The magazine for the international power industry April 2018

Gas & Steam Turbine

Special Issue
WINNING THE FILTRATION FOR HARSH
EFFICIENCY RACE ENVIRONMENTS
NEW METHODS IN CHINA’S GAS POWER
MANUFACTURING BOOM
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1804PEI_C1 1 4/12/18 3:41 PM

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 POWER ENGINEERING INTERNATIONAL
APRIL 2018/// VOLUME 26/// ISSUE 4

Best maintenance practices for aeroderivative gas turbines

Contents
p28

44 Diary

44 Ad Index

Features

4 The race for efficiency 26 China’s gas distributed energy boom

How digitalization, storage and additive manufacturing As China’s energy landscape evolves, the country is
are playing a role in gas turbine development. setting requirements on cogeneration.

10 Selecting the right filter 28 Interview: MTU Power

A new standard for filtration gives operators a clearer Gregor Stöcker of MTU Power on the firm’s new direction
picture of gas turbine performance in harsh environments. and maintenance tips for aeroderivative gas turbines.

14 Gas turbines for CHP 32 Minimizing running costs for pumps

Why gas turbines are succeeding in China, where they How design improvements can help pumps cope with
are increasingly used in combined heat and power changing operating conditions.
applications.

36 Keys to gas turbine success

20 Q&A: MAN Diesel & Turbo High ratings for gas turbine reliability, availability and
Dr Sven-Hendrik Wiers of MAN Diesel & Turbo on China, maintainability may be ascribed to four key factors.
CHP and the company’s R&D direction.

40 Q&A: GE Power Services

24 An upgrade with substantial benefits
New GE Power Services CEO Scott Strazik on his back-to-
How an upgrade to a gas turbine fleet added 5 GW to basics business plan for today’s challenges.
Iran’s power capacity.

On the cover
Cover design: Scott Jones

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1804PEI_1 1 4/12/18 3:37 PM

 ADVERTORIAL

MONITORING
POWER
EQUIPMENT
IN TRANSIT
SPONSORED CONTENT BY:

W
ith increasing globalization and the customer the service that they want, says Sven- products will get damaged, because otherwise
world’s hunger for power comes Olof Olsson, founder and CEO of Mobitron. customers wouldn’t come to us asking for help.
a growing need to transport more He continues to tell that many customers
power equipment over longer distances Power equipment most likely to be turn to Mobitron after their product has been
by more diverse methods. But whether it is damaged damaged, in order to make sure it doesn’t
large or small, unwieldy or compact, a lot According to Olsson transformers are the happen again in future.
can go wrong when transporting sensitive most common type of power equipment to - If you can collect data to find out
power equipment from its point of manu- be damaged during transit, although gas what happened, you can also use this data
facture to its destination on-site. Given the turbines are also “very sensitive to shocks in for insurance and guarantee cases to see who
vagaries of travel by road, freight, ship or air, different directions”. Gearboxes can also be was responsible for the equipment when it
it is unavoidable that during the transport damaged if they are handled with forces happened and who will pay for the damages.
process the equipment is out of monitoring in directions which their construction isn’t For example, one of the most critical point
distance for some period of time, and a really built for. in the transport process from manufacturer to
major accident doesn’t need to happen for - In our experience, it is possible that site is during lifting operations.
damage to occur. all electronic and technical equipment that will - In a harbour, lifting on or off a ship
Mobitron has been addressing this issue be transported is going to be damaged. We is critical, as is lifting from the carrier to the
since 1991 with dedicated monitoring systems know anything can happen during a transport, equipment’s position on-site. And of course, it
designed to provide detailed information on and even if you are very careful during your happens that ships at sea may encounter bad
what happens to sensitive cargo during the planning, you don’t know everything that is weather conditions and that the movement
transport process. The firm’s Cargolog Impact going to happen. on board isn’t what was expected, and things
Recorder System, a wireless data logger, helps When asked how often power equipment is can happen (even though that is not that
to measure and register potential accidents damaged during transport, Olsson says common). If we’re talking about a piece of
that can result in damage. The data logger - It is hard for us to say because our equipment like a transformer, we are talking
is attached directly to the equipment and customers use our products without our in- about something very heavy and massive, and
provides information on how it is handled volvement – but we know from experience that in that case, we do see problems during lifting.
throughout the entire logistics chain. Maybe there is a crane which is not in the
At the beginning, Cargolog was used as a
dedicated measurement system for record-
ing temperature, humidity and vibrations. This
has now developed into today’s advanced
recording tool for monitoring transports with
integrated GPS and GSM/GPRS.
- The tool is used in different ways
by different customers. Some want us to do
almost all of the work. Help them program the
Impact Recorder, to position where they should
mount it, and read out the data and send
them the report. Other customers work totally
by themselves. Of course, the customers need
more support and help in the beginning, than
after they’ve been using the product for a while.
But it’s very easy to use, so it’s not hard for cus-
tomers to handle. We would like to give each

1804PEI_2 2 4/12/18 3:37 PM


correct dimension for the heavy weight.
Another issue, is whether the equipment is
packed securely, and how it is handled. In case
there is forklift operation it is quite common
that there is damage caused by dumps when
putting down the equipment, and it’s also com-
mon during movement that you hit something
with the equipment.
When transporting power equipment by
road it is just as important to know that the
transport has been trouble-free, as well as track-
ing potential damage
- If the roads are of good quality then
it’s not that common that things happen, but in
the case of transport to a site which is almost
off-road or a long distance out in the country
where road construction isn’t of a good quality,
then it’s a different matter.”
According to Olsson the majority of
damage caused by human error or accident
is 50/50.
- Sometimes the situation can be
underestimated in terms of what the weight is
or how the equipment will react during move-
ment or lifting. Things like transformers might
sometimes be underestimated, in that the
responsible person maybe doesn’t really realize
that the size of the piece really has that huge
weight. Also, stress during lifting and operations
at distribution centres causes problems. They
might have a tight time schedule where they
need to move the goods at quite a high speed,
and maybe sometimes too high a speed. This is
one reason for accidents.
Mobitron offers two product lines
Today Mobitron can offer their customers
two different product lines for monitoring
equipment in transit. The traditional Cargo-
log Impact Recorder is a battery-operated
data logging system, while the Transport
Monitoring System is a system connected
directly to the vehicle and will provide
1804PEI_3 3
For more information, enter 2 at pei.hotims.com
real-time information to the driver. A warning
light will immediately warn the driver if there
is exceeded alarm limits. And, through a
connection with Mobitron’s cloud service,
this information can be accessed remotely
during the trip to provide data on vibration
or shock.
- The system can be programmed to
adapt exactly to the requirements of a specific
transport. For instance, we have the possibility
to record both acceleration, temperature,
humidity etc. but for some transports you might
not be interested in all the measuring functions
and then you can exclude one of them. How
many sensors are used will depend on the
equipment. For an example, on transporting a
wind turbine nacelle it’s one unit on the nacelle
and one additional unit on the gearbox if that
is separately transported. For a very long blade
it’s two units – the typical installation is under
each carrier for the blade, one on front and
one in the rear.”
Much of Mobitron’s current offering has
been developed in consultation with its cus-
tomers. For example, the company implement-
ed Bluetooth communication after a custom-
er’s request.
- We developed this to give customers
the possibility to read out data without wired
communications and we also developed an
APP to help customers get easier access to
the data. And today we have the possibility to
measure the pressure, which is also something
we developed together with a customer that
wanted to measure pressure during transport
of a power transformer. We can see that many
more customers are going to be interested in
this.
GPS positioning is also a requirement
which was requested by a customer who want-
ed to know where the damage of the goods
occurred. They wanted to learn which route
was the best to transport the goods to their end
customer.
- These are only some examples over
the years, but today they are available for all
our customers so we can see this is something
more and more people want to use.
Olsson acknowledges that Mobitron has
competition in its field, but he feels that
- With our new tech with the APP and
cloud service, Cargolog Online we are in the
high rank in this field. The quality of our work is
very high, and we calibrate every single unit we
send out. They all have separate serial numbers
so we can go back and trace them. This is what
differentiates us from other companies – it’s
quality work with every product we send out.
Sponsored content by:
4/12/18 3:37 PM
 H-class turbines
A race for efficiency
“You need to be ahead of the
game, otherwise you don’t
survive,” says Karim Amin of
Siemens, who highlights how
developments in digitalization,
storage and additive
manufacturing are playing a
role in the company’s latest
turbines
4 Power Engineering International April 2018
1804PEI_4 4
S
iemens’ new HL-class turbines are a
synthesis of old and new technologies,
but ultimately they add up to an efficiency
gain that equips gas-fired power plants well for
the challenge of balancing a renewable
energy-dominated power sector.
The HL represents an evolutionary
development step derived from the company’s
proven SGT-8000H technology. It is achieving
greater than 63 per cent efficiency with a mid-
term goal to reach 65 per cent.
Power Engineering International visited
Siemens in Berlin to view the latest of the
German giant’s gas turbines.
Karim Amin, chief executive of Global Sales
in Siemens’ Power and Gas division, says the
requirement is for operation to be very flexible
to complement the intermittence of renewables,
with the HL-class having a ramp-up of 85 MW
per minute in simple cycle.
“We have a very optimized service process
and that was important in the criteria, and you
will see that the service of this turbine is
extremely efficient and cost effective as well.
And there are allowances for start and stop
segments.”
The HL engines are designed to fulfil the
requirements of baseload units as well as of
peakers, which makes them a perfect fit for
energy systems with a rapidly increasing share
of fluctuating renewables.The naming ‘HL-class’
underlines that the engines are based
on the proven H-Class design and are the
technology carrier from 63 per cent to 65 per
cent efficiency.
To achieve top performance, Siemens
developed advanced combustion
technologies, innovative multi-layer coatings
and super-efficient internal cooling features as
well as an optimized water-steam cycle.
Engineers designed the frame using the latest
in digital technology, for example 3D-printed
components for prototype testing and
validation.
The HL-class consists of three engines: SGT5-
9000HL, SGT6-9000HL and SGT5-8000HL. In
simple-cycle operation the air-cooled SGT-
9000HL gas turbine will provide a capacity of
www.PowerEngineeringInt.com
4/12/18 3:37 PM

