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January-February 2011
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HaigHt Notes
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A Four-Letter Word Called Retirement

There has been much talk in recent years about the mass retirement rate predicted to begin in 2011. Companies scrambled to increase their investments in training and recruiting programs to ensure that as a large percentage of the global population turned 65, talent was ready and in place to meet the needs and expectations of customers and shareholders, and ensure that business as usual continued. The problem is that along the way, business as usual changed. 2011 marks what some analysts call the tip of the retirement iceberg. The U.S. Census Bureau released figures predicting that 2.8 million U.S. citizens will turn 65 in 2011. Thats a whopping 316 every hour. In Japan, 23% of its population is now over the age of 65. Some have called the baby-boom generation a demographic time bomb for the workforce, anticipating a mass exodus of labor. In the United States, census data shows that about 76 million people were born between 1946 and 1964 (the baby boomers). But only 46 million more are coming along in Generation X, which follows the boomers. The gap between boomers and Xers led to speculation that we were in for a severe job shortage when the boomers really kicked into retirement mode, which was supposed to be 2011. Now, it seems as if a generation credited with redefining everything from music to politics will now have a strong hand in redefining retirement. As the economy turned, companies offered early retirement as a way to counteract the job cuts needed to save costs. A significant number of boomers opted for this, but rather than settling down they went back to school or started their own companies. Now analysts are saying that the mass retirement that had been predicted to begin this year might not be realized thanks to myriad factors, among them, years of job cuts and a still fragile economy that isnt yet replacing jobs. Not the best news for graduates who had been promised a multitude of opportunities upon graduation. Some analysts now suggest that the job outlook for graduates will be much worse than anyone could have imagined. In addition to frail economies and shrinking job markets, graduates also must contend with early retirees taking advantage of the same training and education opportunities they have utilized. Now, hiring companies have an employee pool to draw from that consists of young people fresh with education but no experience and a generation of experienced engineers with fresh training. Young and old, retirement is quickly becoming a four-letter word. Graduates are ready for a generation to step aside so that they can move into the workforce they have studied to enter. But a large percentage of baby boomers are not ready or financially able to step aside. It seems a generation that reshaped the world isnt quite finished. Changes to the retirement age have made global headlines recently. China and the U.K. are two examples where 65 is now being challenged as the age of retirement. Time will ultimately reveal the outcome, and thanks to improved health and science measures a lot of us are living and working a lot longer. Perhaps for me and my fellow Gen Xers, 80 will be the new 65. A
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2 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
Contents
January-February 2011
Features
TRAINING & EDUCATION CIMAC Sets Sights On Shanghai.............................................................................6 Apprenticeship To Success ...................................................................................16 Worldwide Training Program Started By MTU .....................................................36 INDUSTRy NEWS Distributed I/O Systems ..........................................................................................8 Diesel Switch Approved For Marine Use ..............................................................13 Intelligent Combustion Monitoring ......................................................................19 New Accelerometer And Interface Kit From The PCB Group ...............................38 FW Murphy Expands Powerview 101 Flexibility With New Configuration Software ........................................................................54 Paradox Engineering Opens Office In Singapore ..................................................56 Turbocharger Design System Software .................................................................60 EMISSIONS WORLDVIEW Recycling Wastewater With Biogas Fuel Cells ......................................................10 POWER GENERATION Allweiler Fuel-Injection Skids For Iraqi Power Plants ..........................................12 MAN Introduces New Industrial Gas Turbine ......................................................14 Sequencing A Faster Start-Up ...............................................................................18 A Standard Decision On Paralleling ......................................................................40 Cultivating Biogas-Fueled Power ..........................................................................46 LSA 40 Low-Voltage Alternator.............................................................................51 Flexibility And Performance .................................................................................62 TURBINE OVERhAUL & REPAIR Laser Precision For Turbine Alignment ................................................................20 Siemens Joins Power Diagnostics And Specialty Monitors ...................................33 An Ensemble Cast At Chromalloy .........................................................................42 WORLDS BEST POWER PLANTS The Worlds Best Power Plants 2011 ....................................................................22
Cover designed by Brenda Burbach
On The Cover: Our annual look at The Worlds Best Power Plants highlights several noteworthy projects around the globe. Follow dgtww on:
Global Markets Global Coverage

MARINE PROPULSION A Powerful Defender .............................................................................................37 MAN Powers LNG Carrier ....................................................................................52 Automated And Integrated Control System ..........................................................57 Two Giants Join In Hercules-C .............................................................................58 INDUSTRy NEWS & ANALySIS Update On European Energy Policies ...................................................................44 OIL & GAS AEP Joins Effort To Build More Efficient CO2 Compression System....................48 Dresser Waukesha Rolls Out New Gen-Set ...........................................................53 RAIL TRACTION Saving Fuel Through Speed Control .....................................................................50
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Departments
Industry Drivers ......................................................................................................4 Dateline ...................................................................................................................9 Featured Products .................................................................................................39 Newsmakers ..........................................................................................................61 Advertisers Index .................................................................................................66 Marketplace ...........................................................................................................66 World Viewpoint ...................................................................................................68
Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 1 3
Industry drIvers
ROLLS-ROYCE
Rolls-Royce has achieved full power operation of its first production MT30-powered main turbine generator set delivered to the U.S. Navy. The MT30, delivered to the U.S. Navy for the DDG-1000, USS Zumwalt program, achieved full power operation at 36 MW during testing at the U.S. Navys land-based test site in Philadelphia, Pennsylvania, U.S.A. The MT30 has been developed to meet the growing demand by navies for higher power gas turbines in the 34 to 40 MW range and can be configured for mechanical or generator drive.
Cummins is investing US$70 million in the facility and related production equipment, with 85% of the products made in Turkey to be exported to Cummins customers across Europe, the Middle East, Asia and Africa.
EJ BOWMAN
A new charge-air heat exchanger designed specifically for larger capacity turbocharged diesel engines has been launched by U.K.-based EJ Bowman Ltd. The new unit, JK 190, is intended for use with engines rated up to 650 kW and extends Bowmans existing chargeair cooler program by offering a product for larger capacity marine propulsion systems, as well as engine test and development programs, the company said.
ALFA LAVAL
Alfa Laval, a company that specializes in heat transfer, centrifugal separation and fluid handling, signed an agreement to acquire Aalborg Industries Holding A/S for US$732 million. The closing of the transaction is subject to clearance from regulatory authorities. Aalborg Industries has about 2600 employees and is expected to generate sales of about US$484 million in 2010. Headquartered in Aalborg, Denmark, the company provides critical products, systems and service to the marine and offshore markets, as well as the power industry. Its products include boiler systems, thermal fluid systems, waste heat recovery systems and inert gas systems.
Dresser-ranD
ELECTRO-MOTIVE DIESEL
Electro-Motive Diesel Inc. signed a contract with Societe Nationale Industrielle Et Miniere (SNIM) to manufacture six SD70ACS heavy haul ac dieselelectric locomotives. The SD70ACS is a 3360 kW ac locomotive that includes an EMD IGBT ac drive system. The locomotive also features a pulse filtration system and movable sand plows on the pilot and trucks. Designed for SNIMs mining operation, the units will carry minerals and be capable of operating in harsh desert environments, according to the company. The SD70ACS is also equipped with the EMD 710-T1 diesel engine, the EM2000 microprocessor locomotive control system and the FIRE display system. The units, which will start being delivered in the fourth quarter of 2011, are designed to increase the amount of minerals that are carried per trip, the company said.
WAUKESHA BEARINGS
Waukesha Bearings Corp., Pewaukee, Wisconsin, U.S.A., has acquired KMC Inc., West Greenwich, Rhode Island, U.S.A., and Bearings Plus Inc., Houston, Texas, U.S.A. Both acquired companies are involved in the design, analysis and manufacturing of engineered fluid film bearings and seals. Financial terms were not disclosed. Waukesha Bearings is a unit of Dover Corp.s Fluid Management segment.
Dresser-Rand has been selected to supply power generation and compression equipment for five offshore projects that include a floating, production, storage and offloading vessel; a semisubmersible; a tension leg platform; and two fixed-leg platforms located in various fields around the world. The scope of the orders includes eleven gas turbine generator sets, three gas turbine mechanical drive packages and five DATUM compression trains in pressure boosting and export gas services. The orders are expected to ship in late 2011 through the second quarter of 2012.
CORRECTION
The power range of Siemens gas turbine range listed in Diesel & Gas Turbine Worldwides November 2010 issue has been updated to: Gas Turbine Power Range: Electric Generator Drive: 5.0 to 375 MW, Mechanical Drive: 5.0 to 161 MW; Steam Turbine Power Range: Electric Generator Drive: 0.04 to 1900.0 MW, Mechanical Drive: 0.04 to 150 MW.
CAPSTONE
CUMMINS
Cummins Inc. will break ground in early 2011 on a multiphased manufacturing site at the Aegean Free Trade Zone in Izmir, Turkey, the company said. The company plans to first build a filtration manufacturing plant and follow with a facility to produce alternators for its power generation business. Production is expected to begin at the 92 900 m site in early 2012 and Cummins expects to employ 800 people in Turkey within five years.
Capstone Turbine Corp., a clean technology manufacturer of microturbine energy systems, has received an order for nine C1000 power packages for a large independent oil and gas exploration and production company in the Eagle Ford Shale play in South Texas, U.S.A. The C1000 power packages together will provide prime power to central processing facilities and metering stations at remote well sites in the Eagle Ford Shale play. The microturbines, fueled by pipeline gas, will produce electricity to provide all power to the on-site equipment, including heaters, pump motors, circulation pumps and distribution panels, Capstone said.
GE
GE has signed a framework agreement to form a joint venture to help modernize the power generation sector in Russia. GE and state corporation Russian Technologies and Inter Rao Ues JSC intend to form a joint venture to manufacture, assemble, sell and service heavyduty gas-fired gas turbines in Russia. The joint venture will manufacture GEs 6FA gas turbines at a factory to be built in the vicinity of Rybinsk, Russia. The turbines are intended to address a growing need in Russia for midsized power blocks in combined heat and power applications.
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Training & EducaTion
by brent haight
CIMAC Sets Sights On Shanghai

A conversation with CIMAC President Yasuhiro Itoh
Yasuhiro Itoh, managing director of Niigata Power Systems Co., was named as the new CIMAC president for 2010 to 2013.
The next CIMAC Congress will take place in 2013 but planning is already under way to ensure the 27th gathering is a success. The CIMAC Congress, held every three years, brings together manufacturers of diesel and gas engines and gas turbines and the users of these prime movers in such applications as ship propulsion, power generation and rail traction. The 26th Congress was held in Bergen, Norway, in June and hosted more than 900 delegates from 39 countries. More than 230 papers were presented. During the 2010 Congress, Yasuhiro Itoh, managing director of Niigata Power Systems Co., was named as CIMAC president for 2010 to 2013, with responsibilities for the 27th CIMAC Congress in Shanghai, China, in May 2013. CIMAC, the International Council on Combustion Engines, was founded in 1950 as an industry forum to dis-
cuss new ideas and developments within the engine and components industry together with institutes and universities. That spirit continues to this day but now also includes a greater emphasis on end-user attendance by soliciting technical presentations from operators and designers of ships, power plants and locomotives. Former CIMAC president, Karl Wojik, created a clear strategy for CIMAC and aligned all of the CIMAC roles to create a worldwide association for large engines, said Itoh. My goal is to build on what he established by continuing to grow and strengthen this organization, a special emphasis being CIMACs geographic reach. Accordingly, one of the key tasks on Itohs agenda is to increase CIMAC participation from China and Korea. We will be seeking increased involvement from Asian countries, said Itoh. Japan has a long history with CIMAC and has been very involved with the organization. I would like to see similar commitments from China and Korea. Japan, Korea and China make up a very large portion of the manufacturing and engineering of large engines. We are in contact with key personnel in China and Korea to try and increase the involvement from companies within those countries. We are looking for ways to promote the con-
gress within that region and increase the involvement from companies located there. The 2013 Congress will be held in Shanghai. I believe it will be very successful. We are meeting with appropriate personnel to ensure participation is as strong as it can be from Asian country manufacturers. Myriad challenges face engine communities today. When CIMAC gathers in 2013, considerable focus will be on emissions. According to Itoh, regardless of the application, emissions are one of the biggest challenges for the engine landscape. Itoh sees stricter regulations as a growth opportunity for engine and turbine manufacturers around the world. Environmental protection and associated regulations are the driving force of technology improvements, said Itoh. A strong company will be stronger. Weak companies will be weaker due to such very high challenges. Emissions are among the key challenges of the engine communities right now. Within the marine industry, for example, IMO Tier 3 is approaching. IMO Tier 2 can be achieved by an in-engine solution. For Tier 3, there are a lot of different approaches. So far we dont know which is the best solution. It is both pre- and post-cylinder solutions
continued on page 8
CIMAC, the International Council on Combustion Engines, was founded in 1950. The CIMAC Congress is held every three years. The 27th CIMAC Congress will take place in Shanghai, China, in May 2013.
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Answers for energy.

aftertreatment or two-stage turbocharging for example that are currently making progress. There are a lot of terms in use today: low sulfur diesel, dual-fuel engines, heavy fuel oil, water injections, cold ironing, alternative fuels, common rail these are all popular terms in the industry today. There is an endless list of possibilities. But there are a host of options that are in development and in the market today that wont be around in three to five years. Some of the technologies being developed today will be scrapped, and some will be greatly improved. By the next CIMAC Congress, it might be a lot clearer which of these technologies is right, which will still exist. Itoh added, The question was asked at the panel discussion during the Congress this year, What comes after heavy fuel? What is next? One panelist answered, It is heavy fuel. LNG does not yet have a sufficient infrastructure. SCR if every ship installed SCR, is it possible to provide a catalyst to all of the engines? Is it possible to provide urea in all ports? It is not a viable solution yet. There is no single right answer today. Hence, we will continue to explore new technologies and developments. CIMACs focus goes beyond the engine and the turbine to include the complete engine room. Itoh said the technologies needed to address todays challenges will also come from beyond the engine. The discussion must include the integrated systems and controls as well, he said. CIMAC was founded in 1950 to discuss the problems facing large engines. The first CIMAC Congress was held in 1951, Itoh said. The key topic was heavy fuel. Nearly 60 years later, we are still discussing heavy fuel. But combustion is not the single biggest issue within the CIMAC organization. Past issues have been heavy fuel, greater fuel economy, increasing power. Now it is the time of emissions. This is not only a focus for the engine, but for all of the integrated systems and controls as well. A
Industry news
by robErTa prandi
Distributed I/O Systems

Regulateurs Europa Ltd. introduced Iceni, a new product range for the companys portfolio of control and monitoring systems
A typical node with Iceni input/output modules, master module and power supply. Iceni is a new product range by Regulateurs Europa, part of the Heinzmann group.
Regulateurs Europa Ltd., part of the Heinzmann group, believes that Iceni is a significant addition to the companys portfolio of control and monitoring systems. In fact, the Iceni modules can be used to either communicate with PC or PLC equipment, or extend the range of RE Viking35 digital governor ECUs, said the company. Iceni provides a range of digital and analog input/output modules that can be plugged together to form nodes on a distributed I/O system. These nodes can be positioned at strategic points around the plant, enabling local field devices to be wired to the modules rather than individually back to the master station, thus simplifying the plant wiring. The DIN rail-mounted modules have up to eight channels according to the module type. Configuration parameters of specific I/O channels and fieldbus communications are set using an integral graphic color display and front panel pushbuttons to navigate the menu system, thus eliminating the need for a dedicated programmer or laptop, said Regulateurs Europa. With a temperature range of -20 to 70C, Iceni has been developed to withstand the high temperatures of an engine room environment, but is equally suited for a much wider role, said Nick Mace, sales manager at Regulateurs Europa.
This product has been developed for all applications, both to enhance our range of control and monitor solutions or as a device for other OEMs, he added. Mace said each network node is controlled by a master module that always occupies the first slot; a combination of input/output modules is then plugged into the master module to cover the specific requirements. The master module can access the input process image to determine the plant status and also write to the output process image area to control plant devices. Each node is completed with a single power supply module or two power supply modules if redundancy is required. The master module is currently available with Modbus RTU communication protocol, but more protocols, including CANopen, will be available soon, said Mace. The status of individual channels is easily identifiable by the LED indicators on the front panels. As an aid to commissioning, local plant status information, including analog input values, can be displayed on the graphic display without the fieldbus connection being present, said Mace. This permits wiring and device operation to be verified locally, completely independent of the fieldbus controller. To help fault finding, diagnostic information on the fieldbus and the input/output modules is available on the graphic display. Changeover alarm contacts are provided on the master and power supply modules, and these can be used to alert the operator that a node is not available or to enable backup control systems. The Iceni modules are currently being prepared for marine approval by DNV (Det Norske Veritas) and Lloyds Register. A
Dateline
FeBruAry *Feb 8-10 Middle East Electricity 2011 - Dubai International Exhibition Centre, Dubai, United Arab Emirates; IIR Middle East, Office 301, Sultan Business Center, P.O. Box 28943, Dubai, U.A.E. Tel: +(971)-(4) 336 5161 Fax: +(971)-(4) 336 0137 E-mail: infoex@iirme.com Web: www.middleeastelectricity.com *Feb 9-10 Gas/Electric Partnership Conference Northwest Forest Convention Center, Cypress, Texas, U.S.A.; Gas/Electric Ventures, 5327 Mandell Blvd., Houston, Texas 77005, U.S.A. Tel: +1 (713) 529-3216 Fax: +1 (713) 529-3318 Web: www.gaselectricpartnership.com *Feb 13-16 1 st Middle East Turbomachinery Symposium - Sheraton Doha Resort and Convention Hotel, Doha, Qatar; Turbomachinery Laboratory, Texas A&M University, College Station, Texas 77843, U.S.A. Tel: +1 (979) 458-8878 Fax: +1 (979) 845-1835 E-mail: martha@turbo-lab.tamu.edu Web: http://middleeastturbo.tamu.edu MArch *March 20-23 Western Turbine Users Conference Palm Springs Convention Center, Palm Springs, California, U.S.A.; Western Turbine Users Inc., 6475 E. Pacific Coast Highway, Suite 140, Long Beach, California 90803, U.S.A. Tel: +1 (513) 442-0986 Fax: +1 (513) 442-0986 Web: www.wtui.com *March 21-24 GasTech 2011 - Amsterdam RAI, Amsterdam, Netherlands; dmg world media (uk) ltd., Northcliffe House, 2 Derry St., London, W8 5TT, U.K. Tel: +44 020 7938 6000 Web: www.dmgworldmedia.com *March 22-24 China Offshore Oil & Gas Exhibition - New China International Exhibition Center, Beijing, China; Beijing Zhenwei Exhibition Co. Ltd., 801 Building E, Triumph Town, No. 170 Bei Yuan Rd., Chaoyang District, Beijing, China. Tel: +86 10 58 23 65 59 Fax: +86 10 58 23 65 67 E-mail: lwj@zhenweiexpo.com Web: www.ciooe.com.cn/en *March 23-26 Europort Istanbul 2011 - Istanbul Expo Center, Istanbul, Turkey; NTSR International Fair & Convention Organizations; Kinciler Cd., Ertrk Sk. No: 5 Kat: 3, 34810, Istanbul, Turkey. Tel: +90 216 425 6300 Fax: +90 216 425 6302 E-mail: info@europort-istanbul.com *March 24-25 7 th Dessau Gas Engine Conference Dessau, Germany; WTZ Rosslau, STC Rosslau GmbH, Mill series 2a, 06862 Dessau-Rosslau, Germany. Tel: +49 34901 883-0
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Fax: +49 34901 883 120 Web: www.wtz.de *March 30-31 Globalcon - Pennsylvania Convention Center, Philadelphia, Pennsylvania, U.S.A.; Association of Energy Engineers, 4025 Pleasantdale Rd., Suite 420, Atlanta, Georgia 30340, U.S.A. Tel: +1 (770) 279-4392 Fax: +1 (770) 381-9865 E-mail: ashley@aeecenter.org Web: www.globalconevent.com
* Boldface indicates shows and conferences in which Diesel & Gas Turbine Worldwide is participating. A more complete listing of trade shows is available at www.dieselgasturbine.com
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Emissions Worldview
by dj slater
The DFC3000 fuel cell power plant from FuelCell Energy Inc. is the largest power plant in the DFC line. It has an output of 2800 kW with a 47% efficiency rating. Inland Empire Utilities Agency (IEUA), a water and wastewater service provider in Chino, California, U.S.A., is installing a DFC3000 plant and fueling it with biogas formed from the wastewater.
Recycling Wastewater With Biogas Fuel Cells

