March 2012

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Haight Notes
Natural Gas Will Continue
To Outpace Renewables
The green bubble is popping. There
have been some very public setbacks
in the green movement recently. While
emerging technologies aren’t without
their growing pains, it seems that the final
“pin” to pop the growing green bubble
will be natural gas — primarily its avail-
ability and its price.
The United States Energy Information
Administration (EIA) released its Short
Term Energy Outlook in February.
Over the next 25 years, natural gas and
renewable fuels gain a larger share of the
United States’ generating mix of electric-
ity. In the EIA’s reference study, annual
generation from natural gas increases
by 39% from 2010 to 2035. Eighty-five
gigawatts of new gas capacity is added
through 2035, as stable capital costs and
low fuel prices make it the most attractive
source of new capacity.
Renewable energy generation grows
33% from 2010 to 2035. Non hydro re-
newables account for a majority of this
growth, with wind, solar, biomass and
geothermal generation all significantly
larger at the end of the projection horizon.
Coal’s share of the electricity genera-
tion mix drops from 45% to 39% be-
tween 2010 and 2035. Thirty-three giga-
watts of coal capacity are retired and only
14 gigawatts of new coal capacity already
under construction are completed. A few
factors disadvantage the relative econom-
ics of coal-fired capacity: projected low
natural gas prices, the continued rise of
new coal-fired plants’ construction costs
and concerns over potential greenhouse
gas emissions policies.
Annual generation from nuclear pow-
er plants grows by 11% from 2010 to
2035, but its share of the generation mix
declines. A total of 10 gigawatts of new
nuclear capacity are projected through
2035, as well as an increase of 7 gigawatts
achieved from uprates to existing nuclear
units. About 6 gigawatts of existing nu-
clear capacity are retired, primarily in the
last few years of the projection.
2 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
In its Short Term Energy Outlook,
the EIA expects that after growing 13%
in 2011, the total renewable energy sup-
ply will decline by 3.6% in 2012. This
decrease is the result of a return to long-
term average hydropower resource levels
with hydropower supply falling by 0.5
quadrillion Btu (16%).
Fossils fuels are still king. Absent a
significant oil supply disruption, the EIA
expects world markets to continue to
gradually tighten in 2012 and 2013, as
increases in global consumption outpace
production growth in countries outside of
the Organization of the Petroleum Export-
ing Countries (OPEC). World liquid fuels
consumption grows by an annual average
of 1.3 million barrels per day (bbl/d) in
2012 and 1.5 million bbl/d in 2013. Sup-
ply from non-OPEC countries increases
by 0.8 million bbl/d in 2012 and 0.9 mil-
lion bbl/d in 2013. The EIA expects that
the market will rely on both inventories
and increases in production of crude oil
and noncrude liquids from OPEC mem-
bers to meet world demand growth.
World liquid fuels consumption grew
by an estimated 0.8 million bbl/d to 87.9
million bbl/d in 2011. The EIA expects
that this growth will accelerate over the
next two years, with consumption reach-
ing 89.3 million bbl/d in 2012 and 90.7
million bbl/d in 2013. OECD consump-
tion fell by 490 000 bbl/d in 2011 and
is expected to decline again in 2012 as
very modest consumption growth in the
United States and Japan will be more than
offset by a decline in consumption in Eu-
rope. Non-OECD countries are expected
to account for most of the world’s con-
sumption growth over the next two years,
with the largest contributions coming
from China and the Middle East. A
Brent Haight
bhaight@dieselpub.com
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 Contents
March
Features
2012 Vibration Detection & Analysis
Listening Out For Vibration Issues..........................................................................4
March 2012

Vibrabsorber Shakes Off Vibration........................................................................30

Portable Vibration Analyzer...................................................................................46

Overhaul, Service & Repair

Remanufacturing Vs. Rebuilding..............................................................................8
A New Life For Worn Cylinder Bores....................................................................24
New Machining Center For B&G...........................................................................42
Cover designed by Amanda Ryan

Emissions Worldview
Inside The Engine Room: Central Utility Plant, John Wayne Airport...................12
FlexEnergy And DOD Team Up At Fort Benning..................................................36
Second Generation EGR.........................................................................................44

WW_MarchCover.indd 1 2/15/12 8:46 AM

Turbomachinery Controls
On The Cover: Overhaul, LVDT Sensors Serve Crucial Role In Gas Turbine Operating Efficiency...............18
Service & Repair special cov-
Rockwell Extends Its Reach...................................................................................34
erage begins on p. 8
Unitrol 1000 Family Gets First Pilot Installation..................................................56

Marine Propulsion
New LNG-Powered Tugs........................................................................................28
Follow dgtww on: Laborde Gives Barges And Pushboats Their Push.................................................40
1500 KW Thruster In Operation In Offshore Vessel.............................................48
Austal Makes Waves In Wind Farm Sector............................................................54
Metso Looks To Break The Ice...............................................................................58

Global Markets Power Generation

Wärtsilä’s Caribbean Success.................................................................................38
Global Coverage
Black Hills Corp. Power Station Operational.........................................................50
www.dieselgasturbine.com Clean Across The Border........................................................................................52

Oil & Gas

Paradox Engineering For The Oil And Gas Market................................................60

PRINTED IN THE U.S.A.

Departments
® Dateline....................................................................................................................9
MEMBER OF BPA WORLDWIDE
DIESEL & GAS TURBINE WORLD­WIDE (ISSN 0278-
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Jan/Feb & July/Aug issues combined, by Diesel &
Gas Turbine Pub­lications, 20855 Water­town Road, Newsmakers...........................................................................................................41
Waukesha, WI 53186-1873 U.S.A. Subscription rates
are $85.00 per year/$10.00 per copy worldwide.
Periodicals postage paid at Waukesha, WI 53186 and Featured Products..................................................................................................43
at additional mailing offices. Copyright 2012 Diesel
& Gas Turbine Pub­li­cations. Canadian Publication
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Literature Library...................................................................................................46
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ON L2E 6V2, Canada. E-mail: slizdas@dieselpub.com. Advertisers’ Index..................................................................................................63
POSTMASTER: Send address changes to: Circulation
Man­ager, Diesel & Gas Turbine Worldwide, 20855
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Marketplace............................................................................................................63
1873 U.S.A.
World Viewpoint....................................................................................................64

Diesel & Gas Turbine Worldwide M a r c h 2 0 1 2 3

Vibration Detection & Analysis by ian cameron
Kittiwake Holroyd supplies acoustic emission instruments for the early detection of problems
in various applications.
Listening Out For
Vibration Issues
Acoustic emission technology simplifies monitoring process and places the
power of vibration techniques into the hands of engineers
Traditional vibration techniques,
including vibration monitoring and
analysis, have a long, established rep-
utation spanning decades.
However, some argue that these
long-established techniques remain
complex, requiring expert knowledge,
understanding and input.
According to one company, an al-
ternative method of condition moni-
toring involves acoustic emission (AE)
technology, which the company ar-
gued simplifies the process and places
the power of vibration techniques into
the hands of every engineer.
4 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
Matlock, England-based Kittiwake
Holroyd supplies AE instruments for
the early detection of problems in vari-
ous applications relating to monitoring
the condition of rotating machinery.
The company believes that vibra-
tion analysis (VA) as a technique
will have a place for many end users,
although it said there is often a re-
quirement for a costly, unsustainable
level of knowledge required to effect
a good diagnosis. For VA, the defect
repetition frequencies are critically
dependent upon the machine compo-
nent design and geometry, as well as
the precise running speed. Vibration
can occur independently in X, Y or Z
axis and so orientation of the sensor is
as important as location, it said.
Trevor Holroyd, technical director,
Kittiwake Holroyd, said, “For a de-
tailed interpretation, it is also neces-
sary to know internal machine geome-
tries such as shaft speeds and meshing
frequencies and to analyze the data
before making a diagnosis. VA is valu-
able, but often overly complicated.
“The areas in which vibration and
AE both apply can be illustrated as
overlapping circles. AE provides an
earlier warning — detecting wear and
small defects — whereas with vibra-
tion, damage must have occurred to
detect a signal. AE will pick up a lack
of lubrication, friction and cracking,
which vibration will not. Although it
must be acknowledged that the total-
ity of information obtained from AE
will be more limited than that derived
from vibration.”
The company said AE is not more
reliable per se, but as it doesn’t re-
quire a vibration expert to interpret
the results, it could be viewed as
more reliable when used by mainte-
nance staff in general.
“AE doesn’t invalidate vibration
techniques,” Holroyd said. “It ex-
tends the impact beyond what we’ve
been able to achieve to date. The sig-
nal processing required by AE is not
something that can be performed by
anyone; it’s a high-frequency signal so
the user must have the knowledge to
interpret the lines on a stethoscope.
But recent developments have enabled
this processing at the sensor level. The
sensor output can now provide pre-
characterized numbers advising on the
condition of the machine. AE technol-
ogy has been effectively deskilled, en-
abling wider application use.
“Suitable for continuously running
machinery as well as machinery oper-
ating intermittently, slowly or for short
durations, AE allows the user to diag-
nose problems with machinery at an
early stage, and then carry out main-
tenance procedures and monitor the
improvement. It provides real-time
continued on page 6
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Vibration Detection & Analysis
The company claimed that as awareness of the capabilities of AE increases, so does the number
of applications it suits.
information with early sensitivity to
faults and applicability to a wide range
of rotational speeds,” Holroyd added.
The company claimed that as
awareness of the capabilities of AE in-
creases, so does the number of appli-
cations that it is suited to — many of
which have proven difficult for other
forms of condition monitoring to ad-
dress. For example, it said, the analy-
sis of signals, whether from AE sen-
sors or VA accelerometers, requires a
sufficiently long period of a machine
running at constant speed so that a
statistically meaningful signal charac-
terization can be made.
“That is where the similarity stops,”
Holroyd said. “AE can be effective
after around 10 seconds of measure-
ments. For example, the algorithm
used to derive the widely used acous-
tic emission parameters of distress
and dB Level in the MHC range of
products from Kittiwake Holroyd re-
quires a 10-second period of running
at an approximately constant speed.
“This is compared to Fast Fourier
Transform (FFT)-based vibration anal-
ysis, which typically needs 60 to 120
seconds’ measurement time and tight
tolerances on machine speed for an ef-
fective signal interpretation,” he said.
Holroyd added that in those cases
6 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
where a handheld instrument is used
for periodic condition maintenance
(CM), it may be possible to interrupt
normal machine operation and put it
into a special continuously running
mode for the duration of CM measure-
ments. However, such disruption is not
always possible and never convenient.
Furthermore, it is not compatible
with the current trend toward CM
automation, which requires continu-
ous online monitoring with perma-
nently installed sensors inputting CM
data or status into SCADA systems or
PLCs, the company said.
“For vibration techniques to be ef-
fective you need equipment that’s not
cheaply coupled, with clever people
to get the best from it. Every result
must be analyzed to understand
what’s good and what’s bad,” Holroyd
said. “For those that cannot afford
in-house vibration experts, there are
vibration specialists who offer a con-
tract monitoring service — again, re-
quiring investment. While for some,
the criticality of certain applications
coupled with the scale of some com-
panies might justify this cost, others
could still benefit from the efficiencies
realized by similar CM techniques.
“Ultimately, maintenance person-
nel are responsible for keeping ma-
chinery running. If they are empow-
ered to monitor condition themselves,
identify where action is needed and
then check that the action taken has
solved the problem, then de-skilled
AE technology has significant advan-
tages of cost, speed, flexibility and
ease of field application when com-
pared to traditional vibration analysis
techniques. It is the efficient and ef-
fective approach to CM,” he said.
Based on frequencies much higher
than are monitored in the repetitive
synchronous movement of vibration,
AE technique is suitable for both
land- and marine-based applications.
These frequencies are the result of
shock, impact, friction and cracking,
for example. Therefore, it’s possible
to detect impending failure before
damage occurs, as well as monitoring
its progress thereafter.
“AE technology spawned from the
aviation industry, where vibration
analysis simply couldn’t be easily ap-
plied,” Holroyd said. “It is designed
to allow users with little knowledge of
the subject to check bearings and ma-
jor slideways for condition in a way
that would be near impossible using
traditional vibration techniques.”
In land-based applications, ac-
cording to Holroyd, AE is favored by
maintenance personnel as a front-line
technique, allowing maintenance staff
to assess machine condition without
knowing the bearing’s ISO number,
speed, size or history. This allows
them to focus maintenance activities
when and where they are required
with minimum disruption to op-
erations and, most importantly, to
check there and then that a repair has
been effective.
He added, “In a marine setting, vibra-
tion analysis is typically undertaken on
ships using outside, third-party consul-
tants. With AE technology, it’s given to
a ship’s engineer and by the end of their
shift they will have an accurate assess-
ment of all the engine room pumps,
turbine and generator bearings, crane
slewing rings and any ancillary air leaks
in the engine room.” A
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Overhaul, Service & Repair

Kato Engineering recently dou-

bled the size of its Mankato, Min-
nesota, U.S.A. remanufacturing
facility. Here, a technician tests
the vibration balancing of rotor.