567 MW for the 50-Hertz market and 388 MW in
the 60-Hertz version. SGT5-8000HL will provide
481 MW in simple-cycle operation.
The turbines are designed to plug in to
Siemens’ suite of digital products running on
MindSphere, the firm’s cloud-based operating
system for the Internet of Things (IoT).
“It’s designed to allow for the digitization
road map we have,” Amin said. “You can
connect it through IoT, Mindsphere and it has
more than 3000 sensors. At the end of the day,
the impact is the highest efficiency large output
together with a smaller footprint.”
CAPEX, OPEX and fuel economy
“We think that when you look at certain gas
processes for this instance, it can reduce the
cost of electricity by around 5 per cent
compared to the existing rate, amounting to
around €15–20 million a year. It has a visible
impact on the economics of EPA for a traditional
asset that runs from 15 to 25 years.”
When asked if the development of the new
product might indicate some confidence in a
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1804PEI_5 5
turnaround for the fortunes of gas power in
Germany and Europe in general, Amin
explained that success was contingent on
certain criteria.
“For a considerable period of time in
Germany and Europe, gas power was not being
dispatched. Now you are seeing that with
ancillary services, reactive power and grid
stability some of these plants have started
running again, and now it all depends on the
economic values that are attached to
them.”
“How much was the capex when they were
built, how much have the prices changed, and
the services cost attached to that and so on.
Whatever plant is more efficient gets dispatched
first, and our job as a service organization is to
provide service upgrade packages that make
it less costly to open again.”
Amin and his colleagues spent a year
analyzing potential ways forward for gas-fired
power offerings. Did the advances being made
in rival technologies such as battery storage
inform their approach?
“Siemens is working on storage from a much
broader aspect. Storage and renewables are
going to change the landscape one more time
completely once there is an efficient scalable,
economic storage solution.”
Siemens is accelerating its drive in
technological upgrades and competitiveness
by transferring newly developed key
technologies to its entire gas turbine portfolio.
At the initial launch of the technology, Willi
Meixner, chief executive of the Power and Gas
Division, neatly encapsulated the motive in
developing it.
“Driven by digitalization, speed in technology
development is rapidly gaining momentum in
the power generation arena,” he said. “It took
us ten years, from 2000 to 2010, to increase the
efficiency of our combined-cycle power plants
from 58 to 60 per cent, a further six years to
reach 61.5 per cent in 2016, and now we are
taking the next step to 63 per cent and beyond.
But we know that speed and efficiency alone
are not sufficient. Reliability and cost
effectiveness of our solutions as well as
partnership, support in financing and insurability
are also key to our customers”.
In the near future, all Siemens customers will
benefit from further efficiency and performance
increases. This approach is part of a series of
activities to help customers compete in a rapidly
changing market – working to significantly
reduce lead and construction times through
standardization and modularization.
Guido Schuld, Product Family Owner (Large
Gas Turbines), said the thinking behind the
H-class turbines
HL-Class came from a wide variety of people
under the company’s roof.
“Unlike the usual procedure at Siemens, this
mixed group of people together contributed
to the development of a new turbine class,”
said Schuld. “For example, we looked at new
ways of manufacturing, but also analyzed which
technologies will likely be available five or six
years from now, and made sure these turbines
are ready to incorporate these new production
technologies. People from manufacturing and
colleagues from technology & innovation were
key in these assessments.
“We considered how difficult this market is
developing, so our strategy department began
looking at how it might evolve in the future. On
top of this we also looked at new manufacturing
methods such as digital printing, and of course
some components are not yet ready.
“Turbine blades are still made in a
conventional way. We are considering what
manufacturing tech might be available in three
or four years’ time and that the engine
architecture of the HL Class allows for the
incorporation of these new methods.”
Schuld also provided a detailed account
of what the HL comprised and how its new-
found efficiencies are being gained.
“So if it’s just an evolution how do you
achieve efficiency levels above 63 per cent?
The answer is on the compressor side, especially
improvements on the combustion side and the
turbine section itself.
“From the compressor side, this is the third
generation of a so-called family compressor
– the first generation for a 5000F engine was a
60 HZ and then developed for a H-Class family
of 50 to 60 Hz, and this is the third generation.
It makes use of advanced 3D blading which
improves the efficiency of the entire compressor,
and allows us (despite having a higher
compressor ratio of 24:1 compared to 20:1 for
the 8000H) to reduce the number of stages of
the compressor, meaning less complexity.”
The HL class comes with 12 compressor
stages, while the H Class had 13 compressor
stages.To further reduce complexity, the HL-class
has one inlet guide vane and two variable
guide vanes, in comparison to the SGT-8000-H
series which had one inlet guide vane and
three variable guide vanes.This amounts to less
complexity with higher efficiency.
To achieve top performance, the turbines
operate at high combustion temperatures. For
this purpose, Siemens specialists have
developed advanced combustion
technologies, innovative multi-layer coatings
and super-efficient internal cooling features, as
well as an optimized water-steam cycle.
Power Engineering International April 2018 5
4/12/18 3:37 PM
 H-class turbines
Driven by digitalization, speed in technology development is rapidly gaining momentum
More gains are made in the hotter parts of
the engine and the combustion system.
Siemens refers to the ACE, or Advanced
Combustor for High Efficiency – the concept is
once again aimed at the development of the
H-Class family’s PCS or Platform Combustion
System.
“Concept-wise, we have a pilot burner in
the middle surrounded by a number of pre-
mixed flames,” explains Schuld. “What we did
6 Power Engineering International April 2018
1804PEI_6 6
here is increase the number of premixed flames
compared to the SGT-8000H series.”
“With the H-Class we had eight and with the
HL we have 25 premix flames helping us to
reduce NOx, because final temperature has to
go up if you want to improve the efficiency of
the engine of the entire internal combined
cycle. It also helps us with the part load.
“This engine can go down to a part load of
30 per cent, which again serves the market
Credit: Siemens
when more renewable energy is coming inward.
It not only delivers fast ramp-up but low part-
load operation capability.
“To show how similar the concepts are, the
HL part oxygen completion burner has already
been tested one year ago in an SGT-8000H
series engine installed here at our test centre
in Berlin. We took the new burner and operated
at the conditions of the SGT-8000H series.
“We see a new concept with more premixed
burners and flames and full oxygen mixing, and
also the transition piece shortened in order to
reduce residence time of the combustion
gasses within the combustor itself.
“With turbine blades, it’s a real challenge
with air cooled engines and improving
efficiency. You must get the firing temperature
up.”
When increasing burning temperature, there
are two ways to protect the blades – one is
improved cooling and the other is improved
protection.
“Improved cooling to some extent is easy
as you just use more cooling air,” says Schuld.
“But when you use more cooling air, the
efficiency of the engine goes down because
the air isn’t available for combustion in power
generation.
“What we realized is the importance of the
thermal barrier coating on the blade, making
www.PowerEngineeringInt.com
4/12/18 3:37 PM
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 H-class turbines
it thicker. The thermal barrier coating has a
different thermal behaviour than the base
material of the actual blade. It’s a ceramic
material and during startup and shutdown it
experiences thermal stresses.”
Siemens came up with a technology to
increase the thermal coating with so-called
laser engraving, or thin cuts in the thermal
barrier coating, and this helps to reduce the
stresses on the coating, which avoid spallation
– the biggest risk of damage to coating.
They also found a second root cause of
spallation. During commissioning of the engine,
on the compressor side, there are gradable or
metallic seals. In commissioning there is
controlled rubbing of the compressor and small
metal pieces that go into the engine.
8 Power Engineering International April 2018
1804PEI_8 8
“Even if you try to clean everything there will
always be some metal dust remaining in the
engine,” explains Schuld. “The first time you try
to start up the engine the metal dust melts and
gets plucked through the thermal barrier
coating of the main area and, if you have metal
deposits there, it changes the thermal coating
behaviour and causes spallation.
“We noticed this as you see spallation a lot
during the first couple of hundred operating
hours, and after that you don’t see it any longer.
What we came up with is a very simple concept.
We have a sacrificial layer on the main one
and that just disappears within the first couple
of hundred operating hours. Below that layer
you have the proper, original barrier coating
then protected.
“You also have to improve cooling of the
blade without consuming more air. We bought
a manufacturing licence from a US-based
company called Microsystems.This technology
allows us to manufacture very sophisticated
cooling channels inside the blade.This was not
possible until now but reduces the amount of
cooling air needed.”
This means major changes to the SGT-8000H
series, with an internally cooled blade needed
because of the higher exhaust temperature to
improve the overall combined-cycle efficiency.
With the HL class there is an exhaust temperature
of around 680oC compared to the SGT-8000H
series range of 630–640oC.
“An additional change with the HL class is
that the thermal barrier coating is used for the
first seven air foils, as against the H8000 where
it only applies for the first six air foils. It’s a free-
standing blade, which we use to reduce losses
and improve the overall combined-cycle
efficiency.
“This is not to mention the benefit to
customers in available spare parts, along with
it being much more flexible to market changes.
It will allow plant owners to react quicker as we
can use the same casing.”
Testing and validation is vital for Siemens in
the development of the offering. Executives
highlighted the role of the company’s
€100 million Clean Energy Centre in that
responsibility.
The centre has a focus on combustion and
component testing and allows Siemens to
test combustion parts under real engine
conditions.
“The approach results in improved
technology and a proof point for the customer
in endured durability,” according to Schuld.“Also
for the insurance companies it provides
increased insurability – it’s much easier for the
customer to achieve financing and bankability
in their projects.
“All blades can be replaced even without
a rotor lift of the engine for the turbines. There
is also a roll-in/roll-out concept for the turbine
build carriers so no requirement to lift the rotor
out with the batteries.
“In terms of maintenance improvement
concept, the first combustor inspection
combined with a stage 1 over-inspection is only
necessary after 33,000 base operating hours
– or between six and ten years for the first
inspection.”
There is also the operational regime change
to be factored in. Some units bought five years
ago as baseload now start twice a day, which
meant changing the starting process.
“So for the H-class you would have to perform
www.PowerEngineeringInt.com
4/12/18 3:37 PM
 H-class turbines

the combustor inspection after 900 starts, but EPC perspective. It’s cheaper and more flexible to efficiency before because of abundant
this has been extended to 1250 starts, really compared to all the other alternatives.” hydrocarbons and gas. Also the tools: we were
addressing the requirements of customers What is driving the pace of change to always doing stuff in two dimensions, and
according to the market changes,” said increase because it’s taken such a lot of time designing in two dimensions. Now additive
Schuld. to get to 60 per cent efficiency? On that theme, manufacturing and digitalization is helping a
“After 66,000 base operating hours we do Amin is unequivocal. lot. It’s a race for efficiency – you need to be
a major overhaul, looking at the combustor “From a commercial point of view, customers ahead of the game, otherwise you don’t
turbine compressor and the casing.” were not paying too much attention to total survive.”
If you were to isolate one outstanding motive cost of ownership or tariff-based models.There
for the HL-Class, it would be the requirement for was a lot of specific price discussion and dollar- Kelvin Ross is Chief Editor of PEI magazine
adaptability to the new renewable energy per-kilowatt was driving decisions in the industry,
dominated environment this technology finds and their capex played a major role. Visit www.PowerEngineeringInt.com
itself in. “This is changing. They didn’t pay attention for more information
Schuld says: “We really believe we have an
engine which addresses new market
requirements with more renewables coming
into the market.
“You need engines with fast ramp-up so they
can operate in combination with the
proliferation of power generation from
renewables, and on the other hand the high
efficiency also allows for customers who still
have baseload plants to substantially improve
the lifecycle cost of the engine compared to
other frames, the proof of service concept and
also digitalization.
“I refer to the engine as future-proof, which
means it is designed to plug into the Siemens
cloud MindSphere and, as more and more
applications become available, that will result
in more improvement for customers from an
operational flexibility point of view.”
Looking at the market in general, Schuld
said there are some requirements for capacity
in the UK and also in Germany.He acknowledged
that the market in the EU has been stagnant
for quite some time.
Developing on that,Amin pointed to a more
positive scenario outside Europe.“Countries in
Asia and the Middle East like Pakistan and Saudi
Arabia, one of the biggest gas turbine markets
in the world, are clearly going for H-Class in their
recent tenders and are saying they aren’t doing
F-Class any more. Even China is now saying it’s
going for H-Class and above.
“We see 120 or 130 units per year and the
years to come will remain at this range. The
make-up of these units is clearly changing
though, with less in the middle range and more
in the higher classes or decentralized classes.
When we talk about where the HL will fit, in
Europe it is a capacity discussion while in other
markets its not capacity they opt for, it is
baseload because of the higher efficiency and
lower capex.
“Renewables are here to stay, and will grow,
and our position is that gas is a good partner
for them because you get into high levels of
efficiency and it’s much faster to install from an
For more information, enter 4 at pei.hotims.com

www.PowerEngineeringInt.com Power Engineering International April 2018 9

1804PEI_9 9 4/12/18 3:37 PM

 Gas turbine filtration

A step
in the right direction
The new ISO 16890 standard

allows gas turbine operators to
get a clear picture of how a
turbine will perform in often
harsh environments,
writes Steve Hiner
A
gas turbine consumes vast quantities
of air, and selecting the right filtration
solution is a critical part of ensuring its
ongoing performance and reliability as well as
preventing unnecessarily high maintenance
overheads.
Evaluation of local environmental conditions
and operational goals will help determine
which solution is optimum for a specific
installation. Remember that contaminants can
be solids, liquids or gases and each presents
its own challenges, which the evaluation of dry
particle efficiency alone from any of these
standards is not going to tell you.
If a filter becomes blocked it can result in
sudden pressure spikes, unplanned turbine
outages and associated lost production.
Hydrocarbon mists or moisture from mist or fog
may produce droplets that are small enough
to enter the filter media but large enough to
become stuck within it.
When these liquids combine with dust and
other solid particles already captured, they form
a muddy or sticky substance that can rapidly
block a filter or, worse, can be drawn through
the filter and deposited in the turbine.
Salt is a particular challenge because of
how easily it changes from solid to liquid in the
presence of moisture and changes in humidity.
If it enters the internals of the turbine it may
combine with sulphur within the fuel and cause
rapid hot end corrosion.
Designing a system to handle moisture,
reduce the risk of sudden blockages and
prevent moisture bypass can be just as
important to the filter design as its particulate
efficiency.
To best protect a turbine and a plant’s
profitability, filter design needs to take all of these
factors and more into account to produce a
filter that will perform in the real world.
Filter ratings
Historical standards for filter efficiency ratings
have been based on the needs of the heating,
ventilation, and air conditioning (HVAC) industry
and have not truly reflected performance in
the real world when installed in the harsh
environments associated with gas turbines.
Although still very much aimed at the HVAC
market, the new ISO 16890 standard relating to
filter efficiency has some parts which better
relate to gas turbine performance when
compared with the current EN779 or
ASHRAE 52.2 test standards.
The main issue with referring to standard
ratings for filter efficiency when selecting a filter
for a gas turbine application is that the rating

10 Power Engineering International April 2018 www.PowerEngineeringInt.com

1804PEI_10 10 4/12/18 3:37 PM

 500 MW rotor lP Moving
Blades attachments repair
by disc Welding and optimization
of Moving Blade Profiles
one of the projects doosan Škoda Power worked on last year was an lP rotor repair for the german customer lausitz energie
Kraftwerke ag. the customer contacted doosan Škoda Power with a requirement to solve a recurring problem concerning
their 500 MW turbine's lP rotor. after being in operation for some time, indications of cracking had occurred in the lP rotor,
in the regions of the pin holes used for fork-type lP2 and lP2a moving blades attachments.
Based on metallographic and fractographic examinations, the root cause of
this recurring problem was identified as stress corrosion.
The solution of this task was divided into two main parts:
I) MovIng Blade ProfIles and attachMents oPtIMIzatIon
In this part of the task, it was necessary to re-design the moving blades. 3-D
models of the guide wheel and LP rotor, which included the existing moving
blade attachments and their original blades, were created using 3D scanning
and reverse engineering. Necessary calculations (i.e. static, dynamic, flow)
were made based on the operational parameters supplied by the customer,
result of which was a proposal of new moving blades for LP2 and LP2a stages
with optimized profiles.
The main change in the design of the moving blades was:
a) Reduction in blade profile weight,
- with the same safety coefficient of the blade root stress, but for a smaller
surface less load in the blade root was achieved
- lower pre-twisting moment in the blades required, which also results in
less force being transferred into the rotor disc through the pins, therefore
less load in the disc
b) Replacement of the existing rhombic shroud by the L-shroud
- L-shroud requires less contact force for the same blade pre-twisting
moment
- Doosan Škoda Power uses a half of the value of the blade pre-twisting
moment as standard (this moment is transferred into the rotor disc),
which also results in less stress
c) Use of the fork-type attachment in Doosan Škoda Power blades
II) rePaIrIng the daMaged lP rotor MovIng dIscs
The damaged LP rotor discs themselves were repaired alongside optimizing
the moving blades. The LP rotor was supplied with already debladed LP2 and
LP2a stages. The actual repair of the rotor discs consisted of first removing the
damaged parts in the rotor discs by way of lathing, and subsequently welding
Preparing the rotor
discs for welding
after the moving
blades disassembly
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1804PEI_11 11
them back on. Due to a lack of space between the individual rotor stages, it
was necessary to disassemble the moving blades in the adjacent stages LP1,
LP1a and LP3, LP3a.
The welding of the rotor discs was done with submerged arc using the SAW121
method, with the rotor being positioned horizontally. We had all the necessary
qualifications for the material used in the LP rotor in this welding process: the Wel-
ding Procedure Specification (WPS) and Procedure Qualification Record (PQR).
Due to the volume of the welded material, it was necessary to conduct the who-
le welding process in two main steps – welding the interlayer and the first layer,
followed by welding of the second layer. Any welding process involves a heat
input resulting in residual stress in the welding area. Post welding and an inter-
operational heat treatment were applied to release any residual stress that may
have been present. Heating elements were attached to the surface areas of
the welded discs. The quality of the weld deposit was being checked using the
NDT ultrasonic testing and surface hardness testing after every interoperational
heat treatment.
LP2 stage after
the repair – detail of
the new attachments
and new blades
After the discs were welded on, the necessary heat treatment and NDT done,
and the new moving blade attachments were turned, the rotor was ready to
be fitted with the newly designed moving blades of the LP2 and LP2a stages.
They were also ready to have the previously disassembled moving blades of
the LP1, LP1a and LP3, LP3a stages re-attached.
Before the actual assembly of the moving blades, the shot-peening method
was applied to improve the mechanical properties of the rotor's surface. The
purpose of this process is to enhance fatigue strength, strengthen and com-
press the rotor's surface, as well as to improve the cracking and fatigue resistan-
ce, which also helps with improving the resistance to cracks that are the result
of the aforementioned stress corrosion.
In the final phase of the repair, high-speed dynamic balancing of the rotor
was conducted in Doosan Škoda Power's own balancing tunnel in accor-
dance with the ISO 11342 standard. The rotor was then ready to be transpor-
ted back to the Jänschwalde Power Plant.
During the summer downtime, the repaired rotor was installed into the steam
turbine and has been fully in operation since August 2017. Based on the succe-
ssful execution of this repair, Lausitz Energie Kraftwerke AG contracted Doosan
Škoda Power to repair other three LP rotors that have the identical problem.
daniel opplt
head of service technical department
http://www.doosanskodapower.com
4/12/18 3:37 PM
 Gas turbine filtration
does not reflect how well the filter will perform
in the real world or what specific benefit it will
bring to the gas turbine.
To this end, there really is no replacing real-
world experience of filter performance within
specific environmental conditions.The changes
within ISO 16890, however, do take us a step
forward in understanding how filter selection
affects gas turbine performance.
The new ISO standard was launched at the
end of 2016 and the older EN 779 will be
withdrawn in Europe in mid-2018. EN779 tested
a filter in both clean and artificially loaded
condition to adjudge its initial and through-life
efficiency. The filter was artificially loaded with
a standard test dust called ‘ASHRAE’, which was
originally developed to test vacuum cleaners
and so was not representative of the real world
for gas turbine filters.
The filter’s efficiency was measured and
reported at one particular particle size, that of
0.4 microns.The appropriate rating of F7, F8, F9
etc was then given depending on how the test
results compared to a rating table within that
standard.
The problem with this is that the test did not
simulate real world conditions or provide an
indication of the impact the selection of a
particular rating would have on gas turbine
performance. Efficiency at 0.4 microns is
somewhat meaningless to the turbine operator.
In fact, filters that are artificially loaded with
this type of test dust in the lab tend to experience
a significant increase in their efficiency.
It has been shown that this does not occur
in the majority of cases in the real world, leading
to a general overestimation of the likely filter
performance when reported to the EN779
standard.
The new ISO 16890 standard, however,
performs the measurement and presents the
results somewhat differently. It is only the initial
efficiency of the filter that is now measured, with
an artificial loading stage being optional and
only used to determine the likely life of the filter,
not trying to estimate its through-life
efficiency.
With regards to the initial efficiency, no longer
is this evaluated at a single arbitrary and
relatively meaningless point of 0.4 microns
particle diameter.
Instead it uses a particulate matter (PM)
reporting system as defined by the World Health
Organization for airborne contaminants.
In addition, the measurements are
normalized to representative real-world airborne
particulate distributions for both rural and urban
environments in an attempt to make them even
more representative – although, once again,
12 Power Engineering International April 2018
1804PEI_12 12
this new standard has been developed to fit
well with HVAC users. PM numbers for the local
external environment are often readily available
and can now be used with the filter performance
from this standard to determine the conditions
after filtration inside a building.
While these PM particle size ranges have
not been purposely defined to relate to gas
turbines, it is by coincidence that their specific
ranges, if interpreted correctly (as will be shown
later), can now be useful to evaluate the likely
PM numbers for ISO 16890 are defined as follows:
PM Number
PM10
PM2.5
PM1.0
impact of filter performance on turbine
performance.
In the US the comparable standard,ASHRAE
52.2, will continue as it is for the time being.This
was originally based on EN 779 but has
changed in recent years to also give filter ratings
based on three particle size ratings (0.3–1 µm,
1–3 µm and 3–10 µm) and, as such, is more in
line with the new ISO standard.
However, ASHRAE 52.2 does not normalize
the results to a typical atmospheric dust
distribution and still uses the results from a similar
artificial dust loading step to EN779, which uses
the same ASHRAE vacuum cleaner dust as part
of the filter’s overall MERV rating.
The new ISO standard therefore gives a
clearer picture that is more representative of
likely real-world performance.
It should be noted that all of these standards
are only guidelines and not legal obligations
for turbine users, who are free to choose any
or none of these standards when selecting
filters.
Impact on gas turbines
Different particle sizes impact on gas turbine
performance in different ways.
Particles of contaminants larger than five or
ten microns (µm), such as sand and mineral
dust, are hard and abrasive. If sufficient
quantities of these are allowed to flow into the
compressor and hot gas path parts of the
turbine, they will chip away at the metal inside,
causing erosion.
The change in the metal structure impacts
aerodynamic performance of the turbine and,
over time, as sections of metal become thinner,
increased local stresses can result in parts
breaking loose, creating serious or even
catastrophic damage to the turbine.
In desert regions, particularly those subject
to frequent sand and dust storm events, dust
loading can be exceptionally high and erosion
of turbine parts is a primary concern.
Small particles less than one or two microns
can attach to gas turbine blades and change
Particle size range
<10 µm (0.3 - 10 µm)
<2.5 µm (0.3 - 2.5 µm)
<1 µm (0.3 - 1 µm)
their smooth, precisely engineered aerodynamic
shape that has been optimized for performance.
Operators may see a reduction in power output
of the turbine by as much as 10 per cent and
an increase in fuel consumption, both caused
by compressor blade fouling.
The rate at which fouling occurs will depend
upon which contaminants are present in the
air flow and how ‘sticky’ they are.
Operators can remove fouling materials and
recover most of the lost turbine performance
through on-line or, for greater effect, off-line
washing.
Selecting a filter to protect from these
contaminants helps to reduce the frequency
of off-line washes with its associated lost
production, as well as the rate of reduction of
power output between washes.
In the hot section of the turbine, hundreds
of tiny precision holes are used in the blades
to allow cooling air to flow. This cooling air
protects the turbine blades from excessive
temperatures that may distort or even melt
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4/12/18 3:37 PM
 Gas turbine filtration

