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Haight Notes
A Four-Letter Word
Called Retirement
There has been much talk in recent
years about the mass retirement rate
predicted to begin in 2011. Compa-
nies scrambled to increase their in-
vestments in training and recruiting
programs to ensure that as a large
percentage of the global population
turned 65, talent was ready and in
place to meet the needs and expecta-
tions of customers and shareholders,
and ensure that business as usual con-
tinued. The problem is that along the
way, business as usual changed.
2011 marks what some analysts
call the tip of the retirement iceberg.
The U.S. Census Bureau released fig-
ures predicting that 2.8 million U.S.
citizens will turn 65 in 2011. That’s a
whopping 316 every hour. In Japan,
23% of its population is now over the
age of 65.
Some have called the baby-boom
generation a demographic time bomb
for the workforce, anticipating a
mass exodus of labor. In the United
States, census data shows that about
76 million people were born between
1946 and 1964 (the baby boomers).
But only 46 million more are coming
along in Generation X, which follows
the boomers. The gap between boom-
ers and Xers led to speculation that
we were in for a severe job shortage
when the boomers really kicked into
retirement mode, which was sup-
posed to be 2011.
Now, it seems as if a generation cred-
ited with redefining everything from
music to politics will now have a strong
hand in redefining retirement.
As the economy turned, companies
offered early retirement as a way to
counteract the job cuts needed to save
costs. A significant number of boomers
opted for this, but rather than settling
down they went back to school or start-
ed their own companies. Now analysts
are saying that the mass retirement that
2 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
had been predicted to begin this year
might not be realized thanks to myriad
factors, among them, years of job cuts
and a still fragile economy that isn’t yet
replacing jobs.
Not the best news for graduates who
had been promised a multitude of op-
portunities upon graduation.
Some analysts now suggest that the
job outlook for graduates will be much
worse than anyone could have imag-
ined. In addition to frail economies
and shrinking job markets, graduates
also must contend with early retirees
taking advantage of the same train-
ing and education opportunities they
have utilized. Now, hiring companies
have an employee pool to draw from
that consists of young people fresh
with education but no experience and
a generation of experienced engineers
with fresh training.
Young and old, retirement is quick-
ly becoming a four-letter word. Grad-
uates are ready for a generation to
step aside so that they can move into
the workforce they have studied to
enter. But a large percentage of baby
boomers are not ready or financially
able to step aside.
It seems a generation that reshaped
the world isn’t quite finished.
Changes to the retirement age have
made global headlines recently. China
and the U.K. are two examples where
65 is now being challenged as the age of
retirement. Time will ultimately reveal
the outcome, and thanks to improved
health and science measures a lot of us
are living and working a lot longer. Per-
haps for me and my fellow Gen Xers, 80
will be the new 65. A
Brent Haight
bhaight@dieselpub.com
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 Contents
January-February Features
2011 Training & Education
CIMAC Sets Sights On Shanghai.............................................................................6
Apprenticeship To Success....................................................................................16
Worldwide Training Program Started By MTU......................................................36

Industry News
Distributed I/O Systems...........................................................................................8
Diesel Switch Approved For Marine Use...............................................................13
Intelligent Combustion Monitoring.......................................................................19
New Accelerometer And Interface Kit From The PCB Group................................38
FW Murphy Expands Powerview 101 Flexibility
Cover designed by Brenda Burbach

With New Configuration Software.........................................................................54

Paradox Engineering Opens Office In Singapore...................................................56
Turbocharger Design System Software..................................................................60

Emissions Worldview
Recycling Wastewater With Biogas Fuel Cells.......................................................10

Power Generation
Allweiler Fuel-Injection Skids For Iraqi Power Plants...........................................12
MAN Introduces New Industrial Gas Turbine.......................................................14
On The Cover: Our annu- Sequencing A Faster Start-Up................................................................................18
al look at The World’s Best A Standard Decision On Paralleling.......................................................................40
Power Plants highlights sever- Cultivating Biogas-Fueled Power...........................................................................46
al noteworthy projects around LSA 40 Low-Voltage Alternator..............................................................................51
the globe. Flexibility And Performance..................................................................................62

Turbine Overhaul & Repair

Laser Precision For Turbine Alignment.................................................................20
Follow dgtww on: Siemens Joins Power Diagnostics And Specialty Monitors....................................33
An Ensemble Cast At Chromalloy..........................................................................42

World’s Best Power Plants

The World’s Best Power Plants 2011.....................................................................22

Marine Propulsion
Global Markets A Powerful Defender..............................................................................................37
MAN Powers LNG Carrier.....................................................................................52
Global Coverage Automated And Integrated Control System...........................................................57
Two Giants Join In Hercules-C..............................................................................58
www.dieselgasturbine.com
Industry News & Analysis
Update On European Energy Policies....................................................................44

OIL & GAS

AEP Joins Effort To Build More Efficient CO2 Compression System....................48
PRINTED IN THE U.S.A. Dresser Waukesha Rolls Out New Gen-Set............................................................53

Rail traction
Saving Fuel Through Speed Control......................................................................50

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Featured Products..................................................................................................39
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Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 1 3

Industry Drivers
ROLLS-ROYCE
M Rolls-Royce has achieved full pow-
er operation of its first production
MT30-powered main turbine generator
set delivered to the U.S. Navy.
The MT30, delivered to the U.S. Navy
for the DDG-1000, USS Zumwalt pro-
gram, achieved full power operation at
36 MW during testing at the U.S. Navy’s
land-based test site in Philadelphia, Penn-
sylvania, U.S.A.
The MT30 has been developed to meet
the growing demand by navies for higher
power gas turbines in the 34 to 40 MW
range and can be configured for mechani-
cal or generator drive.
ELECTRO-MOTIVE
DIESEL
R Electro-Motive Diesel Inc. signed
a contract with Societe Nationale
Industrielle Et Miniere (SNIM) to manu-
facture six SD70ACS heavy haul ac diesel-
electric locomotives.
The SD70ACS is a 3360 kW ac locomo-
tive that includes an EMD IGBT ac drive
system. The locomotive also features a
pulse filtration system and movable sand
plows on the pilot and trucks. Designed
for SNIM’s mining operation, the units
will carry minerals and be capable of op-
erating in harsh desert environments, ac-
cording to the company.
The SD70ACS is also equipped with the
EMD 710-T1 diesel engine, the EM2000
microprocessor locomotive control sys-
tem and the FIRE display system.
The units, which will start being de-
livered in the fourth quarter of 2011,
are designed to increase the amount of
minerals that are carried per trip, the
company said.
CUMMINS
I Cummins Inc. will break ground in
early 2011 on a multiphased man-
ufacturing site at the Aegean Free Trade
Zone in Izmir, Turkey, the company said.
The company plans to first build a filtra-
tion manufacturing plant and follow with
a facility to produce alternators for its
power generation business.
Production is expected to begin at the
92 900 m² site in early 2012 and Cum-
mins expects to employ 800 people in
Turkey within five years.
4 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
Cummins is investing US$70 million in
the facility and related production equip-
ment, with 85% of the products made in
Turkey to be exported to Cummins’ cus-
tomers across Europe, the Middle East,
Asia and Africa.
ALFA LAVAL
I Alfa Laval, a company that special-
izes in heat transfer, centrifugal
separation and fluid handling, signed an
agreement to acquire Aalborg Industries
Holding A/S for US$732 million. The
closing of the transaction is subject to
clearance from regulatory authorities.
Aalborg Industries has about 2600 em-
ployees and is expected to generate sales
of about US$484 million in 2010. Head-
quartered in Aalborg, Denmark, the com-
pany provides critical products, systems
and service to the marine and offshore
markets, as well as the power industry. Its
products include boiler systems, thermal
fluid systems, waste heat recovery systems
and inert gas systems.
WAUKESHA BEARINGS
I Waukesha Bearings Corp., Pe-
waukee, Wisconsin, U.S.A., has
acquired KMC Inc., West Greenwich,
Rhode Island, U.S.A., and Bearings Plus
Inc., Houston, Texas, U.S.A.
Both acquired companies are involved
in the design, analysis and manufactur-
ing of engineered fluid film bearings and
seals. Financial terms were not disclosed.  Range: — Electric Generator Drive: 5.0
Waukesha Bearings is a unit of Dover
Corp.’s Fluid Management segment.
CAPSTONE
O Capstone Turbine Corp., a clean
technology manufacturer of micro-
turbine energy systems, has received an
order for nine C1000 power packages for
a large independent oil and gas explora-
tion and production company in the Eagle
Ford Shale play in South Texas, U.S.A.
The C1000 power packages together will
provide prime power to central processing
facilities and metering stations at remote
well sites in the Eagle Ford Shale play. The
microturbines, fueled by pipeline gas, will
produce electricity to provide all power to
the on-site equipment, including heaters,
pump motors, circulation pumps and dis-
tribution panels, Capstone said.
EJ BOWMAN
I A new charge-air heat exchanger de-
signed specifically for larger capac-
ity turbocharged diesel engines has been
launched by U.K.-based EJ Bowman Ltd.
The new unit, JK 190, is intended for
use with engines rated up to 650 kW
and extends Bowman’s existing charge-
air cooler program by offering a product
for larger capacity marine propulsion sys-
tems, as well as engine test and develop-
ment programs, the company said.
Dresser-Rand
O Dresser-Rand has been selected
to supply power generation and
compression equipment for five offshore
projects that include a floating, produc-
tion, storage and offloading vessel; a semi-
submersible; a tension leg platform; and
two fixed-leg platforms located in various
fields around the world.
The scope of the orders includes eleven
gas turbine generator sets, three gas tur-
bine mechanical drive packages and five
DATUM compression trains in pressure
boosting and export gas services. The
orders are expected to ship in late 2011
through the second quarter of 2012.
CORRECTION
I The power range of Siemen’s gas
turbine range listed in Diesel & Gas
Turbine Worldwide’s November 2010 issue
has been updated to: Gas Turbine Power
to 375 MW, Mechanical Drive: 5.0 to 161
MW; Steam Turbine Power Range: —
Electric Generator Drive: 0.04 to 1900.0
MW, Mechanical Drive: 0.04 to 150 MW.
GE
P GE has signed a framework agree-
ment to form a joint venture to help
modernize the power generation sector
in Russia. GE and state corporation Rus-
sian Technologies and Inter Rao Ues JSC
intend to form a joint venture to manu-
facture, assemble, sell and service heavy-
duty gas-fired gas turbines in Russia.
The joint venture will manufacture GE’s
6FA gas turbines at a factory to be built
in the vicinity of Rybinsk, Russia. The tur-
bines are intended to address a growing
need in Russia for midsized power blocks
in combined heat and power applications.
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Training & Education by brent haight
CIMAC Sets Sights On Shanghai
A conversation with CIMAC President Yasuhiro Itoh
Yasuhiro Itoh, managing director of Niigata
Power Systems Co., was named as the new
CIMAC president for 2010 to 2013.
The next CIMAC Congress will take
place in 2013 but planning is already
under way to ensure the 27th gather-
ing is a success. The CIMAC Congress,
held every three years, brings together
manufacturers of diesel and gas en-
gines and gas turbines and the users
of these prime movers in such ap-
plications as ship propulsion, power
generation and rail traction. The 26th
Congress was held in Bergen, Norway,
in June and hosted more than 900 del-
egates from 39 countries. More than
230 papers were presented.
During the 2010 Congress, Yasuhiro
Itoh, managing director of Niigata Pow-
er Systems Co., was named as CIMAC
president for 2010 to 2013, with re-
sponsibilities for the 27th CIMAC Con-
gress in Shanghai, China, in May 2013.
CIMAC, the International Council
on Combustion Engines, was founded
in 1950 as an industry forum to dis-
6 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
cuss new ideas and developments gress within that region and increase
within the engine and components the involvement from companies lo-
industry together with institutes and cated there. The 2013 Congress will
universities. That spirit continues to be held in Shanghai. I believe it will be
this day but now also includes a great- very successful. We are meeting with
er emphasis on end-user attendance appropriate personnel to ensure par-
by soliciting technical presentations ticipation is as strong as it can be from
from operators and designers of ships, Asian country manufacturers.”
power plants and locomotives. Myriad challenges face engine com-
“Former CIMAC president, Karl munities today. When CIMAC gathers
Wojik, created a clear strategy for in 2013, considerable focus will be on
CIMAC and aligned all of the CIMAC emissions. According to Itoh, regard-
roles to create a worldwide associa- less of the application, emissions are
tion for large engines,” said Itoh. “My one of the biggest challenges for the
goal is to build on what he established engine landscape. Itoh sees stricter
by continuing to grow and strengthen regulations as a growth opportunity
this organization, a special emphasis for engine and turbine manufacturers
being CIMAC’s geographic reach.” around the world.
Accordingly, one of the key tasks “Environmental protection and asso-
on Itoh’s agenda is to increase CIMAC ciated regulations are the driving force
participation from China and Korea. of technology improvements,” said
“We will be seeking increased in- Itoh. “A strong company will be stron-
volvement from Asian countries,” said ger. Weak companies will be weaker
Itoh. “Japan has a long history with CI- due to such very high challenges.
MAC and has been very involved with “Emissions are among the key
the organization. I would like to see challenges of the engine communi-
similar commitments from China and ties right now. Within the marine
Korea. Japan, Korea and China make industry, for example, IMO Tier 3
up a very large portion of the manu- is approaching. IMO Tier 2 can be
facturing and engineering of large en- achieved by an in-engine solution.
gines. We are in contact with key per- For Tier 3, there are a lot of different
sonnel in China and Korea to try and approaches. So far we don’t know
increase the involvement from com- which is the best solution. It is both
panies within those countries. We are pre- and post-cylinder solutions
looking for ways to promote the con- continued on page 8
CIMAC, the International Council on Combustion
Engines, was founded in 1950. The CIMAC Con-
gress is held every three years. The 27th CIMAC
Congress will take place in Shanghai, China, in
May 2013.
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Training & Education
— aftertreatment or two-stage tur-
bocharging for example — that are
currently making progress. There are
a lot of terms in use today: low sulfur
diesel, dual-fuel engines, heavy fuel
oil, water injections, cold ironing, al-
ternative fuels, common rail — these
are all popular terms in the indus-
try today. There is an endless list of
possibilities. But there are a host of
options that are in development and
in the market today that won’t be
around in three to five years. Some
of the technologies being developed
today will be scrapped, and some
will be greatly improved. By the next
CIMAC Congress, it might be a lot
clearer which of these technologies is
right, which will still exist.”
Itoh added, “The question was asked
at the panel discussion during the Con-
gress this year, ‘What comes after heavy
fuel? What is next?’ One panelist an-
swered, ‘It is heavy fuel.’ LNG does not
yet have a sufficient infrastructure. SCR
… if every ship installed SCR, is it pos-
sible to provide a catalyst to all of the
engines? Is it possible to provide urea
in all ports? It is not a viable solution
yet. There is no single right answer to-
day. Hence, we will continue to explore
new technologies and developments.”
CIMAC’s focus goes beyond the
engine and the turbine to include the
complete engine room. Itoh said the
technologies needed to address to-
day’s challenges will also come from
beyond the engine. “The discussion
must include the integrated systems
and controls as well,” he said.
“CIMAC was founded in 1950 to
discuss the problems facing large en-
gines. The first CIMAC Congress was
held in 1951,” Itoh said. “The key
topic was heavy fuel. Nearly 60 years
later, we are still discussing heavy
fuel. But combustion is not the single
biggest issue within the CIMAC orga-
nization. Past issues have been heavy
fuel, greater fuel economy, increasing
power. Now it is the time of emis-
sions. This is not only a focus for the
engine, but for all of the integrated
systems and controls as well.” A
see directlink @
www.dieselgasturbine.com
8 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
Industry News by roberta prandi
Distributed I/O Systems
Regulateurs Europa Ltd. introduced Iceni, a new product range for the
company’s portfolio of control and monitoring systems
A typical node with Iceni input/output mod-
ules, master module and power supply. Iceni
is a new product range by Regulateurs Eu-
ropa, part of the Heinzmann group.
Regulateurs Europa Ltd., part of the
Heinzmann group, believes that Iceni
is a significant addition to the compa-
ny’s portfolio of control and monitor-
ing systems. In fact, the Iceni modules
can be used to either communicate
with PC or PLC equipment, or extend
the range of RE Viking35 digital gover-
nor ECUs, said the company.
Iceni provides a range of digital and
analog input/output modules that can
be plugged together to form nodes on
a distributed I/O system. These nodes
can be positioned at strategic points
around the plant, enabling local field
devices to be wired to the modules
rather than individually back to the
master station, thus simplifying the
plant wiring.
The DIN rail-mounted modules
have up to eight channels according
to the module type. Configuration pa-
rameters of specific I/O channels and
fieldbus communications are set using
an integral graphic color display and
front panel pushbuttons to navigate
the menu system, thus eliminating the
need for a dedicated programmer or
laptop, said Regulateurs Europa.
“With a temperature range of -20°
to 70°C, Iceni has been developed
to withstand the high temperatures
of an engine room environment, but
is equally suited for a much wider
role,” said Nick Mace, sales manager
at Regulateurs Europa.
“This product has been developed
for all applications, both to enhance
our range of control and monitor so-
lutions or as a device for other OEMs,”
he added.
Mace said each network node is
controlled by a master module that
always occupies the first slot; a com-
bination of input/output modules is
then plugged into the master module
to cover the specific requirements.
The master module can access the
input process image to determine
the plant status and also write to the
output process image area to control
plant devices.
Each node is completed with a
single power supply module or two
power supply modules if redundan-
cy is required.
“The master module is currently
available with Modbus RTU commu-
nication protocol, but more protocols,
including CANopen, will be available
soon,” said Mace.
“The status of individual channels is
easily identifiable by the LED indica-
tors on the front panels. As an aid to
commissioning, local plant status in-
formation, including analog input val-
ues, can be displayed on the graphic
display without the fieldbus connec-
tion being present,” said Mace. “This
permits wiring and device operation
to be verified locally, completely inde-
pendent of the fieldbus controller.”
To help fault finding, diagnostic
information on the fieldbus and the
input/output modules is available on
the graphic display. Changeover alarm
contacts are provided on the master
and power supply modules, and these
can be used to alert the operator that
a node is not available or to enable
backup control systems.
The Iceni modules are currently
being prepared for marine approval
by DNV (Det Norske Veritas) and
Lloyd’s Register. A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
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Texas 77005, U.S.A.
Tel: +1 (713) 529-3216
Organizations; Kinciler Cd., Ertürk Sk. Fax: +49 34901 883 120
Web: www.wtz.de
Tel: +90 216 425 6300
Fax: +90 216 425 6302 *March 30-31
E-mail: info@europort-istanbul.com Globalcon - Pennsylvania Convention
Center, Philadelphia, Pennsylvania,
U.S.A.; Association of Energy Engineers,
*March 24-25 4025 Pleasantdale Rd., Suite 420,
7 th Dessau Gas Engine Conference -
Atlanta, Georgia 30340, U.S.A.
Dessau, Germany; WTZ Rosslau, STC Tel: +1 (770) 279-4392
Rosslau GmbH, Mill series 2a, 06862 Fax: +1 (770) 381-9865
Dessau-Rosslau, Germany. E-mail: ashley@aeecenter.org
Tel: +49 34901 883-0 Web: www.globalconevent.com
participating. A more complete listing of trade shows is available at www.dieselgasturbine.com

PERFORMANCE:
Fax: +1 (713) 529-3318
Web: The first time, every time.
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Fax: +1 (979) 845-1835
E-mail: martha@turbo-lab.tamu.edu
Web:
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March
*March 20-23
Western Turbine Users Conference -
Palm Springs Convention Center, Palm
Springs, California, U.S.A.; Western
Turbine Users Inc., 6475 E. Pacific
Coast Highway, Suite 140, Long Beach,
California 90803, U.S.A.
Tel: +1 (513) 442-0986
Fax: +1 (513) 442-0986
Web: www.wtui.com

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Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 1 9

WaukeshaBearing.indd 1 1/14/11 4:27:41 PM

 by dj slater

Emissions Worldview to automatically supplement biogas.