Remanufacturing ous lean” operation, which created

space for remanufacturing without

Vs. Rebuilding
adversely impacting the production
of new generators.
Generators brought in for reman-
Kato Engineering expands remanufacturing facility
ufacturing go through the same pro-
duction line as new generators and,
Centrally located in Mankato, fer a complete remanufacturing pro- at the end, are tested to ensure they
Minnesota, U.S.A., Kato Engineer- cess. The remanufacture concept has meet the same design criteria as a
ing expanded its remanufacturing been very favorably received by our new machine.
facility, doubling its capacity. The customers, who see the value of hav- “Kato Engineering operates on a
Mankato facility now has a total of ing it completely remanufactured and ‘first in, first out’ order in the factory,
28 871 m2, including the reallocat- load tested rather than just rebuilt.” so getting a remanufactured generator
ed 557 m2 for remanufacturing. Lindblom said Kato is a “continu- continued on page 10
Kato Engineering designs and
manufactures generators (alterna-
tors), motor-generator sets and con-
trols for prime, standby and peak-
shaving power. Concentrating in the
200 kW to 25 MW range, Kato sup-
plies equipment for a variety of uses,
including oil and gas, transportation
and cogeneration.
According to Mike Lindblom, prod-
uct support manager at Kato, the idea
of offering remanufacturing at Kato
started out as a warranty process.
“If one of our generators failed, we
wanted it back so we could do a failure
analysis in order to improve the design
and overall quality of the product,”
said Lindblom. “Through evolution,
this idea of bringing product back to
our shop grew until we decided to of- Precision assembly of the generator stator.

8 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide

Dateline follow dgtww on

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*Sept 26-Mar 23 E-mail: breeze@zhenweiexpo.com
Diesel Progress Online Show X - At
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Progress Magazine; Diesel Progress,
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april
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Sight Exhibition Center, Tokyo,
Japan; UBM Japan Co. Ltd.,
Kanda 91 Building, 1-8-3 Kaji-cho,
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Tel: +81-3-5296-1020
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february * ­Boldface indicates shows and conferences in which Diesel & Gas Turbine Worldwide is
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Feb 27-29
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E-mail: exhibit@offshorearabia.ae
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march
*March 7-8
GlobalCon - Atlantic City
Convention Center, Hall B, Atlantic
City, New Jersey, U.S.A.; The
Association of Energy Engineers,
4025 Pleasantdale Rd., Suite 420,
Atlanta, Georgia 30340, U.S.A.
Tel: +1 (770) 279-4392
Fax: +1 (770) 381-9865

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Miratech_Mar12_WW.indd 1 2/13/12 12:31 PM

Overhaul, Service & Repair
Kato generator being disassembled for inspection.
back into operation may take slightly
longer than sending it to a local job
shop. But there is an ‘express lane’
for remanufactured units depend-
ing upon the needs of the customer,”
said Lindblom. “Our shop is nimble
enough that a remanufactured unit
can be dropped into the process and
prioritized based on the urgent needs
of the customer.”
The remanufacturing process be-
gins with communications between
Kato and the customer in an attempt
to determine the condition of the
generator, which includes trouble-
shooting and problem assessment.
Remanufactured stator being prepared for the VPI process.
10 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
Once the problem is determined and
it’s confirmed that it cannot be cor-
rected in the field, the generator is
sent in for remanufacturing.
When the unit arrives in Mankato,
there is a visual inspection and static
tests are performed. A teardown fol-
lows, with a technician taking critical
measurements of the unit. During dis-
assembly and assessment every com-
ponent is photographed, palletized and
numbered. Anything that may have
contributed to a failure is documented.
“We have skilled engineers onboard
that can determine what caused the
failure and how to prevent future fail-
ures from recurring,” said Lindblom.
“When the problem is uncovered and
confirmed, a report along with a price
quote and delivery window is pro-
vided to the customer. The customer
may choose to have the generator
remanufactured or returned. Nine
times out of 10 we get the go-ahead
to start the remanufacturing process,”
Lindblom said.
In the event of a stator remanufac-
ture, Kato starts with a core loss test.
This test sets a benchmark for the sta-
tor condition with the next step be-
ing the burn-out process. Care has to
be taken to ensure the temperature
doesn’t reach a point where it affects
the surrounding metal.
“Some shops have burn-out ovens,
but don’t monitor the temperature or
check for hot-spots that can weaken the
stator,” said Lindblom. “If a generator
owner is considering a local shop to do
a stator repair, asking about their burn-
out process is a must before sending the
generator to this facility.”
After the burn-out is completed,
a second core loss test is conducted
and compared with the first to en-
sure no core damage has occurred.
The remanufacturing process then
begins once the generator takes its
place on the production line. Time to
completion depends on the size and
complexity of the generator. Once the
unit has been reassembled, it is tested
to make sure it meets the same speci-
fications as the day when it was origi-
nally built and tested at the plant.
“New test data and original test
data are compared to make sure the
generator meets the same standards
as new, which is difficult to do in the
field,” said Lindblom. “This is a key
part of the process. Who knows the
generator better than the manufactur-
er? The warranty on new generators is
12 months from date of operation or
18 months from the day it’s shipped
from Mankato, while remanufactured
units get a 12-month warranty from
the day they leave the plant as the
generators usually are quickly re-
turned to service.” A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
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see directlink @ www.dieselgasturbine.com

Emissions Worldview
Photo courtesy of John Wayne Airport.
The new John Wayne Airport Terminal cogen facility in Orange County, California, U.S.A.
Inside The Engine Room:
Central Utility Plant,
John Wayne Airport
New cogeneration plant utilizes Miratech solutions
to meet strict emissions regulations
Renamed after The Duke (John
Wayne) in 1979 and owned and op-
erated by the County of Orange, Cali-
fornia, U.S.A., John Wayne Airport
is a modern, busy facility that served
nearly 11 million passengers in
2011. It’s the second-busiest airport
in southern California (LAX is only
64 km away), yet it has the shortest
runway of any major airport in the
United States.
Sharing a border with posh New-
port Beach, John Wayne Airport
strives to be a positive reflection of
the sleek, modern, “ahead of the
curve” area in which it is located. Evi-
Dan Vnuk is a writer with Marketing &
Technology Insights.
12 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
dence of this is an ongoing improve-
ment plan that includes a new central
utility plant using natural gas-fueled
engines for cogeneration to provide
95% of the electrical power needs
and most of the thermal load of the
airport. The plant captures waste heat
from the engines to produce chilled
water to provide cooling for the air-
port. It’s important to note that the
airport has to meet both stringent
noise abatement rules along with
the strictest air-quality requirements
found anywhere in the nation.
According to Britt Griffith, man-
ager, airport maintenance, “John
Wayne Airport continues to grow in
the number of passengers each year,
yet we’re land-locked on a very small
by dan vnuk
‘footprint’ of less than 202 ha and
can’t expand.”
The airport had an electrical sub-
station on-site and purchased power at
a large-user rate from the local utility,
which it then stepped-down for use
on-site. “We had heard that our util-
ity rates could possibly double after we
removed the substation site in order
to expand,” Griffith explained. “Once
we lost it and our ability to step-down
power, we would be buying power at
the 12 kV rate, or twice the cost. We
had not done cogeneration before, but
it gave us a redundancy factor because
we could use natural gas or still get
electricity from the grid.”
The idea of a cogeneration plant
was considered in 2003 when a local
engineering company, Popov Engi-
neers, was asked by airport personnel
to determine the most efficient way
to keep utility rates in check with the
planned airport expansion and pro-
duce the chilled water it would need.
Recommending the construction of
a cogeneration facility using natural
gas-fueled reciprocating engines, Pop-
ov Engineers developed the bridging
document of the original plant design
used by the contractor, West Coast
Air Conditioning Company Inc., as a
model to complete the design of the
central utility plant. In addition, Par-
sons Transportation Group handled
management and oversight of archi-
tect-engineer and construction agree-
ments, which include monitoring,
reporting and making recommenda-
tions regarding program costs, sched-
ules and budgets.
Work on the Central Utility Plant
began in September 2009 as part of
an airport improvement program
that includes an additional third
terminal and parking structure. The
US$30.5 million utility plant proj-
ect is funded by airport revenues
and is a design-build project that al-
lows contractors to both design and
construct the facility.
The plant, which came online in
continued on page 14
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Emissions Worldview
An operator at John Wayne Airport inspects the Cummins gen-set operations.
March 2011, supplies the Thomas F.
Riley Terminal complex with power
and with chilled water to serve the air-
conditioning system. It employs four
natural gas-fueled Cummins QSV81
G 18-cylinder, reciprocating engine-
driven gen-sets, each rated 1750 kW
with a total rating of 7 MW; two 535
ton Broad absorption chillers and
three Carrier 680 tonne water-cooled
centrifugal chillers were included.
The plant uses Siemens controls.
In California, a constant supply
of chilled air is vital to meet the ter-
minal’s HVAC needs. The new sys-
tem was designed to support chilled
water to the terminal that’s made by
chillers using waste heat or by tra-
ditional electricity. The waste heat is
preferred because it boosts the sys-
tem’s overall efficiency. If enough
waste heat isn’t available, then the
electric chillers are turned on by the
system’s computer, but this doesn’t
happen very often. “80% of our nor-
mal chilled water needs are covered
by waste heat,” said Mike O’Leary,
project manager at the plant. “The
plant was sized large enough to han-
dle an addition to the new terminal,
but the overall airport is limited to
202 ha, so it’s doubtful that it will
ever need to be enlarged.”
The cogen plant’s engine emissions
control uses a urea injection compo-
nent supplied by Miratech Corp. in a
14 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
computer-controlled system that al-
lows the plant to comply with all South
Coast Air Quality Management District
(SCAQMD) regulations. The SCAQMD
air emission standards are among the
strictest in the world and the toughest
in the nation, according to Griffith.
The plant relies on a Miratech
selective catalytic reduction (SCR)
emissions compliance system to re-
duce exhaust pollutants including
oxides of nitrogen (NOx), carbon
monoxide (CO) and unburned hy-
drocarbons (HC) comprising hazard-
ous air pollutants (HAPs) and vola-
tile organic compounds (VOCs). The
systems work in two efficient stages:
the oxidation stage for CO and HC
reduction and then the NOx reduc-
tion stage. Between the oxidation
and SCR catalysts, aqueous urea is
injected into the exhaust stream via
mixing pipe section. In the process,
the urea is hydrolyzed and breaks
down in the exhaust stream to form
ammonia. Urea is often preferred in-
stead of ammonia because it’s non-
toxic, and easier to transport and
store. Permitting for urea is easier
too. The ammonia reacts with NOx
inside the proprietary SCR catalyst
formulation to form harmless water
and nitrogen.
In the oxidation stage, oxidation
catalyst elements with surface coat-
ings impregnated with precious met-
als reduce CO, HAPs and VOCs —
oxidizing these pollutants to form
water and carbon dioxide. The SCR
net effect is to meet engine exhaust
targets of 5/33/15 ppm at 15% O2
NOx/CO/VOC. The overall benefit of
the Miratech system is that it allows
the plant to operate 365 days a year
providing power and chilled water
to the airport, all within strict emis-
sions compliance.
The cogeneration plant’s power is
supplied to the airport’s concessions,
baggage handling, parking structure
and terminal common areas but not
to airfield areas like the tower. The
airport traffic operations rely on
grid power with a UPS backup sys-
tem. “It’s not an FAA requirement.
It’s just that the economics weren’t
there,” Griffith said. “In the past,
up to 85% of the power purchased
from the utility (Southern California
Edison) went to supply the terminal
and parking structure. We contin-
ue to get approximately 5% of our
power supply from Southern Cali-
fornia Edison Co. via a 12 kV feed.
This source of power can be used if
the engine generator service is inter-
rupted for any reason.”
The plant uses an “N+1” engine/
generator configuration in that there
are four units on-site but only three
engines are needed to meet the an-
ticipated demands of the airport. “Al-
though the combined rating is 7 MW
for the gen-sets, we are only permit-
ted for 5 MW but the airport’s normal
demand is 3.6 MW,” said O’Leary.
“The idea is that we would run a max-
imum of three units under all normal
circumstances. But in an emergency,
we could bring on the fourth engine.
We have tested the plant in ‘island’
mode to make sure that if something
ever did happen to the utility grid we
would not be affected.”
The central utility plant is
equipped with waste heat recovery
equipment typically associated with
the natural gas engine/generator sets.
The recovered waste heat can gener-
ate up to 970 tonnes refrigeration ca-
pacity via absorption chillers, which
continued on page 16
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Emissions Worldview
The Miratech selective catalytic reduction
(SCR) urea injection system.
satisfies most of the airport’s need
for chilled water year-round. The
central utility plant is also equipped
with three Carrier chillers running
on electricity to help satisfy any extra
chilled water demands. Two Broad
heat exchangers capture the waste
heat for hot-water absorption chill-
ers using heat from the exhaust and
the engine’s water jacket.
“The facility came online in March
of 2011,” Griffith said. “The start-
up had its challenges, as any start-
up does, because we are merging
so many technologies in building a
combined heat and power plant. The
cogeneration really helps boost our
overall efficiency.” SAICA uses recovered paper for the
“We are permitted for three engines,
the fourth engine aids in uptime and
maintenance, and all four are run in
rotation to keep the hours the same
on all. It’s like an installed spare, act-
ing as a buffer,” said O’Leary. “This
is a critical facility so the expense of
a fourth engine redundancy is justi-
fied, and it’s also there for peak de-
mand times. If we lost Edison com-
pletely and a gen-set were to fail, the
computer can turn off non-essential,
nonmission-critical loads, and turn
off power to the parking structure
first. In a catastrophic failure, the
plant is designed to save itself — with
the most important thing being not
losing the plant itself. A catastrophic
event would be seismic-oriented in
this area, but terrorist activity is not
out of the question.” A
16 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
Industry Drivers
WÄRTSILÄ
M Kleven Maritime of Norway has
contracted Wärtsilä to design a new
LNG-powered platform supply vessel (PSV)
for Norwegian operator Rem Offshore.
Rem Offshore’s new LNG-powered
PSV will be a Wärtsilä Ship Design VS499
LNG PSV, a vessel originally based on the
VS489 LNG PSV design.
In addition to vessel design, Wärtsilä’s
scope of supply includes dual-fuel (DF)
main engines and generating sets, electri-
cal power and propulsion systems, inte-
grated automation and a power manage-
ment system. The DF engines can also
operate on marine diesel oil if required.
The vessel will be built at the Kleven Verft
yard in Norway.
GE
P Sociedad Anónima Celulosa Ara-
gonesa (SAICA), a large paper re-
cycler in Spain, is using GE’s Jenbacher
gas engine technology to turn biogas into
energy at its cogeneration plant in Zara-
goza, Spain.
manufacturing of new paper, a process
that has helped the company recycle 2.1
million tons per year within its five sites.
SAICA’s cogeneration plant features three
of GE’s Jenbacher J620 gas engines, which
use biogas from the wastewater treatment
to generate electricity. While standard
biogas plants are typically 1 to 2 MW, the
SAICA plant is more than 8 MW.
MAN DIESEL & TURBO
M Dubai-based Grandweld Shipyards
has been appointed to build two
Anchor Handling Tug Supply (AHTS)
vessels for undisclosed offshore opera-
tors. The AHTS newbuildings will each
be powered by two eight-cylinder MAN
L27/38 main engines delivering a total
of 2 x 2720 kW in a standard twin screw
propulsion layout for driving two ducted
cp propellers. The calculated bollard pull
is 90 tons. The engines will be shipped
from Denmark in 2012.
The L27/38 medium-speed propulsion
engine is designed for heavy-duty appli-
cations like offshore supply and serv­ice
vessels, anchor handlers, tugs and work-
boats. The L27/38 is characterized by
good performance over the entire load
range, optimized for high-torque layout
and dynamic behavior, good acceleration
ability with invisible smoke from idling
to full load, low fuel oil consumption
and low NOx emissions, MAN Diesel &
Turbo said.
The engine also features a pipeless
and modularized design principle. The
front-end box is designed with all auxil-
iary system components for easy access
and service. An integrated closed system
circuit for lube oil — including engine-
driven pump, automatic filter, cooler and
thermostatic valves — offers safety, easy
and cost-effective handling, and shipyard
installation, according to the company.
R usTurboMash
P RusTurboMash LLC, a joint ven-
ture of Siemens Energy and Iskra-
Avigaz, inaugurated a new compressor
manufacturing plant in Perm, Russia.
Siemens holds a 51% stake in the joint
venture, with Iskra-Avigaz holding the
rest. The combined investment of the two
companies is E60 million.
The initial plan in the upcoming months
is to gradually start with the production of
stator components for small compressors,
Siemens said. By late 2012, the plant is ex-
pected to produce complete compressors.
These actions will help create as many as
250 jobs, according to the company.
“Russia is a strategic market for Siemens,”
said Ralf Kannefass, head of the Turbo
Equipment business segment of the Oil
and Gas Division of Siemens Energy.
“We’ve been operating in Russia for many
years. Together with our partner, we’ll pro-
duce our latest generation of compressors
in a state-of-the-art manufacturing plant.”
The new plant in Perm will deliver
compressors with drives in the rating
range between 6.3 and 32 MW. The first
machines will be delivered to and in-
stalled in a compressor station operated
by Gazprom.
continued on page 22
see directlink @ www.dieselgasturbine.com
Turbomachinery Controls by john matlack and lee hudson
LVDT Sensors Serve Crucial
Role In Gas Turbine
Operating Efficiency
Serving as feedback devices, LVDT linear position sensors provide
necessary feedback on control valve status
With the increasing demand for
electric power throughout the world,
gas turbine manufacturers are chal-
lenged not only to build more tur-
bines, but also to design them to oper-
ate more efficiently. Controlling valve
performance is the basis for turbine
efficiency improvements. Valves regu-
late the flow of steam, water or gas
throughout the different components
of a turbine. By accurately monitoring
and controlling the flow from these
valves, turbines operate more efficiently
with minimal wasted energy.
John Matlack is global business development
manager and Lee Hudson is applications en-
gineer at Macro Sensors.
18 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
Gas turbines incorporate a variety
of control valves, inlet guide vane ac-
tuators, transfer valves, gate valve, ro-
tating valve, etc. The proper opening
of these valves depends on the plant’s
control schemes. Typically, gas tur-
bine power plants operate under a
highly developed control algorithm.
Plant operators, therefore, need
to know the position of valves at all
times to ensure proper operation.
Though many valve users may only
need to know if a valve is open or
closed, some operators need to know
the exact position in their application.
Though actuators move the valves,
feedback devices translate valve posi-
tion back to a turbine control systems
Shown is Macro Sensors’ HLR 750 series of
UL/ULC listed AC-operated linear variable
differential transformers (LVDTs), used for
operation with gas turbines and in other haz-
ardous environments. These 19 mm diameter
hermetically sealed sensors offer reliable and
contactless position measurement for criti-
cal applications in power plants using gas or
steam turbines such as vane pitch servo con-
trols, fuel valve position feedback, governor
controls, shaft end play and runout, and gen-
erator shell expansion measurement.
indicating “if” and “how much” a valve
is opened or closed. Linear variable dif-
ferential transformers (LVDTs) serve
as the sensors that provide valve po-
sition measurements to ensure proper
turbine operations.
Constructed of stainless steel and rat-
ed for operation in high temperatures
to withstand the harsh environments
of gas turbine power plants, these
LVDT linear position sensors convert
the rectilinear motion of an object,
to which it is coupled mechanically,
continued on page 20
Turbomachinery Controls