Inland Empire Utilities Agency signs agreement for 2.8 MW fuel cell system
Inland Empire Utilities Agency (IEUA), a water and wastewater service provider in Chino, California, U.S.A., has signed a 20-year power purchase agreement with UTS BioEnergy, which will install, operate and maintain a 2800 kW fuel cell power plant at the utility. The fuel cell power plant will provide power and thermal energy to IEUAs largest water recycling plant in Ontario, California. The decision to operate a biogasfueled fuel cell system is part of an initiative implemented after an energy shortage and blackouts in California in 2001. Thats when we discussed how we could be more independent from the grid, said Tom Love, the general manager and CEO of IEUA. We wanted to find new ways to create more fuel and secure our energy costs. In addition to energy independence, emission regulations from the California Air Resources Board (CARB) and the Air Quality Management District (AQMD) prompted the move to fuel cell power, which emits virtually no NOx, SOx or particulate matter (PM).
Love said new regulations require that the allowable amount of natural gas that can be used to supplement biogas has been reduced from 60% to 10%. By the time the second phase of the regulations take effect in July 2012, IEUAs generator engines will need to be retrofitted with new emission control equipment, he said. We looked at several alternatives, such as retrofitting our engines, mothballing them, buying electricity from the local utility or buying fuel cells, he said. Our research, based on 20-year life-cycle costs, confirmed that fuel cells were our best option. The 2800 kW power plant, which is provided by FuelCell Energy Inc., Danbury, Connecticut, U.S.A., operates on a minimum of 75% biogas produced from the wastewater at the utility with natural gas supplementing the rest, Love said. Called the DFC3000, it is the largest fuel cell power plant system in the DFC portfolio from FuelCell Energy, said the company. The power plant has a programmable logic controller (PLC)-based control system that allows natural gas
to automatically supplement biogas. The standard output voltage is 13 800 V with a standard frequency of 60 Hz. The optional output ac voltages are 4160 to 12 700 V with an optional frequency of 50 Hz, said FuelCell Energy. The system has an efficiency rating of 47% and takes about 90 hours to go from a cold start to producing its full power output. The power will be used to supply 60% of the wastewater treatment plants power needs, Love said. Heat from the fuel cell system will be used to heat the municipal wastewater digesters, which provide the biogas. The power plant has an exhaust temperature of 371C, said Juan Josse, the vice president of engineering at UTS BioEnergy. The plant will recover heat from the exhaust with a gas/liquid heat exchanger. The exhaust gases are then cooled to 133C and the recovered energy, about 4.4 million Btu/hr, is used to heat the plant digesters, Josse said. The digester gas treatment system cleans the gas, removing moisture, particulates, sulfur VOCs and siloxanes, Josse said. The fuel cell receives the clean digester gas and, if there is not enough to maintain the full electrical output, it uses natural gas. FCE supplies the gas treatment system and the controls, both of which can be accessed remotely, he said. The entire unit, which consists of six matched modular skids, measures 6.4 m high by 12.5 m wide by 23.8 m long, according to FuelCell Energy. IEUA will purchase power generated from the fuel cell power plant, which is expected to be operational by late 2012, at a set price over the next 20 years. The power plant purchase is not the first step by IEUA to go greener. In 2008, the service provider installed 3.5 MW of solar power equipment at four of its facilities, Love said, and the goal is to operate independently of the grid by 2020 through a combination of fuel cell, solar, wind and other renewable energy sources. a
GE Energy
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Power Generation
Seven fuel-injection skids from Allweiler will be delivered to Iraqi power plants for Siemens gas turbines. These systems can switch between several different liquid fuels without shutting down the turbines.
Allweiler Fuel-Injection Skids For Iraqi Power Plants

The German pump manufacturer has been awarded a US$6.9 million order to deliver fuel-injection skids for Siemens gas turbines in Iraq
Allweiler received an order for fuel-injection skids that will be integrated into expanded power plants in Kirkuk, Iraq, as well as new plants that will be constructed in Baiji and Baghdad, Iraq. The skids will be delivered through Siemens. The first two systems will be completed in early 2011, but Allweiler said the Iraqi Ministry of Electricity has ordered an additional five skids and has the option to purchase three more. All the fuel-injection skids have been designed with the ability to switch between several different liquid fuels without shutting down the turbines, and for redundancy with two high-pressure pumps. The gas turbines can be operated with EL fuel oil and S heavy oil or EL fuel oil and crude oil. Switching between the various fuels occurs within approximately two minutes while the turbines continue to run.
This was the biggest technical challenge in the development of these skids. But our solution to this requirement gave us the edge we needed to win the contract, said Stefan Kleinmann, vice president of the industry business segment and member of the management board at Allweiler AG. When switching between fuels, the system must withstand temperature differences of more than 120C without interruption. Johann Engelmann, director of sales and service, explained, When the turbine is started, were pumping low-viscosity fuel oil within a temperature range of 5 to 25C, but during normal and continuous operation the system is moving higher-viscosity crude and heavy oil at temperatures up to 130C. The temperature change is on the order of 60C per minute. As a result, the system must have the ability to compensate for temperature-related changes. Precise control
of liquid pressure before and after the pumps is critical for proper operation. If pressure decreases during the fuel changeover, gas bubbles will form in the liquid and may result in severe damage to the pumps and emergency shutdown of the turbines. Highly refined valve control with fast reaction times can prevent it, said Allweiler. The pumps used in the system produce 287 kW of drive power; discharge pressure is approximately 100 bar at a liquid temperature of 130C. Allweiler AG, a business unit of Colfax, develops pump technology and supplies systems for power plants. Allweilers in-house plant engineering services also deliver turnkey fuel, lubeoil and purge-water skids for all types of power plants. The company recently celebrated its 150th anniversary of pump manufacturing in Germany. A
Industry news
Diesel Switch Approved For Marine Use

The Diesel Switch MKII is equipped with a three-way blending valve
Switzerland-based Aquametro AG and Jowa Technology AB have partnered to launch the Diesel Switch MKII, a fuel-blending and fuel switchover unit that has been approved by Germanischer Lloyd. Marpol regulations prescribe that ships will need to switch over to low sulphur fuel in some emissioncontrolled areas. Thus it will be necessary to have onboard capability to blend fuels and to completely switch over from one fuel type to another. The Diesel Switch MKII is equipped with a three-way blending valve, which adjusts the fuel ratio of heavy fuel oil and marine diesel oil or marine gas oil in relation to a set value that is controlled by a logic controller, with touchscreen display. The unit is completed with tempera-
ture and pressure sensors, so that the controller is able to regulate the permissible fuel temperature changes (as prescribed by the engine manufacturer). It also monitors fuel temperature in relation to viscosity and the lowest permissible viscosity before the engine. According to Aquametro, Diesel Switch MKII guarantees the fuel blending procedure and makes sure that prescribed limits of sulphur content are adjusted, proven and then stored in a special history file, available for inspection. Diesel Switch MKII also performs a compatibility check for both used fuel qualities, before any blending or changeover. The manufacturer said that the units are easy to install, both in new applications as well as for retrofit
The Diesel Switch MKII adjusts the fuel ratio for fuel blending and switch-over, with a controller that monitors temperature and pressure and features a touchscreen display for operators.
projects. In addition, every complete mounted unit undergoes a full test before installation onboard. Aquametro is a specialist in metering technology since 1928, while Jowa Technology is a Sweden-based manufacturer of oily water treatment systems such as separators and emulsifiers. A
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Power Generation
by roberto chellini
MAN Diesel & Turbo introduced the 6.2 MW GT6 gas turbine for mechanical drive and power generation applications. It is available in a two-shaft configuration, with a one-shaft configuration planned for introduction in a year.
MAN Introduces New Industrial Gas Turbine

Two-shaft GT6 gas turbine rated 6.2 MW, one-shaft version planned
MAN Diesel & Turbo has introduced its new GT6 industrial gas turbine, developed for mechanical drive of its compressors and for power generation applications. The GT6 has been completely developed in-house during the last six years and is now available in the twoshaft configuration. The one-shaft version will follow in one year. The introductory rating is 6.2 MW, but the program is to go up to 8 MW and subsequently uprated to cover the power range from 6 to 10 MW. MANs THM models will continue to cover the 10 to 13 MW power range, while a scaled up version of the new GT6 could cover the 15 to 20 MW range further in the future. This two-shaft machine features
an 11-stage compressor, with a 1:15 pressure ratio, driven by a two-stage, air-cooled, high-pressure turbine. The second shaft features a two-stage low-pressure power turbine. In the single-shaft configuration, the turbine section will feature three stages, with the first two air cooled. The generator will be coupled on the cold-end side to allow an axial exhaust duct to the stack or to the HRSG. The combustion system features six cans fitted with dry-low emission burners to minimize NOx and CO emissions. This combustion system has been designed from the very beginning as DLN for natural gas-fueled units; a system for liquid fuels will be implemented further on. The machine is built up in mod-
ules for easy assembly and maintenance operation. The auxiliary gearbox carrying the electric starter motor and the main lube oil pump also serves as front support for the whole gas turbine. The turbine air intake casing, on the auxiliary gearbox, contains the first journal bearing and the double-acting axial thrust bearing, both of the tilting pad type. Both bearings are easily accessible without the need to open the horizontally split casing, said MAN. The drum-type shaft features a front hub section followed by three rotor discs and a rear hub. Hirth serrations ensure correct axial positioning and centering of the rotor components once the central tie rod is tightened; they also absorb the torque transmitted by the HP turbine. The 11 blade rows of the axial compressors are mounted on the rotor drums. The stator vanes are mounted on the vane carrier, and the inlet guide vanes and the first three rows of stationary vanes are of the variable geometry type. A high accuracy electric servo motor,
Power Generation
The GT6 features an 11-stage compressor, with a 1:15 pressure ratio, driven by a twostage, air-cooled, high-pressure turbine. The second shaft features a two-stage low-pressure power turbine.
connected to the turbine digital control system, actuates the four variable geometry rows from the completely closed position at start-up, until 75% of speed to the fully open position at 95% of speed and full load. The discs of the two-stage HP turbine are mounted on the rear hub before the second journal bearing. The unshrouded first stage and the shrouded and interlocked secondstage turbine blades are anchored to the discs by fir-tree roots. Both discs and blades are cooled by a stream of air from the axial compressor diffuser. The intermediate turbine casing, as well as hosting the compressor diffuser, serves as support to the six combustion chambers, the hot gas transition ducts and the two nozzle guide vane carriers. At the end of the intermediate casing, six struts support the rear bearing casing and serve as lube oil ducts for bearing lubrication. The combustion chambers, positioned with 35 inclination relative to the center line, feature a vortex-stabilized burner section, a large volume for combustion and supply through the transition ducts, and hot gases at uniform temperature to the first turbine nozzles. Both combustion tube sleeves and transition ducts are impingement cooled with air from the compressor outlet. At start-up and low load, the burners operate in the diffusion mode
and shift automatically to the premix mode as soon as the turbine picks up load to ensure minimum production of NOx and CO. The two-stage power turbine has been optimized for a high efficiency within a wide speed range, it can operate between 45 and 105% of nominal speed (12 000 r/min). The two discs of the low-pressure turbine are bolted, with Hirth serrations, at the inner end of the power shaft in an overhung position. The shaft is supported by two tilting pad journal bearings the rear one being combined with a pivot shoe-type thrust bearing. The bearing casing is placed in the center of the low-pressure turbine casing. Boroscope access is provided all along the air and hot gas path to ensure quick inspection and reduced maintenance time.
After assembly, the prototype was placed on a specially built test stand at the Oberhausen, Germany, facilities for a series of tests. First firing took place on Nov. 19, 2010. With newly designed digital control system and intensive component testing, it was possible to reach full load only one week after first ignition. Tests of the prototype are still under way at the time of writing. At the end of the testing program, the GT6 will be available in the package form complete with all its auxiliaries for mechanical and generator drive applications. A
The stator vanes are mounted on the vane carrier, and the inlet guide vanes and the first three rows of stationary vanes are of the variable geometry type. The discs of the two-stage HP turbine are mounted on the rear hub before the second journal bearing.
by roberta prandi
(Left) The apprentice shop in GEs Jenbacher gas engine plant, where young apprentices spend two years learning basic skills in various machining operations, before starting training in the workshop. (Right) Paul Ladsttter is one of the apprentices at GE Jenbachers gas engine division in Austria. He won the Skills Austria state competition and is now Austrian State Champion in CNC milling operations.
Apprenticeship To Success
GE Jenbacher has long tradition of apprenticeship program, with over 90% retention rate
GEs Jenbacher gas engine business, Jenbach, Austria, part of GE Energy, has an extensive apprenticeship program that hosts an average of 100 young people, depending on the varying apprenticeship length, which is between three and four years. Usually about 25 new apprentices start with GEs Jenbacher gas engine division every year. Currently there are 88 in Jenbach, said Martin Fiedler, global supply chain leader of GEs Jenbacher gas engine business. Supported by a history that goes back more than 60 years, the apprentice program is constantly evolving and adapting to new technologies and market demands. A new program to train field service technicians will be introduced in 2011, when we will start for the first time with a total of 30 new apprentices, explained Fiedler. Other specializations include mechanical engineers, electricians, mechatronic specialists and assembly operators. All apprentices spend the first two years mainly in the apprentice shop,
where they get a basic knowledge and practice with several machining centers, Fiedler said. They are coordinated by the head of apprentices, supported by three supervisors. He continued, All apprentices practice with different jobs, including a bit of all machining operations that are performed in Jenbach. At the end of the two years, apprentices move to the workshop, and start working in different manufacturing areas. Fiedler emphasized that every area has a supervisor who is in charge of the apprentices. All the young apprentices at GEs Jenbacher gas engine division come from the Austrian Tyrol region. Fiedler said the companys program has quite a strong reputation, so there is never a shortage of applications. Actually, we usually have far more applications than we can take, said Fiedler. Last year we had 150 requests and only 25 young people were accepted. The selection at GEs Jenbacher gas engine business is strict the first
thing the company considers is the result from the school diploma. Applicants then have to pass an interview and a thorough test. Apprentices usually come to us after about nine years in school. They are 15 or 16 years old and only a few have a limited, basic mechanical knowledge, said Fiedler. For this kind of program there is a significant public subsidy in Austria. During the course of the program, apprentices dont only have to work, they have to spend 10 weeks of every year in school. During this period they are salaried by GEs Jenbacher gas engine division. After so many resources have been dedicated, the company tries to hold the apprentices at the end of the period. Retention rate is quite high, above 90%. Even in 2009, in the middle of the global crisis, we kept over 50% of the apprentices, said Fiedler. After the program is completed, there is a six-month employment period in the company. After that, for most of the boys, there is a year break as they have to serve in the army. While apprenticeship is quite a tradition in German-speaking countries, its extension and complexity at GEs Jenbacher gas engine division created some curiosity when the company was acquired by GE. Although there were some doubts at first, our apprentice program is becoming a best practice within GE. The company is very successful with its program. Every year, it participates to the Tyrolean competition for apprentices and has collected 83 gold medals. In 2010, the company crowned the Austrian State Champion in CNC milling operations, Paul Ladsttter, who won at Skills Austria, the Austrian State competition. Ladsttter is now qualified to attend the 41st World Skills 2011 competition, which will be held in London in autumn 2011. The World Skills is an international professional competition with more than 800 participants from 51 member states. A
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Power Generation
by ian cameron
An SUS panel. ComAp said the new SUS feature changes the start-up sequence of the multiple generators and allows the sets to start online and already synchronized to each other immediately.
Sequencing A Faster Start-Up

