 Flex-Plant 10 is design rated (at 85°F) to deliver 150MW of gas turbine power in 10 minutes (non-spinning reserve) for peak backup of intermittent renewable generation and full 275MW plant output at 48. This can partly be attributed to a logistics plan developed by Siemens for special rail car usage and transit clearance to ensure that gas turbine and generator delivery to site went smoothly. it is a reactive process. the gas turbine and ammonia injection system operate in a proactive process to avoid NOx excursion at the stack. As soon as the gas turbine gets a signal to ramp up. The technology is hugely important in a state that has one of the strictest legislations in the country for NOx emissions. the significantly lower peak stress means the boiler can handle 10-minute start-ups while maintaining the same design life span of conventional drum-type HRSGs. the water/steam separators have been located outside of the drum. Essentially. A third Flex-Plant is scheduled to begin operation in Sherman. n . also for Panda Power. The design of the DrumPlus boilers ensures that no hold points are imposed on the gas turbine during startup. Ready to meet demand Despite having to be built on an existing site subject to space constraints. there is a NOx limit of 2 ppm over an hour. With its second Flex Plant now in operation. This project. will be followed by another project in Temple. Basically. HRSGs 42 days early. that is scheduled for completion a year later. Clean Ramp technology essentially links into the controls of the gas turbine and SCR. Transient NOx emissions are seen 16 GAS TURBINE WORLD September – October 2013 El Segundo performance. . The portfolio of options includes: ● Dry Low NOx1+ combustion which allows operators to run their gas turbines up to 32. reduce its fuel use by 1.9 percent higher fuel efficiency and 33 percent greater outage intervals (32.” Primary interest one day might be peak firing.5 percent. depending on where you are in the world and what type of customer you are – whether a merchant.” says Fintan Tuffy. The other two 9Es are scheduled for this same upgrade when overhauled. This was carried out as part of a scheduled engine maintenance overhaul. o Investment. Since its return to service.000 hours (equivalent to almost an additional year of operation). Across all three units. Fully upgrading a 500MW plant could be worth over $500.000 hours/1. fuel efficiency and maintenance intervals. ● broader suite of OpFlex controls which help expand operating profiles across all modes of power plant operation.880kW) while fuel efficiency has increased by approximately 1.Expanding performance while resetting the clock on old assets By Victor de Biasi Advanced gas path upgrades coupled with model-based controls software can improve performance and value of old 9F and 9B/E gas turbine units.4 percent (generating an additional 5. responsible for gas 18 GAS TURBINE WORLD September – October 2013 turbine fleet analysis and performance management services.5 percent. gas turbine output has increased by 3. the site expects to increase its output capacity by 17. 0.25 million a year in fuel savings. the shared goal is to deliver technologies blended through a collaborative process between GE and owner-operators to identify customized solutions that best achieve desired outcomes. so we are really looking at life extension strategies. o Frame 9B/E.000 annually in extra revenue and up to $1. Fr 9B/E program GE refers to the improvement program for 9B/E-class gas turbines as a “LifeMax Advantage” platform (LMA) configured to reset the clock and significantly extend the life cycle of aging assets which typically average over 17 years in service.8 percent more power. Dubal installed an advanced gas path upgrade plus DLN1+ and OpFlex advance controls systems on one of three 9E gas turbine units. And both incorporate advanced gas path upgrades (similar to the 7F upgrade GE introduced 2-3 years ago) designed to increase power output.64MW. customers were just interested in output and efficiency. “Ten years ago. Ultimately. “We are seeing huge value in combining hardware with software. Now. state-owned utility or cogen operator – you may be looking for slightly different results. 2 percent higher fuel efficiency and 33 percent greater outage intervals (32. another time it may be to bring down operating costs and extend maintenance intervals. . General Manager.300 starts). efficiency and operational profitability of old units: o Frame 9F-3. “Owner-operators have access to a suite of upgrade solutions that will enable 9B/E-class gas turbines recapture lost performance and lower operating costs.” notes Tuffy. In April 2013. and ● flange-to-flange replacement components for core engine upgrades including compressor and combustion systems.000 hours) for maintenance. Both programs combine hardware and software technologies to enhance power plant performance. Up to 6 percent more power.” LifeMax blends advancements in hot gas path components with OpFlex model-based controls software to in- crease power output. Dubai Aluminium (Dubal) is the first GE customer for an LMA upgrade. and extend major overhaul intervals to 32.000 hours between scheduled overhaul maintenance intervals. operation and durability. Up to 3. “These units are coming to the end of their original design life. New controls software that go with gas path upgrading have been developed to help satisfy a growing variety of operational needs. G E has introduced separate technology upgrade programs for its large 50 Hz fleets of Fr 9B/E and Fr 9F-class gas turbine installations in service around the world. enables gas turbines to recover from lean-lean operation to pre-mixed operation without any change in load. Owner-operators can benefit from an extension of maintenance intervals and parts life through more durable hardware components and software technology that automate operational adjustments to reduce stresses on parts.” says Tayeb Al Awadi. so we started with the 7F. With older fleets struggling to compete in a market where performance is key. Fleet Analytics & Performance Management Power Generation Services GE Power & Water said: “We wanted to initially focus on our F technology. “This collaborative effort with GE will also put our sites in