1940s, the LVDT is a rugged yet ver-

satile sensor that performs in applica-
tions on land, in the air and under the
sea. Since the 1950s, power generation
remains one of the largest market seg-
ments serviced by LVDT linear posi-
tion sensors. As simple devices with
only a few coils of wire and a ferrous
core, LVDTs can withstand high levels
of shock and vibration, get extremely
dirty and still operate according to
their specifications.
The ability to separate LVDT elec-
tronics, which are located in the turbine
control system, from the LVDT coils is
one of the main reasons these sensors
can survive so well in power plants.
With electronics remotely located, an
LVDT can withstand high tempera-
tures of 176° to 204°C on the turbine,
while sensors with built-in electronics
would have to be specially configured
at a much higher price to offer electri-
The LVDT is an electromechanical transducer that can mechanically convert the cal components that can withstand this
rectilinear motion of an object to which it is coupled into a corresponding elec- level of heat.
trical signal. Shown are the components of a typical LVDT. The transformer’s As gaseous vapors are present in gas
internal structure consists of a primary winding centered between a pair of turbines, LVDTs installed on turbines
identically wound secondary windings, symmetrically spaced about the prima- must meet intrinsically safe parameters
ry. In operation, the LVDT’s primary winding is energized by alternating current and be approved by certified agencies
of appropriate amplitude and frequency known as the primary excitation. The such as UL, FM, CSA and ATEX. As
LVDT’s electrical output signal is the differential AC voltage between the two LVDT coil designers must take these
secondary windings, which varies with the axial position of the core within the requirements into consideration when
LVDT coil. Usually, this AC output voltage is converted by suitable electronic establishing a design, a standard has
circuitry to high level DC voltage or current that is more convenient to use. been set based on the environment
called an “ignition curve.” Designed
with an inductance below the ignition
into a corresponding electrical signal years, LVDTs are commonly configured curve, the LVDT linear position sen-
that is used by a programmable logic in multiple redundant arrays to ensure sor in standard operation or in a fault
controller as part of a control system. no unscheduled turbine downtime. condition never has enough power to
LVDT linear position sensors can mea- Should a control system determine ignite any gaseous vapors present.
sure movements as small as a few mil- that more or less steam/water/gas is re- While other technologies have been
lionths of an inch up to several inches, quired for proper turbine operations, it investigated to serve as feedback de-
but some are capable of measuring po- signals actuators to move the gate, ball vices, the power generation industry
sitions up to ±0.5 m. When connected or butterfly to make the necessary valve has standardized on LVDT technology.
to appropriate signal conditioners, adjustments. When the actuator begins Lasers become blind due to dirt and
LVDTs provide a complete valve posi- to move a valve, a corresponding LVDT grime; capacitive and eddy current sen-
tion measurement system. linear position sensor sends an analog sors don’t have the capability to mea-
Mounted redundantly either in two electrical signal, proportional to the sure long strokes. Potentiometers, mag-
or three sensor groups on actuators that amount of valve displacement, to the netostrictive sensors and string-pots
move the gate of a gate valve or ball/ control system. With LVDT feedback (draw wire sensors) have difficulty with
butterfly of a rotating valve, the LVDT provided in real time, the actuator can the temperature, vibration and intrinsic
linear position sensors “tell” the tur- continually be adjusted until the de- safety requirements.
bine control system how far a valve is sired opening is reached (zero to 100% LVDT technology uses the trans-
“opened” or “closed.” As power genera- opened or closed), as indicated by the former principle to measure linear dis-
tion companies expect their plants to position feedback. placement. A primary coil is excited
have an operating lifetime of 20 to 40 Introduced in the market in the mid continued on page 22
20 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
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Turbomachinery Controls
with an AC signal. The ferrous core AC
couples that signal onto two secondary
coils that are wound 180° out of phase.
If the core is centered between the two
secondary coils, the voltage is coupled
equally on each secondary. However,
since they are out of phase, the output is
zero when the secondary coils are add-
ed together. If the core is positioned to
couple more voltage onto one second-
ary than the other, the output increases
linearly proportional to the amount the
core was displaced (see Figure 1).
When attached to a gate valve in a
redundant configuration, LVDTs are
designed to give an unusual output.
LVDTs, by nature, have a null position
that produces a zero Vac output. Because
turbine valves were designed so long
ago, engineers used techniques that do
not have the sensor go through zero be-
cause the turbine control system would
not know if the core was at the zero po-
sition or if there was a failure such as a
break cable. To combat this problem, a
tap is taken off of the primary coil and
that voltage is added to the secondary
output. This shifts the output so that the
voltage is always positioned somewhere
over the linear range of the sensor.
With a sweet spot between 1.27
and 30.48 cm of stroke length, LVDT
position sensors offer high accuracy
and durability. Development of new
winding techniques, such as comput-
erized layer winding and improved
microprocessing, have considerably
reduced the length of the linear po-
sition sensor body compared with its
measurable stroke length.
And today’s LVDTs are so well made
that they offer high repeatability — the
ability to reproduce the same output
for repeated trials of exactly the same
input under constant operating and en-
vironmental conditions. While offering
improved performance and reliability,
LVDT linear position sensors remain
very cost effective. Based on their reli-
able performance, repeatability, accu-
racy and costs, LVDTs serve an impor-
tant role in turbine operations as well as
plant rehabilitation projects to ensure
optimum efficiency. A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
22 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
Industry Drivers
SIEMENS
P The Nhon Trach 2 combined-cycle
power plant has started commer-
cial operation in Vietnam. Siemens sup-
plied the power block comprising main
components such as gas turbines, heat-
recovery steam generators, steam turbine,
generator, and instrumentation and con-
trols. The general contractor Lilama erect-
ed the power plant for customer Petro
Vietnam Nhon Trach 2 Joint Stock Co.
With an installed capacity of 760 MW
and an efficiency of more than 57%,
Nhon Trach 2 will make an ecofriendly
contribution toward meeting the coun-
try’s power demands. Due to Siemens’
burner technology, the plant’s NOx emis-
sions are at less than 15 ppm, according
to the company.
The Nhon Trach 2 combined-cycle
plant is located south of Dong Nai Prov-
ince, about 35 km from Ho Chi Minh
City. For the multishaft plant in which
the gas turbines and the steam turbine are
each coupled with a dedicated generator,
Siemens supplied the power block on a
turnkey basis. It comprises two SGT5-
4000F gas turbines, two heat-recovery
steam generators, an SST5-5000 steam
turbine, three SGen-1000A air-cooled
generators, the entire electrical equip-
ment and instrumentation and controls
(SPPA-T3000) as well as the ancillary and
auxiliary systems. In the future, Siemens
will assume responsibility for providing
maintenance of the main components.
Vietnam is one of the fastest-growing
countries in Southeast Asia and its pow-
er demand is increasing 11 to 13% each
year. Power plants with a combined ca-
pacity of 21 GW are installed there, which
is only sufficient to meet one-tenth of ac-
tual power demand.
CATERPILLAR
M Caterpillar Marine Power Systems
was selected to provide two 6 M 25
C and two 9 M 25 C propulsion engines
for an Ostensjo Rederi AS offshore sup-
ply newbuild. Each 6 M 25 C engine will
provide 2000 kW at 750 r/min. The 9 M
25 C engines will each provide 3000 kW
at 750 r/min. All engines feature an air in-
jection system designed to ensure load re-
sponse remains in a low rpm range. Each
engine is also packaged with the Siemens
Bluedrive PlusC diesel-electric propulsion
system. The vessel is slated to begin op-
erations in fall 2013.
“With the new air injection system,
Caterpillar can offer a tool that improves
the load acceptance capabilities of the
engine at any condition,” said Andreas
Banck, supervisor of the Diesel Engine
Test Team of Caterpillar Motoren GmbH.
“It’s a simple system with a proven design
and as reliable as the engine. Compressed
air will be injected after the turbocharger,
thus having a diffuser effect that supports
the turbocharger performance.”
To reduce environmental emissions,
the engines feature an SCR catalyst oper-
ating over the load range of 10 to 100%
and a reduction in fuel consumption
throughout the operation cycle for an
offshore supply vessel, Caterpillar said.
Fuel consumption testing results have
demonstrated the effectiveness of the
IMO II-compliant MaK engines, with
average fuel consumption expected to be
at least 15% below the fuel consumption
of comparable propulsion systems in off-
shore vessels operating today, according
to Caterpillar.
Manufactured in Kiel, Germany, the M
25 engine series features high-efficiency
turbochargers and a reduced number of
components designed for ease of instal-
lation and system integration, Caterpil-
lar said. The vessel is being constructed
at the Astilleros Gondán S.A. shipyard in
Castropol, Spain. The engines will be de-
livered in spring 2012.
MOTORTECH
I Motortech of Germany has an-
nounced two new sales partner-
ships. The company said Reagan Equip-
ment Co. Inc. of Gretna, Louisiana, U.S.A.,
is its new distributor for the southeastern
United States.
Reagan will distribute Motortech
products for stationary gas engines. The
products include ignition controls and
monitoring, industrial spark plugs, wir-
ing systems, gas regulation and gas engine
management, including detonation, speed
control and cogeneration management.
Alberta, Canada-based Collicutt Com-
pression is the new Motortech distributor
for Canada for the same range of products.
continued on page 26
 Guiding Buyers To Suppliers For
76 Years And Counting
More than ever, engineers and purchasers around the world are turning to GSGnet.net for
information about products and technologies used in engine-powered equipment and engine systems.