ComAp adds rapid synchronization to generator controls range
Engine and generator set controller manufacturer ComAp has announced a new rapid synchronizing feature to add to its range. The Prague, Czech Republic-based company said the benefits of multiset synchronizing installations are recognized by users around the world. It added that optimization of gen-set loading ensures reduced fuel consumption and emissions, while helping to extend the service intervals and, ultimately, engine life. Built-in redundancy means total failure is less likely and maintenance does not mean 100% loss of generating capability. This can also be coupled with lower capital costs and lead times when compared to larger capacity equipment and lower spares costs during the operating life, ComAp claimed. ComAps Radim Girgas, director of the companys high-end controls division, added, However, all this comes with one drawback time.
Or more importantly, the time required to synchronize all the sets onto the bus together. This is not normally an issue where time is available such as islanded power station applications, but is essential when the system in question is being used for standby, he said. While ComAp provides a fast synchronizing controller thanks to its high-speed phase angle measurement and correction algorithms, there is still a certain amount of time required to achieve all the sets synchronized and ready. This blackout time while the sets synchronize is not just inconvenient, it also costs money. In addition, any critical systems running on uninterruptable power supply [UPS] need to be fed during this period, so the UPS needs to be sized accordingly, leading to further costs, explained Girgas. Modern rotary UPS systems provide instant backup without the associated battery costs of traditional UPS
technology, but only produce useful power for short periods following the failure of the grid supply, limiting their usefulness where multiset installations are preferred. This small but significant drawback tends to limit standby-type applications for using multiple parallel sets, although we believe we offer a solution with our SUS variant application. ComAp said its new SUS feature changes the start-up sequence of the multiple generators and allows the sets to start online and already synchronized to each other immediately. According to the company, this means that the system is available at full capacity in the shortest possible time typically eight to 10 seconds from start command to available, which it believes is faster than traditional synchronizing methods, with the time remaining constant even if the number of generators is increased to 10 or 20 or 32. To allow for slow-starting engines or other problems and avoid delaying availability of the system, any engines that fail to reach running speed within a specified time are rejected from the scheme and, if able, are left to perform traditional synchronizing after the majority of sets have become available, said ComAp. Should insufficient sets become available to meet the loads initial requirements, the system will automatically attempt traditional synchronizing in an attempt to restore power, it added. ComAp said the SUS feature also provides an additional function by allowing one or more sets to start and provide soft magnetizing of feed transformers so that the system does not need to be sized to cope with this peak inrush current. This can be beneficial in the cost of the installation, but also aids the problem where the grid supply is not capable of supplying the inrush. The islanded generator plants can start and soft magnetize the feed transformer, and allow the grid mains breaker to be synchronized and closed, the company said. A
Industry news
Intelligent Combustion Monitoring

Technology designed for two-stroke diesel engines, integrates ABB Cylmate system
Wrtsil has introduced its intelligent combustion monitoring system for two-stroke diesel engines. The system monitors the condition of the components in the combustion chamber. According to Wrtsil, the system can lead to fuel cost savings of up to 2% by running engines at optimal firing pressures. The system measures the pressures and angle values in each cylinder during the combustion process. By monitoring the position of the crankshaft, and having a mathematical model of the engine, the system provides real-time data for diagnostic analysis, Wrtsil said. The monitored data covers the thermal and mechanical overload of individual cylinders, the optimal fuel efficiency, power readings, cylinder conditions, load-dependent monitoring of the combustion parameters and comparisons between cylinders. The system also monitors gas leaks, exhaust valve components and fuel equipment. Wrtsils system integrates with the ABB Cylmate system, a feature made possible by a cooperation and distribution agreement Wrtsil and ABB signed earlier this year. Under the agreement, Wrtsil handles global sales, installation and lifetime service of the system. Any further development of the systems technology will be carried out jointly by the two companies, Wrtsil said. The Cylmate system is a tool developed by ABB for diesel engine performance monitoring. The system, which fits marine and power plant applications, measures the combustion pressure in each cylinder, continuously and in parallel, under all load conditions. The Cylmate system consists of a pressure transducer on each cylinder and an angle transducer at the engine flywheel, which are all connected to the Cylmate transducer bus, ABB said. The systems controller collects all measured data within each engine
working cycle through the transducer bus. Evaluated data, alarms and events are sent through the systems Ethernet LAN to the Cylmate operaHarco_Mar08_WW.qxp 9/30/08 2:26 tor station as well as other connected systems, according to ABB. Similar to the Cylmate system,
Wrtsils intelligent combustion monitoring system automatically transmits data to the companys server for further evaluation by enPM Page 1 A gine experts.
Turbine Overhaul & repair
by roberta prandi
Schematic of the new laser-based Centralign Ultra Expert alignment system, used for precise alignment of internal elements of rotating machines, such as bearing rings, diaphragms, nozzles, inner shells and turbine casings.
Laser Precision For Turbine Alignment

Prftechnik offers a new generation laser alignment system for internal elements of rotating machines
The new generation laser alignment system Centralign Ultra Expert by Prftechnik Alignment Systems has been developed for the alignment of gas and steam turbines. The system is used for precise alignment of internal elements of rotating machines, such as bearing rings, diaphragms, nozzles, inner shells and turbine casings. Bernardo Quintana-Redlinger, director of Machinery Service at Prftechnik, said the efficiency and smooth operation of turbines depends largely on maintaining a short distance between the turbine components and the rotor. Good alignment of the rotor to the other internal turbine components is therefore extremely important, and turbines should not only be aligned carefully during initial installation, but also with every equipment overhaul. The Centralign Ultra Expert mea-
surement system is a new-generation product, deriving from the companys Centralign Ultra system that has been used to align turbine shells to rotors for many years. This system is a laser-optical measurement method that saves an immense amount of time when compared with conventional methods such as the piano wire technique, theodolite telescopes or the installation of a dummy shaft, added Quintana-Redlinger. In addition, it consistently achieves high levels of accuracy. Centralign Ultra Expert features a precise and stable laser combined with a stationary control sensor designed to automatically correct the value in case of laser drift. A mobile measurement sensor ensures high accuracy and has a resolution of 1 m, said the company. The laser is designed for precision
at distances up to 40 m and with upper halves on or off. The system can be used with diameters from 120 mm to 5 m. The ease of installation of Centralign Ultra Expert can be easily demonstrated with our experience in the field, said Nicolas Meunier, sales and application engineer at Prftechnik Alignment Systems. That is the case, for example, of one 20 MW steam turbine, whose half-casings had to be aligned with the rotor during scheduled maintenance, he said. The turbine housing was opened to remove the rotor, which was then brought to an external company that repaired or replaced the rotor blades as necessary and then balanced the rotor. In parallel, the guide vanes and seals on the turbine were replaced with new ones.
Turbine Overhaul & repair The Biggest of its Kind
A technician from the Prftechnik Machinery Service Team prepares the installation of the control sensor for Centralign Ultra Expert in a 20 MW steam turbine, after overhaul.
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After the new and overhauled components were remounted on the turbine, the Prftechnik Machinery Service Team performed the measurement with Centralign Ultra Expert. The laser and the control sensor were mounted and adjusted on the exterior of the turbine. After the adjustment was completed, it was ensured that neither of the two components could move, explained Meunier. The laser beam served as the reference line for the subsequent measurement and each individual turbine element was measured. The team used sensor brackets developed and patented by Prftechnik, thus the center point of each half-casing was determined. After the measurement points were recorded, two half-casings could be defined as a reference. A graphic image showing all horizontal and vertical deviations relative to these references these are generally either the oil deflectors or the bearings was displayed on the Rotalign Ultra computer, added Meunier. Based on these deviations, the correction values for the different beds of the half-casings could be
quickly determined. The mechanics and technicians were immediately able to implement the necessary measures to correct the positioning of the elements. Another advantage of Centralign Ultra Expert is in fact that individual segments can be worked on immediately after the first measurement data are received, since there is no wire or dummy shaft to prevent the removal of the half-casings, said Meunier. In addition, measurement data are immediately available in electronic form and can be analyzed and further processed with the Alignment Center PC software. Alignment Center is a Windowsbased software platform for all shaft and geometrical alignment applications by Prftechnik. It is compatible with previous and current Prftechnik products. For Centralign Ultra, the system offers exclusive turbine-specific features, such as choice of different turbine elements, laser trend monitoring, specific correction methods and customizable color reports. A
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Editors Note: Each year Diesel & Gas Turbine Worldwide invites engine manufacturers to submit one specific power generation project they feel merits special attention due to advances in one or more of the following: efficiency increase, environmental aesthetics, operational characteristics, emission improvements and construction principles. The coverage is limited to plants commissioned during the 2010 calendar year. This longstanding tradition has become a popular feature and this years edition once again highlights several noteworthy projects around the globe. Enjoy.
Alstom Power
Emsland Combined-Cycle Power Plant, Germany
A new 876 MWe GT26-based multishaft combined-cycle power plant began operations at the Emsland site in Germany in September 2010. The plant is owned by RWE Power and contributes to supply diversity in the RWE generation fuel mix. Alstom has constructed the plant under a full engineering, procurement and construction contract. The new Emsland KA26 combinedcycle power plant is designed for medium-load operation (5500 operating hours per year) and for 200 start-ups per year, and is able to generate electricity and supply steam. The plant operates at ambient temperatures of between -20 and 40C and is equipped with a natural ventilation wet cooling tower. To maximize the efficiency of the plant, the Alstom Integrated Cycle Solution (ICS) mul-
Owned by RWE Power, a new 876 MWe GT26-based multishaft combined-cycle power plant began operations at the Emsland site in Germany in September 2010.
tishaft configuration with two GT26 gas turbines and one steam turbine was chosen. The 2-on-1 multishaft configuration allows the utilization of a larger steam turbine, compared with 2 x 1-on-1 single-shaft arrangement, to offer higher overall plant efficiency, which was a key requirement for this project, the company said. The project features a number of new innovations developed by Alstom Power. The plant is based on two GT26 gas turbines that are capable of fast start and quick response to changing demand conditions, with high efficiency and low emissions even at part load. As well as featur-
ing the latest rating of the GT26 gas turbine, it also includes innovations in the water/steam cycle. The plant, for example, employs Alstoms optimized for cycling and constructability (OCC) HRSGs of the once-through type, and is currently one of the largest CCPP plants in Europe using a oncethrough cycle design. The choice of the once-through cycle principle meant that for this particular project, higher live steam parameters could be used leading to higher efficiency. The heat recovery steam generator also provides heat (hot water) for preheating the fuel gas to help maximize the overall plant efficiency and feedwater for the gas turbine cooling air coolers. The plant delivers a net efficiency above 59% at full load, making it currently one of the worlds most efficient power plants. The plant also uses the current largest last-stage blades in the STF30c steam turbine, which enable more of the energy to be extracted from the steam. With this optimized water/steam cycle, the plant delivers both operational cost savings to the client by way of its high efficiency and reduces the environmental impact through that improved efficiency, two of the main targets of the project design.
GE Energy
Darling Downs Power Station, Australia
The 640 MW Darling Downs Power Station, one of the largest gas-fired
continued on page 24
GE supplied three Frame 9E gas turbines to the Darling Downs Power Station, one of the largest gas-fired combined-cycle power plants in Australia. Shown here is the Frame 9E rotor.
combined-cycle power plants in Australia, is the centerpiece of Origins multibillion-dollar investment to provide cleaner electricity for Queensland. Constructed by a consortium including GE Energy and CH2M Hill, the plant was successfully commissioned in the second quarter of 2010. GE supplied three Frame 9E gas turbines, three HRSGs and one C-7 combined-cycle steam turbine for the power island, which emits approximately half the greenhouse emissions of a conventional coal plant of similar size, according to the company. The 9E includes a dry-low NOx combustor system that helps to maintain emission compliance by extending the fuel flexibility. CH2M Hill undertook engineering, procurement, construction and joint commissioning activities with GE, and provided a plant design that helps to decrease water consumption and is among the quietest in the world. The plant uses coal seam gas as fuel. Recognizing the water shortages during droughts that Queensland periodically faces, Origin Energy specified a plant that used air-cooled condensers, which help to decrease water usage. The CH2M Hill design enables the Darling Downs plant to use less than 3% of the water that would likely have been required by a conventional coal-fired plant. In addition to in-
corporating an ultra-quiet air-cooled condenser, CH2M Hill provided a one mega-liter/day reverse osmosis (RO) water treatment plant to produce ultrapure boiler feedwater. To further help reduce environmental impacts, the design team utilized the ground water treatment system to recover both demineralizer RO reject and evaporative cooler blowdown wastewater streams, thus reducing fresh groundwater supply requirements. In addition, condensate from the air-cooled condenser was used as waste heat input to a wet surface air cooler (WSAC) to reduce off-site wastewater impact. The WSAC, in combination with the wastewater recovery operations, is capable of reducing off-site wastewater trucking to less than 30% of the original design. CH2M Hill and GE coordinated an international team of in-house designers and engineers, which adapted industry-leading system designs into the highly regulated Queensland environment, with particular emphasis on the strict gas regulations and the grid interface. An analysis was performed on all major systems, and the design was enhanced for safety. Origin required that the new plant achieve world-class noise limits. To achieve strict far-field noise limits at the plant boundary, GE provided ultraquiet combustion turbine-generator enclosures and CH2M Hill designed and constructed acoustically tight turbine halls in addition to specifying and procuring some of the quietest balance-of-plant equipment available. The project is located in regional Queensland, a northeast state of Australia more than 200 km from Brisbane and 40 km west of Dalby, the closest town. A 550-bed construction camp was developed to attract a qualified workforce to the remote site. To help provide safe travel to and from the site, busing was provided to avoid the many hazards typical to bush driving, including flooding, heavy fog, dust storms and kangaroos.
The projects environmental stewardship extended through plant commissioning. The commissioning team evaluated alternate approaches for cleaning the steam systems and settled on an evolutionary approach using in-situ hydro lasing, air blow and degreasing. By eliminating a steam blow, the team saved over 20 million liters of water, and an additional four mega-liters were saved by gaining acceptable steam quality within 48 hours of unit first-fire.
Guascor
Granarolo S.p.A. Plant, Italy
Guascor, through its Italian subsidiary Guascor Italia, has finished the commissioning and start-up of the third combined heat and power (CHP) plant with its new generation Miller cycle engines, the HGM560. The plant has been built in Bologna, Italy, and can produce 2.4 MWe of total electrical power through the use of two HGM560 engines, each one producing 1.2 MWe of power. The plant can produce more than 19 million kWh of electrical energy and 19 million kWh of thermal energy every year. The energy will be generated to satisfy the needs of the Granarolo S.p.A. plant in Bologna. Granarolo S.p.A. is a market leader in dairy production, supplying more
The Granarolo S.p.A. plant in Bologna, Italy, can produce 2.4 MWe of total electrical power through the use of two Guascor HGM560 engines, each one producing 1.2 MWe.
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than 30% of Italian milk production with seven milk processing plants. The high energy efficiency of the cogeneration systems guarantees the reduction of pollutants and will permit important economic savings for the group, the company said. A second CHP power plant that uses this same technology has been running in Modena, Italy, since the beginning of summer 2010. The official inauguration was held Dec. 16. The plant produces 3.6 MWe total (three HGM560 engines, with the power of 1.2 MWe each). In this case, the thermal energy is used to integrate a district heating network that provides heating and hot sanitary water to an entire area of Modena. The plant can produce electrical energy for the needs of more than 9000 families and, at the same time, recover thermal energy to satisfy more than 3000 families for an entire year. The first CHP power plant of 2.0 MWe and the same quantity of thermal energy (two HGM560 engines with the power of 1.0 MWe each) is in service at a food processing plant and has been running in the province of Ravenna since spring 2010. Guascor Group is operating in renewable energy and high-efficiency cogeneration around the world. The company has been present in the Italian market since 1998 and is recognized for its activity in designing and building turnkey power plants. Guascor Italia has produced more than 170 CHP power plants that principally use natural gas and biogas.
MAN Diesel & Turbo

Powerships, Offshore Africa, The Middle East And The Mediterranean
The in-house, hi-touch, medium-speed engine (HiMSEN) is HHI-EMDs in-house brand engine designed with the basic concept of Practicality, Hi-Touch and Hi-Tech.
The two power plants are located in Camaari and Candeias, having an output of 160 MW (9H25/33 x 64 sets) and 300 MW (9H25/33 x 120 sets), respectively. The Camaari 160 MW plant has been successfully commissioned in 2010, while the Candeias 300 MW plant is to complete commissioning in the first half of 2011.
A contract with the Turkish company Karadeniz Powership Co. Ltd. includes 21 MAN Diesel & Turbo 18V51/60DF dual-fuel engines and three 14V48/60 HFO engines. The total output is 400 MW. The large-bore diesel engines are to be installed onboard four powerships. The first of the three powerships went into service in May 2010. The ships are former freighters, which are converted into floating diesel power plants. Thanks to their mobility, they can be connected to local power grids to temporarily cover demands whenever on-site power plants are insufficient or new power plants cannot be built quickly enough. Unlike power barges power plants on pontoons the powerships are equipped with their own propulsion
The Camaari, Brazil, 160 MW plant has been successfully commissioned in 2010. The plant utilizes 64 HiMSEN 9H25/33 engines.
Karadeniz Powership Co. uses former freighters that are converted into floating diesel power plants. Powerships, like the Kaya Bey, provide midterm power for countries aiming to avoid electricity shortages.
Hyundai Heavy Industries Co. Ltd.