a better position with more available power and flexibility for electricity markets with Advanced Gas Path upgrades An AGP upgrade essentially involves applying the latest hot gas path technology to the three rotating and stationary sets of components in the hot gas path section – buckets.” Depending on gas turbine frame type and configuration. In addition to gas path upgrades. says GE.” said Enka O&M Chairman Mr. All five LMA options are scheduled for installation on Dubal’s second 9E gas turbine in November 2013. For example. Dubal’s vice president. power & desalination. The extra power will be used to increase smelter production while also reducing operating costs. when completed. Adapazar and İzmir power stations) which. Fr 9F-3 program GE refers to the improvement program for 9F-class gas turbines as a “FlexEfficiency Advantage” platform (FEA) configured to expand gas turbine output. Tahsin Kösem. the AGP upgrade increases output of the 9F-3 by up to 6 per cent and fuel efficiency by up to 2 per cent. New features will be added in the future as a result of ongoing collaboration between GE and customers. “With 900 units around the world. Explaining the expansion to cover the 9F and 9E.000 hours with 1300 starts (extending outage intervals up to 33 per cent). with a targeted completion date of 2018 for the last one. “The performance improvements this solution delivers to our plants will allow us to maximize the value of the energy we provide through power purchase agreements. they are investigating how to start up faster and turn down to minimum loads at night. Enka will also lower its emissions footprint by retrofitting the gas turbine units with a Dry Low NOx (DLN)2. It is expected that up to 8 percent additional output can be achieved on 9E-class gas turbines by installing the Peak Power option. AutoRecover.6+ combustion system upgrade. Maintenance intervals can be as long as 32.8 per cent and fuel efficiency by up to 0. the AGP upgrades will help the installed base compete in the market. At the same time. as well as better cooling and sealing processes to minimize the energy wasted as a result of cooling. shrouds and nozzles – to improve gas turbine efficiency and output. the three rows of components would be removed and replaced with newer technologies. Enka. emissions spikes and longer term maintenance costs. Here. General Manager. OpFlex Peak Power technology enables operation at higher firing temperatures. will deliver close to 150MW of additional capacity. the FEA portfolio includes Dry Low NOx combustion technologies and a broad suite of controls software options that can expand the operational flexibility of F-class machines. it is probably our single biggest fleet in our 60 Hz market.000 hours. maintenance intervals can be extended by up to 33 per cent or as long as 32. Fintan Tuffy. On the 9E. during the second major inspection of all ten units. with installations on the remaining unit to follow in 2014. efficiency and operating windows. Now we are taking some of the lessons learned and some of the technologies from our 7F introductions and applying them to our 50 Hz equipment. Turkish power producer. many 9F-3 gas turbine power plants today are running in cyclic operation. without increases in emissions or combustion instability. The upgrade is typically carried out during a major inspection or when the hot section of the machine is open. Dubal is also installing new OpFlex AutoRecover and Peak Fire software plus a Mark VIe controls upgrade to drive further output and efficiency site improvements while holding down overall maintenance costs. recently placed the first order for GE’s 9F-class advanced gas path upgrades on 10 gas turbine installations (at Gebze. output increases up to 3. typically in as little as 10-15 seconds. “Incorporating these new technologies into our power station is central to our longterm strategy of producing aluminum products as efficiently and cost-effectively as possible for our customers. Project engineers explain that this capability can help avoid load interruption. It includes the use of new materials that allow higher firing temperatures. As a result. Installation of the technologies is scheduled to begin in late 2015. GAS TURBINE WORLD September – October 2013 19 . The case for AGP upgrades in Europe and the Middle East is being driven by the changing market conditions.9 per cent. based on GE’s highload pre-mix transfer technology. 9%. that enable customers to unleash more potential from their existing gas turbine and balance of plant assets.25 million dollars annually in fuel costs. Georgia collects around 30. These platforms feature technology innovations.and softwarebased. says GE. Tracking center. The insights derived from analysis of this operational “big data” can be applied to help customers expand their earning power while reducing operational costs and risk. GE’s Monitoring & Diagnostics Center in Atlanta. treat minor issues before they lead to catastrophic events. Performance advancements based in part on extensive data analytics of its global installed gas turbine fleet are being integrated into 9F-3 and 9E new gas turbines units. As these “intelligent” machines communicate their operating statistics through an average of 100 physical sensors and 300 virtual sensors on each gas turbine. n 20 GAS TURBINE WORLD September – October 2013 9F gas path upgrade.000 hours of operating data daily for storage and evaluation that is generated by more than 1600 gas turbines across the globe. derived from extensive data analytics of the GE fleet’s real-world operating data. and dynamically adjust performance to improve efficiency and reduce parts wear and tear. says GE. Program engineers estimate that unlocking the full capacity of a 500MW power plant could be worth more than $500. both hardware. Power output of the 9F-3 can be increased by up to 6% and fuel efficiency by up to 2%.” Large data pool As of September 2013. both hardware and software. . the GE team can help operators translate that information into actionable decisions.8% and fuel efficiency by up to 0. GE says it is tapping into knowledge gained from this data analysis to develop new technology breakthroughs. GE says it has achieved 100 million hours of operational data documented on its globally monitored gas turbine fleet of more than 1600 units.demand increases being forecasted across Turkey. operators can more effectively identify potential barriers before they occur. Power output of the 9E can be increased by up to 3. while a public utility could reduce its heat rate efficiency curve by 1 percent and save up to $1. 