Within the last 12 months GSGnet.net has had:

• More than 300,000 individual page views • More than 80,000 visits • More than 73,000 unique visitors
• More than 250,000 ad impressions • An average time of more than 7 minutes per visit

Searches on Google, Yahoo, Bing, etc., directed users to GSGnet.net

more than 61,000 times, demonstrating high search engine optimization.

Combined with the Global Sourcing Guide, the companion print version now in its 76th year of annual
publication, Diesel & Gas Turbine Publications GSGnet.net and Global Sourcing Guide provide
the most comprehensive information on engines, power transmissions, hydraulics, emissions systems
and the many other product technologies used in engine-driven machinery and equipment.

If you buy engines and components, you need to look here!

If you sell engines and components, you need to be here!
See for yourself at GSGnet.net or call 800-558-4322 or 262-754-4100 to order your print edition!
Overhaul, Service & Repair by roberta prandi

iClad by Pallas is a miniaturized processing head for laser cladding in aperture

diameters down to 26 mm and working depths up to 500 mm.

A New Life For Worn Cylinder Bores

iClad laser cladding technology with a new rotating head allows the reconditioning of cylinder bores
directly on large diesel engines

Although laser cladding is a well-
proven technology for repairing or
optimizing engine parts, convention-
al heads are not able to reach some
internal contours or blind bores.
German specialist Pallas has devel-
oped a new technique called iClad, a
miniaturized processing head for ap-
erture diameters down to 26 mm and
working depths up to 500 mm.
Each iClad head consists of three
modules: powder feed, main body
and fiber plug. In contrast to conven-
tional heads, the working distance
between head and component is just
a few millimeters. In standard heads,
it is up to 20 mm.
Depending on the processing point,
the laser beam can exit either at an an-
gle of 30° or 90°. Blind bores can easily
be coated with a 30° head because the
laser’s working point is in front of the
head. On through bores, a 90° angle
is used.
Recently, iClad was upgraded with
24 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
a rotating head for a repair project of
worn cylinder bores in rail diesel en-
gines. This version can treat internal
contours of components with eccen-
tric bores or nonrotationally symmetric
openings of 50 mm or more in diam-
eter and with a depth of up to 500 mm,
said Pallas.
The project started with the Bel-
gian railway operator commission-
ing to Belgium-based Laser Coating
Diamond Technology (LaserCo DT)
the reconditioning of worn cylinder
bores by laser cladding of the up-
per and lower piston reversal points.
LaserCo DT specializes in wear pro-
tection for metals through laser clad-
ding and diamond coating.
LaserCo DT’s Managing Direc-
tor, Hugues Desmecht, asked the
Fraunhofer Institute for Laser Tech-
nology (ILT) in Aachen, Germany, to
carry out a feasibility study. The study
was carried out in close cooperation
with Pallas, who originally developed
iClad jointly with ILT and now mar-
kets the system.
The study consisted of applying iClad
laser cladding to two of the six damaged
cylinder bores in an eight-cylinder die-
sel engine for railway application. “In
the new iClad, the rotary drive is inte-
grated into the head,” said Stephan Ka-
lawrytinos, managing director at Pallas.
“Even when inserted horizontally, the
head ensures uniform powder applica-
tion independent of its rotation angle.
“In this specific application, how-
ever, the rotating head was inserted
vertically into the cylinder bores via a
five-axis system.”
One main argument for using the
rotating iClad head was that, because
of the sheer weight, it would be im-
possible to rotate a whole 700 kg die-
sel engine around a fixed processing
head. Individually centering each cyl-
inder was not a viable option either,
because of the massive costs involved.
continued on page 26
 IN PLANT MAINTENANCE
One Since 1968
Tool Series...

is ALL you ever need!

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Overhaul, Service & Repair
The iClad processing head has been upgraded with a rotating head for the repair project of
worn cylinder bores in rail diesel engines.
Kalawrytinos said the aperture diam-
eter of the cylinder bore is 178 mm; the
lower area to be coated is situated at a
depth of about 340 mm and consists
of a ring segment about 60 mm high.
Conventional heads can only be ap-
plied at an angle in the bores, since the
nozzles are located at the tip of the pro-
cessing head. Thus, in spite of an aper-
ture diameter of almost 180 mm, their
use is limited to a depth of approxi-
mately 40 mm. In contrast, the rotating
iClad head is vertically inserted into the
cylinder bore and can process the entire
internal surfaces at an angle of 90°.
The worn cylinder lining at the up-
per and lower dead points was to be
clad with a coating thickness of >1
mm. This called for the cladding of a
stainless-steel alloy to ensure not only
the necessary wear resistance but also
good corrosion resistance in acidic
and alkaline environments.
The worn bores were first ma-
chined to a specific dimension at the
facility of LaserCo DT’s customer in
order to remove all traces of wear and
tear and to create a smooth surface for
the laser cladding.
At ILT, the engine block was placed
on a steel support, then aligned and ex-
actly adjusted. Dr. Andreas Weisheit,
group manager cladding and heat
treatment at ILT, and his team to-
26 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
gether with Kalawrytinos then set up
the rotating internal processing head.
Both outside cylinder bores in the low-
er damaged ring segments were proc-
essed. The required coating thickness
of 1 mm was achieved by applying two
coatings in two overlapping rotational
movements of the five-axis system. A
CNC program was developed for this
purpose. Starting at the bottom edge at
a depth of about 300 mm, the coating
was applied to the surface in helical
form. A 3 kW Nd:YAG laser was used
as the laser source.
“This proves beyond a doubt that
laser cladding in cylinder bores is a
technically feasible and cost-effective
alternative to the purchase of replace-
ments,” said Weisheit. “The coating
applied with the iClad rotating inter-
nal contour processing head features
excellent surface quality.”
Kalawrytinos sees great potential for
the application of the unique head.
“The iClad’s five-axis processing capa-
bility allows precision reconditioning
of worn bores at reasonable costs and
in previously unheard-of timeframes.
“We feel this is a complete success
that offers ground-breaking perspec-
tives for the repair of parts previously
beyond reach or repair.” A
SEE DIRECTLINK @
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Industry Drivers
PROGRESS RAIL
R Nearly a year after the announce-
ment, Progress Rail Services Corp., a
wholly owned subsidiary of Caterpillar Inc.,
officially opened its locomotive manufactur-
ing facility in Muncie, Indiana, U.S.A.
Progress Rail announced the site selec-
tion in October 2010 and began work
in January. In less than 10 months, the
facility has produced completed diesel-
electric locomotives for the company’s
customers. The Muncie facility is the
first locomotive assembly plant to open
in the United States in many years, Prog-
ress Rail said.
Caterpillar and its subsidiaries are
recognized as providers of diesel engine
technology, which allows Progress Rail
and EMD to offer the broadest range
of locomotive engine products, such as
two- and four-cycle locomotive engines.
Within the past year, Progress Rail also
announced two additional locomotive
assembly plants: one in Sete Lagoas,
Minas Gerais, Brazil, and another in Sa-
hagun, Mexico.
WOOD GROUP GTS
I Wood Group GTS (GTS) has en-
tered into a strategic alliance with
Pratt & Whitney Power Systems (PWPS)
to jointly service the GE Frame 7FA in-
dustrial gas turbine aftermarket. Under
this alliance, GTS has received a 10-year
license for sale and distribution of PWPS
manufactured combustion hardware, hot
gas path components and high-technology
repair services. 
The alliance will improve GTS’ abil-
ity to support power plant owners and
operators with long-term maintenance
agreements, the company said. PWPS will
continue to directly sell parts and repair
services on a transactional basis. There
are more than 1000 GE “F” technology
gas turbines in operation, with 70% be-
ing 7FA units, according to Wood Group.
This license enables GTS to further en-
hance its long-term service offering for
“F” technology machines, adding a com-
prehensive parts and repair capabilities
to a portfolio including DLN combustion
technology, remote monitoring and diag-
nostics, power augmentation, field service
and technical support.
continued on page 31
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see directlink @ www.dieselgasturbine.com

Marine Propulsion by ian cameron

An illustration of the vessel and its propulsion system. Two vessels

have been ordered by Norwegian company Buksér og Berging AS
and will enter service in late 2013.

New LNG-Powered Tugs

Combined power and propulsion system will feature lower fuel consumption,
increased efficiency and environmental benefits

Rolls-Royce has signed a contract to
deliver engines and propulsion systems
for what it said are the world’s first liq-
uefied natural gas (LNG)-powered tugs.
The two vessels have been ordered
by Norwegian company Buksér og
Berging AS and will enter service in
late 2013 for Norwegian energy com-
pany Statoil, and Gassco, the operator
of the gas transportation network off
the Norwegian coast.
“I feel that this is a breakthrough
both for Rolls-Royce and also within
the tug propulsion sector,” said Robert
Løseth, Rolls-Royce, senior vice presi-
dent – Merchant, Propulsion Systems
and Engines. “In the tug business, we
have always had a strong standing for
the supply of azimuth thrusters —
with a market share of around 40%
— but our standing for engines was
less strong.
28 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
“This new contract for LNG-pow-
ered tugs is real change within the
tug industry. We believe this could
prompt many more such contracts,
especially in areas where there are
large LNG terminals.”
In addition to two gas engines and
a single LNG tank, Rolls-Royce will
deliver a mechanical direct-driven
azimuth propulsion system for each
tug that will provide the quickest
response time for maneuvering,
which is critically important for tug
operators. The combined power
and propulsion system will also en-
able the lowest possible fuel con-
sumption in all operating modes.
Rolls-Royce will also provide auto-
mation and control systems for the
two escort vessels.
Vetle Sverdrup, commercial direc-
tor at Buksér og Berging AS, said,
“We wanted to base the design of the
new tugs on the spark-ignition, lean-
burn engine concept, and the ability
to accommodate direct drive in addi-
tion to a low emissions profile. The
propulsion system on high-perfor-
mance escort tugs needs to accom-
modate rapid load pick up over the
entire load range. Due to the above,
we chose to work closely with Rolls-
Royce on this project.”
Under the contract, Rolls-Royce
will supply two Aquamaster thrust-
ers, two Bergen C6 Ing mechanical
drive Tier 3 compliant engines, each
producing 1.7 MW of power, RR
Acon control and monitoring for gas
system and a single AGA Cryo LNG
tank with LNG system based on two
coldboxes. The tugs accommodate
seven people and will be built at the
Sanmar shipyard in Tuzla, Turkey.
Marine Propulsion