Camaari Plant, Brazil
Engine and Machinery Division (HHI-EMD) of Hyundai Industries Co. Ltd. has supplied 184 engines to two power plants in Brazil. Utilizing 2500 kW HiMSEN 9H25/33 engines, the two plants have a total output of 460 MW.
The Candeias 300 MW power plant, which consists of 120 HiMSEN 9H25/33 engines, is home to the largest number of HiMSEN engines at a single power plant. The HiMSEN engine is HHI-EMDs in-house brand engine designed with the basic concept of Practicality, HiTouch and Hi-Tech. It offers low fuel consumption, eco-friendliness and easy maintenance derived from its modular design, according to the company.
engines and do not need to be towed. They are planned for use in Africa, Pakistan and other regions in the Middle East and the Mediterranean. The units are ideal for the planned purpose. The engines fuel flexibility centers on the capability to operate on either gaseous or liquid fuel, and to switch between them seamlessly at full rated output. The powerships can make use of the local infrastructure be it an oil or gas supply. And that is not the only benefit the dual-fuel engines bring: a further advantage of dual-fuel engines is that when pow-
ered by gas, in particular, they ensure low-emission and therefore ecologically friendly combustion. The 51/60DF engine used for the actual powerships was first used on liquid gas tankers, on which evaporated gas from the cargo tanks can be used to power the engine. MAN Diesel & Turbo dual-fuel engines have been gaining in popularity in the power generation industry for some time, thanks to their efficiency, fuel flexibility and environmental benefits all factors that have enabled this relatively new engine to quickly establish itself on the market. Karadeniz Powership Co. currently has three powerships in operation, one in Pakistan and two in Iraq. Powerships are fast-track, quickly deployed, utility-grade power plants meeting a countrys urgent demands of electricity. Powerships capacities range from 45 to 220 MW and provide midterm solutions for three to five years with direct connectivity to local grids from onboard high-voltage grid stations. Powerships provide faster transportation and greater access capabilities. Reciprocating dual-fuel engines are installed on powerships, creating ideal base load and flexible generation capacities. State-of-the-art waste-heat recovery systems allow for future flexibility to support desalination solutions. The powerships provide power to countries aiming to avoid electricity shortages, increase time for decisionmakers to bridge generation gaps and choose the best long-term solution for their country. Powerships are more economical than short-term solutions, suffering from shortage, operating existing old power plants. And they have an immediate impact on sustainable growth of the economy, said the company. Powerships have state-of-the-art technology with high quality and fast delivery, and have no completion or site risk. Operation of powerships is ideal in areas with poor logistic infrastructure. They are unaffected by floods, landslides and earthquakes, and have minimal use
of land space a mobility advantage for future use in other locations. Additional details on Karadeniz Powership vessels can be found in June 2010, D&GTW, p. 29.
and charging to increase the electrical efficiency of the TCG 2032 gen-sets up to 43%. This was an improvement
MWM
Precision Energy Ltd. Plant, Banlgadesh
Mannheim, Germany-based MWM has shipped 15 gas gen-sets with an output of 4 MWe each to Bangladesh. The project was started in spring 2009 and was installed in spring 2010. According to MWM, this short timeline was achieved thanks to planning and production of the 15 gen-sets within three months. The buyer is a power plant of Precision Energy Ltd., a specially formed subsidiary of a group of companies in Bangladesh. Bangladesh, with its population of about 150 million, is one of the most densely populated countries. Meanwhile, the countrys daily demand for electricity has grown to 5200 MW, compared to 4000 MW actually produced. With its 15 large gas gen-sets, the natural gas-powered plant in Ashugong, will generate a
MWM shipped 15 gas gen-sets with an output of 4 MWe each to the Ashugong power plant.
of 2.6%. At the same time, the electrical power was increased to 3000 kW for the V12 and 4000 kW for the V16. Due to continuous development and improvement, the orderable gensets today have reached an electrical efficiency of 43.5% with an electrical output of a maximum 4300 kWe. Additionally, the MWM TCG 2032 combines durability and low lube-oil consumption. The zero-pressure gas train and the optimized high-pressure turbocharger ensures continuous supply of full power, even under tropical conditions, the company said. In Asia, the MWM products are marketed by the companys own subsidiary, MWM Asia Pacific Ltd., in Singapore. This location enables the company to ensure quick service and supply of spare parts in the entire Asia/Pacific region and also for the 15 gen-sets installed in Ashugong.
This Precision Energy Ltd. natural gaspowered plant in Ashugong, Bangladesh, will generate a total of 60 MWe.
Siemens Energy
Irsching 5 Combined-Cycle Power Plant, Germany
total of 60 MWe. All of the electrical power will be fed into the public grid to help supply the demand of electricity in Bangladesh. Shortly before this project, in spring 2009, MWM launched an efficiency package including further developments in combustion technologies
On May 17, 2010, after around two years of construction, the Irsching 5 combined-cycle power plant near Ingolstadt, Germany, was put into operation in an official ceremony. The
Irsching 5 combined-cycle power plant near Ingolstadt, Germany.
owner of the new plant is Gemeinschaftskraftwerke Irsching GmbH (GKI), a project company consisting of E.ON Kraftwerke GmbH, N-ERGIE AG, Mainova AG and HEAG Sdhessische Energie AG. E.ON Kraftwerke is responsible for plant operation. Siemens built the 847 MW (net) plant as a turnkey project. With its high efficiency level, and the associated low emissions, along with its short start-up times, this plant sets new standards for this performance class, said Michael Suess, CEO of the
Fossil Power Generation Division of Siemens Energy. This new natural gas-fired plant is equipped with two SGT5-4000F gas turbines, one SST5-5000 steam turbine, three hydrogen-cooled generators with electrical systems and the SPPA-T3000 I&C system from Siemens. Thanks to its F-class gas turbine technology and the quadruple-flow low-pressure steam turbine, this plant now achieves an efficiency level of more than 59.5%, thus minimizing its CO2 emissions. The stateof-the-art burner technology used at the plant also keeps NOx emissions at a low level (<15 ppm). Irsching 5 is designed for 250 starts annually. The plant reaches its full output in only 30 to 40 minutes to account for the more stringent grid requirements with regard to the integration of wind power. Combined-cycle power plants are part of Siemens Environmental Portfolio. In fiscal 2010, revenue from the
Portfolio totaled about US $36.7 billion (E28 billion).

Solar Turbines Inc.

Calabasas Landfill Gas-To-Energy Facility, U.S.A.
Start-up phase for the Calabasas Landfill Gas-to-Energy Facility in Agoura, California, U.S.A., began on June 1, 2010. Commercial operation was declared on July 12, 2010. The plant broke new ground for
The Calabasas landfill gas-to-energy facility in Agoura, California, U.S.A.
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The Calabasas landfill gas-to-energy facility in Agoura utilizes three Mercury 50 gas turbines from Solar Turbines Inc.
operation on very low Btu landfill gas while simultaneously achieving industry-low emission levels. Plant equipment consists of three Solar Turbines Inc. Mercury 50 gas turbines, ISO rated at 4.6 MW each, three 150% gas treatment, blending and compression skids, continuous emissions monitoring (NOx), and miscellaneous support equipment. Strict local landfill gas surface emission limits combined with local soil conditions result in landfill gas that
averages only 30% methane, as compared to typical landfill gas, which usually runs around 50% methane. In 2004, the fuels low quality posed a problem, as there were few technologies available that could burn the Calabasas landfill gas. There was not enough fuel to make a boiler/steam turbine plant economically feasible. Reciprocating engines could not operate with fuel of this low quality, which left industrial gas turbines as the most reasonable alternative. However, the South Coast Air Quality Management Districts emission restrictions for gas turbines provided no margin on actual performance. Therefore, no manufacturers would guarantee their equipment to meet the set limits. The Los Angeles County Sanitation District (LACSD) became aware of Solar Turbines Mercury 50, a DOE-funded low-emission, high-efficiency gas turbine, and proposed using it at Calabasas. Though the Mercury had been designed strictly for natural gas, Solar
took on the challenge of modifying it to burn landfill gas. Prior to this time, Solar required a minimum of 40% methane for its turbines. After testing the Mercury 50 in the factory with simulated landfill gas (natural gas diluted with CO2), Solar guaranteed operation down to 32% methane. However, for initial plant start-up, 40% methane would be required; six months of on-site testing was stipulated to achieve operation on the 32% methane fuel. The facility air
Gas compression and siloxane removal at the Calabasas plant.
permit allowed the LACSD to blend up to 25% methane to the landfill gas methane. Slight adjustments to the landfill gas collection operation, plus the addition of natural gas, allowed the two parties to meet. The project was launched. Six years after the original idea, plant start-up began. As initially planned, the turbines were initially lit off with fuel having 40% methane or more. Once the units were running, it was decided to attempt operation on lower quality fuel. Rather than taking six months to adapt the Mercury 50 to the 32% methane fuel, it was done in one day. A few days later, the turbines were starting and operating successfully on unblended fuel, which has been the case ever since, Solar said. In addition, the Mercurys emissions were unaffected by the fuels low quality, with emission source test results averaging 7 ppm NOx and 3 ppm CO (at 15% O2) on all three turbines.
Tognum, MTU Onsite Energy

Giessen-Marburg University Clinic, Germany
Large quantities of electricity, cooling power and heat are needed to run a clinic. The university clinic of Giessen-Marburg, Germany, for example, has around 1150 beds and consumes on average 35 000 kWh daily. The clinic one of 50 run by healthcare provider Rhn-Klinikum AG is to generate over half of its energy requirement in-house instead of using the public grid. That is the reason for the clinics decision to opt for a combined solution from MTU Onsite Energy using three complementary technologies: gas-powered combined heat and power modules (CHPs), a fuel cell for trigeneration (heat, power and cooling) and diesel engines for standby power gen-sets. It is the first time that all three technologies are to be combined at one lo-
Three GR 385 N5 (top) gas-powered combined heat and power modules (CHPs) in combination with a HotModule HM346 fuel cell (middle) provide electricity, heat and cooling at the Giessen location of the University Clinic of Giessen and Marburg, Germany. Two standby gen-sets driven by MTU 20V 4000 G23 and 12V4000 G23 diesel engines provide parts of the clinic with emergency power should the public grid break down.
cation, the company said. The power supply will be controlled by Energiezentrale Giessen GmbH, a company specially set up by Rhn-Klinikum AG and Giessens public utility. Combined cooling, heat and power generation will be achieved by three natural gas-powered GR 385 N5 CHP modules based on Series 400 12-cylinder gas engines in combination with a HotModule HM346 fuel cell also driven by natural gas. Heat and power will be generated costeffectively and sustainably with an outstanding overall efficiency of up to 90%. The fuel cell is to take up the base load while the combined heat and power modules will be automati-
cally switched online and offline according to requirements. Two diesel gen-sets powered by MTU Onsite Energy engines will provide the clinics standby power. The electricity generated through combined cooling, heating and power will be fed to the power supply. Each of the three CHP modules will be laid out for 385 kW electrical output, while the fuel cell generates 345 kW. Any surplus power will be fed into Giessens public grid. Thermal energy or heat will be harnessed from the waste heat produced by the fuel cell and engines and from the high-temperature emissions of the CHP modules. The HotModule will be capable of 230 kW thermal output, while the engine on each of the CHP modules will generate 231 kW, plus about 260 kW in the form of emissions. The clinic will utilize the thermal energy in two ways for heating the building and providing hot water and for air conditioning using absorption refrigerators. For clinics especially, combined cooling, heating and power is an ideal solution. Ultra-modern facilities, in particular, need higher cooling capacities, for example for their IT installations, large-scale medical equipment, operating theatres and for air conditioning the building as a whole. According to RhnKlinikum AG, cooling its IT installations alone uses up 12% of its total energy requirement. In 2008, the clinic inaugurated its new pediatric facility and in spring 2011 another new building with an additional 650 beds is to be opened. Thus, the combined heat and power modules will not just be activated for spikes in demand, but, like the fuel cell, work around the clock. Next to the fuel cell and CHP modules, MTU Onsite Energy is to supply two diesel engines for the standby gensets, which will provide parts of the clinic with emergency power should the public grid break down. In this
30 J a n u a r y - F e b r u a r y 2011 Diesel & Gas Turbine Worldwide
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event, the larger of the two gen-sets, driven by a 20V 4000 G23 diesel engine, will ensure that building facilities continue to function, while the smaller unit with a 12V 4000 G23 diesel engine will feed power to medical equipment. A standby gen-set based on an MTU engine has been in operation in the pediatric facility since 2008.
Wrtsil
Aliaga Power Plant, Turkey
The Aliaga power plant in Aliaga, Turkey, was inaugurated on Sept. 29, 2010. It is so far Wrtsils largest gasfired power plant based on reciprocating technology. The Aliaga combined-cycle power plant, situated within ALOSBI, has been built in three phases. The first phase was contracted in 2006, with two extensions added later in 2008. Wrtsil equipment was specified for all three stages of the plants development. Altogether, the power plant has 28 Wrtsil 20V34SG gas-fired generating sets and two steam turbines manufactured by Skoda. The plant has the capability to produce more than 270 MW of electricity in combined-cycle mode. The two steam turbines are connected on the steam side with exhaust gas boilers, one for each of the 28 gas engines. It is not necessary to operate all gas engines at the same time to provide steam, but about 20% of the gas
The Aliaga, Turkey, combined-cycle gas power plant, producing more than 270 MW of electricity, is based on 28 Wrtsil 20V34SG gas engines and two steam turbines in a combined-cycle arrangement.
engines have to be supplying steam to make the steam plant operate. The nominal steam conditions to the steam turbines are 15 bar and 340C. The main contractor for the entire plant has been the Turkish electrical engineering and contracting company zyavru. It has had the total responsibility for the entire construction of the Aliaga Power Plant. Besides Wrtsil being the supplier of the gas power generating sets and Skoda of the Czech Republic providing the steam turbines, a large number of Turkish subcontractors have been involved. Mavi Proje has done the civil works and the company HT provided the mechanical part of the plant. Balikesir Electromechanical Industrial Plants Corp. has delivered the bulk of transformers for the plant.
At the time of the inauguration, six of the Wrtsil engines were running, with the remainder to come onstream as soon as the transmission line investment serving the plant has been completed. The electricity produced by the Aliaga plant will be sold to the Turkish spot market through a balancing mechanism, and will serve around 350 000 households. This is a proud day for Wrtsil, said Vesa Riihimki, group vice president, Wrtsil Power Plants. The Aliaga Cakmaktepe power plant is the worlds biggest gas-fired power plant based on reciprocating combustion engines. It stands as testimony to the efficiency and reliability of our power plant technology. Wrtsil has a workshop located onsite to provide full-service support to the plants operations, and also maintains the first phase (four engines producing 35 MW of energy) of the Aliaga Cakmaktepe power plant under a maintenance agreement. We are committed to fully supporting Turkeys rapid economic growth with efficient electricity-generating solutions, and this commitment is evidenced by the fact that we already have two offices employing 110 people established in the country, said Riihimki. a
An internal view from one of the two power buildings of the Aliaga plant shows a row of 12 Wrtsil 20V34SG gas engines.
by roberta prandi
Siemens Joins Power Diagnostics And Specialty Monitors

Power Diagnostics remote monitoring system can be combined with Siemens specialty monitors for power plant operation and maintenance
Blade tip vibration monitoring and blade stress diagnostics are among several specialty monitor and diagnostic systems offered by Siemens.
As fossil fuel-powered energy plants are becoming more sophisticated and as they are increasingly being used to balance power needs
of fluctuating renewable resources, the flexibility and reliability of the power plants will need to be more closely monitored.
Renewable energy, like wind and solar energy, is of increasing importance, but especially wind power is not easy to forecast and not at all under control of the utilities due to the nature of the wind, said Andreas Feldmller, head of service technology implementation at Siemens AG - Energy Service Division. As a consequence, the volatile renewable energy will be fully supplied to the grid and the remaining power demand less predictable and more fluctuating than in the past will have to be covered by the existing power plants. This will lead to more and faster start-ups and more frequent part-load operation with fast load ramps to increase or decrease power. To this extent, Siemens developed
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XX J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 1 XX


diagnostics takes place in defined intervals such as monthly or quarterly. The specialty monitors data, including operational values from the plant controls, is sent to Siemens via CD/ DVD or a network data exchange. The third level of the service concept for specialty monitors uses a daily Power Diagnostics service. Data from the specialty monitors or a higherlevel diagnostic platform is sent with a certain set of predefined operational data to the Power Diagnostics Centre (PDC), which allows the use of advanced Siemens diagnostic tools to correlate all available plant data and analyze trends and unexpected deviations with the help of the expert network, Feldmller said. Power Diagnostics is Siemens data acquisition system, first commissioned in 1998. Nowadays, approximately 400 units are monitored worldwide, including gas turbines, steam turbines, generators and combined-cycle balance-ofplant equipment. Power Diagnostics uses a data acquisition system at the site, which transfers the plant data to the Siemens network to detect deviation from normal behavior. Siemens Power Diagnostics engineers check data consistency and completeness on a daily basis. The PC-based data acquisition system is passively connected to the control system, receiving data from the I&C system along a one-way nonreactivedata highway, with no influence to the sites I&C system, said Feldmller. The site-based data acquisition system also has real-time data viewing capabilities and graphing tools that can be used locally by plant personnel as well as remotely per customer request for immediate expert support. Training is also available by the Power Diagnostics engineering technician during installation of the system. Feldmller also emphasized that the Power Diagnostics uses software based on standard, commercially available products. These tools are completed with proprietary software for diagnostics, data processing and data mining using OEM knowledge. A
Schematic of Siemens single-shaft rotor train with special monitoring and diagnostic systems.
several systems called specialty monitors to continuously observe specific components or functions in a plant. Specialty monitors work as standalone as well as add-on solutions, though the highest benefit can be achieved by connecting these monitors to a higher-level diagnostic platform, explained Feldmller. In combination with a diagnostic platform, it is possible to combine data from the monitors with information from standard plant DCS to correlate and process all data together. In addition to the operation monitors typically displayed in the control room of the power plant, specialty monitors give additional insight in the behavior or condition of individual plant components. For example, the foreign object detection system (FODS) continuously monitors the potential loss of combustion chamber parts to protect the turbine blades and vanes from subsequent damage caused by foreign objects, Feldmller said. The system detects potential blockages of the first row vanes and therefore prevents consequential damage of turbine blades and vanes. FODS is an acoustic system based on the analysis of structure-borne noise and the detection of burst signals produced by the impact of loose parts to the chamber or to the guide blades of the turbine. The next example is a specialty monitor that measures the blade tip vibrations of a steam turbines last-
stage blades. This module may have a special importance for plants that operate in a more flexible manner, as low-load operation may create higher stresses in the blades than full-load operation, said Feldmller. Another specialty monitor in this application is related to generators and other high-voltage components, as described by Feldmller, The specialty monitor Siemon HF 10-2 is designed to detect partial discharges and to give power plant operators advance notice of possible damage to insulation. These partial discharges bridge a portion of the high-voltage insulation, and their highfrequency nature can be detected. While specialty monitors are often stand-alone systems, Siemens allows customers to adopt these tools according to the operators needs, following a three-level approach. The first level uses specialty monitors to allow the operators a closer and continuous look at the performance or condition of their components. The equipment is permanently installed in the plant and the operator judges trends and deviations from normal behavior on his own, Feldmller said. In this case, several specialty monitors may also be connected to a higher-level diagnostic platform. In the second level, a Power Diagnostics service contract is signed between the customer and the equipment supplier to involve the engineering expertise of the supplier to judge the plant components. In such instances, expert-based
At MTU Friedrichshafen, 83 young people from the Cooperative State University started training in September 2010. The same training model has been adopted within the Tognum group by MTU South Africa and MTU Asia.
Worldwide Training Program Started By MTU

