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July-August 2015 www.dieselgasturbine.com

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GE.indd 1 3/23/15 2:53 PM DIESEL & GAS TURBINE PUBLICATIONS President & CEO...... Michael J. Osenga Executive Vice President...... Michael J. Brezonick Diesel & Gas Turbine Worldwide HAight Notes Editor & Publisher...... Brent Haight Executive Editor...... DJ Slater Deputy Editor...... Mark Thayer Regional Manager/Editor...... Ian Cameron Reader Mail — Order Survey 2015 Regional Manager/Editor...... Roberto Chellini Regional Manager/Editor...... Roberta Prandi Field Editor/Business Manager...... Bo Svensson he July-August issue of Diesel place that do not allow us to share spe- Associate Editor...... Jack Burke & Gas Turbine Worldwide brings cific OEM order data. Associate Editor...... Chad Elmore Associate Editor...... Art Aiello the third installment of our an- Associate Editor...... Angela Jarrell nual Order Survey. Each year, we Can you tell me how many units XYZ Co. Copy Editor...... Jerry Karpowicz Digital Content Manager...... Catrina Boettner produce three reports based on reported? Advertising Manager...... Sarah Yildiz Tdata collected directly from OEMs which No. Sorry. Neither written nor verbal, all Circulation Manager...... Margaret Pieper are designed to provide order details on data is confidential and can’t be disclosed Production Manager...... Marisa Roberts Graphic Artist...... Brenda Burbach large-horsepower prime movers used in or discussed. Graphic Artist...... Carla Lemke power generation, mechanical drive and Graphic Artist...... Alyssa Loope marine propulsion applications. Can you provide a specific order break- PUBLICATION HEADQUARTERS The Power Generation Order Survey down by country? 20855 Watertown Road, Suite 220 Waukesha, Wisconsin 53186-1873, U.S.A. (May 2015 D>W) examines recipro- The information that is published in each Telephone: +1 (262) 754-4100 Telefax: +1 (262) 754-4175 cating engines, steam turbines and gas order survey is all that is available. We have UNITED STATES - HOUSTON turbines for power generation service. worked with participating OEMs to cre- Brent Haight, Editor & Publisher Mark Thayer, Deputy Editor The Mechanical Drive Order Survey (June ate a regional breakdown that is widely 12777 Jones Road, Suite 225 2015 D>W) is devoted to engine orders accepted throughout the industries that Houston, Texas 77070, U.S.A. Telephone: +1 (281) 890-5310 Telefax: +1 (281) 890-4805 for mechanical drive applications includ- each report covers. We send the regional ing pumps, compressors, oil exploration breakdown to OEMs at the beginning of GERMANY Lisa Hochkofler, Advertising Manager machinery, rail and other industrial appli- the survey process and publish it with each Gabriele Dinsel, Advertising Manager cations. The Marine Propulsion Order Sur- report so readers can see which specific Niemöllerstr. 9 73760 Ostfildern, Germany vey (July-August 2015 D>W) examines countries fall into each geographic region. Telephone: +49 711 3416 74 0 Telefax: +49 711 3416 74 74 mechanical drive, auxiliary and diesel- UNITED KINGDOM electric marine propulsions systems. If you add up the regional codes/fuel Ian Cameron, Regional Manager/Editor Linda Cameron, Advertising Manager Each time a survey is published, we re- type/engine speed ranges/etc., they 40 Premier Avenue, Ashbourne ceive a flurry of questions from readers sometimes don’t match the total num- Derbyshire, DE6 1LH, United Kingdom Telephone: +44 20 31 79 29 79 Telefax: +44 20 31 79 29 70 about the survey process and the data ber of units reported. Why? that is presented. With the conclusion OEMs provide the data that is presented ITALY Roberto Chellini, Regional Manager/Editor of this year’s Order Survey, I thought I’d in each report. From time to time an OEM 44, Via Delle Forbici I-50133 Firenze, Italy share the five most commonly asked will not provide specific information for Telephone: +39 055 50 59 861 Telefax: +39 055 57 11 55 questions and their answers, for those of a certain data field or (in the case of fuel

Roberta Prandi, Regional Manager/Editor you who might have always wondered, type) may double report a unit (diesel fuel Via Fitta, 21A but never asked. and natural gas). We make every effort I-38062 Arco, Italy Telephone: +39 0464 014421 Telefax: +39 0464 244529 to clarify the data, but ultimately we will How is the information gathered? publish what is provided by the OEM rath- SWEDEN Bo Svensson, Field Editor/Business Manager Each year we send the survey directly er than attempt to interpret, predict or Dunderbacksvagen 20 612-46 Finspong, Sweden to OEMs, who complete and return otherwise influence the data we receive. Telephone: +46 70 2405369 Telefax: +46 122 14787 them to us. Order data from each OEM

JAPAN is combined to provide an overview of As a reminder, PDF versions of each Order Akiyoshi Ojima, Branch Manager the specific prime-mover/application. Survey are available at our website. 51-16-301 Honmoku Sannotani, Naka-ku Yokohama, 231-0824 Japan Each published report includes a list of We continually re-evaluate the Order Sur- Telephone: +81 45 624 3502 Telefax: +81 45 624 3503 participating OEMs. vey to ensure it is as detailed and compre- HONG KONG hensive as possible without introducing S.H. Mok, Branch Manager Rm 1903A, 19/F, Sunbeam Commercial Building Can you send me individual OEM or- transparencies that would limit OEM par- 469-471 Nathan Road der details? ticipation. Your questions, comments and Kowloon, Hong Kong A Telephone: +852 31187930 Telefax: +852 23321565 No. Our legal team has worked with the suggestions are always welcome. legal teams of myriad OEMs to produce KOREA Myung-Shin Lee, Sales Manager documents that forbid the sharing, dis- 191-1, Pyungchang-dong, Chongno-ku closing or discussion of specific OEM Seoul, Korea 100-648 Telephone: +82 2 391 4254 Telefax: +82 2 391 4255 order details. We have legally binding Brent Haight

Reprints of all articles published in Diesel & Gas Turbine policies, procedures and documents in [email protected] Worldwide are available. Please address inquiries to: [email protected] Tel: +1 (262) 754-4147 • Telefax: +1 (262) 754-4177 Diesel & Gas Turbine Worldwide 2 July-August 2015

WW163.indd 1 7/15/15 4:41 PM Diesel & Gas Turbine Worldwide is the leading authority for prime-mover products, technologies and news. www.dieselgasturbine.com

34Testing Clean july Energy -august

Noise & Heat Reduction 6 Quiet Piping 10 Take The Heat ontents

C Controls, Sensors & Instrumentation 14 Military Orders Rigorous Controls 16 Cylinder Pressure-Based Controls In High Power Density Gas Engines 21 On The Level 22 Collaborative Concoction 45 ABB Expands Symphony Plus Range Marine Propulsion 24 An Addition To The ABB Azipod Family 38 40 New Trend For Long-Haul Tugs? Liquid Gas Injection Marine Propulsion Order Survey 26 Hold Fast Industry News 30 Next-Generation Ignition 38 Liquid Gas Injection Power Generation 34 Testing Clean Energy

In Every Issue 2 Haight Notes 4 PMO Report 40New Trend For 8 Events & Meetings Long-Haul Tugs? 20 Featured Products 42 Industry Drivers 43 Newsmakers 44 Literature Library 46 Index of Advertisers celebrating 47 Marketplace 48 World Viewpoint

80years Follow @dgtww on:

MEMBER OF BPA WORLDWIDE® DIESEL & GAS TURBINE WORLDWIDE (ISSN 0278-5994) Volume 47, Number 6. Published monthly except, Jan/Feb & July/ Aug issues combined, by Diesel & Gas Turbine Publications, 20855 Watertown Road, Waukesha, WI 53186-1873 U.S.A. Subscription rates are $85.00 per year/$10.00 per copy worldwide. Periodicals postage paid at Waukesha, WI 53186 and at additional mailing offices. Copyright © 2015 Diesel & Gas Turbine Publications. All Rights Reserved. Materials protected by U.S. and international copyright laws and treaties. Unauthorized duplication and publication is expressly prohibited. Canadian Publication Mail Agreement # 40035419. Return Undeliverable Canadian Addresses to: P.O. Box 456, Niagara Falls, ON L2E 6V2, Canada. E-mail: [email protected]. POSTMASTER: Send address changes to: Circulation Man PRINTED IN THE U.S.A. ager, Diesel & Gas Turbine Worldwide, 20855 Watertown Road, Suite 220, Waukesha, WI 53186-1873 U.S.A. Cover Design: Alyssa Loope Alyssa Design: Cover Diesel & Gas Turbine Worldwide 3 July-August 2015

WW_JulyAugust TOC.indd 1 7/20/15 10:07 AM Additional information on these Prime-Mover Orders is available at PMOReport www.dieselgasturbine.com/pmo-report/

CATERPILLAR MARINE for a vessel currently under construction by Minaminippon • Caterpillar Marine will supply Edison Chouest Offshore Shipbuilding Co. Ltd. four Cat C280-16 generator sets, each rated 5060 bkW at 900 r/min for two new vessels being constructed at Edison MITSUBISHI HITACHI POWER Chouest’s La Ship shipyard in Houma, Louisiana, U.S.A. SYSTEMS AMERICAS INC. • Mitsubishi Hitachi Power Systems Americas Inc. will sup- GE ply three M501J gas turbines to Virginia Electric and Power • GE will supply a 9HA gas turbine to Bouchain, France, for a Company for the Greensville County Power Station in Vir- new Électricité de France gas-fired power plant. ginia, U.S.A.

GE MARINE ROLLS-ROYCE • GE Marine will supply one GE LM2500 gas turbine and two • Rolls-Royce will supply four electricity generating sets for diesel engines in a combined diesel and gas turbine propul- two combined heat and power plants operated by P3P for sion system for the United States Coast Guard’s eighth Na- British tomato growers APS Salads. The gen-sets are based tional Security Cutter, Midgett. on medium speed 12-cylinder Type B35:40 gas engines from Bergen Engines. • GE Marine will supply two LM2500 aeroderivative marine gas turbines for the Japanese Maritime Self Defense Force’s new • Rolls-Royce will supply 589 MTU 8V 199 TE21 diesel en- 26DD destroyer. gines for use in the British army’s new Scout armored fight- Ellwood.qxp 11/11/09 8:43 AM Page 1 ing vehicle. MAN DIESEL & TURBO • MAN Diesel & Turbo will supply a 7S50ME-B9.3-LGI engine SIEMENS • Siemens will supply two SGT6-8000H gas turbines and two generators for the Empalme I combined cycle power plant in Sonora, Mexico.

• Siemens will supply an SGT5-4000F gas turbine, a dual cas- ing SST-800/600 steam turbine, an SGen-1200A generator, an SGen-100A generator and the related electrical and I&C equipment for the Ciner Kazan Soda combined cycle cogeneration power plant in Turkey.

• Siemens will supply 24 Siemens H-Class gas turbines, eight units for each of Egypt’s planned Beni Suef, Burullus and New Capital power plants. We MaMannufacture and WÄRTSILÄ • Wärtsilä will supply two Wärtsilä 9L46 gensets to the Pock- Remanufacture the wood Pond power generating station in the British Virgin Is- lands, owned by the British Islands Electricity Corp. World’orld’s LarLargest Engine • Wärtsilä will supply a 12-cylinder Wärtsilä 32 main en- Crankshafts gine for a fishing vessel being built by Simek AS in Norway on behalf of the U.K. operator Antares (Whalsay) Fishing Ellwood Crankshaft Group Company Ltd. A Irvine, PA, USA 16329 Hermitage, PA, USA 16148 1-800-247-1326 or 724-347-0250 Prime Mover: A machine that transforms energy from a chemical, thermal, electrical or pressure form into a mechanical form. Electric [email protected] motors, engines and turbines are examples of prime movers. www.ellwoodcrankshaftgroup.com Perez, Robert. 2013. Illustrated Dictionary Of Essential Process Machinery Terms; DGTP Inc., Waukesha, Wisconsin, U.S.A.

Diesel & Gas Turbine Worldwide 4 July-August 2015

WW159.indd 1 7/20/15 10:10 AM RENEWING IS FREE!

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the prime-mover magazine since 1969

WW_Renew_Calendar.indd 1 7/16/15 2:12 PM NOISE & HEAT Photo courtesy of Walter Stauffenberg GmbH & Co. KG reduction

With a specially shaped, two-part elastomer insert, the new NRC clamps by Stauff are capable of mechanically absorbing vibrations in the pipe to reduce noise.

Quiet Piping New clamps make pipe and tube installations less noisy

tauff introduced its new NRC clamp, which are so vital for this appli- and control rooms, in crew quarters, and clamps for noise- and vibration- cation, with the pipe-retaining forces re- for the reduction of underwater noise in reduced installation of pipes quired,” said Ulrich König, chief research order to protect the environment. and tubes with outside diam- and development officer of the Stauff Stauff added that there is a rising de- eters between 6 and 88.9 mm. Group. “Thanks to the functional design, mand for the reduction of noise emis- SThe company explained that the work- we have expanded the possibilities of sions in mobile and stationary applica- ing principle of the NRC clamps is based the DIN 3015 standard, without deviat- tions, such as in harbors and loading on polyamide clamp bodies following ing from it in the dimensions relevant areas. This is sanctioned by the Europe- the design of its existing Standard Series for the installation.” an Community according to the cross- that comply with the German Industry The NRC clamps are completely compati- industry guidelines of the Outdoor Di- Standard DIN 3015, Part 1. The clamps ble with commonly used steel or stainless- rective 2000/14/EC (on noise emissions feature a specially shaped, two-part steel mounting hardware, and if necessary in the environment by equipment for elastomer insert that mechanically ab- can simply be replaced or retrofitted. use outdoors) and to the 2006/42/EC Di- sorbs vibrations in the pipe and, as a re- Stauff explained that, particularly in rective on machinery. sult, reduces noise to a minimum. the field of civil shipping — for example, Apart from the regular NRC clamps, The insert is particularly distinguished on cruise ships, yachts or port boats — Stauff also provides another version es- by how little of its surface is in contact effective noise damping has become pecially meant for use on the high seas, with the pipe and clamp body, and as a important in recent years as a criterion which is manufactured completely with result is far more effective than the pre- in the planning of machinery, devices flame-resistant materials according to viously known solutions, Stauff said. and systems, and selecting the corre- international standards and directives, The tongue-groove contour of the in- sponding components, since it makes a and meets the demanding requirements sert and body, which is reversed and great contribution to comfort and facili- for preventive fire protection. thus diverges from DIN 3015, enables tates communication on board. Further- In addition, Stauff pointed out that the system to be used for the widest more, it is known that noise emissions all of the materials used in its products possible range of pipe diameters per can have grave effects on a wide range are distinguished by their durability, clamp size, which contributes to flexibil- of maritime animals. as for example against corrosion by ity and versatility. The International Maritime Organization seawater, mineral oil and other oils, “This patented system permits com- has also dealt with the determination of and by their wide operational temper- bining the absorbing properties of the noise thresholds, for example in engine ature range. A

Diesel & Gas Turbine Worldwide 6 July-August 2015

WW152.indd 1 7/15/15 4:47 PM Stop heat Stop noise*

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Isolite_StopHeat_AL.indd 1 7/14/15 8:58 AM events & Meetings