The standard output voltage is
13 800 V with a standard frequency
of 60 Hz. The optional output ac
voltages are 4160 to 12 700 V with
an optional frequency of 50 Hz, said
FuelCell Energy.
The system has an efficiency rating
of 47% and takes about 90 hours to
go from a cold start to producing its
full power output.
The power will be used to sup-
ply 60% of the wastewater treatment
plant’s power needs, Love said. Heat
from the fuel cell system will be used
to heat the municipal wastewater di-
The DFC3000 fuel cell power plant from FuelCell Energy Inc. is the largest power plant in the gesters, which provide the biogas.
DFC line. It has an output of 2800 kW with a 47% efficiency rating. Inland Empire Utilities The power plant has an exhaust
Agency (IEUA), a water and wastewater service provider in Chino, California, U.S.A., is install- temperature of 371°C, said Juan
ing a DFC3000 plant and fueling it with biogas formed from the wastewater. Josse, the vice president of engineer-
ing at UTS BioEnergy. The plant will
Recycling Wastewater recover heat from the exhaust with
a gas/liquid heat exchanger. The ex-

With Biogas Fuel Cells
Inland Empire Utilities Agency signs agreement for 2.8 MW fuel cell system
Inland Empire Utilities Agency
(IEUA), a water and wastewater serv-
ice provider in Chino, California,
U.S.A., has signed a 20-year power
purchase agreement with UTS BioEn-
ergy, which will install, operate and
maintain a 2800 kW fuel cell power
plant at the utility. The fuel cell power
plant will provide power and thermal
energy to IEUA’s largest water recy-
cling plant in Ontario, California.
The decision to operate a biogas-
fueled fuel cell system is part of an
initiative implemented after an en-
ergy shortage and blackouts in Cali-
fornia in 2001.
“That’s when we discussed how we
could be more independent from the
grid,” said Tom Love, the general man-
ager and CEO of IEUA. “We wanted
to find new ways to create more fuel
and secure our energy costs.”
In addition to energy independence,
emission regulations from the Califor-
nia Air Resources Board (CARB) and
the Air Quality Management District
(AQMD) prompted the move to fuel
cell power, which emits virtually no
NOx, SOx or particulate matter (PM).
Love said new regulations require
that the allowable amount of natural
gas that can be used to supplement
biogas has been reduced from 60%
to 10%. By the time the second phase
of the regulations take effect in July
2012, IEUA’s generator engines will
need to be retrofitted with new emis-
sion control equipment, he said.
“We looked at several alterna-
tives, such as retrofitting our engines,
mothballing them, buying electricity
from the local utility or buying fuel
cells,” he said. “Our research, based
on 20-year life-cycle costs, confirmed
that fuel cells were our best option.”
The 2800 kW power plant, which
is provided by FuelCell Energy Inc.,
Danbury, Connecticut, U.S.A., oper-
ates on a minimum of 75% biogas pro-
duced from the wastewater at the util-
ity with natural gas supplementing the
rest, Love said. Called the DFC3000,
it is the largest fuel cell power plant
system in the DFC portfolio from
FuelCell Energy, said the company.
The power plant has a program-
mable logic controller (PLC)-based
control system that allows natural gas
haust gases are then cooled to 133°C
and the recovered energy, about 4.4
million Btu/hr, is used to heat the
plant digesters, Josse said.
The digester gas treatment system
cleans the gas, removing moisture,
particulates, sulfur VOCs and silox-
anes, Josse said. The fuel cell receives
the clean digester gas and, if there is
not enough to maintain the full elec-
trical output, it uses natural gas. FCE
supplies the gas treatment system and
the controls, both of which can be ac-
cessed remotely, he said.
The entire unit, which consists of
six matched modular skids, measures
6.4 m high by 12.5 m wide by 23.8 m
long, according to FuelCell Energy.
IEUA will purchase power generated
from the fuel cell power plant, which is
expected to be operational by late 2012,
at a set price over the next 20 years.
The power plant purchase is not
the first step by IEUA to go greener.
In 2008, the service provider installed
3.5 MW of solar power equipment at
four of its facilities, Love said, and the
goal is to operate independently of
the grid by 2020 through a combina-
tion of fuel cell, solar, wind and other
renewable energy sources. a
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM

10 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide

GE Energy

I prom se
– Todd Walters, Product Services Manager,
Filtration Technologies

I promise
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downtime can cost you tens of thousands of dollars, you need a supplier with
the resources and application expertise to get you up and running quickly. That’s
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That’s not just a promise. It’s the promise of something better.

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see directlink @ www.dieselgasturbine.com

Power Generation

Seven fuel-injection skids from Allweiler will be delivered to Iraqi power plants for Siemens gas turbines. These systems can switch between
several different liquid fuels without shutting down the turbines.

Allweiler Fuel-Injection Skids

For Iraqi Power Plants
The German pump manufacturer has been awarded a US$6.9 million order to deliver fuel-injection skids
for Siemens gas turbines in Iraq

Allweiler received an order for
fuel-injection skids that will be inte-
grated into expanded power plants
in Kirkuk, Iraq, as well as new plants
that will be constructed in Baiji and
Baghdad, Iraq. The skids will be de-
livered through Siemens.
The first two systems will be com-
pleted in early 2011, but Allweiler said
the Iraqi Ministry of Electricity has or-
dered an additional five skids and has
the option to purchase three more.
All the fuel-injection skids have
been designed with the ability to
switch between several different liq-
uid fuels without shutting down the
turbines, and for redundancy with
two high-pressure pumps.
The gas turbines can be operated
with EL fuel oil and S heavy oil or EL
fuel oil and crude oil. Switching be-
tween the various fuels occurs within
approximately two minutes while the
turbines continue to run.
“This was the biggest technical chal-
lenge in the development of these skids.
But our solution to this requirement
gave us the edge we needed to win the
contract,” said Stefan Kleinmann, vice
president of the industry business seg-
ment and member of the management
board at Allweiler AG.
When switching between fuels, the
system must withstand temperature dif-
ferences of more than 120°C without in-
terruption. Johann Engelmann, director
of sales and service, explained, “When
the turbine is started, we’re pumping
low-viscosity fuel oil within a tempera-
ture range of 5° to 25°C, but during
normal and continuous operation the
system is moving higher-viscosity crude
and heavy oil at temperatures up to
130°C. The temperature change is on
the order of 60°C per minute.”
As a result, the system must have
the ability to compensate for temper-
ature-related changes. Precise control
of liquid pressure before and after the
pumps is critical for proper operation.
If pressure decreases during the fuel
changeover, gas bubbles will form in
the liquid and may result in severe
damage to the pumps and emergency
shutdown of the turbines. Highly re-
fined valve control with fast reaction
times can prevent it, said Allweiler.
The pumps used in the system
produce 287 kW of drive power; dis-
charge pressure is approximately 100
bar at a liquid temperature of 130°C.
Allweiler AG, a business unit of Col-
fax, develops pump technology and
supplies systems for power plants.
Allweiler’s in-house plant engineering
services also deliver turnkey fuel, lube-
oil and purge-water skids for all types
of power plants. The company recently
celebrated its 150th anniversary of pump
manufacturing in Germany. A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM

12 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide

 Industry News

Diesel Switch Approved

For Marine Use
The Diesel Switch MKII is equipped with a three-way blending valve

Switzerland-based Aquametro AG ture and pressure sensors, so that the

and Jowa Technology AB have part-
nered to launch the Diesel Switch
MKII, a fuel-blending and fuel switch-
over unit that has been approved by
Germanischer Lloyd.
Marpol regulations prescribe that
ships will need to switch over to
low sulphur fuel in some emission-
controlled areas. Thus it will be nec-
essary to have onboard capability to
blend fuels and to completely switch
over from one fuel type to another.
The Diesel Switch MKII is equipped
with a three-way blending valve, which
adjusts the fuel ratio of heavy fuel oil
and marine diesel oil or marine gas oil
in relation to a set value that is con-
trolled by a logic controller, with touch-
screen display.
The unit is completed with tempera-
controller is able to regulate the permis-
sible fuel temperature changes (as pre-
scribed by the engine manufacturer). It
also monitors fuel temperature in rela-
tion to viscosity and the lowest permis-
sible viscosity before the engine.
According to Aquametro, Die-
sel Switch MKII guarantees the fuel
blending procedure and makes sure
that prescribed limits of sulphur con-
tent are adjusted, proven and then
stored in a special history file, avail-
able for inspection.
Diesel Switch MKII also performs
a compatibility check for both used
fuel qualities, before any blending
or changeover.
The manufacturer said that the
units are easy to install, both in new
applications as well as for retrofit
The Diesel Switch MKII
adjusts the fuel ratio for fuel
blending and switch-over, with a controller
that monitors temperature and pressure and
features a touchscreen display for operators.
projects. In addition, every complete
mounted unit undergoes a full test
before installation onboard.
Aquametro is a specialist in meter-
ing technology since 1928, while Jowa
Technology is a Sweden-based manu-
facturer of oily water treatment systems
such as separators and emulsifiers. A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM

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Power Generation by roberto chellini

MAN Diesel & Turbo introduced the 6.2 MW GT6 gas turbine for mechanical drive and power generation applications. It is available in a two-shaft
configuration, with a one-shaft configuration planned for introduction in a year.

MAN Introduces New ules for easy assembly and mainte-

Industrial Gas Turbine
Two-shaft GT6 gas turbine rated 6.2 MW, one-shaft version planned
MAN Diesel & Turbo has intro-
duced its new GT6 industrial gas tur-
bine, developed for mechanical drive
of its compressors and for power gen-
eration applications.
The GT6 has been completely de-
veloped in-house during the last six
years and is now available in the two-
shaft configuration. The one-shaft ver-
sion will follow in one year.
The introductory rating is 6.2 MW,
but the program is to go up to 8 MW
and subsequently uprated to cover
the power range from 6 to 10 MW.
MAN’s THM models will continue to
cover the 10 to 13 MW power range,
while a scaled up version of the new
GT6 could cover the 15 to 20 MW
range further in the future.
This two-shaft machine features
14 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
an 11-stage compressor, with a 1:15
pressure ratio, driven by a two-stage,
air-cooled, high-pressure turbine.
The second shaft features a two-stage
low-pressure power turbine. In the
single-shaft configuration, the turbine
section will feature three stages, with
the first two air cooled. The generator
will be coupled on the cold-end side
to allow an axial exhaust duct to the
stack or to the HRSG.
The combustion system features
six cans fitted with dry-low emission
burners to minimize NOx and CO
emissions. This combustion system
has been designed from the very be-
ginning as DLN for natural gas-fueled
units; a system for liquid fuels will be
implemented further on.
The machine is built up in mod-
nance operation.
The auxiliary gearbox carrying the
electric starter motor and the main
lube oil pump also serves as front
support for the whole gas turbine.
The turbine air intake casing, on the
auxiliary gearbox, contains the first
journal bearing and the double-acting
axial thrust bearing, both of the tilting
pad type. Both bearings are easily ac-
cessible without the need to open the
horizontally split casing, said MAN.
The drum-type shaft features a
front hub section followed by three
rotor discs and a rear hub.
Hirth serrations ensure correct axial
positioning and centering of the rotor
components once the central tie rod is
tightened; they also absorb the torque
transmitted by the HP turbine. The 11
blade rows of the axial compressors
are mounted on the rotor drums. The
stator vanes are mounted on the vane
carrier, and the inlet guide vanes and
the first three rows of stationary vanes
are of the variable geometry type. A
high accuracy electric servo motor,
Power Generation
connected to the turbine digital con-
trol system, actuates the four variable
geometry rows from the completely
closed position at start-up, until 75%
of speed to the fully open position at
95% of speed and full load.
The discs of the two-stage HP tur-
bine are mounted on the rear hub be-
fore the second journal bearing.
The unshrouded first stage and the
shrouded and interlocked second-
stage turbine blades are anchored to
the discs by fir-tree roots.
Both discs and blades are cooled
by a stream of air from the axial com-
pressor diffuser.
The intermediate turbine casing,
as well as hosting the compressor
diffuser, serves as support to the six
combustion chambers, the hot gas
transition ducts and the two nozzle
guide vane carriers.
At the end of the intermediate cas-
ing, six struts support the rear bear-
ing casing and serve as lube oil ducts
for bearing lubrication.
The combustion chambers, posi-
tioned with 35° inclination relative to
the center line, feature a vortex-stabi-
lized burner section, a large volume
for combustion and supply through
the transition ducts, and hot gases at
uniform temperature to the first tur-
bine nozzles. Both combustion tube
sleeves and transition ducts are im-
pingement cooled with air from the
compressor outlet.
At start-up and low load, the burn-
ers operate in the diffusion mode
The GT6 features an 11-stage
compressor, with a 1:15 pres-
sure ratio, driven by a two-
stage, air-cooled, high-pressure
turbine. The second shaft fea-
tures a two-stage low-pressure
power turbine.
and shift automatically to the premix After assembly, the prototype was
mode as soon as the turbine picks up placed on a specially built test stand
load to ensure minimum production at the Oberhausen, Germany, facili-
of NOx and CO. ties for a series of tests. First firing
The two-stage power turbine has took place on Nov. 19, 2010. With
been optimized for a high efficiency newly designed digital control system
within a wide speed range, it can op- and intensive component testing, it
erate between 45 and 105% of nomi- was possible to reach full load only
nal speed (12 000 r/min). one week after first ignition. Tests of
The two discs of the low-pressure the prototype are still under way at
turbine are bolted, with Hirth serra- the time of writing.
tions, at the inner end of the power At the end of the testing program,
shaft in an overhung position. The the GT6 will be available in the pack-
shaft is supported by two tilting pad age form complete with all its auxil-
journal bearings — the rear one be- iaries for mechanical and generator
ing combined with a pivot shoe-type drive applications. A
thrust bearing. The bearing casing is SEE DIRECTLINK @
placed in the center of the low-pres- WWW.DIESELGASTURBINE.COM
sure turbine casing.
Boroscope access is provided all
along the air and hot gas path to en-
sure quick inspection and reduced
maintenance time.
The stator vanes are mounted on the vane carrier, and the inlet guide vanes and the first three
rows of stationary vanes are of the variable geometry type. The discs of the two-stage HP
turbine are mounted on the rear hub before the second journal bearing.
Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 1 15
Training & Education by roberta prandi

thing the company considers is the

result from the school diploma. Ap-
plicants then have to pass an inter-
view and a thorough test.
“Apprentices usually come to us af-
ter about nine years in school. They
are 15 or 16 years old and only a
few have a limited, basic mechanical
knowledge,” said Fiedler.
For this kind of program there is a
significant public subsidy in Austria.
During the course of the program,
apprentices don’t only have to work,
they have to spend 10 weeks of ev-
ery year in school. During this period
they are salaried by GE’s Jenbacher
gas engine division.
(Left) The apprentice shop in GE’s Jenbacher gas engine plant, where young apprentices spend After so many resources have been
two years learning basic skills in various machining operations, before starting training in the dedicated, the company tries to hold
workshop. (Right) Paul Ladstätter is one of the apprentices at GE Jenbacher’s gas engine divi- the apprentices at the end of the pe-
sion in Austria. He won the Skills Austria state competition and is now Austrian State Cham- riod. “Retention rate is quite high,
pion in CNC milling operations. above 90%. Even in 2009, in the mid-
dle of the global crisis, we kept over

Apprenticeship To Success 50% of the apprentices,” said Fiedler.

GE Jenbacher has long tradition of apprenticeship program,
with over 90% retention rate
GE’s Jenbacher gas engine busi-
ness, Jenbach, Austria, part of GE
Energy, has an extensive apprentice-
ship program that hosts an average of
100 young people, depending on the
varying apprenticeship length, which
is between three and four years.
“Usually about 25 new apprentices
start with GE’s Jenbacher gas engine
division every year. Currently there
are 88 in Jenbach,” said Martin Fiedler,
global supply chain leader of GE’s
Jenbacher gas engine business.
Supported by a history that goes back
more than 60 years, the apprentice pro-
gram is constantly evolving and adapt-
ing to new technologies and market
demands. “A new program to train field
service technicians will be introduced
in 2011, when we will start — for the
first time — with a total of 30 new ap-
prentices,” explained Fiedler.
Other specializations include
mechanical engineers, electricians,
mechatronic specialists and assem-
bly operators.
“All apprentices spend the first two
years mainly in the apprentice shop,
where they get a basic knowledge
and practice with several machining
centers,” Fiedler said. “They are co-
ordinated by the head of apprentices,
supported by three supervisors.”
He continued, “All apprentices prac-
tice with different jobs, including a bit
of all machining operations that are
performed in Jenbach.”
At the end of the two years, appren-
tices move to the workshop, and start
working in different manufacturing
areas. Fiedler emphasized that every
area has a supervisor who is in charge
of the apprentices.
All the young apprentices at GE’s
Jenbacher gas engine division come
from the Austrian Tyrol region.
Fiedler said the company’s program
has quite a strong reputation, so there
is never a shortage of applications.
“Actually, we usually have far more
applications than we can take,” said
Fiedler. “Last year we had 150 re-
quests and only 25 young people
were accepted.”
The selection at GE’s Jenbacher gas
engine business is strict — the first
After the program is completed,
there is a six-month employment pe-
riod in the company. After that, for
most of the boys, there is a year break
as they have to serve in the army.
While apprenticeship is quite a tra-
dition in German-speaking countries,
its extension and complexity at GE’s
Jenbacher gas engine division created
some curiosity when the company
was acquired by GE. “Although there
were some doubts at first, our ap-
prentice program is becoming a best
practice within GE.”
The company is very successful
with its program. Every year, it par-
ticipates to the Tyrolean competition
for apprentices and has collected 83
gold medals. In 2010, the company
crowned the Austrian State Cham-
pion in CNC milling operations, Paul
Ladstätter, who won at Skills Austria,
the Austrian State competition.
Ladstätter is now qualified to attend
the 41st World Skills 2011 competi-
tion, which will be held in London in
autumn 2011. The World Skills is an
international professional competi-
tion with more than 800 participants
from 51 member states. A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM

16 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide

Insight onsite.™
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Power Generation by ian cameron
An “SUS” panel. ComAp said the new SUS feature changes the start-up sequence of the
multiple generators and allows the sets to start online and already synchronized to each
other immediately.
Sequencing A
Faster Start-Up
ComAp adds rapid synchronization to generator controls range
Engine and generator set controller
manufacturer ComAp has announced
a new rapid synchronizing feature to
add to its range.
The Prague, Czech Republic-based
company said the benefits of multiset
synchronizing installations are rec-
ognized by users around the world.
It added that optimization of gen-set
loading ensures reduced fuel con-
sumption and emissions, while help-
ing to extend the service intervals
and, ultimately, engine life.
Built-in redundancy means to-
tal failure is less likely and mainte-
nance does not mean 100% loss of
generating capability. This can also
be coupled with lower capital costs
and lead times when compared to
larger capacity equipment and lower
spares costs during the operating life,
ComAp claimed.
ComAp’s Radim Girgas, director
of the company’s high-end controls
division, added, “However, all this
comes with one drawback — time.
18 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
Or more importantly, the time re-
quired to synchronize all the sets
onto the bus together.
“This is not normally an issue
where time is available such as island-
ed power station applications, but is
essential when the system in question
is being used for standby,” he said.
“While ComAp provides a fast syn-
chronizing controller thanks to its
high-speed phase angle measurement
and correction algorithms, there is
still a certain amount of time required
to achieve all the sets synchronized
and ready.
“This blackout time while the sets
synchronize is not just inconvenient,
it also costs money. In addition, any
critical systems running on uninter-
ruptable power supply [UPS] need to
be fed during this period, so the UPS
needs to be sized accordingly, leading
to further costs,” explained Girgas.
“Modern rotary UPS systems pro-
vide instant backup without the asso-
ciated battery costs of traditional UPS
technology, but only produce useful
power for short periods following the
failure of the grid supply, limiting
their usefulness where multiset instal-
lations are preferred.
“This small but significant drawback
tends to limit standby-type applica-
tions for using multiple parallel sets,
although we believe we offer a solution
with our ‘SUS’ variant application.”
ComAp said its new SUS feature
changes the start-up sequence of the
multiple generators and allows the sets
to start online and already synchronized
to each other immediately. According
to the company, this means that the
system is available at full capacity in the
shortest possible time — typically eight
to 10 seconds from start command to
available, which it believes is faster than
traditional synchronizing methods,
with the time remaining constant even
if the number of generators is increased
to 10 or 20 or 32.
To allow for slow-starting engines
or other problems and avoid delay-
ing availability of the system, any en-
gines that fail to reach running speed
within a specified time are “rejected”
from the scheme and, if able, are left
to perform traditional synchronizing
after the majority of sets have become
available, said ComAp.
Should insufficient sets become avail-
able to meet the load’s initial require-
ments, the system will automatically
attempt traditional synchronizing in an
attempt to restore power, it added.
ComAp said the SUS feature also
provides an additional function by
allowing one or more sets to start
and provide soft magnetizing of feed
transformers so that the system does
not need to be sized to cope with this
peak inrush current.
This can be beneficial in the cost
of the installation, but also aids the
problem where the grid supply is
not capable of supplying the inrush.
The islanded generator plants can
start and soft magnetize the feed
transformer, and allow the grid
mains breaker to be synchronized
and closed, the company said. A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Industry News

Intelligent Combustion Monitoring

Technology designed for two-stroke diesel engines, integrates ABB Cylmate system
Wärtsilä has introduced its intelli- working cycle through the transduc- Wärtsilä’s intelligent combustion
gent combustion monitoring system for er bus. Evaluated data, alarms and monitoring system automatically
two-stroke diesel engines. The system events are sent through the system’s transmits data to the company’s
monitors the condition of the compo- Ethernet LAN to the Cylmate opera- server for further evaluation by en-
nents in the combustion chamber. Harco_Mar08_WW.qxp
tor 9/30/08
station as well as other 2:26
connected PM
ginePage 1 A
experts.
According to Wärtsilä, the system systems, according to ABB. SEE DIRECTLINK @
can lead to fuel cost savings of up to Similar to the Cylmate system, WWW.DIESELGASTURBINE.COM
2% by running engines at optimal fir-
ing pressures. The system measures
the pressures and angle values in each
cylinder during the combustion proc-
ess. By monitoring the position of the
crankshaft, and having a mathemati-
cal model of the engine, the system
provides real-time data for diagnostic
analysis, Wärtsilä said.
The monitored data covers the
thermal and mechanical overload
of individual cylinders, the optimal
fuel efficiency, power readings, cyl-
inder conditions, load-dependent
monitoring of the combustion pa-
rameters and comparisons between
cylinders. The system also monitors
gas leaks, exhaust valve components
and fuel equipment.
Wärtsilä’s system integrates with
the ABB Cylmate system, a feature
made possible by a cooperation and
distribution agreement Wärtsilä and
ABB signed earlier this year. Un-
der the agreement, Wärtsilä handles
global sales, installation and lifetime
service of the system. Any further de-
velopment of the system’s technology
will be carried out jointly by the two
companies, Wärtsilä said.
The Cylmate system is a tool de-
veloped by ABB for diesel engine per-
formance monitoring. The system,
which fits marine and power plant
applications, measures the combus-
tion pressure in each cylinder, con-
tinuously and in parallel, under all
load conditions.
The Cylmate system consists of a
pressure transducer on each cylinder
and an angle transducer at the engine
flywheel, which are all connected
to the Cylmate transducer bus, ABB
said. The system’s controller collects
all measured data within each engine SEE DIRECTLINK @ WWW.DIESELgasturbine.COM

Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 1 19

Turbine Overhaul & Repair by roberta prandi

Schematic of the new laser-based Centralign Ultra Expert alignment system, used for precise alignment
of internal elements of rotating machines, such as bearing rings, diaphragms, nozzles, inner shells and
turbine casings.