9E gas path upgrade. Armed with these data-driven insights.000 annually in increased revenue. 00 (includes priority delivery) (includes airdrop delivery) ORDER ONLINE www. worldwide. spec and cost-out your own gas turbine power projects. Vol.” BUY THE BOOK. Domestic USD 170. 2013 GTW Handbook. There’s only one way to plan. every new model and every reference plant design on the market. 30 200+ pages Putting the Power in Your Hands. GTW Handbook is the comprehensive resource that global power professionals reach for. And you’ll find it all in the 2013 GTW Handbook. when success depends on “doing it by the book.gasturbineworld.com . You need the most current and accurate performance ratings available for every production engine.BY THE BOOK.00 Foreign USD 200. using a piloted air-blast type nozzle. which surely is the most challenging of marine environments. In addition to hovercraft. the new engine is being proposed for other potential marine and industrial roles.S. meaning more than 300 engines over the next 20 years. Power density As an aero-derivative engine. including operational units and spares.4 x 2. This low emissions. The SSC will be powered by four MT7 gas turbines. Navy’s current air cushion landing craft. The combustor liner and transition are air-cooled. Light weight and small size engine is well-suited for power generation. materiel. This first round of engines will be delivered to Textron in 2015.000 rpm output shaft speed on marine diesel fuel with a specific fuel consumption of 0. o Gensets.S.MT7 marine gas turbine to power new hovercraft fleet By Robert Farmer New turboshaft engine will power next-gen amphibious hovercraft being developed to rapidly transport personnel. Boost power for stealthy high-speed displacement hull designs running on combined diesel and gas turbine powered waterjet propulsion. o Offshore. Navy SSC project. The pressurized compressor discharge air flows through this array of multiple holes. R olls-Royce Marine is supplying the main propulsion systems for the new ship-to-shore connector (SSC) hovercraft vehicles being developed as next generation replacements for the U. Power output is quoted in a nomi- nal range of 4. enabling each SSC to transport up to 74 metric tons of cargo at speeds over 35 knots.000 shaft hp) at 15. with a dry weight of less than 1. which has contracted for MT7 gas turbines for the initial development craft. gas compression or pump drive on platforms and FPSO vessels. with extensive use of corrosion and erosionresistant materials and coatings. cooling the surface with an insulating layer (or film) of air to protect the metal.000 to 7. about 5 x 2.5% efficiency). As opposed to conventional combustor cooling designs. the engine will improve fuel efficiency by 11 percent over its predecessors. specifically: o Patrol boats. and vehicles from ship to shore. Compact generator set could produce 4 to 5MW of base load power at over 33% net simple cycle efficiency for surface ship combatants. Critical parts are protectively coated to withstand sand erosion and salt and water ingestion corrosion attack during hovercraft operation. kerosene and F76 military diesel. marine diesel. The engine is fully marinized for offshore and coastal service. low smoke combustor is designed to handle a variety of liquid fuels including distillate.9 ft in size (LxWxH) including all engine-driven auxiliaries. slots or channels. First 22 GAS TURBINE WORLD September – October 2013 test hovercraft should begin sea trials in 2017 and become operational in 2020. each nominally rated at 6000 to 7000 shp. This single annular combustor has multiple fuel nozzles at the head end. For the U. A 14-stage axial high-pressure (HP) compressor is followed by an effusion-cooled combustor. Fully funded. This allows engine operation at high combustion and high turbine inlet temperatures for . hundreds of very small diameter holes are machined into the liner wall at an angle to the incoming airflow. driving lift and propulsion systems through gearboxes. And offshore mission range has been extended to 25 miles from 15 miles for the air cushion hovercraft now in service. the program could extend to 73 craft. According to R-R engineers. which use large cooling holes.000 to 5. but not its cold-drive torque tube. the marine MT7 is rather compact. Engine design The MT7 is a two-shaft gas turbine. RollsRoyce Marine is working with hovercraft builder Textron Marine & Land Systems.000 lbs.000 kW continuous (about 6. the MT7 will deliver a 25% increase in power compared to the current air cushion landing craft engines. At the same time. with effusion film cooling. with an axial compressor and twostage axial gas generator turbine on one shaft and an aerodynamically coupled two-stage free power turbine forming the second shaft. they note.4 lb/hp-hr (34. maximum power and performance. fully annular combustor. with higher efficiency at part-loads and surge-free compressor operation with rapid acceleration and deceleration capabilities. lube oil pressure and scavenge pumps. drives concentrically out the front end of the engine. The guide vanes also provide more efficient variable speed operation. MT7 turboshaft engine features a 14-stage compressor (with variable geometry vanes on six stages) and 2-stage high pressure turbine on the first spool.1” 34.5% efficiency) for continuous duty output on a 100°F day. operating on marine diesel and allowing for 12-inch inlet and 20-inch exhaust losses. Drives include the dual pressure fuel pumps. and an AC alternator. providing precise engine control. GAS TURBINE WORLD September – October 2013 23 .4 lb/hp-hr SFC (34. A primary lubrication system provides regulated oil pressure. controls the combustor igniters and regulates engine bleed valves. and low pressure sump venting. Aeroderivative MT7 engine is rated at 5.9” Marine MT7 gas turbine. The compressor rotor drives the bottom-mounted accessory gearbox through a jackshaft and bevel gear arrangement. The free power turbine airfoils are not cooled. driven by a two-stage axial free power turbine. An engine-mounted full authority digital electronic control system (FADEC) for fuel control includes advanced health monitoring and prognostics functions. These are used to modulate air flow and improve engine performance across a range of different operating conditions.230 shp and 0. MT7’s modular design and con59. the compressor features six stages of variable geometry guide vanes at the forward end. with shaft rotation counterclockwise when viewed from exhaust end.7:1. The lube oil sumps are sealed so that the engine can operate through a wide range of angles. filtering and cooling. 