18-20 Engineering Congress Shanghai, China Power-Gen Natural Gas Orlando, Florida, U.S.A. +852 2811 8897 Columbus, Ohio, U.S.A. +1 (770) 271-7869 www.epchinashow.com +1 (918) 831-9160 www.energycongress.com www.power-gennaturalgas.com 19-21

aug IAGT 2015 Symposium 4-6 Banff, Alberta, Canada Power-Gen Middle East www.iagtcommittee.com 1-3 Abu Dhabi, United Arab Emirates Power-Gen Asia +44 1992 656610 20-23 Bangkok, Thailand oct www.power-gen-middleeast.com Kormarine +44 1992 656 634 www.powergenasia.com Busan, South Korea sep 5-7 +1 (203) 840-5821 Offshore Marine and Workboats - www.kormarine.com 14-17 Middle East Turbomachinery Symposium Abu Dhabi, United Arab Emirates Houston, Texas, U.S.A. +44 1206 545121 27-29 +1 (979) 845-7417 www.middleeastworkboats.com High-Horsepower Summit http://turbolab.tamu.edu Dallas, Texas, U.S.A. 5-8 +1 (888) 993-0302 22-25 www.hhpsummit.com NEVA Argentina Oil & Gas Expo St. Petersburg, Russia Buenos Aires, Argentina +44 1449 741801 +54 11 4514 1400 27-30 http://neva.transtec-neva.com www.aogexpo.com.ar/en Gastech Singapore 30 - Oct. 2 14-16 +44 203 615 2847 World Energy EP Shanghai www.gastechsingapore.com

As part of ASEAN POWER WEEK Conference & Exhibition 1 – 3 September 2015 IMPACT Exhibition & Convention Centre Bangkok, Thailand www.powergenasia.com INVESTING IN A SUSTAINABLE TOMORROW MAKE PLANS TO BE PART OF ASIA’S PREMIER POWER EVENT EVENT AND JOIN OVER 7,500 POWER INDUSTRY PROFESSIONALS UNDER ONE ROOF

POWER-GEN Asia, as part of ASEAN Power Week alongside Renewable Energy World Asia and the POWER-GEN Asia Financial Forum, has become the leading force in delivering a platform for the power industry to meet, share information on the challenges facing the power industry and discuss solutions for advancing Asia’s energy future. EARLY BIRD DISCOUNT – SAVE OVER 10% Register yourself and your colleagues by 1 August 2015 as conference delegates and benefit from the Early Bird Discount Rate, plus free entry to the exhibition. There is no better place to meet the key decision makers in the power generation industry. REGISTER FOR ONE EVENT AND GAIN ACCESS TO ALL 3 CO-LOCATED EVENTS REGISTER NOW AT WWW.POWERGENASIA.COM

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PowerGEN_Asia_PGA_JulAug_WW.inddWW160.indd 1 1 7/17/15 10:1610:32 AM 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/events/

Follow dgtww on: 2-5 1-4 9-10 International Seminar Rotor Marintec China GlobalCon Dynamics & Bearing Shanghai, China Boston, Massachusetts, U.S.A. +852 2827 6211 Cologne, Germany www.marintecchina.com +1 (770) 279-4392 +49 2267 6585 0 www.globalconevent.com nov www.arla-online.com 8-10 Power-Gen International 15-16 Las Vegas, Nevada, U.S.A. Power & Electricity World Africa 3-5 +1 (918) 831-9160 Power Nigeria www.power-gen.com Johannesburg, South Africa Lagos, Nigeria +27 11 516 4031 +971 4 336 5161 www.terrapinn.com/exhibition/ www.power-nigeria.com 2016 power-electricity-world-africa/ index.stm 3-6 22-25 Europort Asia Turbomachinery & Pump 20-23 Rotterdam, Netherlands feb Symposium Western Turbine Users Group Singapore +31 10 293 32 50 +1 (979) 845-7417 Palm Springs, California, U.S.A. www.europort.nl http://atps.tamu.edu +1 (513) 604-8018 www.wtui.com 1-3 21-23 International Workboat Show 1-3 Shipping Middle East Electricity (M.E.E.) New Orleans, Louisiana, U.S.A. Dubai, United Arab Emirates Stamford, Connecticut, U.S.A. +1 (207) 842-5442 +971 4 407 2472 +1 (203) 406-0109 x3717

dec www.workboatshow.com www.middleeastelectricity.com www.cmashipping2016.com mar 3340 Clark C ad_Layout 1 3/4/15 11:03 AM Page 1

Need Rugged, Explosion-Proof Solenoid Valves for Gas Turbine, Fuel Plate, or Generator Applications?

Clark Cooper EH70 and ER Series Valves are currently being installed in new or overhauled gas turbines, and are available with a standard CRN or explosion-proof ETL certified coil for power generation applications such as gas turbine fuel plate (diesel or CNG) pollutant control, generator (trip valves) in hydrogen purge systems for emergency shut down, and others. EH70 Series – Powerful, ER Series – “Customizable” full-port, universal mount, pilot- rotary shaft, pilot or direct assisted, direct operated valve operated, 2 or 3-way valve • 1/2˝ to 2˝ pipe sizes (2-way) • 1/2˝ to 6˝ pipe sizes (2-way) ER Series • Pressure ratings from and (3-way) options 0 - 1,500 PSIG • Temps ranging from -350° • Temps ranging from cryogenic to 550°F -350° to 400°F • Stainless steel, naval bronze, • Stainless steel valve body and other valve body materials EH70 Series • UL/CSA certified for • Normally open or normally hazardous locations closed designs • ETL and CRN Listed • CRN Listed Continuous duty coils for all AC/DC voltages Wide range of options and accessories to suit any need

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ClarkCooper_Apr15_WW.indd 1 3/4/15 6:02 PM

WW160.indd 2 7/17/15 10:32 AM NOISE & HEAT reduction

by Bo Take The Heat Svensson Brazed-plate heat exchangers are efficient, compact and flexible

or almost all types of engines, be they reciprocating engines or gas turbines, there is a need for reliable cooling of various fluids. Sometimes there is also a requirement for heating fluids. One manufacturer, SWEP, spoke about some of the advantages brazed-plate heat Fexchangers (BPHE) offer for many applications. The compactness of BPHEs is highly valued in oil-cooling applications for engines and other applications where space for the heat exchanger is limited. Sometimes access for maintenance is restricted. The footprint of a BPHE unit is 60% smaller than for a plate heat exchanger (PHE) with gaskets, and around 75% smaller than for a shell-and-tube heat exchanger (S&T), SWEP said. Another advantage offered by the BPHE is that it can be lo- The SWEP XXL-range, including the B633 and B649 cated vertically or horizontally as preferred, integrated in the BPHEs, offers a heat transfer capacity above 11 NTU (heat engine architecture. In an engine application, it can be lying transfer units) and flow capacities up to 435 3m /hr in the over the engine rather than placed alongside it. range of 10 to 50 kPa pressure drop when 90°C water SWEP BPHEs cover the needs of several different types of oil is cooled with 60°C water. This graph is based on 25 to cooling, e.g., hydraulic, engine and transmission oil cooling. 100% of maximum number of plates. “The latest and most challenging technology introduction to the heat exchanger market has been the so-called XXL-range, presently meaning 6 in. (152.4 mm) ports,” said Henrik Bjerre, SWEP’s XXL-range models B633 and B649 are suitable for ap- project manager at SWEP. “Increasing the size of a BPHE, and in plications such as engine-oil cooler, condenser and evaporator particular the port diameter, carries many technical challenges. in steam and Organic Rankine Cycle (ORC) plants, and heat re- Manufacturing of these units fully depends on the capillary covery in chillers. The company said these heat exchangers are forces to get the brazing material to the right location in the right amount, which in turn requires extremely tight tolerances The asymmetric plate pattern over a large surface, for hundreds of stacked plates carrying used by SWEP makes it each other’s weight.” possible to optimize the channel geometry according to the application area, and thereby combine excellent heat transfer with a low- pressure drop and a reduced fluid charge. continued on page 12 The plate design of a symmetric BPHE is always a compromise, where thermal performance is balanced against pressure loss of fluids. Improving heat transfer too much would result in excessive pressure loss.

Diesel & Gas Turbine Worldwide 10 July-August 2015

WW151.indd 1 7/15/15 4:54 PM Boosting Your Energy Options New gas engines with two-stage turbocharging

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MAN_BoostingEnergy_AL.indd 1 6/25/15 1:13 PM NOISE & HEAT reduction

The B633 is a high capacity BPHE, suitable for a diversity of applications. Together with the larger B649, these are the first heat exchangers on the market with 152.4 mm connections.

with less weight, footprint and internal volume than technologies like shell and tube, coaxial and plate-type heat exchangers. SWEP said the plate design of a symmetric BPHE is a compromise, where thermal performance is balanced against pressure loss of fluids. Improving heat transfer too much would result in excessive pressure loss, which would reduce the system’s performance. “The asymmetric plate pattern we use makes it possible to optimize the channel geometry according to the application area, thereby combining excellent heat transfer with a low pressure drop and a reduced fluid charge,” Möller said. “The result is a powerful improvement of system efficiency and sus- tainability, taking into consideration both thermal and hydraulic performance as well as a reduced refrigerant charge. And there is no need to do compromises.” Möller said SWEP’s portfolio of products offers solutions to the first BPHEs on the market with DN150 (152.4 mm) connec- cope with challenges ranging from extremely viscous trans- tions and offer capacities at high temperature and pressure on mission oil to copper-free alternatives for sensitive oil or ag- par with PHE products without the wear and tear of parts. The gressive water. A working pressure of the B633/B649 at 155°C is 25 bar for the inner and outer circuits of the exchanger. BPHEs can be very efficient. “Up to 95% of the material in a brazed-plate heat exchanger is used to transfer heat, as op-

Up to 95% of the material in a

brazed-plate heat exchanger The working “ is used to transfer heat. pressure of the B649 at 155°C Andreas Möller, segment manager, is 25 bar for the Engines & Energy, SWEP ” inner as well as for the outer circuit of the posed to other technologies, which use much of their material exchanger. The for support equipment, shell, or frames,” said Andreas Möller, same is valid segment manager, Engines & Energy. “The benefit of this is sav- for the smaller ings in energy consumption, space, spare parts and transporta- B633 BPHE. tion and installation.” AsyMatrix is SWEP’s asymmetric plate design technology for BPHEs. The asymmetric channel configuration combines maximum heat transfer on the oil side with minimum pressure drop on the secondary side. The increased energy efficiency and better use of the structural material delivers a more sustainable solution in suitable applications. BPHEs offer the best performance-to-size ratio of heat transfer technologies available today, the company said. The self- supporting plate geometry of a BPHE delivers high performance

Diesel & Gas Turbine Worldwide 12 July-August 2015

WW151.indd 2 7/15/15 4:55 PM MTU_JA15_WW.indd 1 6/10/15 10:15 AM High-voltage MIL-SPEC panel protection.

by Ian Military Orders Rigorous Controls Cameron Performance, reliability are key factors

echnology supplied by com- ment for electromagnetic compatibil- chanical equipment and subsystems, panies for use in military appli- ity (MIL-S-167, rev. 1A) which may be designed or procured for cations must be designed and • electromagnetic interference (MIL- the North Atlantic Treaty Organization manufactured to the highest S-461, rev. F) (NATO) navies and other international standards to ensure that it • high-impact mechanical shock test- naval organizations and agencies. T performs correctly and reli- ing requirements for shipboard ma- He added that all CMR Group MIL- ably. Equipment and components have chinery (MIL-S-901, rev. D) SPEC equipment is designed and clas- to meet stringent standards of perfor- “While MIL-STD 461 is the basis for sified as “essential to the safety and mance to comply with what is known as electromagnetic compliance for most continued combat capability of end MIL-SPEC (United States defense stan- navies around the world, most civilian users” and provide continuous perfor- dard) standards. organizations, including CMR Group mance throughout the product opera- CMR Group (Controle Mesure Regula- and its customers, use these specifica- tional life. tion) supplies MIL-SPEC-grade marine en- tions to test component robustness in Massariello said that in addition to gine control equipment, instrumentation, harsh environments with high electro- compliance with previously mentioned controls and power management for off- magnetic pollution, which can be ap- critical performance criteria, equipment shore, marine, engine and industrial appli- plied to nonmilitary oriented products,” is also compliant with the following, in cations. Core product groups include elec- said Flavio Massariello, deputy technical which compliance is maintained by con- tronics and software, custom engineering manager, engine controls department tinuous review and analysis: solutions, fuel systems, industrial sensors, at CMR Group France. “This is because • MIL-STD-108 E, “Definitions of Basic switchboards and wiring systems. MIL-STD 461 effectively establishes Requirements for Enclosures for Elec- Three critical areas for military applica- verification requirements for immunity tric and Electronic Equipment” tions of marine engine control equip- from electromagnetic interference — • MIL-DTL-2212 J, “Contactors and Con- ment are as follows: emissions and susceptibility — applied trollers, Electric Motor AC or DC, and • vibration testing of shipboard equip- to electronic, electrical and electrome- Associated Switching Devices”

Diesel & Gas Turbine Worldwide 14 July-August 2015

WW150.indd 1 7/15/15 4:58 PM Controls, Sensors & instrumentation module technology (signal acquisition). “These developments deliver added value, giving the CLARINUX system the ability to handle multiple sensor interfaces for the monitoring, management and control of a wide range of engine performances and functions. CMR Group’s Clarine-121 304.3 mm display unit can be integrated within the control panel for full graphic display, and is compatible with engine control units’ electronic controller parameters (high-pressure common rails engines, gas engines, dual-fuel engines, electronic fuel injection engines). “Stainless-steel control panels can be designed and built in compliance with military standards of shock, vibration Resilient MIL-SPEC panel mounts. and electromagnetic interference and low magnetic signature. Evidence of the compatibility of the system to these • MIL-E-2036 D, “Enclosure for Elec- applications based upon CMR Group’s specialist standards has been confirmed tric and Electronic Equipment, Naval CLARINUX Local Control Panel (LCP) by testing in French and other European Shipboard” system and featuring the latest SCM-2 government laboratories." A • DOD-STD-2143, “Magnetic Silencing Requirements” • MIL-E-917 E, “Electric Power Equip- ment Basic Requirements” • MIL-P-15024 E, “Plates, Tags, and Bands for Identification of Equipment” • MIL-STD-454 N, “Standard General Re- quirements for Electronic Equipment” “CMR Group can deliver high-performance products for the naval fleet environment — one of the harshest and most demanding in the marine sector,” Massariello said. “With our detailed knowledge of military standards, CMR Group brings real added value as a technical partner in consulting original equipment manufacturers (OEMs) to guide them through the labyrinth of military standards, evaluating the appro- priate solutions and identifying the most robust and cost-effective solutions. “This is an approach that’s proven suc- cessful for CMR Group in the work un- dertaken for customers in the marine sector, reflected in contracts for the provision for, among others, propulsion and power generation control systems for engines that need specifically engineered MIL-SPEC technology for

Diesel & Gas Turbine Worldwide 15 July-August 2015

WW150.indd 2 7/15/15 4:58 PM Shinkawa_June14_WW.indd 1 5/12/14 10:43 AM Cylinder Pressure-Based Controls In High Power Density Gas Engines Prechamber control loop based on miniaturized cylinder pressure

E’s 10 MW Jenbacher J920 injection in combination with cylinder fective pressure levels, which on gas FleXtra gas engine offers specific sensors to allow each cylinder engines implies using a lean-burn one of the best electrical to be controlled to operate at optimal combustion concept. This is due to the efficiencies in its class and performance. The J920 FleXtra mechani- fact that the operating range of the is designed for durability, cal structure is designed to allow peak engine narrows down. Gsimple installation, and maintainability. firing pressure well above 200 bar. The limit toward a richer combustion It consists of three modules, including The J920 FleXtra is equipped with the without EGR is the tendency of a gas a generator, engine and turbocharger next generation of GE’s Jenbacher gas engine to knock and misfire. Misfiring auxiliary module, in a prefabricated, engine management system with cyl- happens when the in-cylinder mixture standardized generator-set module. inder individual optimization, adaptive becomes leaner. In this case, it is not Based on the experience of GE’s type condition-based controls, protection of possible to properly ignite the mixture 6 gas engine combustion systems, the core components and an intelligent safe any more, and it is scavenged to the ex- J920 Jenbacher FleXtra unit is equipped operation mode. haust. This leads not only to an obvious with an advanced prechamber combus- The most important aim in the J920 drop in efficiency, but represents a sig- tion system with spark ignition. Indi- FleXtra design was to ensure a supe- nificant increase in hydrocarbon emis- vidual gas mixing is achieved by port rior efficiency at high brake mean ef- sions as well.