Young people training in Friedrichshafen and several other locations around the world, within the Tognum group
Starting September 2010 apprentices and students all around the world have been involved in their vocational training with the various subsidiaries of Tognum group. Anyone who aims to develop, build and maintain outstanding propulsion and power plants must have a workforce trained to outstanding standards. Thats why our German locations have always placed particular emphasis on high-quality vocational training and its why our companies abroad are now doing the same, explained Joachim Coers, Tognum CFO and executive board member with responsibility for human resources, and director of labor relations at Tognums largest subsidiary, MTU Friedrichshafen, Germany. With a total of 83 young people in training from the Cooperative State University in Friedrichshafen, Germany, that MTU location receives the lions share of the new generation of employees. Sixty students are starting courses in industrial mechanics, construction mechanics, technical pat-
tern making, mechatronics and electronics for automation technology, while two others are beginning their training as technical draftspersons. In addition, seven young people are embarking on commercial training courses and a further 14 are undertaking integrated studies programs at the Friedrichshafen location, leading to Bachelor of Engineering, Bachelor of Arts or Bachelor of Science qualifications. In total, 311 young people are currently training at the Lake Constance, Germany, location. Training programs are also under way at the German subsidiaries LOrange and MTU Onsite Energy Gas Systems in Augsburg, Germany, as well as at the Tognum SKL location in Magdeburg, Germany. In Stuttgart and Glatten, Germany, 13 LOrange trainees are starting their courses while one student has begun a Bachelor of Engineering study program in October. Three young people will be starting three-year courses in mechatronics in Augsburg, and in Magdeburg, four students are start-
ing vocational training in machining technology, mechatronics and industrial mechanics. A structured program for training future assembly technicians has now been in place at MTU South Africa for three years, and five new trainees will soon learn about the intricacies of engine assembly and servicing. Our system closely resembles the German model and uses both workshop training and vocational college courses to prepare our young people for their jobs as assembly technicians, explained Michael Baumann, managing director MTU South Africa. In October 2010, for the first time, 14 aspiring assembly technicians began training as after-sales workshop technicians at five MTU Asia locations. This program aims to cover our very real need for good next-generation technicians, said Peter Kneipp, president MTU Asia. With its solidly founded technical training programs designed to prepare the workforce of the future, Tognum is not only creating a worldwide basis for future success, it is also offering young people the chance to achieve top-class vocational qualifications and secure excellent career prospects, said Matthias Jobmann, head of human resources at Tognum. A
Marine ProPulsion
Island Tug opted to keep the existing ZF 5.037:1 gears and sent them out to be refurbished and adapted from the direct link they had to the old engines to a flexible link to the new Cummins engines. The new Rice nozzles and threeblade propellers were installed with the trailing edge of the nozzles cut away to all the placement of the rudders within 15 to 18 cm of the wheels for improved handling. Even with the reduction in power output from the main engines, the new configuration is expected to produce improved performance. Island Tug said that according to RAL predictive graphs, the new nozzles will produce a static bollard pull of 15 422 kg, and with a 5500 tonne barge, the vessel should run at 7 knots loaded and 9 knots empty an efficiency increase of 8%. In addition to the new powertrain, the tug received additional upgrades and fixes. The sponsons were opened up, blasted, painted inside and divided into four compartments before being resealed. The entire bulwark steel around the aft deck and stern was replaced, the towing pins were updated with new parts and the Burrard single drum winch was rebuilt. Some of the bunk rooms and the galley were also refurbished, and the deck was refinished with a sound dampening system that includes layers of a cork-concrete mix and perforated aluminum topped with an acrylic flake finish. The entire project took about a year to complete. A
Island Tug and Barges Island Defender tows 25 000 barrel fuel barges and 5500 tonne deck barges. The vessel received an overhaul complete with its third set of engines.
A Powerful Defender
Island Defender tug gets Cummins repower
The Island Defender tugboat has had its share of jobs and homes since it was built in 1977. The tug was originally built as the Hamilton Bailey and was used for log towing in Vancouver, British Columbia, Canada. Later, the boat was shipped to the Great Lakes and renamed the Josee M. Eventually, the well-traveled tug made its way back to the Pacific Coast and sold to Vancouvers Island Tug and Barge, where it was renamed Island Defender. Originally, the tug was outfitted with a pair of 358 kW Caterpillar D346 main engines. When it was relocated to the Great Lakes, it was repowered with a pair of Detroit DDEC V16-92 engines rated 820 kW each at 2100 r/min. Now back in Vancouver and working for Island Tug and Barge towing 25 000 barrel fuel barges and 5500 tonne deck barges, the vessel received an overhaul complete with its third set of engines. For its third set of engines, the 21 by 7.28 m Island Defender received a pair of Cummins KT19s rated 373 kW each. The reduced output from the previous Detroit engines will ac-
tually increase the tugs profitability as Canadian crewing regulations require a full-time engineer in tugs with more than 746 kW, and the smaller engines use less fuel. The engines are soft mounted and connected to the drivetrain via a Centa Link coupling, a design expected to reduce vessel noise. Cummins also supplied the engine monitoring and control panels in the main wheel house. Also added were a Krill fuel management and monitoring system, new shafts and Kobelt shaft brakes, Rice nozzles and propellers and a pair of John Deere gen-sets.
The 21 by 7.28 m Island Defender received a pair of Cummins KT19s rated 373 kW each. The engines are soft-mounted and connected to the drivetrain via a Centa Link coupling, a design expected to reduce vessel noise.
Industry news
The Model 352B70 sensor (left) has a 5000 g measurement range and a titanium housing to ensure durability in harsh environments. The Model 400B76 (right) allows users to read Transducer Electronic Data Sheet (TEDS) from sensors and write TEDS to sensors with a single mouse click.
New Accelerometer And Interface Kit From The PCB Group

PCB Piezotronics Inc. introduces Model 352B70 accelerometer; The Modal Shop unveils Interface Kit Model 400B76
PCB Piezotronics Inc. has released the newest sensor in its family of accelerometers designed for extreme testing in shaker labs. PCB Piezotronics, a member of the PCB Group, manufactures accelerometers, force sensors, load cells, microphones, pressure transducers, pressure transmitters, strain sensors, torque sensors, vibration sensors, signal conditioners, cables and accessories. The Model 352B70 has a 5000 g measurement range to accommodate the varying amplitudes experienced during high random vibration test profiles. It features a built-in two-pole low-pass filter to reduce the possibility of saturation due to high-frequency energy and is hermetically sealed in a titanium housing to ensure its durability in harsh environments. The sensor is also electrically
isolated to prevent unwanted electrical interference or ground loops and has a low-mass design, weighing 4.3 g, the company said. It also comes with mounting studs and an adhesive base to allow for a variety of mounting capabilities. The Modal Shop, a division of the PCB Group, has released the latest version of the Transducer Electronic Data Sheet (TEDS) Interface Kit, Model 400B76. The Modal Shop specializes in sound and vibration sensing systems for the multichannel, acoustics, modal and NVH markets. In addition to sensors, calibrators and system sales, a wide array of test equipment is available in its rental program. The new kit offers the capability to communicate with TEDS sensors over the USB port of a Windows-based computer. A graphical interface allows users
to read TEDS from sensors and write TEDS to sensors with a mouse click. The kit supports multiple IEEE 1451.4-compliant TEDS sensors. The principal types of supported transducers are single-axis and triaxial accelerometers, impact hammers, impedance heads, charge amplifiers, microphones and microphone preamplifiers. Model 400B76 supports IEEE 1451.4 and IEEE preliminary templates, which include IEEE transducer templates numbers zero to 28, as well as manufacturers templates such as the geometry formats established by LMS International. According to the company, the kit is designed for reading, verifying and updating TEDS sensor information and format, including calibration information. a
Featured Products
JMP IMPellers
JMP manufactures rubber impellers that feature a special surfacecoating designed to decrease wear and tear for longer use, according to the company. Developed with a unique composition of rubbers, JMPs impellers are designed to endure harsh marine conditions. JMP offers flexible impellers for Caterpillar, Cummins, Doosan (Daewoo), DDC, Jabsco, John Deere, Johnson Pump, Kashiyama, Komatsu, Mitsubishi, Onan, Sherwood, Volvo Penta and Yanmar engines, with custom impellers also available.
Repairs to diesel engine components for the marine and power industries
DIgItal servo InclInoMeter

Meggitt Sensing Systems, a Meggitt group division, has introduced the Sensorex SX41100 series, a servo inclinometer family featuring analog and digital outputs and a maximum linearity error of less than +0.02% FS. The series is designed to provide angular measurements within extreme testing environments, such as those found within offshore platform safety systems, the company said. The SX41100 series can provide an output signal, proportional to the angle being measured, over a range of +1 to +70. The series is also a part of companys rugged enhanced digital sensor (REDS) family, incorporating Meggitts Sensorex digital hybrid compensation circuit design, resulting in inclinometers with +5 V analog, 4 to 20 mA or RS232 and RS485 ASCII digital outputs.
Typical damage to cast iron components can be any or all of the following: Corrosion Erosion Mechanical Damage Fractures A diesel engine cylinder head repaired/restored to as new condition
HIgH-teMPerature Pressure sensors
IMI Sensors, a division of PCB Piezotronics Inc., has launched its Series 176 high-temperature pressure sensors for gas turbine monitoring. The sensors detect and measure dynamic pressure phenomena and combustion instability in extreme heat environments generated by gas turbines. The sensors are also ATEX and CSA certified for use in hazardous areas, the company said. The sensors are suited for gas turbine monitoring with sensitivities up to 2.5 pC/kPa and ranges from 1.3 to 27.6 bar static.
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Power Generation
Kohlers new Decision-Maker Paralleling System is a factory prototype-tested system engineered to provide a reliable, expandable paralleling capability for the companys line of industrial gaseous- and diesel-powered generator sets from 100 kW to 3.25 MW.
A Standard Decision On Paralleling

Kohlers new Decision-Maker system designed for expandable paralleling capability
Kohler Power Systems has introduced a standardized approach to paralleling backup power generation systems. The new Decision-Maker Paralleling System is a Kohler designed and branded, factory prototypetested system engineered specifically for gen-set paralleling and can be specified across Kohlers entire line of industrial gaseous- and diesel-powered generator sets from 100 kW to 3.25 MW. With Decision-Maker Paralleling System, Kohler Power Systems offers an alternative to large-kilowatt single-generator backup power systems, as well as the traditionally complex, highly customized approach to paralleling, said Jim Kukla, marketing manager, industrial generators, Kohler Power Systems. Paralleling doesnt need to be a complex exercise, which is why Kohler focused on developing a factory prototype-tested system. Because Kohler took the initiative to design an end-to-end system and test each component together, specifying engineers and electrical contractors dont need to worry about power system component interface problems and can find peace of mind in the reliable redundancy, power output flexibility and system scalability attributes
that define Kohlers Decision-Maker Paralleling System. The new paralleling system incorporates three components the DecisionMaker 6000 control unit, a power distribution switchboard and a master control panel. In a multigenerator array, each generator comes equipped with a DEC 6000, Kohler said. The unit provides interconnected communications for power synchronization and load sharing as well as system protective functions and breaker control through system-wide monitoring of generator frequency, voltage and load. The power distribution switchboard provides a power output consolidation hub and houses the necessary breakers for the generators and loads. By combining the power from multiple generators, Kohler said the switchboard provides the final desired power output to support a facilitys electrical load needs. Adding enhanced capability to the Decision-Maker Paralleling System, Kohlers Master Control Panel (MCP) supports load shedding/adding based on critical load needs. Designed with a full system graphical interface, the MCP monitors system electrical and mechanical loads, and includes event logging and alarm functionality. In addition to
load management, the MCP also facilitates generator management, balancing operating hours across the paralleled generator sets to equalize maintenance needs, the company said. The Decision-Maker Paralleling System delivers the same backup power production as a single high-output generator, but with redundancy and thus more reliability, flexibility and fuel options and in a cost-competitive manner, Kukla said. In paralleling environments, the standby power source is backed up through having multiple generator sets at the same site. As a result, critical loads have multiple layers of redundancy and enhanced power reliability. As a factory prototype-tested system, Kohler said the DecisionMaker Paralleling System facilitates future expansion of generator set facilities, while easing the initial capital cost of a backup power system in the near term. Specifying engineers and electrical contractors can install a genset configuration that meets a facilitys current electrical load requirements but can also expand the generator array in a streamlined fashion as power demands grow, Kohler said. A
Featured Products
IntellIgent ValVe Controller
signed for remotely controlling motors in industrial areas where flammable gases are present. Optitrols heavy-duty enclosure confines electrical arcing, preventing ignition of flammable atmospheres found in chemical plants, refineries and other classified industrial areas during the operation of motors and other electrical equipment, the company said. The malleable iron enclosure and its cover have
a triple coat of zinc, chromate and epoxy powder to prevent corrosion. O-Z/Gedney uses its global design expertise to offer Optitrol in dozens of possible combinations of products. All are available in both dead-end and feed-through 12.7 mm, 19.1 mm and 25.4 mm hubs. Heavyduty contacts are rated 10 Amps, 600 Vac.
Metso has upgraded the Neles intelligent valve controller, ND9000, which now incorporates a range of enhancements to the devices diagnostics, control performance, robustness and commissioning. The ND9000, which was first released in 2003, is designed to help process plants improve process efficiency through control valve constructions, Metso said. The upgraded ND9000 has a reduced calibration time of 30 to 75%, depending on the actuator volume, as well as better reactions to buttons and a running index to display the progress of a calibration run.
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Tops-on and tops-off measurements Alignment in diameters ranging from 120 mm -5000 mm up to 40 m distance Detection of deformations and ovalization of elements Control sensor monitoring and automatically correcting any laser drift Optimal choice of centerline for entire assembly with minimal correction values for each element Instant display of corrections for each bore
Control StatIonS, PIlot lIghtS
O-Z/Gedney has a new line of factorysealed, explosion-proof and dust-ignition proof control stations and pilot lights. The products, part of O-Z/ Gedneys new Optitrol series, are de-
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11/22/10 10:18:39 AM
Pruftechnik_JanFeb11WW.indd 1
by amanda m. klemp
Chromalloy opened a new castings facility in Tampa, Florida, U.S.A., expanding its manufacturing capabilities in both quantity and size of gas turbine hot section components.
An Ensemble Cast At Chromalloy

New casting facility expands turbine component manufacturing capabilities
Chromalloy, a company that repairs and manufactures new parts for gas turbines, has opened a new casting facility in Tampa, Florida, U.S.A. The facility expands upon previous capabilities, tripling the companys Tampa location capacity to manufacture components for the hot section in gas turbines used in power generation, marine, heavy-frame industrial and aero applications. The new casting facility in Tampa was designed to pour up to 136 kg of alloy at any given time for turbine hot section parts such as blades, vanes, nozzles and shrouds. The site is also equipped to cast larger frame IGT parts that the company didnt have the capacity to do before. Chromalloy installed larger material handling devices, larger furnaces and larger testing inspection equipment. The company is now
equipped to manufacture parts that will fit up to a 122 cm envelope and weigh 68 to 79 kg. Tom Trotter, vice president and general manager of Chromalloy Castings in Tampa, said, Weve got some terrific repair techniques that were applying in the power generation markets and those are opening up possibilities. Chromalloys business concept is to offer customers an alternative to OEM repairs and replacement parts. Trotter explained, Chromalloy has developed many proprietary repair techniques that we utilize, and our business model is different. We would prefer to repair a part and not have the operator going through the expense of buying a new spare part. But, if we cant repair it, we have the capability now with the expansion in Tampa to be able to produce the part for the operator, he said.
The company offers design engineering, tooling, casting, machining, repair technology and coatings. Despite the fact that Chromalloy has the full design capability, we typically use the OEM design as kind of the baseline, said Trotter, explaining the engineering that goes into cast replacement hot parts for turbines. Because we do have the design and analysis capability and because we do repairs on these parts during the repair cycle, we know and weve been able to build a database on what the failure modes of these individual components are. So in many cases what we will do is redesign the part to address those failure modes and be able to provide a better part to the operator than what the OEM might be running with today, said Trotter. The company said it develops its own intellectual property by reverse engineering parts produced by the original equipment manufacturers. Once the part is designed, it goes through a casting process, which Chromalloy said can meet tolerances as tight as five- to eight-hundredths of a millimeter. Chromalloy employs investment
turbine overhaul
& repair
tion. During the testing process, each manufactured component is x-rayed for quality control. Because aero turbines make up the majority of the companys business, Chromalloy has to manufacture those turbine components up to FAA standards and regulations. As a result, Chromalloy engineers and manufactures all components for all industries it services up to FAA standards. Along with the opening of its new facilities, Chromalloy also announced plans to expand the new facility to produce its own ceramic cores onsite. The ceramic cores are used in the molding process to form the air passageways in hollow components. The expanded Tampa facility replaces the previous Tampa location. The company said it was important to build the new location within 15 to 20 minutes of the old to retain its workforce. A
Chromalloy installed larger material handling devices, larger furnaces and larger testing inspection equipment. The company is now equipped to manufacture parts that will fit up to a 122 cm envelope and weigh 68 to 79 kg.
casting to manufacture its aftermarket parts. The process begins by injecting a wax pattern. With the pattern, the mold assembly is produced and the assembly is then dipped six to seven times in a ceramic slurry.
Once dipped, the wax is removed from the ceramic shell and the melted alloy is poured into the shell. The shell is then removed and the parts are removed from the gating. From there, they go to finishing and inspec-
Lets generate ideas.