The tugs have an overall length ignited gas engines. There is no switch- lems with the cleanliness of oils as
of 35 m, beam of 15.4 m and a over of fuels needed. Ramp-up time is there is no pollution going into the
7.5 m draft. very important for tug captains who oil from the engine. Because the en-
The LNG system is designed by often increase power in a very short gines are Tier 3 compliant engines, it
AGA Cryo and integrated with the time. Also, as the engines are medi- means there is no need for aftertreat-
Rolls-Royce propulsion system. um-speed engines, they can be serv- ment. The engine has an efficiency of
This single tank LNG system has iced onboard unlike other types of 48.5% compared with diesel engines
received full gas redundancy ap- tug engines that often have to be re- that offer around 44%.” A
proved by Norwegian Maritime Di- Harco_Mar08_WW.qxp
moved for servicing. 9/30/08 2:26 PM Page 1SEE DIRECTLINK @
rectorate (NMD) so no diesel back- “LNG engines don’t have prob- WWW.DIESELGASTURBINE.COM
up is required.
According to Rolls-Royce, the
operational benefits of a gas-fueled
propulsion system are a cleaner
engine room, less waste oil and no
switchover problems. The new gas
engines are also service friendly
and need less maintenance, the
company said.
The gas engines can operate on low
load without any restriction and have
a very quick and step-less ramp-up
time from zero to 100% load.
The fuel system is designed for
weekly bunkering intervals and the
bunkering time is estimated to be
45 minutes. Bunkering will be car-
ried out by the ship’s crew.
NOx emissions are lower at low
engine loads, which is the reverse
trend of most diesel engines, mak-
ing it the optimal solution for tugs
that are spending most of the time at
lower engine loads, said Rolls-Royce.
Rolls-Royce added that the envi-
ronmental benefits associated with
spark-injection engines include of-
fering 92% reduced NOx emissions,
17% reduced greenhouse gas emis-
sions, 98 to 100% reduced SOx emis-
sions, 98% reduced particulates, and
an absence of oil spill during bunker-
ing or in ship engine room bilges.
The company also said further ad-
vantages included a lack of sludge
from purifiers, no fuel oil waste,
leakage or spill oil (thus reducing
any fire risk), improved long-term
compliance with local port regula-
tions and potential benefits from
taxation/green port dues.
The vessels are designed by Buksér
og Berging AS together with Marin
Design AS in Kolvareid, Norway.
Løseth said, “There are a number of
key advantages that arise from spark- see directlink @ www.dieselgasturbine.com
Diesel & Gas Turbine Worldwide M a r c h 2 0 1 2 29
Vibration Detection & Analysis by roberta prandi
Vibrabsorber Shakes
Off Vibration
The rubber-metal, anti-vibration supports by AMC-Mecanocaucho are used in
stationary applications with especially high vibration damping requirements
For over 40 years, AMC-Mecano-
caucho has been developing a full
range of rubber-metal, anti-vibration
supports. The company’s product
portfolio is used in sectors such as
power generation, air compressors
and blowers, pumps and pumping
equipment, industrial vehicles, marine
propulsion and auxiliary equipment,
and acoustic isolation of premises.
The AMC-Mecanocaucho Vibrab-
sorber is used particularly in station-
ary gen-sets, where an isolation effi-
ciency above 95% is a must. Typical
applications are hospitals, residential
areas, libraries and so on.
Vibrabsorbers are supports made of
springs with a mechanical anchoring
system for static applications that offer
great reliability in the isolation of low-
frequency vibrations. They feature an
inverted double cone inside the spring
that limits the compression of the
spring in case of an unexpected over-
load, acting as an end-of-stroke buffer.
Vibrabsorber is also available with
a Sylomer mat to isolate the mid-high
frequency vibrations that are trans-
mitted through the coils of metal
springs. Such high and midrange fre-
quencies, if not isolated, do spread
throughout the buildings or struc-
tures generating noise.
Aitor Lopetegi, export manager
of AMC-Mecanocaucho, said the
30 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
At AMC-Mecanocaucho, dy-
namic test benches are used
to determine the stiffness
of anti-vibration mounts, as
well as the damping coeffi-
cients of compounds.
company’s evaluation for an anti-
vibration project always starts with
thorough calculations. “We calculate
our anti-vibration solutions by tak-
ing into account data such as weight,
mount positions, type of machine and
frequency of excitation.
“After studying each customer’s
specific needs for the application
and the isolation performance re-
quired, AMC-Mecanocaucho can de-
sign new products according to the
existing conditions.”
The next step is test and dynamic
characterization, for which AMC-
Mecanocaucho utilizes its own
laboratory with advanced dynamic
testing equipment.
AMC-Mecanocaucho published a
very interesting theory on vibration
insulation. Among the most interest-
ing topics in the analysis are the eval-
uation of static and dynamic stiffness,
damping coefficient and long-term
behavior of the damping elements.
Static and dynamic stiffness comes
into play as the stiffness of a rubber
anti-vibration mount changes when
a dynamic force is applied to it. This
parameter depends on architectural
structure, the compound used and
even the frequency of excitation.
“Generally speaking, dynamic stiff-
ness is always greater than static stiff-
ness, so calculations based on static
stiffness may lead to wrong conclu-
sions,” said Lopetegi. “In some cases,
it is possible to reach limits of dynam-
ic stiffness that are two and even three
times greater than the static stiffness.”
The damping coefficient depends
basically on the compound used in
manufacturing of the anti-vibration
mount. It is a crucial parameter that
must be addressed when designing
anti-vibration suspensions.
As for long-term behavior of the
damping element, if an elastomeric
element is under a static load, this
load produces a progressive increase
in deformation. This phenomenon
may be important in a wide variety of
applications, from mounts for build-
ings to engine mounts.
This creeping effect depends on the
geometry of the mount, and above
all on the way the rubber is worked.
Designs that use rubber in shear are
more conducive to “creep” than de-
signs that use rubber in compression
or shear and compression.
“Dynamic stiffness can only be estab-
lished by measurement on a dynamic
test bench. Similarly, the damping coef-
ficients of compounds are further val-
ues that can be measured with this type
of machine,” said Lopetegi.
“One concept that must be taken
into account when designing an anti-
vibration mount is its durability. A
dynamic testing machine allows us to
conduct fatigue tests that reproduce
the real working conditions of the
part so that its useful life can thus be
predicted accurately.”
The latest computing tools in use at
AMC-Mecanocaucho can also gener-
ate virtual models of solid rigid multi-
ples and study how they interact with
each other and with the environment.
As a result, the company can ascertain
the natural frequencies of the system,
which are very important to prevent
them from coinciding with the exci-
tation frequencies so as not to have
resonance problems.
The full theory on vibration insulation
is available on AMC-Mecanocaucho’s
website, www.mecanocaucho.com. A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Industry Drivers

FLOWSERVE ture, high-sensitivity, high-resonance an overall thickness of 0.76 mm and di-

I Flowserve Corp., a provider of

flow control products and services,
said it received a three-year contract in
gauge piezoresistive pressure transduc-
ers that are offered in ranges of 1, 3.5
and 6.9 bar with 225 mV full-scale out-
ameter of 6.3 mm, and are available in
ranges of 0.02 and 5.9 bar with 200 mV
full-scale output.
September by Bangchak Petroleum Public put. The 8515C series are miniature, The 8530BM37 series are minia-
Co. Ltd. (Thailand) to implement its on- high-sensitivity piezoresistive pressure ture, high-sensitivity, high-resonance
line assurance program. transducers, designed for surface air flow absolute piezoresistive pressure trans-
The Bangchak program will incorpo- and other aerodynamic measurements ducers, that are rugged to 20 000 g
rate the IPS APEX data acquisition system requiring high output in a small, light- shock, offering linearity and thermal
and initially focus on monitoring the criti- weight package. These transducers have transient stability.
cal, enhanced hot separator pump system continued on page 32
that is part of the refinery’s HyCycle Uni-
cracking process unit.
This online asset management program
incorporates Web-based data aggregation
tools and is designed to enable special-
ized technical experts from Flowserve to
monitor process conditions and anticipate
failure modes for critical plant assets, the
company said.
A vital part of the program is the
Flowserve Technology Advantage Portal, a
Web-based data/information aggregation
system. Through this portal, Bangchak
plant operators and Flowserve technical
experts can collaboratively view plant as-
set information from several sources. In
addition, information can be exchanged
regarding equipment and process condi-
tions to ensure maximum equipment and
unit availability.
Cylmate® Sensors. Pressure under control.
MEGGITT
I Meggitt Sensing Systems, a Meg-
gitt group division, has expanded
its Guaranteed InStock program to in-
clude 19 Endevco high-sensitivity piezo-
resistive pressure transducer models,
with more than 400 units available for
immediate shipment. 
Save money by tuning and controlling the combustion pressure stroke-by-stroke.
All of Meggitt’s Endevco piezore- Cylmate pressure sensors used on electronically controlled diesel engines enabling
sistive pressure transducers feature a improved energy efficiency and lower the risk for off-hire costs.
The unique and reliable Cylmate pressure sensor has proven its maintenance- and
four-arm strain gauge bridge design, calibration-free performance during years of continuous operation.
5 year warranty. www.abb.com/pressductor
implanted into a MEMS diaphragm,
for wideband frequency response and
twice the sensitivity of traditional flat
diaphragms for improved resolution,
the company said. The transducers are
also shipped in special electrostatic
discharge (ESD) packaging for added
protection during shipment and han-
dling. Available series models include ABB AB
the Endevco model 8510 C series, the Force Measurement
Phone: +46 21 32 50 00
Endevco model 8515C series and the Fax: +46 21 34 00 05
Endevco 8530BM37 series.
The 8510C series are rugged, minia-
see directlink @ www.dieselgasturbine.com
Diesel & Gas Turbine Worldwide M a r c h 2 0 1 2 31