This technical paper by GE’s Jenbacher gas engines product line was presented at the Dessau Gas Engine Conference 2015. Authors are: H. Kopecek, N. Spyra, A. Birgel, K. Spreitzer, C. Trapp. Special contributions regarding software auto-coding and engine controller implementation led by Michael Waldhart is well appreciated by the authors.

GE’s J920 Jenbacher FleXtra gas engine has been designed based on the experience of GE’s type 6 gas engine combustion systems, and is equipped with an advanced prechamber combustion system with spark ignition and individual-cylinder gas mixing. This engine features the next generation of GE’s Jenbacher gas engine management system with cylinder individual optimization.

Diesel & Gas Turbine Worldwide 16 July-August 2015

WW161.indd 1 7/16/15 1:14 PM the prime-mover magazine since 1969

Coming Online The Evolution Of Gas Turbines For Power Generation

By Dr. Rakesh K. Bhargava

WW_GT_Poster_GTxcel.indd 1 7/23/15 11:19 AM Coming Online The Evolution Of Gas Turbines For Power Generation

July 1939 June 1949 June 1903 A Air Intake World’s First Utility-Type Gas Turbine U.S. Entered Gas Turbine Power World’s First Gas B Compressor, Three Stages Became Operational Double-Entry Centrifugal Generation Market Turbine With Net The first utility-type gas turbine supplied by BBC A GE Model 3001A installed at the Belle Isle station Power Output Impellers + Three Stages (now Alstom) became operational at Neuchatel of Oklahoma Gas & Electric Co. in Oklahoma City, Jens William Ægidius Elling Single-Entry Impellers, power station in Neuchatel, Switzerland. After more Oklahoma, U.S.A., was the first gas turbine used for in Norway designed and Water Injection Between than 60 years of service, it was moved to a museum utility power generation in the United States. The constructed a gas turbine with The Stages, h = 70+% at Alstom’s facility in Birr, Switzerland, in 2002. It gas turbine was declared an ASME National Historic World’s First Combined- a net power output of 8.1 kW. C Compressed Air Bleed became one of ASME’s Mechanical Engineering The design included intercool- Mechanical Engineering Landmark in 1984. Cycle Plant D Combustion Chamber Landmarks in 1988. ing and use of steam injection. The plant built by Austrian utility NEWAG With Insulation First Large Commercial Gas Design Features: P: 3.5 MW; TIT: 760°C; PR: 6; at Korneuburg ‘A’ power station in Austria Design Features: P: 4 MW; TIT: 547°C; PR: 4.4; η : First Gas Turbine With Intercooling, Design Features: P: 8.1 kW; TIT: E Fuel Feed Turbine Became Operational sc Reheat And Recuperation Compressor: 15 stages; Turbine: two stages consisted of two BBC (now Alstom) gas The first large commercial gas turbine was a BBC 17.4%; Compressor: 23 stages; Turbine: seven stages 400°C; PR: 7; Compressor: six F Water Cooler Using an intercooled, reheat and recuperated Brayton turbines (Type 12), each rated at 25 MW with (now Alstom) unit driven by flue gases from a stages (centrifugal); Turbine: W Water Supply cycle, the gas turbine supplied by BBC (now Alstom) 26% simple-cycle thermal efficiency and Houdry Cracking process at Marcus Hook one stage (radial) S Steam Duct and installed at a power plant in Beznau, Switzerland, one steam turbine rated at 25 MW. The gas Refinery in Philadelphia, Pennsylvania, U.S.A. turbines were designed with intercooling. G Exhaust became the most efficient gas turbine at the time. T Turbine, Centripetal Type, Design Features: P: 900 kW; TIT: 510°C; PR: 3.1 Design Features: P (cc): 75 MW; TIT: 625°C; Design Features: P: 27 MW; TIT: 650°C; PR: 8; η : 34% net Dia 275 mm, h = 70+% sc PR: 12; η : 32% December 1936 cc 1946 1961

1995-1996 June 1990 Annular Hybrid Burner Ring Combustor 1968 Technology Introduced First F-Class Gas Turbine First Industrial Siemens’ 60 Hz V84.3A (new designation SGT6-4000F), GE introduced the first F-class gas turbine (TIT First Commercialized Aeroderivative Gas an upgrade to the V84.3, used annular hybrid burner range of 1200° to 1300°C). The first Frame 7F Complete Radial Design Turbine Introduced World’s First Closed-Loop, ring combustor technology instead of the twin-silo (model PG7191F became operational at Virginia Gas Turbine For Power Generation combustor design. The unit also utilized Pratt and Electric & Power’s Chesterfield power station) The first complete radial design Steam Cooling Of Stationary was also GE’s first implementation of cold-end Pratt and Whitney’s first Whitney’s aero-engine technology in the compressor gas turbine, the Kongsberg FT4 two-spool gas turbine, HGP Components and turbine sections to enhance performance. drive instead of hot-end drive. Vapenfabrikk AS (now Dresser- MHI’s M501G, installed at the T-Point plant in a 1x1 derived from its J75 aircraft GTCC Plant Achieved Record Net Rand) Model KG2, became op- engine, became operational at combined-cycle configuration in Takasago, Japan, Horizontal-Silo Combustor Design Features: P: 150 MW; TIT: 1260°C class; PR: Thermal Efficiency Of 47% erational at the Norwegian Water was the world’s first closed-loop, steam-cooled gas 13.5; η : 34.5%; Compressor: 18 stages; Turbine: Edgemoore power station of Configuration Introduced sc An Austrian utility, NEWAG, commissioned a 125 MW plant in a 1x1 & Electricity Board in a standby turbine (only for combustor’s transitions and stage- Delmarva Power & Light Co. Siemens changed its combustor design on the three stages combined-cycle configuration using one BBC (now Alstom) GT13D gas power generation service in one blade ring). 60 Hz V84.3 gas turbine from the vertical-silo turbine at the Korneuburg “B” plant near Vienna, Austria, and achieved Lofoten, Norway. Design Features: P: 15 MW; configuration used on the V84.2 and earlier the highest combined-cycle thermal efficiency of the time, 47%. LPT: two stages; HPT: one Design Features: P: 254 MW; TIT: 1500°C class; models to a horizontal-silo configuration, Design Features: P: 1.2 MW; η : PR: 20; η : 38.7%; Compressor: 17 stages; Turbine: sc stage; PT: three stages sc resulting in reduced cooling-air requirements. 15.4%; Compressor: one stage; Design Features: P: 81 MW; TIT: 990°C, PR: 9.3; ηsc: 31.8%; Compressor: four stages Turbine: one stage 1993-1994 17 stages; Turbine: five stages April 1963 February 1997 June 1980

Sponsored By:

WW_GT_Poster_GTxcel.indd 2 7/23/15 11:20 AM Coming Online By Dr. Rakesh K. Bhargava The Evolution Of Gas Turbines For Power Generation

Sponsored By:

WW_GT_Poster_GTxcel.indd 3 7/23/15 11:28 AM December 1997 September 2003 December 2004 Annular Sequential Combustion System Introduced First Closed-Loop Steam Cooling Small Gas Turbine Reached ABB (now Alstom) introduced the annular sequential combustion system Of Stationary And Rotating HGP 38.5% Efficiency in its GT24 gas turbine, which first became operational at Jersey Central Solar Turbines achieved high efficiency (38.5%) and low NO Components x Power & Light Co.’s Gilbert power station in Milford, New Jersey, U.S.A. GE was first to use closed-loop steam cooling of both emissions (5 ppmv) in a unit with a power rating less than The annular combustion system included two annular combustion Only Industrial Aeroderivative Gas rotating and stationary hot gas path components on its 5 MW. The first Mercury 50 gas turbine, developed as a part of chambers, called EV (EnVironmental) and SEV (Sequential EnVironmen- Turbine With Three Spools First 50 Hz 9H gas turbine in a single-shaft combined-cycle the U.S. Department of Energy’s ATS program and installed at First Use Of Single-Crystal Casting tal), respectively. The system allowed increasing gas turbine thermal Introduced For Power Generation configuration at Baglan Bay power station in South San Diego Veterans Administration hospital in La Jolla, Cali- Rotor Blades In Industrial Gas Turbines efficiency without increasing TIT value, and also resulted in lower Rolls-Royce’s three-spool Trent-60 gas turbine, derived Wales, U.K. The unit featured a four-stage turbine com- 60 m Long Single-Shaft BFG-Fired GTCC fornia, U.S.A., was a single-shaft machine NO emissions. utilizing recuperated Brayton cycle and Siemens used single-crystal technology in heavy- X from its Trent 800 aircraft engine, became operational at pared to three stages in previous GE models. The world’s largest BFG-fired plant used MHI’s M701F gas implemented with ultra-lean pre- duty machines (first two stages of its V84.3A gas Whitby cogeneration plant in Whitby, Ontario, Canada, turbine in a single-shaft combined-cycle arrangement Design Features: P: 166 MW; TIT: mix combustion technology. turbine) to increase the TIT range and improve in a cogeneration application. The machine can operate Design Features: P (cc): with total shaft length of about 60 m. The gas turbine 1260°C class; PR: 30; η : 37.9%; net material strength and other mechanical properties of sc in 50/60 Hz application without using a gearbox. 480 MW; TRIT: 1400°C was installed at Kimitsu Cooperative Thermal Power Co.’s Compressor: 22 stages; Design Features: rotor blades. The first V84.3A (new designation SGT6- class; PR: 23; η : ~60%; Unit No. 5 in Chiba Prefecture in Japan. The gas turbine, HPT: one stage; LPT: cc P: 4.6 MW; TIT: 4000F) was installed at Kansas City Power & Light’s Design Features: P: 51.2 MW; PR: 35; η : 42%; LPC: Compressor: 18 stages; with TIT of 1300°C, produced net plant output of 300 MW four stages sc 1093°C; PR: 9.9; η : Hawthorn station in Kansas City, Missouri, U.S.A. two stages; IPC: eight stages; HPC: six stages; LPT: five Turbine: four stages at 50% net thermal efficiency. sc stages; IPT: one stage; HPT: one stage 38.5%; Compressor: 10 stages; Turbine: Design Features: P: 167 MW; TIT: 1300°C class; PR: 17; June 2004 two stages ηsc: 38%; Compressor: 15 stages; Turbine: four stages September 1998 June 1997

May 2005

January 2010 July 2011 Downgrade Achieves Higher Efficiency

100 MW Class Simple Brayton Siemens’ V94.2A gas turbine (new designation First GTCC Plant To

June 2014 Cycle GT Exceeded 38% Efficiency SGT5-3000E) was designed by downgrading the

Surpass 61% Efficiency

The first Hitachi (now MHPS) H-80 50 Hz World’s Highest- V94.3A (new designation SGT5-4000F) to achieve MHI’s (now MHPS) first 501J gas turbine using a GT Combustion dual-shaft gas turbine, developed for drop-in higher efficiency than its predecessor, the V94.2

steam-cooled combustor and first-stage turbine Efficiency Gas Turbine

Technology Achieved repowering of existing 100 MW class CCPP and GE’s first LMS-100PA gas turbine with inter- (new designation SGT5-2000E). While improve- Less Than 1 ppm NO blade ring, installed in a 1x1 combined-cycle First Operating Air-Cooled X arrangement at T-Point plant in Takasago, Japan, installed at Shin Oita Power Station of Kyushu cooled Brayton cycle entered commercial ments are typically achieved through upgrades, the Oxidation combustion, H-Class Gas Turbine Electric Power in Aosaki, Japan, exceeded 38% operation in a simple cycle peaking service downgrade of the later model improved efficiency developed by Ener-Core, was surpassed 61% efficiency. Siemens’ first air-cooled 50 Hz H-class gas tur- 50 MW Class Gas Turbine Achieves efficiency. at Basin Electric Power Cooperative’s Groton from 34.7% to 36.8%. The first modified unit became implemented with Flex Energy’s bine, the SGT5-8000H, installed in a single-shaft 39.5% Efficiency Generation Station near Groton, South Dakota, operational at BASF Ludwigshafen chemical complex microturbine (Model MT250 Design Features: P: 327 MW; TIT: 1600°C class; PR: 23; combined-cycle configuration, became opera- Siemens’ twin-shaft gas turbine, the SGT-750, η : 41%; Compressor: 15 stages; Turbine: four stages Design Features: P: 112.4 MW; TRIT: 1488°C; U.S.A. This two-spool aeroderivative gas in a cogeneration application. rated at 250 kW) burning achieved 39.5% efficiency in a cogeneration appli- sc tional at E.ON’s Irsching-4 plant (now called Ul- PR: 19.3; ηsc: 38.2%; GGC: 17 stages; GGT: two turbine was derived from GE’s CF6 class aircraft low-calorie landfill gas and cation at Wingas Oil & Gas Co.’s landfall station rich Hartman). During testing, the plant achieved stages; PT: two stages engine and heavy duty machine MS6001FA. successfully demonstrated NOX of Nord Stream pipeline in Lubmin, Germany. 578 MW and 60.75% net efficiency. emissions less than 1 ppm. The Design Features: P: 103 MW; TIT: 1380°C; PR: unit was installed at Attero’s Design Features: P: 375 MW; TIT: 1488°C class; Design Features: P: 37.03 MW; TIT: 1260°C; PR: 23.8; 42; η : 44%; LPC: six stages; HPC: 14 stages; PR: 19.2; η : 40%; Compressor: 13 stages; sc landfill facility located in Schin- η : 39.5%; GGC: 13 stages: GGT: two stages; PT: sc sc HPT: two stages; IPT: two stages and PT: nen, Netherlands. Turbine: four stages two stages five stages December 2013 July 2011 July 2006

Sponsored By:

WW_GT_Poster_GTxcel.indd 4 7/23/15 11:28 AM December 1997 September 2003 December 2004 Annular Sequential Combustion System Introduced First Closed-Loop Steam Cooling Small Gas Turbine Reached ABB (now Alstom) introduced the annular sequential combustion system Of Stationary And Rotating HGP 38.5% Efficiency in its GT24 gas turbine, which first became operational at Jersey Central Solar Turbines achieved high efficiency (38.5%) and low NO Components x Power & Light Co.’s Gilbert power station in Milford, New Jersey, U.S.A. GE was first to use closed-loop steam cooling of both emissions (5 ppmv) in a unit with a power rating less than The annular combustion system included two annular combustion Only Industrial Aeroderivative Gas rotating and stationary hot gas path components on its 5 MW. The first Mercury 50 gas turbine, developed as a part of chambers, called EV (EnVironmental) and SEV (Sequential EnVironmen- Turbine With Three Spools First 50 Hz 9H gas turbine in a single-shaft combined-cycle the U.S. Department of Energy’s ATS program and installed at First Use Of Single-Crystal Casting tal), respectively. The system allowed increasing gas turbine thermal Introduced For Power Generation configuration at Baglan Bay power station in South San Diego Veterans Administration hospital in La Jolla, Cali- Rotor Blades In Industrial Gas Turbines efficiency without increasing TIT value, and also resulted in lower Rolls-Royce’s three-spool Trent-60 gas turbine, derived Wales, U.K. The unit featured a four-stage turbine com- 60 m Long Single-Shaft BFG-Fired GTCC fornia, U.S.A., was a single-shaft machine NO emissions. utilizing recuperated Brayton cycle and Siemens used single-crystal technology in heavy- X from its Trent 800 aircraft engine, became operational at pared to three stages in previous GE models. The world’s largest BFG-fired plant used MHI’s M701F gas implemented with ultra-lean pre- duty machines (first two stages of its V84.3A gas Whitby cogeneration plant in Whitby, Ontario, Canada, turbine in a single-shaft combined-cycle arrangement Design Features: P: 166 MW; TIT: mix combustion technology. turbine) to increase the TIT range and improve in a cogeneration application. The machine can operate Design Features: P (cc): with total shaft length of about 60 m. The gas turbine 1260°C class; PR: 30; η : 37.9%; net material strength and other mechanical properties of sc in 50/60 Hz application without using a gearbox. 480 MW; TRIT: 1400°C was installed at Kimitsu Cooperative Thermal Power Co.’s Compressor: 22 stages; Design Features: rotor blades. The first V84.3A (new designation SGT6- class; PR: 23; η : ~60%; Unit No. 5 in Chiba Prefecture in Japan. The gas turbine, HPT: one stage; LPT: cc P: 4.6 MW; TIT: 4000F) was installed at Kansas City Power & Light’s Design Features: P: 51.2 MW; PR: 35; η : 42%; LPC: Compressor: 18 stages; with TIT of 1300°C, produced net plant output of 300 MW four stages sc 1093°C; PR: 9.9; η : Hawthorn station in Kansas City, Missouri, U.S.A. two stages; IPC: eight stages; HPC: six stages; LPT: five Turbine: four stages at 50% net thermal efficiency. sc stages; IPT: one stage; HPT: one stage 38.5%; Compressor: 10 stages; Turbine: Design Features: P: 167 MW; TIT: 1300°C class; PR: 17; June 2004 two stages ηsc: 38%; Compressor: 15 stages; Turbine: four stages September 1998 June 1997

May 2005

January 2010 July 2011 Downgrade Achieves Higher Efficiency

100 MW Class Simple Brayton Siemens’ V94.2A gas turbine (new designation First GTCC Plant To

June 2014 Cycle GT Exceeded 38% Efficiency SGT5-3000E) was designed by downgrading the

Surpass 61% Efficiency

Sponsored By:

WW_GT_Poster_GTxcel.indd 5 7/23/15 11:29 AM 1800 140

1600 Gas Turbine Ordered Capacity 120 1400 100 1200

1000 80

800 60

600 40 400 Yearly Capacity (GW) Gas Turbine Units (Qty) 20 200

0 0 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 7 7 8 8 8 8 8 8 8 8 8 8 9 9 9 9 9 9 9 9 9 9 0 0 0 0 0 0 0 0 0 0 200 9 201 0 201 1 201 2 201 3 201 4 77 - 78 - 79 - 80 - 81 - 82 - 83 - 84 - 85 - 86 - 87 - 88 - 89 - 90 - 91 - 92 - 93 - 94 - 95 - 96 - 97 - 98 - 99 - 00 - 01 - 02 - 03 - 04 - 05 - 06 - 07 - 08 - (Data Courtesy Of Diesel & Gas Turbine Rakesh Bhargava Worldwide Order Survey) Year April 2015

Gas Turbine Order Trends (1977-2014)

70 Heavy-Duty M501J 60 Aeroderivative Heavy-Duty (CC) LM6000PG 50 Aeroderivative (CC) LMS-100 L-30A 40 Beznau 30

Efficiency (%) Neuchtal 20

Belle Isle 10

0 1930 1940 1950 1960 1970 1980 1990 2000 2010 2020

Rakesh Bhargava Year April 2015

Thermal Efficiency – Power Generation Application (1939-2014)

Sponsored By:

Diesel & Gas Turbine Sourcing Guide

WW_GT_Poster_GTxcel.indd 6 7/23/15 11:29 AM 1-2 MW 2-10 MW 10-30 MW 30-60 MW 60-120 MW 120-180 MW >180 MW

100

40 % Of Year l y T o t a 20

0 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 0 1 2 3 4 5 6 7 8 9 7 7 8 8 8 8 8 8 8 8 8 8 9 9 9 9 9 9 9 9 9 9 0 0 0 0 0 0 0 0 0 0 200 9 201 0 201 1 201 2 201 3 201 4 77 - 78 - 79 - 80 - 81 - 82 - 83 - 84 - 85 - 86 - 87 - 88 - 89 - 90 - 91 - 92 - 93 - 94 - 95 - 96 - 97 - 98 - 99 - 00 - 01 - 02 - 03 - 04 - 05 - 06 - 07 - 08 -

(Data Courtesy Of Diesel & Gas Turbine Rakesh Bhargava Worldwide Order Survey) Year April 2015

Global Gas Turbine Orders History – By Power Range (1977-2014)

North America Central & South America Africa Western Europe

Central, South East Asia Far East Middle East Eastern Europe & Russia & Australia

100

40 % Of Year l y T o t a

0 1 20 1 2009 2010 2012 2013 2014 77-78 78-79 79-80 80-81 81-82 82-83 83-84 84-85 85-86 86-87 87-88 88-89 89-90 90-91 91-92 92-93 93-94 94-95 95-96 96-97 97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05 05-06 06-07 07-08 08-09 (Data Courtesy Of Diesel & Gas Turbine Rakesh Bhargava Worldwide Order Survey) Year April 2015

Global Gas Turbine Orders History – By Region (1977-2014)

the prime-mover magazine since 1969

WW_GT_Poster_GTxcel.indd 7 7/23/15 11:29 AM This poster was developed by Dr. Rakesh Bhargava, founder and president of In- novative Turbomachinery Technologies. Dr. Bhargava is a Fellow of ASME and an active member of the API Committee on Standards on Mechanical Equipment (SOME). He has more than 35 years of experience with gas turbines, rotating and reciprocating machines and packaged process equipment, and delivers lectures, papers and training on gas turbine and rotating equipment technology and issues. He would like to thank Dr. Carlos Koeneke, Ron Natole, Septimus Van Der Linden, John Mcllvoy and gas turbine manufacturers for sharing the requested information.

Nomenclature & Acronyms ATS Advanced Turbine System BFG Blast Furnace Gas CCPP Combined-Cycle Power Plant GGC Gas Generator Compressor the prime-mover magazine since 1969 GGT Gas Generator Turbine Delivered 10 times per year to more than 21 000 GTCC Gas Turbine Combined Cycle global subscribers, Diesel & Gas Turbine Worldwide is HPC High-Pressure Compressor the leading authority for prime-mover products, tech- HPT High-Pressure Turbine nologies and news. Available in print and digital form, IPC Intermediate-Pressure Compressor you can subscribe for free at www.dieselgasturbine. IPT Intermediate-Pressure Turbine com/subscribe/. LPC Low-Pressure Compressor LPT Low-Pressure Turbine MPC Medium-Pressure Compressor P Power (MW)

Pnet(cc) Net Output of CCPP PR Pressure Ratio (-) PT Power Turbine TIT Turbine Inlet Temperature (°C) TRIT Turbine Rotor Inlet Temperature (°C)

ηcc Thermal Efficiency – For a complete list of references, visit Combined Cycle (%) dgtww.co/GTPower

WW_GT_Poster_GTxcel.indd 8 7/23/15 11:30 AM CONTROLS, SENSORS & instrumentation

To move this limit to higher lambda ra- taining an ignitable mixture. Hence gas mixing is the short time for mixture tios, an innovative prechamber design is the design of the engine has separate preparation. If fuel gas is admitted too used on the J920 FleXtra, with the spark pipes for air and fuel gas. The gas is fed early into the intake port, the gas can plug placed in a chamber separated to each individual cylinder just in front potentially flow to the next cylinders from the main combustion chamber. of the intake ports by means of port in- downstream of the PI valve or the gas This prechamber is connected to the jection (PI) valves. With this separated can slip through the cylinder into the main combustion chamber via several approach, safety is increased and ad- exhaust duct during valve overlap. Ad- bores. After ignition, the flame torches ditional benefits with respect to con- mitting the gas too late would not allow from the combustion reach into the trols are achieved. However, due to the all the gas to enter the cylinder within main combustion chamber and ensure knocking tendency of gas engines, a ho- the next cycle. Residual gas is accumu- the very lean mixture is ignited. mogenous mixture in the cylinder has to lated at the intake port and it is poten- The misfire limit can therefore be be achieved through the advanced port tially purged into the exhaust duct as shifted and the operation range of the design of the J920 FleXtra. hydrocarbon slip during the next gas engine can be extended. Lower hydro- Central low-pressure gas admission, exchange cycle. carbon emissions are produced due to widely used in gas engines with less Especially for engines with early Miller less flame quenching effects. than 5 MWel, offers a robust and cost cycle, valve overlap and two-stage turbo- To achieve high lambda combustion efficient solution for mixing gas with air. charged engines with high scavenging in combination with advanced Miller For larger gas engines in the 10 MWel differential pressure, the time frame for valve timing, very high boosting pres- range, port injection is the innovative proper gas admission is less than 20 m/s. continued on page 18 sures are necessary. For this, GE is us- mixing concept. The advantages of Using port injection instead of a cen- ing a two-stage turbocharging layout higher efficiency, better transient be- tral gas mixer adds challenges as well as that achieves increased pressure ratio havior and eliminating the risk of def- opportunities to the control strategy of at efficiencies higher than 75%. lagration compensate the higher effort the engine. Cylinder-individual gas ad- To charge the J920 FleXtra with mix- compared to central gas mixing. mission valves close to the intake valves ture would lead to big volumes con- The main challenge for port-injection offer the possibility to act on the gas

Diesel & Gas Turbine Worldwide 17 July-August 2015

WW161.indd 2 7/16/15 1:14 PM gas amount of all PI valves is controlled by GE’s Jenbacher Leanox concept. But having a gas admission valve for each cylinder requires a strategy to control and adjust the gas amount and the ignition timing for each cylinder. Each PI valve has flow tolerances, aging effects and different boundary conditions at the inlet and outlet due to oscillations in the gas and in the air rail. The J920 FleXtra closed loop control concept with cylinder-pressure-based combustion feedback makes the gas admission not only robust against different boundary conditions and changes over the lifetime, but it also optimizes each cylinder individually. Closed-loop, pressure-based control allows not only operating the J920 engine The chart displays the results of different in an optimum mode when the engine engine operation, in terms of air mass flow is new, but also to react on degradation versus indicated mean effective pressure. of the engine during its lifetime. To be robust over the engine’s lifetime, the controller is set up in steps: in a first step the signals are checked for plau- sibility, and the status of the engine as well as the status of each cylinder is as- sessed. In a next step the engine controller decides how to operate each cylinder based on the signals. If abnormal combustion like knock oc- curs on a cylinder, the engine controller stabilizes the combustion. In case a signal of a sensor is inaccurate or shows significant noise, the cylinder is operated in a safe mode, which is based on the settings of the latest cycles with proper signals. The port injection valves are key components for the J920 FleXtra engine as they impact the engine performance cycle- by-cycle. The requirement on accuracy is high; the flow of the valves has to be very Typical start-up behavior of the J920 FleXtra. The gas precise from cycle-to-cycle, and tight- engine is able to reach full load in less than five minutes ness is key to good controllability. For after the request under preheated conditions. long service intervals and short engine downtime, the valves have to withstand several hundred million cycles without a significant decrease in performance. amount of the cylinder within the next to individual cylinders can be stopped, Besides traditional benchmark crite- cycle. For idle speed control, fast load and the engine’s power output reduced ria like highest full-load efficiency and rejection like in isolated mode, or grid from one cycle to another. lowest emissions, gas engines are con- code compliance, the gas admission On the J920 FleXtra engine, the overall tiunually facing additional challenges

Diesel & Gas Turbine Worldwide 18 July-August 2015

WW161.indd 3 7/16/15 1:15 PM CONTROLS, SENSORS & instrumentation

on transient performance and grid code different cylinders, trying to locate the and low emissions, the J920 engine is compliance. Fast-raising segments like cylinder-individual optimum for differ- able to ramp up and down in power at peaking or other applications related to ent operation conditions. 80 kW/s, and takes about 100 from zero ancillary services require power plants Under transient load events, the control- to full load and reverse. Further, this en- with fast load-tracking capabilities with- ler immediately adapts the existing con- gine is capable of operating as the single out any tradeoff in plant efficiency or trol optimization algorithms for highest power-generation unit in isolated grids, start-up reliability. Besides a robust — steady state efficiency automatically to ensuring high stability and low impact and at the same time versatile — me- maintain fast load response of the engine. on grid frequency and voltage in case of chanical and thermodynamic design of Besides its very high efficiency level fast load steps. A the engine, the control strategy plays a key role here. Key technology to be able to meet all these requirements is the J920 FleXtra cylinder individual combustion control system making use of in-cylinder pressure sensing, distributed controllers with embedded software architecture, the main controller and the cylinder individual gas supply via port injection valves. The in-cylinder pressure sensors are specially designed to withstand the harsh conditions regarding peak firing pressures and temperatures inside the cylinders. At the same time, these sensors, together with the corresponding signal conditioning units, must maintain an accuracy of less than 1% of full scale over the whole operation range. Besides a robust sensor design, it is important to develop adequate software features that immediately detect any sensor failures — before any subsequent control action on that ill-conditioned signal could take place. A whole set of such algorithms is implemented on the J920 FleXtra engine controller to reli- ably detect and classify any fault of the pressure signal. Based on the fault classification per- formed by the main controller, the engine is either intended to stop or can be further operated under limited conditions. The engine controller uses the cycle- based combustion information to cal- culate the optimum amount of gas as well as the optimum ignition timing for each cylinder individually. Hence, engine operation at maximized efficiency is en- sured under different boundary conditions like requested load, gas quality, intake air temperature or ambient conditions. The system especially reduces the spread of peak firing pressures among

Diesel & Gas Turbine Worldwide 19 July-August 2015

WW161.indd 4 7/20/15 10:32 AM Harco_May15_WW.indd 1 2/19/15 9:43 AM featured products alves t e m S ys oring Ball V Ball

Binsfeld Engineering Inc. has released Upgra d e Drive Fan Horton Inc. introduced the first gen- Emerson Process Management has the TorqueTrak TPM2 torque and pow- eration of its line of complete fan and introduced the Fisher Z500 line of er monitoring system for marine, ener- fan drive upgrade packages available metal-seated ball valves. gy and power generation applications. for towable generator sets. The valves are engineered to with- e Moni t u e Torq The TPM2 model features a digital Currently available for a number of Cat- stand higher temperatures, pressures, RS422 full duplex, serial interface with erpillar and Multiquip gen-sets, the up- and erosive conditions than a standard user selectable sample rates ranging grade packages are designed to improve on/off ball valve, the company said. A from 10 to 4800 samples per second. the performance of units operating with bi-directional sealing design offers a Signal resolution is 15 bits for eight in- first-fit direct drive fans, Horton said.T he solution to process backpressure and put ranges from 0 to 32 mV/V down to package’s key component, Horton’s vari- shutoff requirements in both flow di- 0 to 0.25 mV/V. able speed fan drive, ensures that the rections, safeguarding control valves The TPM2 uses strain gage technology unit’s fan turns at the optimal speed to and other equipment in the line. and does not require shaft modifica- provide proper engine cooling. Fisher Z500 valves are designed with tion or machine disassembly, Binsfeld In addition to engine cooling, the up- an integral metal seat and self-ener- said. The system is ideal for continuous grade packages provide decreased radi- gized metal body gasket to help elimi- long-term measurement and available ator clogging, reduced operating noise nate leak paths and withstand extreme for shaft diameters from 19 to 1016 mm. and potential fuel savings up to 10%. temperature changes, Emerson said. www.binsfeld.com www.hortonww.com www.emersonprocess.com

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W&O.inddWW_JulyAugust_Products.indd 1 1 7/17/154/10/15 12:15 1:58 PM Controls, Sensors & instrumentation

Variohm EuroSensor’s new SST300 single- or dual-axis inclinometers offer high precision in a small package — just 50 mm in diameter and about 50 mm in height.