them. Particles between about 1 and 3 microns tend to plug these

vital cooling air passages and cause the parts to exceed temperature
limits, reducing component life and increasing the risk of failure.
Knowing this, the PM ranges specified within ISO 16890 can be
used to relate to GT performance as follows:
• PM1.0 will tend to indicate the degree to which a gas turbine
compressor will become fouled;
• PM2.5 will tend to indicate the degree to which the blades in
the turbine section may experience cooling hole plugging which
can lead to catastrophic failure;
• PM10 will tend to indicate the degree to which the blades
throughout the machine may experience erosion of their profiles,
which will lead to reduced life and can also lead to catastrophic
failure.
This then shows how filter performance measured to ISO 16890
can be a benefit to operators as it offers a stronger understanding of
how the filter will perform in situ and what affect it is likely to have on

FLEXIBILITY
the turbine.

Different challenges

FIRST
To be absolutely clear, the new PM rating within ISO 16890 does not
give a single number that completely defines how a filter will perform
in particular environmental conditions, and filters cannot simply be
compared using their rating alone. Each turbine installation presents
different challenges – whether from hygroscopic salt from nearby
seawater, seasonal dust storms, fog events, snow and ice, or a multitude
of other factors that may affect turbine performance and reliability.
Electric actuators for all types of
To fully evaluate an installation and factor in specific site goals for industrial valves
maintenance intervals and process criticality, a holistic approach is Reliable and long-term service. AUMA
required in the selection of an appropriate filtration solution.
Manufacturers such as Parker use their experience and advanced
offers a comprehensive actuator portfolio.
test procedures to consider the full range of environmental factors ■■ Customised solutions for all types of
and worst possible conditions a filter may face in the real world. power plants: from CHP to large-scale
The new ISO 16890 standard is a step in the right direction for gas
turbine operators to glean a clear picture of how a turbine will perform
power plants
in the often harsh environments associated with gas turbine installations. ■■ Variable speed for high precision
However, it is still by no means a panacea on which to solely base
control
filter selection. Indeed, different filters and filter media materials with
■■ Interfaces to all conventional fieldbus
the same PM number may well give completely different results once
installed. systems
It is, of course, turbine performance that ultimately matters and ■■ Service worldwide
this is the only reason filters are installed. Arguably, the only true
judgement of how a filter is performing is still the resulting real-world
Discover our solutions for
performance of the turbine after a filter is installed.
the power plant industry
Steve Hiner is chief engineer at Parker Gas Turbine Filtration,
www.auma.com
formerly CLARCOR Industrial Air

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1804PEI_13 13 4/12/18 3:37 PM

 Combined heat and power
The 26 MW Anting combined heat and power plant
Credit: MAN Diesel & Turbo
Designing gas turbines
for Chinese CHP
Both low emissions and high
efficiency are becoming
increasingly important for gas
turbines in China. MAN Diesel &
Turbo explains why its 6–7 MW
class MGT6000 product family
has been successful in the
Chinese market, where the gas
turbines are used for combined
heat and power applications
14 Power Engineering International April 2018
1804PEI_14 14
S
mall gas turbines in the power range up
to 20 MW have been used for years as
electricity generators for peak power
demand as well as for baseload-operated
stations mostly in combined heat and power
(CHP) applications, where besides power
demand steam and/or hot water is required
for industrial purposes or district heating. Short
installation times and high flexibility in transient
operating conditions combined with very low
emissions are some of the features which are
criteria to select gas turbines for power
generation applications. In addition, such small
gas turbines are also widely used as mechanical
drivers for compressor applications in upstream
as well as in midstream markets.
Some years ago, MAN has introduced the
6–7 MW class MGT6000 product family into the
market.This product family is very successful in
the Chinese market where the gas turbines are
used for high efficiency CHP applications
combined with very low emissions.
Design and performance
The MGT6000 single-shaft version is a robust
gas turbine with cast casings, horizontally split
at the compressor section to allow top or
bottom casing removal for complete rotor
access to compressor blades and vanes. Power
output is at the cold compressor end with
engine shaft speed reduced by a load
reduction gearbox. The air intake casing is
located at the front end of the gas generator
and supports the front of the compressor
section. The front-end radial/thrust bearing
arrangement is located within the middle of
the inlet casing. This feature provides easy
access to the bearing.The auxiliary gearbox is
directly connected to the front flange of the air
inlet casing and houses the main lube oil
mechanical pump. An electric starting motor
drives through the gearbox to the compressor
shaft.
The 11-stage axial compressor is designed
for a pressure ratio of 15. Its construction allows
for simplified installation and overhaul activities.
The inlet guide vane and three downstream
rows of stator vanes are adjustable to optimize
the aerodynamic behaviour and enhance the
stability margin at part load operation.This also
allows high exhaust gas temperature for
excellent part load CHP efficiency by varying
part-load airflow.
The six individual Advanced Can
Combustion (ACC) chambers are evenly
distributed along the circumference, inclined
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 Combined heat and power
MGT6000 gas turbine
Credit: MAN Diesel & Turbo
relative to the centreline of the shaft and
flanged to a single piece inter stage casing.
This means simplifying inspection and service
activities, as both the combustion chambers
and the transition ducts may be installed or
easily removed from the complete machine. A
simple borescope access allows the inspection
of the entire combustion chamber, the transition
duct and the first row of turbine stator vanes.
The combustion chamber design contains
a vortex-stabilized burner section within the
combustor can, followed by a transition duct
leading into the first stage turbine nozzle.
The combustors are of modular design,
easily accessed, removable and exchangeable
in the field.The burner has a swirl chamber and
two different gas fuel injectors which are
operated in diffusion mode (pilot gas), in pre-
mix mode, or in the combined diffusion and
pre-mix mode depending on load. With this
design, emissions below 10 ppm can be
achieved over a wide power range.
As with the compressor rotor, extensive
access for borescope inspection is easy for the
entire combustor section and for the turbine
nozzles and blades. Ignition of the flame is
through individual high-energy torch igniters,
one for each combustor can.
Electric Power Output
Efficiency
Exhaust gas flow
Exhaust gas temperature
Emissions (gas fuel, ref. to 15% O2, dry) at 50 – 100% load:
NOx
CO
Table 1. MGT6000 Performance and Emission Data
16 Power Engineering International April 2018
1804PEI_16 16
The turbine is a three-stage axial flow design.
Like the compressor rotor, the three turbine discs
are assembled and held in place with Hirth
couplings and centre tie-bolt.
The first two turbine stator vanes and the
rotor blades are internally cooled. The tip area
of the first stage rotor blades is provided with a
rubbing edge to reduce tip clearance losses.
The second row blades have contacting pre-
loaded tip shrouds.
The gas turbines are delivered as pre-
mounted units on a steel base frame, complete
with lubrication and auxiliary systems as well
as enclosure, inlet and exhaust system modules,
engine and driven equipment controls, fire
detection and suppression system. Such pre-
assembled packages help to minimize erection
and engine installation work at site.
For customer support (e.g., for maintenance
purposes or remote diagnostics), the control
system is equipped with a remote data
transmission interface. This allows the
transmission of data for analysis, diagnostics
and maintenance support or to allow remote
monitoring for the operator.
The MGT6000 power generation unit has
been designed to meet international
requirements for power generation and is able
6.63 MW
32.2%
26.2 kg/s
505°C
15 ppm
24 ppm
to compensate for grid instabilities. Due to
ongoing changes worldwide in electrical power
generation structures, the technical
requirements for power generation units are
also changing.A very robust design with regard
to grid failures, disturbances and instabilities is
required, which means that the machine needs
to stay in operation in many of these cases.
This results in a design which allows rapid
load changes while the machine remains in
operation – even in case of a sudden power
drop of 100 per cent. The MGT6000 power
generation package has been tested in order
to prove its capability to meet the requirements
regarding the dynamic and static behavior for
power generation units operated in an electrical
grid or in island mode.As part of the test, sudden
load changes, e.g. a 100 per cent power drop
or a 60 per cent load increase in less than
50 milliseconds, were applied and successfully
handled without initiating shutdowns and
without exceeding the allowed frequency and
voltage variation limits.
Therefore the MGT6000 power generation
unit is able to fulfil increasingly stringent
requirements with regard to dynamic behaviour
in case of grid failures, availability and reliability.
Distributed generation with CHP
CHP technologies are nowadays proven,
reliable and cost-effective systems focusing on
decentralized power generation where heat
recovery is used to produce steam, hot water
and/or cooling for a wide range of industries
like food processing, breweries, automotive,
agriculture and pulp and paper, among others.
These plants generally have high process-
related constant thermal and electrical
requirements. In the food industry, process
heating uses approximately 30 per cent of total
energy, while process cooling and refrigeration
demands about 15 per cent of total energy
output. Breweries use particularly large amounts
of energy because many steps in the brewing
process actually involve heating or cooling. In
the chemical industry, energy costs account
for up to 15 per cent of manufacturing costs
on average; in addition, steam is required for
chemical processes.
In typical process solutions for CHP
applications, a by-pass stack as well as a
supplementary firing unit are used. Both features
are optional and can be deployed depending
on project-specific requirements.
With such CHP configurations, overall system
efficiency of up to 90 per cent can be achieved
(ISO conditions, zero inlet/exhaust pressure
losses) while having very low emissions in a
wide range of operational loads. Compared
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 Find out how we can increase the
life of your gas and steam turbines