ABB_AB_Mar12_WW.indd 1 1/19/12 12:55 PM

Industry Drivers
ROLLS-ROYCE
P Rolls-Royce has received a US$22
million contract to supply eight
Bergen B32:40 16V reciprocating engine
generator sets to Baraka Patenga Power
Ltd. (BPPL).
The engines will power BPPL’s 50
MW power plant under construction at
Patenga, 14 km south of the port city of
Chittagong in southeastern Bangladesh.
The Patenga power plant will play an im-
portant role in supporting the develop-
ment of the Bangladeshi local economy
by supplying electricity to the national
grid, said Faisal Ahmed Chowdhury,
BPPL’s chairman.
This order brings the Rolls-Royce fleet
of B32:40 16V engines sold to customers
in Bangladesh to 48 units. The units are
capable of delivering more than 300 MW
of power.
In July, BPPL signed a Power Purchase
Agreement with Bangladesh Power De-
velopment Board to develop the 50 MW
independent power plant project on a
“Build-Own-Operate” basis for a 15-
year term. BPPL is a 51% subsidiary of
Barakatullah Electro Dynamics Ltd., the
Dhaka listed Bangladeshi power genera-
tion company.
NAES
P NAES Corp., a broad-based pro-
vider of services to the energy in-
dustry, has entered into an agreement
with MinnTex Power Holdings LLC to
perform operations and maintenance
serv­ices for the Guadalupe Power Project
located in Marion, Texas, U.S.A.
The Guadalupe Power Project
achieved commercial operations in
April 2001, with NAES assuming opera-
tions in March. The 1000 MW project
consists of two, two-on-one combined-
cycle power blocks of “F” technology
combustion turbines. A zero liquid dis-
charge water/waste treatment facility is
also employed.
WEG
I WEG S.A. has signed an agreement
with GE Energy to acquire the
Electric Machinery unit of Converteam.
The acquisition is expected to close before
the end of the year subject to customary
closing conditions and approval by the
see directlink @ www.dieselgasturbine.com
U.S. Department of Justice. Financial Call your nearest
terms were not disclosed.
WEG’s acquisition of Electric Machin-
ery follows the acquisition of Converteam
MOTORTECH Sales Partner!
by GE on Sept. 2, 2011. As part of the Distributed by:
merger review process prior to the acqui-
sition, GE agreed with the U.S. Depart-
ment of Justice to divest the Electric Ma-
chinery unit of Converteam after closure.
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balancing and technical support.
EM has an installed base of more
than 5500 units in operation. Rev-
enues in 2011 are estimated to reach Collicutt Compression
8133 Edgar Industrial Close
US$56 million. Red Deer, Alberta, CA
Phone: 1-403-309-9250
YUCHAI info@collicutt.com
www.collicutt.com
M China’s Yuchai Power delivered
what it called its first slow-speed
diesel engine at a signing ceremony on
Nov. 11, 2011 in Zhuhai. The engine,
Wärtsilä’s RT-flex35, which has been
developed with technology licensed
from the Finnish company, covers a
power range of 3475 to 6960 kW at
Stewart & Stevenson
5840 Dahlia Street
Commerce City, CO 80022
142 to 167 r/min. The engine is used Phone: 1-303-287-7441
All trademarks, logos, and symbols are exclusive objects to the right of their owners and are used for reference purpose only.
for propulsion in small and medium- j.newmann@ssss.com
sized commercial vessels. www.ssss.com
Yuchai said it produced the engine in
eight months and that the Zhuhai factory
that builds them was itself constructed
in just 12 months. So far, orders for 35
units have been placed by Chinese ship-
builders, Yuchai said. CPI - Service
The unveiling has been heralded as Gillette, WY 82716
1117 Energy Street
a step closer to greater Chinese auton- Phone: 1-307-682-5418
omy within slow- and medium-speed info@c-p-i.com
www@c-p-i.com
diesel engine manufacturing. Current-
ly, China relies on foreign components
for up to 70% of its high-power die-
sel engines by value. Parts such as the
crankcase, turbochargers and fuel sys-
tems have traditionally been sourced
from MAN Diesel & Turbo, Mitsubishi Martin Machinery L.L.C.
or Wärtsilä. Phone: 1-660-458-7000
sales@martinmachinery.com
continued on page 35
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Turbomachinery Controls by dj slater
Rockwell Extends
Its Reach
Company’s new power range for PowerFlex 750 Series AC drives 900 kW
As manufacturers across the world
continue to rely on motors to power
their operations, the push to use that
power more efficiently has become a
common theme. According to Rock-
well Automation, motors are one
of a manufacturer’s biggest assets
but also consume massive amounts
of electricity.
Over the years, Rockwell Automa-
tion has used its drive technology to
mitigate this concern and now has the
capability to address even more op-
erations. The company has extended
the power range of its Allen-Bradley
PowerFlex 750 Series AC drives to
900 kW as well as added 600/690
34 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
The expanded power range for the
PowerFlex 750 Series AC drives has
a variety of features, such as ad-
vanced diagnostics, a roll-out design
and control options.
V ratings. Before the move, the
PowerFlex 750 Series’ power range
stretched to 450 kW.
The new drives provide users
with application flexibility, ad-
vanced diagnostics and a common
DC bus option. The drives are de-
signed for heavy industrial applica-
tions such as wastewater treatment
plants, conveyer and crushing sys-
tems, earthmovers and pipelines,
the company said.
“There’s a high demand now to get
energy savings out of large horse-
power operations,” said John Cher-
ney, global product manager, Rock-
well Automation. “The cost savings
from more efficient operations can
be substantial.”
Cherney said this development is
part of the final phase for the 750
Series of AC drives, which includes
the PowerFlex 753 and 755 models.
With line extensions in early 2012,
the PowerFlex 750 Series will reach
from 0.75 to 1500 kW.
“What we’re doing now is starting
to parallel [the drives] in twos and
threes, going to the higher and higher
power sizes,” he said. “The first struc-
ture was 700 hp [522 kW], and then
we put two of those side by side for
1350 hp [900 kW]. That’s just the
natural progression of paralleling
those units and going larger and larg-
er in the power size.”
The reason for the power range
addition was to address applications
in that range, as well as expand the
PowerFlex 755’s reach in the global
marketplace, Cherney said. Inter-
nationally, he said, the 690 V capa-
bilities are growing in popularity,
which prompted Rockwell Automa-
tion to design the drive for 600/690
V applications.
“What this expansion does is
broaden our reach … in all major
markets of the world,” he said. “That’s
a very large step.”
The PowerFlex 755 drives first
launched in 400 and 480 V, which
are suitable for North American,
South American and European mar-
kets, Cherney said. The 600 and 690
V support Canada and other regions
of the world, especially Asia.
The common DC bus option al-
lows users to connect the PowerFlex
755 AC drive to a common DC bus
configuration, which uses differ-
ent drive cycles to share energy. In
this configuration, a DC bus acts
as a common energy source that
feeds energy from a generating load
to a motoring load. This improves
the application’s energy efficiency
by managing energy from a shared
source, which increases system per-
formance and reduces losses, ac-
cording to Rockwell Automation.
Similar to all PowerFlex 755 drives,
the latest frame size includes an em-
Turbomachinery Controls
bedded Ethernet port and five option slots, allowing us-
ers to tailor the drive to their application. Option modules
include I/O, feedback, safety, additional communications
and an auxiliary power supply.
“It’s like a computer, in that you can build it to suit your
needs,” said Stephanie Winterhalter, commercial program
manager, Rockwell Automation. “If customers need addi-
tional I/O, they can do it.”
Installation and maintenance on the PowerFlex 755
drives isn’t a cumbersome task, Cherney said. The roll-
out design provides the user with easy access to the drive
for installation and maintenance. The drive’s converter
and control pod can also remain in the unit while the
inverter is rolled out, which means that the control wiring
can stay connected, he said.
“Your yearly maintenance of the machine is a one-person
job,” Cherney said.
Another key feature of the drive is the controller inter-
face, which is universal throughout Rockwell Automation’s
drive products.
“Other companies might have one controller for drives
up to 25 hp [18.5 kW], while the 30 to 75 hp [22.2 to 55.5
kW] range might have a different controller interface,” he
said. “That’s just a nightmare for customers to deal with.
With us, you buy one drive and you’ve got the control
panel for all our drives.”
The PowerFlex 755 also has preventive diagnos-
tic features, such as its ability to monitor the motor
it’s driving, said Sergio Gama, Rockwell Automation’s
market development director. When a user provides
the drive with information about the motor, the drive
will not only estimate the life of the motor, but also
monitor its behavior and alert the user when it might
need maintenance.
Additional features, made possible by a recent firm-
ware upgrade, include interior permanent magnet motor
control for application flexibility and energy efficiency,
and the “stop dwell” function that prevents a motor from
coasting to a stop.
Another feature is automatic device configuration,
a feature that Cherney said makes life much easier for
customers. With automatic device configuration, Allen-
Bradley Logix controllers can automatically configure
a drive upon replacement, meaning that users can now
replace drives without having to configure and program
them manually.
“When you replace the drive, the controller identifies
it and automatically reassigns the IP address, reconfig-
ures the drive’s parameters and upgrades any software
or firmware,” he said. “This is all done without any hu-
man intervention, aside from someone physically in-
stalling the drive.”
Gama added, “Customers want to get up and running
as quickly as possible. They want to improve their time
to market.” A
SEE DIRECTLINK @ WWW.DIESELGASTURBINE.COM
Industry Drivers
IMI SENSORS
I IMI Sensors, the industrial monitoring division of PCB
Piezotronics, announced that GOST-R certification has
been obtained for its predictive maintenance line of ICP acceler-
ometers as well as 4 to 20 mA vibration transmitters and vibration
switches. GOST-R certification is required of instrumentation
that will be used in Russia in potentially hazardous or explosive
areas, the company said.
The certification covers IMI’s industrial ICP accelerometer se-
ries designed for permanent mount applications. Series 602, 603,
606, 607 and 608 accelerometers have gained approval. Precision
accelerometer models in Series 622, 623 and 628 are also certi-
fied, according to IMI.
All vibration transmitters in the company’s growing 4 to 20 mA
product offering are also approved, which includes all 64X se-
ries models and the 649 series reciprocating machinery protector.
All three of IMI’s vibration switch offerings have been approved,
including the 686B programmable switch. Select models in the
electronic vibration switch series 685B are approved as well as the
mechanical switch 685A08, IMI said.
DRESSER-RAND
I Dresser-Rand, a global supplier of rotating equipment to
the oil, gas, petrochemical, power and process industries,
is expanding its Turbine Technology Services facility in Hous-
ton, Texas, U.S.A., to include a center of excellence for F-class
rotor repair.
The facility also provides repairs on mature and F-Class frame
industrial gas and steam turbines and includes complete in-house
coating capability, automated five-axis laser welding, a metallur-
gical laboratory, a high-capacity vacuum and conventional heat
treating facility, and a machine and weld shop.
The facility is also ISO 9001:2008 certified.
Dresser-Rand Turbine Technology Services currently has 8175
m2 under roof. The new F-class rotor shop will add an additional
2229 m2 with a 68 tonne crane and 15.2 m under-hook, ade-
quate for F-class rotors up to Frame 9, Dresser-Rand said. The
expanded area will allow Dresser-Rand to provide service for all
brands of industrial gas and steam turbine rotors, including blade
replacement, unstacking and restacking, balancing and nonde-
structive testing.
In addition to the Houston facility, Dresser-Rand is globally
expanding its industrial gas and steam turbine repair capability.
Locations in South America, Europe and Asia are currently being
equipped with additional capacity.
MAN PRIMESERV
M MAN PrimeServ Shanghai has signed two maintenance
contracts — worth more than E4 million — with COSCO,
the state-owned Chinese shipping group.
The first contract covers the retrofit of 32 vessels from the
COSCO Bulk Carrier fleet with slide-fuel valves. It also includes
the retrofit of 7+6 vessels with Alpha Lubricators.
The second contract is with COSCO Shanghai and covers the
maintenance of 24 sets of TCA88 turbochargers aboard 12 vessels.
continued on page 37
Diesel & Gas Turbine Worldwide M a r c h 2 0 1 2 35

Emissions Worldview
FlexEnergy And DOD
Team Up At Fort Benning
Commercial system to generate clean energy from landfill methane
with near-zero emissions
Irvine, California, U.S.A.-based en-
ergy technology company FlexEnergy
is successfully operating the first com-
mercial deployment of its Flex Power-
station FP250 system at the Depart-
ment of Defense’s (DoD’s) Army post
at Fort Benning, Georgia, U.S.A. The
Flex Powerstation is the only turbine to
offer both pollution control and power
generation, and converts previously
wasted landfill gas into 250 kW of re-
newable electricity, the company said.
The clean energy produced has near-
zero emissions and generates enough
electricity to power 250 homes.
“FlexEnergy is pleased to deliver a
renewable source of energy for our na-
tion’s security operations, while at the
same time reducing greenhouse gases
and protecting our environment,” said
Brad Hancock, director of Federal Pro-
grams for FlexEnergy, and former dep-
uty director of Facilities Energy for the
office of the secretary of defense.
“Fort Benning had 20% methane
coming out of their landfill and nothing
to do with it except flare it. They actu-
ally had to add propane during flaring
because it was such a low concentra-
36 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
The Flex Powerstation hooks directly
into the existing methane collection
system infrastructure.
tion, wasting gas and creating NOx and
SOx because of the combustion,” Han-
cock said. “When we placed the Flex
Powerstation there and hooked it into
their landfill collection system, we were
able to cut that 20% flare off. We’re
now creating power without wasting
gas and with near-zero emissions.”
The company said it began with two
technologies that are well understood
— turbines and oxidizers. FlexEnergy
teamed with Ingersoll Rand, which
was producing small gas turbines at
that time, purchased a turbine from
them and mated it to the oxidizer.
FlexEnergy ended up buying out the
Ingersoll Rand manufacturing capa-
bility for turbines in addition to their
Portsmouth, New Hampshire, U.S.A.,
manufacturing facility.
Instead of combusting the methane
as is typically done in a reciprocating
engine or turbine, they use all sources
of methane gas, even low-quality gas
from closed landfills, as usable clean
electricity through the system archi-
tecture and proprietary technology of
the patented thermal oxidizer.
“Typically, when you are going to
by mike rhodes
use methane as a fuel source, you need
a minimum of 35% methane by vol-
ume to make it combustible. When
the oxidizer comes in, it uses methane
at a much lower concentration,” said
Hancock. “Our data shows we can go
down to 5% by volume, and we can
dilute it further to 1.5% when it’s run-
ning through the machine. The reason
we say 5% is that if it gets below that
level, our ability to control the mixture
becomes problematic.”
Hancock said the Flex Powerstation
hooks directly into the existing meth-
ane collection system infrastructure al-
ready in place. The oxidizer technology
reduces the need for fuel filtering and
replaces the combustion cycle, thus
no NOx or SOx emissions are created.
“All that is expended is water and car-
bon dioxide, and that’s where the really
clean emissions come from at the Fort
Benning landfill,” Hancock added.
The project was funded under the
DoD Environmental Security Technol-
ogy Certification Program (ESTCP),
which seeks innovative and cost-ef-
fective technologies to address high-
priority environmental and energy
requirements for the DoD. FlexEnergy
partnered with the Southern Research
Institute (SRI), a third-party verifier
that submitted a proposal to the ESTCP
in 2007 to monitor the systems on the
equipment and landfill and produce
reports that track and discuss the meth-
ane fuel source, the emissions and out-
puts from the units.
FlexEnergy estimates there are 400
landfills across the DoD, with 60 to
70 of those locations able to support
the FP250, including some sites that
could facilitate multiple machines.
Dr. Jeffrey Marqusee, executive di-
rector of the Strategic Environmental
Research and Development Program
(SERDP) and director of the ESTCP,
said, “It’s a great testament that this is
operating effectively, and it shows it can
be replicated in installations across the
DoD and in the private sector.” A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Industry Drivers

AVEVA/FARO ty, using waste heat from the existing APL equipment for the mainline pipeline

I AVEVA, a provider of engineer-

ing design and information man-
agement products for the plant, power
and marine industries, and FARO, a
company specializing in high-precision
laser scanning and 3-D documentation
technology, have signed an interoper-
ability agreement.
Under the agreement, AVEVA and
FARO will cooperate closely to provide
an efficient integration between FARO’s
laser scan hardware technology and
AVEVA’s portfolio of laser engineering
and design software products. Following
compressor station, avoiding associated
CO2 emissions and maximizing energy ef-
ficiency, GE said.
The Alliance Pipeline transports
about 45 million m3/d of natural gas
from British Columbia and northwest-
ern Alberta through Saskatchewan,
North Dakota, Minnesota and Iowa to
a terminal in Chicago, Illinois, U.S.A.
GE has supplied all of the compression
system, including 16 gas turbine-driven
compression systems.
NRGreen Power will start the construc-
tion of the facility basement in May 2012.
The ORegen system will be delivered to
NRGreen at the end of 2012, with instal-
lation and commissioning expected to
take about six months. Commercial op-
eration is planned by 2013.
continued on page 39

INSULATION TECHNOLOGY
the recent acquisition of the LFM soft-
ware division of Z+F UK, this partner-
ship further demonstrates AVEVA’s com-
mitment to the 3-D data capture market,
POWER GENERATION
the company said. MEET THE NEXT GENERATION

HPS LOADBANKS
P HPS Loadbanks, formerly known
as Crestchic USA, has introduced
the HPS 3.3 MVA resistive/reactive load-
bank. The new loadbank is a three-phase
unit rated 2640 kW at 480 V, 60 Hz.
It can be operated from a handheld, PC
or manual control system, and can use a
main bus or 70 Amp, 480 V, three-phase
external source. The loadbank, which
measures 2.4 m wide, 3 m long and 2.6
m high, operates in extreme weather con-
ditions up to 49°C and has a life-span of
more than 15 years. It weights 1000 kg.
HPS Loadbanks is a specialty division of
Hawthrone companies. HPS delivers Crest-
chic Loadbanks, Vantran transformers and
similar product lines to North America.

GE OIL & GAS

O The ORegen waste heat recovery
system, a technology developed by
GE Oil & Gas that enables a gas turbine
to produce extra power without any ad-
ditional emissions or fuel consumption New Emission Standards Mean Higher Temperatures.
or water use, will be installed at Alliance
Pipeline’s (APL) Whitecourt Compressor Higher Temperatures Demand Better Insulation Technology.
Station about 200 km northwest of Ed-
monton, Alberta, Canada.
WE ARE THAT TECHNOLOGY. CALL 951-736-9911
GE Oil & Gas has received a contract
Thermal Structures, Inc., Emission Standards Compliance Made Easy
to supply the ORegen system to NRGreen
2362 Railroad St. Corona, CA 92880-5410 www.thermalstructures.com
Power, who is coordinating the project.
ORegen will produce 14 MW of electrici-
see directlink @ www.dieselgasturbine.com
Diesel & Gas Turbine Worldwide M a r c h 2 0 1 2 37

ThermalStructures_Mar11WW.indd 1 2/8/11 9:53:21 AM

Power Generation by bo svensson

With a total power

of 430 MW, deliv-
ered by Wärtsilä,
the Quisqueya I
and II power plant
complex in the Do-
minican Republic
becomes one of the
largest in the world.