Laser Precision For Turbine Alignment

Prüftechnik offers a new generation laser alignment system for internal elements of rotating machines

The new generation laser alignment
system Centralign Ultra Expert by
Prüftechnik Alignment Systems has
been developed for the alignment of
gas and steam turbines.
The system is used for precise align-
ment of internal elements of rotating
machines, such as bearing rings, dia-
phragms, nozzles, inner shells and
turbine casings.
Bernardo Quintana-Rüedlinger, di-
rector of Machinery Service at Prüftech-
nik, said the efficiency and smooth op-
eration of turbines depends largely on
maintaining a short distance between
the turbine components and the ro-
tor. “Good alignment of the rotor to the
other internal turbine components is
therefore extremely important, and tur-
bines should not only be aligned care-
fully during initial installation, but also
with every equipment overhaul.”
The Centralign Ultra Expert mea-
20 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
surement system is a new-generation
product, deriving from the company’s
Centralign Ultra system that has been
used to align turbine shells to rotors
for many years.
“This system is a laser-optical mea-
surement method that saves an im-
mense amount of time when compared
with conventional methods such as the
piano wire technique, theodolite tele-
scopes or the installation of a dummy
shaft,” added Quintana-Rüedlinger.
“In addition, it consistently achieves
high levels of accuracy.”
Centralign Ultra Expert features
a precise and stable laser combined
with a stationary control sensor de-
signed to automatically correct the
value in case of laser drift. A mobile
measurement sensor ensures high ac-
curacy and has a resolution of 1 µm,
said the company.
The laser is designed for precision
at distances up to 40 m and with
upper halves on or off. The system
can be used with diameters from
120 mm to 5 m.
“The ease of installation of Cen-
tralign Ultra Expert can be easily dem-
onstrated with our experience in the
field,” said Nicolas Meunier, sales and
application engineer at Prüftechnik
Alignment Systems.
“That is the case, for example, of
one 20 MW steam turbine, whose
half-casings had to be aligned with
the rotor during scheduled mainte-
nance,” he said.
The turbine housing was opened
to remove the rotor, which was then
brought to an external company that
repaired or replaced the rotor blades
as necessary and then balanced the
rotor. In parallel, the guide vanes and
seals on the turbine were replaced
with new ones.
Turbine Overhaul & Repair
A technician from the Prüftechnik Machinery Service Team prepares the installation of the
control sensor for Centralign Ultra Expert in a 20 MW steam turbine, after overhaul.
After the new and overhauled
components were remounted on the
turbine, the Prüftechnik Machinery
Service Team performed the measure-
ment with Centralign Ultra Expert.
“The laser and the control sensor
were mounted and adjusted on the ex-
terior of the turbine. After the adjust-
ment was completed, it was ensured
that neither of the two components
could move,” explained Meunier.
“The laser beam served as the ref-
erence line for the subsequent mea-
surement and each individual turbine
element was measured.”
The team used sensor brackets de-
veloped and patented by Prüftech-
nik, thus the center point of each
half-casing was determined. After the
measurement points were recorded,
two half-casings could be defined as
a reference.
“A graphic image showing all hori-
zontal and vertical deviations relative
to these references — these are gener-
ally either the oil deflectors or the bear-
ings — was displayed on the Rotalign
Ultra computer,” added Meunier.
Based on these deviations, the
correction values for the different
beds of the half-casings could be
see directlink @ www.dieselgasturbine.com
quickly determined. The mechanics
and technicians were immediately
able to implement the necessary
measures to correct the positioning
of the elements.
“Another advantage of Centralign
Ultra Expert is in fact that individual
segments can be worked on immedi-
ately after the first measurement data
are received, since there is no wire or
dummy shaft to prevent the removal
of the half-casings,” said Meunier.
In addition, measurement data are
immediately available in electronic
form and can be analyzed and further
processed with the Alignment Center
PC software.
Alignment Center is a Windows-
based software platform for all shaft
and geometrical alignment applica-
tions by Prüftechnik. It is compatible
with previous and current Prüftech-
nik products.
For Centralign Ultra, the system
offers exclusive turbine-specific fea-
tures, such as choice of different tur-
bine elements, laser trend monitor-
ing, specific correction methods and
customizable color reports. A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
The Biggest of its Kind
Designed to cope with the
toughest demands in the tough-
est environments: the OSE 120,
the largest of the Westfalia
Separator ® eagleclass series, is
designed specially to meet the
challenges in large sized power
plants. With the highest
throughput rate of its kind the
OSE 120 builds the reliable
backbone of fuel treatment
systems of GEA Westfalia
Separator Group, for turbine-
as well as engine power plants.
Whether installed at the arctic
circle, in tropical jungles or
sandy deserts the OSE 120 will
perform. Smart. Strong. Reliable.
OSE 120 – the top model of the
Westfalia Separator ® eagleclass:
Highest throughput capaci-
ties for diesel engines
and gas turbines
Highly service- and mainte-
nance-friendly design
Higher efficiency and higher
sustainability: the Westfalia
Separator® eagleclass convinces
through its compact design,
the use of fewer components
and wearing parts as well as
minimized power consumption.
Your direct route to service:
www.westfalia-separator.com / service
Liquids to Value
GEA Mechanical Equipment
GEA Westfalia Separator Group
EN-4-20-002
Werner-Habig-Straße 1 · 59302 Oelde (Germany)
Phone +49 2522 77-0 · Fax +49 2522 77-1778
www.westfalia-separator.com
 Editor’s Note: Each year Diesel &
Gas Turbine Worldwide invites engine
manufacturers to submit one specific
power generation project they feel merits
special attention due to advances in one
or more of the following: efficiency in-
crease, environmental aesthetics, opera-
tional characteristics, emission improve-
ments and construction principles. The
coverage is limited to plants commis-
sioned during the 2010 calendar year.
This longstanding tradition has
become a popular feature and this
year’s edition once again highlights
several noteworthy projects around
the globe. Enjoy.
Alstom Power
Emsland Combined-Cycle Power
Plant, Germany
A new 876 MWe GT26-based mul-
tishaft combined-cycle power plant
began operations at the Emsland site
in Germany in September 2010. The
plant is owned by RWE Power and
contributes to supply diversity in the
RWE generation fuel mix. Alstom has
constructed the plant under a full
engineering, procurement and con-
struction contract.
The new Emsland KA26 combined-
cycle power plant is designed for me-
dium-load operation (5500 operating
hours per year) and for 200 start-ups
per year, and is able to generate elec-
tricity and supply steam. The plant
operates at ambient temperatures
of between -20° and 40°C and is
equipped with a natural ventilation
wet cooling tower. To maximize the
efficiency of the plant, the Alstom
Integrated Cycle Solution (ICS) mul-
22 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
Owned by RWE Power, a new 876 MWe
GT26-based multishaft combined-cycle pow-
er plant began operations at the Emsland
site in Germany in September 2010.
tishaft configuration with two GT26
gas turbines and one steam turbine
was chosen. The 2-on-1 multishaft
configuration allows the utilization of
a larger steam turbine, compared with
2 x 1-on-1 single-shaft arrangement,
to offer higher overall plant efficien-
cy, which was a key requirement for
this project, the company said.
The project features a number of
new innovations developed by Als-
tom Power. The plant is based on two
GT26 gas turbines that are capable
of fast start and quick response to
changing demand conditions, with
high efficiency and low emissions
even at part load. As well as featur-
ing the latest rating of the GT26 gas
turbine, it also includes innovations
in the water/steam cycle. The plant,
for example, employs Alstom’s opti-
mized for cycling and constructability
(OCC) HRSGs of the “once-through”
type, and is currently one of the largest
CCPP plants in Europe using a once-
through cycle design. The choice of
the once-through cycle principle
meant that for this particular project,
higher live steam parameters could be
used — leading to higher efficiency.
The heat recovery steam generator
also provides heat (hot water) for
preheating the fuel gas to help maxi-
mize the overall plant efficiency and
feedwater for the gas turbine cool-
ing air coolers. The plant delivers a
net efficiency above 59% at full load,
making it currently one of the world’s
most efficient power plants. The plant
also uses the current largest last-stage
blades in the STF30c steam turbine,
which enable more of the energy to
be extracted from the steam.
With this optimized water/steam
cycle, the plant delivers both opera-
tional cost savings to the client by
way of its high efficiency and reduces
the environmental impact through
that improved efficiency, two of the
main targets of the project design.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
GE Energy
Darling Downs Power Station,
Australia
The 640 MW Darling Downs Power
Station, one of the largest gas-fired
continued on page 24
see directlink @ www.dieselgasturbine.com

GE supplied three Frame 9E gas turbines to
the Darling Downs Power Station, one of
the largest gas-fired combined-cycle power
plants in Australia. Shown here is the Frame
9E rotor.
combined-cycle power plants in Aus-
tralia, is the centerpiece of Origin’s
multibillion-dollar investment to pro-
vide cleaner electricity for Queensland.
Constructed by a consortium includ-
ing GE Energy and CH2M Hill, the
plant was successfully commissioned
in the second quarter of 2010.
GE supplied three Frame 9E gas
turbines, three HRSGs and one C-7
combined-cycle steam turbine for the
power island, which emits approxi-
mately half the greenhouse emissions
of a conventional coal plant of similar
size, according to the company. The
9E includes a dry-low NOx combus-
tor system that helps to maintain
emission compliance by extending
the fuel flexibility.
CH2M Hill undertook engineering,
procurement, construction and joint
commissioning activities with GE,
and provided a plant design that helps
to decrease water consumption and is
among the quietest in the world.
The plant uses coal seam gas as fuel.
Recognizing the water shortages
during droughts that Queensland pe-
riodically faces, Origin Energy speci-
fied a plant that used air-cooled con-
densers, which help to decrease water
usage. The CH2M Hill design enables
the Darling Downs plant to use less
than 3% of the water that would likely
have been required by a conventional
coal-fired plant. In addition to in-
24 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
corporating an ultra-quiet air-cooled
condenser, CH2M Hill provided a
one mega-liter/day reverse osmosis
(RO) water treatment plant to pro-
duce ultrapure boiler feedwater.
To further help reduce environ-
mental impacts, the design team
utilized the ground water treatment
system to recover both demineraliz-
er RO reject and evaporative cooler
blowdown wastewater streams, thus
reducing fresh groundwater supply
requirements. In addition, conden-
sate from the air-cooled condenser
was used as waste heat input to a
wet surface air cooler (WSAC) to
reduce off-site wastewater impact.
The WSAC, in combination with
the wastewater recovery operations,
is capable of reducing off-site waste-
water trucking to less than 30% of
the original design.
CH2M Hill and GE coordinated
an international team of in-house de-
signers and engineers, which adapted
industry-leading system designs into
the highly regulated Queensland en-
vironment, with particular emphasis
on the strict gas regulations and the
grid interface. An analysis was per-
formed on all major systems, and the
design was enhanced for safety.
Origin required that the new plant
achieve world-class noise limits. To
achieve strict far-field noise limits at
the plant boundary, GE provided ultra-
quiet combustion turbine-generator
enclosures and CH2M Hill designed
and constructed acoustically tight tur-
bine halls in addition to specifying and
procuring some of the quietest bal-
ance-of-plant equipment available.
The project is located in regional
Queensland, a northeast state of Aus-
tralia more than 200 km from Bris-
bane and 40 km west of Dalby, the
closest town. A 550-bed construction
camp was developed to attract a qual-
ified workforce to the remote site. To
help provide safe travel to and from
the site, busing was provided to avoid
the many hazards typical to bush
driving, including flooding, heavy
fog, dust storms and kangaroos.
The project’s environmental stew-
ardship extended through plant com-
missioning. The commissioning team
evaluated alternate approaches for
cleaning the steam systems and set-
tled on an evolutionary approach us-
ing in-situ hydro lasing, air blow and
degreasing. By eliminating a steam
blow, the team saved over 20 million
liters of water, and an additional four
mega-liters were saved by gaining
acceptable steam quality within 48
hours of unit first-fire.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Guascor
Granarolo S.p.A. Plant, Italy
Guascor, through its Italian sub-
sidiary Guascor Italia, has finished
the commissioning and start-up of
the third combined heat and power
(CHP) plant with its new generation
Miller cycle engines, the HGM560.
The plant has been built in Bologna,
Italy, and can produce 2.4 MWe of
total electrical power through the use
of two HGM560 engines, each one
producing 1.2 MWe of power.
The plant can produce more than
19 million kWh of electrical energy
and 19 million kWh of thermal en-
ergy every year. The energy will be
generated to satisfy the needs of the
Granarolo S.p.A. plant in Bologna.
Granarolo S.p.A. is a market leader
in dairy production, supplying more
continued on page 26
The Granarolo S.p.A. plant in Bologna, Italy,
can produce 2.4 MWe of total electrical pow-
er through the use of two Guascor HGM560
engines, each one producing 1.2 MWe.
 Cutting-edge blades to trim your costs.
With over 1-million hours of F-class operation.
It’s in our power.™

Advanced designs. High-temperature alloys. Advanced coatings. Our industrial gas turbine
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Power Systems

see directlink @ www.dieselgasturbine.com

than 30% of Italian milk production
with seven milk processing plants.
The high energy efficiency of the
cogeneration systems guarantees the
reduction of pollutants and will per-
mit important economic savings for
the group, the company said.
A second CHP power plant that
uses this same technology has been
running in Modena, Italy, since the
beginning of summer 2010. The of-
ficial inauguration was held Dec. 16.
The plant produces 3.6 MWe total
(three HGM560 engines, with the
power of 1.2 MWe each). In this case,
the thermal energy is used to inte-
grate a district heating network that
provides heating and hot sanitary wa-
ter to an entire area of Modena. The
plant can produce electrical energy
for the needs of more than 9000 fam-
ilies and, at the same time, recover
thermal energy to satisfy more than
3000 families for an entire year.
The first CHP power plant of 2.0
MWe and the same quantity of ther-
mal energy (two HGM560 engines
with the power of 1.0 MWe each) is
in service at a food processing plant
and has been running in the province
of Ravenna since spring 2010.
Guascor Group is operating in re-
newable energy and high-efficiency
cogeneration around the world. The
company has been present in the Ital-
ian market since 1998 and is recog-
nized for its activity in designing and
building turnkey power plants. Guas-
cor Italia has produced more than
170 CHP power plants that princi-
pally use natural gas and biogas.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Hyundai Heavy
Industries Co. Ltd.
Camaçari Plant, Brazil
Engine and Machinery Division
(HHI-EMD) of Hyundai Industries Co.
Ltd. has supplied 184 engines to two
power plants in Brazil. Utilizing 2500
kW HiMSEN 9H25/33 engines, the two
plants have a total output of 460 MW.
26 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
The in-house, hi-touch, medium-speed en-
gine (HiMSEN) is HHI-EMD’s in-house brand
engine designed with the basic concept of
“Practicality, Hi-Touch and Hi-Tech.”
The two power plants are located
in Camaçari and Candeias, having an
output of 160 MW (9H25/33 x 64
sets) and 300 MW (9H25/33 x 120
sets), respectively. The Camaçari 160
MW plant has been successfully com-
missioned in 2010, while the Cande-
ias 300 MW plant is to complete com-
missioning in the first half of 2011.
The Camaçari, Brazil, 160 MW plant has been
successfully commissioned in 2010. The plant
utilizes 64 HiMSEN 9H25/33 engines.
The Candeias 300 MW power
plant, which consists of 120 HiMSEN
9H25/33 engines, is home to the larg-
est number of HiMSEN engines at a
single power plant.
The HiMSEN engine is HHI-EMD’s
in-house brand engine designed with
the basic concept of “Practicality, Hi-
Touch and Hi-Tech.” It offers low fuel
consumption, eco-friendliness and easy
maintenance derived from its modular
design, according to the company.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
MAN Diesel & Turbo
Powerships, Offshore Africa, The
Middle East And The Mediterranean
A contract with the Turkish company
Karadeniz Powership Co. Ltd. includes
21 MAN Diesel & Turbo 18V51/60DF
dual-fuel engines and three 14V48/60
HFO engines. The total output is 400
MW. The large-bore diesel engines are
to be installed onboard four power-
ships. The first of the three powerships
went into service in May 2010.
The ships are former freighters,
which are converted into floating die-
sel power plants. Thanks to their mo-
bility, they can be connected to local
power grids to temporarily cover de-
mands whenever on-site power plants
are insufficient or new power plants
cannot be built quickly enough. Un-
like power barges — power plants
on pontoons — the “powerships” are
equipped with their own propulsion
Karadeniz Powership Co. uses former freight-
ers that are converted into floating diesel
power plants. Powerships, like the Kaya Bey,
provide midterm power for countries aiming
to avoid electricity shortages.
engines and do not need to be towed.
They are planned for use in Africa,
Pakistan and other regions in the Mid-
dle East and the Mediterranean.
The units are ideal for the planned
purpose. The engine’s fuel flexibility
centers on the capability to operate
on either gaseous or liquid fuel, and
to switch between them seamlessly at
full rated output. The powerships can
make use of the local infrastructure
— be it an oil or gas supply. And that
is not the only benefit the dual-fuel
engines bring: a further advantage of
dual-fuel engines is that when pow-
ered by gas, in particular, they ensure
low-emission and therefore ecologi-
cally friendly combustion.
The 51/60DF engine used for the
actual powerships was first used on
liquid gas tankers, on which evapo-
rated gas from the cargo tanks can
be used to power the engine. MAN
Diesel & Turbo dual-fuel engines
have been gaining in popularity in the
power generation industry for some
time, thanks to their efficiency, fuel
flexibility and environmental benefits
— all factors that have enabled this
relatively new engine to quickly es-
tablish itself on the market.
Karadeniz Powership Co. currently
has three powerships in operation, one
in Pakistan and two in Iraq. Power-
ships are fast-track, quickly deployed,
utility-grade power plants meeting a
country’s urgent demands of electric-
ity. Powerships’ capacities range from
45 to 220 MW and provide midterm
solutions for three to five years with
direct connectivity to local grids from
onboard high-voltage grid stations.
Powerships provide faster transporta-
tion and greater access capabilities.
Reciprocating dual-fuel engines are
installed on powerships, creating ideal
base load and flexible generation capac-
ities. State-of-the-art waste-heat recov-
ery systems allow for future flexibility
to support desalination solutions.
The powerships provide power to
countries aiming to avoid electricity
shortages, increase time for decision-
makers to bridge generation gaps and
choose the best long-term solution for
their country. “Powerships are more
economical than short-term solu-
tions, suffering from shortage, oper-
ating existing old power plants. And
they have an immediate impact on
sustainable growth of the economy,”
said the company. “Powerships have
state-of-the-art technology with high
quality and fast delivery, and have no
completion or site risk.”
Operation of powerships is ideal in
areas with poor logistic infrastructure.
They are unaffected by floods, landslides
and earthquakes, and have minimal use
of land space — a mobility advantage
for future use in other locations.
Additional details on Karadeniz Pow-
ership vessels can be found in June
2010, D&GTW, p. 29.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
MWM
Precision Energy Ltd. Plant,
Banlgadesh
Mannheim, Germany-based MWM
has shipped 15 gas gen-sets with an
output of 4 MWe each to Bangladesh.
The project was started in spring 2009
and was installed in spring 2010. Ac-
cording to MWM, this short timeline
was achieved thanks to planning and
production of the 15 gen-sets within
three months.
The buyer is a power plant of Preci-
sion Energy Ltd., a specially formed
subsidiary of a group of companies in
Bangladesh. Bangladesh, with its pop-
ulation of about 150 million, is one
of the most densely populated coun-
tries. Meanwhile, the country’s daily
demand for electricity has grown to
5200 MW, compared to 4000 MW
actually produced. With its 15 large
gas gen-sets, the natural gas-powered
plant in Ashugong, will generate a
This Precision Energy Ltd. natural gas-
powered plant in Ashugong, Bangladesh,
will generate a total of 60 MWe.
total of 60 MWe. All of the electrical
power will be fed into the public grid
to help supply the demand of electric-
ity in Bangladesh.
Shortly before this project, in spring
2009, MWM launched an efficiency
package including further develop-
ments in combustion technologies
Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 1 27
and charging to increase the electrical
efficiency of the TCG 2032 gen-sets
up to 43%. This was an improvement
MWM shipped 15 gas gen-sets with an output
of 4 MWe each to the Ashugong power plant.
of 2.6%. At the same time, the elec-
trical power was increased to 3000
kW for the V12 and 4000 kW for the
V16. Due to continuous development
and improvement, the orderable gen-
sets today have reached an electrical
efficiency of 43.5% with an electri-
cal output of a maximum 4300 kWe.
Additionally, the MWM TCG 2032
combines durability and low lube-oil
consumption. The zero-pressure gas
train and the optimized high-pressure
turbocharger ensures continuous sup-
ply of full power, even under tropical
conditions, the company said.
In Asia, the MWM products are
marketed by the company’s own
subsidiary, MWM Asia Pacific Ltd.,
in Singapore. This location enables
the company to ensure quick service
and supply of spare parts in the entire
Asia/Pacific region and also for the 15
gen-sets installed in Ashugong.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Siemens Energy
Irsching 5 Combined-Cycle Power
Plant, Germany
On May 17, 2010, after around two
years of construction, the Irsching 5
combined-cycle power plant near In-
golstadt, Germany, was put into op-
eration in an official ceremony. The
continued on page 28