On The Level Kiene 7/7/04 3:33 PM Page 1 Variohm EuroSensor rolls out new inclinometer SIMPLE. RUGGED. RELIABLE. ariohm EuroSensor introduced its SST300 series single or dual axis inclinometers with a combined KIENE Cylinder Pressure Indicators absolute accuracy of ±0.01°. The sensor is available in for measuring diesel engine six measurement ranges up to ±60° and offers optional firing pressures... temperature drift accuracy of ±0.05° at ambient temper- Vatures between -40° and 85°C. • Easy to use — simple and reliable. The company said the SST300 series offers high precision for • Reduce maintenance costs. other important measurement parameters, including cross- axis sensitivity, offset, repeatability and hysteresis. • Improve engine availability. The compact cylindrical sensor measures just 50 mm in diameter with a nominal height of around 50 mm. Three fixing slots on • Use to balance cylinders. the base flange and a generous installation misalignment factor • Pinpoint engine problems. makes for a straightforward setup of the sensor, Variohm said. The inclinometer is approved for IP67 protection and has a high • Optimize fuel consumption. resilience to shock and vibration. The company said it also has a mean time between failures rating from 25 000 hours up. • Fits any standard indicator valve. The new SST300 series is suited to demanding tilt monitoring • Recommended and used by major applications, including drilling platforms and structural moni- engine builders. toring. The series includes a wide range of options for output, mechanical installation and electrical connection. A choice of • Minimal investment to monitor engine condition. interfaces is available, as for example RS232, RS485, CANopen, as well as integrated mil-spec connectors. Contact us now for more information. Variohm EuroSensor designs, manufactures and sources a Phone: 1-800-264-5950 comprehensive range of sensor technologies for linear and Fax: 630-543-5953 rotary position, load, force, vibration and temperature, for ap- KIENE www.kienediesel.com DIESEL ACCESSORIES, INC. E-mail: [email protected] plications in agriculture, construction, and research markets. A

Diesel & Gas Turbine Worldwide 21 July-August 2015

WW154.indd 1 7/16/15 1:23 PM Controls, Sensors & instrumentation

The Altronic Telematics System is an engine and compressor automation platform with built-in telematics for remote diagnostics and set point control.

Collaborative Concoction Altronic, Enbase Energy Technology introduce the Altronic Telematics System

ltronic and Enbase Energy Tech- personnel can remotely perform these operating a proven set of controller hard- nology have collaborated to functions for an entire fleet. ware, including Altronic DE-3000 systems, create the Altronic Teematics According to Altronic, the ATS provides while simultaneously tapping into new System (ATS). The system the industry’s first Wi-Fi human-machine web/browser-based data collection and is an engine and compres- interface, making secure readings at- analysis tools without regard to physical Asor automation platform with built-in tainable on Wi-Fi enabled smartphones, location — all served up to the user on telematics for remote diagnostics and tablets and other devices, allowing for smart phones, tablets and/or laptop PCs.” set point control. ATS also includes a mo- integration with operator SCADA sys- Enbase Energy Technology, headquar- bile application and analytics dashboard tems without running cable or installing tered in Houston, Texas, U.S.A., is an oil that drives engine and compressor opti- additional gateways. and gas technology company focused mization and uptime performance. “The Telematics System jointly devel- on field automation, mobile applica- There is no third-party hardware and oped with Enbase changes the game tions and predictive analytics, serving no field supervisory control and data entirely by effectively blurring the line E&P, midstream and energy service com- acquisition (SCADA) wiring required, between the local control panel and the panies world-wide. according to Altronic, allowing opera- remote monitoring/data analysis func- Altronic is the lead plant for Hoerbiger tors and packagers to receive critical in- tions,” said David Bell, senior vice presi- Engine Solutions, part of the Compres- formation wirelessly. With the ability to dent of sales and service at Altronic. “By sion Technology Business Unit. Hoer- remotely configure set points on com- providing access to the operating data biger is active throughout the world as patible Altronic controllers, field tech- and system configuration away from the a leading player in the fields of compres- nicians no longer need to perform this panel — 10 feet, 10 miles, or 10,000 miles sion technology, drive technology and work on-site. A small staff of centralized away — the user retains full confidence in automation technology. A

Diesel & Gas Turbine Worldwide 22 July-August 2015

WW158.indd 1 7/16/15 1:27 PM HItachi_OurFoundation_AL.indd 1 7/7/15 3:58 PM ABB said that with its new Azipod D, shipping segments such as offshore drilling, construction and support vessels and ferries could benefit from the higher flexibility, reliability and energy efficiency provided by Azipod technology.

by Ian An Addition To The ABB Cameron Azipod Family Latest model could appeal to new shipping sectors

BB has unveiled a new addition to its family of Azipod propulsion system is a streamlined, steerable pod motor electric propulsion products in a move the company mounted below the ship with the propeller connected di- said makes the technology suitable to a wider range rectly to the motor shaft. of vessel types. ABB said its gearless Azipod system is already widely in The Azipod system was first developed some 28 service with cruise vessels, icebreakers, ice-going cargo Ayears ago, but ABB has developed a new version — the Azipod vessels and accommodation ships. With the Azipod D, ship- D — with power ranges from 1.6 to 7 MW. The Azipod electric ping segments such as offshore drilling, construction and

Diesel & Gas Turbine Worldwide 24 July-August 2015

WW155.indd 1 7/17/15 1:51 PM MARINE propulson

support vessels and ferries could benefit from the flexibility, reliability and energy efficiency provided by Azi- pod technology. ABB hopes Azipod characteristics will make the technology particularly appealing to the offshore shipping sector where most vessels operate in a dynamic posi- tioning mode and require high reliability. The new thruster gives designers and ship builders increased design flexibility to accommodate a wide range of hull shapes and propeller sizes and offers simple installation, the company said. The Azipod D requires up to 25% less installed power, partly due to the new hybrid cooling that increases the performance of the electric motor by up to 45%, ABB said. There are open propeller and ducted versions of the new Azipod covering the needs of high-thrust and high-speed applications. The gearless construction, high motor efficiency and High-Performance advanced hydrodynamic design result in fuel consump- Separators tion that is typically 10 to 15% lower than with geared thrusters, ABB said. Safeguarding your diesel Technical solutions on the latest version have been tested and proven in either Azipod C or Azipod X thrust- engines and gas turbines ers. Introduced in 2000, the gearless Azipod C is available as an open propeller version, Azipod CO for typical ship applications, and as a nozzled version, Azipod CZ. The power range of the C series varies from 1 to 4.7 MW, Technology from GEA Westfalia Separator Group and according to ABB, the thruster improves three as- protects the performance, safety and economy of pects of operational profitability over a vessel’s lifetime your power generator systems worldwide. — efficiency, reliability and cargo capacity. As conventional geared propulsors are powered with an inboard induction motor, an advanced feature of the Our separators shield your diesel engines and gas gearless thruster is the permanent magnet propulsion turbines from all aggressive by-products in fuel oils, motor, said ABB. reducing service downtimes and failures. The company added that unlike normal electric motor types, the rotor of a permanent magnet motor is natu- Diesel engines are safe from destructive “cat fines” rally magnetized thus saving the additional power consumption for magnetizing. in low-sulphur residual oils. Gas turbines are In a separate move, ABB announced it recieved a US$60 protected from corrosion caused by sodium million contract to deliver Azipod XO propulsion and and potassium in untreated oils. power systems to two Norwegian Cruise Line vessels built by Meyer Werft of Germany and due for delivery in 2018 and 2019. ABB also announced it had received record levels of orders for the marine part of the group’s business, driven GEA Westfalia Separator Group GmbH by growth in demand for electrical propulsion systems Werner-Habig-Straße 1, 59302 Oelde, Germany especially in the cruise and ice-going segments. Phone: +49 2522 77-2118, Fax: +49 2522 77-32118 In 2014, the company won orders worth US$200 mil- [email protected], www.gea.com lion to deliver power plants and Azipod propulsion systems to cruise customers and US$900 million to deliver solutions to ice-going and icebreaking projects. A engineering for a better world

Diesel & Gas Turbine Worldwide 25 July-August 2015 EN-01-004

WW155.indd 2 7/17/15 1:54 PM

GEA_Safeguarding_JulAug_WW.indd 1 7/7/15 1:12 PM Marine Propulsion 2015order survey MECHANICAL DRIVE MARINE PROPULSION ORDERS, January – December 2014

Engine Operating Speed Ranges Fuel Regions/Regional Codes (r/min) Total Engine Output Number Output For Range Of Each Output (MW) Units Below 300 to 720 to Above Diesel Heavy Natural Range (MW) 300 600 1000 1000 Fuel Fuel Gas Western Europe Eastern Europe, Russia & CIS Middle East Far East Southeast Asia & Australia Central Asia North Africa Central, West, East & South Africa North America Central America & Caribbean South America 0.50 to 1.00 2637 1633 0 0 1 2636 2637 0 0 531 10 101 833 483 2 0 2 649 8 18 1.01 to 2.00 2403 3289 14 8 446 1935 2268 129 4 628 52 152 646 453 4 0 8 381 1 78 2.01 to 3.50 525 1359 18 3 222 282 490 30 5 142 14 36 136 126 41 0 0 12 0 18 3.51 to 5.00 155 680 45 1 48 61 102 49 4 27 2 8 61 38 9 0 0 18 0 0 5.01 to 7.50 196 1259 176 0 12 8 18 178 0 9 2 1 181 0 0 1 0 2 0 0 7.51 to 15.00 735 7570 717 2 0 16 16 717 2 10 7 0 669 29 4 5 0 4 0 7 15.01 to 30.00 244 4607 244 0 0 0 0 214 30 0 6 0 234 4 0 0 0 0 0 0 30.01 to 50.00 76 3300 76 0 0 0 0 76 0 0 1 0 73 2 0 0 0 0 0 0 50.01 and above 19 1171 19 0 0 0 0 19 0 0 0 0 19 0 0 0 0 0 0 0 Totals 6990 24 868 1309 14 729 4938 5531 1412 45 1347 94 298 2852 1135 60 6 10 1066 9 121

by Brent Data in this survey does not represent units shipped, but only Hold Fast Haight the total orders received during calendar-year 2014. Geographic location is the ship-building site. iesel & Gas Turbine Worldwide’s Marine Propulsion For reference, the geographic breakdown that was presented Order Survey is the last of three reports designed to participating OEMs along with the survey forms is included to provide details on the markets of large recipro- in this report. cating engines, steam turbines and gas turbines It is important to note, some units reported in the 2015 Ma- D used in power generation, mechanical drive and rine Propulsion Order Survey did not have complete informa- marine propulsion applications. tion. In some cases OEMs chose not to provide engine output, We divide the data into three reports in order to provide a fuel type or geography for some of their reported orders. more in-depth look at key market segments for prime movers. The Power Generation Order Survey (see May D>W 2015, p. Overview 28) examines reciprocating engines, steam turbines and gas turbines for power generation service. The Mechanical Drive The 2015 Marine Propulsion Order Survey echoes the theme Order Survey (see June D>W 2015, p. 26) is devoted to en- of the 2015 Power Generation Order Survey — Hold Fast. gine orders for mechanical drive applications including pumps, Last year’s Marine Propulsion Order Survey revealed the be- compressors, oil exploration machinery, rail and other industri- ginning of a turnaround for an industry plagued by years of de- al applications. The Marine Propulsion Order Survey examines cline. The 2015 survey shows an industry holding fast, despite mechanical drive, auxiliary and diesel-electric marine propul- myriad challenges that have little to do with shipbuilding and sions systems. are affecting most industries worldwide. Total units reported in the 2015 Marine Propulsion Order Sur- Procedures vey (2014 data) equaled 12 123, a decrease of only 0.3% compared to last year’s report. Good news considering it could have The Marine Propulsion Order Survey includes prime movers been much worse. Low oil prices, economic uncertainties and beginning at 500 kW (0.5 MW). New orders are broken into die- geopolitical concerns continue to influence business decisions sel-electric, mechanical drive and auxiliary generating set or- around the globe. ders. Fuel types include diesel fuel, heavy fuel and natural gas. The Far East was once again the top geographic location (all All data found in the survey was provided by participating reported driver types). With 6198 units destined for the Far original equipment manufacturers (OEMs). An accompanying East, the region claimed 51% of all orders last year. table identifies those companies that participated in the 2015 The Far East continues to set the tone for the global shipbuild- survey. Every effort is made to ensure this survey is as complete ing market, but the landscape is shifting. Orders destined for and comprehensive as possible and would not have the level the Far East, which includes China, Japan and South Korea (the of detail it contains without the generous contributions of the word’s three largest shipbuilding nations) fell 13% compared participating companies. to last year’s survey.