,
ing
ing

ing

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 Combined heat and power
to conventional production of electricity and
steam using coal firing, the reduction of CO2
greenhouse gas production is in the range of
100,000 tonnes per year for each MGT6000 CHP
unit.
But besides high efficiency and low
emissions, industrial CHP applications also have
to show good return on investment. Considering
average operation times of 8000 hours per year
and an average cooling time of 2400 hours
per year as well as typical gas and electricity
prices, static pay back times between two years
(district heating application) and 4.5 years
(CHP application with power generation, steam
and cooling) can be achieved.
MGT gas turbines in China
MAN looks back at a century-long history in
China, where the company today operates
more than 750 turbomachinery casings. For
power generation applications with gas
turbines, several MGT gas turbines have been
sold so far to China. All of them are operating
or are scheduled to operate in CHP applications.
The first four MGT6000 series gas turbines
where set into operation in January 2016 in the
Anting/Shanghai power station for end
customer CSVW (Volkswagen China/Shanghai
Motors). This project was executed together
with Shanghai Aerospace Energy Co Ltd which
took the EPC responsibility and supplied boilers,
air intake and exhaust systems as well as
generators. In this power station, four boilers
generate steam for automobile production lines
and hot water. In total, the plant generates
18 Power Engineering International April 2018
1804PEI_18 18
Exchanging a MGT6000
Credit: MAN Diesel & Turbo
approximately 26 MWe, and heat for production.
All four CHP lines have operated approximately
35,000 hours in total since commissioning
(status as of February 2018). Two CHP units
always feed one production grid.As the factory
is operating in island mode, the CHP units have
to support all of the electrical and thermal load
requirements of the production grids according
to their direct demand.This leads to daily load
changes.
Air pollution is also a severe issue in the
Shanghai area. With the installation of the four
CHP units, pollutant output is reduced
significantly compared to a conventional coal-
fired boiler plant. In particular, emissions of NOx,
CO and smoke are very low and a major
reduction in CO2 greenhouse gas production
is achieved.
Air pollution also affects the CHP plants’
operational performance since the gas turbines’
air inlet filter can be clogged by pollution
particles. In addition, micro particles also enter
the air intake path and form deposits on the
rotating and stator parts of the compressor.This
leads to reduction of air flow and compressor
efficiency. Whereas air intake filters need to be
replaced according to their degree of
contamination, compressor losses can be
recovered to a great extent by washing the
compressor via nozzles which are installed in
the compressor inlet. A performance recovery
of 90 per cent is not uncommon after successful
wash of a fouled compressor.
During 2018, further CHP plants will be
commissioned in the town of Changsha. The
plant will include an MGT6000 gas turbine as
well as a THM series gas turbine.Together these
CHP sets will generate about 17 MW of power
and 35 MW of steam for an industrial park.They
will replace existing coal-fired facilities. These
power stations will also be built together with
Shanghai Aerospace Energy Co Ltd as EPC.
Additional MGT6000 gas turbines will go into
operation. Two of them will be used for power
generation of approximately 6 MW and steam
as thermal power of 13 MW for paper production
facilities. These industries will operate more or
less continuously.
Another CHP plant will supply power and
steam for an industrial park which is producing
electroplating and printings. Also, these CHP
plants will intensively contribute to the shift from
coal-fired to gas-fired power and heat in the
People’s Republic.
Maintenance concepts
Economical operation of gas turbine-fired CHP
plants calls for preventive maintenance
concepts which help to operate the plant with
a low number of disturbances.
This concept includes routine maintenance
measures conducted by the operating
personnel and periodic scheduled
maintenance measures, e.g., inspections of
the core engine and systems on an annual
basis or after 8000 equivalent operating hours.
This includes boroscope inspections of the core
engine which can be conducted via openings,
avoiding the need for disassembly. In addition,
lube oil analysis as well as an audit of control
system and auxiliary systems are conducted.
After 40,000 equivalent operation hours an
overhaul of the core engine is foreseen. For this
overhaul the core engine is removed from the
package and can be replaced by an exchange
unit.
During the development of the MGT6000
gas turbine series, special attention was given
to the service aspects of the unit. The core
turbine can be removed within 48 hours. This
exchange time covers the installation of a
replacement core engine and depends on
project- and site-specific conditions, e.g.,
agreed work shift models and accessibility of
the gas turbine.These maintenance works can
be included in different service and
maintenance agreement types.
Ulrich Orth, Andreas Spiegel, Detlef Viereck,
Marcel Sicker and Sven-Hendrik Wiers
work at MAN Diesel & Turbo in Germany
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1804PEI_19 19 4/12/18 3:37 PM

 Combined heat and power

Q&A
Dr Sven-Hendrik Wiers,
MAN Diesel & Turbo
MAN Diesel & Turbo’s vice-president, Gas Turbines discusses the Chinese market, gas turbines for combined heat and power
applications and where the company’s R&D is headed

r Sven-Hendrik Wiers is vice-president,

D Gas Turbines at MAN Diesel & Turbo and

co-author of the article on p14 of this
issue. He is based in Oberhausen, Germany.
Tildy Bayar spoke with him about gas
turbines for combined heat and power
applications, the Chinese market and where
MAN’s R&D is focused.

Q: Based on your sales of MGT6000 gas

turbines in China, what are your projections
for future growth in that market? And, do you
have local manufacturing in the country?
A: Thanks to the change in regulations, China
decided to shut down all coal-fired boilers up
to 10 MW, and due to that fact a lot of coal-fired
boilers in the class from 5–10 MW will be
replaced by gas turbines.
Gas turbines are a clean technology if
compared to coal and China definitely has an
environmental issue with all the coal-fired power
plants and boilers producing heat and steam
for industrial processes.
One of the most efficient ways to produce
power and heat/steam/cooling is, and will be
in future, the combined heat and power (CHP)
plant. For decentralized CHP plants, also in
combination with renewables, I see a growing
market.
As for local manufacturing: yes, the entire
package including boiler and generator is local
content manufactured by our partners in China.
We do the packaging at MAN’s workshop
in Changzhou; however, the core gas turbine
itself comes from our facility in Oberhausen in
Germany.

Q: Besides the need to address air pollution,

what other drivers exist for the growth of CHP
in China, and in Asia more generally?
A: The main driver is the environmental impact
and the shift from coal to gas. In certain areas
Dr Sven-Hendrik Wiers
they have also installed LNG terminals and
China also signed a gas contract with Russia

20 Power Engineering International April 2018 www.PowerEngineeringInt.com

1804PEI_20 20 4/12/18 3:37 PM

 HEAT EXCHANGERS
AND
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• Brazing and Welding, performed by
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EN 9606, EN 15614, EN 13585, EN
13134
• NDT operators qualified according to
EN ISO 9712, SNT-TC-1A, ASME V
• EAC mark of conformity.
• AHRI Std. 410 Performance
certification.

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Fatigue assestmennt.

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1804PEI_21 21 4/12/18 3:37 PM

 Q&A
A MGT 6000 power generation unit
Credit: MAN Diesel & Turbo
in order to secure the gas supply following its
decision to convert from coal to gas.
This accounts for China, but then look at
Southeast Asia which is still a growing market.
There is population growth on all Indonesian
islands, and they all need power. Of course
renewables are an option, but on a small island
gas turbines or engines are definitely needed
if you also want heat or cooling for industrial
processes in the food industry, pulp and paper
and households, for example.
22 Power Engineering International April 2018
1804PEI_22 22
Q: Have you taken special design,
configuration or installation measures with
the MGTs to deal with China’s pollution?
A: There is definitely a need for clean power in
Asia. After the Paris Climate Agreement two
years ago, there is a growing target to reduce
the CO2 footprint worldwide and limit global
warming by combining, in a smart way,
renewables with clean power from gas turbines
or similar technologies – and they can be also
fired by renewable gases, for example.
Synthetic gases which are produced by
renewables are a very clean option to produce
power and steam. MAN can offer a hybrid
system combining a gas turbine, gas engines,
battery systems, renewables and power-to-gas
technology.
One unique feature of MAN Diesel & Turbo
is that we have both engines and turbines in
our portfolio. If these machines are combined
with renewables and battery systems and there
is smart power management software as an
www.PowerEngineeringInt.com
4/12/18 3:37 PM
 Q&A

umbrella which enhances the whole plant, the carbon footprint can
be optimized substantially.
A growing number of countries will demand such systems in future,
because global warming is not only limited to China. It’s an issue for all
of us, and as an industry we are asked to develop innovative
solutions.
We are also installing an online monitoring and diagnostic which is
linked to our database. We can compare certain machine data and
predict its behaviour. And of course we can also predict if failure could
occur, and act in advance – the so-called predictive maintenance.
Q: What issues is your team focused on right now in terms of gas
turbine development? And, where can you see future development
needing to focus?
A: In the turbine, advanced cooling technologies have been applied
in order to improve efficiency and reduce fuel consumption. We also
introduced jet engine technology to our gas turbines to reduce gaps
and clearances and to optimize sealing systems – all in line with the
overall target of increasing the efficiency of our system solutions.
Of course, on the combustion side you have to develop and work
on more advanced combustion chambers. This is key to reaching
significant NOx values. Our current combustion chamber is able to do
this, but of course we’re working on further improvements for the
combustion process.
Additive manufacturing will gain importance in future, and we already
use it today. By applying additive manufacturing we are able to introduce
advanced cooling and repair technologies.
existing technology. Due to the fact that regulations did change worldwide,
there was a need to develop this kind of combustion technology with a
lean pre-mix combustion chamber.
For a couple of years we’ve talked about backup power and the
need for gas turbines to be much more flexible, which requires a different
kind of design philosophy. This is all driven by a change in regulations
and the related growth in renewables.
Q: Are gas turbines or gas engines better for CHP?
A: You have a need for both solutions. The question is always about the
process: is it power-driven or heat-driven? It really depends on the
customer’s needs and what the driver is.
We as MAN Diesel and Turbo can offer both solutions to our customers
and this is the real benefit.
Tildy Bayar is Features Editor of PEi magazine
Visit www.PowerEngineeringInt.com
for more information
Others simply sell you a product –
we offer a solution.
OHL Gutermuth
A control and shut off technique you can rely on.

This represents an advantage for the customer, because they don’t

have to exchange the whole part but can simply repair it – that’s an
important operating cost advantage. We’re doing a lot of R&D to further
improve this and to be able to introduce the best available technology.
For the industrial gas turbines in the power range from 5–20 MW, the
matter of cost is also an important aspect. We can apply more
sophisticated materials, coatings etc, but at the end of the day I think
there is a limit to what the customer is willing to pay for efficiency
improvements.This limits the technology the manufacturers are able to
employ.
Look at the huge gas turbines in the field, which have an inlet Customized
temperature of 1600°C. Such technology could be introduced in an Valve Design
industrial gas turbine but the question is, would the customer be willing „MADE IN GERMANY“

to pay for that improvement? There’s still a business case which has to
alves
be considered. ESD Best V 0
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If the regulator and authorities would release stricter regulations, SOLAR since r1s
then maybe more companies will be willing to pay for advanced POWER Yea
technology. Nevertheless, we work with a jet engine company in
Germany and of course we use similar sealing and cooling technology, OHL Gutermuth Industrial Valves GmbH
Helmershäuser Str. 9+12 · 63674 Altenstadt / Germany
but we cannot apply the same materials and coatings because of
Phone +49.60 47. 80 06-0 · Fax +49.60 47.80 06-29
their high costs. www.ohl-gutermuth.de · og@ohl-gutermuth.de
Certain emissions standards must be met, because it’s state-of-the-art
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www.PowerEngineeringInt.com Power Engineering International April 2018 23

1804PEI_23 23 4/12/18 3:37 PM

 Case study
Turbine upgrade pays off
How an upgrade to a gas
W
With 180 units operating across the
turbine fleet has added country, V94.2 is the largest turbine
5 GW to Iran’s power fleet currently active in Iran’s power
capacity sector.
Considering its significant share in Iran’s
turbine market, even minor improvements in
V94.2’s performance will bring substantial
benefits for the nation’s power grid, such as
increasing its overall capacity and boosting
the grid’s efficiency.
The V94.2 family has long been a favourite
choice of Iran’s power sector due to its reliability,
accessibility, high output, domestic
manufacturing and services and low investment
cost.
Iran’s growing economy and its rising power
demand, the push for rehabilitation and
renovation of national infrastructure and
environmental commitments, such lower fuel
consumption and lower carbon footprint in line
with the COP21 agreement, are factors that
have encouraged Iranian power plant
developer MAPNA Group’s executives to opt
for long-term investment in the gas turbine.
This was combined with MAPNA’s strategy
to develop homegrown technology and boost
24 Power Engineering International April 2018
1804PEI_24 24
its competitive advantage domestically and
internationally.
he first steps to upgrade the V94.2 were taken
in 2011 under an R&D scheme dubbed MAP2+.
The project focused on modification of the
mechanical design and combustion elements
of the turbine to improve its efficiency and gross
output. The final product, called MGT-70(1),
boasted an output of 166 MW and an efficiency
rate of 34.5 percent.
The project was then redefined in a broader
scope under the title MAP2B. Before developing
the final product of MAP2B, an in-between
version, MGT-70(2), was introduced in 2013, with
slightly increased combustion temperature,
modified hot gas path, improved performance
of cooling, and an output of 170 MW.
MGT-70(2) was put into operation in the
MAPNA-owned 954 MW Assaluyeh power plant
in 2013.
Throughout the last phase of the MAP2B
project, Unit 6 of the Parand combined-cycle
power plant, located 30 km south of Tehran,
was turned into an advanced laboratory
named MAP-Lab for prototype testing as well
as future research activities.
Special advanced measuring equipment
which gathers a large volume of data from the
machine, analyzed by MAPNA engineers, were
used in the tests.
MGT-70(3) tests were finally carried out in
late June 2017, in +40°C temperature, in
circumstances which allowed reliable
monitoring of various parameters such as
compressor stability.
www.PowerEngineeringInt.com
4/12/18 3:38 PM
 Case study

Thanks to cutting-edge design, gross output

has increased from 157 MW in the V94.2 version
3 to 185 MW in MGT-70(3) at ISO conditions,
while its efficiency has reached over 36.4 per
cent with a significant 2 per cent leap. A mere
15°C reduction in combustion degree, which
only slightly decreases output and efficiency,
can stretch the span between two successive
overhaul operations for an additional 8000
hours, increasing the lifetime of the turbine.
These advantages were gained through a
full 3D redesign of compressor blade and vane
airfoils; full 3D redesign of turbine blade and
vane airfoils; redesign of cooling and heat
transfer of turbine blades and vanes; redesign
of turbine secondary air system (sealing and
cooling); redesign of journal-thrust bearing;
new base material for all turbine blades and
the first four stages of compressor, and
advanced coating for hot gas path.
Not only has MAPNA enhanced the
performance of the gas turbine, but it has also
developed additional packages for gas
turbines and combined-cycles to improve
performance, flexibility and reliability. A
triplepressure steam cycle which employs an
MGT-70(3) gas turbine reaches to 54 per cent
efficiency for the E-Class plant.
Supporting the national grid
Upgrading the 180 units of V94.2 turbines
operating across Iran and converting them
into the MGT-70(3) version could add over 5
GW to the country’s current electric power
capacity.
There are also other advantages to this
conversion campaign. For example, a
massive amount of fuel can be saved due
to significant efficiency increases.
This substantial drop in fuel consumption
and expenses translates into a sharp cut in
carbon emissions for each upgraded unit in
compliance with Iran’s environmental
commitments under the 2016 Paris
Agreement.
Other advantages of the new MAPNA
product include extended lifetime,
guaranteed services and spare parts for long-
term operation, uprated electrical generator,
additional control features to attain maximum
output, and saving the budget allocated to
construction of new power plants.
The new product found a home quite
early, with installation in the 3 GW combined-
cycle power plant which is being constructed
by MAPNA Group in Rumaila, near Basra in
southern Iraq.
Currently, two units of MGT 70(3) are under
installation at Rumaila plant, while six other
service upgraded units have been
commissioned and delivered to Iranian
customers.
Visit www.PowerEngineeringInt.com
for more information