Irsching 5 combined-cycle power plant near
Ingolstadt, Germany.
owner of the new plant is Gemein-
schaftskraftwerke Irsching GmbH
(GKI), a project company consisting
of E.ON Kraftwerke GmbH, N-ERGIE
AG, Mainova AG and HEAG Südhes-
sische Energie AG. E.ON Kraftwerke
is responsible for plant operation.
Siemens built the 847 MW (net)
plant as a turnkey project. “With its
high efficiency level, and the associ-
ated low emissions, along with its
short start-up times, this plant sets
new standards for this performance
class,” said Michael Suess, CEO of the
Fossil Power Generation Division of Portfolio totaled about US $36.7 bil-
Siemens Energy. lion (E28 billion).
This new natural gas-fired plant SEE DIRECTLINK @
is equipped with two SGT5-4000F WWW.DIESELGASTURBINE.COM
gas turbines, one SST5-5000 steam
turbine, three hydrogen-cooled gen- Solar Turbines Inc.
erators with electrical systems and Calabasas Landfill Gas-To-Energy
the SPPA-T3000 I&C system from Facility, U.S.A.
Siemens. Thanks to its F-class gas
turbine technology and the quadru- Start-up phase for the Calabasas
ple-flow low-pressure steam turbine, Landfill Gas-to-Energy Facility in
this plant now achieves an efficiency Agoura, California, U.S.A., began on
level of more than 59.5%, thus mini- June 1, 2010. Commercial opera-
mizing its CO2 emissions. The state- tion was declared on July 12, 2010.
of-the-art burner technology used at The plant broke new ground for
the plant also keeps NOx emissions
at a low level (<15 ppm). Irsching 5
is designed for 250 starts annually.
The plant reaches its full output in
only 30 to 40 minutes to account
for the more stringent grid require-
ments with regard to the integration
of wind power.
Combined-cycle power plants are
part of Siemens’ Environmental Port- The Calabasas landfill gas-to-energy facility
folio. In fiscal 2010, revenue from the in Agoura, California, U.S.A.

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The Calabasas landfill gas-to-energy facility in
Agoura utilizes three Mercury 50 gas turbines
from Solar Turbines Inc.
operation on very low Btu landfill
gas while simultaneously achieving
industry-low emission levels.
Plant equipment consists of three
Solar Turbines Inc. Mercury 50 gas
turbines, ISO rated at 4.6 MW each,
three 150% gas treatment, blending
and compression skids, continuous
emissions monitoring (NOx), and
miscellaneous support equipment.
Strict local landfill gas surface emis-
sion limits combined with local soil
conditions result in landfill gas that
averages only 30% methane, as com-
pared to typical landfill gas, which
usually runs around 50% methane.
In 2004, the fuel’s low quality posed
a problem, as there were few tech-
nologies available that could burn the
Calabasas landfill gas. There was not
enough fuel to make a boiler/steam
turbine plant economically feasible.
Reciprocating engines could not oper-
ate with fuel of this low quality, which
left industrial gas turbines as the most
reasonable alternative. However, the
South Coast Air Quality Manage-
ment District’s emission restrictions
for gas turbines provided no margin
on actual performance. Therefore, no
manufacturers would guarantee their
equipment to meet the set limits. The
Los Angeles County Sanitation Dis-
trict (LACSD) became aware of Solar
Turbines’ Mercury 50, a DOE-funded
low-emission, high-efficiency gas tur-
bine, and proposed using it at Cala-
basas. Though the Mercury had been
designed strictly for natural gas, Solar
took on the challenge of modifying it
to burn landfill gas.
Prior to this time, Solar required a
minimum of 40% methane for its tur-
bines. After testing the Mercury 50 in
the factory with simulated landfill gas
(natural gas diluted with CO2), Solar
guaranteed operation down to 32%
methane. However, for initial plant
start-up, 40% methane would be re-
quired; six months of on-site testing
was stipulated to achieve operation on
the 32% methane fuel. The facility air
continued on page 30
Gas compression and siloxane removal at the
Calabasas plant.
permit allowed the LACSD to blend
up to 25% methane to the landfill gas’
methane. Slight adjustments to the
landfill gas collection operation, plus
the addition of natural gas, allowed
the two parties to meet. The project
was launched.
Six years after the original idea,
plant start-up began. As initially
planned, the turbines were initially lit
off with fuel having 40% methane or
more. Once the units were running, it
was decided to attempt operation on
lower quality fuel. Rather than taking
six months to adapt the Mercury 50 to
the 32% methane fuel, it was done in
one day. A few days later, the turbines
were starting and operating success-
fully on unblended fuel, which has
been the case ever since, Solar said.
In addition, the Mercury’s emissions
were unaffected by the fuel’s low qual-
ity, with emission source test results
averaging 7 ppm NOx and 3 ppm CO
(at 15% O2) on all three turbines.
SEE DIRECTLINK @
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Tognum, MTU
Onsite Energy
Giessen-Marburg University Clinic,
Germany
Large quantities of electricity, cool-
ing power and heat are needed to
run a clinic. The university clinic of
Giessen-Marburg, Germany, for ex-
ample, has around 1150 beds and
consumes on average 35 000 kWh
daily. The clinic — one of 50 run by
healthcare provider Rhön-Klinikum  AG and Giessen’s public utility.
AG — is to generate over half of its
energy requirement in-house instead
of using the public grid. That is the
reason for the clinic’s decision to opt
for a combined solution from MTU
Onsite Energy using three comple-
mentary technologies: gas-powered
combined heat and power modules
(CHPs), a fuel cell for trigeneration
(heat, power and cooling) and diesel
engines for standby power gen-sets.
It is the first time that all three tech-
nologies are to be combined at one lo-
30 J a n u a r y - F e b r u a r y 2011 Diesel & Gas Turbine Worldwide
Three GR 385 N5 (top) gas-powered com-
bined heat and power modules (CHPs) in
combination with a HotModule HM346
fuel cell (middle) provide electricity, heat
and cooling at the Giessen location of the
University Clinic of Giessen and Marburg,
Germany. Two standby gen-sets driven by
MTU 20V 4000 G23 and 12V4000 G23 die-
sel engines provide parts of the clinic with
emergency power should the public grid
break down.
cation, the company said. The power
supply will be controlled by Ener-
giezentrale Giessen GmbH, a compa-
ny specially set up by Rhön-Klinikum
Combined cooling, heat and power
generation will be achieved by three
natural gas-powered GR 385 N5
CHP modules based on Series 400
12-cylinder gas engines in combina-
tion with a HotModule HM346 fuel
cell also driven by natural gas. Heat
and power will be generated cost-
effectively and sustainably with an
outstanding overall efficiency of up to
90%. The fuel cell is to take up the
base load while the combined heat
and power modules will be automati-
cally switched online and offline ac-
cording to requirements. Two diesel
gen-sets powered by MTU Onsite En-
ergy engines will provide the clinic’s
standby power.
The electricity generated through
combined cooling, heating and power
will be fed to the power supply. Each
of the three CHP modules will be
laid out for 385 kW electrical output,
while the fuel cell generates 345 kW.
Any surplus power will be fed into
Giessen’s public grid.
Thermal energy or heat will be har-
nessed from the waste heat produced
by the fuel cell and engines and from
the high-temperature emissions of
the CHP modules. The HotModule
will be capable of 230 kW thermal
output, while the engine on each of
the CHP modules will generate 231
kW, plus about 260 kW in the form
of emissions. The clinic will utilize
the thermal energy in two ways —
for heating the building and provid-
ing hot water and for air condition-
ing using absorption refrigerators.
For clinics especially, combined
cooling, heating and power is an
ideal solution. Ultra-modern facili-
ties, in particular, need higher cool-
ing capacities, for example for their
IT installations, large-scale medi-
cal equipment, operating theatres
and for air conditioning the build-
ing as a whole. According to Rhön-
Klinikum AG, cooling its IT installa-
tions alone uses up 12% of its total
energy requirement. In 2008, the
clinic inaugurated its new pediatric
facility and in spring 2011 another
new building with an additional 650
beds is to be opened. Thus, the com-
bined heat and power modules will
not just be activated for spikes in
demand, but, like the fuel cell, work
around the clock.
Next to the fuel cell and CHP mod-
ules, MTU Onsite Energy is to supply
two diesel engines for the standby gen-
sets, which will provide parts of the
clinic with emergency power should
the public grid break down. In this
continued on page 32
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event, the larger of the two gen-sets,
driven by a 20V 4000 G23 diesel en-
gine, will ensure that building facilities
continue to function, while the smaller
unit with a 12V 4000 G23 diesel en-
gine will feed power to medical equip-
ment. A standby gen-set based on an
MTU engine has been in operation in
the pediatric facility since 2008.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Wärtsilä
Aliaga Power Plant, Turkey
The Aliaga power plant in Aliaga,
Turkey, was inaugurated on Sept. 29,
2010. It is so far Wärtsilä’s largest gas-
fired power plant based on recipro-
cating technology.
The Aliaga combined-cycle power
plant, situated within ALOSBI, has been
built in three phases. The first phase
was contracted in 2006, with two ex-
tensions added later in 2008. Wärtsilä
equipment was specified for all three
stages of the plant’s development. Alto-
gether, the power plant has 28 Wärtsilä
20V34SG gas-fired generating sets and
two steam turbines manufactured by
Skoda. The plant has the capability to
produce more than 270 MW of elec-
tricity in combined-cycle mode.
The two steam turbines are con-
nected on the steam side with exhaust
gas boilers, one for each of the 28 gas
engines. It is not necessary to operate
all gas engines at the same time to pro-
vide steam, but about 20% of the gas
An internal view from one of the two power buildings of the Aliaga plant shows a row of 12
Wärtsilä 20V34SG gas engines.
32 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
The Aliaga, Turkey, combined-cycle gas power plant, producing more than 270 MW of electric-
ity, is based on 28 Wärtsilä 20V34SG gas engines and two steam turbines in a combined-cycle
arrangement.
engines have to be supplying steam
to make the steam plant operate. The
nominal steam conditions to the steam
turbines are 15 bar and 340°C.
The main contractor for the entire
plant has been the Turkish electrical
engineering and contracting company
Özyavru. It has had the total respon-
sibility for the entire construction of
the Aliaga Power Plant. Besides Wärt-
silä being the supplier of the gas power
generating sets and Skoda of the Czech
Republic providing the steam turbines,
a large number of Turkish subcontrac-
tors have been involved. Mavi Proje has
done the civil works and the company
HT provided the mechanical part of the
plant. Balikesir Electromechanical In-
dustrial Plants Corp. has delivered the
bulk of transformers for the plant.
At the time of the inauguration,
six of the Wärtsilä engines were run-
ning, with the remainder to come on-
stream as soon as the transmission
line investment serving the plant has
been completed. The electricity pro-
duced by the Aliaga plant will be sold
to the Turkish spot market through a
balancing mechanism, and will serve
around 350 000 households.
“This is a proud day for Wärtsilä,”
said Vesa Riihimäki, group vice presi-
dent, Wärtsilä Power Plants. “The
Aliaga Cakmaktepe power plant is the
world’s biggest gas-fired power plant
based on reciprocating combustion
engines. It stands as testimony to the
efficiency and reliability of our power
plant technology.”
Wärtsilä has a workshop located on-
site to provide full-service support to
the plant’s operations, and also main-
tains the first phase (four engines pro-
ducing 35 MW of energy) of the Aliaga
Cakmaktepe power plant under a
maintenance agreement. “We are com-
mitted to fully supporting Turkey’s
rapid economic growth with efficient
electricity-generating solutions, and
this commitment is evidenced by the
fact that we already have two offices
employing 110 people established in
the country,” said Riihimäki. a
SEE DIRECTLINK @
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Turbine Overhaul & Repair by roberta prandi
Siemens Joins Power Diagnostics
And Specialty Monitors
Power Diagnostics remote monitoring system can be combined with Siemens specialty monitors for power plant
operation and maintenance
As fossil fuel-powered energy
plants are becoming more sophis-
ticated and as they are increasingly
being used to balance power needs
XX J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
“Renewable energy, like wind and so-
lar energy, is of increasing importance,
but especially wind power is not easy
Blade tip vibration
to forecast and not at all under control
monitoring and
of the utilities due to the nature of the
blade stress diag-
wind,” said Andreas Feldmüller, head
nostics are among
of service technology implementation at
several specialty
Siemens AG - Energy Service Division.
monitor and diag-
“As a consequence, the volatile re-
nostic systems of-
newable energy will be fully supplied
fered by Siemens.
to the grid and the remaining power
demand — less predictable and more
fluctuating than in the past — will
have to be covered by the existing
power plants. This will lead to more
and faster start-ups and more frequent
of fluctuating renewable resources, part-load operation with fast load
the flexibility and reliability of the ramps to increase or decrease power.”
power plants will need to be more To this extent, Siemens developed
closely monitored. continued on page 34
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Turbine Overhaul & Repair
several systems called specialty moni-
tors to continuously observe specific
components or functions in a plant.
“Specialty monitors work as stand-
alone as well as add-on solutions,
though the highest benefit can be
achieved by connecting these moni-
tors to a higher-level diagnostic plat-
form,” explained Feldmüller.
In combination with a diagnostic
platform, it is possible to combine
data from the monitors with informa-
tion from standard plant DCS to cor-
relate and process all data together.
In addition to the operation moni-
tors typically displayed in the control
room of the power plant, specialty
monitors give additional insight in
the behavior or condition of individ-
ual plant components.
“For example, the foreign object
detection system (FODS) continu-
ously monitors the potential loss of
combustion chamber parts to protect
the turbine blades and vanes from
subsequent damage caused by foreign
objects,” Feldmüller said.
“The system detects potential block-
ages of the first row vanes and there-
fore prevents consequential damage
of turbine blades and vanes.”
FODS is an acoustic system based
on the analysis of structure-borne
noise and the detection of burst sig-
nals produced by the impact of loose
parts to the chamber or to the guide
blades of the turbine.
The next example is a specialty
monitor that measures the blade tip
vibrations of a steam turbine’s last-
34 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
Schematic of Sie-
mens single-shaft
rotor train with spe-
cial monitoring and
diagnostic systems.
stage blades. “This module may have
a special importance for plants that
operate in a more flexible manner, as
low-load operation may create higher
stresses in the blades than full-load
operation,” said Feldmüller.
Another specialty monitor in this ap-
plication is related to generators and
other high-voltage components, as de-
scribed by Feldmüller, “The specialty
monitor Siemon HF 10-2 is designed
to detect partial discharges and to give
power plant operators advance notice
of possible damage to insulation. These
partial discharges bridge a portion of the
high-voltage insulation, and their high-
frequency nature can be detected.”
While specialty monitors are often
stand-alone systems, Siemens allows
customers to adopt these tools ac-
cording to the operators’ needs, fol-
lowing a three-level approach.
“The first level uses specialty moni-
tors to allow the operators a closer
and continuous look at the perfor-
mance or condition of their compo-
nents. The equipment is permanently
installed in the plant and the opera-
tor judges trends and deviations from
normal behavior on his own,” Feld-
müller said. “In this case, several spe-
cialty monitors may also be connected
to a higher-level diagnostic platform.
“In the second level, a Power Di-
agnostics service contract is signed
between the customer and the equip-
ment supplier to involve the engineer-
ing expertise of the supplier to judge
the plant components.”
In such instances, expert-based
diagnostics takes place in defined in-
tervals such as monthly or quarterly.
The specialty monitor’s data, includ-
ing operational values from the plant
controls, is sent to Siemens via CD/
DVD or a network data exchange.
The third level of the service con-
cept for specialty monitors uses a daily
Power Diagnostics service. “Data from
the specialty monitors or a higher-
level diagnostic platform is sent with a
certain set of predefined operational data
to the Power Diagnostics Centre (PDC),
which allows the use of advanced Sie-
mens diagnostic tools to correlate all
available plant data and analyze trends
and unexpected deviations with the help
of the expert network,” Feldmüller said.
Power Diagnostics is Siemens’ data
acquisition system, first commissioned
in 1998. Nowadays, approximately 400
units are monitored worldwide, includ-
ing gas turbines, steam turbines, gen-
erators and combined-cycle balance-of-
plant equipment.
Power Diagnostics uses a data acqui-
sition system at the site, which trans-
fers the plant data to the Siemens net-
work to detect deviation from normal
behavior. Siemens Power Diagnostics
engineers check data consistency and
completeness on a daily basis.
“The PC-based data acquisition sys-
tem is passively connected to the con-
trol system, receiving data from the I&C
system along a one-way nonreactive-
data highway, with no influence to the
site’s I&C system,” said Feldmüller.
The site-based data acquisition sys-
tem also has real-time data viewing
capabilities and graphing tools that
can be used locally by plant person-
nel as well as remotely per customer
request for immediate expert support.
Training is also available by the Pow-
er Diagnostics engineering technician
during installation of the system.
Feldmüller also emphasized that the
Power Diagnostics uses software based
on standard, commercially available
products. These tools are completed
with proprietary software for diagnos-
tics, data processing and data mining
using OEM knowledge. A
SEE DIRECTLINK @
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see directlink @ www.dieselgasturbine.com
Training & Education
Worldwide Training
Program Started By MTU
Young people training in Friedrichshafen and several other locations
around the world, within the Tognum group
Starting September 2010 apprentic-
es and students all around the world
have been involved in their vocational
training with the various subsidiaries
of Tognum group.
“Anyone who aims to develop,
build and maintain outstanding pro-
pulsion and power plants must have
a workforce trained to outstanding
standards. That’s why our German lo-
cations have always placed particular
emphasis on high-quality vocational
training and it’s why our companies
abroad are now doing the same,” ex-
plained Joachim Coers, Tognum CFO
and executive board member with
responsibility for human resources,
and director of labor relations at
Tognum’s largest subsidiary, MTU
Friedrichshafen, Germany.
With a total of 83 young people in
training from the Cooperative State
University in Friedrichshafen, Ger-
many, that MTU location receives the
lion’s share of the new generation of
employees. Sixty students are starting
courses in industrial mechanics, con-
struction mechanics, technical pat-
36 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
tern making, mechatronics and elec-
tronics for automation technology,
while two others are beginning their
training as technical draftspersons.
In addition, seven young people are
embarking on commercial training
courses and a further 14 are under-
taking integrated studies programs at
the Friedrichshafen location, leading
to Bachelor of Engineering, Bachelor
of Arts or Bachelor of Science quali-
fications. In total, 311 young people
are currently training at the Lake
Constance, Germany, location.
Training programs are also un-
der way at the German subsidiaries
L’Orange and MTU Onsite Energy
Gas Systems in Augsburg, Germany,
as well as at the Tognum SKL location
in Magdeburg, Germany.
In Stuttgart and Glatten, Germany,
13 L’Orange trainees are starting their
courses while one student has begun
a Bachelor of Engineering study pro-
gram in October. Three young peo-
ple will be starting three-year courses
in mechatronics in Augsburg, and in
Magdeburg, four students are start-
At MTU Friedrichshafen, 83 young people
from the Cooperative State University
started training in September 2010. The
same training model has been adopted
within the Tognum group by MTU South
Africa and MTU Asia.
ing vocational training in machining
technology, mechatronics and in-
dustrial mechanics.
A structured program for train-
ing future assembly technicians has
now been in place at MTU South
Africa for three years, and five new
trainees will soon learn about the
intricacies of engine assembly and
servicing. “Our system closely re-
sembles the German model and
uses both workshop training and
vocational college courses to pre-
pare our young people for their jobs
as assembly technicians,” explained
Michael Baumann, managing direc-
tor MTU South Africa.
In October 2010, for the first time,
14 aspiring assembly technicians be-
gan training as after-sales workshop
technicians at five MTU Asia locations.
“This program aims to cover our very
real need for good next-generation
technicians,” said Peter Kneipp, pres-
ident MTU Asia. “With its solidly
founded technical training programs
designed to prepare the workforce of
the future, Tognum is not only creat-
ing a worldwide basis for future suc-
cess, it is also offering young people
the chance to achieve top-class
vocational qualifications and secure
excellent career prospects,” said
Matthias Jobmann, head of human
resources at Tognum. A
SEE DIRECTLINK @
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Marine Propulsion
Island Tug and Barge’s Island Defender tows 25 000 barrel fuel barges and 5500 tonne deck
barges. The vessel received an overhaul complete with its third set of engines.
A Powerful Defender
Island Defender tug gets Cummins repower
The Island Defender tugboat has
had its share of jobs and homes
since it was built in 1977. The tug
was originally built as the Hamil-
ton Bailey and was used for log tow-
ing in Vancouver, British Columbia,
Canada. Later, the boat was shipped
to the Great Lakes and renamed the
Josee M. Eventually, the well-traveled
tug made its way back to the Pacific
Coast and sold to Vancouver’s Island
Tug and Barge, where it was renamed
Island Defender.
Originally, the tug was outfitted with
a pair of 358 kW Caterpillar D346
main engines. When it was relocated to
the Great Lakes, it was repowered with
a pair of Detroit DDEC V16-92 engines
rated 820 kW each at 2100 r/min.
Now back in Vancouver and working
for Island Tug and Barge towing 25 000
barrel fuel barges and 5500 tonne deck
barges, the vessel received an overhaul
complete with its third set of engines.
For its third set of engines, the 21
by 7.28 m Island Defender received
a pair of Cummins KT19s rated 373
kW each. The reduced output from
the previous Detroit engines will ac-
tually increase the tug’s profitability
as Canadian crewing regulations re-
quire a full-time engineer in tugs with
more than 746 kW, and the smaller
engines use less fuel.
The engines are soft mounted and
connected to the drivetrain via a Centa
Link coupling, a design expected to re-
duce vessel noise. Cummins also sup-
plied the engine monitoring and con-
trol panels in the main wheel house.
Also added were a Krill fuel man-
agement and monitoring system, new
shafts and Kobelt shaft brakes, Rice
nozzles and propellers and a pair of
John Deere gen-sets.
Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 1 37
Island Tug opted to keep the exist-
ing ZF 5.037:1 gears and sent them
out to be refurbished and adapted
from the direct link they had to the
old engines to a flexible link to the
new Cummins engines.
The new Rice nozzles and three-
blade propellers were installed with
the trailing edge of the nozzles
cut away to all the placement of
the rudders within 15 to 18 cm of
the wheels for improved handling.
Even with the reduction in power
output from the main engines, the
new configuration is expected to
produce improved performance. Is-
land Tug said that according to RAL
predictive graphs, the new nozzles
will produce a static bollard pull of
15 422 kg, and with a 5500 tonne
barge, the vessel should run at 7
knots loaded and 9 knots empty —
an efficiency increase of 8%.
In addition to the new powertrain,
the tug received additional upgrades
and fixes. The sponsons were opened
up, blasted, painted inside and divid-
ed into four compartments before be-
ing resealed. The entire bulwark steel
around the aft deck and stern was re-
placed, the towing pins were updated
with new parts and the Burrard single
drum winch was rebuilt.
Some of the bunk rooms and the
galley were also refurbished, and the
deck was refinished with a sound
dampening system that includes lay-
ers of a cork-concrete mix and per-
forated aluminum topped with an
acrylic flake finish. The entire project
took about a year to complete. A
SEE DIRECTLINK @
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The 21 by 7.28 m Island Defender
received a pair of Cummins KT19s
rated 373 kW each. The engines
are soft-mounted and connected
to the drivetrain via a Centa Link
coupling, a design expected to re-
duce vessel noise.
Industry News