Diesel & Gas Turbine Worldwide 26 July-August 2015

WW164.indd 1 7/17/15 5:18 PM MARINE AUXILIARY GENERATING SET ORDERS, January – December 2014

Engine Operating Speed Fuel Regions/Regional Codes Total Engine Ranges (r/min) Output Number Output For Range Of Each Output 300 to 720 to Above Diesel Heavy Natural (MW) Units Range (Mwe) 600 1000 1000 Fuel Fuel Gas Western Europe Eastern Europe, Russia & CIS Middle East Far East Southeast Asia & Australia Central Asia North Africa Central, West, East & South Africa North America Central America & Caribbean South America

0.50 to 1.00 2560 1497 0 1640 808 686 1762 0 163 26 5 2091 102 53 0 1 88 4 27

1.01 to 2.00 1390 1441 0 608 374 386 586 10 190 6 16 673 68 296 0 3 92 0 46

2.01 to 3.50 352 791 0 194 158 169 173 10 38 16 0 181 3 0 0 0 97 1 16

3.51 to 5.00 200 738 0 200 0 6 158 36 13 0 0 185 0 0 0 0 0 2 0

5.01 and 7 40 0 7 0 2 5 0 0 0 0 5 0 0 0 0 2 0 0 above Totals 4509 4507 0 2649 1340 1249 2684 56 404 48 21 3135 173 349 0 4 279 7 89

DIESEL-ELECTRIC MARINE PROPULSION ORDERS, January – December 2014

Engine Operating Speed Ranges Fuel Regions/Regional Codes Total Engine (r/min) Output Number Output For Range Of Each Output 300 to 720 to Above Diesel Heavy (MW) Units Range (Mwe) 600 1000 1000 Fuel Fuel Western Europe Eastern Europe, Russia & CIS Middle East Far East Southeast Asia & Australia Central Asia North Africa Central, West, East & South Africa North America Central America & Caribbean South America 0.50 to 1.00 4 3 0 4 0 2 2 0 0 0 4 0 0 0 0 0 0 0 1.01 to 2.00 97 103 0 92 5 93 1 57 0 0 24 8 1 0 0 7 0 0 2.01 to 3.50 298 638 0 102 196 291 7 119 8 3 60 16 0 0 0 88 4 0 3.51 to 5.00 56 247 0 56 0 40 12 4 12 0 28 8 0 0 0 4 0 0 5.01 to 7.50 50 231 12 38 0 30 8 24 0 0 22 0 0 0 0 4 0 0 7.51 and above 111 903 79 32 0 36 26 26 0 0 73 12 0 0 0 0 0 0 Totals 616 2125 91 324 201 492 56 230 20 3 211 44 1 0 0 103 4 0

That trend may continue. Orders at Chinese shipyards (ranked While North America posted 18% growth in orders compared third in the word) have fallen 77% in first-quarter 2015 com- to last year, low oil prices continue to impact investments in pared to last year. exploration and development, limiting demand for offshore Western Europe and North America once again came in sec- drilling and support vessels, which will impact orders in 2015. ond and third respectively. Western Europe logged 16% of the total orders reported, while North America received 12% of all Mechanical Drive Orders orders reported. continued on page 28 The region to watch is Southeast Asia & Australia, which Total reported mechanical drive orders reported this year claimed the number four spot with 11% of 2014 orders, a 39% were 6990 units, a 2% decrease compared to last year’s survey. growth compared to last year. Southeast Asia & Australia is Units sized 0.50 to 1.00 MW accounted for 39% of the mechani- poised to take over the number three spot in our survey, as the cal drive orders. Philippines continues its rise as a shipbuilding world leader and Engine operating speeds above 1000 r/min comprised 74% the outlook for North American shipyards remains cautious. of the total mechanical drive units ordered in 2014. Diesel fuel

Country Information For Regions/Regional Codes, D>W Annual Market Surveys

Western Europe Liechtenstein Spain Belarus Kyrgyzstan Tajikistan Iraq Andorra Luxembourg Sweden Bosnia and Latvia Turkmenistan Israel Austria Italy Switzerland Herzegovina Lithuania Ukraine Jordan Belgium Ireland United Kingdom Bulgaria Moldova Uzbekistan Kuwait Denmark Malta Croatia Poland Lebanon Finland Netherlands Eastern Europe, Czech Republic Republic of Macedonia Middle East Oman France Norway Russia & CIS Estonia Romania Bahrain Qatar Germany Portugal Albania Georgia Russia Cyprus Saudi Arabia Greece San Marino Armenia Hungary Serbia Egypt continued Iceland Slovenia Azerbaijan Kazakhstan Slovac Republic Iran on page 28

Diesel & Gas Turbine Worldwide 27 July-August 2015

WW164.indd 2 7/17/15 5:19 PM Far East Western Europe Total Units Ordered, Five-Year Data d Total Units Ordered, Five-Year Data

8000 2200 7000 6000 2100 5000 4000 Units Ordere 2000 3000 2000 1900 1000 0 1800

Number Of 2010 2011 2012 2013 2014

Number Of Units Ordered 2010 2011 2012 2013 2014 Years Years

North America Southeast Asia & Australia Total Units Ordered, Five-Year Data Total Units Ordered, Five-Year Data 1600 1600 1400 1400 1200 1200 1000 1000 800 800 600 600 400 400 200 200 0 0 Number Of Units Ordered Number Of Units Ordered 2010 2011 2012 2013 2014 2010 2011 2012 2013 2014 Years Years

again dominated the fuel type, representing 83% of the orders. board for the first time, logging the most orders that month. Top geographic location reflects the Far East’s continued Analyst reports show that Philippine yards won new build- dominance in the shipbuilding industry. Mechanical drive ma- ings of 590 000 compensated gross tonnage (cgt), followed rine propulsion engines destined for the Far East accounted for by Korea with 530 000 cgt, China with 290 000 cgt and Ja- 43% of 2014 orders. pan with 150 000 cgt of orders in April. One contract, be- Western Europe claimed the number two spot (20%) followed tween Hanjin Heavy Industries and CMA CGM, France’s big- by Southeast Asia & Australia (17%). gest shipping company, revealed that the Philippines will As reported in last year’s Marine Propulsion Order Survey, be building three of the world’s largest container vessels at the Philippines rose to the world’s fourth-largest shipbuild- Subic. The 20 000 TEU ships are planned to be delivered by ing country behind China. Increased activity there helped de- the second half of 2017. throne North America as the number three geographic loca- Currently operating a total of around 121 shipyards across its tion for mechanical drive marine propulsion engine orders in territory, the Philippines is predicted to produce over 4.8 mil- this year’s survey. lion in ship gross tonnage between 2015 and 2018, the most Look for Southeast Asia & Australia orders to continue to in- in Southeast Asia. continued on page 28 crease, next challenging Western Europe for the number two geographic location. Auxiliary Generating Mechanical drive marine propulsion engine orders destined Set Orders for Southeast Asia & Australia increased 36% between 2013 and 2014. Marine auxiliary gen-set orders totaled 4509 units, an increase Activity in the Philippines remains strong. In April, the Phil- of 11% compared to last year. Engines in the output range of ippines reached the top of the global shipbuilding leader- 0.50 to 1.00 MW once again recorded the most orders (57%).

Country Information For Regions/Regional Codes, D>W Annual Market Surveys Country Information For Regions/Regional Codes, D>W Annual Market Surveys

Syria South Korea Kiribati Tahiti Maldives Islands Central, West, Comoros Turkey Taiwan Laos Tonga Nepal East & South Africa Congo United Arab Emirates Malaysia Thailand Pakistan Angola Cote d’Ivoire Yemen Southeast Asia Marshall Islands Tuvalu Sri Lanka Benin Djibouti & Australia Micronesia Vanuatu Botswana Equatorial Guinea Far East Australia Palau Vietnam North Africa Burkina Faso Eritrea China Brunei Papua New Guinea Algeria Burundi Hong Kong Burma Philippines Central Asia Libya Cameroon Ethiopia Japan Cambodia Samoa Afghanistan Morocco Cape Verde Gabon Mongolia Fiji Islands Singapore Bangladesh Tunisia Cen. African Rep. Gambia North Korea Indonesia Solomon Islands India Chad Ghana

Diesel & Gas Turbine Worldwide 28 July-August 2015

WW164.indd 3 7/17/15 5:35 PM Marine Propulsion 2015order survey Combined Geographic Total – All Reported Driver Types

Southeast Western Eastern Europe, Middle Far East Asia & Central North Central, West, East & North America Central America & South America Europe Russia & CIS East Australia Asia Africa South Africa Caribbean

1981 162 322 6198 1352 410 6 14 1448 20 210

Engines operating at speeds between 720 and 1000 r/min Mechanical Drive Marine Propulsion received 59% of the reported orders. Heavy fuel was the top Manufacturers Participating In The Survey fuel, accounting for 60% of all engines ordered. • Caterpillar Inc. The Far East was the top geographic location for marine aux- • Caterpillar Marine Power Systems iliary gen-set orders, accounting for 70% of the total. Round- • Cummins Marine ing out the top three spots: second place was Western Europe • Fairbanks Morse (9%) followed by Central Asia (8%). • Hyundai Heavy Industries • MAN Diesel & Turbo Diesel-Electric Orders (including SEMT Pielstick license-built engines) • Mitsubishi Heavy Industries Marine Diesel-electric marine propulsion orders totaled 616 units, a 36% Machinery & Engine Co. Ltd. decrease compared to last year. • Niigata Power Systems Demand was highest in the output range of 1.01 to 2.00 MW (48%). • Rolls-Royce Engines operating at speeds of 720 to 1000 r/min received 53% • Wärtsilä of the orders. • Yanmar Co. Ltd. Diesel fuel was the top choice, claiming 80% of the total orders. Western Europe edged out the Far East to claim the top geo- Marine Auxiliary Generating Unit Engine graphic location for diesel-electric orders, claiming 37% of all Manufacturers Participating In The Survey orders. The Far East claimed 34% of order, followed by North • Caterpillar Inc. • Caterpillar Marine Power Systems America (17%). • Cummins Marine • Hyundai Heavy Industries Annual Surveys • Niigata Power Systems • Rolls-Royce On behalf of Diesel & Gas Turbine Worldwide, thank you to • Wärtsilä all contributors for your continued participation in this an- • Yanmar Co. Ltd. nual survey process. It is our hope that the three surveys combined will provide an accurate snapshot of the entire Diesel-Electric Marine Propulsion large-horsepower prime-mover landscape, with fine-tuned Manufacturers Particpitating In The Survey detail provided for three market segments through each • Caterpillar individual report — power generation, marine propulsion • Caterpillar Marine Power Systems and mechanical drive. Electronic versions of past surveys • Cummins Marine are available at our website: www.dieselgasturbine.com. • Hyundai Heavy Industries Questions, comments and suggestions should be directed • Rolls-Royce to [email protected]. a • Wärtsilä

Country Information For Regions/Regional Codes, D>W Annual Market Surveys Country Information For Regions/Regional Codes, D>W Annual Market Surveys

Guinea Mauritius South Africa North America Cuba Panama Colombia Guinea Bissau Mozambique Sudan Canada Dominica Puerto Rico Ecuador Ivory Coast Namibia Swaziland U.S.A. Dominican Republic Virgin Islands Guyana Kenya Niger Tanzania El Salvador West Indies Paraguay Lesotho Nigeria Togo Central America & Guatemala Peru Suriname Liberia Rwanda Uganda Caribbean Haiti South America Uruguay Madagascar Senegal Zaire Bahamas Honduras Argentina Venezuela Malawi Seychelles Zambia Bermuda Jamaica Bolivia Mali Sierra Leone Zimbabwe Belize Mexico Brazil Mauritania Somalia Costa Rica Nicaragua Chile

Diesel & Gas Turbine Worldwide 29 July-August 2015

WW164.indd 4 7/17/15 5:20 PM industry news

The new FTI (fast turbulent igniters) from Woodward are designed to enable higher combustion efficiencies and reduced emissions.

by Alan Next-Generation Ignition Oetken Improved ignition in high-BMEP, lean-burn gas engines

s high-BMEP gas engines move ing the spark energy, which shortens ficulty managing residual exhaust gases toward leaner air-fuel ratio plug life. To counter decreasing spark during the exhaust stroke, causing in- operations to meet increas- plug life, J-gap manufacturers often in- consistent exchange of burned gas and ingly more stringent emis- crease the electrode area, which has a fresh charge in the prechamber, which sions requirements, the “quenching” effect on the ignition, or also leads to misfire and knock. Aair-fuel mixtures become more difficult they use precious metals that increase Woodward’s new FTI (fast turbulent igni- to ignite. Lean mixtures have slower manufacturing complexity and cost. In tion) igniters are a leap forward in spark laminar flame speeds that can result in addition, the J-gap spark plug’s spheri- igniters for high-BMEP, lean-burn gas en- engine misfire. Also, in large-bore en- cal flame front has slower combustion gines fueled by natural gas or biogases. gines the flame front has to travel fur- speed as the flame front moves across When customized for specific engine ther, so high fuel-charge turbulence is the combustion chamber. This type of requirements, FTI igniters can extend op-

used often to increase the flame front flame front is often enhanced by high erating limits to lower NOx emissions and speed, but this increased turbulence in-chamber turbulence, which increases increase engine efficiency by enabling makes the flame initiation more sus- ignition variability. engine timing to operate closer to top ceptible to ignition variability. The relatively recent introduction of dead center (TDC). These new igniters use In high-performance gas engines, shot- prechamber spark plugs has addressed a unique prechamber design with patent- to-shot combustion variation typical of some of these issues. But conventional ed features that dramatically reduces the continued on page 32 some spark plug designs can lead to prechamber spark plugs tend to extend combustion coefficient of variation (COV) poor ignition quality, excessive knock into the combustion chamber, such that while extending the igniter’s operating margins, poor engine efficiency, and heat is absorbed in the end cap, which life without precious metal electrodes. higher exhaust emissions. increases the risk of pre-ignition and The FTI igniter’s proprietary design Traditional J-gap spark plugs try to thermal runaway. In addition, conven- provides high-velocity ignition jets for address performance issues by increas- tional prechamber spark plugs have dif- consistent “shot-to-shot” ignition. The

Alan Oetken is project manager of new product launches at Woodward Inc., Loveland, Colorado, U.S.A.