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1804PEI_25 25 4/12/18 3:38 PM

 Distributed energy

A 6F.01 turbine
Credit: GE

‘China is at the dawn of a major

boom in gas distributed energy’
As the country’s energy

structure and industry
landscape evolves, it is setting
requirements on cogeneration,
says Yang Dan, president of GE
Power China
The Huaneng Guilin Gas Distributed Energy Project
Credit: GE
G
E Power has announced the
conclusion of several milestone
projects in Asia.
It has celebrated the commercial operation
of China Huaneng Group’s Huaneng Guilin
Gas Distributed Energy Project, using three 6F.01
turbines.
The project marks the first 6F.01 gas turbines
in operation globally and builds on GE’s already
strong 6F gas turbine performance in China,
with more than 30 units operating commercially.
“The project marks a breakthrough for many,
as the first-ever gas power project for the city
of Guilin and the first-ever distributed energy
project by China Huaneng Group,” said Li
Xiaodong, general manger of Huaneng Guilin
Gas Distributed Energy Co.
“With GE, we are advancing the city’s smart
energy intiatives, supplying high-efficiency and
cleaner energy, and supporting the city’s
ambition to increase prosperity.”
Guilin, in Guangxi Zhuang Autonomous
Region, is a world-famous tourism destination
in China, known for its incredible natural
landscape. As it is developing industrially, the
city is not only looking for cleaner energy, but
also a modern and efficient heat supply for
many businesses including life science,
pharmaceuticals and technology industries.
Featuring an innovative combined cooling,
heating and power (CCHP) configuration, the
project will be capable of self-determining its
electricity output based on heat demand while
also supplying heating and electricity to nearby
factories. It is also capable of providing heating
and cooling to surrounding public, commercial
and residential areas. These benefits, centred
around the 6F.01 technology, will help the region
see more reliable, cost-effective and flexible
power for many years.
“China is at the dawn of a major boom in
gas distributed energy, and as China’s energy

26 Power Engineering International April 2018 www.PowerEngineeringInt.com

1804PEI_26 26 4/12/18 3:38 PM


structure and industry landscape evolves, the
country is setting requirements on cogeneration,”
said Yang Dan, vice-president of GE and
president of GE Power China.
“From design and manufacturing to
installation, our global and local teams are
joining hands to provide timely, reliable and
customizable solutions to make 6F.01 a good
fit to the market. With a strong commitment in
localization, we will continue to create more
value for customers and contribute to cleaner,
safer and more efficient power systems.”
With advanced materials and technologies
adopted from GE’s successful H- and F-class
gas turbines, the 6F.01 boasts an industry
leading combined-cycle efficiency of 57 per
cent and fuel utilization rate of 81.15 per cent.
The turbine is also the most efficient 50 MW gas
technology and has the best heat cogeneration
capabilities in its class, making it an ideal choice
for gas distributed energy projects.
Malaysia CCPP
GE Power Services has signed a 21-year deal
with Malaysia’s Southern Power Generation for
a 1440 MW combined-cycle power plant.
The Track 4A plant in Pasir Gudang, Johor,
is under construction and under the terms of
the agreement, GE will provide services solutions
for two GE 9HA.02 gas turbines – the first to be
installed in Malaysia.
It will also deploy its Predix Asset Performance
Management (APM) software to help improve
Guilin is known for its incredible natural landscape
Credit: GE
The Huaneng Guilin project marks the first 6F.01 gas turbines in operation globally
Credit: GE
www.PowerEngineeringInt.com
1804PEI_27 27
the plant’s visibility, reliability and availability
and also utilize its Fleet360 platform of gas plant
solutions.
“With the largest base of installed gas
turbines in Malaysia, GE has grown hand in
hand with the country’s power development
needs,” said Ramesh Singaram, president of GE
Power APAC.
The agreement also includes GE’s Predix
APM suite of digital solutions. APM improves
asset visibility, reliability and availability and
reduces operating and maintenance costs:
data processed by the APM solution can help
balance maintenance costs, improve
inspection intervals and provide invaluable
insights into operational risks.
Data collected from sensors throughout the
facility will be monitored at GE’s Monitoring &
Diagnostics (M&D) Center in Kuala Lumpur.The
plant will be jointly constructed with Taiwanese
Distributed energy
EPC partner CTCI Corporation. It will consist of
two generating blocks, each equipped with a
9HA.02 gas turbine, generator and heat
recovery steam generator from GE.
Yokohama project
GE’s Power Services has also announced that
its largest ever flange-to-flange (F2F)
replacement project in Japan was successfully
completed on time at Block 7 and Block 8 of
TEPCO Fuel & Power’s Yokohama plant in Japan.
GE said the project is expected to save
approximately $71 million in annual fuel costs.
The project involved a total of eight gas
turbines ranging from 9FA.01 to 9FA.03 models
being upgraded to improve performance and
reduce lifecycle cost for TEPCO.
GE’s solution enabled TEPCO to incorporate
all gas turbine replacements and upgrades to
the latest technology at minimal disruption to
plant operations. It achieved increased total
plant output of gas turbine combined cycle
by 216 MW and improved efficiency of 1.7 per
cent under customer load conditions. It also
lowered emissions by 30,000 tonnes annually
per unit.
In a flange-to-flange replacement exercise,
the entire engine from inlet flange to exhaust
flange is replaced as one piece.This addresses
multiple power generation needs at once,
including asset life extension, performance
recovery, emissions controls, and fuel flexibility.
In addition to the gas turbine upgrade at
the Yokohama plant, GE also successfully
completed the world’s first 9EMax four-stage
gas turbine at TEPCO’s Futtsu plant in Chiba.
The now completed upgrade is the first of a
total of six 9EMax upgrades to be implemented
at the plant and is expected to increase output,
improve thermal efficiency from 47.2 per cent
to 51.4 per cent and reduce emissions.
Kelvin Ross is Chief Editor of PEi magazine
Visit www.PowerEngineeringInt.com
for more information
Power Engineering International April 2018 27
4/12/18 3:38 PM
 Aeroderivative turbines

‘Efficiency is p
That’s the mantra at newly-

L
ast month, MTU Aero Engines rebranded
rebranded MTU Power. Gregor its gas turbine competencies under the
Stöcker talks with Kelvin Ross name MTU Power.
about the company’s new The new brand consolidates the existing
direction and offers engineering, manufacturing and aftermarket
maintenance tips for aero- expertise across all MTU’s business units: Aero
derivative gas turbines Solutions, Brush Seals and MTU Maintenance.
Gregor Stöcker, of Industrial Gas Turbines at
MTU Power, says the overall aim is to “harmonize
the extensive experience, in-depth knowledge
and creative, never-give-up mentality within the
company and bring its services even closer to
the customer.
“We want customers to be able to find what

28 Power Engineering International April 2018 www.PowerEngineeringInt.com

1804PEI_28 28 4/12/18 3:38 PM


s power’
they are looking for, fast. And we want to be
more visible in the market.”
‘Closer to the customer’, he explains, means:
“We want our customers to be able to find us
and the information they need quickly – as a
company with significant roots in the aerospace
industry, this was at times confusing.
www.PowerEngineeringInt.com
1804PEI_29 29
“But we also mean being physically close
to the customer and we have been working
really hard on this. We moved our US-based
level II shop to Dallas,Texas in 2016, so the focus
last year was on maturing the services we offer
there.
“We also increased capabilities overall, for
Aeroderivative turbines
instance by adding a DLE mapper to our team
as well as introducing local heat treatment for
lever arms and improving the cooling fluid
systems of our grinding machines. And we
expanded our lease and rotables pool, too.”
He explains the need to expand the lease
and rotables pool.“One of the things we say is
Power Engineering International April 2018 29
4/12/18 3:38 PM
 Aeroderivative turbines
‘efficiency is power’. Lease engines and rotables
are used to avoid downtimes when a customer’s
turbine is with us for maintenance, repair and
overhaul.
“Take the US market, where a lot of LMs are
used as peakers to help cope with spikes in
power demand. The machines see multiple
starts and shutdowns, leading to more material
fatigue. If I’m a peaker operator and my hot
section fails, I need a replacement fast so I can
be back up and running when the grid needs
me. Electricity demand isn’t going to wait for
anyone.”
Looking outside the US, Stöcker believes “we
are seeing some recovery in the gas market in
Europe”.
“For instance, the UK government
announced recently that the country would
be shutting down all coal-fired plants by 2025
and introducing more gas and nuclear energy
to compensate for this. Of course, Asia-Pacific
is a growing market with demand for power
trains for LNG plants. And in Africa, the oil and
gas segment is on the up. We’re getting a lot
of interest in and from that region.”
He says that overall, MTU has “certainly seen
the effects of a low oil price in recent years, with
customers from the oil and gas industry, in
particular, looking to save as much as they can
on maintenance without compromising on
reliability.Though cost-saving has always been
a priority, of course.”
Stöcker highlights how MTU Power helps
customers reduce and optimize costs. “On a
general level, we perform customized
workscoping, which means that the workscope
is defined entirely according to customers’
needs – from ‘light’ performance restoration to
complete overhaul.
“We won’t exchange in new material if there
is a repair available, as repairing is always more
cost effective than replacing. Repairs generally
‘Repairing is always more cost-effective than replacing’
30 Power Engineering International April 2018
1804PEI_30 30
The new brand consolidates engineering, manufacturing and aftermarket expertise
cost up to 20 per cent of a new part and we
perform the large majority of repairs in-house.
We can also build in overhauled material as a
cost-reduction method.”
Asked to highlight any particular issues he
is seeing at the moment, he highlights water
washes. “We had an interesting LM6000 case
last year.The turbine showed strong oxidation/
corrosion on the stage 1–3 low pressure turbine
nozzles, although the turbine only had
25,000 hours of service time, which is about half
what we would expect before seeing it for
performance restoration.
“The resulting oxide layers caused numerous
cracks and the parts’ wall thickness was
significantly lower than originally. During
investigation, we discovered that the aluminide-
coated surfaces had been exposed to
unusually aggressive contaminants, as found
in engine cleaners.
“When too little water is used during a
compressor wash, the washing agent and dirt
can be re-deposited on the turbine components.
Credit: MTU Power
Credit: MTU Power
So our tip to operators would be to really pay
attention to the water during washes, making
sure there is enough for dilution and rinsing.
Ideally, surfactants would also only be used for
compressor washes.
“We also saw a fuel system contamination
through dirty water that caused a number of
issues with the respective LM6000 and LM2500
turbines recently. Fuel systems aren’t pressurized
during the water wash procedure and we
believe the contaminated water wash fluid was
able to enter the fuel system via the gas
injection swirlers. Our recommendation here
would be to use instrumentation air during the
wash, or reduce the need for water washes in
general through the installation of a three-stage
high-efficiency particle air (HEPA) filter system
into the air take.”
But Stöcker is keen to highlight services that
can be done in the field to avoid a shop visit
altogether.
“We would always recommend regular
inspection, for instance. But field service experts
can also be a good option for troubleshooting
or organizing module exchanges.
“Take for instance a hot section exchange,
as mentioned above. It is possible to make the
swap without removing the power turbine and
turbine mid-frame from the package or opening
the flange that connects the two.
“Of course, this takes care. Sometimes the
power turbine seal will clamp to the stage 1
disk, and you want to avoid any seal ring
damage. But, with support, the intrusion can
be minimal, just like the downtime.”
Kelvin Ross is Chief Editor of PEi magazine
Visit www.PowerEngineeringInt.com
02/2016 - Petergraf
for more information
www.PowerEngineeringInt.com
4/12/18 3:38 PM
 A new generation is born
New products.
New technologies.
New service capabilities.
Ansaldo Energia: a global player
in the power generation market.
02/2016 - Petergraf

For more information, enter 13 at pei.hotims.com

www.ansaldoenergia.com

1804PEI_31 31 4/12/18 3:38 PM

 Pump maintenance
Minimizing running
costs for pumps
Large scale, high performance
pumps have traditionally been
designed to meet the
specifications of a particular
application without the need for
speed control. But changes in
operating conditions after the
initial installation can result in a
pump not operating near its
best efficiency point, which
makes the overall process less
efficient, writes Alex Myers
32 Power Engineering International April 2018
1804PEI_32 32
I
n line with everything from our cars to home
appliances, factories, buildings and
infrastructure, the power generation
industry is under pressure to become more
efficient.
As the number of renewable energy
generation sites increases, the traditional
generating sites have to compensate for
variable availability in addition to natural
demand fluctuations. However, the original
design of cogeneration plants using combined-
cycle gas turbines (CCGT) is to operate with a
fixed power output and, as such, the equipment
in these plants was designed to fulfil this
task.
Gas-fired plants are increasingly required to
operate ‘off-peak’ which means the output
needs to be varied in order to match the
demand. In this situation, the fixed amount of
generated steam pressure has to be broken
down across valves on the high pressure feed
system.
Configuring a variable speed drive to the
feedwater pumps can provide significant
improvements in efficiency that will also help
to minimize operating costs.
Improved efficiency
A gas-fired cogeneration plant located within
a refinery in Germany used a boiler feedwater
pump to provide 1000 m3 per hour of water,
with a head of 1355 metres.
The pump was set up at a fixed speed
operating at 2980 rpm and required a 4.1 MW
(5500 hp) motor to power it. Since the original
installation of the pump, the customer’s
production cycle had changed significantly
and the pump needed to run on partial load
due to changes in power demand.
In order to meet the required variable flow
of between 500 m3/h and 1000 m3/h, the power
plant was using a valve at the discharge to
throttle the flow.This meant that the generated
head was being throttled and the energy and
cost of creating it was wasted.
This incurred inefficiency could be avoided.
In order to improve the efficiency of the feed
pump, it was necessary to modify its operating
range by configuring a speed control
mechanism.
Initially, the customer considered two more
conventional options: a variable frequency
drive and a hydro dynamic speed coupling.
www.PowerEngineeringInt.com
4/12/18 3:38 PM
 FROM RELIABLE EFFICIENCY
TO KEEPING THE LIGHTS ON
SHELL TURBO MAKES IT POSSIBLE

Power companies are under immense pressure to

keep the lights on. As a result, modern turbine oils
must be able to cope with increased stress and
considerable design and operational challenges.
Although selecting an underperforming lubricant
rarely results in immediate failures, it can lead to
long-term increases in maintenance costs and heavy
power-outage penalties. In contrast, adopting a total-
cost-of-ownership1 approach with a high-performing
lubricant from the Shell Turbo range can help to
reduce costs by unlocking reliable efficiency. Ask
us how we can work with you to make it possible.
shell.com/lubricants

SHELL LUBRICANTS
TOGETHER ANYTHING IS POSSIBLE

1
Total cost of ownership is defined by Shell Lubricants as
the total amount spent on industrial equipment, including the
cost of acquisition and operation over its entire working life
and the cost of lost production during equipment downtime.