The Model 352B70 sensor (left) has a ±5000 g measurement range and a titanium housing to ensure durability in harsh environments. The Model
400B76 (right) allows users to read Transducer Electronic Data Sheet (TEDS) from sensors and write TEDS to sensors with a single mouse click.

New Accelerometer And Interface Kit

From The PCB Group
PCB Piezotronics Inc. introduces Model 352B70 accelerometer; The Modal Shop unveils Interface Kit Model 400B76

PCB Piezotronics Inc. has released
the newest sensor in its family of ac-
celerometers designed for extreme
testing in shaker labs. PCB Piezo-
tronics, a member of the PCB Group,
manufactures accelerometers, force
sensors, load cells, microphones,
pressure transducers, pressure trans-
mitters, strain sensors, torque sensors,
vibration sensors, signal conditioners,
cables and accessories.
The Model 352B70 has a ±5000 g
measurement range to accommodate
the varying amplitudes experienced
during high random vibration test
profiles. It features a built-in two-pole
low-pass filter to reduce the possibili-
ty of saturation due to high-frequency
energy and is hermetically sealed in a
titanium housing to ensure its dura-
bility in harsh environments.
The sensor is also electrically
isolated to prevent unwanted elec-
trical interference or ground loops
and has a low-mass design, weigh-
ing 4.3 g, the company said. It also
comes with mounting studs and an
adhesive base to allow for a variety
of mounting capabilities.
The Modal Shop, a division of the PCB
Group, has released the latest version of
the Transducer Electronic Data Sheet
(TEDS) Interface Kit, Model 400B76.
The Modal Shop specializes in sound
and vibration sensing systems for the
multichannel, acoustics, modal and
NVH markets. In addition to sensors,
calibrators and system sales, a wide ar-
ray of test equipment is available in its
rental program.
The new kit offers the capability to
communicate with TEDS sensors over
the USB port of a Windows-based com-
puter. A graphical interface allows users
to read TEDS from sensors and write
TEDS to sensors with a mouse click.
The kit supports multiple IEEE
1451.4-compliant TEDS sensors. The
principal types of supported transduc-
ers are single-axis and triaxial acceler-
ometers, impact hammers, impedance
heads, charge amplifiers, microphones
and microphone preamplifiers.
Model 400B76 supports IEEE 1451.4
and IEEE preliminary templates, which
include IEEE transducer templates num-
bers zero to 28, as well as manufacturers’
templates such as the geometry formats
established by LMS International.
According to the company, the
kit is designed for reading, verifying
and updating TEDS sensor informa-
tion and format, including calibra-
tion information. a
see directlink @
www.dieselgasturbine.com

38 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide

Featured Products

JMP Impellers
JMP manufactures
rubber impellers that
feature a special surface-
coating designed to de-
crease wear and tear for Repairs to
longer use, according
to the company. De- diesel engine
veloped with a unique components
composition of rub-
bers, JMP’s impellers
for the marine
are designed to endure harsh marine conditions. JMP offers flex- and power
ible impellers for Caterpillar, Cummins, Doosan (Daewoo), DDC, industries
Jabsco, John Deere, Johnson Pump, Kashiyama, Komatsu, Mit-
subishi, Onan, Sherwood, Volvo Penta and Yanmar engines, with
custom impellers also available.
SEE DIRECTLINK @ WWW.DIESELGASTURBINE.COM

Digital Servo Inclinometer

Meggitt Sensing Sys-
tems, a Meggitt group di-
vision, has introduced the
Sensorex SX41100 series, Typical damage
a servo inclinometer family to cast iron
featuring analog and digital components can
outputs and a maximum be any or all of
linearity error of less than the following:
+0.02% FS. The series is • Corrosion
designed to provide angu-
lar measurements within extreme testing environments, such as • Erosion
those found within offshore platform safety systems, the company • Mechanical
said. The SX41100 series can provide an output signal, propor- Damage
tional to the angle being measured, over a range of +1° to +70°. • Fractures
The series is also a part of company’s rugged enhanced digital sen-
sor (REDS) family, incorporating Meggitt’s Sensorex digital hybrid
compensation circuit design, resulting in inclinometers with +5 V A diesel engine
analog, 4 to 20 mA or RS232 and RS485 ASCII digital outputs. cylinder head
SEE DIRECTLINK @ WWW.DIESELGASTURBINE.COM
repaired/restored
to ‘as new’
High-Temperature Pressure Sensors condition

All work
carries a 12
IMI Sensors, a division of PCB Piezotronics Inc., has launched month guarantee
its Series 176 high-temperature pressure sensors for gas turbine
monitoring. The sensors detect and measure dynamic pressure Samson Road, Hermitage Industrial Estate,
Coalville, Leicestershire LE67 3FP UK
phenomena and combustion instability in extreme heat environ-
Tel: +44 (0)1530 811308
ments generated by gas turbines. The sensors are also ATEX and
Email: sales@castironwelding.co.uk
CSA certified for use in hazardous areas, the company said. The Web: www.castironwelding.co.uk
sensors are suited for gas turbine monitoring with sensitivities up
to 2.5 pC/kPa and ranges from 1.3 to 27.6 bar static.
SEE DIRECTLINK @WWW.DIESELGASTURBINE.COM
continued on page 41

see directlink @ www.dieselgasturbine.com

Power Generation

Kohler’s new Decision-Maker Paralleling System is a fac-

tory prototype-tested system engineered to provide a
reliable, expandable paralleling capability for the com-
pany’s line of industrial gaseous- and diesel-powered
generator sets from 100 kW to 3.25 MW.

A Standard Decision On Paralleling

Kohler’s new Decision-Maker system designed for expandable paralleling capability

Kohler Power Systems has intro-
duced a standardized approach to
paralleling backup power generation
systems. The new Decision-Maker
Paralleling System is a Kohler de-
signed and branded, factory prototype-
tested system engineered specifically
for gen-set paralleling and can be
specified across Kohler’s entire line of
industrial gaseous- and diesel-pow-
ered generator sets from 100 kW to
3.25 MW.
“With Decision-Maker Paralleling
System, Kohler Power Systems offers
an alternative to large-kilowatt sin-
gle-generator backup power systems,
as well as the traditionally complex,
highly customized approach to par-
alleling,” said Jim Kukla, marketing
manager, industrial generators, Kohler
Power Systems. “Paralleling doesn’t
need to be a complex exercise, which
is why Kohler focused on developing a
factory prototype-tested system.
“Because Kohler took the initiative
to design an end-to-end system and
test each component together, speci-
fying engineers and electrical contrac-
tors don’t need to worry about power
system component interface problems
and can find peace of mind in the reli-
able redundancy, power output flexi-
bility and system scalability attributes
that define Kohler’s Decision-Maker
Paralleling System.”
The new paralleling system incorpo-
rates three components — the Decision-
Maker 6000 control unit, a power dis-
tribution switchboard and a master
control panel. In a multigenerator ar-
ray, each generator comes equipped
with a DEC 6000, Kohler said. The
unit provides interconnected commu-
nications for power synchronization
and load sharing as well as system pro-
tective functions and breaker control
through system-wide monitoring of
generator frequency, voltage and load.
The power distribution switch-
board provides a power output con-
solidation hub and houses the neces-
sary breakers for the generators and
loads. By combining the power from
multiple generators, Kohler said the
switchboard provides the final de-
sired power output to support a facil-
ity’s electrical load needs.
Adding enhanced capability to the
Decision-Maker Paralleling System,
Kohler’s Master Control Panel (MCP)
supports load shedding/adding based
on critical load needs. Designed with a
full system graphical interface, the MCP
monitors system electrical and mechan-
ical loads, and includes event logging
and alarm functionality. In addition to
load management, the MCP also facili-
tates generator management, balancing
operating hours across the paralleled
generator sets to equalize maintenance
needs, the company said.
“The Decision-Maker Paralleling
System delivers the same backup pow-
er production as a single high-output
generator, but with redundancy and
thus more reliability, flexibility and
fuel options — and in a cost-compet-
itive manner,” Kukla said.
In paralleling environments, the
standby power source is backed up
through having multiple generator
sets at the same site. As a result, criti-
cal loads have multiple layers of re-
dundancy and enhanced power reli-
ability. As a factory prototype-tested
system, Kohler said the Decision-
Maker Paralleling System facilitates
future expansion of generator set fa-
cilities, while easing the initial capital
cost of a backup power system in the
near term. Specifying engineers and
electrical contractors can install a gen-
set configuration that meets a facility’s
current electrical load requirements
but can also expand the generator ar-
ray in a streamlined fashion as power
demands grow, Kohler said. A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM

40 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide

Featured Products

Intelligent Valve signed for remotely controlling motors
Controller in industrial areas where flammable
gases are present.
Optitrol’s heavy-duty enclosure con-
fines electrical arcing, preventing igni-
tion of flammable atmospheres found
in chemical plants, refineries and other
classified industrial areas during the op-
eration of motors and other electrical
equipment, the company said. The mal-
leable iron enclosure and its cover have
a triple coat of zinc, chromate and epoxy
powder to prevent corrosion.
O-Z/Gedney uses its global design exper-
tise to offer Optitrol in dozens of possible
combinations of products. All are available
in both dead-end and feed-through 12.7
mm, 19.1 mm and 25.4 mm hubs. Heavy-
duty contacts are rated 10 Amps, 600 Vac.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
continued on page 55

Metso has upgraded the Neles intel-

ligent valve controller, ND9000, which
now incorporates a range of enhance-

Reduce Steam & Gas

ments to the device’s diagnostics, con-
trol performance, robustness and com-
missioning. The ND9000, which was
first released in 2003, is designed to
help process plants improve process
Turbine Outage Time
efficiency through control valve con-
structions, Metso said. The upgraded CENTRALIGN® Ultra Expert
ND9000 has a reduced calibration time
• Tops-on and tops-off measurements
of 30 to 75%, depending on the actua-
tor volume, as well as better reactions to • Alignment in diameters ranging from 120 mm - 5000 mm up to 40 m distance
buttons and a running index to display • Detection of deformations and ovalization of elements
the progress of a calibration run. • Control sensor monitoring and automatically correcting any laser drift
SEE DIRECTLINK @
• Optimal choice of centerline for entire assembly with minimal correction
WWW.DIESELGASTURBINE.COM
values for each element

Control Stations, • Instant display of corrections

for each bore
Pilot Lights

O-Z/Gedney has a new line of factory-

sealed, explosion-proof and dust-ig-
nition proof control stations and pi-
lot lights. The products, part of O-Z/ w w w. p r u f t e c h n i k . c o m
Gedney’s new Optitrol series, are de-
see directlink @ www.dieselgasturbine.com

Pruftechnik_JanFeb11WW.indd 1 11/22/10 10:18:39 AM

Turbine Overhaul & Repair by amanda m. klemp
An Ensemble Cast
At Chromalloy
New casting facility expands turbine component manufacturing capabilities
Chromalloy, a company that re-
pairs and manufactures new parts for
gas turbines, has opened a new cast-
ing facility in Tampa, Florida, U.S.A.
The facility expands upon previous
capabilities, tripling the company’s
Tampa location capacity to manufac-
ture components for the hot section
in gas turbines used in power genera-
tion, marine, heavy-frame industrial
and aero applications.
The new casting facility in Tampa
was designed to pour up to 136 kg of
alloy at any given time for turbine hot
section parts such as blades, vanes,
nozzles and shrouds.
The site is also equipped to cast
larger frame IGT parts that the com-
pany didn’t have the capacity to do
before. Chromalloy installed larger
material handling devices, larger fur-
naces and larger testing inspection
equipment. The company is now
42 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
equipped to manufacture parts that
will fit up to a 122 cm envelope and
weigh 68 to 79 kg.
Tom Trotter, vice president and gen-
eral manager of Chromalloy Castings in
Tampa, said, “We’ve got some terrific
repair techniques that we’re applying
in the power generation markets and
those are opening up possibilities.”
Chromalloy’s business concept is to
offer customers an alternative to OEM
repairs and replacement parts.
Trotter explained, “Chromalloy
has developed many proprietary re-
pair techniques that we utilize, and
our business model is different. We
would prefer to repair a part and not
have the operator going through the
expense of buying a new spare part.
But, if we can’t repair it, we have the
capability now — with the expansion
in Tampa — to be able to produce the
part for the operator,” he said.
Chromalloy opened a new
castings facility in Tampa,
Florida, U.S.A., expanding
its manufacturing capabili-
ties in both quantity and
size of gas turbine hot sec-
tion components.
The company offers design engi-
neering, tooling, casting, machining,
repair technology and coatings.
“Despite the fact that Chromalloy
has the full design capability, we typi-
cally use the OEM design as kind of
the baseline,” said Trotter, explaining
the engineering that goes into cast re-
placement hot parts for turbines.
“Because we do have the design and
analysis capability — and because we
do repairs on these parts — during
the repair cycle, we know and we’ve
been able to build a database on what
the failure modes of these individual
components are.
“So in many cases what we will do
is redesign the part to address those
failure modes and be able to provide a
better part to the operator than what
the OEM might be running with to-
day,” said Trotter.
The company said it develops its
own intellectual property by reverse
engineering parts produced by the
original equipment manufacturers.
Once the part is designed, it goes
through a casting process, which
Chromalloy said can meet tolerances
as tight as five- to eight-hundredths of
a millimeter.
Chromalloy employs investment
turbine overhaul & repair

tion. During the testing process, each

Chromalloy installed larger material handling devices, larger furnaces and larger testing in-
spection equipment. The company is now equipped to manufacture parts that will fit up to a
122 cm envelope and weigh 68 to 79 kg.
casting to manufacture its aftermar-
ket parts. The process begins by in-
jecting a wax pattern. With the pat-
tern, the mold assembly is produced
and the assembly is then dipped six
to seven times in a ceramic slurry.
Once dipped, the wax is removed
from the ceramic shell and the melted
alloy is poured into the shell. The
shell is then removed and the parts
are removed from the gating. From
there, they go to finishing and inspec-
manufactured component is x-rayed
for quality control.
Because aero turbines make up
the majority of the company’s busi-
ness, Chromalloy has to manufac-
ture those turbine components up
to FAA standards and regulations.
As a result, Chromalloy engineers
and manufactures all components
for all industries it services up to
FAA standards.
Along with the opening of its new
facilities, Chromalloy also announced
plans to expand the new facility to
produce its own ceramic cores on-
site. The ceramic cores are used in the
molding process to form the air pas-
sageways in hollow components.
The expanded Tampa facility re-
places the previous Tampa location.
The company said it was important
to build the new location within 15
to 20 minutes of the old to retain its
workforce. A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM

Let’s
generate
ideas.
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API_HeatTransfer_JF11_WW.indd 1 1/11/11 4:11:11 PM

Industry News & Analysis
Total installed cogeneration capacity by installation size (in GWe) for combined heat and power (CHP) in Europe, with expected growth projec-
tions including micro-CHP to 2050.
Update On European Energy Policies
COGEN Europe summarizes the situation with European energy goals, strategies and the revised CHP directive
The EU energy and climate goals
(20% reduction in CO2 emissions,
20% renewables in end-use energy
and a reduction of 20% of primary
energy use by 2020) have been incor-
porated into “Europe 2020,” the new
economic strategy adopted by the Eu-
ropean Council in June 2010.
As part of this strategy, the flagship
initiative “Resource-efficient Europe”
aims, among other things, to decou-
ple economic growth from the use
of resources. The energy and climate
objectives for 2020 now form an inte-
gral part of this strategy.
The wider use of the cogeneration
principle contributes centrally to Eu-
rope achieving its energy efficiency
and CO2 reduction targets. Hence,
the next 12 months, which contain
increased focus on European energy-
efficiency policy through an action
plan and new legislation, also involve
Information supplied by COGEN Europe, a
European trade association that promotes
cogeneration power technologies.
44 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
scrutiny and revision of the policies
around cogeneration.
Cogeneration was recognized by
the EU in 2004 as having a funda-
mentally beneficial role in improving
energy efficiency in Europe and was
the focus of a specific Cogeneration
Directive as a result. The Directive
has two main thrusts. First, it sets
out the fundamental definitions for
high-efficiency cogeneration in the
EU, establishing that a high-effi-
ciency cogeneration plant will save
a minimum of 10% primary energy
compared to separate production
and enabling cogeneration to gain
aid and support from Member States
within the state aid guidelines. Sec-
ond, the Directive commits the 27
EU Member States to a succession of
analysis, reporting and action, which
when pursued will increase the use
of cogeneration principle across a
wider range of economic and soci-
etal sectors.
COGEN Europe is leading a Euro-
pean project of independent stake-
holders monitoring the Cogeneration
Directive implementation by the EU
Member States. The project, called
CODE (www.code-project.eu), is
partly funded by the European Com-
mission under the IEE program.
CODE produced the first analysis of
Member States’ reports on the po-
tential of cogeneration in Europe to
2020. It was the first to reveal that,
collectively, the 27 Member States
identified 120 GWe of additional
economic potential for CHP across
Europe by 2020.
The Member States approached
the analysis unconstrained apart
from the high-efficiency definition of
the Directive. Additionally, the proj-
ect showed the considerable barriers
that still exist to new cogeneration,
largely around connection to the
grid, and also the different commer-
cial returns that can be expected in
different Member States depending
on the degree of energy market lib-
eralization and the support mecha-
nisms in place.
Industry News & Analysis