28. The separate low pressure LP shaft.5 feet in diameter.000 rpm at full load. The control system has dual-redundant architecture. Bare engine is about 5 feet long (not including torque tube) and less than 2. With an overall pressure ratio of 16. A torque tube at the compressor front end drives into lift fan and propulsion fan gearbox systems on the SSC. Starting is through a pneumatic air turbine starter motor that drives into a pad on the accessory gearbox.5” Two-spool marine design. with one controller metering the fuel while the redundant controller is in hot standby. with a concentric output torque tube out the front compressor end. The active duty controller also positions compressor variable vane geometry. The compressor is directly coupled to and driven by an axial twostage HP turbine featuring internal air-cooled nozzles and blades on both stages. and an air cooled 2-stage free power turbine as the second spool. Accessories Nominal power shaft speed is 15. dry sump scavenge. weighs just 972 lbs dry. SSC craft ratings Ratings are at Navy standard day 100°F ambient temperature.or 60-Hz air-cooled generator through epicyclic reduction gearbox could be packaged as a compact module that would also be suitable for industrial power on offshore platforms and FPSO vessels. The compact CODOG propulsion package allows for a small superstructure (very low radar profile) combined with a high-speed displacement hull. Such a vessel would excel in fast attack and high-speed patrol and interdiction roles with stealthy radar signature and low waterborne noise. performance upgrades.000 rpm) on demand.700 shp for max speed. operating and maintenance expertise. the already marinized and shock-resistant MT7 would provide 4000 to 5000kW of shipboard electric power at an estimated generator set efficiency of over 33% burning marine diesel oil. and easily accessible components. n Ship-to-shore transport. . R-R executives point out that “field-proven AE aero engine upgrades exist today that could increase the MT7 available power by up to 20 percent and extend engine life. One potential naval ship role en- visions high-speed attack craft built around a combined propulsion system using Kamewa waterjet propulsors powered by twin MTU high-speed diesels for routine cruising and the MT7 gas turbine for high-speed boost. Indiana (former Allison Engine works). high reliability and maintainability characteristics. says R-R Marine. sea level. Other applications R-R designers note that the MT7 is “suited to a variety of system configurations” in that it offers ship designers and builders increased flexibility in terms of propulsion system layout for both mechanical and electrical drives.” For the hovercraft application. men and equipment from ships onto land.” MT7 engines and components are built at Rolls-Royce manufacturing 24 GAS TURBINE WORLD September – October 2013 facilities in Indianapolis. specific ratings at those standard Navy conditions are assigned to the MT7 gas turbine engine for its power role in the ship-to-shore connector craft program. 40% relative humidity and include 12inch inlet and 20-inch exhaust losses (water gauge) for the SSC installation. this potential power growth capability could allow larger payloads or provide life cycle cost savings if the extra power is not needed. are said to allow reduced maintenance time and costs. There are two power output requirements that are critical: one is for maximum continuous power of 5. Currently.250 to 15. This provides a wealth of support capabilities including spares. modules. Project engineers point out that the gas turbine engine could also be configured into a very lightweight singlelift mechanical drive package to power high-speed centrifugal or axial gas compressors for gas lift and reinjection or for oil and water pump drive operation on offshore installations. Both outputs are to be available at power turbine output shaft speeds of 95 to 100% (14. Common core Common core technology. To ensure high reliability. Only minor variations from the aircraft engine design are required for the SSC application. MT7 is a direct derivative of the AE 1107C-Liberty turboshaft gas turbine design (aka T406) that ended up retaining over 90% component commonality with the aero parent. all the engine-mounted actuators and sensing devices that interface with the FADEC are also duplex designs. the AE engine family’s total cumulative operating time now exceeds 52 million hours.struction. As ship’s service generator set. The small MT7 gas turbine driving a 50. compressor bleed air system and power take-off shaft to suit the hovercraft role. Next generation amphibious hovercraft will be powered by four MT7 gas turbines driving lift and propulsion fans through gearboxes at over 35 knot speeds carrying a payload of 74 tons for rapid deployment of vehicles. note company design engineers: mainly a new engine controller. training. with “oncondition” maintenance capability as standard. Marine MT7 operators also stand to benefit from an over 80% parts commonality with the company’s other AE family of engines currently in volume production which include the popular AE 2100 turboprop and the AE 3007 turbofan. in the same facilities that produce the other AE engine family members. All told. is one of the keys to the MT7’s initial cost. Basically all of the internal engine design and components are identical.230 shp (on a 100°F day) and the other is for maximum intermittent power of 5. turbine operators are under more pressure than ever to reduce emissions and make their operations more “green”. commissioned in 2002. It’s simple and fast to implement. and offers a positive return on investment within 12 months.0 Steam to Fuel Ratio Power and Heat Rate 40% Contact us to learn how we can quickly help your turbine generate more power — and more profits.5 5. all while keeping costs down. 0 Power 20% 0% -10% Heat Rate -20% -30% -40% 0 0.5 2. It’s the only emissions control technology that actually improves efficiency.0 1.0 1. and degrade performance.5 3.chengpower. CLN® pays you back.0 4. pp. with a track record of over 2 million operating hours across more than 200 global installations.com .5 1. Easier said than done – nearly all emissions control systems are expensive.0 2.5 2.5 4. That’s where the CLN system* comes in. commissioned in 2002.5 1. 