Wärtsilä’s Caribbean Success

Company provides 24 power generating sets to Quisqueya I and II, making the Dominican Republic
power plant complex the largest in the world

During the last half of 2011 Wärtsilä
secured two contracts in the Domini-
can Republic, providing a collective
24 power generating sets in com-
bined-cycle applications for a total
electrical output of 430 MW. The two
plants, Quisqueya I and II, are iden-
tical and will be located at the same
site although owned by two different
companies. The contracts amount to
over E300 million.
The plants each consist of 12 Wärtsilä
18V50DF combustion engines in a
steam turbine combined-cycle appli-
cation, operating primarily on gaseous
fuel but with heavy fuel oil for backup.
The boilers located in the exhaust duct
of each engine are feeding superheated
steam at 15 bar to one steam turbine/
condenser common to 12 engines.
The first of the two contracts was
awarded to Wärtsilä in September
2011. The turnkey contract covered
the supply of a gas-fired combined-
cycle power plant. The contract was
signed with Barrick Gold of North
America Inc., a subsidiary of the Can-
ada-based Barrick Gold Corp. The
Quisqueya I power plant will serve
and supply electricity for the Pueblo
Viejo gold mine. The value of this first
contract was E155 million.
“The dual-fuel flexibility of these
Wärtsilä engines is a key advantage
since they can run both on liquid fu-
els and on natural gas,” said Sampo
Suvisaari, general manager, Central
America and the Caribbean, Wärtsilä
Power Plants. “This power plant rep-
resents the three values of Wärtsilä
Smart Power Generation: energy effi-
ciency, fuel flexibility and operational
flexibility. Barrick Gold is familiar
with Wärtsilä’s capabilities, having
earlier purchased two other Wärtsilä
power plant solutions.”
The second contract, landed in De-
cember 2011, is for the supply of an-

Although owned separately, both Quisqueya plants will be constructed on the same site as a single plant and be operated from one control
room. The two power plant contracts amount to over €300 million.

38 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide

Power Generation Industry Drivers

EATON
I Industrial manufacturer Eaton Corp. has completed its ac-
quisition of E.A. Pedersen Co., a manufacturer of medium-
voltage switchgear primarily for the electrical utilities industry. The
transaction was announced Dec. 16, 2011.
The Omaha, Nebraska, U.S.A.-based company’s products in-
clude metal-clad switchgear, power control buildings and relay
control panels. E.A. Pedersen does business as Pedersen Power
Products and employs about 150 people.

The two Quisqueya plants will each feature Wärtsilä 18V50DF gen-
erating sets in combined cycle, running primarily on natural gas with
the capability to switch to heavy fuel oil as needed.
CUMMINS
I Cummins Inc. and XiangFan Kanghao M&E Engineering Co.
Ltd. have announced a 50:50 joint-venture to develop, assemble
and distribute generator drive engines from Dongfeng Cummins Engine
Co. Ltd. (DCEC) and Xi’an Cummins Engine Co. (XCEC) to China-
based generator manufacturers. Financial details were not disclosed.
The joint venture, which will be based in Xiangyang City of Hu-
bei Province, is scheduled to begin operation in April 2012 with an
installed capacity to handle up to 40 000 units per year and capabil-
ity to expand in the future, Cummins said. The joint venture will
become the exclusive channel partner for DCEC and XCEC G-Drive
engines in China.
“The primary focus of this new partnership is to further expand
the G-drive business
Ellwood.qxp of Cummins’
11/11/09 8:43joint
AMventures
Page in
1 China, includ-
ing Dongfeng Cummins and Xi’an Cummins,” said Leo Zhao, gen-
eral manager of Cummins Power Generation China.

other complete dual-fuel power plant to the Dominican Re-

public. The turnkey project has been ordered by Empresa
Generadora de Electricidad Haina (EGE Haina), one of the
country’s largest power generation companies. EGE Haina
is a 50% state-owned and 50% privately owned company
and owns several power plants in the Dominican Republic.
This power plant, Quisqueya II, will also feature 12
Wärtsilä 18V50DF generating sets in combined cycle, run-
ning primarily on natural gas and with the capability to
switch to heavy fuel oil as needed. This will be an identi-
cal twin power plant to Barrick Gold’s Quisqueya I plant
located at the same site.
The Quisqueya II plant is scheduled to be fully oper-
ational during the second half of 2013, and will supply
We Manufacture and
base-load electricity to the national grid. The value of this Remanufacture the
second order is approximately E150 million.
Although owned separately, both plants will be con- World’s Largest Engine
structed on the same site as a single plant that can be op-
erated from one control room. The two power plants will Crankshafts
have a total output of 430 MW.
Alfa Laval will provide the exhaust boiler systems for Ellwood Crankshaft Group
the two plants. To increase the efficiency of the plants, Irvine, PA, USA 16329
the combustion engines are cooled with closed-loop radi- Hermitage, PA, USA 16148
ators and the steam cycle with cooling towers. Alfa Laval 1-800-247-1326
heat exchangers will be used for the engine cooling, and or 724-347-0250
the separators for oil treatment will also be provided by ecgsales@elwd.com
Alfa Laval. A www.ellwoodcrankshaftgroup.com
see directlink @ www.dieselgasturbine.com
see directlink @ www.dieselgasturbine.com
Diesel & Gas Turbine Worldwide M a r c h 2 0 1 2 39
Marine Propulsion by mike rhodes

The LA Carriers tug Karen Koby, powered by

twin Mitsubishi S12R-Y2MPTK engines.

Laborde Gives Barges And Pushboats

Their Push
McKinney Industries and LA Carriers receive Mitsubishi Engines for their latest craft

Laborde Products Inc., a provider
of diesel engines, diesel-powered
equipment, service and support for
the marine and industrial markets,
has completed two Mitsubishi engine
supply projects, one for McKinney
Companies and another for LA Carri-
ers. To power their boats, both com-
panies turned to Laborde to provide
Mitsubishi engines. Laborde is the
largest Mitsubishi Marine distributor
in North America with a territory in
the United States ranging from Texas
to Florida and New Orleans, Louisi-
ana, to Minneapolis, Minnesota.
McKinney Companies has served
the Gulf petroleum and dry cargo
industries from its headquarters on
the Mississippi River and Intracoastal
40 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
Waterway for more than 40 years.
Based in Baton Rouge, Louisiana,
McKinney Marine operates four 746
to 1342 kW towing vessels; McKin-
ney Harbor Towing Inc. operates a
barge fleeting facility; and McKin-
ney Salvage and Heavy Lift recovers
sunken boats and barges.
The latest addition to the tow-
ing fleet is the Mac Andrew McK-
inney. Built by Verret Shipyard in
Plaquemine, Louisiana, the Mac An-
drew McKinney is 20.7 m long with a
9.2 m beam and 3.0 m draft. To pow-
er the pushboat, Laborde Products
supplied an S12A2 Mitsubishi engine
rated 701 kW at 1940 r/min, and the
162 gt boat averages 5.8 knots and
reaches a top speed of 7.6 knots.
Designed for the extremely heavy-
duty tug and pushboat applications,
Mitsubishi engines typically offer
significantly larger displacement and
more mass. Each cylinder has its
own head and the engine has large
inspection covers on the crankcase
and oil pan.
“We wanted a Tier 2 diesel engine
with hydraulic governor,” said Andy
McKinney, vice president of opera-
tions. “We also preferred to avoid
the hassle of complex computers
and electronics, so we chose a low-
maintenance all-mechanical model.”
Laborde also recently supplied two
Mitsubishi engines for the LA Carriers
30 m tug, the Karen Koby. LA Carri-
ers was founded in 1986 as a small
Marine Propulsion
An S12A2 Mitsubishi engine, rated 701 kW at 1940 r/min, propels
McKinney Companies’ newest push boat, the Mac Andrew McKinney.
management firm for barges but has since grown to manage
an array of barges and has acquired or built five tugs and is
constructing another. Movement by barge remains one of
the most cost-effective means of transporting cargoes. Ac-
cording to the company, it transported roughly 275 000
net tons of product, the majority of which was scrap iron but
also included industrial salt, new steel products, synthetic
dirt, urea, fertilizer, coal, grain, oats, rice hulls, and vermicu-
lite, corn sweetener, scrap metal and other bulk commodities.
The twin Mitsubishi S12R-Y2MPTK engines are each rat-
ed 1007 kW at 1650 r/min with an idling speed of 600 to
650 r/min and maximum overspeed capacity of 2100 r/min.
They are EPA Tier 2, ABS classed fully mechanical marine
propulsion engines with Woodward governors. Laborde
also supplied ABS classed ZF W 7610 marine transmissions
for the project.
The FPT generators are 50 kW at 1800 r/min, with
a Newage generator end, structural steel skid and an
FW Murphy control/shutdown panel. Laborde also sup-
plied an FPT NEF-67 129 kW engine for the tug’s tow-
ing winch.
“The difference that really stands out is that the engine
has no electronically controlled injectors,” said Tommy Plai-
sance, LA Carriers operations manager. “That the engine is
mechanical, yet meets EPA emission requirements, contin-
ues to impress us.”
“Our Mitsubishi big displacement and simple mechani-
cal engine design fits their operation well,” said Doug Oeh-
rlein, COO of Laborde Products. “LA Carriers chose this
engine because there is no need for computers to trouble-
shoot and work on the engine. This was important since
they expect their boat to travel throughout the world, so
they will have the capability to work on the engines them-
selves no matter where they are.” A
SEE DIRECTLINK @ WWW.DIESELGASTURBINE.COM
Newsmakers
MIRATECH: Miratech has named Michael D. Cronkhite as
an account manager for the company’s gas compression divi-
sion and Mike Hobbs as its sales administrator for its cus-
tomer support department. Cronkhite will manage Miratech’s
gas compression accounts in the Marcellus Shale region and be
based in the company’s Tulsa, Oklahoma, U.S.A., headquar-
ters. Before joining Miratech, Cronkhite was a lead application
engineer for Mercury Marine Corp., providing on-site product
integration and technical sales support to boat manufacturers
in the Midwest United States. Hobbs will coordinate sales ac-
tivities and act as a liaison between engineering, sales and the
customer to offer support, service and responsive communica-
tion over several project requirements. He has more than 10
years of business-to-business account management and sales
experience. Before this role, Hobbs was a steel and metals sales
specialist with Hilti Corp.
DONALDSON: Donaldson Co. announced that it has ap-
pointed Eugene Wu as vice president for its Asia Pacific busi-
ness. Wu, 43, will assume the leadership of Donaldson’s Asia
Pacific business from David Timm, who retired in January as
previously announced. Wu will report to Bill Cook, Donald-
son’s chairman, president and CEO. Most recently, Wu was
chief advisor to the chairman of the Wanhua Industrial Group.
Prior to that, he was global vice president and president of Asia
Pacific for Greif Inc.
GE: GE Energy’s Industrial Solutions business has appointed
Adrian Thomas as its new regional sales leader for Canada.
Thomas is responsible for driving sales of electrification prod-
ucts and services across the continent, such as switchboards
and panel boards, uninterruptible power supplies, metering
products, circuit breakers, motor controls and capacitors.
Based in Montreal, Quebec, Canada, Thomas and his team will
also contribute to the growth of the country’s electric vehicle
infrastructure. Thomas brings more than 15 years of experi-
ence to his new position, beginning his career at GE Canada
as a large motors designer and later transitioning to a market-
ing role for GE Energy. He also held various positions with
TMEIC, an industrial systems, drive and motor manufacturer
in Roanoke, Virginia, U.S.A., where he covered growing mar-
kets in Taiwan, India and North America.
SEAKEEPER: Seakeeper has named Steve Shaw as its newest
field service manager. Shaw, who has S. Shaw
16 years of experience in the United
States marine industry, is responsible
for handling the service needs of Sea-
keeper’s customers and partners, the
company said. The move was made
due to a demand for gyro stabiliza-
tion products, which are designed to
eliminate discomfort and seasickness
by minimizing a ship’s rocking mo-
tion. Shaw most recently served as the head of service for an
East Coast shipyard.
Diesel & Gas Turbine Worldwide M a r c h 2 0 1 2 41
Overhaul, Service & Repair by mike rhodes
New Machining Center For B&G
Addition of sixth center to increase large block capabilities, accuracy and reliability
To meet the increasing demands
that the energy markets have put on
their business, B&G Machine has
added a sixth block machining center
capable of handling 2983 kW-plus en-
gines to their machine shop in Seattle,
Washington, U.S.A.
“We’re seeing an influx due to the
demands in the mining industry and
especially the oil and gas industry —
specifically hydraulic fracking,” said
David Bianchi, vice president of sales
and marketing, B&G Machine. “As
we look down those paths with the
current workload we have, as well as
what we’re forecasting, we needed to
expand our capabilities in both our
block department and our cylinder
head department.”
The company said it has been
working closely with the OEMs and
42 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
direct customers that are servicing
the energy markets and tracking
where their engines have been sold
and when those engine overhauls
are going to pop up. “The demands
based on the OEM models in the
field are such that we know a wave
of work is coming in. We are posi-
tioning ourselves to align with that,”
Bianchi said.
The new machine, the Rottler
F99Y, was designed specifically for
many of the later model engines and
built with twice the normal spindle r/
min, said the company. It will operate
at 2000 r/min and has infinitely vari-
able feed rates, enabling B&G to sur-
face any block up to 3.66 m to well
within the OEM requirements.
The machine is built for larger
(1 MW-plus) gas and diesel engine
The Rottler F99Y will operate
at 2000 r/min and has infinitely
variable feed rates, enabling
B&G to surface any block up to
3.66 m to well within the OEM
requirements.
blocks, and all boring and surfac-
ing is done using the main line as
a reference, which the company
said is the best way to machine an
engine block. The machine repeats
within 0.000254 mm on three axes,
allowing B&G to “blueprint” exact
OEM specifications.
“At our machine shop, we do all
the major components — cylinder
blocks, cranks, camshafts, connect-
ing rods and cylinder heads. With the
larger engines that we’re starting to
see like the CAT3520 and C175V20,
the 20-cylinder MTU 4000 Series, the
Cummins 18-cylinder QSK78 and the
Waukesha 9390, we are able to serv-
ice all those engine blocks,” said John
Bianchi, president and CEO of B&G
Machine. “In this range, the machine
allows us the capacity to do engines
Overhaul, Service & Repair Featured Products