Remarkably, all Member States have some support

mechanism for cogeneration, however, few are effec-
tive. Of those that are effective, Germany and Belgium
set the benchmark for what is required for success, as
both countries having successfully stimulated growth in
cogeneration under their support schemes. The CODE
project is now in its final phase and will develop a pro-
posal for a European Cogeneration Roadmap for Europe
to be published in June 2011. Want to prevent
fouling?
What is the role for cogeneration to 2050? 2010
saw the first modeling and projections of how Europe
might move to a de-carbonized electricity supply for
2050. COGEN Europe published the industry’s own
projections of the role of cogeneration to 2050 on Dec.
1, 2010. The report highlights the foundation role that
the cogeneration principle can play in a resource-effi-
cient Europe and, taking into account future projec-
tions in fuel mix to 2020, charts the expected growth
of cogeneration — including micro-CHP — through
to 2050.
What is clear is that cogeneration has a huge amount to
offer in energy efficiency, CO2 reduction, innovation and
jobs in the near and medium term. Moreover, it is one of
the few realistic de-carbonization options open for high-
temperature industrial heat.
The drive to energy efficiency will be a leading theme
of the next few years in energy policy, and rightly so.
Europe needs to be resource efficient in a time when
budgets are being cut and unemployment is rising. The
size of the energy-efficiency challenge was highlighted in
November 2010 by DG Energy of the European Com-
mission, which published its latest assessment of prog-
ress toward the 20% energy savings target for 2020. By
its most recent projections, and taking into account all
existing energy-efficiency legislation, Europe will achieve

Ask us how!
energy savings of only 9% by 2020 compared to its target
of 20%. There has never been a better time for Member
States to support cogeneration. Fouling is a major problem for most tur-
In November 2010 the EU published its new energy bomachinery operators. One solution is
strategy “Energy 2020.” Echoing one of the main themes a well designed air cleaning system and
of the COGEN Europe report, “Cogeneration as the foun- the right filter choice.
dation of Europe’s 2050 low carbon energy policy,” the
Energy 2020 strategy advocates a far more demand-ori- Want to know more? Give us a call - today!
ented approach to energy thinking, putting the users at
the heart of strategy rather than the suppliers. The new
strategy puts energy efficiency as the first priority for en- Camfil Farr Power Systems
ergy policy in this time of economic recovery and energy
and climate challenges. Within energy efficiency, cogen- EUROPE/ASIA AMERICAS
Sweden tel: +46 33 178500 Canada tel: +1 450 6293030
eration is highlighted as a principle that must be more Germany tel: +49 421 478860 Toll-free tel: +1 800 9769382
India tel: +91 124 4874100
strongly promoted.
The options for cogeneration in new EU energy strategy MIDDLE EAST OCEANIA
Dubai tel +971 4 8871796 Australia tel: +61 7 33757066
will be extensively covered in the upcoming COGEN Eu-
rope Annual Conference on March 24, 2011, in Brussels,
Belgium. For more information on this event, visit www.
cogeneurope.eu. A www.camfilfarr.com
SEE DIRECTLINK @ WWW.DIESELGASTURBINE.COM

see directlink
see directlink @
@www.dieselgasturbine.com
www.dieselPrOGress.cOm

Camfil_JF11_WW.indd 1 1/4/11 10:07:21 AM

Power Generation by roberta prandi
Cultivating Biogas-Fueled Power
MTU introduces Series 4000 biogas engines for CHP applications
When the profit margins from con-
ventional agricultural crops, such as
corn, cereals or potatoes, dropped in
Germany at the end of the 1990s, many
farming enterprises looked for alterna-
tive ways of doing business and increas-
ing revenue. One avenue that gained
interest rapidly was the installation of
biogas-fueled combined heat and pow-
er (CHP) plants. Further increasing in-
terest were subsidies from the German
government for producing electricity
from biogas under specific conditions.
Reinhard and Hermann Gross, who
owned a 1800 ha farm in Löningen,
Germany, opted to expand their op-
eration with a biogas CHP plant. In
2001, the brothers founded GF-Bio-
Energie Hasetal GmbH, and built
a biogas-operated heat and power
plant, fueled by agricultural waste,
manure and chicken dung.
Initially, the power plant comprised
46 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
10 dual-fuel aggregates, each deliver-
ing a maximum of 80 kW power. At
the same time, a biogas plant with five
anaerobic digesters was built.
With time, the stringent emis-
sions regulations and the need for
higher efficiency pushed the two
brothers to rethink the concept of
their biogas plant and they switched
to Otto gas engines.
Thus, in 2008 three CHP modules
by MTU Onsite Energy were installed,
featuring the company’s 400 Series
biogas engines with an electrical out-
put of 350 kW each.
Based on this experience, it was a
short step for the two entrepreneurs
to decide to try a pre-series unit of the
new MTU 4000 Series biogas engines,
which successfully completed practi-
cal trials at the farm, surpassing about
7500 hours of operation. In Decem-
ber, MTU announced the biogas Se-
The MTU Onsite
Energy CHP mod-
ule installed at GF-
Bio-Energie Hasetal
GmbH, featuring
a new 12-cylinder
4000 Series biogas
engine, with 1166
kW electrical power,
over 1300 kW ther-
mal output and an
electrical efficiency
of 42.5%.
ries 4000 engines would be available
to market in March.
A CHP module with a 12-cylinder
4000 biogas engine rated for 1166
kW of electrical power and over 1300
kW of thermal output was installed in
2009. The GC 1166 B5 module pro-
duces electricity and heat, and has the
same output as three of the previous
modules operated by the 400 Series
engines. MTU Onsite Energy also said
the new unit registered an electrical
efficiency of 42.5%.
The manufacturer said the new 4000
Series biogas engines are based on the
diesel engine from which a natural gas
version was already derived.
Some design and manufacturing
changes were introduced for use with
biogas, such as more robust steel pistons
and modified combustion chamber ge-
ometry. The engine control system was
also adapted for biogas operation.
 Power Generation
The assembly line of the 4000 Series engines at the MTU Onsite Energy plant in Friedrichshafen,
Germany. The new biogas versions will be introduced to the market in stages beginning in
March 2011.
After six months in operation, the
engine was inspected at the MTU head-
quarters in Friedrichshafen, Germany.
The company said all components,
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including the newly designed ones,
showed virtually no sign of wear.
Since October 2010, the CHP
module with the 4000 Series biogas
Telephone: +44 (0)1522 516655  www.napier-turbochargers.com
engine has been working as a base-
load unit for the biogas plant, with
the smaller 400 Series modules work-
ing as satellite units. These satellites
will produce power and heat for local
use, optimizing the utilization of the
produced heat.
The 12-cylinder 4000 Series bio-
gas engine was also equipped with
a catalyst that will reduce the emis-
sions of formaldehyde. So the CHP
plant by GF-Bio-Energie Hasetal
GmbH will profit not only from the
state contribution for biogas electric-
ity production, but also from an ad-
ditional formaldehyde bonus by the
German government.
MTU Onsite Energy announced
that the market introduction of the
4000 Series biogas engines for power
generation will take place in stages
from March 2011, with 8-, 12-, 16-
and 20-cylinder versions covering
an output range from around 770 to
2000 kW. a
see directlink @
www.dieselgasturbine.com
Oil & Gas by dj slater
AEP Joins Effort To Build
More Efficient CO2
Compression System
Investment grows in supersonic shockwave compression technology
American Electric Power (AEP) has
committed US$2 million to support
the commercial development of ad-
vanced compression technology for
carbon dioxide (CO2) as part of an
ongoing initiative that includes the
U.S. Department of Energy’s National
Energy Technology Lab (NETL), Ram-
gen Power Systems LLC and Dresser-
Rand. The initiative is developing a
supersonic shockwave compression
system that will reduce the cost and
energy consumption associated with
compressing CO2 for storage in porous
rock formations deep underground.
Sequestering CO2 in underground
formations requires compressing the
gas to more than 103 bar. Existing
compression technology represents a
substantial part of the capital and op-
erating costs of developing CO2 cap-
ture and storage systems. Ramgen’s
advanced compression system will use
supersonic shockwaves to compress
CO2 for capture and storage, accord-
ing to the company. If successful, the
shockwave compression technology
is projected to reduce the capital cost
of CO2 compression equipment by as
much as 50% and reduce operating
costs of a carbon capture and seques-
tration (CCS) system by at least 15%.
48 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
Ramgen used the Rampressor test rig to show-
case the capabilities of a shockwave compres-
sion system.
“If we are successful, this system
will be a game changer,” said Peter
Baldwin, Ramgen’s president. “The
industry has been good with incre-
mental change, and this has the po-
tential to be a game changer.”
Compressor designs for CO2 cap-
ture and storage demand a pressure
ratio of 100:1 and require stainless-
steel construction in the presence of
water vapor, according to Ramgen.
The most significant cost, however,
comes from the aerodynamic design
practice that limits the design pres-
sure ratio per stage on heavier gases.
Ramgen’s proposed system would
be able to reach the 100:1 pressure
ratio in two stages of compression
instead of eight, which is typical for
most compressors, according to Ram-
gen. The compressor system, which
could run at about 8 MW, could
achieve about 39 kg/sec. at a 10:1
pressure ratio, Baldwin said.
The technology behind this sys-
tem comes from the Rampressor, the
company’s core design, which fea-
tures a rotating disk that operates at
the high peripheral speeds necessary
to achieve supersonic effect in a sta-
tionary environment, said Ramgen.
The rim of the disk has three raised
sections and cavities that mimic the
effect of the center-body and chan-
nels of a conventional ramjet inlet.
Air enters through a common inlet
and is then ingested into the annu-
lar space between the supersonically
spinning disk and the outer edge of
the casing, according to the company.
When the air flow enters this space,
the raised sections of the rim create
a “ramming” effect, generating shock
waves and air compression. The disk
chambers are angled, so the com-
pressed air is rotated into a collector
and then into the compressed air sys-
tem. The compression process is also
oil free, requiring no oil for lubrica-
tion or sealing, according to Ramgen.
The idea behind using shockwaves
in compressors originated with Shawn
Lawlor, Ramgen’s founder and chief
technology officer. Lawlor knew that
the U.S. Air Force had spent consid-
erable money and research in super-
sonic flight capabilities to improve the
effectiveness of shock compression,
Baldwin said. He then wondered if
that technology could be applied to
stationary equipment.
The idea became a reality about 10
years in the making. In recent years,
other entities have taken notice of
Ramgen’s work, AEP being the latest.
Before AEP, the U.S. Dept. of Energy
provided a four-year, US$11 million
grant for Ramgen to develop the com-
pressor system. On Aug. 10, 2009,
the Dept. of Energy awarded Ram-
gen a US$20 million grant from the
American Recovery and Reinvestment
Act in order to accelerate the develop-
ment of a commercial-scale unit. The
Oil & Gas
A cross-section of the Rampressor test rig.
commercial product, the HP-12, is
the high-pressure stage of a matched
set that would be suitable for 200 to
250 MW coal-fired power plants, ac-
cording to Ramgen.
Ramgen said that its proposed su-
personic shockwave compression
system offers four distinct advantages
when compared with existing com-
pressor technologies. The system can
achieve high compression efficiency
and is capable of producing very
high, single-stage compression ratios.
The system’s simplicity and size make
it less expensive to manufacture, and
it is capable of significant waste heat
recovery, according to Ramgen.
“I think that I speak for the entire
company in saying that it is very re-
warding, both personally and pro-
fessionally, to be involved in such
an important initiative,” Baldwin
said. “At some point in our careers,
we all say ‘We want to make a dif-
ference.’ The folks at Ramgen are
making a difference.”
AEP’s involvement is another set of
good news for Ramgen, Baldwin said,
especially considering its work in ad-
vancing CCS technologies. AEP be-
gan capturing and sequestering CO2
Oct. 1, 2009, from 20 MW of the flue
gas at its Mountaineer Plant in New
Haven, West Virginia, U.S.A., using
chilled ammonia technology devel-
oped by Alstom. The company said
that the Mountaineer CCS project is
the first integrated CO2 capture and
sequestration project at an operating
coal-fueled power plant.
On Dec. 4, 2009, AEP received
US$334 million in funding from the
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“Advancing technologies to cap-
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dioxide from coal-fueled power
plants is critical if we are going to
reduce global concentrations of
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AEP executive vice president, Gen-
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Rail Traction
GE’s Trip Optimizer calculates the optimal speed profile for a trip based on the specific train’s
makeup and route and then automatically controls the throttle to maintain that planned speed
to save fuel.
Saving Fuel Through
Speed Control
GE Transportation Trip Optimizer for rail applications
determines optimal speed
GE Transportation has developed a
technology, under the ecomagination
umbrella, designed to reduce fuel
consumption in locomotives by calcu-
lating the optimal locomotive speed.
GE’s Trip Optimizer was found to
save 12.5 million liters of fuel (a 7%
average savings) in the first 8 million
kilometers of track run using it.
The Trip Optimizer functions like
an intelligent version of a car’s cruise
control, said GE. It calculates the op-
timal speed profile for a trip based on
the specific train’s makeup and route,
and then automatically controls the
throttle to maintain that planned
speed to save fuel.
The software integrates into the lo-
comotive’s control system and moni-
tors performance while utilizing GPS
tracking to evaluate routes, and plots
optimal train velocity on the opera-
tor’s display. The locomotive opera-
50 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
tor sets the parameters for trip time
and velocity.
It was designed to operate in ei-
ther automatic control or advisement
mode. Automatic control maintains
the planned speed automatically,
while advisement mode informs the
operator which throttle and dynamic
braking levels to use to optimize fuel
efficiency and speed, said GE.
In auto control, a real-time closed-
loop control system continually ad-
justs throttle application based on
data fed back to the controls from
the train. Speed and acceleration
data are fed into the operating sys-
tem, processed and commands are
sent to the engine to automatically
govern the throttle.
The system comprises a wireless
system, onboard planner, closed-loop
control and operator interface.
Using energy and momentum
equations, the system uses train
weight, length, power output, track
profile for grade and curve informa-
tion received over a wireless connec-
tion — this is all automatic so the
engineer doesn’t have to manually
enter it. The onboard planner then
takes the information and calculates
the optimal velocity for fuel savings,
said GE. Once under way and in au-
tomatic mode, the system is designed
to continuously monitor the planned
velocity and actual velocity and uses
the closed-loop control logic to keep
the train’s speed on course.
The system also monitors actual
power consumed against the plan,
and if there is a noticeable difference
the system will automatically set a new
plan for optimal fuel consumption
and speed. Factors that may induce
differences include errors in weight
or length data, locomotive power de-
rate, wind and others, said GE.
The Trip Optimizer is fully inte-
grated into the locomotive. The con-
trol software is updated to include
the system’s functionality, a configu-
ration developed for a seamless flow
of locomotive data to operate the
unit while minimizing lag time for
the commanded control requests, ex-
plained GE.
It is also configured with the fac-
tory displays so the verification of
train data, the rolling map and situ-
ation awareness information for the
auto control can be accessed on one
of two built-in displays.
The Trip Optimizer can be installed
either as an OEM factory installation,
such as with GE Evolution locomo-
tives, or as an aftermarket system.
Pierre Comte, president GE Trans-
portation Intelligent Control Sys-
tems said, “Trip Optimizer generates
fuel savings ranging from 3 to 15%
per locomotive depending on terri-
tory as measured by North American
train operators. It is a significant ele-
ment in the future of fuel conserva-
tion with the added benefit of reduc-
ing emissions for railroads around
the world.” A
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Power Generation

LSA 40 Low-Voltage
Alternator
New compact alternator for rugged applications

Ipsen delivers
The LSA 40 al-
ternator by Leroy-Somer solutions.
is a new product in the
company’s Partner low- With more than 60 years of thermal
voltage range. The alternator is a four-pole, processing expertise, Ipsen provides
three‑phase alternator with power ratings from 10
the solutions heat treaters need to
to 23 kVA at 1500 r/min and 12.5 to 28 kVA at 1800 r/min.
be successful.
The Leroy-Somer Electric Power Generation division • Energy and cost efficiency
has introduced the LSA 40, a four-pole, three‑phase alter-
nator offering power ratings from 10 to 23 kVA at 1500 • Reliable and robust equipment
r/min for 50 Hz and 12.5 to 28 kVA at 1800 r/min for 60 • Manufacturing and service
Hz. The alternator is also available in a dedicated single-
phase version.
locations worldwide
LSA 40 comes with two field excitation versions: shunt, • 24-hour service
with high starting capacity, and AREP, with high starting
capacity and short-circuit capacity. • Aftermarket support –
Available in a single-bearing or two-bearing version, LSA parts and service
40 has been designed to be mechanically suitable for most • Engineered components –
engines on the market. It is also interchangeable with alter-
upgrades and retrofits
nators from the previous Leroy-Somer Partner range.
The company said the LSA 40 is a compact, versatile al- • Thermal processing and furnace
ternator, characterized by high efficiency levels, allowing maintenance training
more electric power from the same engine.
In addition, it has low reactance, which gives it a high ca- Visit www.IpsenUSA.com and learn
pacity for starting electric motors and the ability to withstand more about our TurboTreater® and
disturbance from distorting loads, said Leroy-Somer. TITAN® vacuum heat treating systems.
According to the manufacturer, LSA 40 is simple to in-
stall and has a modular terminal box for ease of access to
the terminals and the AVR. It was designed to be small and
lightweight. Due to rugged construction, LSA 40 is able to
operate in demanding applications.
Leroy-Somer’s EPG division specializes in low-, medium-
and high-voltage alternators, with a power range between SPEED UNIFORMITY EFFICIENCY
3.5 and 2360 kVA for low-voltage and between 1 and 20
MW for low-, medium- and high-voltage products suitable
for a wide variety of applications. A
SEE DIRECTLINK @ WWW.DIESELGASTURBINE.COM