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1804PEI_33 33 4/12/18 3:38 PM

 Pump maintenance
However, both of these alternatives had a
number of disadvantages: chiefly the size,
inconvenience and cost of installation for the
medium voltage variable speed drive (VSD)
and the inherent efficiency losses of the
coupling.
These two options did have advantages
though: the VSD offered good energy efficiency
and the coupling was compact and relatively
easy to fit, sitting between the main motor and
pump.
Sulzer proposed the use of a third option,
one that was developed for the renewable
power industry and delivered the benefits of
both alternatives and none of the
negatives. The variable speed electro-
mechanical drive (CONTRON) offered a
compact, convenient solution that could be
installed between the motor and pump and
was extremely energy efficient, even more so
than the large VSD.
For this particular application the
combination of a variable speed drive and a
mechanical geared assembly would prove to
be the ideal solution. The CONTRON electro-
mechanical drive train allows the main motor
to remain mounted in line with the pump, but
uses a planetary gear arrangement driven by
a high power servo motor and variable speed
34 Power Engineering International April 2018
1804PEI_34 34
Original arrangement:
Shaft power at low operating point with
fixed speed arrangement
1700m @ 500m3/h at 71.0% efficiency
(5,580 ft @ 2200 USGPM at 71.0%)
Power: 2944 kW (3950 hp)
drive system as an override that takes over
progressively as the required operating speed
drops.
The real headline here is that the addition
of the CONTRON makes the entire power
transmission system supplying motive power to
the pump up to 95 per cent efficient.
Savings
The new arrangement provided a power saving
of 1090 kW, which translates into a considerable
saving every year that has been estimated
between €218,000 ($237,000) and €436,000
depending on the annual operating hours.
Furthermore, the initial installation costs are
lower than those for a variable speed drive and
the overall efficiency is higher.
As with all control technologies there are
both advantages and constraints that must be
considered when implementing this type of
system.The overall footprint of the solution can
be a major factor, especially on retrofit situations.
In this case, the electro-mechanical drivetrain
Furthermore, the initial installation costs are
lower than those for a variable speed drive and
the overall efficiency is higher.
As with all control technologies, there are
both advantages and constraints that must be
Electro-mechanical drive:
Shaft power at low operating point with
controlled speed
1143m @ 500m3/h at 75.8% efficiency
(3750 ft @ 2200 USGPM at 75.8%)
Power: 1854 kW (2485 hp)
considered when implementing this type of
system. The overall footprint of the solution
can be a major factor, especially in retrofit
situations.
In this case, the electro-mechanical
drivetrain enables the main drive motor to be
connected directly to the grid, removing the
need for bulky speed control equipment.
However, this solution does have limitations and
can currently only be used with equipment
drawing up to 20 MW (26,800 hp) of power and
with a maximum speed of 14,500 rpm.
Nevertheless, these constraints still allow for
a considerable amount of equipment to benefit
from the latest innovation in speed control for
large scale pumps.
Further opportunities
Pumping applications around the world
www.PowerEngineeringInt.com
4/12/18 3:38 PM
 Pump maintenance

account for a significant percentage of global

energy consumption. Creating savings such
as those in the example above will have a
major benefit for applications that use medium
and high voltage drives to power high
performance pumps, such as those used in
the oil and gas, petrochemical and mining
industries.
As pressure increases on most industries to
reduce manufacturing costs and minimize
overheads, so it becomes all the more
important to question the conventional
thinking on motor control. There is, of course,
no single answer for every application but as
new solutions become available they should
be examined for suitability.
In situations where pumping applications
experience a change in duty requirements,
many will benefit from an improvement in
design.This can be delivered by retrofit experts
that offer advice, design proposals and
complete installation services based on years
of experience.

Alex Myers is Retrofit Sales Director at Sulzer

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 Design and validation
Design and validation
are keys to success
High ratings for gas turbine reliability, availability and maintainability may be ascribed to four key
factors, Carlos Koeneke of MHPS tells Tildy Bayar
E
fficiency is undoubtedly the Holy Grail for
gas turbine OEMs – but reliability,
availability and maintainability (RAM) are
also crucial aims. Validation of operational
turbines is necessary to back up OEMs’ claims.
Carlos Koeneke, vice-president, project
engineering at Mitsubishi Hitachi Power Systems
Americas (MHPSA), a subsidiary of Mitsubishi
Hitachi Power Systems (MHPS), says his firm’s
fleet has consistently received top marks from
independent third-party validation company
Strategic Power Systems, which is used by
several major gas turbine OEMs and collects
operational data directly from their customers
around the world under the auspices of its
Operational Reliability Analysis Programme.
Koeneke says MHPS’s high RAM ratings for
its advanced class gas turbines are due to
several key design and manufacturing decisions
as well as a unique method of validation testing.
MHPS’s steam cooled M501G machine
features a turbine inlet temperature (TiT) of
1500°C. Koeneke has presented RAM data for
2012–2017 based on 24 M501G turbines in
MHPS’s fleet. These data, which have been
verified by Strategic Power Systems, show a
99.26 per cent RAM factor for the M501Gs.
36 Power Engineering International April 2018
1804PEI_36 36
Although he offers several factors that he
believes explain MHPS’s high RAM ratings,
Koeneke cautions that it’s not enough to have
a well-designed and correctly installed
machine. It’s also necessary to have good
operating practices on the part of the turbine
owner as well as good maintenance routines.
From an OEM point of view, though, he
believes that there are four main factors that
have contributed to MHPS’s RAM success.
Using proven materials
MHPS has traditionally targeted a high Turbine
Inlet Temperature (TiT) as the most effective way
to increase the efficiency of advanced class
gas turbines and the corresponding combined
cycles. The company says its latest model, the
air cooled M501JAC, has demonstrated a TiT
of 1650°C.
In explaining MHPS’s high RAM numbers for
its M501G fleet, Koeneke points first to the use
of a Turbine Rotor Cooling Air (TCA) Cooler
approach, which effectively reduces the
temperature of the air used to cool the gas
turbine’s rotating hot gas path components.
He says the resulting reduction in cooling air
temperature allows for operation at high TiT and
A 501G gas turbine
Credit: MHPS
high efficiency while using low alloy steel discs
and eliminating the requirement for single
crystal hot gas path components.
Avoiding the use of sophisticated alloys that
are resistant to creep but are also susceptible
to failures when exposed to high temperatures
and the stresses typically encountered in
advanced class gas turbines, he says, is a
fundamental premise of MHPS’s design
approach.
“We use several external coolers,” he says.
“We started with a concept from our
Westinghouse partnership time in the late 1960s,
all the way up to today.
“You have two choices” for cooling, he
explains.“One is to cool the cooling air so that
the parts exposed to very high temperatures
are cooled with cooled air. Or you start using
sophisticated material that can withstand the
high stress and high temperature operating
environment involved in gas turbine parts,
especially the turbine discs.
“If the hot parts are exposed to high
temperatures, you have the risk of failures
associated with creep. One way to avoid this
is by either cooling the air, which is what we do,
while designing the plant to recover the heat
www.PowerEngineeringInt.com
4/12/18 3:38 PM
 Design and vaidation

removed from the cooling air in the bottoming
cycle. The other option is the use of sophisticated
and more expensive materials. If you go towards
sophisticated metals such as high nickel
content discs, they do have better creep
resistance but are weak in terms of surface
imperfections that can lead to cracking. So
there is an advantage in terms of sustaining
higher temperatures, but there is a disadvantage
which can involve disc cracking failures.”
Under one roof
Next, Koeneke describes MHPS’s ‘under one
roof’ approach for refurbishing and
manufacturing hot gas path components. With
this approach,“we can make sure all the parts
are manufactured under our quality control
system and time delivery requirements,” he says.
“Using sub-suppliers can be more cost-
effective, but you end up relying on their quality
control. We know of many casting failures that
have resulted in significant damage with
enormous insurance claims. We have rarely
experienced casting issues.”
He notes that purchasing castings from
different suppliers, engaging other companies
to handle machining and drilling internal
cooling holes, and then having other suppliers
apply the thermal barrier coatings may achieve
certain cost reductions, but there is a downside.
“If someone is trying to do the job less
expensively, there might be some cut corners,
and in some cases the cheaper parts fail”.
“We have the castings done in well-verified
Japanese casting companies we have used
for years, and then we execute the entire
machining process inside our Parts
Manufacturing buildings in either Japan or
Orlando, Florida. There we do absolutely
everything to complete that part, and the part
goes out of the door finished.
“Finishing on time and following strict in-
house quality criteria can be the difference
between being late in your outage or on time,
and it directly affects reliability and availability.”
Conservative design approach
According to Koeneke, a conservative design
approach is also key to RAM success.
While he notes that this is “somewhat
contradictory because increasing turbine inlet
temperature involves risks that make this effort
the most demanding challenge in gas turbine
design”, he says MHPS’s “secret sauce, in our
opinion, is to do it gradually”.
“We’ve been doing this for decades, mainly
with the incentive of generation in Japan and
other Asian countries where fuel is considerably
more expensive than in the US. We went from
F-class to steam cooled G, then applied
conversion to air cooled G, called GAC. Years
later, we introduced the steam cooled J and,
once again, applied the same successful
conversion applied to the G to produce an air
cooled J, called JAC.
“We have always avoided focusing solely
on flexibility, low loads, emissions and other
good flexibility features while neglecting
efficiency. This would have led us to the wrong
assumption that efficiency is not important in
countries with low fuel cost, like the US.
“Despite the low fuel cost, clients here in the
US want efficiency. We continued our progressive
temperature increase trajectory instead of trying
to jack it up at a fast rate with the associated
risks I mentioned before.”
‘Our validation is a power plant’
MHPS commissioned its ‘T-point’ validation plant
on the site of its Takasago Works in Takasago
City, Hyogo Prefecture in 1997. Performance and
durability testing of the M501G series gas
turbines began at that time.
“For decades in the 1960s and ‘70s,” Koeneke
says,“gas turbines were tested at the first client
plants. We were doing lab tests for individual
components, but no testing of the final

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1804PEI_37 37 4/12/18 3:38 PM

 Design and validation
assembled product.This product then went to
the first plant and obviously details came up
at that client’s site, causing headaches, and it
took a long time to identify and correct the
issues.
“In the ‘80s, companies started to do shop
tests. You have a setup in your factory where
you install the very first unit, which is a big effort
because these units weigh several hundred
tonnes. You put it on a stand, connect a lot of
sensors/cables/pipes and many other devices
needed for operation, then run it for a few hours.
You also have to dissipate the energy, which is
another considerable effort. We were using
hydraulic brakes; other approaches for energy
dissipation can be applied.
“The cost associated with large turbines’ fuel
consumption is very high. If you just do a shop
test you’re not getting any financial benefit other
than testing the machine with considerable
fuel expenses. Even in the US, to run a large
frame machine will burn fuel on the order of
$100 million per year – so obviously you cannot
sustain this test operation for a long time.
“We wanted to run the turbine long-term
because there are many failure mechanisms
that don’t occur until a machine has run for a
considerable number of hours and starts. You
never hear a doctor asking a parent to check
the cholesterol of a newborn baby – you’re not
going to have high cholesterol until you are
older. The same thing happens with gas
turbines: low cycle fatigue and other types of
failures occur once the machine has
accumulated a lot of starts and stops, or has
been operated under certain demand
conditions.”
MHPS’s solution was to build a power plant
inside its facility and then contract with Kansai
Electric, the local utility, to sell its power.
“We spent several hundred million dollars
building a power station,” Koeneke says, “not
with the objective of making money – but
having a contract with a local utility allows us
to recover all the expenses associated with the
investment, fuel, O&M etc.
“We bring in a new frame or or a modified
turbine, install it there, and the utility tells us when
to start/stop/ramp up/ramp down.
“During periods of low demand we are
allowed, depending on dispatch, to look inside
the turbine with a borescope, and sometimes
we’re allowed to open it. If a part is found to be
in bad shape, the designers develop
modifications and install the modified part. By
the time we sell a similar machine, the tests at
T-Point continue while the construction of the
new plant takes place. We end up with at least
two to three years of operation with the changes
38 Power Engineering International April 2018
1804PEI_38 38
Figure 1. MHPS validation approach with standard equipment
that we’ve introduced. This has been found to
be great for detecting and correcting problems,
and more importantly for testing the
countermeasures.”
Because “our validation is a power plant
that follows our design criteria, and we’re
connecting the gas turbine to a standard
generator installed on standard pedestals (see
Figure 1), if something is going to go wrong,
there is a high probably we will detect it in our
validation facility,” Koeneke says.
A unique approach
The reason only MHPS has built such validation
facilities involves “a very simple explanation”
according to Koeneke.
“Think about spending several hundred
million dollars for a company that has strict ROI
requirements,” he says.“Under such requirements,
it is easy to conclude you are better off spending
a fraction of that investment on validation and
trying to detect as many potential problems as
possible.”
Japanese companies are different, he says.
The shareholders are more broad-minded, and
the firms’ motivation is also different. For a
Japanese company, the reputation of its
products is fundamentally important. “There’s
an enormous pride associated with this, a way
of doing business,” Koeneke says.
The T-point validation plant has enabled
MHPS to detect many issues due to its long-term
running time, he adds.
“Let’s say we only perform a couple of
hundred hours of validation at a test rig facility,
and sell the subsequent unit soon after the
shop test is finished. The construction of the
subsequent project will take two to three years.
In the meantime, there will be no further shop
test validation done and the new turbine will
not be further validated or improved. On the
contrary, our T-Point unit continues running while
construction of the new plants is ongoing,
Credit: MHPS
allowing us to detect, correct and test the
corrections through long-term validation.
“For example, one issue we detected in our
J class gas turbine involved spallation of the
row 1 blades platform. This could have caused
catastrophic failures, but we noticed it early.The
design team changed the internal cooling
scheme – modifying the source of cooling air
from a relatively hotter source within the blade
to a cooler one – and then we ran the turbine
long enough to be convinced that the parts
were able to sustain the different environment.
“This approach also helps us define realistic
inspection intervals that are based on the
condition of the parts after years of validation.
We progressively increase the intervals rather
than offer long intervals based on engineering
assumptions.”
The gas turbines operating in the validation
plant run under real-life operating conditions,
he notes.
“Kansai Electric decides when we start and
shut down, when we run at maximum or
minimum load.These are real-world conditions
and we have to operate at 3600 rpm because
that’s the grid frequency. It’s true that we can’t
do load tests at different rpm, but when a client
buys a power plant it will be operating at
3600 rpm for 30 years, not under random rpm
conditions.
“Small changes in grid frequency can
happen during the life of the plant and can
induce deviation from the 3600 rpm, but it is
difficult to simulate the unit’s response if the test
facility is not using a standard generator – not
only because of the electric nature of grid
frequency disturbances, but because of the
generator’s large torsional inertia.”
Tildy Bayar is Features Editor of PEi magazine
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 Companies and markets