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API_HeatTransfer_JF11_WW.indd 1 1/11/11 4:11:11 PM
Industry news & AnAlysIs
Total installed cogeneration capacity by installation size (in GWe) for combined heat and power (CHP) in Europe, with expected growth projections including micro-CHP to 2050.
Update On European Energy Policies

COGEN Europe summarizes the situation with European energy goals, strategies and the revised CHP directive
The EU energy and climate goals (20% reduction in CO2 emissions, 20% renewables in end-use energy and a reduction of 20% of primary energy use by 2020) have been incorporated into Europe 2020, the new economic strategy adopted by the European Council in June 2010. As part of this strategy, the flagship initiative Resource-efficient Europe aims, among other things, to decouple economic growth from the use of resources. The energy and climate objectives for 2020 now form an integral part of this strategy. The wider use of the cogeneration principle contributes centrally to Europe achieving its energy efficiency and CO2 reduction targets. Hence, the next 12 months, which contain increased focus on European energyefficiency policy through an action plan and new legislation, also involve
Information supplied by COGEN Europe, a European trade association that promotes cogeneration power technologies.
scrutiny and revision of the policies around cogeneration. Cogeneration was recognized by the EU in 2004 as having a fundamentally beneficial role in improving energy efficiency in Europe and was the focus of a specific Cogeneration Directive as a result. The Directive has two main thrusts. First, it sets out the fundamental definitions for high-efficiency cogeneration in the EU, establishing that a high-efficiency cogeneration plant will save a minimum of 10% primary energy compared to separate production and enabling cogeneration to gain aid and support from Member States within the state aid guidelines. Second, the Directive commits the 27 EU Member States to a succession of analysis, reporting and action, which when pursued will increase the use of cogeneration principle across a wider range of economic and societal sectors. COGEN Europe is leading a European project of independent stake-
holders monitoring the Cogeneration Directive implementation by the EU Member States. The project, called CODE (www.code-project.eu), is partly funded by the European Commission under the IEE program. CODE produced the first analysis of Member States reports on the potential of cogeneration in Europe to 2020. It was the first to reveal that, collectively, the 27 Member States identified 120 GWe of additional economic potential for CHP across Europe by 2020. The Member States approached the analysis unconstrained apart from the high-efficiency definition of the Directive. Additionally, the project showed the considerable barriers that still exist to new cogeneration, largely around connection to the grid, and also the different commercial returns that can be expected in different Member States depending on the degree of energy market liberalization and the support mechanisms in place.
Industry news & AnAlysIs

Remarkably, all Member States have some support mechanism for cogeneration, however, few are effective. Of those that are effective, Germany and Belgium set the benchmark for what is required for success, as both countries having successfully stimulated growth in cogeneration under their support schemes. The CODE project is now in its final phase and will develop a proposal for a European Cogeneration Roadmap for Europe to be published in June 2011. What is the role for cogeneration to 2050? 2010 saw the first modeling and projections of how Europe might move to a de-carbonized electricity supply for 2050. COGEN Europe published the industrys own projections of the role of cogeneration to 2050 on Dec. 1, 2010. The report highlights the foundation role that the cogeneration principle can play in a resource-efficient Europe and, taking into account future projections in fuel mix to 2020, charts the expected growth of cogeneration including micro-CHP through to 2050. What is clear is that cogeneration has a huge amount to offer in energy efficiency, CO2 reduction, innovation and jobs in the near and medium term. Moreover, it is one of the few realistic de-carbonization options open for hightemperature industrial heat. The drive to energy efficiency will be a leading theme of the next few years in energy policy, and rightly so. Europe needs to be resource efficient in a time when budgets are being cut and unemployment is rising. The size of the energy-efficiency challenge was highlighted in November 2010 by DG Energy of the European Commission, which published its latest assessment of progress toward the 20% energy savings target for 2020. By its most recent projections, and taking into account all existing energy-efficiency legislation, Europe will achieve energy savings of only 9% by 2020 compared to its target of 20%. There has never been a better time for Member States to support cogeneration. In November 2010 the EU published its new energy strategy Energy 2020. Echoing one of the main themes of the COGEN Europe report, Cogeneration as the foundation of Europes 2050 low carbon energy policy, the Energy 2020 strategy advocates a far more demand-oriented approach to energy thinking, putting the users at the heart of strategy rather than the suppliers. The new strategy puts energy efficiency as the first priority for energy policy in this time of economic recovery and energy and climate challenges. Within energy efficiency, cogeneration is highlighted as a principle that must be more strongly promoted. The options for cogeneration in new EU energy strategy will be extensively covered in the upcoming COGEN Europe Annual Conference on March 24, 2011, in Brussels, Belgium. For more information on this event, visit www. cogeneurope.eu. A
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Power Generation
by roberta prandi
The MTU Onsite Energy CHP module installed at GFBio-Energie Hasetal GmbH, featuring a new 12-cylinder 4000 Series biogas engine, with 1166 kW electrical power, over 1300 kW thermal output and an electrical efficiency of 42.5%.
Cultivating Biogas-Fueled Power

MTU introduces Series 4000 biogas engines for CHP applications
When the profit margins from conventional agricultural crops, such as corn, cereals or potatoes, dropped in Germany at the end of the 1990s, many farming enterprises looked for alternative ways of doing business and increasing revenue. One avenue that gained interest rapidly was the installation of biogas-fueled combined heat and power (CHP) plants. Further increasing interest were subsidies from the German government for producing electricity from biogas under specific conditions. Reinhard and Hermann Gross, who owned a 1800 ha farm in Lningen, Germany, opted to expand their operation with a biogas CHP plant. In 2001, the brothers founded GF-BioEnergie Hasetal GmbH, and built a biogas-operated heat and power plant, fueled by agricultural waste, manure and chicken dung. Initially, the power plant comprised
10 dual-fuel aggregates, each delivering a maximum of 80 kW power. At the same time, a biogas plant with five anaerobic digesters was built. With time, the stringent emissions regulations and the need for higher efficiency pushed the two brothers to rethink the concept of their biogas plant and they switched to Otto gas engines. Thus, in 2008 three CHP modules by MTU Onsite Energy were installed, featuring the companys 400 Series biogas engines with an electrical output of 350 kW each. Based on this experience, it was a short step for the two entrepreneurs to decide to try a pre-series unit of the new MTU 4000 Series biogas engines, which successfully completed practical trials at the farm, surpassing about 7500 hours of operation. In December, MTU announced the biogas Se-
ries 4000 engines would be available to market in March. A CHP module with a 12-cylinder 4000 biogas engine rated for 1166 kW of electrical power and over 1300 kW of thermal output was installed in 2009. The GC 1166 B5 module produces electricity and heat, and has the same output as three of the previous modules operated by the 400 Series engines. MTU Onsite Energy also said the new unit registered an electrical efficiency of 42.5%. The manufacturer said the new 4000 Series biogas engines are based on the diesel engine from which a natural gas version was already derived. Some design and manufacturing changes were introduced for use with biogas, such as more robust steel pistons and modified combustion chamber geometry. The engine control system was also adapted for biogas operation.
Power Generation
engine has been working as a baseload unit for the biogas plant, with the smaller 400 Series modules working as satellite units. These satellites will produce power and heat for local use, optimizing the utilization of the produced heat. The 12-cylinder 4000 Series biogas engine was also equipped with a catalyst that will reduce the emissions of formaldehyde. So the CHP plant by GF-Bio-Energie Hasetal GmbH will profit not only from the state contribution for biogas electricity production, but also from an additional formaldehyde bonus by the German government. MTU Onsite Energy announced that the market introduction of the 4000 Series biogas engines for power generation will take place in stages from March 2011, with 8-, 12-, 16and 20-cylinder versions covering an output range from around 770 to 2000 kW. a
The assembly line of the 4000 Series engines at the MTU Onsite Energy plant in Friedrichshafen, Germany. The new biogas versions will be introduced to the market in stages beginning in March 2011.
After six months in operation, the engine was inspected at the MTU headquarters in Friedrichshafen, Germany. The company said all components,
including the newly designed ones, showed virtually no sign of wear. Since October 2010, the CHP module with the 4000 Series biogas
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Oil & Gas
by dj slater
Ramgen used the Rampressor test rig to showcase the capabilities of a shockwave compression system.
AEP Joins Effort To Build More Efficient CO2 Compression System

Investment grows in supersonic shockwave compression technology
American Electric Power (AEP) has committed US$2 million to support the commercial development of advanced compression technology for carbon dioxide (CO2) as part of an ongoing initiative that includes the U.S. Department of Energys National Energy Technology Lab (NETL), Ramgen Power Systems LLC and DresserRand. The initiative is developing a supersonic shockwave compression system that will reduce the cost and energy consumption associated with compressing CO2 for storage in porous rock formations deep underground. Sequestering CO2 in underground formations requires compressing the gas to more than 103 bar. Existing compression technology represents a substantial part of the capital and operating costs of developing CO2 capture and storage systems. Ramgens advanced compression system will use supersonic shockwaves to compress CO2 for capture and storage, according to the company. If successful, the shockwave compression technology is projected to reduce the capital cost of CO2 compression equipment by as much as 50% and reduce operating costs of a carbon capture and sequestration (CCS) system by at least 15%.
If we are successful, this system will be a game changer, said Peter Baldwin, Ramgens president. The industry has been good with incremental change, and this has the potential to be a game changer. Compressor designs for CO2 capture and storage demand a pressure ratio of 100:1 and require stainlesssteel construction in the presence of water vapor, according to Ramgen. The most significant cost, however, comes from the aerodynamic design practice that limits the design pressure ratio per stage on heavier gases. Ramgens proposed system would be able to reach the 100:1 pressure ratio in two stages of compression instead of eight, which is typical for most compressors, according to Ramgen. The compressor system, which could run at about 8 MW, could achieve about 39 kg/sec. at a 10:1 pressure ratio, Baldwin said. The technology behind this system comes from the Rampressor, the companys core design, which features a rotating disk that operates at the high peripheral speeds necessary to achieve supersonic effect in a stationary environment, said Ramgen. The rim of the disk has three raised
sections and cavities that mimic the effect of the center-body and channels of a conventional ramjet inlet. Air enters through a common inlet and is then ingested into the annular space between the supersonically spinning disk and the outer edge of the casing, according to the company. When the air flow enters this space, the raised sections of the rim create a ramming effect, generating shock waves and air compression. The disk chambers are angled, so the compressed air is rotated into a collector and then into the compressed air system. The compression process is also oil free, requiring no oil for lubrication or sealing, according to Ramgen. The idea behind using shockwaves in compressors originated with Shawn Lawlor, Ramgens founder and chief technology officer. Lawlor knew that the U.S. Air Force had spent considerable money and research in supersonic flight capabilities to improve the effectiveness of shock compression, Baldwin said. He then wondered if that technology could be applied to stationary equipment. The idea became a reality about 10 years in the making. In recent years, other entities have taken notice of Ramgens work, AEP being the latest. Before AEP, the U.S. Dept. of Energy provided a four-year, US$11 million grant for Ramgen to develop the compressor system. On Aug. 10, 2009, the Dept. of Energy awarded Ramgen a US$20 million grant from the American Recovery and Reinvestment Act in order to accelerate the development of a commercial-scale unit. The
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A cross-section of the Rampressor test rig.
commercial product, the HP-12, is the high-pressure stage of a matched set that would be suitable for 200 to 250 MW coal-fired power plants, according to Ramgen. Ramgen said that its proposed supersonic shockwave compression system offers four distinct advantages when compared with existing compressor technologies. The system can achieve high compression efficiency and is capable of producing very high, single-stage compression ratios. The systems simplicity and size make it less expensive to manufacture, and it is capable of significant waste heat recovery, according to Ramgen. I think that I speak for the entire company in saying that it is very rewarding, both personally and professionally, to be involved in such an important initiative, Baldwin said. At some point in our careers, we all say We want to make a difference. The folks at Ramgen are making a difference. AEPs involvement is another set of good news for Ramgen, Baldwin said, especially considering its work in advancing CCS technologies. AEP began capturing and sequestering CO2 Oct. 1, 2009, from 20 MW of the flue gas at its Mountaineer Plant in New Haven, West Virginia, U.S.A., using chilled ammonia technology developed by Alstom. The company said that the Mountaineer CCS project is the first integrated CO2 capture and sequestration project at an operating coal-fueled power plant. On Dec. 4, 2009, AEP received US$334 million in funding from the
U.S. Department of Energy Clean Coal Power Initiative Round 3 to pay part of the costs to scale up the chilled ammonia process to capture at least 90% of the CO2 from 235 MW of the plants 1300 MW of capacity. The captured CO2, about 1.5 million tonnes per year, will be treated and compressed, then injected into suitable geologic formations for permanent storage approximately 2.4 km below the surface. Advancing technologies to capture and permanently store carbon dioxide from coal-fueled power plants is critical if we are going to reduce global concentrations of greenhouse gases, said Nick Akins, AEP executive vice president, Generation. Now that we have completed construction and are operating the CCS validation system at our plant in West Virginia, our focus is on working to better understand and optimize that process to help ensure that the economics of CCS make sense for our customers and for use on the worlds vast fleet of coal-fueled power plants. In addition to providing financial support, AEP will consult on the development and demonstration of the CO2 compressor that will be tested at Dresser-Rands test facility in Olean, New York, U.S.A., in the second quarter of 2011. AEP has also committed to working with Ramgen and DresserRand on potential future tests of the shockwave compression technology at AEP sites. A
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Rail TRacTion
equations, the system uses train weight, length, power output, track profile for grade and curve information received over a wireless connection this is all automatic so the engineer doesnt have to manually enter it. The onboard planner then takes the information and calculates the optimal velocity for fuel savings, said GE. Once under way and in automatic mode, the system is designed to continuously monitor the planned velocity and actual velocity and uses the closed-loop control logic to keep the trains speed on course. The system also monitors actual power consumed against the plan, and if there is a noticeable difference the system will automatically set a new plan for optimal fuel consumption and speed. Factors that may induce differences include errors in weight or length data, locomotive power derate, wind and others, said GE. The Trip Optimizer is fully integrated into the locomotive. The control software is updated to include the systems functionality, a configuration developed for a seamless flow of locomotive data to operate the unit while minimizing lag time for the commanded control requests, explained GE. It is also configured with the factory displays so the verification of train data, the rolling map and situation awareness information for the auto control can be accessed on one of two built-in displays. The Trip Optimizer can be installed either as an OEM factory installation, such as with GE Evolution locomotives, or as an aftermarket system. Pierre Comte, president GE Transportation Intelligent Control Systems said, Trip Optimizer generates fuel savings ranging from 3 to 15% per locomotive depending on territory as measured by North American train operators. It is a significant element in the future of fuel conservation with the added benefit of reducing emissions for railroads around the world. A
GEs Trip Optimizer calculates the optimal speed profile for a trip based on the specific trains makeup and route and then automatically controls the throttle to maintain that planned speed to save fuel.
Saving Fuel Through Speed Control

GE Transportation Trip Optimizer for rail applications determines optimal speed
GE Transportation has developed a technology, under the ecomagination umbrella, designed to reduce fuel consumption in locomotives by calculating the optimal locomotive speed. GEs Trip Optimizer was found to save 12.5 million liters of fuel (a 7% average savings) in the first 8 million kilometers of track run using it. The Trip Optimizer functions like an intelligent version of a cars cruise control, said GE. It calculates the optimal speed profile for a trip based on the specific trains makeup and route, and then automatically controls the throttle to maintain that planned speed to save fuel. The software integrates into the locomotives control system and monitors performance while utilizing GPS tracking to evaluate routes, and plots optimal train velocity on the operators display. The locomotive opera-
tor sets the parameters for trip time and velocity. It was designed to operate in either automatic control or advisement mode. Automatic control maintains the planned speed automatically, while advisement mode informs the operator which throttle and dynamic braking levels to use to optimize fuel efficiency and speed, said GE. In auto control, a real-time closedloop control system continually adjusts throttle application based on data fed back to the controls from the train. Speed and acceleration data are fed into the operating system, processed and commands are sent to the engine to automatically govern the throttle. The system comprises a wireless system, onboard planner, closed-loop control and operator interface. Using energy and momentum
Power Generation
LSA 40 Low-Voltage Alternator

New compact alternator for rugged applications
The LSA 40 alternator by Leroy-Somer is a new product in the companys Partner lowvoltage range. The alternator is a four-pole, three-phase alternator with power ratings from 10 to 23 kVA at 1500 r/min and 12.5 to 28 kVA at 1800 r/min.
Ipsen delivers solutions.

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The Leroy-Somer Electric Power Generation division has introduced the LSA 40, a four-pole, three-phase alternator offering power ratings from 10 to 23 kVA at 1500 r/min for 50 Hz and 12.5 to 28 kVA at 1800 r/min for 60 Hz. The alternator is also available in a dedicated singlephase version. LSA 40 comes with two field excitation versions: shunt, with high starting capacity, and AREP, with high starting capacity and short-circuit capacity. Available in a single-bearing or two-bearing version, LSA 40 has been designed to be mechanically suitable for most engines on the market. It is also interchangeable with alternators from the previous Leroy-Somer Partner range. The company said the LSA 40 is a compact, versatile alternator, characterized by high efficiency levels, allowing more electric power from the same engine. In addition, it has low reactance, which gives it a high capacity for starting electric motors and the ability to withstand disturbance from distorting loads, said Leroy-Somer. According to the manufacturer, LSA 40 is simple to install and has a modular terminal box for ease of access to the terminals and the AVR. It was designed to be small and lightweight. Due to rugged construction, LSA 40 is able to operate in demanding applications. Leroy-Somers EPG division specializes in low-, mediumand high-voltage alternators, with a power range between 3.5 and 2360 kVA for low-voltage and between 1 and 20 MW for low-, medium- and high-voltage products suitable for a wide variety of applications. A
SPEED UNIFORMITY EFFICIENCY
Marine ProPulsion
The engine model uses the common rail micro-pilot fuel-injection system for liquid fuel, which is necessary when running on gas to ignite the air-gas mixture. The system ensures independent control of injection timing, injection pressure and injection volume. When running on liquid fuel, the 51/60DF works with a conventional fuel-injection system, injecting the fuel oil through a separate main fuel injector in a camshaft-actuated pump-line-nozzle system. The fuel injection control is integrated within the engines Safety and Control System (SaCoSone). The SaCoSone allows the engine to operate safely in both modes while keeping fuel consumption and emissions optimized. In gas mode, the system controls various parameters for each cylinder independently, including air-fuel ratio, load, valve timing, pilotfuel injection and charge-air temperature. This creates optimal combustion while permitting operation within a wide range of the air-fuel ratio, avoiding incomplete-ignition failures, misfiring or knocking, the company said. The 8L51/60DF engines are designed to run on gaseous fuels, such as vaporized LNG or liquid fuels of a wide quality range (HFO/MDO/MGO), and have low emission levels. At 1.5 g/ kWh (IMO cycle E2) in gaseous-fuel operating mode, the 51/60DF complies with future IMO Tier 3 limits for NOx without the need for exhaust-gas treatment or any other countermeasures, the company said. A
The LNG carrier Castillo de Santisteban is powered by five MAN Diesel & Turbo dual-fuel 51/60DF engines. The order for the engines is the first received for this engine type, said MAN.
MAN Powers LNG Carrier