Diesel & Gas Turbine Worldwide 30 July-August 2015

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Siemens_AS15_RaisingPerfPwrPlntOp.indd 1 7/8/15 12:17 PM industry news

Comparison of the ignition flame front of conventional J-gap spark plugs and Woodward FTI plugs, which generate high-velocity ignition jets for consistent “shot-to-shot” ignition.

multijet flame front coming out of the FTI surface” method to obtain fast combus- charging the chamber during each shot. igniters generates its own in-chamber tion like conventional prechamber plugs, Woodward’s FTI igniters provide pat- turbulence. This self-generating turbu- it reduces the possibility of pre-ignition ented innovations that deliver longer lence adds to the existing in-chamber (knock) and thermal runaway often as- life with more consistent ignition of turbulence promoting rapid flame sociated with prechamber spark plugs, lean-fuel mixtures in high-BMEP gas growth throughout the fuel mixture. especially as BMEP is increased. Also, the engines. These improvements enable FTI prechamber design increases the jet FTI igniter properly manages residual ex- better engine performance, higher com- velocity by as much as two times that of haust exchange in the prechamber, keep- bustion efficiencies and reduced emis- conventional prechamber plugs. ing residual gases effects to a minimum sions, while reducing both misfire and Since the FTI doesn’t rely on the “hot after the exhaust stroke and properly re- knock in challenging applications. A

Comparison of the combustion coefficient of variation (COV) of conventional J-gap spark plugs and Woodward FTI

plugs over 100 samples. The more consistent combustion allows FTI igniters to extend operating limits to lower NOx emissions and increase engine efficiency by enabling engine timing to operate closer to top dead center (TDC). continued on page 32

Diesel & Gas Turbine Worldwide 32 July-August 2015

WW156.indd 2 7/16/15 1:42 PM NORTH AMERICAN

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HHPSummit_LowerYourFuel_AL.indd 1 7/17/15 1:20 PM Power generation

Burners, such as this model for the Siemens SGT5-4000F gas turbine, are tested in the company’s new Clean Energy Center near Berlin, Germany.

by Roberta Testing Clean Energy Prandi Siemens’ new Clean Energy Center designed to optimize components, processes of gas turbines

fter an investment of roughly Jerry Klopf, Siemens’ director of the gy in pressure and temperature sensors €100 million, Siemens opened CEC, gas turbines, engineering, ex- that can withstand the most extreme its Clean Energy Center (CEC) plained that the CEC hosts combustion test conditions, strain gauge applica- near Berlin, Germany, in Feb- system rig testing with two test rigs for tions for the rotating components, tip ruary 2015. larger-frame gas turbines and one rig for timing and clearance measurement, AAs the name partly suggests, the new smaller gas turbines. Material testing is combustion dynamics, and telemetry facility is a test center aimed at the opti- also carried out, as well as rig testing for on rotating components, to name a few. mization of components and processes the compressor and turbine sides. Klopf said that one of the most in- for more efficient gas turbines and a Test beds are utilized for off-design teresting capabilities of the new test continued on page 36 more environmentally friendly opera- testing. “We simply test the engine for its center is its ELVis data management tion. The center is fully integrated in known capabilities and beyond,” Klopf system. “ELVis stands for Engine Live the Siemens global engineering group said. “We can vary control parameters at Data Visualization and, in practice, is for research in component testing and will to test these limits.” a web-based system that allows each engine testing, especially for what the The center uses advanced instrumen- piece of test data to be treated as live combustion process entails. tation; for example, the latest technolo- data. ELVis allows us to visualize test

Diesel & Gas Turbine Worldwide 34 July-August 2015

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GTI_Altronic_Nov14WW.indd 1 9/10/14 2:10 PM data in real time at Siemens’ engineering locations worldwide. “From our ELVis room in the Berlin test center, we have live conversations with our engineers in China, India, the United States, Germany, Sweden, and with the colleagues from the Rolls-Royce energy aeroderivative gas turbine and compressor business acquisition in Canada.” The clear advantage is to be able to share experience and valuable data first-hand with the whole Siemens engineering group. It also gives the team unprecedented flexibility in testing management. “We have reached a level of work efficiency that cannot be ob- tained with testing in third-party facilities,” Klopf said. “This said, we still maintain important cooperation projects, for example, with the German Aerospace Center DLR in Cologne, Germany; the National Research Cen- ter (NRC) in Ottawa, Canada; as well as some university partners with smaller testing rigs.” In addition to that, CEC in-house tests are complemented by real-conditions testing of the engines with worldwide customers. ELVis is a very powerful analysis tool, as Klopf said. For every single test, the system filters between 2 and 4 million pieces of measured data. “In more practical terms, after each test is completed, the team needs a mere two hours to produce ‘crystal clear’ test results (meaning significant final data that can be shared with the rest of the group),” Klopf said. “It then takes two hours for the team in the test room to prepare the rig for the next The Berlin gas turbine plant is Siemens’ biggest production site test. The cycle works with maximum worldwide. With 3700 employees, the facility manufactures, tests precision — approximately four hours and validates all Siemens’ large gas turbine models. are needed for the rig to cool down between tests.” Tests, for now, are focused on the com- of more than 61% and an overall effi- tant results are expected in the short bustion process, where the main ad- ciency of the natural gas fuel of 85%1. term. Testing expansion steps could vantages in gas turbine efficiency can The company is working on further ef- also include turbine blades and vanes, continued on page 36 be reached. In fact, Siemens has already ficiency improvements, such as testing and compressor testing. broken some significant limits in the new burner prototypes, combustion The Berlin CEC has been built on a efficiency of gas turbines, for example behavior based on different variables large open land area in Ludwigsfelde, a with the construction of the CCPP Laus- (flame stability, pressure, temperature, site that offered the right characteristics ward in Düsseldorf, Germany, which will ignition, and thermodynamic design), for this kind of installation. It is only 40 reach an electrical output of 595 000 kW and on the next generation H-class minutes from the existing Siemens Ber- with net energy conversion efficiency combustion technology, where impor- lin gas turbine plant.

Diesel & Gas Turbine Worldwide 36 July-August 2015

WW153.indd 2 7/16/15 2:00 PM Power generation Klopf said that the area was already ing steel and plastic, not wood. The 25 people benefit from the close prox- equipped with gas turbine testing tech- exhaust stacks are supplied by BBM imity to the Siemens Berlin gas turbine nology, because it hosted a large aero- Akustik Technologie in Germany, with plant, the biggest Siemens produc- space turbine testing center. In fact, the new noise-dampening features. Klopf tion site worldwide with a workforce CEC has a gas pipe available directly added that a higher airflow is brought of 3700. at its door (20 bar), which is then com- into the rig rooms and evacuated out Dr. Sebastian Piegert, responsible for pressed up to 50 bar at the site’s com- of the stacks, as a measure to make additive manufacturing in Siemens’ pressor station — a station that can han- the internal room atmosphere as non- Gas Turbines/Generators business unit, dle natural gas as well as special gases. explosive as possible. explained that the Berlin plant includes Thanks to a high-pressure fuel tank farm The CEC site hosts its own high-voltage large turbine manufacturing, testing for liquid fuels and fuel gases, the facility connection and switch yard, because and validation, as well as engineering/ will be capable of testing all kind of fu- the installations use an average 40 to research, new apparatus business for els, including hydrogen. Klopf said that 50 MW per day. E-, F- and H-class turbines, and service. there are a lot of customers’ requests for A 10 000 kW diesel gen-set is also The facility dates back to 1904, with gas turbine dual-fuel operation — some available for emergency power, be- the first establishment of the AEG even for three-fuel options — so fuel cause data handling and ancillary sys- steam turbine factory, and over the flexibility is becoming more of a key tems, such as pumps, need back up in years has supplied more than 950 gas functionality for gas turbines. case the main power supply should fail. turbines worldwide, for a total capac- Two different air-preheating systems The plant also features a battery buffer ity of 140 000 MW. In its historically bring the air to the required tempera- for emergency power storage. protected halls, Siemens’ most pow- ture to supply pre-heated air to the test Finally, the CEC has its own work- erful gas turbine, the SGT5-8000H, is cells. Three air compressors are also in- shop with multifunctional capabilities, manufactured too. A stalled, with a capability of 50 kg/s. which allows parallel preparation of Each test cell has its cooling tower, test campaigns and an instant adapta- 1Read more about the Lausward power specially developed by GEA Heat Ex- tion to changed validation needs. plant in D>W, after the start of plant’s changers in Netherlands, only us- As mentioned, Klopf and his team of commercial operation expected in 2016.

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IFT.inddWW153.indd 1 3 5/19/157/16/15 2:292:00 PM Liquid Gas Injection MAN successfully demonstrates the ME-LGI concept

itsui Engineering & Shipbuilding Co. Ltd., a MAN Diesel & Turbo licensee, has successfully demonstrated the ME-LGI (liquid gas injection) concept using the first ME-LGI engine to be commercially produced. The engine, with the type designation 7S50ME-B9.3-LGI, is bound Mfor a vessel under construction by Minaminippon Shipbuilding Co. Ltd. for Mitsui O.S.K. Lines Ltd. The ME-LGI concept can be applied to all MAN Diesel & Turbo low-speed engines, either ordered as an original unit or through retrofitting. With two injection concepts, the ME-GI and the ME-LGI concept greatly expand the company’s dual-fuel portfolio and enable the exploi- tation of more low-flashpoint fuels such as methanol and LPG, the company said. The engine’s “ME” prefix indicates that the new engine benefits from electronic controls that also encompass the fuel being injected by a so-called fuel booster injection valve. This fuel booster, specially developed for the

The LGI combustion chamber consists of two LGI fuel valves and two oil-fuel valves, the latter used for pilot oil when running in LGI mode and as fuel valves when running in normal mode.

Diesel & Gas Turbine Worldwide 38 July-August 2015

WW157.indd 1 7/16/15 2:05 PM industry news

ME-LGI engine, ensures that a low-pressure, fuel-gas supply system can be employed, significantly reducing first-time costs and increasing reliability, according to the company. MAN developed the ME-LGI engine in response to interest from the shipping world in operating on alternatives to heavy fuel oil. Methanol and LPG carriers have already operated at sea for many years and several LPG tankers are currently being built as the global LPG infrastructure grows. MAN Diesel & Turbo is currently working towards a Tier 3-compatible ME-LGI version. “The immediate market acceptance of our ME-GI engine confirmed the growing demand for low-sulfur, non-HFO options in the face of increasingly stricter sulfur limits in fuel,” said Ole Grøne, senior vice president, low speed promotion and sales, MAN Diesel & Turbo. “In turn, extending our dual-fuel engine program with an ME- LGI unit that can run on liquid fuels was therefore a natural step. “The interest in our ME-LGI engine confirms this dual-fuel, low-speed trend and will offer even more alternatives to HFO, which, apart from methanol, will include LPG, dimethyl ether and bio-ethanol, as well as several other, low-sulfur, low-flashpoint fuels.” A

The LGI parts, highlighted in yellow, are based on the ME design.

Diesel & Gas Turbine Worldwide 39 July-August 2015

WW157.indd 2 7/16/15 2:06 PM The Titans are the first class of American long-haul tugs to be built with azimuth stern drives as standard equipment.

by Peter New Trend For Long-Haul Tugs? Marsh Azimuth stern drives grow in popularity

atton Marine of Seattle, Wash- an average age of almost 40 years. Many exemplary service on the demanding ington, U.S.A., is noticing a designs date back to the 1950s. Alaskan routes. Now, with the new tow- trend in the marine sector. Naval architects Jensen Maritime of ing rules being proposed by the USCG, In the last 30 years, a revo- Seattle, in close cooperation with Ric new environmental regulations, and the lution has occurred in ship and Bob Shrewsbury of Western Tow- need to address crew comfort, the need Hhandling and docking. As ships in- boat in Seattle, were responsible for for new long-haul vessels continues to crease in size, traditional tugs with one of the first modern designs for be strong.” single or twin straight-shaft drives long-haul tugs in 1995. Their goal was In 2012, two captains with more than have been replaced by highly special- to create an efficient long-haul tugboat 30 years of experience in the West Coast ized vessels using new technologies, that was able to maneuver and dock its towing business became frustrated with especially azimuth stern drives (ASD) own barges unaided at remote Alaskan the aged tugs. Robert Dorn and Gor- for propulsion and electronically con- ports. Their solution was to replace the don Smith took time off and decided trolled marine diesels. conventional straight shafts with ASDs, to survey the needs of typical offshore More than 300 of these crafts have and add many of the other features of operators, research the best-available been launched in the United States, all the ship-handling tugs. equipment, and build a boat that could featuring increased beam for improved The result was the Titan, a 36.5 m long, become the industry standard. They re- stability, all-round visibility in the pilot 10.6 m wide offshore tug with twin alized they couldn’t improve on the Ti- house, and instant fingertip control of 1491 kW engines. Western Towboat will tan design, so they licensed it from the the drive units to direct the propellers soon launch its seventh Titan. Shrewsburys and contracted with the JT and their thrust in any direction. “Over the years, the installed power Marine shipyard in Vancouver, Washing- Now that this transformation is almost for the Titans’ engines has been in- ton, U.S.A., to build two boats for their complete, naval architects and small creased by over 25% with upgrades new company called Hyak Maritime. shipyards foresee these developments to meet the current EPA demands, but Although the hulls are identical, the applying to the other American tug little else has changed,” said Jonathan Hyak tugs differ from the Western boats fleet — the boats that tow barges on Parrott, Jensen’s vice president of new in the engine room. All Western’s big long coastal routes. Estimates state that design development. tugs are powered by a high-speed V-16 there are 300 to 400 of these boats with “The Titans have continued to provide diesel engines.

Diesel & Gas Turbine Worldwide 40 July-August 2015

WW162.indd 1 7/16/15 2:20 PM MARINE The Hyak tugs feature medium-speed, four-stroke GE 8L250 en- propulsion gines, producing 1998 kW at 900 r/min. The eight-cylinder inline GE engine weighs nearly 18.1 tonnes and stands 3.3 m high. The Hyak main engines are coupled to a pair of Schottel 1515 FP ASDs turning 2600 mm diameter stainless-steel propellers via Centa flexible connectors and carbon-fiber shafts. Two John Deere 6081A Kohler generator sets each provide 195 kW of electrical service; each gen-set also provides full hydraulic power to the winches. The fuel capacity is 598 095 L. Tulio Celano at Crescere Marine Engineering of Columbia City, Oregon, U.S.A., provided detail engineering. The tugs were built to ABS + A1, AMS Machinery Class, Towing Certification All Oceans standards, with the Marpol compliance necessary to work in international ports. Their compact size results in a U.S. regulatory tonnage of 91 and international tonnage of 497, allowing them to operate with smaller crews than offshore tugs. They were measured with 83.8 tonnes of bollard The first two Hyak tugs are now working under the pull and 14.5 knots free running speed, which enabled Crowley colors of Crowley Maritime. Maritime to charter both boats, Hawaii and Washington, for its ocean towing fleet. They were then put into service towing two barges with an oil platform and associated equipment from the rail fuel system. The cylinder assembly includes a cylinder head, Gulf Coast to Gabon in West Africa. intake and exhaust valves, valve linkage and a high-pressure fu- “The GEs in the first two tugs have already demonstrated the el-injection pump and nozzle, which enables quick changeouts fuel efficiency of a 2983 kW boat with the power of a 4474 kW and increased engine uptime. vessel, saving over 3028 L of fuel and 113.5 L of lube oil daily With its success, Hyak moved ahead with an order for a third over a typical tug,” Dorn said. Titan — the Montana. A The GE L250 — bore 250 mm, stroke 320 mm — is specifically engineered for marine applications with its accessories mounted on the engine for maintenance ease. The engine features fuel control and refined timing from a high-pressure, common

The engine room looking forward, with the John Deere gen-sets in the foreground, port GE engine on the left, and switchboards on the main bulkhead.

crank angle [°CA]

Diesel & Gas Turbine Worldwide 41 July-August 2015

Trafag_Dec14_WW.indd 1 9/2/14 9:45 AM WW162.indd 2 7/16/15 2:20 PM industry drivers

GE nia, U.S.A., and will be sent to one of a turnkey basis, three natural gas-fired GE has signed a 20-year contractual GE’s locomotive assembly facilities to combined cycle power plants, each services agreement with GAMA En- be installed into a GE Evolution Series with a capacity of 4.8 GW, for a total erji for an 840 MW combined-cycle Tier 4 locomotive. combined capacity of 14.4 GW. Each of power plant in Kirikkale in central Tur- The Grove City facility, with a total the three power plants, Beni Suef, Burul- key. Once the site has been commis- production of 3000-plus engines a lus and New Capital, will be powered by sioned — expected to happen in early year, serves the global transportation eight Siemens H-Class gas turbines. 2016 — GE will provide planned and industry in building new and remanu- The plants will add power to the grid unplanned maintenance under avail- factured diesel engines for locomo- in stages. Plans call for an initial 4.4 GW ability and performance guarantees tives as well as for marine and station- to go online before summer 2017 and Power Generation for two GE 9F.05 gas turbines and a GE ary power applications. the full 14.4 GW to become available

p 209D steam turbine. The development of the Evolution 38 months after the financing has Series Tier 4 engine was part of the closed and advance payments have ETHOSENERGY larger US$600 million investment been received. Once completed, the EthosEnergy Poland S.A. has received made in the Evolution Series platform. three power plants will be the largest a contract for the design, manufac- GE was able to create an engine that in the world, Siemens said. ture, transportation and assembly of required no aftertreatment to meet Siemens will also deliver up to 12 four 150 MVA 242/13.8 kV generator the emissions targets. GE Transpor- wind farms in the Gulf of Suez and step-up and two 6 MVA 13.8/6 kV aux- tation leveraged other GE business West Nile areas, comprising around iliary transformers for the Porabka-Zar units to develop elements of the Tier 600 wind turbines and an installed ca- hydropower station in Poland. 4 engine, including the power as- pacity of 2 GW. The project also calls for upgrading sembly, exhaust gas recirculation, the control and protection systems common rail fuel system and turbo- ATCO for the facility and designing a new charger. The engine meets the U.S. En- ATCO Emissions Management re- Power Generation

water-cooling system for the trans- vironmental Protection Agency’s (EPA) ceived a contract from Iberdrola En- formers. EthosEnergy will also install Tier 4 locomotive emissions standards, ergy Projects to design and supply two p an anti-explosion transformer protec- which took effect on January 1, 2015. acoustical buildings at the New Salem tion system. GE Transportation said it was able to Harbor Station in Massachusetts, U.S.A.