30% *See Gas Turbine World. which increases operating costs.0 3. Suite #120 Mountain View. 12-17 10% Kapaia Power Station.0 2. supplies over 50% of the power required by the island of Kauai using Cheng Power Systems’ technology.5 3.39. supplies over 50% of the power required by the island of Kuai using Cheng Power Systems’ technology. NOx Emissions 1000 100 ppm These days.Most emissions control systems drain your profits.0 Steam to Fuel Ratio www.com 480 San Antonio Road. CA 94040 Email: info@chengpower. May/June 2009 v. Kapaia Power Station. slow to implement. increasing saleable power while reducing fuel consumption and carbon emissions. Cheng Power Systems’ technologies (including CLN and ACS) are proven. 10 1 0. thanks to the cogeneration and combined cycle design of the Dubal power station. its entire planned production volume was 135.8 to 1 9. o Timetable. Main goal of the combined upgrade projects is to increase power output and efficiency of the overall plant to cut costs and be more competitive. which more than met the load demand of 302MW at startup.8 to 1 753 lb/sec 775 lb/sec 1020°F est 1040°F Air flow Exhaust temperature *Source: 1980 Gas Turbine World Handbook Bilfinger Babcock CZ to remove and replace the old HRSGs with newly designed units. Highlights: o Firing temp.6 MW 88. has increased five-fold in the intervening years. An initial installed capacity of 483MW. Today.8% of the total power generated is fuelfree. six Fr 9Es and three 13E2s) operating in combination with 7 steam turbine generators (two backpressure and five condensing types). smelter capacity is up over one million tons per year with an onsite generating capacity exceeding 2.Dubal upgrading combined cycle plants to lower cost of electricity By Junior Isles Dubai Aluminium is upgrading its 2. W hen Dubai Aluminium (Dubal) began commercial operation in January 1980. Site rated output of Dubal’s upgraded 9B gas turbine units is being increased from 80MW (when first installed) to 88MW on a 35°C hot day. Dubal awarded General Electric a contract in July 2012 to upgrade all five Fr 9B gas turbines.0 MW 11. Dubal is currently upgrading five General Electric Fr 9B combined cycle plants commissioned in 1980 by retrofitting new engineering design technology (including DLN combustion) to the gas turbines and replacing the old HRSGs with newly designed units that will improve overall power output and efficiency.350MW power station comprises 23 gas turbine generators (eight Fr 5s.124°C (2. Electricity needed for smelter operations is said to account for fully one-third the cost of aluminum production. Power generation The power generation capacity of the Dubal combined cycle power station has grown substantially since the smelter’s commissioning in 1979. PG9111B *Installed Upgraded Performance specs 15°C ISO Rating 35°C Rating Base load output Heat rate (per kWh) 82.4% N/A Gross efficiency Firing temperature 1950°F 2055°F Pressure ratio 9. five Fr 9Bs. Unit power output is expected to increase by 10% to 88MW (at 35°C) from 80MW. o Steam output.350MW to supply all of the smelter’s electric power needs. Station project engineers report that.350MW power station to boost power output and reduce cost of electricity for smelter operations.210 Btu N/A 30. gradual improve- . Over the years.055°F). one 13DM. o Power output. Gas turbine upgrade includes raising firing temperature to 1. approximately 36. Gas turbine upgrade and HRSG projects should be completed by the end of April 2015. today’s 2.000 tons per year. From an initial 13 gas turbines. Unit HRSG output is expected to increase by 24% to 228 ton/hr from 180 ton/hr. This was followed in May 2013 by a contract with 26 GAS TURBINE WORLD September – October 2013 Comparative 9B power output. Each gas turbine is ducted to its own HRSG (thirteen single-pressure and ten dual-pressure types) that produce waste heat recovery steam for the seven steam turbine generators and a seawater desalination plant that produces up to 30 million gallons of drinking water per day. August 2012 • Volume 42 No.Stay Ahead of the Curve 2013 Performance Specs 29th Edition Saturn 110 MW upgrade may use nanotechnology January . engineering trends. operators. power plant budget prices. industrial and marine turbine operators around the globe. index to GT product and service suppliers.com . oil & gas. Evaluation and Procurement IGCC cutting COE price levels by 20% 30MW at 41% with low NOx page 19 page 14 page 20 Shale gas boom fueling electrical load demand ISI adds 6MW to Trent rating SGT-300 mech drive ready to make debut page 24 July . Includes design ratings for all GT makes and models. buyer’s-eye-view of the new model year’s field of gas turbines for utility. worldwide orders and installations.gasturbineworld. (Annual) 2013 GTW Handbook is available at www. project planners and EPCs. industrial and marine operation.February 2013 Volume 43 No. 3 Wind energy being stored as hydrogen Can CLN really reach zero CO? page 14 page 12 page 10 200MW with 15-minute start and 38% efficiency For Project Planning. 4 page 24 November – December 2012 • Volume 42 No. (Annual) GTW PERFORMANCE SPECS Comprehensive. Operation and Maintenance GAS TURBINE WORLD MAGAZINE The industry’s most in-depth periodical devoted to Gas Turbine news. 6 page 25 Your Guidebooks to the Changing World of Industrial GT Projects. (Bi-monthly) GTW HANDBOOK The “go-to” reference for Gas Turbine buyers. oil & gas. owners. Proposals. The industry’s premier resource for performance comparison. emerging technologies and the defining issues that impact utility. technology assessment and product specification. Application. 