Five dual-fuel MAN 51/60DF engines to form diesel-electric propulsion plant
MAN Diesel & Turbo is playing a part in powering a 300 m LNG carrier. Five dual-fuel MAN 51/60DF engines, each delivering 8000 kW at 514 r/min, serve as the diesel-electric propulsion plant for the new LNG vessel Castillo de Santisteban, which was delivered by Korean shipbuilder STX Offshore & Shipbuilding to shipping company Empresa Naviera Elcano. The vessel has been assigned by her charterer, Spanish energy company Repsol Gas Natural LNG (Stream), to the Peruvian Camisea/Pampa Melchorita gas project, a gas liquefaction plant in South America. The carrier has a carrying capacity of 173 600 m3 LNG. When it comes to ship propulsion technology, the future is gas, said Klaus Deleroi, senior vice president, MAN Diesel & Turbo SE. Not only for LNG carriers, but also for cargo vessels, ferries and even cruise liners. Knowing this, it is important for MAN Diesel & Turbo to have a strong reference already at sea with our new 51/60 dual-fuel engine, and that is exactly what we have with the Castillo de Santisteban. The entry of the LNG vessel into active service represents a milestone for MAN Diesel & Turbo in that the order for the ships dual-fuel engines was the
first received for this engine type, said the company. The engine is designed for LNG carrier and gas-fueled ship propulsion systems and focuses on the safety requirements stipulated by classification societies for gas operation. MAN Diesel & Turbos 51/60DF dual-fuel engine offers a 1000 kW per cylinder output at 514 r/min for 60 Hz generator sets in both its gaseous and liquid-fuel operating modes. For marine applications, it is offered in inline versions with six, seven, eight and nine cylinders and vee-configuration versions with 12, 14, 16 and 18 cylinders in a power range from 6000 to 18 000 kW, according to MAN Diesel & Turbo.
The engine room on the LNG carrier Castillo de Santistenban contains five Man Diesel & Turbo dual-fuel 51/60DF engines.
Oil & Gas
by amanda m. klemp
Dresser Waukesha has introduced a power generation configuration for its 275GL Series of gas engines, offered with both the 16-cylinder 16V275GL+ (seen here) and the 12-cylinder 12V275GL+ gas engines.
Dresser Waukesha Rolls Out New Gen-Set

New 275GL+ engines offered for oilfield power generation configuration
Dresser Waukesha has introduced a power generation configuration for its 275GL Series of gas engines. Packaged as the companys Enginator gensets, the 275GL+ powered units are targeted at oilfield applications. The new power generation units are the latest additions to the 275GL Series, which was originally introduced in 2009 for gas compression. The new gen-sets are offered with both the 16-cylinder 16V275GL+ and the 12-cylinder 12V275GL+ gas engines. The 16-cylinder version is rated 3480 kWe at 50 Hz and 1000 r/min and; at 60 Hz and 900 r/min, the unit is rated 3110 kWe. The 12-cylinder model has an output of 2600 kWe at 50 Hz and 2330 kWe at 60 Hz. In an Enginator gen-set configuration, the engine drives the generator through an elastic coupling. The switchgear, which is built and designed by Dresser Waukesha, is optional in the package. The engine is water cooled and the generator is air cooled. The company incorporated its
proprietary Engine System Manager (ESM) controls in the 275GL+ engines. ESM includes the central engine control unit, ignition, NOx modules, ignition coils and harnessing. For NOx levels, the company said both the 12V275GL+ and 16V275GL+ engines are capable of 0.5 g/bhphr NOx, 1.8 g/bhp-hr CO and 0.7 g/bhp-hr NMHC emissions levels without aftertreatment, which corresponds to 1/2 TA Luft NOx levels and meets the requirements for most nonattainment areas in the United States. While the engines were originally introduced for gas compression applications, the move to power generation was fairly simple. There are different requirements for a power generation engine versus a gas compression engine, said Douglas Kiesling, director design and analytical engineering at Dresser Waukesha. Essentially, a power generation engine needs to run at a constant speed, while a gas compression engine runs at a constant load but at varying r/mins.
Its a minimal effort to recalibrate the engine, but it is an essential change, said Kiesling. He said a combination of changing the spark, altering fuel delivery and managing turbocharger wastegate and bypass calibrations prepared the engine to run at the constant speed and meet the engine speed requirements and limits for power generation. The company said the engines are designed to run on low-quality gas pulled right from the ground and to operate at full power with heating values down to 23.6 MJ/m3 and at almost 70% load. In addition, the air intake and turbochargers are configured to allow operation at altitudes up to 1219 m and 914 m, for the 12and 16-cylinder versions respectively, without de-rate. One of the things that is unique about running an engine on field gas is that the gas that comes right out of the ground is not the cleanest fuel. It has a lot of contaminant, lots of liquids and heavier carbon compounds that havent been removed, Kiesling said. So you need an engine that can quickly react to those changes in fuel quality, and the 275 engine is very good at that, he explained. Fuel flexibility was achieved through a robust combustion process design, which includes fuel delivery, cylinder design, air handling and turbochargers. These elements are configured to handle a wide range of fuels and frequent swings in fuel quality. Kiesling explained, Achieving greater fuel flexibility requires widening the design parameters that affect combustion and matching them to a wider range of fuel qualities. He said Dresser Waukesha targets specific design parameters to allow the most efficient combustion process for the varying fuel qualities. Though the 275 GL Series engines were targeted initially to gas compression applications, their fuel flexibility will allow them to work in any application with varying fuel qualities. A
Industry news
FW Murphy Expands PowerView 101 Flexibility With New Configuration Software

Newly released software said to offer OEMs lower product development costs, shorter time to market
FW Murphys new software package for its PowerView 101 includes several new customizable features.
FW Murphy has announced a new software package that allows stationary and off-highway engine OEMs the ability to configure its PowerView display according to their needs. With the introduction of the new PV101 3.1 software, engine manufacturers can now use a laptop computer to customize the PowerView 101 display quickly and easily. This new software is in response to customer demand for a way to quickly and efficiently change the parameters of the PowerView 101 on their own, said Robbie Captain, product manager at Murphy. Prior to the availability of this soft-
ware, the displays were configured by Murphy to meet a particular customers needs before shipping. Now OEMs can load their own specific display configurations in-house with a laptop, speeding their time to market. Anyone familiar with J1939 communications will be able to use the softwares intuitive, drop-down menus to configure the interaction between the display and the engine, added Captain. This software will also be very helpful when testing prototypes prior to production, or to make changes on engine displays, he said. The software provides users with
a license key and will be eligible to receive any future updates. According to Captain, the software will be especially welcomed by OEMs seeking ways to meet Tier 4 engine compliance. It will save them time and money because they can now make their own changes on-site and no longer need to send the display back to us for reconfiguration, he said. Since its introduction two years ago, the PowerView 101 has gained wide acceptance as a powerful multifunction tool that allows operators to monitor several different engine, transmission or machine parameters and service codes on a single, compact screen, according to Murphy. In that short time span, according to Murphy, it has become the standard for users that need real-time monitoring, full diagnostics and multiple languages. FW Murphy, established in 1939, is an ISO 9001 registered manufacturer committed to providing products and services for equipment management and control. The Murphy product line has evolved from its original Swichgage, according to the company, and now includes a broad range of engine and enginedriven equipment controls and monitoring systems. Murphy now offers J1939 instrumentation solutions for machinery such as gas compressors, off-highway and construction equipment, standby generator controls, irrigation and water pumping. The company said that it is also an approved supplier to major OEMs including Caterpillar, John Deere and Cummins. A
Featured Products
TemperaTure module
Emerson Process Management has added a temperature module for its CSI 6500 machinery health monitor. The new A6630 temperature module complements the vibration monitoring capabilities already available in the CSI 6500 and provides critical bearing temperature measurements, Emerson said. The module accepts RTD and thermocouple signals directly, reducing the installation cost and complexity of temperature monitoring, according to the company. In keeping with the API 670 specification, the A6630 has six or fewer channels per module, 4 to 20 mA outputs, and relay logic for voting and automatic machine trips. Additionally, the CSI 6630 is hot swappable and supports the Easy Integration feature for fast connection to the DeltaV and Ovation process automation systems, the company said.
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Industry news
by roberta prandi
PE.WSN is a complete wireless sensor networking system by Swiss-based Paradox Engineering. It was designed to allow a rapid and cost-effective design and deployment of a reliable wireless network for data acquisition from sensors. The company also introduced the PE.AMI advanced metering infrastructure.
Paradox Engineering Opens Office In Singapore

The Swiss-based virtual network operator opens Asia-Pacific branch office and launches two product lines
Swiss-based Paradox Engineering has opened a new branch office in Singapore. The new location, called Paradox Engineering Asia-Pacific, is set to become the companys business hub of the Asia Region. Paradox operates as virtual network operator (VNO) in the supply of international hybrid network solutions encompassing multiple technologies such as satellite, managed VPN over raw Internet and/or customer networks, industrial wireless sensor networks and automatic meter reading. This regional office has an immediateterm plan to team five people, providing support for sales and operations in the region, with plans to support the new operation through the consolidated and streamlined approach of virtual teaming by Paradox Engineerings headquarters in Switzerland. Our company is able to extend our customers business beyond all boundaries, said Gianni Minetti, Paradox Engineerings chief executive
officer. As we often quote, we are international enough to ensure global coverage but small enough to offer customer-tailored solutions. With the opening of our new office in Singapore, well be closer to our customers and better able to meet their requirements and expectations. He also said, In todays business world, the tightly coupled capabilities of virtual network operator, together with Paradox Engineerings design and manufacture of field data collection solutions, represent the perfect vehicle for companies wishing to unleash the potential of these data and transform them into business opportunities. The timing of the Singapore office opening coincides with the Paradox Engineering launch of two new product lines: PE.WSN, an industrial wireless sensor network platform, and PE.AMI, automatic meter reading for utilities. PE.WSN is a complete wireless sensor networking system designed to provide all the hardware and software
elements fundamental to rapid, costeffective design and deployment of a wireless network for data acquisition from sensors, said the company. It represents new opportunities for accessing information previously considered unreachable, and unlock and transform data into a valuable new asset for business, said Minetti. PE.AMI advanced metering infrastructure is a high-specification system including communications hardware and software, and associated system and data management software to create a network connecting advanced meters and utility business systems. These two systems, designed and manufactured by Paradox Engineering, are part of its strategy to serve the market with platforms that address the growing demand for energy management through real-time and fine-grained data collection, the company said. A
Marine ProPulsion
by roberta prandi
Norisys4, the new open automation platform by Noris, is based on field bus and Ethernet communication protocols and can be used with the companys remote propulsion control system Noristar and with the Norimos alarm monitoring and control system.
Automated And Integrated Control System

Noris Automation launches its new Norisys4 platform
Norisys4, a new system platform by Noris Automation, was designed to be used with the companys remote propulsion control system Noristar, as well as for Norimos, the companys alarm monitoring and control system. Shipping companies, shipyards and captains call for integrated, open and easy-to-use systems, which facilitate their daily work and guarantee a high safety level. Modern automation systems regularly offer numerous options in addition to process monitoring and control functions without flooding the user with data, said Uwe Ulrich, managing partner of Noris Automation in Rostock, Germany. Thus, system integration, common for a long time in the industry sector, becomes more and more prevalent also onboard. The new control system, Norisys4, was brought from scratch to maturity phase in less than one year, said Ulrich. It combines the advantages of a modular concept with the latest software and hardware technology, in a robust construction, designed for harsh environments. He added that the system incorpo-
rates field bus and Ethernet, and removes the strict separation between PLC and PC technology, reducing possible error sources. Visualization is also included in the system, and data can be accessed from any Ethernet port using neutral PC technology, such as notebooks. Norisys4 brings web technology onto the ships propulsion plant, said Ulrich. The communication interface is redundant at both field level and control level. The core of the system is a programmable logic controller (PLC) according to IEC 61131 standard, with a 32 Bit, 400 MHz processor and an integrated web server. It offers sufficient capacity for highly dynamic applications, plus a reserve capacity. A free, programmable serial interface, as well as CAN and Ethernet interfaces with two separate transceivers each, are part of the system. Communication between control computer and the newly developed extension boxes is based on the MODbus standard. The efficiently implemented communication structure to the extension boxes allows for data exchange rates
of more than 500 data words in less than 250 milliseconds. The extension boxes and the software offer the possibility of a compact and customerspecific setup, said Ulrich. Apart from the classic tasks, the new control system offers added values through its secure data logging function, supported by the control computers USB interface and a secure digital high capacity (SDHC) card slot. Norisys4 supplies thorough network integration directly on the control unit. It is represented as a network node with an integrated FTP server and web server, added Ulrich. System functions displayed in the ships network, remote maintenance and web-enabled visualization complete the offer with corresponding onboard infrastructure. In addition, the deployment of libraries with basic functions as well as customer-specific libraries are a permanent feature in the development for or with the customer, said Noris Automation. A
Marine ProPulsion
Two Giants Join In Hercules-C

Two European marine engine manufacturers, MAN Diesel & Turbo and Wrtsil Corp., agree to pursue Hercules-C joint research
Wrtsil and MAN Diesel & Turbo have announced their continued partnership for the third chapter of the Hercules project. The overall vision of the Hercules research program is for sustainable and safe energy production from marine power plants. The technological themes of the Hercules initiative, since its inception in 2002, have been higher efficiency, reduced emissions and increased reliability for marine engines. However, for taking marine engine technology a step further toward improved sustainability in energy production and total energy economy, an extensive integration of
the new technologies is required. The proposed Hercules-C project, expected to run for three years from 2012 to 2015, addresses this challenge by adopting a combination approach for engine thermal processes, system integration and optimization, as well as engine reliability and lifetime. In this way, Hercules-C aims for marine engines that are able to costeffectively produce the required power for the propulsion of ships
Wrtsil and MAN Diesel & Turbo have joined together in the Hercules-C project, which aims to reduce fuel consumption, while optimizing power production and usage in marine applications.
Marine ProPulsion
throughout their life cycle, with responsible use of natural resources and respect for the environment. Hercules-C follows two earlier Hercules projects. In Hercules-A, from 2004 to 2007, large-scale research platforms were established, with the main objective being to screen the potential of a broad range of emission reduction technologies. Significant improvements were achieved as a result of this work. In Hercules-B, running 2008 to 2011, the quest for reducing emissions was retained, focusing on several specific technologies. At the same time, however, more importance was placed on improved efficiency and, as a result, reduced fuel consumption and fewer CO2 emissions. The Hercules-C Project is planned to run over a three-year period and has a targeted budget of US$24.6 million (E19 million), bringing the total combined budget of the Hercules programs (2004 to 2015) to US$102.4 million (E79 million). The specific objectives of HerculesC are to achieve further reductions in fuel consumption, while optimizing power production and usage. This will be achieved through advanced engine developments in combustion and fuel injection, as well as through the optimization of ship energy management and engine technologies supporting transport mission management. Green product life-cycle technologies will be introduced to maintain the technical performance of engines throughout their operational lifetime. This includes advanced materials and tribology developments to improve safety and reliability, as well as sensors, and monitoring and measurement technologies to improve the controllability and availability of marine power plants. The third specific objective of Hercules-C is to achieve near-zero emissions by integrating the various technologies developed from the previous collaborative research efforts. A
Hercules-C is the third chapter in the Hercules project, which involves both MAN Diesel & Turbo and Wrtsil. The first segment of the Hercules program began in 2004. By the end of Hercules-C, in 2015, the goal is to achieve near-zero emissions.
Industry news
by brent haight
TurboMatch allows users to perform preliminary design of the compressor and turbine in context of a turbocharger system.
Turbocharger Design System Software

TurboMatch from Concepts NREC matches a turbocharger design to the specific engine system
Concepts NREC has introduced a new software product designed to fill the engineering design gap between engines and turbochargers. TurboMatch provides an integrated approach to the design and analysis of the complex interaction between the compressor, turbine and other components of a turbocharger and the engine. According to the company, TurboMatch is the first commercially available software that allows advanced compressor and turbine design as part of an overall engine system. Headquartered in Wilder, Vermont, U.S.A., Concepts NREC provides turbomachinery design, engineering services, manufacturing and CAE/CAM software. TurboMatch works in conjunction with Concepts NRECs Agile Engineering Design System software for turbomachinery design and analysis, and targets OEMs, diesel and gas engine companies and organizations that provide turbocharger design and engineering. We are essentially adding more of
a front end to everything weve had before, said George Zitka, senior sales manager for Concepts NREC. This software was developed to fill a need. Turbocharging internal combustion engines is a key technology. With tightening emission regulations, manufacturers are seeing that turbocharging is the way to bring emissions down while still maintaining horsepower. With a turbocharger, you have a compressor and a turbine that are connected by a common shaft so they need to rotate at the same speed. They need to have an accurate transfer of horsepower from one to the other. This matching software allows someone to look at it from a higher level and figure out what the turbocharger needs to look like to match the engine properly. But then we take it to the next level by guiding the whole solution into our pre-existing software solution, which then gets into the detail design of what the compressor looks like, for example. In the design mode, users can size the compressor and turbine to meet the required engine size and boost pres-
sure, and automatically match the power and rotational speed of the two components, Zitka said. According to Zitka, TurboMatch gives anyone responsible for the design, specification or building of turbocharged engines a tool for developing products that meet tightening emission standards and regulations. It enables users to change compressor and turbine sizes and then predict the effect on the match. It also allows a study of the effect of wastegates, variable geometry, exhaust gas recirculation and component losses on the match and performance. Concepts NREC works with all the major turbocharger manufacturers, said Dr. Nick Baines, distinguished corporate fellow at Concepts NREC. In talking with our customers, we perceived increasing demand for turbocharger systems that accommodate smaller engine sizes and lower emission standards. There was a missing link between design of a turbocharger and the overall engine system. A
Newsmakers
FW MURPHY: FW Murphy has hired Marc Pavelick as its regional sales manager for the U.S. Midwest territory, with a heavy focus on industrial stationary products. Those products include engine displays and gauges, instrument panels, engine and motor controls, annunciators and sensors. Murphys Midwest territory includes Ohio, Indiana, Michigan, Illinois, Wisconsin, Minnesota, Iowa, Nebraska, North Dakota and South Dakota. Pavelick, who has 33 years of sales experience in industrial engine and other related industrial and automotive markets, previously worked as a manager of market and business development for SuperFlow Technologies Group in Des Moines, Iowa, U.S.A. UNIVERSAL PLANT SERVICES: Earl Cornett, Jesse Jackson and Mitch Yaley, three compressor specialists within the oil
J. Jackson E. Cornett
since 1989, with her most recent position being general manager, strategy for Shell chemicals in London, England. She also was a deputy site manager and production manager for Pernis Refinery. GE OIL & GAS: Andrew Way has been named vice president of services for GE Oil & Gas. Way will be responsible for leading continued growth of the business
equipment repair, maintenance, upgrade and remote monitoring and diagnostics capabilities across all segments of the oil and gas industry. Way started his GE career in 1996 in the sourcing organization of GE Aircraft Engines. He held roles of increasing responsibility in Aircraft Engines and Engine Services before moving to Equipment Services in 2001 where he continued on page 65
and gas industry, have joined Universal Plant Services. They have a combined industry experience in excess of 75 years with several well-known OEMs, according to Universal Plant Services. Their industry knowledge and experience will be instrumental in the continued growth and development of the company, said Stewart H. Jones, senior vice president of the company.
M. Yaley
WRTSIL: Wrtsil has appointed Trudy Schoolenberg as vice president of Global R&D in the companys industrial operations. Schoolenberg will be responsible for global research and development of Wrtsil products. Schoolenberg previously worked at Shell in several leadership positions
EuroportIstanbul2011_JF.indd 1 1/7/11 9:38:14 AM
Power Generation
by steve hartman
Flexibility And Performance