The plant operates four 125 MW meet NOx and PM emissions reduc- Iberdrola, the engineering, procure- Francis hydraulic turbines situated tions by at least 70% from Tier 3 emis- ment and construction company 500 m underground. It is the only un- sions standards. for the project, is building a new derground power plant in Poland, the combined-cycle gas turbine electric company said. Siemens generating plant on the site of the de- Power Generation

Siemens has signed contracts worth commissioned coal-and-oil-fired Sa- Wärtsilä €8 billion for high-efficiency natural lem Harbor Station generating plant. p Wärtsilä and Carnival Corp. have gas-fired power plants and wind pow- ATCO will design and supply acous- partnered to optimize engine-room er installations that will boost Egypt’s tic envelopes for the combustion tur- operations aboard Carnival’s fleet power generation capacity by more bine generator/heat recovery steam of 101 ships across its nine global than 50% compared to the currently generator and steam turbine genera- brands. Wärtsilä engine control and installed base. The projects will add tor buildings, and also provide other monitoring systems, safety and fuel- an additional 16.4 GW to Egypt’s na- noise mitigation offerings to comply efficiency packages will be installed tional grid to support the country’s with the city’s noise policy and the I ndustry N ews and tested in pilot projects on several rapid economic development and Massachusetts Department of Envi- Power Generation

i Carnival vessels. meet its growing population’s de- ronmental Protection regulations. mand for power. The structural steel is specifically de- p GE Transportation The contracts — which represent signed for a pre-manufactured panel- GE Transportation has completed the Siemens largest order ever — were ized acoustic wall system and is engi- R ail

first production test of its GE Evolu- signed with an official ceremony in neered to carry the heavy loads of the tion Series Tier 4 engine. This produc- Berlin, Germany, by Egyptian Presi- architectural louver system, a structure r tion test evaluates the performance, dent Abdel Fattah El-Sisi and German not commonly found on power plants, emissions and mechanical properties Vice Chancellor Sigmar Gabriel. according to ATCO. ATCO’s panelized of the engine. This is the first engine Together with local Egyptian part- design will reduce installation time to go through the company’s newly ners Elsewedy Electric and Orascom and will be constructed entirely from built test cell in Grove City, Pennsylva- Construction, Siemens will supply, on the exterior, the company said.

Diesel & Gas Turbine Worldwide 42 July-August 2015

WW_JulyAugust_Industry Drivers.indd 1 7/17/15 12:00 PM news makers

Dr.-Ing. Alexander Nürnberg has Hernandez previously served as gen- industrial equipment manufacturing. taken over as chair of the board of di- eral manager – European Operations, for Prior to this role, Powell served as se- rectors of Reintjes GmbH, after Univ.- Chromalloy in Holland, France and the nior project manager for Kuhn North Prof. Dr.-Ing. Horst Rulfs passed away U.K. Prior to that, he served Pratt & Whit- American in Brodhead, Wisconsin, at the beginning of the year. Dr. Nürn- ney as general manager for the com- U.S.A. He has also worked in product

ES R E I N TJ berg has been a member of the Rein- pany’s Turkish Engine Center in Istanbul management for Case/Case IH, In- tjes board of directors since May 2011. and as general manager of the Parts gersoll Rand and Liebherr Construc- Since 1996, Nürnberg has been man- Repair Operations in Loyang, Singapore. tion Equipment. aging director of HATLAPA Uetersener Maschinenfabrik GmbH & Co. KG, a shipbuilding supplier for deck machinery, steering gears and compressors. A. Smith A. Rashid Along with new Reintjes Chief Execu-

tive Officer Klaus Deleroi, he belongs S . CMR U. to the association Marine Equipment Fairbanks Morse Engine, an EnPro In- Asif Rashid has been appointed as and Systems and took over its man- dustries company, has added two new the new managing director of control agement in 2003. He is also chairman members to its staff: Andrew Smith instrumentation and electrical engi- of the Center of Maritime Technolo- and Jeff Powell. Smith joins the compa- neering at CMR U.S. gies in Hamburg, Germany. ny as the leader of its marine segment, Prior to his U.S. move, Rashid was and Powell as a product manager. the managing director of CMR CPC in France and has also held senior roles at General Motors, Delphi, SPX and Fairbanks Morse E ngine Fairbanks E. Hernandez Kennametal Inc. J. Powell Load bank manufacturer and test- PAS Technologies Inc. has appointed ing solutions company Crestchic has Enrique Hernandez as vice president Smith previously served as vice made a trio of senior appointments. The of integration and transitions. president of business development company, headquartered in Burton-on- Hernandez is responsible for leading with Rolls-Royce Naval Marine. Prior Trent, England, has appointed Garry Crestchic S Technologies PA the company’s acquisition integration to that, he was a marine engineering Chamberlain as technical proposals and new program introductions. He artificer in the Royal Navy (U.K.) on manager; Neil Barber as head of Engi- brings more than 20 years of opera- surface ships and submarines. neering and Louise Passey as finance tional experience in repair and manu- Powell, who will oversee the redesign manager. The company specializes in facturing operations, team building and of the company’s opposed-piston en- worldwide load bank supply in the change management across cultures gine, comes to Fairbanks Morse Engine oil and gas, marine, data center and and disciplines. with nearly 20 years of experience in power generation sectors.

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High-Temp SCR Systems Engineering Services Mitsubishi Hitachi Power Systems FEED Engineering Inc. (FEI) has has published literature on its SCR released literature on its engineer- systems for high-temperature appli- ing services. The company’s engi- cations. Information is provided on neering services are based on four the benefits of the SCR systems, as design principles: reliability, effi- well as catalyst selection flexibility, ciency, safety, and environmental. initial and life-cycle costs and con- FEI is a representative of COMM struction and installation. Engineering Inc. www.mhpowersystems.com www.feedengineering.com

Portable Heaters Heat Exchangers Aerotech Herman Nelson Interna- Advanced Industrial Components tional has published a brochure on (AIC) has published a brochure its portable heaters. The company about its line of heat exchangers. provides a range of heaters, from The brochure provides informa- off-grid and flameless heaters to tion on each product line, offering recirculating and oil-fired electric descriptions and specifications of heaters. each heat exchanger. www.hermannelson.com www.aicheatexchangers.com

Decommissioning Diesel Filtration System Service Refuel Systems has produced litera- A-Line E.D.S. decommissions trans- ture on its internal diesel filtration formers and associated electri- system. The filtration systems are cal equipment, as well as provides designed to address problems as- transformer recycling and removal sociated with emulsified water and services. Other capabilities are biodiesel blended fuels, as well as presented in a brochure from the capturing particulate down to 0.5 company. of a micron. www.alineeds.com www.refuelsystems.com

Industrial Construction Heat Exchange Products CCC Group Inc. has released a bro- Cooper Core Ltd. is a Canadian- chure on its capabilities. Founded owned designer and manufacturer in 1947, the company provides in- of heat exchange products. Its tegrated construction, fabrication products include radiators, turbo- and specialty engineering services charge air coolers, intercoolers, oil to the United States and abroad. coolers, fuel coolers, process cool- www.cccgroupinc.com ers, and tube and shell coolers. www.coppercore.com

Diesel & Gas Turbine Worldwide 44 July-August 2015

WW_JulyAugust_Literature.indd 1 7/17/15 12:11 PM Controls, SEnsors & instrumentation ABB Expands Symphony Plus Range SD Series designed for total plant automation

The new Symphony Plus SD Series control and I/O products by ABB are utilized for total plant automation.

BB has launched its Symphony Plus SD Series of flex- in operation all over the world, including more than 4500 in ible control and input/output (I/O) products, for power and water applications. A total plant automation across various application types, irrespective of size or physical location. The SD Series is designed to improve energy HIGH PERFORMANCE THERMAL INSULATION Aefficiency and productivity in diverse operating envi- FOR HIGH PERFORMANCE MARINE VESSELS ronments within the power and water industries. The new range is especially suited for applications where control is distributed over a wide area often in harsh conditions, ABB said. The new series is the latest addition to the Symphony Plus product family, ABB’s flagship automation platform for the power generation and water sectors. “The launch of the SD Series is a reaffirmation of ABB’s commitment to continue investing in the Symphony Plus platform based on an ‘evolution without obsoles- cence’ approach of introducing new technology with enhanced benefits while protecting the long-term in- SHEET METAL, FOIL ENCAPSULATED, INTEGRAL - WE’VE GOT THE SOLUTION vestment by ensuring full compatibility with existing installations,” said Massimo Danieli, managing director of ABB’s power generation business, a part of the company’s Power Systems division. The SD Series is a portfolio of DIN (Deutsches Institut für Normung) rail-mounted control and I/O products based on a scalable architecture and flexible design. ABB said the energy-efficient solution pays for itself through reduced long-term energy, operational and maintenance costs. These products can withstand extreme operating condi- INSULATION EXPERTS 951-736-9911 | www.thermalstructures.com | [email protected] tions such as temperatures from -20° to 70°C without the 2362 Railroad St. Corona, CA 92880 | 2800 Airwest Blvd. Plainfield, IN 46168 (Mid-West Division) need for additional environmental protection. ABB reported more than 6500 Symphony installations

Diesel & Gas Turbine Worldwide 45 July-August 2015

ThermalStructures.indd 1 4/10/15 2:00 PM WW149.indd 1 7/20/15 10:59 AM * Further information on this company’s products can be found in the 2015 indexOf Advertisers Diesel & Gas Turbine Sourcing Guide (www.Dieselandgasturbineguide.net) and/or Need Fast Answers? Go To www.dieselgasturbine.com the 2015 Compression Technology Sourcing Follow dgtww on: Supplement (at CTSSnet.net).

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Clark Cooper 9 Kistler Instrumente AG 43

*CMR Group Fourth Cover *MAN Diesel & Turbo 11 *Ellwood Crankshaft Group 4 *MTU Friedrichshafen GmbH Onsite Energy Diesel 13 GE Marine 1 *OPRA Turbines Third Cover *GEA Westfalia Separator Group GmbH 25 Power-Gen Asia 8 HARCO 19 Shinkawa Electric 15 HHP Summit 2015 33 Siemens Energy International 31 *Hilco Division - The Hilliard Corporation Second Cover

Hitachi Nico Transmission Co., Ltd. 23 Thermal Structures, Inc. 45

IFT GmbH - INNOVATIVE FILTER TECHNOLOGY 37 Trafag AG sensors & controls 41

ISOLITE GmbH 7 W&O Supply, Inc. 20

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Wind Power Hits Turbulence

f a recent power generation trade show scheme for the power source a year Predictably, the announcement was in Amsterdam proved one thing, it was earlier than expected. met with concern not just from envi- that, in many parts of the world, the “We have a long-term plan to keep the ronmentalists but also from the more equipment supply industry is some- lights on and our homes warm, power hard-headed, commercially savvy busi- what flat and, in some cases, in disarray. the economy with cleaner energy, and ness community. IThat situation is not just confined to keep bills as low as possible for hard- “Cutting the Renewables Obligation power generation involv- scheme early sends a worry- ing gas turbines and large ing signal about the stability of diesel engines. the U.K.’s energy policy frame- In and around the fringes work,” said the U.K.’s Confed- of the exhibition, renew- But is it wise for us to eration of British Industry, able power and its seem- which speaks on behalf of ingly relentless march for- assume“ that renewables will 190 000 businesses. “This is a ward was prominent. blow not just to the industry, There was much debate be reliable when it comes to and (it) could damage our rep- about the role of tradition- keeping the lights on in utation as a good place to in- al conventional power and vest in energy infrastructure.” the question remained as the future? One environmentalist group to how much of a role it added: “Ministers have just would play in the coming moved to raise everyone’s years in providing basic energy bills by blocking the supplies to homes, busi- ” cheapest form of clean power, nesses and factories. working families,” U.K. Energy and Cli- whilst continuing to back the impossi- But is it wise for us to assume that re- mate Change Secretary Amber Rudd said. bly expensive Hinkley C (a planned new newables will be reliable when it comes “As part of our plan, we are committed 3.2 GW U.K. nuclear power station) and to keeping the lights on in the future? to cutting our carbon emissions by fos- going ‘all out’ for unpopular, risky and Against the backdrop of pro-conven- tering enterprise, competition, opportu- unproven fracking.” tional power sources and their new- nity and growth. We want to help tech- It added that the decision will “send a found momentum, the old argument nologies stand on their own two feet, not clear message to international investors surfaced: “What do you do for power encourage a reliance on public subsidies. that the U.K. government is willing to when the wind doesn’t blow and the “So we are driving forward our commit- wreck our power sector to please their sun doesn’t shine?” ment to end new onshore wind subsi- most ideological backbenchers.” As delegates returned home from dies and give local communities the final The subsidy decision is not a victory for the exhibition with the “green” mes- say over any new wind farms. Onshore supporters of gas turbine or diesel-en- sage still ringing in their ears, the U.K. wind is an important part of our energy gine generated power, but a reminder government pushed back against on- mix and we now have enough subsi- that the road to a renewable-powered shore wind farms, announcing in mid- dized projects in the pipeline to meet future will be far from smooth and is June its intentions to close a subsidy our renewable energy commitments.” likely to take longer than anticipated. A

Diesel & Gas Turbine Worldwide 48 July-August 2015

WW148.indd 1 7/16/15 2:21 PM BACK INSIDE COVER

OIL & GAS: ONSHORE AND OFFSHORE OP16 RADIAL POWER GENERATION, FLARE ELIMINATION MARINE: AUXILIARY AND STANDBY POWER, VOC UTILIZATION FOR ONBOARD POWER GENERATION GAS TURBINE INDUSTRIAL: COGENERATION, TRIGENERATION, DIRECT DRYING GENSETS DISTRICT HEATING: HOTELS, SKI RESORTS, DISTRICT COOLING, REMOTE SITES WASTE TO ENERGY: MUNICIPAL WASTE, SYNGAS, PYROLYSIS GAS OPRA Turbines will exhibit at: Power Gen Asia, 1-3 September, Bangkok, Thailand The Green Expo, 23-25 September, Mexico City, Mexico Vietnam Oil & Gas Show, 21-23 October, Ho Chi Minh, Vietnam Power Gen International, 8-10 December, Las Vegas, USA

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