1 May – June 2012 • Volume 42 No. Engineering. including all associated civil and control systems modifications on the existing footprint after decommissioning and disposal of the existing units. from 180 t/h to 228 t/h (at 45°C ambient) and noise levels will be effectively reduced to 85 dBA. This will see the operating pressure rise to about 5 bar for the low pres28 GAS TURBINE WORLD September – October 2013 sure part of the steam turbine. HRSG replacement Deutsche Babcock. Engineers are mulling a mix of single. Design features David Ilik. ap- HRSG option.656 1. which more than met 302MW demand. According to the contract. Bilfinger Babcock CZ’s Project Manager of the Dubal project said: “The decision on the option will be taken six months from the contract date of signing.656 2. 2015. that have been in operation for more than 30 years. head of Engineering at Bilfinger Babcock CZ. oil and gas. n Dubal capacity and load growth.or dual-pressure will be taken at the end of this year.5 bar. depending on the ambient temperature.350 1.127 Capacity (MW) 1.407 1. testing and commissioning works for the upgraded Fr 9B gas turbine HRSGs. The decision on whether these last two units will be single. The turnkey contract covers design. higher parameter steam turbine. an EPC provider for power.295 1. “We increase the heating surface and reduce the pinch point and approach point.and dual-pressure designs. as are the single-pressure boilers. supply. installation. steam pressure 20 bar(a). The project is split into six separate Provisional Acceptance Certificates (for the five HRSGs plus the feedwater station) with roughly four months between deliveries. the boilers for Units 4 and 5 could potentially be designed as dual-pressure HRSGs or single-pressure HRSGs. operate at a maximum continuous rating of 136 t/h ambient temperature 28°C.2% thermal efficiency in 2012 producing more power while burning less fuel per MW generated.656 1. is scheduled for April 23. The smaller the pinch and approach temperature. which can vary from 5°C to 45°C. Improved performance After conversion.” Pinch point is the difference between exhaust gas temperature and temperature at the evaporator. has partnered with associate company Bilfinger Babcock CZ on the HRSG project.900 1979-82 1982-89 1989-95 1995-98 1998-02 2002-04 2004-05 2005-06 2006-08 2008-12 . If the dualpressure boiler option is used for units 4 and 5. proach point is the difference between the saturation temperature and economizer outlet temperature. Depending on the turbine upgrade. then outlet steam parameters will be in the range of 90 to 100 bar. petrochemical and chemical industries. The temperature of the exhaust gas from the upgraded Fr 9B gas turbines is expected to fluctuate between 520°C and 580°C. This change may also require investment in a new. Dubal’s initial installed capacity of 483MW. explained how the higher efficiency is achieved. The new boilers receiving this hot exhaust gas will play a key role in increasing the overall efficiency of the combined cycle units. The existing single-pressure boilers. Jan Dvorak.329 483 553 675 883 1979-82 1982-89 1989-95 1995-98 1998-02 2002-04 2004-05 2005-06 2006-08 2008-12 Load (MW) 302 346 481 674 915 1. desalination.ments in efficiency enabled the station to operate at 44. three of the boilers will be replaced by singlepressure HRSGs. manufacture.623 1. has grown five-fold in the intervening years. the plant steam capacity of each HRSG is projected to increase by 24 percent. together with the final acceptance certificate.” The steam turbines and desalination equipment are at the moment designed to operate at 1. the more efficient is the HRSG. with an option on the two remaining boilers.096 1. Handover of the last unit. 2. has always been a group you can rely upon. or just disappear. Yet.000 hours of top engineering talent have been invested in the process. under the same ownership for 25 years.com www. Independent.com . They change ownership. Just make high quality software products. outsource development and support. new versions are back-compatible with older ones.thermoflow. no matter if your application is district heating. For example. Thermoflow’s heat balance design and cost estimation software suite offers you the stable solution! Knowledge = Power +1 508 303 5033 info@thermoflow. despite the vast enhancements in scope and capability over 25 years. responsible only to you. cogeneration or desalination. the latest release of GT PRO can read a file saved in 1992. Our philosophy is old-fashioned. by contrast. conventional coal gasification or solar thermal. the customer. Nearly every year since 1987 a new version of the Thermoflow suite has been created with ever increasing capabilities and user-friendliness. Thermoflow.Software companies come and go. keep maintaining them well. About 300. sometimes in the middle of a project. and keep supporting our customers well. How many software products show this level of stability and respect for their customers’ legacy? No matter if your interest is combined cycle. Mongolia Three projects in build and another five approved Inner Mongolia. commercial operation to supply gas to Beijing is scheduled to start at the end of this year. Ukraine China to build four IGCC plants under advance credit agreement Ukrainian President Viktor Yanukovych has reached an agreement with China for the construction of 4 coal-based IGCC power plant in Ukraine. Last year. Shanxi Province and northeastern Liaoning Province. US Kemper County 582MW IGCC plant start-up delay Southern Company recently announced a delay in the schedule to begin operation of its 582MW Kemper County coal project that is currently under construction by its subsidiary. the Kemper County project achieved several major construction milestones.4 billion. include after-tax charges of $93 million and $704 million respectively.3 billion cubic meters of syngas each year. the project cost was estimated to be over $3.6 billion cubic meters. China Coal-to-gas project ready to supply gas Now that the initial phase of the Hexigten coal gasification project in north China has been completed and