Q&A
A back-to-basics plan for
today’s challenges
Just six months after taking the helm, new CEO Scott Strazik sees plenty of room for optimism about the future for GE Power
Services and believes that Europe is the ideal proving ground to demonstrate why

cott Strazik has been with GE for 18 years,

S starting in the company’s Finance unit,

then Aircraft, before moving to Power
where he has been for five years, first as Chief
Financial Officer before taking up his current
leadership role in October.
It’s a daunting role, with profit in the power
division down 88 per cent in the final quarter
of 2017, and job loss announcements indicating
a move towards a leaner approach to the
sector.
However, Strazik says his team is working hard
in consultation with its customer base, and he
told Power Engineering International he is
excited about prospects for the year ahead.
Europe has been a ghost town for gas
turbine manufacturers for much of the last
decade – but this is exactly where the company
is producing a push in 2018. This month GE
Power Services signed a milestone agreement
with Edison, part of Electricité de France (EDF
Group) and Italy’s second largest integrated
energy company, to enhance performance at
its Candela combined-cycle power station in Scott Strazik
Puglia. The Italian government’s adoption of a
capacity market system has facilitated the much has changed in three decades. Gas and I feel good about it.Yes, we have probably
project and may well encourage more. grew 3 per cent last year and coal 1 per cent, a half decade of renewables growth, half a
The deal encompasses hardware upgrades yet the power business is suffering. How do decade of anaemic industrial growth in Europe
to the existing GE 9F.03 gas turbine, increasing you plan a strategy in the face of a growing and not always the best government policy –
both the plant’s output to 400 MW and its global influence of distributed and renewable but I look at our business today and the
efficiency by about one percentage point.The energy? utilization rates in the fleet seem to be levelling
deal also incorporates GE’s predictive off and some markets growing for the first time
maintenance software and cybersecurity A: Fossils continue to play as material a role as in a while.
solution improving asset visibility, reliability and they have. I don’t know if it’s the volatility in our I look at where we are with customer need
security, while decreasing operating and financials or in the market at large, but it is one in Europe, and output isn’t necessarily the
maintenance costs at the plant. It’s a first of a at which it’s not a very manageable environment biggest criterion for demand. I look at the need
kind implementation in southern Europe. to plan for.Yes, we’ve seen a very evolving grid for efficiency and with still reasonably high gas
Strazik spoke with Diarmaid Williams about dynamic, and you’re sitting in one of the more prices the need for more ramping capability
the future for GE’s gas turbines in terms of both interesting markets in Europe. with our gas turbines.
technology development and global In trying to navigate the changing We feel like we can navigate our new
distribution. landscape, even when I look at places like products for the next five years in a smart and
Europe that are probably the furthest along in confident way. I talk a lot about Europe with the
Q: With fossil fuels currently accounting for the evolution of renewables growth, I look at customers and the team because I feel if we
81 per cent of the world’s energy mix, not our business and the fit we have within the grid can navigate Europe we will be able to navigate

40 Power Engineering International April 2018 www.PowerEngineeringInt.com

1804PEI_40 40 4/12/18 3:41 PM


a lot of the markets where we are competing
and serving customers.
There is still a lot of opportunity out there for
us to serve our customers and play a vital role
in the market and I don’t see that changing
any time soon.
Q: How much of what GE Power Services
does has to be worked out in cooperation
with what GE Renewables and GE Distributed
Energy are doing? Particularly in Europe, it
seems that distributed power and renewable
power have the whip hand. In markets like
that, what is the approach? Is there a certain
amount of coordination?
A: There is.Today is not a bad illustration of that,
in that I am spending the day at our Global
Research Centre with our energy research
centre team, but also with the leadership teams
of our various energy businesses such as gas,
wind and other renewables, talking about
where we are going with our technologies.
We also have leadership from our aircraft
engines business spending the day with us, for
that matter.They are invested in material science
and how that technology can help our gas
turbines.
We are talking more about the holistic value
within the energy system and what we can do
to play together, and I think you will see more
and more coordination. In some ways you’re
already starting to see that when you see us
launching our energy reservoir and talking
about how we are going to combine storage
with some of our smaller gas turbines.
I think that the next step of evolution is how
we add wind turbines into a combined solution,
and that day will come without question. It’s
the next chapter.
Q: With the digital aspect, the quality of
equipment, efficiencies being produced and
emissions reductions achieved, GE’s gas
power offerings have never looked stronger
despite the challenging nature of the market
at the moment. How much of a positive
contribution can GE Power make to global
emission reduction by rolling out its current
gas-fired offerings?
A: I think about it almost in three categories.
You have to look at it in terms of where our new
HA machines are going and where they are
www.PowerEngineeringInt.com
1804PEI_41 41
usually replacing existing power. In the US, for
example, they are replacing coal plants and
in places like Taiwan, Japan and Korea they
are replacing a lot of nuclear capability.
You have that high efficiency play that, to a
large extent, is replacing other forms of
baseload technology that’s ultimately good for
the environment and good for the grid. That’s
one part of how we can contribute.
The other part is frankly being an effective
complement to the growth of renewables,
because someone is going to have to continue
to support the levelized nature of an
unpredictable fuel source and gas is perfect
for that. I look at our new unit growth on the
high efficiency side and there is a one-for-one,
very explicit value between gas in/coal and
nuclear out.
Maybe a less direct connection, but a very
real is one where gas is going to continue to
be a better complement and enabler for
renewables to grow and a levelizer for grids all
over the world. And, depending on where we
are on renewables penetration growth, that will
vary drastically with how quickly gas is playing
that levelizer. It’s less relevant when it’s the first
5 per cent of the grid that’s coming from
renewables, but it’s very relevant when its 15 to
20 to 25 per cent.
Q: Speaking to GE executives last year, there
was a great belief that clean coal power
must remain at the top of the agenda, as
developing nations keen to use their resource
would otherwise choose to develop more
polluting plants. Is this still the position for
the steam business, and do you think there
is enough awareness out there about what
GE can do to mitigate the extent of global
emissions?
A: No question. I would say the drivers there
are economics, depending on the costs of coal
and which part of the world in terms of the
environmental dynamic. There is also the fact
that no matter where you are geographically,
our customers want that diversification mix.
So, you do continue to see some level of
new coal build taking place. Admittedly is not
happening in the most developed countries
in the world. But even in the US, depending on
what part of the US you are in, very large utilities
in some parts of the country expect to retire
coal power in the coming years and decades
Q&A
but continue to see it as relevant central part
of their grid mix. We look at our steam business
and still see a very valuable franchise both for
us and for the market at large, and one we are
going to continue to protect and nurture.
Q: Despite the challenging environment the
power division has had to contend with in
recent years, and the impact on bottom line,
the unit still has a lot to offer, though in
perhaps a leaner, more organizationally
flexible guise. How do you see it evolving?
A: I would certainly say we have a portfolio of
offerings that can support a lot of the challenges
we see in the world today.
Specific to gas, I think there are areas of the
business we can run better and execute to
serve customers in a more efficient way. When
I take a step back and look at all we have taken
on over the last 24-plus months, the Alstom
acquisition really changed the portfolio of
offerings for our teams in the field.
Our aero-derivatives business historically was
a standalone independent organization within
power that we integrated within our gas
business. In that context, we’ve taken in a lot of
solutions and, in the process, there are some
things we could have executed better.
A lot of what we are talking abut in terms of
2018 is a back-to-basics story of executing as
a very efficient, focused-flow business that can
serve our customers the best we can. There is
very little that I see in the challenges that our
customers are facing that intimidates me, or
that doesn’t make me think we can’t solve their
problems. We just have to lean forward and
do it.
Q: Does it take long to achieve the kind of
new cohesion you are seeking?
A: I feel we are building quite a bit of momentum
although I am just six months in. We also have
the benefit from the foundation that was already
there, and I think this is the year that we get
there.
I feel there is no reason why we can’t walk
into 2019 with a level of mojo on how we are
performing in the fleet and innovating in new
and different ways, using the toolkit of
opportunities we have. We need to go out there
and prove it for the customers to ultimately
reinforce how they do business with us. It’s there
Power Engineering International April 2018 41
4/12/18 3:41 PM
 Q&A
Edison’s 360 MW Candela combined-cycle plant in Puglia, Italy, where GE is set to upgrade
its 9F.03 gas turbine for a 40 MW capacity increase
for the taking, and this is not in any way a
business or a marketplace that is anything
other than encouraging for me.
Q: One of the drivers for GE is to help more
populations gain access to electricity – we
note your recent gas power project in Angola
for example. When addressing similar
markets out there for your gas power portfolio
and helping to power more communities like
that, how much of a competitor are
renewables or hybrid technologies?
A: There are a lot of parts of the world that still
need faster distributed power.This is particularly
true for parts of the world that don’t have
electricity 24 hours a day. But there are also the
regions that have the biggest credit challenges.
A lot of the challenge involves keeping the
whole of the solution together. That’s not just
the gas turbine technology but helping to link
these solutions with the fuel base, with the gas
turbine, with the financing solution. It takes time
and Angola is a case in point, taking 24 months
to ultimately deliver that total solution.
In Southeast Asia, sub-Saharan Africa and
small pockets of Latin America there are real
opportunities very analogous to Angola that
we’re working very hard to attract.They tend to
42 Power Engineering International April 2018
1804PEI_42 42
take time because you are not just delivering
a technology solution, you are offering fuel and
financing in parallel.
In places like Indonesia where we have done
similar projects in the last few years there is not
just a need to power homes but there is also
some level of industrial demand. With the
economic growth that they are looking for, there
is a requirement to have reliable power and
they are not going to be relying on hybrid and
renewable for that, at least not in the near future.
Some of our aero-derivative solutions are
very well-fitting because they are very power
dense – we’ll often take the technology of
aircraft engines for our power solutions. They
don’t take up a lot of space but ultimately can
generate 30+ MW of power – more than the
size of a village. It helps to facilitate economic
growth with reliable electricity.
Places like Nigeria, Ghana and Indonesia
are not just wanting the lights on. They have a
base of economic opportunity needing
reliability of power that our space dense gas
solutions are likely a better fit in the near term
to solar and battery.These may work in a small
village but will not necessarily drive a lot of
economic growth. With these Angola-style
solutions, we can be a catalyst for economic
growth.
Q: Have the benefits of your Predix technology
helped in attracting more interest in the
overall power offering, in terms of bottom line
and efficiency gains?
A: At the end of the day our biggest asset by
far is the data we have. We’ve got a 7400 MW
gas turbine installed base that is pumping out
an immense amount of data every day.
To be honest, when we look at how our fleet
is run by our customers, we think we can help
them run it a lot more efficiently and help them
normalize a more complicated and dynamic
grid with our digital solutions in a very real and
meaningful way.
I feel like we are still in our early innings in
how we use that data, not just in a reactive way
but in a very proactive real time way that
maximizes the efficiency of the machine utilizing
gas. We’re just beginning to make sense of how
we really create that value and help our
customers support their business environment
and ultimately make more money.
Diarmaid Williams is International Digital
Editor of PEi
Visit www.PowerEngineeringInt.com
for more information
www.PowerEngineeringInt.com
4/12/18 3:41 PM
 WWW.POWERGENAFRICA.COM

For more information, enter 18 at pei.hotims.com

POWERING UP
17-19 JULY A CONTINENT
2018 JOIN US FOR AFRICA’S PREMIER
POWER INDUSTRY EVENT
EXHIBIT IN 2018
SANDTON CONVENTION CENTRE
JOHANNESBURG
SOUTH AFRICA If you offer new solutions to the African power sector then you
need to exhibit at POWER-GEN & DistribuTECH Africa 2018
Meet key buyers interested in the Sub-Saharan African power
sector, connect with 3,000+ professionals and create sales leads with
targeted B2B Matchmaking.

ATTEND IN 2018
Host Utility:

Early Bird Offer closes 15 June - Save up to $415!

Presented by: Register NOW and make sure you take in everything POWER-GEN
& DistribuTECH Africa has to offer, including both Technical and
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Supporting Association:
Owned & Produced by:
Electricity Thermal Power Renewable Power Delivery
Industry Strategy Generation Energy & Customers

1804PEI_43 43 4/12/18 3:41 PM

 Diary
May July
European Biomass Conference & Exhibition
ICCI Powered by POWER-GEN 14–17 May POWER-GEN Africa
2–4 May Copenhagen, Denmark 17–19 July
Istanbul, Turkey www.eubce.com Johannesburg,
www.icci.com.tr/en South Africa
African Utility Week www.powergenafrica.com
All-Energy 15–17 May
Cape Town, South Africa
2–3 May
Glasgow, Scotland, UK www.african-utility-week.com September
www.all-energy.co.uk
Asia Power Week
China G-POWER June 18–20 September
3–5 May Jakarta,
Shanghai, China Localised energy policies and community Indonesia
www.powerchinashow.com/en/ energy www.asiapowerweek.com
4 June
North Africa Renewable Energy Summit London, UK December
9–10 May www.westminsterforumprojects.co.uk
Casablanca, Morocco POWER-GEN International
www.moroccorenewable.org Electrify Europe 4–6 December
19–21 June Orlando, Florida, US
Taiwan Offshore Wind Energy Summit Vienna, Austria www.power-gen.com
15–16 May www.electrify-europe.com
Taipei, Taiwan
w w w. n e o v e n t u re c o r p . c o m / e v e n t s /
taiwanoffshore

Ad Index
ABB MOTORS AND GENERATORS 7 FACO SPA 21 PEI SUBSCRIPTIONS 35
ANSALDO ENERGIA 31 FINCANTIERI 19 POWER-GEN INTERNATIONAL 2018 39
ASIA POWER WEEK 2018 C4 GEORG FISCHER 37 POWER-GEN AFRICA 2018 43
AUMA RIESTER GMBH 13 HOWDEN GROUP LTD C2 SHELL 33
DOOSAN SKODA POWER 11 MASEN 15 VOITH TURBO GMBH & CO KG 25
ELECRTRIFY EUROPE 2018 C3 MOBITRON AB 2-3 WAUKESHA BEARINGS 9
ETHOSENERGY 17 OHL GUTERMUTH GMBH 23

PennWell Global Energy Group, The Water Tower, Gunpowder Mill, Powdermill Lane, Waltham Abbey, Essex EN9 1BN, United Kingdom.
Phone: +44 1992 656 600 Fax: +44 1992 656 700 Web: www.PowerEngineeringInt.com
Publisher Tom Marler tomm@pennwell.com Chief Editor Kelvin Ross peinews@pennwell.com Deputy Editor Tildy Bayar peinews@pennwell.com Associate Editor Nigel Blackaby
Design Karl Weber & Scott Jones Production Kimberlee Smith Advertisement Sales Manager Roy Morris roym@pennwell.com
Corporate Headquarters PennWell Corporation, 1421 S. Sheridan Road, Tulsa , OK 74112 USA. Phone: +1 918 835 3161 Fax: +1 918 831 9834
Chairman Robert F. Biolchini, 1939-2017 Vice Chairman Frank T. Lauinger President and Chief Executive Officer Mark C. Wilmoth
Executive Vice President, Corporate Development and Strategy Jayne A. Gilsinger Senior Vice President, Finance and Chief Financial Officer Brian Conway
Sr. VP Audience Development and Book Publishing June Griffin Senior Vice President Power Division Richard G. Baker Magazine Audience Development Manager Emily Martin
For Assistance with Marketing Strategy or Ad Creation, Please Contact:
PennWell Marketing Solutions Vice President: Paul Andrews. Phone: +1 240 595 2352. Email: pandrews@pennwell.com
Subscriber Customer Service: PO Box 47570, Plymouth, MN 55447, USA. Email: PEI@kmpsgroup.com Phone: 1-800-869-6882 Fax: 1-866-658-615