Staying in tune with changing market conditions
Todays dynamic, rapidly changing energy markets pose significant and ongoing challenges for utility executives, managers and power plant operators. As businesses seek ways to decrease costs while maintaining or growing revenue, power plant asset owners need to remain flexible as conditions change. Recent advances in software technologies and engineered performance for gas turbines can help plant personnel adapt to market conditions, even as variables such as the economy, fuel sources and regulations continually shift. One factor that plant owners and operators must consider is the shift to cleaner sources of fuel, which may impact utilization and capacity factors. Since 1987, nearly 70% of new electricity generation in the United States has come from gas-fired generating units, according to The Future of Gas, a study managed by the Massachusetts Institute of Technology Energy Initiative. This is due to the cleaner-burning nature of natural gas as a fuel source and the efficiency improvements made possible by new combined-cycle gas turbine technology. Consequently, there has been a trend toward oversupply of gas-fired generating capacity during the last 20 years, causing lower capacity factors across the fleet. The recent economic downturn has added to this market condition, creating a significant
Steve Hartman is general manager, Thermal Services Engineering, GE Energy.
drop in electricity demand. In developed countries, demand may take three years or more to return to pre-recession levels, according to some estimates. In addition to changing utilization, the United States is on the cusp of a significant national policy shift toward greater regulatory oversight and stricter environmental protection requirements. For example, according to the American Public Power Association, Congress is currently considering 35 different proposed pieces of legislation with various emission standards that could take effect between now and 2017. This does not include state and local regulations that may develop in parallel with national standards. Whatever the regulatory course, oil, gas and power companies will face new requirements around emissions and clean water, as well as regulation of other pollutants. Power generation providers (some exposed to extreme operating conditions) must invest in assets to maintain continuity of service, even as emerging regulations add new considerations for plant operators and industrial executives. Electrical generation, transmission, distribution, metering and consumption also is undergoing a shift that ultimately will change the way communities use power. As the power grid is wired for two-way communication, consumers increasingly will depend on cleaner, smarter and more efficient sources of power. Over the next 10 years, renewable
power generation is predicted to grow at a rate three times that of other traditional sources, such as coal or gas, according to the U.S. Energy Information Administration. This reinforces the need to upgrade the worlds aging energy infrastructure. At a capacity factor well below fossil units, these new power sources will require much more reliable sources of backup power more frequently. Wind farms and solar generating stations, for example, cycle naturally during the day. The likelihood of grid disturbances or power fluctuations will increase as these new sources of power are integrated. Traditional fossil plants must prepare for such transients and be able to either take advantage of new ancillary markets around spinning reserve, nonspinning reserve, VAR support or as a unit that can provide additional reserve margin for enhanced grid stability. All of these issues can increase the frequency of plant trips and raise operations and maintenance (O&M) costs. Other potential consequences may include penalties and fines due to emissions excursions or operational issues as a result of changing fuel mix, changes in frequency of the grid or other grid dynamics. Amidst all these challenges, generating stations must ensure that they are available to dispatch quickly and reliably when called upon ideally without adding significant hardware or protection systems.
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POWER-GEN Europe has steadily become the premier conference and exhibition in Europe and the place where the power industry meets to share information and do business. This year POWER-GEN Europe returns to Milan. POWER-GEN Europe has steadily become the premier conference and exhibition in Europe and the place where the power event, POWER-GEN Europe features a multiple track conference that offers Europe returns to Milan. A three-dayindustry meets to share information and do business. This year POWER-GENinsightful and thoughtprovoking presentations along with the latest strategies and technological developments by the leading A three-day event, POWER-GEN Europe features a multiple track conference that offers insightful and thoughtexperts in the power industry. The conference is backed up a busy exhibition floor populated by the major provoking presentations along with the latest strategies and technological developments by the leading players in the power industry. experts in the power industry. The conference is backed up a busy exhibition floor populated by the major Co-locatedthe power industry. players in with Renewable Energy World Europe and Nuclear Power Europe, POWER-GEN Europe not only offers three key elements of power generation but also offers unrivalled networking opportunities for attendees, Co-located with Renewable Energy World Europe and Nuclear Power Europe, POWER-GEN Europe not only delegates and exhibitors. offers three key elements of power generation but also offers unrivalled networking opportunities for attendees, Please visit and exhibitors. delegates www.powergeneurope.com for further information on exhibiting and sponsorship at POWER-GEN Europe or contact: Please visit www.powergeneurope.com for further information on exhibiting and sponsorship at POWER-GEN Gilbert Weir Jnr. Europe or contact: T: +44 (0) 1992 656 617 Gilbert Weir Jnr. E: gilbertw@pennwell.com T: +44 (0) 1992 656 617 E: gilbertw@pennwell.com
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Addressing the Flexibility Challenge The story is not all doom and gloom, however. Unpredictable market conditions also provide power generation asset owners with opportunities to take advantage of both the flexibility and performance of their units. To respond to these rapidly changing market conditions, power generation suppliers have come to companies like GE in search of a range of tailored, cost-effective solutions that alleviate growing concerns around technology flexibility. GE introduced its OpFlex enhancements to help maximize turbine and plant operating envelopes enabling customers to meet the demands of a changing power market. With highly variable fuel costs and market capacity, plants are seeking ways to maximize revenue potential during peak conditions and reduce operating costs during off-peak periods. A key part of these enhancements is corrected parameter control (CPC), a new, robust turbine control methodology leveraged from the DLN1+ combustor program. Traditional gas turbine control uses a single temperature control curve where multiple operational boundaries are implicit in a feed-forward control schedule. This schedule is not corrected for changing ambient conditions, and so must be conservative to still accommodate operation across a wide ambient range; otherwise, it must be adjusted or tuned seasonally to ensure proper turbine operation. CPC changes the way the turbine is controlled. Through measurement of traditional noise parameters (e.g., humidity) and separation of operational boundaries into four separate control algorithms, turbine operation can be much more tightly controlled. This, by itself, enables reduced variation in turbine NOx and CO emis-
sions and an expanded low-emission operating envelope. CPC is then coupled with an emissions signal from a units CEMS, or equivalent, to provide real-time emissions feedback. This enables control parameters that are normally set and left static following initial combustor tuning to now be actively controlled as both load and ambient conditions vary. Turbine performance can now further be optimized while still maintaining low emissions, thus increasing turbine operating flexibility. The variation in emission levels is reduced, thus enabling operation closer to limits with no increase in risk of exceeding limits. It is also critical for the unit to perform reliably and remain within allowable emission requirements. OpFlex enhancements, for instance, provide operators with a slider bar option that allows refined control of NOx emission targets and will automatically maintain the emissions at the operator setpoint, while maximizing unit performance. Improving the Efficiency Equation Also essential when considering gas turbine power plant flexibility and performance is the option to improve overall output and efficiency of the unit. As power plants age, asset owners expect overall equipment degradation as well as the inability to provide as much power as newer, more advanced machines. One way that customers have taken advantage of new technologies avoiding both massive capital investment and strict permitting processes required for new generating stations is by maximizing the existing gas turbine footprint and supporting systems through upgrades of the existing machines compressor and/or hot gas path. Customers with older versions of GEs F-class
machines can improve the overall performance and recover lost efficiencies due to aging equipment or natural degradation over time. Hot gas path upgrades can improve hardware performance and enhance unit flexibility. These changes can dramatically improve unit performance, recovering up to 1% of lost efficiency. This can create significant fuel savings per megawatt-hour of generation, as well as 20 or more additional megawatts of power, should the owner decide to increase the overall output of the machine. Owners gain not only increased performance, but also decreased fuel costs and lower total O&M costs per megawatt-hour. Operators also gain the flexibility to provide the grid with additional power if the unit is called upon for more generation. In addition, the replacement components often extend the overall life of the asset, reducing the likelihood of equipment downtime due to maintenance or unplanned replacement of aging components. Energy markets are changing quickly in todays environment. Global business is in dramatic flux as the economy gains strength, the pace varying by geography. As conditions rapidly change, power plant asset owners can take advantage of technology advancements to keep pace. Whether owners seek improved flexibility or better performance, they should consult with partners who can help them operate in a cleaner, smarter, more efficient manner. By improving overall unit performance and flexibility, owners can best position their portfolio of power generation assets to increase revenue, lower O&M costs and maintain compliance, regardless of market uncertainties around the corner. A
Newsmakers
continued from page 61 was promoted to CEO of GE Equipment Services U.K. In 2007, Way joined the GE Oil & Gas business as its Global Services operations leader. He was promoted to Global Supply Chain & Manufacturing leader in December 2008. HORTON: Horton has hired Michel Locquegnies as its director of international business development, focusing on the companys development of international markets, particularly Asia and Latin America. Locquegnies has more than 25 years of international business experience, including opening and managing businesses in Europe and Asia, as well as working with OEMs, distributors and value-added resellers on a global basis,
M. Locquegnies
the company said. Most recently, he was with Cenco Inc. a New Brighton, Minnesota, U.S.A.-based supplier of jet engine testing equipment. STACO ENERGY: J. Hall Staco Energy Products Co. announced that Jim Hall has joined the company as its marketing manager. In this role, Hall will be responsible for all strategic and tactical marketing, as well as developing a brand and communication strategy for power quality and UPS products. Hall is also the president of Blade Systems Alliance, an association focused on the development and adoption of blade server technologies. He previously served as the strategic manager for IT markets for Liebert, Emerson Network Power. TOGNUM: Peter Kneipp, who recently
managed the Asia/ P. Kneipp Pacific sales region for the Tognum Group, replaces Rainer Breidenbach who left the company at the end of 2010 on the board of management. Kneipp joined MTU Friedrichshafen in 1989 as a project manager for marine propulsion systems. Early in his career, he was involved in projects that enabled him to acquire experience in the Asia-Pacific region, where he has worked and lived since 1997. He began in Singapore, then transferred to Australia in 2000, where for several years he held the position of managing director of MTUs subsidiary, MTU Detroit Diesel Australia. Following an interim period in the United States at MTU Detroit Diesel, Kneipp became president and CEO of MTU Asia Ltd., the fastest growing Tognum subsidiary, in 2004.
Marketplace
FOR SALE
15.1MW G.E. GAS TURBINE FR5LA GEN. UNIT 3/60/13,800V #2 OIL: (GAS) 1840 HOURS
Gas Turbine Plants

Mid America Engine
P O W E R G E N E R AT I O N S P E C I A L I S T S
MAJOR WEBCAST / ONSITE AUCTION TUES., WED., THURS., FEB. 15, 16 & 17
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Monday thru Friday, Feb. 7th to 11th, 2011 and day before sale.
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Locations thru-out Alabama, Louisiana, Texas, MIssissippi & Florida
Complete Accumulation of Components to Construct
(2) 49,000-dwt Jones Act Tankers
Over 10,000 Tons of UNUSED Steel (Plate, Bulb Flats, Structural, Tube) Over 6,000 Tons of Modules, Stainless Steel Pipe, Copper Nickel Pipe and Fittings Pipe Racks to be Sold as Scrap WEB SITE: www.wabashpower.com 100s of NEW Spools of Wire Over 100 MW of gas turbines IN STOCK (3) MaK Marine Diesel Engines RingPower Classified.qxp 2/22/10 New & Used PM Turbine units available 1:23 Solar Page 1 Type 12 VM32C 5760Kw POWER Complete turn key plants offered on a Fast-Track basis (4) VEM 4,650 KW Propulsion EQUIPMENT CO. 50 Hz or 60 Hz Low NOx Motors 444 Carpenter Avenue, Wheeling, IL 60090 Liquid fuel and Dual Fuel available (2) Ship Sets of L3 Navigation and Integrated Bridge Systems (4) Lufkin M/N HS5350-KTB Parallel Shaft Horizontally Offset PRE-OWNED CAT POWER SYSTEMS Reduction Gears 2011 AM bash_Nov10_WW.indd 1 9/30/10 2:11:40 PM MidAmerica_Turbine.indd 1 7/7/10 9:02:02 Luffing deck Crane & Knuckle Boom
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COMPLETE POWER MODULE (2) SMIT Inert Gas Generators (2) Titanium, Plate Heat Exchangers Life Boat, Rescue Boat, Anchors and Anchor Chain S-Man Thermal Oil Heating Systems (2) Framo Hydraulic Power Units, Rudders (2) Ship Sets of Electrical Including Switchgear, Transformers, and Wire Backup Generator (2) Incinerators Galley and Kitchen Equipment Furniture
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Many assets were never used, never installed, and are still in the original shipping crates from vendors
Earlier previews available by appointment. Please contact Kevin Gamm with Myron Bowling at 1-513-235-6430 or Mark Reynolds with Hilco Industrial at 1-205-595-5999.
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*ABB Turbo Systems ...................................................... 31 API Heat Transfer ......................................................... 43 Camfil Farr Power Systems AB .................................... 45 Capstone Turbine Corporation .................................... 35 Cast Iron Welding Services Ltd. .................................. 39 ComAp ......................................................................... 55 Ellwood Crankshaft Group .......................................... 55 Europort Istanbul 2011 ................................................ 61 GE Energy Filtration Technologies .............................. 11 *GE Oil & Gas .............................................. Fourth Cover *GEA Westfalia Separator GmbH .................................. 21 Globalcon 2011 ............................................................ 67 GTE Industries ....................................................... 13, 33 Hannover Messe/Hanover Fair 2011 ............................ 59 HArCO......................................................................... 19 Harsco Industrial Air-X-Changers ................................ 17 IPSEN, Inc. .................................................................. 51
*MAN Diesel SE ............................................................... 5 DATE: January MTU Onsite Energy ...................................................... 23 *MWM GmbH .......................................................... 28, 29 CONTACT: John Blomberg Napier Turbochargers Ltd ............................................ 47 OPrA Gas Turbines ......................................Third Cover Power-Gen Europe 2011............................................... 63 Pratt & Whitney Power Systems .................................. 25 Prftechnik Alignment Systems GmbH ........................ 41 *Siemens AG Energy ........................................................ 7 SMM India 2011 ........................................................... 58 *Thermal Structures, Inc. ............................ Second Cover Universal LLC .............................................................. 49 *Wrtsil Corporation ..................................................... 1 Waukesha Bearings ........................................................ 9 11th China International Petroleum & Petrochemical Technology & Equipment Exhibition (CIPPE) ......... 65
*Further information on this companys products can be found in the Diesel and Gas Turbine Publications 2010 Global Sourcing Guide and at www.GsGnet.net.
by ian cameron, ashbourne, england
Cell, Cell, Cell!

As we enter 2011 it seems the energy and power generation sectors will endure a roller-coaster ride featuring good news, major merger and acquisitions activity, and unfulfilled technology dreams. The latter being a particularly interesting point. In the generally slumbering post-Christmas, pre-New Year period when news agendas seem dominated by tales of shoppers spending excesses, a leading player in the engine building and power systems markets suddenly made a stark announcement. It revealed that it was discontinuing its fuel cell activities for stationary power generation. It had, it said, carefully examined the most recent demand forecasts and carried out a thorough risk/reward analysis and had opted against further active engagement in this area. More grimly, it continued that the company has come to the conclusion that the fuel-cell business is unlikely to become commercially viable in the medium term, given current market conditions and subsidy schemes. The company pointed out that during the course of the year management had looked at additional market initiatives in support of fuelcell technology in Asia and had analyzed potential partnerships for serial production there, too. Alas, talks with a possible Asian partner ended without agreement in late December. So there we have it a sorry but economically understandable situation, but a course of action that may temporarily take some of the renewable energy out of the sails of those organizations championing the potential and prospects for fuel cells. Such as, perhaps, the organization Fuel Cells U.K., which it said, acts on behalf of its members to accelerate the development and commercialization of fuel cells in the U.K. And some of those members are, themselves, leading diesel engine and gas turbine builders. At the same time as the new coalition government took over the political reigns in the U.K., Fuel Cells U.K. advised that, Fuel cells and hydrogen could revolutionize the energy landscape, bringing high efficiency, low carbon solutions for transport, residential, portable and premium power applications. Maybe so, but not, as is proved above, if the numbers dont add up. So what else might we see on the rest of the power generation and energy landscape as we move through 2011? Some industry observers are predicting that waste-to-energy technologies are ready to hit the big time this year. This, they suggest, will be prompted by oil topping US$100 a barrel in 2011 (their estimate not mine), thus encouraging investment in waste to energy and also leading to an increased use of natural gas and therefore making it a more viable energy alternative. No doubt wind power will continue to be a popular option a point underlined recently by Siemens when it announced it had received its largest onshore wind order to date with a purchase from U.S. utility MidAmerican Energy, headquartered in Iowa. Siemens will deliver 258 wind turbines, each with a capacity of 2.3 MW and with an eventual combined capacity sufficient to supply 190 000 households with electricity. It has also been suggested by one investment bank that traditional energy companies will pursue acquisitions in renewable energy principally focused on companies in the wind, solar, waste to energy and energyefficiency markets. And which 2010 headline-grabbing energy company is tipped as a possible entrant into the renewable energy sector? Why, none other than BP. No surprise there then. A
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T U R B I N E S
GE Oil & Gas
The Power Crystal upgrade kit has over 15 years of proven experience operating in aircraft engines. Now were using it to improve power output and parts durability for on and offshore gas turbines. The Power Crystal upgrade kit for our Frame 5 turbines can deliver 4-6% more power and a 40F increase in firing temperature without additional cooling or significant impact on NOx emissions. The increased material strength and heat resistance enable a longer mean time between maintenance resulting in extra production days and increased revenues. geoilandgas.com/powercrystal
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January-February 2011

thermal structures, Inc.

2362 Railroad St. Corona, Ca 92880-5410

THE JOYS OF ELECTRICITY. LONG MAY THEY CONTINUE.

CHANGE HAPPENS. THE ENERGY BUSINESS NEEDS FLEXIBILITY.

WRTSIL is a registered trademark.

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