fully tested. will have a combined capacity of about 4500MW.8 billion cubic meters in 2011 to 27. Southern now expects the project to be completed in the last quarter of 2014 and the costs to exceed $4 billion.IGCC and Gasification The total production capacity of “underconstruction” coal gasification projects in Inner Mongolia has reached 17. Other major coal gasification projects are also reported underway in northwest China’s Xinjiang Uygur Autonomous Region. Coal gasification projects are a key part of the region’s economic development. The Hexigten coal gasification plant. with estimated reserves of more than 800 billion tons of coal. Both are projected to start operations around 2020. the country managed to cut gas imports from 44. in three phases. Another five gasification projects in the region. By the third quarter of 2013. including first fire of the facility’s two gas turbines. Ukraine’s national oil and gas stock company has signed a credit agreement with China Development Bank Corporation for $3. or nearly half of the capital’s current annual gas demand. Yanukovych said that the plants will be built as a part of the policy of reducing Ukraine’s dependence on imported natural gas fuel. using the same amount of feedstock. Mississippi Power.3 billion cubic meters in 2012. which will be built in the city of Iwaki and town of Hirono.2 billion and will operate on domestic coal feedstock. have a combined capacity of 20 billion cubic meters. Industry project engineers point out that higher efficiency of IGCC technology can be expected to generate 20 percent more power than conventional coal power plants. Naftogaz Ukrainy. Japan Two coal-based IGCC power plants planned for Fukushima Tokyo Electric Power Co (Tepco) and Mitsubishi Heavy Industries have announced plans to build two integrated gasification combined cycle (IGCC) stations at Fukushima. Operations were targeted to commence in 2014. Company earnings for the three months and nine months ended September 30. began construction in August 2009 with an estimated investment of $4. the projected cost of the IGCC plant was estimated at $2. This stage of project development is capable of producing 1. for which preparatory work has been approved.7 billion under state guarantee for projects involving the replacement of gas with coal. In the second half of this year. Mitsubishi group companies will have a majority stake in the new plants while cashstrapped Tepco will be in charge of running the facilities as soon as they are operational for commercial service. The two facilities. When Mississippi Power held a ground-breaking ceremony in December 2010 for start of construction. with a May 2014 deadline to start service to retain certain tax incentives. is being developed as a clean energy resource base for Beijing and north China. each with a design capacity to produce 4 billion cubic meters of syngas per year when fully operational. In April 2013. 2013. Coal-water slurry fuel technology and the construction of plants for the gasification of coal will make it possible for . the first such project to be approved in the coun30 GAS TURBINE WORLD September – October 2013 try. the gasification plant will have a total capacity of 4 billion cubic meters annually. When completed. three coal-based gas projects began construction in the region. Steam turbine testing was completed in late September. which were completed August 28 and September 4. related to increased cost estimates for the construction of the Kemper County project.2 billion. weight • Track power.3361 International: 1.762. combined cycle and mechanical drive applications. Common Searches • See price and performance changes by specific models over time • Compare OEM offerings by price.783. pressure ratio and efficiency upgrades of specific models • Review industry pricing and gas turbine design performance trending Ask a Sales Rep for a Live Demonstration Toll Free: 1. year and power output for simple cycle.. The database presents OEM gas turbine design ratings by model..5147 Key Search Fields • • • • • • • • • • • • • • Handbook Year OEM Company Name Gas Turbine Series Gas Turbine Model 1st Year Unit Available 50/60 Hz Frequency ISO Base Rating kW Heat Rate Btu/kWh Pressure Ratio Flow lb/sec Exhaust Temperature Turbine Speed rpm Weight Size LxWxH Simple Cycle Electric Power Plants • Combined Cycle Electric Power Plants • Mechanical Drive Gas Turbines . Industrial Info Resources & Searchable Online Database NEW: Gas Turbine World Online Database Access Handbook Performance Specs (from 1976) and Gas Turbine Plant Prices (from 1982) to current year in a searchable online database.GET INSTANT ACCESS TO Performance Specs & Plant Prices Online. type.713. footprint. frequency.800. . Urea has the highest nitrogen content of all solid nitrogen fertilizers. Dakota Gas executives say they are in the final stages of a Front-End Engineering and Design study for the production facility. a subsidiary of Basin Electric. Donetsk. while reducing maintenance costs compared to standard commercially available refractory technology. The company also has introduced a proprietary refractory lining system for gasifier vessels that extends the operating life cycle and overall availability of the gasifier. create new jobs. China Coal to methanol expansion project Jiutai Group has selected GE’s 8. The compressors will be manufactured at GE’s service center in Houston. Urea is a granular fertilizer commonly used in agricultural applications. Dakota Gasification Company president and chief executive officer.7 MPa high-pressure gasification technology for a coal-to-methanol factory expansion project in Inner Mongolia. which converts coal to syngas. environmentally friendly technologies. according to Yang Dan. Submit News Articles & Images Email news articles. This extended slurry technology can be used to improve efficiency and reduce capital expenditure. contact information and high-resolution image files to gtwnews@gmail. Future coal-to-chemical projects in particular stand to benefit from GE’s integrated Radiant Syngas Cooler (RSC). particularly for less expensive. “We’re excited about the potential to build onto the fertilizer products we already produce.5 billion a year in avoided gas imports. For this project. Gas