see directlink @ www.dieselgasturbine.com

Marine Propulsion
The LNG carrier Castillo de Santisteban is powered by five MAN Diesel & Turbo dual-fuel 51/60DF
engines. The order for the engines is the first received for this engine type, said MAN.
MAN Powers LNG Carrier
Five dual-fuel MAN 51/60DF engines to form diesel-electric propulsion plant
MAN Diesel & Turbo is playing a
part in powering a 300 m LNG carrier.
Five dual-fuel MAN 51/60DF engines,
each delivering 8000 kW at 514 r/min,
serve as the diesel-electric propulsion
plant for the new LNG vessel Castillo
de Santisteban, which was delivered
by Korean shipbuilder STX Offshore
& Shipbuilding to shipping company
Empresa Naviera Elcano.
The vessel has been assigned by her
charterer, Spanish energy company
Repsol – Gas Natural LNG (Stream), to
the Peruvian Camisea/Pampa Melcho-
rita gas project, a gas liquefaction plant
in South America. The carrier has a
carrying capacity of 173 600 m3 LNG.
“When it comes to ship propulsion
technology, the future is gas,” said
Klaus Deleroi, senior vice president,
MAN Diesel & Turbo SE. “Not only for
LNG carriers, but also for cargo vessels,
ferries and even cruise liners. Knowing
this, it is important for MAN Diesel &
Turbo to have a strong reference already
at sea with our new 51/60 dual-fuel en-
gine, and that is exactly what we have
with the Castillo de Santisteban.”
The entry of the LNG vessel into ac-
tive service represents a milestone for
MAN Diesel & Turbo in that the order
for the ship’s dual-fuel engines was the
52 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
first received for this engine type, said
the company. The engine is designed
for LNG carrier and gas-fueled ship
propulsion systems and focuses on the
safety requirements stipulated by clas-
sification societies for gas operation.
MAN Diesel & Turbo’s 51/60DF
dual-fuel engine offers a 1000 kW per
cylinder output at 514 r/min for 60
Hz generator sets in both its gaseous
and liquid-fuel operating modes. For
marine applications, it is offered in in-
line versions with six, seven, eight and
nine cylinders and vee-configuration
versions with 12, 14, 16 and 18 cyl-
inders in a power range from 6000
to 18 000 kW, according to MAN
Diesel & Turbo.
The engine model uses the com-
mon rail micro-pilot fuel-injection
system for liquid fuel, which is nec-
essary when running on gas to ignite
the air-gas mixture. The system en-
sures independent control of injec-
tion timing, injection pressure and
injection volume.
When running on liquid fuel, the
51/60DF works with a conventional
fuel-injection system, injecting the fuel
oil through a separate main fuel injector
in a camshaft-actuated pump-line-noz-
zle system. The fuel injection control
is integrated within the engine’s Safety
and Control System (SaCoSone).
The SaCoSone allows the engine to
operate safely in both modes while
keeping fuel consumption and emis-
sions optimized. In gas mode, the sys-
tem controls various parameters for
each cylinder independently, including
air-fuel ratio, load, valve timing, pilot-
fuel injection and charge-air tempera-
ture. This creates optimal combustion
while permitting operation within a
wide range of the air-fuel ratio, avoid-
ing incomplete-ignition failures, mis-
firing or knocking, the company said.
The 8L51/60DF engines are de-
signed to run on gaseous fuels, such
as vaporized LNG or liquid fuels of a
wide quality range (HFO/MDO/MGO),
and have low emission levels. At 1.5 g/
kWh (IMO cycle E2) in gaseous-fuel
operating mode, the 51/60DF com-
plies with future IMO Tier 3 limits for
NOx without the need for exhaust-gas
treatment or any other countermea-
sures, the company said. A
SEE DIRECTLINK @
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The engine room on the LNG
carrier Castillo de Santistenban
contains five Man Diesel & Tur-
bo dual-fuel 51/60DF engines.
Oil & Gas by amanda m. klemp
Dresser Waukesha has introduced a power generation configuration for its 275GL Series of
gas engines, offered with both the 16-cylinder 16V275GL+ (seen here) and the 12-cylinder
12V275GL+ gas engines.
Dresser Waukesha Rolls
Out New Gen-Set
New 275GL+ engines offered for oilfield power generation configuration
Dresser Waukesha has introduced
a power generation configuration for
its 275GL Series of gas engines. Pack-
aged as the company’s Enginator gen-
sets, the 275GL+ powered units are
targeted at oilfield applications. The
new power generation units are the
latest additions to the 275GL Series,
which was originally introduced in
2009 for gas compression.
The new gen-sets are offered with
both the 16-cylinder 16V275GL+ and
the 12-cylinder 12V275GL+ gas en-
gines. The 16-cylinder version is rated
3480 kWe at 50 Hz and 1000 r/min
and; at 60 Hz and 900 r/min, the unit
is rated 3110 kWe. The 12-cylinder
model has an output of 2600 kWe at
50 Hz and 2330 kWe at 60 Hz.
In an Enginator gen-set configura-
tion, the engine drives the genera-
tor through an elastic coupling. The
switchgear, which is built and designed
by Dresser Waukesha, is optional in the
package. The engine is water cooled
and the generator is air cooled.
The company incorporated its
proprietary Engine System Manager
(ESM) controls in the 275GL+ en-
gines. ESM includes the central en-
gine control unit, ignition, NOx mod-
ules, ignition coils and harnessing.
For NOx levels, the company said
both the 12V275GL+ and 16V275GL+
engines are capable of 0.5 g/bhp-
hr NOx, 1.8 g/bhp-hr CO and 0.7
g/bhp-hr NMHC emissions levels
without aftertreatment, which corre-
sponds to 1/2 TA Luft NOx levels and
meets the requirements for most non-
attainment areas in the United States.
While the engines were originally
introduced for gas compression ap-
plications, the move to power genera-
tion was fairly simple.
“There are different requirements
for a power generation engine versus a
gas compression engine,” said Douglas
Kiesling, director – design and analyti-
cal engineering at Dresser Waukesha.
“Essentially, a power generation en-
gine needs to run at a constant speed,
while a gas compression engine runs at
a constant load but at varying r/mins.
Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 1 53
“It’s a minimal effort to recali-
brate the engine, but it is an essential
change,” said Kiesling.
He said a combination of changing
the spark, altering fuel delivery and
managing turbocharger wastegate and
bypass calibrations prepared the en-
gine to run at the constant speed and
meet the engine speed requirements
and limits for power generation.
The company said the engines are
designed to run on low-quality gas
pulled right from the ground and to
operate at full power with heating
values down to 23.6 MJ/m3 and at al-
most 70% load. In addition, the air
intake and turbochargers are config-
ured to allow operation at altitudes
up to 1219 m and 914 m, for the 12-
and 16-cylinder versions respectively,
without de-rate.
“One of the things that is unique
about running an engine on field
gas is that the gas that comes right
out of the ground is not the cleanest
fuel. It has a lot of contaminant, lots
of liquids and heavier carbon com-
pounds that haven’t been removed,”
Kiesling said.
“So you need an engine that can
quickly react to those changes in fuel
quality, and the 275 engine is very
good at that,” he explained.
Fuel flexibility was achieved through
a robust combustion process design,
which includes fuel delivery, cylinder
design, air handling and turbocharg-
ers. These elements are configured to
handle a wide range of fuels and fre-
quent swings in fuel quality.
Kiesling explained, “Achieving
great­er fuel flexibility requires wid-
ening the design parameters that af-
fect combustion and matching them
to a wider range of fuel qualities.”
He said Dresser Waukesha targets
specific design parameters to allow
the most efficient combustion pro-
cess for the varying fuel qualities.
Though the 275 GL Series engines
were targeted initially to gas compres-
sion applications, their fuel flexibility
will allow them to work in any appli-
cation with varying fuel qualities. A
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Industry News
FW Murphy Expands
PowerView 101 Flexibility With
New Configuration Software
Newly released software said to offer OEMs lower product development costs, shorter time to market
FW Murphy’s new software package for its PowerView 101 includes several new customiz-
able features.
FW Murphy has announced a new
software package that allows station-
ary and off-highway engine OEMs
the ability to configure its PowerView
display according to their needs.
With the introduction of the new
PV101 3.1 software, engine manufac-
turers can now use a laptop computer
to customize the PowerView 101 dis-
play quickly and easily.
“This new software is in response
to customer demand for a way to
quickly and efficiently change the
parameters of the PowerView 101
on their own,” said Robbie Cap-
tain, product manager at Murphy.
“Prior to the availability of this soft-
54 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
ware, the displays were configured by
Murphy to meet a particular custom-
er’s needs before shipping. Now OEMs
can load their own specific display
configurations in-house with a laptop,
speeding their time to market.”
“Anyone familiar with J1939
communications will be able to use
the software’s intuitive, drop-down
menus to configure the interaction
between the display and the en-
gine,” added Captain. “This soft-
ware will also be very helpful when
testing prototypes prior to produc-
tion, or to make changes on engine
displays,” he said.
The software provides users with
a license key and will be eligible to
receive any future updates. Accord-
ing to Captain, the software will be
especially welcomed by OEMs seek-
ing ways to meet Tier 4 engine com-
pliance. “It will save them time and
money because they can now make
their own changes on-site and no lon-
ger need to send the display back to
us for reconfiguration,” he said.
Since its introduction two years
ago, the PowerView 101 has gained
wide acceptance as a powerful mul-
tifunction tool that allows operators
to monitor several different engine,
transmission or machine parameters
and service codes on a single, com-
pact screen, according to Murphy.
“In that short time span,” according
to Murphy, “it has become the stan-
dard for users that need real-time
monitoring, full diagnostics and
multiple languages.”
FW Murphy, established in 1939,
is an ISO 9001 registered manufac-
turer committed to providing prod-
ucts and services for equipment
management and control. The Mur-
phy product line has evolved from
its original Swichgage, according to
the company, and now includes a
broad range of engine and engine-
driven equipment controls and mon-
itoring systems.
Murphy now offers J1939 instru-
mentation solutions for machinery
such as gas compressors, off-highway
and construction equipment, standby
generator controls, irrigation and wa-
ter pumping. The company said that
it is also an approved supplier to ma-
jor OEMs including Caterpillar, John
Deere and Cummins. A
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Featured Products

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Industry News by roberta prandi
Paradox Engineering Opens Office
In Singapore
The Swiss-based virtual network operator opens Asia-Pacific branch office and launches two product lines
Swiss-based Paradox Engineering
has opened a new branch office in
Singapore. The new location, called
Paradox Engineering Asia-Pacific, is
set to become the company’s business
hub of the Asia Region.
Paradox operates as virtual network
operator (VNO) in the supply of in-
ternational hybrid network solutions
encompassing multiple technologies
such as satellite, managed VPN over
raw Internet and/or customer net-
works, industrial wireless sensor net-
works and automatic meter reading.
This regional office has an immediate-
term plan to team five people, provid-
ing support for sales and operations
in the region, with plans to support
the new operation through the con-
solidated and streamlined approach of
virtual teaming by Paradox Engineer-
ing’s headquarters in Switzerland.
“Our company is able to extend
our customers’ business beyond all
boundaries,” said Gianni Minetti,
Paradox Engineering’s chief executive
56 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
officer. “As we often quote, we are in-
ternational enough to ensure global
coverage but small enough to offer
customer-tailored solutions. With the
opening of our new office in Singa-
pore, we’ll be closer to our customers
and better able to meet their require-
ments and expectations.”
He also said, “In today’s business
world, the tightly coupled capabilities
of virtual network operator, together
with Paradox Engineering’s design and
manufacture of field data collection
solutions, represent the perfect vehicle
for companies wishing to unleash the
potential of these data and transform
them into business opportunities.”
The timing of the Singapore office
opening coincides with the Paradox
Engineering launch of two new product
lines: PE.WSN, an industrial wireless
sensor network platform, and PE.AMI,
automatic meter reading for utilities.
PE.WSN is a complete wireless sen-
sor networking system designed to
provide all the hardware and software
PE.WSN is a complete wire-
less sensor networking sys-
tem by Swiss-based Paradox
Engineering. It was de-
signed to allow a rapid and
cost-effective design and
deployment of a reliable
wireless network for data
acquisition from sensors.
The company also intro-
duced the PE.AMI advanced
metering infrastructure.
elements fundamental to rapid, cost-
effective design and deployment of a
wireless network for data acquisition
from sensors, said the company.
“It represents new opportunities for
accessing information previously con-
sidered unreachable, and unlock and
transform data into a valuable new as-
set for business,” said Minetti.
PE.AMI advanced metering infra-
structure is a high-specification system
including communications hardware
and software, and associated system
and data management software to cre-
ate a network connecting advanced
meters and utility business systems.
These two systems, designed and
manufactured by Paradox Engineer-
ing, are part of its strategy to serve
the market with platforms that ad-
dress the growing demand for en-
ergy management through real-time
and fine-grained data collection, the
company said. A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Marine Propulsion by roberta prandi
Automated And Integrated
Control System
Noris Automation launches its new Norisys4 platform
Norisys4, a new system platform by
Noris Automation, was designed to
be used with the company’s remote
propulsion control system Noristar,
as well as for Norimos, the company’s
alarm monitoring and control system.
“Shipping companies, shipyards and
captains call for integrated, open and
easy-to-use systems, which facilitate
their daily work and guarantee a high
safety level. Modern automation sys-
tems regularly offer numerous options
in addition to process monitoring and
control functions without flooding the
user with data,” said Uwe Ulrich, man-
aging partner of Noris Automation in
Rostock, Germany. “Thus, system in-
tegration, common for a long time in
the industry sector, becomes more and
more prevalent also onboard. A free, programmable serial inter-
“The new control system, Norisys4,
was brought from scratch to maturi-
ty phase in less than one year,” said
Ulrich. “It combines the advantages
of a modular concept with the latest
software and hardware technology,
in a robust construction, designed for
harsh environments.”
He added that the system incorpo-
rates field bus and Ethernet, and re-
moves the strict separation between
PLC and PC technology, reducing
possible error sources.
Visualization is also included in the
system, and data can be accessed from
any Ethernet port using neutral PC
technology, such as notebooks. “Nori-
sys4 brings web technology onto the
ship’s propulsion plant,” said Ulrich.
The communication interface is re-
dundant at both field level and con-
trol level. The core of the system is a
programmable logic controller (PLC)
according to IEC 61131 standard,
with a 32 Bit, 400 MHz processor
and an integrated web server. It offers
sufficient capacity for highly dynamic
applications, plus a reserve capacity.
face, as well as CAN and Ethernet in-
terfaces with two separate transceivers
each, are part of the system. Communi-
cation between control computer and
the newly developed extension boxes
is based on the MODbus standard.
“The efficiently implemented com-
munication structure to the extension
boxes allows for data exchange rates
Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 1 57
Norisys4, the new open auto-
mation platform by Noris, is
based on field bus and Ether-
net communication protocols
and can be used with the com-
pany’s remote propulsion con-
trol system Noristar and with
the Norimos alarm monitoring
and control system.
of more than 500 data words in less
than 250 milliseconds. The extension
boxes and the software offer the pos-
sibility of a compact and customer-
specific setup,” said Ulrich.
Apart from the classic tasks, the new
control system offers added values
through its secure data logging func-
tion, supported by the control com-
puter’s USB interface and a secure dig-
ital high capacity (SDHC) card slot.
“Norisys4 supplies thorough net-
work integration directly on the con-
trol unit. It is represented as a net-
work node with an integrated FTP
server and web server,” added Ulrich.
“System functions displayed in the
ship’s network, remote maintenance
and web-enabled visualization com-
plete the offer with corresponding
onboard infrastructure.”
In addition, the deployment of li-
braries with basic functions as well
as customer-specific libraries are a
permanent feature in the develop-
ment for or with the customer, said
Noris Automation. A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Marine Propulsion
Two Giants Join
In Hercules-C
Two European marine engine manufacturers, MAN Diesel & Turbo
and Wärtsilä Corp., agree to pursue Hercules-C
joint research
Wärtsilä and MAN Diesel & Tur-
bo have announced their continued
partnership for the third chapter of
the Hercules project.
The overall vision of the Hercules
research program is for sustainable
and safe energy production from ma-
rine power plants. The technologi-
cal themes of the Hercules initiative,
since its inception in 2002, have been
higher efficiency, reduced emissions
and increased reliability for marine
engines. However, for taking marine
engine technology a step further to-
ward improved sustainability in en-
ergy production and total energy
economy, an extensive integration of
58 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
the new technol-
ogies is required.
The proposed
Hercules-C project,
expected to run for
three years from
2012 to 2015, ad-
dresses this challenge by
adopting a combination ap-
proach for engine thermal pro-
cesses, system integration and
optimization, as well as en-
gine reliability and lifetime. Wärtsilä and MAN Diesel & Turbo have
In this way, Hercules-C aims for joined together in the Hercules-C project,
marine engines that are able to cost- which aims to reduce fuel consumption,
effectively produce the required while optimizing power production and us-
power for the propulsion of ships age in marine applications.
 Marine Propulsion

throughout their life cycle, with re-
sponsible use of natural resources
and respect for the environment.
Hercules-C follows two earlier Her-
cules projects. In Hercules-A, from
2004 to 2007, large-scale research
platforms were established, with the
main objective being to screen the
potential of a broad range of emission
reduction technologies. Significant
improvements were achieved as a re-
sult of this work.
In Hercules-B, running 2008 to
2011, the quest for reducing emissions
was retained, focusing on several spe-
cific technologies. At the same time,
however, more importance was placed
on improved efficiency and, as a re-
sult, reduced fuel consumption and
fewer CO2 emissions.
The Hercules-C Project is planned
to run over a three-year period and
has a targeted budget of US$24.6 mil-
lion (E19 million), bringing the total
combined budget of the Hercules pro-
grams (2004 to 2015) to US$102.4
million (E79 million).
The specific objectives of Hercules-
C are to achieve further reductions in
fuel consumption, while optimizing
power production and usage. This will
be achieved through advanced engine
developments in combustion and fuel
injection, as well as through the opti-
mization of ship energy management
and engine technologies supporting
transport mission management.
Green product life-cycle technologies
will be introduced to maintain the tech-
nical performance of engines through-
out their operational lifetime. This
includes advanced materials and tribo-
logy developments to improve safety
and reliability, as well as sensors, and
monitoring and measurement technol-
ogies to improve the controllability and
availability of marine power plants.
The third specific objective of
Hercules-C is to achieve near-zero Hercules-C is the third chapter in the Hercu-
emissions by integrating the various les project, which involves both MAN Diesel
technologies developed from the previ- & Turbo and Wärtsilä. The first segment of
ous collaborative research efforts. A the Hercules program began in 2004. By the
SEE DIRECTLINK @ end of Hercules-C, in 2015, the goal is to
WWW.DIESELGASTURBINE.COM achieve near-zero emissions.

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Industry News by brent haight
Turbocharger Design System Software
TurboMatch from Concepts NREC matches a turbocharger design to the specific engine system
Concepts NREC has introduced a
new software product designed to
fill the engineering design gap be-
tween engines and turbochargers.
TurboMatch provides an integrated
approach to the design and analysis
of the complex interaction between
the compressor, turbine and other
components of a turbocharger and
the engine. According to the com-
pany, TurboMatch is the first com-
mercially available software that
allows advanced compressor and
turbine design as part of an overall
engine system.
Headquartered in Wilder, Ver-
mont, U.S.A., Concepts NREC pro-
vides turbomachinery design, engi-
neering services, manufacturing and
CAE/CAM software.
TurboMatch works in conjunction
with Concepts NREC’s Agile Engi-
neering Design System software for
turbomachinery design and analysis,
and targets OEMs, diesel and gas en-
gine companies and organizations
that provide turbocharger design
and engineering.
“We are essentially adding more of
60 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
a front end to everything we’ve had
before,” said George Zitka, senior
sales manager for Concepts NREC.
“This software was developed to fill
a need. Turbocharging internal com-
bustion engines is a key technology.
With tightening emission regulations,
manufacturers are seeing that turbo-
charging is the way to bring emissions
down while still maintaining horse-
power. With a turbocharger, you have
a compressor and a turbine that are
connected by a common shaft so they
need to rotate at the same speed. They
need to have an accurate transfer of
horsepower from one to the other.
“This matching software allows
someone to look at it from a higher
level and figure out what the turbo-
charger needs to look like to match
the engine properly. But then we take
it to the next level by guiding the
whole solution into our pre-existing
software solution, which then gets
into the detail design of what the
compressor looks like, for example.
In the design mode, users can size the
compressor and turbine to meet the
required engine size and boost pres-
TurboMatch allows users to perform
preliminary design of the compres-
sor and turbine in context of a turbo-
charger system.
sure, and automatically match the
power and rotational speed of the two
components,” Zitka said.
According to Zitka, TurboMatch
gives anyone responsible for the de-
sign, specification or building of tur-
bocharged engines a tool for devel-
oping products that meet tightening
emission standards and regulations.
It enables users to change compres-
sor and turbine sizes and then predict
the effect on the match. It also allows
a study of the effect of wastegates,
variable geometry, exhaust gas recir-
culation and component losses on the
match and performance.
“Concepts NREC works with all the
major turbocharger manufacturers,”
said Dr. Nick Baines, distinguished
corporate fellow at Concepts NREC.
“In talking with our customers, we
perceived increasing demand for tur-
bocharger systems that accommodate
smaller engine sizes and lower emis-
sion standards. There was a missing
link between design of a turbocharger
and the overall engine system.” A
see directlink @
www.dieselgasturbine.com
Newsmakers

FW MURPHY: FW Murphy has hired
Marc Pavelick as its regional sales man-
ager for the U.S. Midwest territory, with
a heavy focus on industrial stationary
products. Those products include engine
displays and gauges, instrument panels,
engine and motor controls, annuncia-
tors and sensors. Murphy’s Midwest ter-
ritory includes Ohio, Indiana, Michigan,
Illinois, Wisconsin, Minnesota, Iowa, Ne-
braska, North Dakota and South Dakota.
Pavelick, who has 33 years of sales expe-
rience in industrial engine and other re-
lated industrial and automotive markets,
previously worked as a manager of mar-
ket and business development for Super-
Flow Technologies Group in Des Moines,
Iowa, U.S.A.
since 1989, with her most recent po-
sition being general manager, strat-
egy for Shell chemicals in London,
England. She also was a deputy site
manager and production manager for
Pernis Refinery.
GE OIL & GAS: Andrew Way has been
named vice president of services for GE
Oil & Gas. Way will be responsible for
leading continued growth of the business’
equipment repair, maintenance, upgrade
and remote monitoring and diagnostics
capabilities across all segments of the oil
and gas industry.
Way started his GE career in 1996 in
the sourcing organization of GE Air-
craft Engines. He held roles of increas-
ing responsibility in Aircraft Engines
and Engine Services before moving to
Equipment Services in 2001 where he
continued on page 65

UNIVERSAL PLANT SERVICES: Earl

Cornett, Jesse Jackson and Mitch Yaley,
three compressor specialists within the oil
J. Jackson E. Cornett

M. Yaley and gas industry,

have joined Univer-
sal Plant Serv­­ices.
They have a com-
bined industry ex-
perience in excess
of 75 years with
several well-known
OEMs, according
to Universal Plant
Services. “Their industry knowledge and
experience will be instrumental in the
continued growth and development of
the company,” said Stewart H. Jones, se-
nior vice president of the company.