Power Engineering International, ISSN 1069-4994, is published ten times a year, monthly except during July and December, by PennWell Global Energy Group, ©Copyright 2018 by
PennWell Corporation, 1421 S. Sheridan Rd., Tulsa, OK 74112, USA. All rights reserved. Subscriptions/circulation and reader enquiry office: Power Engineering International, P. O. Box
47570, Plymouth, MN 55447, USA. Paid annual subscription rates: Worldwide $62 Digital Version. E.U. $178, No. America $220. United Kingdom $147. All other countries $220. Single or
back copies: $26 for all regions.
Reprints: If you would like to have a recent article reprinted for a conference or for use as marketing tool, please contact Rae Lynn Cooper. Email: raec@pennwell.com.
USA circulation only: Power Engineering International,“Periodicals POSTAGE PAID at Rahway NJ”. Subscription price is $210 Periodicals Postage Paid at Rahway NJ. Postmaster send
address corrections to: Power Engineering International, C/O Mercury Airfreight International Ltd. 365 Blair Road, Avenel, NJ 07001. ® “Power Engineering International” is a registered
trademark of PennWell Corporation. POSTMASTER: Send address changes to Power Engineering International, P. O. Box 47570, Plymouth, MN 55447, USA. Member American Business
Press • Business Publications Audit3 • Printed in the United Kingdom • GST No. 12681315

44 Power Engineering International April 2018 www.PowerEngineeringInt.com

1804PEI_44 44 4/12/18 3:41 PM

 BROUGHT TO YOU BY POWER-GEN & DISTRIBUTECH

Register now for

19 -21 • JUNE • 2018

savings on conference
delegate rates.
Visit the registration page on
www.electrify-europe.com MESSE WIEN | VIENNA | AUSTRIA
to find out more

ARTIFICIAL INTELLIGENCE AND

BLOCKCHAIN – THEIR ROLE IN OUR MARKET
Both Artificial Intelligence and the Blockchain have arrived in the power market.
So what are they, and what will be their unique impacts on our business structures?

Get the answers at Electrify Europe. For further information please visit www.electrify-europe.com or contact:

EXHIBIT SALES
WORLDWIDE EUROPE NORTH AMERICA & CANADA
Leon Stone Sophia Perry Jared Auld
T: +44 (0) 1992 656 671 T: +44 (0) 1992 656 641 T: +1(918) 831-9440
E: leons@pennwell.com E: sophiap@pennwell.com E: jareda@pennwell.com

For more information, enter 19 at pei.hotims.com

Owned and Produced by: Presented by:

1804PEI_C3 3 4/12/18 3:41 PM

 ASIA
PO
POWER WEEK
18-20 SEPTEMBER 2018
ICE I BSD CITY I JAKARTA I INDONESIA

BE PART OF ASIA’S
PREMIER
PRE POWER EVENT
Compriising POW
Comprising POWER-GEN Asia and Renewable Energy World Asia, the 26th
edition of Asi ia’s premier power industry event delivers a platform to
Asia’s
meet, share, inform
info and learn about the latest advances in thinking
and iinn technology for the Asian power market.

Asia Power WeeWeek is also excited to be staging the event in

Indonesiia for the first time - Southeast Asia’s largest economy,
Indonesia
wiith some of th
with the most ambitious electric power system
development goa goals in the region. Make sure you join us as
we cover every aaspect of the power generation industry
with more than 8,500 industry professionals from
around the wo world.

FIND OUT MORE AND REGISTER AT

WWW.ASIA
WWW.ASIAPOWERWEEK.COM

8,500+ 50+ 200+

Attendees Conference International
Sessions Speakers

7 200+ Multiple
Conference Leading Networking
Tracks Exhibitors Opportunities

ASIA’S TRANSITIONING
ENERGY
ENER LANDSCAPE
WWW.ASIAPOWERWEEK.COM

Owned and Produce

Produced by: Official Publications:

For more information, enter 20 at pei.hotims.com

1804PEI_C4 4 4/12/18 3:41 PM

 19 -21 JUNE 2018 MESSE WIEN | VIENNA | AUSTRIA

BROUGHT TO YOU BY POWER-GEN & DISTRIBUTECH

EVENT PREVIEW

Digital Transformation
Blockchain
Energy Storage

Emobility Artificial Intelligence

Digitalization
Cyber Security
Demand Side Response Decentralization

1804PEIElectrifyEuro_1 1 4/12/18 3:14 PM

 INVITATION
We are delighted and excited to welcome you to Electrify Europe, an event which brings together the
innovators, disruptors and thought-leaders that are shaping the 21st Century energy sector.

The power industry is experiencing unprecedented technological and structural change, from electric
vehicle infrastructure and energy storage to new ways of conducting business using blockchain, AI
and Internet of Things technology. And all the while still managing demand and tackling the ever-
present threat of cybercrime.

New entrants are challenging siloed approaches to generation, distribution and consumption and
this convergence will change the industry beyond recognition.

This change presents significant challenges – however, it also offers great potential for you and
your business, and you will find out how to seize these opportunities in the conference rooms and
exhibition arenas at Electrify Europe.

Built upon the foundations of POWER-GEN Europe and DistribuTECH, Electrify Europe is the only
event in the region which gives delegates a chance to explore this end-to-end disruption.

All of this would not be possible without the expert input from our advisory board, exhibitors
and sponsors.

We look forward to meeting you and discovering how you can play a role in shaping the future of
electricity in Europe.

Glenn Ensor | Managing Director | PennWell International

1804PEIElectrifyEuro_2 2 4/12/18 3:14 PM

 10 REASONS TO ATTEND
1. Discover the key technologies that 11,000+
are changing the electricity industry ATTENDEES

2. Network with 1000’s

of industry leaders
3. Meet the disruptors shaping
the future 400+
EXHIBITORS
4. Be inspired to introduce new
business models
5. Gain valuable insight about
the rapidly evolving market 70+
CONFERENCE
6. Share your knowledge to influence SESSIONS
the future
7. Find suppliers and make
long-term partnerships
8. Learn how adopt new 250+
working practices SPEAKERS

9. Hear in-depth case studies

10. Pre-plan your visit and make the
right connections with our free
MULTIPLE
business matchmaking NETWORKING
OPPORTUNITES

1804PEIElectrifyEuro_3 3 4/12/18 3:14 PM

 FEATURED
SPEAKERS
JO-JO HUBBARD
Keynote CHIEF OPERATING OFFICER
ELECTRON

LASZLO VARRO
CHIEF ECONOMIST
INTERNATIONAL ENERGY
Keynote AGENCY

STEVEN MARTIN
VICE PRESIDENT &
CHIEF DIGITAL OFFICER GE
Keynote POWER INTERNATIONAL

DR. HELMAR RENDEZ

CHAIRMAN OF THE BOARD
LAUSITZ ENERGIE BERGBAU
Keynote AG AND LAUSITZ ENERGIE
KRAFTWERKE AG (LEAG)

1804PEIElectrifyEuro_4 4 4/12/18 3:14 PM

FEATURED
We have a top-class
line up of speakers at
Electrify Europe and
we are pleased to share

SPEAKERS
just a few of the big
names presenting their
views at our multi-track
conference.

Pierre Dechamps Graham Oakes

European Commission Upside Energy

Next-Generation Storage: Energy Management
Where is R&D taking us? Economics

Emma Gibson Jeremy Wright

Highview Power Storage UK Power Networks

Large-Scale Storage Making Distributed Generation
Technologies Businesses Succeed

Susan Peterson-Sturm Marc Crauwels

Jeremy Wright

ABB Utility Sales at REstore

Opening Panel: Artificial Opening Panel:
Intelligence - State of the Art and Outlook DSR Overview

Be sure to visit www.electrify-europe.com for further information

1804PEIElectrifyEuro_5 5 4/12/18 3:14 PM

 CONFERENCE TOPICS
MEGATRENDS: DECARBONIZATION, DECENTRALIZATION AND DIGITALIZATION
The power sector is undergoing some of the most daunting challenges in its history,
including rapid decarbonisation, digitalisation and disruptive business models.
FEATURED SESSIONS: Perspectives on the Energy Convergence | Digital
Transformation: How to Reap the Benefits and Avoid the Pitfalls | Where is the
Money Coming From?

ARTIFICIAL INTELLIGENCE AND BLOCKCHAIN -THEIR ROLE IN OUR MARKET

Both Artificial Intelligence and the Blockchain have arrived in the power market. So
what are they, and what will be their unique impacts on our business structures?
FEATURED SESSIONS: Artificial Intelligence - State of the Art and Outlook |
Blockchain Explained | Blockchain Application Case Studies

ENERGY STORAGE: A NEW PARADIGM

The projected growth of stored energy - whether at utility, grid or customer level - is
bringing with it huge opportunities, and fundamental structural implications.
FEATURED SESSIONS: Exploring the Impact of Energy Storage at Scale in the
European Power System | Grid-Scale Energy Storage | Storage Experience: ‘Behind
the Meter’ Space

BIG DATA, BIG OPPORTUNITY

The arrival of the Industrial Internet is re-writing energy economics. So how can we
meet the challenge and derive value from vast sets of data that will be produced?
FEATURED SESSIONS: Digital Infrastructure and IoT | Disruptive Landscape
Solution Providers | Data Driven Improvement of Plant Operation

CYBER ATTACKS: HOW VULNERABLE ARE WE?

Why you need a cybersecurity strategy. Here we explore the threats, the response
strategies, the standards and regulations followed by a live Hackathon.
FEATURED SESSIONS: Cybersecurity: What You Need to Know and Do |
Cybersecurity in the IoT Space | Cybersecurity Solutions Applied/Implemented

1804PEIElectrifyEuro_6 6 4/12/18 3:14 PM

 CONFERENCE TOPICS
REPOSITIONING CONVENTIONAL POWER GENERATION
The dash to gas, thermal and alternative fuels is re-inventing power supply architecture
and demand dynamic management and innovative grid management techniques
FEATURED SESSIONS: Stabilizing the Grid: Real Life Experience | Gas Engines:
Technology Update | Hybrid Storage Solutions for Asset Optimization

WHAT HAPPENS WHEN EMOBILITY GOES MAINSTREAM?

The impact of electric vehicles and the wider electrification of public transport on the
power industry is manageable – for now. But what happens when it’s the norm?
FEATURED SESSIONS: What Happens When eMobility Goes Mainstream? |
Vehicle to-Grid & its Stabilization Role | Comparative National eMobility Plans

DEMAND SIDE RESPONSE DEEP DIVE

We look in detail at Demand Side Response: the markets, the role of aggregators,
operational experiences, and its integration into an energy management plan.
FEATURED SESSIONS: DSR Business Models & Value Propositions | DSR Technologies
Showcase | Energy Management Economics

POWER GENERATION - EVERYTHING YOU KNOW IS WRONG

New thinking and fresh business models are urgently required for the rise of distributed
power generation and the management of legacy assets.
FEATURED SESSIONS: Managing our Generation Legacy | Making Distributed
Generation Businesses Succeed | Technologies for Distributed Generation

Be sure to visit www.electrify-europe.com for further information

1804PEIElectrifyEuro_7 7 4/12/18 3:14 PM

 SPONSORS
OWNED & SUPPORTED BY:
PRODUCED BY:

Visit www.electrify-europe.com for more information

ORGANISATIONS & ASSOCIATIONS

1804PEIElectrifyEuro_8 8 4/12/18 3:14 PM

 GET INVOLVED
Register - www.electrify-europe.com/register
3-Day Conference 1-Day Conference 3-day Visitor 1-Day Visitor

€900 << Early Bird Rate €450 << Early Bird Rate €100 << Early Bird Rate €40 << Early Bird
(before 18 May 2018) (before 18 May 2018) (before 18 May 2018) €60 Regular Rate
€1200 Regular Rate €600 Regular Rate €150 Regular Rate (after 18 May 2018)
(after 18 May 2018) (after 18 May 2018) (after 18 May 2018)

Registration Includes: Registration Includes: Registration Includes: Registration Includes:

• Keynotes • Keynotes • Keynotes • Keynotes*
• Conferences • Conferences (on day selected) • Onsite presentations • Presentation Arenas
• Onsite presentations • Onsite presentations • Exhibition Hall conference content*
• Exhibition Hall • Exhibition Hall • Business matchmaking • Exhibition Hall*
• Proceedings • Lunch (on day selected) • hubs Connect
• Lunch • Business matchmaking
• Business matchmaking *On day selected

For exhibition, branding and sponsorship opportunities email

For Conference sales
EEsolutions@pennwell.com
contact:
If you’d like to schedule an interview with our press team John Collins
email EEmedia@pennwell.com T: +44 (0) 1992 656 642
E: johnc@pennwell.com

CONNECT WITH US.

Immerse yourself in Electrify Europe’s social media channels. Use the Official Event Hashtag - #electrifyeurope

MEDIA PARTNERS

1804PEIElectrifyEuro_9 9 4/12/18 3:14 PM

 INFORMATION
MAKE THE RIGHT CONNECTIONS.
Schedule meetings, send and receive messages, and find industry professionals with similar interests within the
electricity sector with hubs CONNECT:www.hubs.com/connect

KEY TIMES.
Tuesday 19 June 2018 Wednesday 20 June 2018 Thursday 19 June 2018
Registration Open 08:00 - 18:00 Registration Open 08:00 - 18:00 Registration Open 08:00 - 17:00

Conference & Conference & Conference &

10:00 - 17:30 09:00 - 17:30 09:00 - 12:30
Keynote Sessions Keynote Sessions Keynote Sessions

Exhibition Floor Open 09:30 - 18:00 Exhibition Floor Open 09:00 - 18:00 Exhibition Floor Open 09:00 - 17:00

Electrify Europe
Halls A & B
Messe Wien Exhibition &
Congress Center
Messeplatz 1, 1021 Wien
Austria

MEDIA PARTNERS

1804PEIElectrifyEuro_10 10 4/12/18 3:14 PM

 THE FIVE Ws
1. WHO WILL YOU MEET?
Thousands of innovators and thought-leaders
2. WHAT WILL YOU LEARN?
how the latest trends and technologies affect you

MEDIA PARTNERS PRESENTED BY:

1804PEIElectrifyEuro_11 11 4/12/18 3:14 PM

 THE FIVE Ws
3. WHY SHOULD YOU ATTEND?
to be inspired to evolve and adapt your business
4. WHERE?
Electrify Europe, Messe Wien, Austria
5. WHEN?
19-21 June 2018.

MEET REPRESENTATIVES FROM THESE COMPANIES AT ELECTRIFY EUROPE

1804PEIElectrifyEuro_12 12 4/12/18 3:14 PM