Turbine World reserves the right to edit printed submissions for clarity and context. and Odessa Regions using Shell technology approved by China. Texas. gasification process design package. Plants for the gasification of brown and bituminous coal will be built in Luhansk. both of which are manufactured in the Great Plains Synfuels Plant’s process.5 million metric tons of “coal-to-methanol” annually. Urea production requires anhydrous ammonia (made from natural gas) and carbon dioxide. a joint venture with the Shenhua Group. delivering one percentage point improvement to the overall plant availability. boosting the efficiency and reducing the emissions of coal-to-chemical facilities. The expansion will enable the factory to boost methanol production to 1. business leader Power Generation China at GE Power & Water. Please accompany image files with copyright/credit information and written permissions for use. efficiency and emissions while processing a wide range of coal feedstocks. In 2012. ND. The credit line is open for 19 years (2012-2031) allowing 4 years for the preparation and coordination of confirmed projects and the signing of individual credit agreements. enabling economic gasification of a wider envelope of coals. and save up to $1. Adopting GE gasification technology is expected to reduce methanol production costs by as much as 11 percent compared to the original facility. GE sees huge potential for its technologies and experience. The successful operation of the demonstration plant will help to propel development of China’s burgeoning coal-to-chemical industry. tested at its facility in Connersville. The expanded methanol production facility is scheduled to begin commercial production in 2016. the advanced refractory lining system used for IGCC plants is expected to perform 50 percent longer than GE’s standard refractory technology. The new hybrid gasification technology was developed using extensive experience from Shell’s coal and residue gasification technologies.com. GE Oil & Gas will also supply three model DH7JM compressors to be used for polyethylene and polypropylene production. has submitted an application for an environmental permit for a urea production plant at its Great Plains Synfuels Plant near Beulah. Subject to a successful FEED study and final board approval. GE’s gasification technology utilizes the company’s latest-generation RSC heat recovery system to capture heat in the form of steam during the gasification process. and advanced refractory technologies. China Gasification technology demonstration phase Wison Engineering Services Co. GE Shenhua Gasification Technology Company.IGCC and Gasification Ukraine to replace around 4 billion cubic meters of imported natural gas with its own coal-derived syngas. with a focus on using coal in a much cleaner way. says Dan. will supply the license for GE’s gasification technology. technical services and key equipment. China Focused on coal to chemicals and IGCC power generation Given the vast coal reserves in China and the importance of the country’s coal-tochemical industry. and offers a more compact design based on water quench technology. This enhanced steam production greatly reduces the need for additional steam or power produced from stand-alone boilers. This is expected to provide a stable market for the sale of around 10 million tons of coal per year. the urea plant would be scheduled for completion in early 2017 with a capacity to produce 1. For instance. reports that its Shell-Wison hybrid gasification technology demonstration plant has successfully started up in Nanjing. lower rank coal feedstock. The company combines GE’s expertise in coal gasification technology with Shenhua’s expertise in applying a broad range of technologies for coal gasification and coalfired power generation.” said Andrew Serri. but costs less to handle. North Dakota Dakota Gas studying urea facility at Synfuels Plant Dakota Gasification Company. Two other agricultural fertilizers currently produced at the Synfuels Plant include anhydrous ammonia and ammonium sulfate. a 100 percent increase in capacity. Purpose of the plant is to demonstrate the 32 GAS TURBINE WORLD September – October 2013 reliability of the technology and evaluate its operating economics. Company says this application is a key preliminary step as part of the investigation of the project.100 tons of urea daily. extended slurry. Indiana and shipped to China during 2014. It also will exceed China’s national energy rules that require industries to utilize more efficient. store and transport than other nitrogen-based fertilizers. GE announced the creation of its GE Shenhua Gasification Technology Company joint venture with the Shenhua Group to develop and deploy energy projects in China. GE is also introducing a proprietary technology to increase slurry concentration above traditional methods. .Introducing oil fuel firing with 25 ppm NOx Best-in-class performance meets best-in-class emissions siemens. And that’s great news for the environment.com/energy Through a continued focus on combustion R&D. That means start-up and operation on oil. In addition to achieving 9 ppm on natural gas. has never been cleaner. not just in the lab or on the test bed. you will meet the lowest possible NOx emissions and will achieve steady state emissions at low load levels. our F-class gas turbines can now meet 25 ppm NOx on fuel oil when gas isn’t available. Answers for energy.this achievement has been proven in operating plants. With this advanced combustion technology.. . as well as natural gas fuel. What’s more. Siemens has achieved best-in-class levels of NOx emissions. or the unique energy challenges you face.GE Power & Water flexible Are you enough for today’s energy demands? You will be. with the FlexEfficiency* Portfolio from GE.com + plants + gas turbines + steam turbines + generators + control systems = services FlexEfficiency Portfolio *Trademark of General Electric Company. So regardless of your region. It’s one of the most flexible power portfolios on the planet. And we’ll bend over backwards to make sure of it. given the increased reliance on renewables. ge-flexibility. . And it is specifically engineered to meet the energy challenges of today’s grid. this one portfolio can help.