WÄRTSILÄ: Wärtsilä has appointed

Trudy Schoolenberg as vice presi-
dent of Global R&D in the company’s
industrial operations. Schoolenberg
will be responsible for global research
and development of Wärtsilä products.
Schoolenberg previously worked at
Shell in several leadership positions
Diesel & Gas Turbine Worldwide J a n u a r y - F e b r u a r y 2 0 1 1 61

EuroportIstanbul2011_JF.indd 1 1/7/11 9:38:14 AM

Power Generation by steve hartman
Flexibility And Performance
Staying in “tune” with changing market conditions
Today’s dynamic, rapidly chang-
ing energy markets pose significant
and ongoing challenges for utility ex-
ecutives, managers and power plant
operators. As businesses seek ways
to decrease costs while maintaining
or growing revenue, power plant as-
set owners need to remain flexible as
conditions change. Recent advances
in software technologies and engi-
neered performance for gas turbines
can help plant personnel adapt to
market conditions, even as variables
such as the economy, fuel sources
and regulations continually shift.
One factor that plant owners and
operators must consider is the shift
to cleaner sources of fuel, which may
impact utilization and capacity factors.
Since 1987, nearly 70% of new electric-
ity generation in the United States has
come from gas-fired generating units,
according to “The Future of Gas,” a
study managed by the Massachusetts
Institute of Technology Energy Initia-
tive. This is due to the cleaner-burning
nature of natural gas as a fuel source and
the efficiency improvements made pos-
sible by new combined-cycle gas tur-
bine technology. Consequently, there
has been a trend toward oversupply
of gas-fired generating capacity during
the last 20 years, causing lower capac-
ity factors across the fleet. The recent
economic downturn has added to this
market condition, creating a significant
Steve Hartman is general manager, Thermal
Services Engineering, GE Energy.
62 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
drop in electricity demand. In devel-
oped countries, demand may take three
years or more to return to pre-recession
levels, according to some estimates.
In addition to changing utilization,
the United States is on the cusp of a
significant national policy shift toward
greater regulatory oversight and strict-
er environmental protection require-
ments. For example, according to the
American Public Power Association,
Congress is currently considering 35
different proposed pieces of legislation
with various emission standards that
could take effect between now and
2017. This does not include state and
local regulations that may develop in
parallel with national standards.
Whatever the regulatory course, oil,
gas and power companies will face
new requirements around emissions
and clean water, as well as regulation
of other pollutants. Power generation
providers (some exposed to extreme
operating conditions) must invest in
assets to maintain continuity of serv-
ice, even as emerging regulations add
new considerations for plant opera-
tors and industrial executives.
Electrical generation, transmission,
distribution, metering and consump-
tion also is undergoing a shift that ul-
timately will change the way commu-
nities use power. As the power grid
is wired for two-way communication,
consumers increasingly will depend
on cleaner, smarter and more efficient
sources of power.
Over the next 10 years, renewable
power generation is predicted to
grow at a rate three times that of oth-
er traditional sources, such as coal
or gas, according to the U.S. Energy
Information Administration. This
reinforces the need to upgrade the
world’s aging energy infrastructure.
At a capacity factor well below fossil
units, these new power sources will
require much more reliable sources
of backup power more frequently.
Wind farms and solar generating
stations, for example, cycle natu-
rally during the day. The likelihood
of grid disturbances or power fluc-
tuations will increase as these new
sources of power are integrated.
Traditional fossil plants must prepare
for such transients and be able to either
take advantage of new ancillary markets
around spinning reserve, nonspinning
reserve, VAR support or as a unit that
can provide additional reserve margin
for enhanced grid stability.
All of these issues can increase the
frequency of plant trips and raise op-
erations and maintenance (O&M)
costs. Other potential consequences
may include penalties and fines due to
emissions excursions or operational is-
sues as a result of changing fuel mix,
changes in frequency of the grid or
other grid dynamics. Amidst all these
challenges, generating stations must
ensure that they are available to dis-
patch quickly and reliably when called
upon — ideally without adding signif-
icant hardware or protection systems.
continued on page 64
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POWER-GEN Europe has steadily become the premier conference and exhibition in Europe and the place where Co-located with:
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A three-day event, POWER-GEN Europe features a multiple track conference that offers insightful and thought-
experts in the power industry. The conference is backed up a busy exhibition floor populated by the major
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Co-located with Renewable Energy World Europe and Nuclear Power Europe, POWER-GEN Europe not only
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Power Generation
Addressing the
Flexibility Challenge
The story is not all doom and gloom,
however. Unpredictable market con-
ditions also provide power generation
asset owners with opportunities to take
advantage of both the flexibility and
performance of their units. To respond
to these rapidly changing market condi-
tions, power generation suppliers have
come to companies like GE in search of
a range of tailored, cost-effective solu-
tions that alleviate growing concerns
around technology flexibility.
GE introduced its OpFlex enhance-
ments to help maximize turbine and
plant operating envelopes — enabling
customers to meet the demands of a
changing power market. With highly
variable fuel costs and market capac-
ity, plants are seeking ways to maxi-
mize revenue potential during peak
conditions and reduce operating costs
during off-peak periods.
A key part of these enhancements
is corrected parameter control (CPC),
a new, robust turbine control meth-
odology leveraged from the DLN1+
combustor program. Traditional gas
turbine control uses a single tempera-
ture control curve where multiple op-
erational boundaries are implicit in a
feed-forward control schedule. This
schedule is not corrected for chang-
ing ambient conditions, and so must
be conservative to still accommodate
operation across a wide ambient
range; otherwise, it must be adjusted
or tuned seasonally to ensure proper
turbine operation.
CPC changes the way the turbine
is controlled. Through measurement
of traditional noise parameters (e.g.,
humidity) and separation of opera-
tional boundaries into four separate
control algorithms, turbine operation
can be much more tightly controlled.
This, by itself, enables reduced varia-
tion in turbine NOx and CO emis-
64 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
sions and an expanded low-emission
operating envelope.
CPC is then coupled with an emis-
sions signal from a unit’s CEMS, or
equivalent, to provide real-time emis-
sions feedback. This enables control
parameters that are normally set and
left static following initial combustor
tuning to now be actively controlled
as both load and ambient condi-
tions vary. Turbine performance can
now further be optimized while still
maintaining low emissions, thus in-
creasing turbine operating flexibility.
The variation in emission levels is re-
duced, thus enabling operation closer
to limits with no increase in risk of
exceeding limits.
It is also critical for the unit to per-
form reliably and remain within allow-
able emission requirements. OpFlex
enhancements, for instance, provide
operators with a “slider bar” option that
allows refined control of NOx emission
targets and will automatically maintain
the emissions at the operator setpoint,
while maximizing unit performance.
Improving the
Efficiency Equation
Also essential when considering
gas turbine power plant flexibility
and performance is the option to im-
prove overall output and efficiency
of the unit. As power plants age, as-
set owners expect overall equipment
degradation as well as the inability
to provide as much power as newer,
more advanced machines. One way
that customers have taken advantage
of new technologies — avoiding both
massive capital investment and strict
permitting processes required for new
generating stations — is by maximiz-
ing the existing gas turbine footprint
and supporting systems through up-
grades of the existing machine’s com-
pressor and/or hot gas path. Custom-
ers with older versions of GE’s F-class
machines can improve the overall
performance and recover lost efficien-
cies due to aging equipment or natu-
ral degradation over time.
Hot gas path upgrades can improve
hardware performance and enhance
unit flexibility. These changes can
dramatically improve unit perform-
ance, recovering up to 1% of lost effi-
ciency. This can create significant fuel
savings per megawatt-hour of genera-
tion, as well as 20 or more additional
megawatts of power, should the own-
er decide to increase the overall out-
put of the machine. Owners gain not
only increased performance, but also
decreased fuel costs and lower total
O&M costs per megawatt-hour. Op-
erators also gain the flexibility to pro-
vide the grid with additional power if
the unit is called upon for more gen-
eration. In addition, the replacement
components often extend the overall
life of the asset, reducing the likeli-
hood of equipment downtime due to
maintenance or unplanned replace-
ment of aging components.
Energy markets are changing quick-
ly in today’s environment. Global busi-
ness is in dramatic flux as the econ-
omy gains strength, the pace varying
by geography. As conditions rapidly
change, power plant asset owners can
take advantage of technology advance-
ments to keep pace.
Whether owners seek improved
flexibility or better performance, they
should consult with partners who
can help them operate in a cleaner,
smarter, more efficient manner.
By improving overall unit perfor-
mance and flexibility, owners can
best position their portfolio of power
generation assets to increase revenue,
lower O&M costs and maintain com-
pliance, regardless of market uncer-
tainties around the corner. A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Newsmakers
continued from page 61 the company said. Most recently, he was managed the Asia/ P. Kneipp
was promoted to CEO of GE Equipment with Cenco Inc. a New Brighton, Min- Pacific sales region
Services U.K. nesota, U.S.A.-based supplier of jet en- for the Tognum
In 2007, Way joined the GE Oil & Gas gine testing equipment. Group, replaces
business as its Global Services operations Rainer Breidenbach
leader. He was promoted to Global Sup- STACO ENERGY: J. Hall — who left the
ply Chain & Manufacturing leader in De- Staco Energy Prod- company at the
cember 2008. ucts Co. announced end of 2010 — on
that Jim Hall has the board of man-
M. Locquegnies HORTON: Horton joined the com- agement. Kneipp
has hired Michel pany as its market- joined MTU Friedrichshafen in 1989 as
Locquegnies as ing manager. In this a project manager for marine propul-
its director of in- role, Hall will be sion systems. Early in his career, he was
ternational busi- responsible for all involved in projects that enabled him to
ness development, strategic and tacti- acquire experience in the Asia-Pacific
focusing on the cal marketing, as well as developing a region, where he has worked and lived
company’s devel- brand and communication strategy for since 1997. He began in Singapore, then
opment of inter- power quality and UPS products. Hall is transferred to Australia in 2000, where
national markets, also the president of Blade Systems Alli- for several years he held the position of
particularly Asia and Latin America. ance, an association focused on the de- managing director of MTU’s subsidiary,
Locquegnies has more than 25 years velopment and adoption of blade server MTU Detroit Diesel Australia. Following
of international business experience, technologies. He previously served as the an interim period in the United States
including opening and managing busi- strategic manager for IT markets for Lie- at MTU Detroit Diesel, Kneipp became
nesses in Europe and Asia, as well as bert, Emerson Network Power. president and CEO of MTU Asia Ltd.,
working with OEMs, distributors and the fastest growing Tognum subsidiary,
value-added resellers on a global basis, TOGNUM: Peter Kneipp, who recently in 2004.
 Marketplace see directlink @ www.dieselgasturbine.com

FOR SALE
15.1MW G.E. GAS TURBINE Gas Turbine Plants MAJOR WEBCAST / ONSITE AUCTION
FR5LA GEN. UNIT 3/60/13,800V TUES., WED., THURS., FEB. 15, 16 & 17
(Fri. Feb. 18th, 2011 if necessary)
#2 OIL: (GAS) 1840 HOURS Mid America Engine
By order of the US Bankruptcy Court,
Eastern District of Louisiana, Case No. 09-13964 Preview Date:
Monday thru Friday, Feb. 7th to 11th, 2011
P O W E R G E N E R AT I O N S P E C I A L I S T S

and day before sale.

Auction Location:
Locations thru-out Alabama,
Louisiana, Texas, MIssissippi & Florida
205-590-3505
sales@maegen.com Complete Accumulation of Components to Construct
(2) 49,000-dwt Jones Act Tankers
• Over 10,000 Tons of UNUSED • COMPLETE POWER MODULE
Steel (Plate, Bulb Flats, • (2) SMIT Inert Gas Generators
IMMEDIATE SHIPMENT Structural, Tube) • (2) Titanium, Plate Heat
• Over 6,000 Tons of Modules, Exchangers
CALL: 800-704-2002 Stainless Steel Pipe, Copper
Nickel Pipe
• Life Boat, Rescue Boat,
Anchors and Anchor Chain
FAX: 847-541-5600 and Fittings
• Pipe Racks to be Sold as Scrap
• S-Man Thermal Oil Heating
Systems
WEB SITE: www.wabashpower.com • 100’s of NEW Spools of Wire (2) Framo Hydraulic Power

wabash
RingPower Classified.qxp
444 Carpenter Avenue, Wheeling, IL 60090
PRE-OWNED CAT® POWER SYSTEMS
bash_Nov10_WW.indd 1
• LARGEST USED INVENTORY
• LOW-HOUR GENSETS & POWER PLANTS
• RECONDITIONED & REBUILT
INTERNATIONAL & DOMESTIC INQUIRIES
• Over 100 MW of gas turbines • IN STOCK • • (3) MaK Marine Diesel Engines Units, Rudders
POWER
2/22/10• New1:23 & Used PM Pageunits
Solar Turbine 1 available Type 12 VM32C 5760Kw • (2) Ship Sets of Electrical
EQUIPMENT CO. • Complete turn key plants offered on a “Fast-Track” basis • (4) VEM 4,650 KW Propulsion Including Switchgear,
• 50 Hz or 60 Hz • Low NOx Motors Transformers, and Wire
• Liquid fuel and Dual Fuel available • (2) Ship Sets of L3 Navigation • Backup Generator
and Integrated Bridge Systems • (2) Incinerators
• (4) Lufkin M/N HS5350-KTB • Galley and Kitchen
Parallel Shaft Horizontally Offset Equipment
Reduction Gears • Furniture
9/30/10 2:11:40 PM
MidAmerica_Turbine.indd 1
2011 • Luffing deck Crane & Knuckle Boom
7/7/10 9:02:02 AM
CLASSIFIED Many assets were never used, never installed,
AD RATES and are still in the original shipping crates from vendors
Earlier previews available by appointment. Please contact
Display or non-display classified
Kevin Gamm with Myron Bowling at 1-513-235-6430 or Mark Reynolds
advertising accepted. with Hilco Industrial at 1-205-595-5999.
Rate is $130.00 per column inch, These are partial listings only. For more information on additional auctions
U.S. toEnergy
or to subscribe Corplists,1k
our email/mailing visitx 1" 3/11/03 11
one inch minimum.
Photographs not accepted. www.hilcoind.com www.maynards.com
www.pplauction.com www.myronbowling.com
No charge for typesetting.
A Buyer’s Premium is in effect • IL License #444000215
Payment must accompany order.
For an immediate price quote fax or
EXPLOSION PROOF

A
e-mail your ad copy to:
Lyndon.Schultz@ringpower.com ...... 904.494.1278 AC&DC ENGINE STARTING SYSTEMS
Steve.Ferlita@ringpower.com........... 904.494.1268 John Blomberg
Hilco_Classified.indd 1 • STARTER MOTORS • ALTERNATORS12/21/10 10:19:04
• SWITCHES • CLASS I, DIV. 1&2, GROUP D
E-mail: jblomberg@dieselpub.com
UNITED STATES ENERGY CORPORATION
Fax: (262) 754-4175 1600 MISSILE WAY, ANAHEIM, CA 92801

www.ringpower-systems.com
Phone: (262) 754-4146 CLIENT: KST & FMT Steel •Tankships
(714) 871-8185 (714) 871-9229 FAX
WWW.USENERGYCORPORATION.COM

AD SIZE: 3.125” X 4.75”

ADVERTISERS’ INDEX Need Fast Answers? Go To
follow dgtww on
Advertiser Page Number
*ABB Turbo Systems....................................................... 31
API Heat Transfer.......................................................... 43
Camfil Farr Power Systems AB..................................... 45
Capstone Turbine Corporation..................................... 35
Cast Iron Welding Services Ltd. .................................. 39
ComAp.......................................................................... 55
Ellwood Crankshaft Group........................................... 55
Europort Istanbul 2011................................................. 61
GE Energy Filtration Technologies............................... 11
*GE Oil & Gas............................................... Fourth Cover
*GEA Westfalia Separator GmbH................................... 21
Globalcon 2011............................................................. 67
GTE Industries........................................................ 13, 33
Hannover Messe/Hanover Fair 2011............................. 59
Harco.......................................................................... 19
Harsco Industrial Air-X-Changers................................. 17
IPSEN, Inc. ................................................................... 51
*Further information on this company’s products can be found in the Diesel and Gas Turbine Publications 2010­Global Sourcing Guide and at www.GSGnet.net.
INSERTION #: HI-3011
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PUBLICATION: Diesel & Gas
Advertiser Page Number
DATE:
*MAN Diesel January
SE................................................................ 5
MTU Onsite Energy....................................................... 23
CONTACT: John Blomberg
*MWM GmbH........................................................... 28, 29
Napier Turbochargers Ltd............................................. 47
OPRA Gas Turbines.......................................Third Cover
Power-Gen Europe 2011............................................... 63
Pratt & Whitney Power Systems................................... 25
Prüftechnik Alignment Systems GmbH......................... 41
*Siemens AG Energy......................................................... 7
SMM India 2011............................................................ 58
*Thermal Structures, Inc. . ........................... Second Cover
Universal LLC............................................................... 49
*Wärtsilä Corporation ..................................................... 1
Waukesha Bearings......................................................... 9
11th China International Petroleum & Petrochemical
Technology & Equipment Exhibition (CIPPE).......... 65

66 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide


Cell, Cell, Cell!
As we enter 2011 it seems the en-
ergy and power generation sectors
will endure a roller-coaster ride fea-
turing good news, major merger and
acquisitions activity, and unfulfilled
technology dreams.
The latter being a particularly inter-
esting point. In the generally slumbering
post-Christmas, pre-New Year period
when news agendas seem dominated
by tales of shoppers’ spending excesses,
a leading player in the engine building
and power systems markets suddenly
made a stark announcement.
It revealed that it was discontinu-
ing its fuel cell activities for station-
ary power generation. It had, it said,
“carefully examined the most recent
demand forecasts and carried out a
thorough risk/reward analysis” and
had opted “against further active en-
gagement in this area.”
More grimly, it continued that “the
company has come to the conclusion
that the fuel-cell business is unlikely
to become commercially viable in the
medium term, given current market
conditions and subsidy schemes.”
The company pointed out that
during the course of the year man-
agement had looked at “additional
market initiatives in support of fuel-
cell technology in Asia” and had ana-
lyzed potential partnerships for serial
68 J a n u a r y - F e b r u a r y 2 0 1 1 Diesel & Gas Turbine Worldwide
production there, too. Alas, talks with
a possible Asian partner ended with-
out agreement in late December.
So there we have it — a sorry but
economically understandable situ-
ation, but a course of action that
may temporarily take some of the
renewable energy out of the sails
of those organizations champion-
ing the potential and prospects for
fuel cells.
Such as, perhaps, the organization
Fuel Cells U.K., which it said, “acts
on behalf of its members to acceler-
ate the development and commercial-
ization of fuel cells in the U.K.” And
some of those members are, them-
selves, leading diesel engine and gas
turbine builders.
At the same time as the new coali-
tion government took over the politi-
cal reigns in the U.K., Fuel Cells U.K.
advised that, “Fuel cells and hydro-
gen could revolutionize the energy
landscape, bringing high efficiency,
low carbon solutions for transport,
residential, portable and premium
power applications.” Maybe so, but
not, as is proved above, if the num-
bers don’t add up.
So what else might we see on the rest
of the power generation and energy
landscape as we move through 2011?
Some industry observers are pre-
by ian cameron, ashbourne, england
dicting that waste-to-energy tech-
nologies are ready to hit the big time
this year. This, they suggest, will be
prompted by oil topping US$100
a barrel in 2011 (their estimate not
mine), thus encouraging investment
in waste to energy and also leading
to an increased use of natural gas and
therefore making it a more viable en-
ergy alternative.
No doubt wind power will con-
tinue to be a popular option — a
point underlined recently by Siemens
when it announced it had received its
largest onshore wind order to date
with a purchase from U.S. utility
MidAmerican Energy, headquartered
in Iowa. Siemens will deliver 258
wind turbines, each with a capacity of
2.3 MW and with an eventual com-
bined capacity sufficient to supply
190 000 households with electricity.
It has also been suggested by one
investment bank that traditional en-
ergy companies will “pursue acquisi-
tions in renewable energy” principally
focused on companies in the wind,
solar, waste to energy and energy-
efficiency markets.
And which 2010 headline-grabbing
energy company is tipped as a possi-
ble entrant into the renewable energy
sector? Why, none other than BP. No
surprise there then. A
Gas Turbine Power
CompaCt, Clean, effiCient, Reliable

SophiStiCated SimpliCity appliCationS

The 2 MW class OP16 gas turbine is so- The OP16 is suitable for both continuous
phisticated simplicity at its best, resulting and standby duty in a number of
in a robust design for high reliability and applications including:
dependability. Its unique all radial confi-
guration, efficient flow path and advanced • Oil & Gas: Onshore and offshore power
metallurgy provides the following charac- generation
teristics: • Marine: Auxiliary and standby power
• Green energy: Cogeneration, bio fuels,
• Compact and low weight flare elimination
• Ultra low emissions and multi fuel
• Highest efficiency in its power class
• Simple, robust and reliable
Three OP16-3 gensets in operation at a
remote oil & gas field

www.opraturbines.com, E-mail info@opra.nl, Phone +31 (0)74 245 21 21 T U R B I N E S

see directlink @ www.dieselgasturbine.com

GE Oil & Gas

The Power Crystal upgrade kit has over 15 years

of proven experience operating in aircraft
engines. Now we’re using it to improve power
output and parts durability for on and offshore
gas turbines. The Power Crystal upgrade kit for
our Frame 5 turbines can deliver 4-6% more
power and a 40°F increase in firing temperature
without additional cooling or significant impact
on NOx emissions. The increased material
Extend mean time
strength and heat resistance enable a longer between maintenance
mean time between maintenance – resulting in
extra production days and increased revenues.
geoilandgas.com/powercrystal
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