Flow, Heat Meter

Dynasonics, a division of Racine Federated Inc., has launched
the new DXN portable ultrasonic flow and heat meter.
“The DXN represents
a new generation in
portable ultrasonic flow
measurement built on
innovative hybrid me-
tering technology that
automatically switches
between transit time
and Doppler modes
as needed,” said John
Erskine, vice president
of sales and marketing for Dynasonics. “The DXN also includes a
The added capacity of the sixth machining center also supports the 7 in. [177.8 mm] full-color touchscreen, the ability to store site-
B&G crankshaft and cylinder head departments. specific settings using plain text and an advanced software interface
that adapts to the needs of our customers.”
specific to the industry as well as redundancy if a machine The DXN is available in a variety of kit configurations, from
were to go down. The added automation and a different a basic kit that includes two sets of transit time transducers,
tooling package make us more efficient as well.” cabling and a compact carrying case up to a complete kit that
“We are in the service industry, so the ability to guar- includes transit time, Doppler, RTD and wall thickness gauge,
antee quality, accuracy and rapid turnaround to the the company said.
customer played heavily in the decision to invest in SEE DIRECTLINK @ WWW.DIESELGASTURBINE.COM
another block machine center,” said David Bowne, vice continued
Drehmoment_79x121_engl:Anzeige 1/4 Seiteonkorr.
page 5115.02.2011
president Production, Machine Shop/Engine Rebuild.
“If something were to happen to one of our centers, the
excuse to the customer of, ‘Oh, sorry, we have a ma-
chine that broke down,’ just isn’t going to work. This is Customized
a huge step for B&G to make sure we have that covered Torque Measuring Flange
should it ever come up.”
The added capacity of this machine also supports the • Measuring range 5 Nm to 1,000 kNm
B &G crankshaft and cylinder head departments. Three • High accuracy 0.05 %
• No bearings, wear-free
Berco crankshaft grinders allow the grinding of any crank-
• Wide temperature range 45 to 160°C
shaft up to 4.27 m. Polishing is completed with variable • High overload capacity
speed polishers and abrasives, meeting the tightest indus- • Customized flange pattern
try reconditioning specifications, said the company. • Cost-effective and compact
The cylinder head work, which can go out to 20.32 for test stands
cm in valve seat, is built around three key pieces of • Optimized dynamic
equipment: the Rottler SG80A, Serdi 100 and a Rottler • ATEX certified
SF2 surfacer. The Serdi 100 seat and guide machine can
cut all three seats in one pass while maintaining concen-
tricity of 0.00508 cm. The Rottler SF2 uses CBN tech-
nology and produces exact roughness (Ra) consistently
across the surface of the cylinder head, B&G said.
The addition of the Rottler F99Y continues an exclu-
sive block department relationship with Rottler. “With
machinery specific to cylinder block, Rottler really is
light years ahead of anybody else,” Bowne said. “We’ve
seen a 40% gain in efficiency over older-model ma-
chines and we work closely with Rottler on tooling de-
sign and innovation. The machines are faster and more Eschenwasen 20 · D-78549 Spaichingen
reliable than anything out there. Rottler is on the cutting Tel. +49 7424-9329-0 · Fax +49 7424-9329-29
edge and we want to be side by side with a company info@sensortelemetrie.de
www.sensortelemetrie.de
like that.” A
SEE DIRECTLINK @ WWW.DIESELGASTURBINE.COM
see directlink @ www.dieselgasturbine.com
Diesel & Gas Turbine Worldwide M a r c h 2 0 1 2 43
MannerSensor_Mar11WW.indd 1 2/15/11 9:32:44 AM

Emissions Worldview

The exhaust gas recirculation (EGR) unit

is designed for a complete integration
of the entire system into one single
unit. Here the EGR system is shown (in
orange) as part of a 6S80 ME engine.

IMO Tier III NOx emissions levels.

Second Generation EGR The new MAN Diesel & Turbo EGR
generation features a compact design
MAN Diesel & Turbo system to be applied aboard a Maersk Line container that requires only minor changes to the
vessel — the 4500 teu new building #2358
engine outline, to the extent that the
new engine type does not require any
Shipping is the most effective trans- ordered by the Maersk Line and will major design changes by shipyards.
port means of moving goods and ac- be delivered in early 2013. Upon de- “We have taken an important step
counts for over 70% of global tonnage. livery, the vessel will serve the trade forward in the development of ex-
However, the environmental effects route between East Africa and the Far haust gas recirculation with the re-
of ship emissions are under increased East. For a test period of three years, lease of this, our second-generation
focus and the U.N. is currently intro- the engine will be operated partly on system. The configuration will mirror
ducing regulations aimed at drasti-
cally reducing NOx and SOx emissions
levels over the next decade. The EGR
system makes it possible to meet the
IMO NOx Tier III emissions levels due
to come into force by January 2016.
MAN Diesel & Turbo is now
launching its second generation of
exhaust gas recirculation (EGR) sys-
tem for prototype testing. The system
will be fully integrated with a Maersk
Line container vessel — the 4500
teu new building #2358. The ves-
sel’s main engine, a two-stroke MAN
B&W 6S80ME-C9 type, will be built
by Hyundai Heavy Industries’ Engine
& Machinery Division. An Alfa Laval Aalborg exhaust gas-pressurized test boiler is installed in the Maersk Line vessel
The new building #2358 is in the Mathilde Maersk. The test installation is located in a pressurized exhaust gas duct, and this
C-class series of 22 container vessels type of boiler will be used for future EGR installations with exhaust gas pressures up to 5 bara.

44 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide

Emissions Worldview
Picture taken during the construction of a sister ship identical to
the Maersk Line new building #2358.
the final design for our Tier III NOx EGR engine program,”
said Søren H. Jensen, vice president and head of research
and development at MAN Diesel & Turbo. “Our main focus
has been on integration of the entire EGR system into one
single unit being part of the engine as a charge-air cooler.”
The EGR process includes a scrubbing and a cooling
process in which the exhaust gas is cleaned and cooled
before being directed back into the engine’s scavenge air.
This reduces the oxygen content of the air in the com-
bustion chamber, thereby reducing the combustion tem-
perature and, as a result, reducing the NOx formation.
Tests at MAN Diesel & Turbo’s Diesel Research Center
in Copenhagen, Denmark, have shown that reaching the
IMO’s forthcoming Tier III NOx emissions requirements is
possible with EGR in its own right. A recirculation of 40%
and more of exhaust gases has been successfully tested in
the test cell’s two-stroke, four-cylinder research engine,
4T50ME-X. A 40% recirculation of exhaust corresponds to
an 80% reduction of NOx.
“Since the first-generation EGR was tested in service,
we have achieved significant technical advances as well
as improvement in performance,” said Jensen. “Our opti-
mization of the EGR performance has resulted in a 40%
recirculation of the exhaust gas so as to meet the Tier III
reduction criterion.”
The EGR unit comprises a cooler, a scrubber, a water
mist catcher and a blower unit. It ensures full fuel flexibility,
ranging from heavy fuel oil to distillates and natural gas. The
rate of the exhaust gas recirculation can be adjusted during
operation by a valve system.
The EGR process has a slight impact on the fuel con-
sumption due to the suppression of the combustion pro-
cess in the cylinder. However, in the future there is a great
potential for regaining energy from the exhaust gas in the
EGR system, said the company. A combination of EGR and
waste heat recovery (WHR) by an EGR boiler upstream the
turbine has significant potential.
Increased fuel consumption can be avoided on vessels
with WHR systems where the steam is utilized in turbines to
generate electrical power for propulsion. To utilize the waste
IGTI_Mar12_WW.indd 1
heat available in the recirculated exhaust gas system, a spe-
cially designed EGR boiler is required in combination with
the traditional WHR boiler system after the turbocharger.
As part of the EGR tests at MAN Diesel & Turbo’s
Diesel Research Center in Copenhagen, Denmark, a first-
generation EGR boiler from Alfa Laval Aalborg was tested.
Based on the information from this first-generation
EGR boiler, a new second-generation EGR boiler has
been designed for long-term testing in service under ex-
treme conditions. The service test has been running since
May 2011 and shows promising results, according to
the company.
The combination of EGR system and EGR/WHR boil-
er technology not only enables the meeting of the IMO
NO x Tier III emission standards, but it also reduces
CO 2 emissions.
“The target group for MAN Diesel & Turbo’s EGR system
is the owners of ships of over 2000 dwt, a segment that
today comprises some 18 000 to 20 000 vessels operating
globally,” said Jensen. “The EGR system offers great value
and has a number of unique selling points, including its
environmental performance, global seafaring flexibility,
added resale value of ships and its disposal with the re-
quirement for daily maintenance.” A
SEE DIRECTLINK @ WWW.DIESELGASTURBINE.COM
ASME International
Gas Turbine Institute
Serving Gas Turbine & Turbomachinery
Professionals Worldwide
IGTI’s professional development offerings
will help enhance your career.
• Basic and intermediate training
on a variety of platforms, including
self-study & hands-on instruction
• Convenient Webinars on salient
industry topics
• Easily-accessible engineering
publications, such as an extensive
archive of gas turbine research
spanning more than 60 years!
• Key employment tools, such as a
networking directory & Job Board
Take advantage of these and more
important opportunities today at
http://igti.asme.org
see directlink @ www.dieselgasturbine.com
Diesel & Gas Turbine Worldwide M a r c h 2 0 1 2 45
2/9/12 5:52 PM
Vibration Detection & Analysis Literature Library
Portable Vibration Analyzer
Ludeca adds to its Prueftechnik family of portable,
route-based vibration data collectors
Ludeca has introduced the VibXpert
II, a new portable vibration analyzer
with full color display, fast data acquisi-
tion and powerful diagnostics tools.
The VibXpert II handheld vibration
analyzer combines a rapid processor
with an energy-efficient color VGA dis-
play. Enhanced with an Fmax of 51 kHz
and up to 102 400 lines of resolution,
all machinery problems can be captured
and analyzed on the VibXpert II large
color screen, according to Ludeca.
The VibXpert II basic platform is a
one-channel vibration data collector
that can be upgraded at any time to two
individually configured channels via a
special passcode. According to Ludeca,
the unit is user upgradable and does
not require hardware changes.
All forms of machine vibrations,
bearing conditions, process data and
visual inspection information can be
collected and stored on the expand-
able compact flash card (up to 8 giga-
byte) for report generation or for later
transfer to the Omnitrend software
for further analysis, reporting and ar-
chiving. Omnitrend PC software han-
dles archiving and evaluation of all
machine condition data. The program
warns users when measurements ex-
ceed tolerance and provides a wide
range of printed records.
46 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
Stationary Applications
Ludeca’s VibXpert II handheld vi-
bration analyzer combines a rapid
processor with an energy-efficient
color VGA display.
FW Murphy provides a range of man-
ufacturing and engineering capabili-
ties, such as mechanical and electronic
hardware design, product testing and
in-house LCD bonding. The company
also provides products for stationary
applications, such as gauges, switches,
controllers and panels for mechanical
engines. This information is available
The VibXpert II vibration analyzer in an FW Murphy brochure.
provides an icon-driven platform that SEE DIRECTLINK @
offers comprehensive analysis func- WWW.DIESELGASTURBINE.COM
tionality for the diagnosis of simple
or very complex vibration problems,
the company said. Capabilities include Catalyst Products
order spectrum, phase, cepstrum,
cross-channel phase, orbits, run-
up and coast-down measurements,
bump test, negative averaging and
more. Analysis tools, including var-
ious cursor types, machine-specific
frequency markers, signal post pro-
cessing and extensive bearing data-
bases, are included for evaluating
each spectrum. Alarm notifications
based on ISO standards or user-
defined standards are visually identi-
fied with the aid of colored LEDs.
VibXpert II is a lightweight vibra- A brochure on catalyst products from
tion meter with a dustproof and water- Hypercat Advanced Catalyst Products
resistant housing (IP65). VibXpert II (ACP) is available. Hypercat’s proprie-
is delivered with a carrying pouch, tary catalytic materials use nanotechnol-
which includes a breakaway shoulder ogy, which allows the company to man-
strap for safety during data collection. ufacture catalysts with reduced PGMs
The VibXpert II vibration analyzer without sacrificing efficiency, function
features modular functionality in- or durability. Hypercat has catalyst
cluding dynamic balancing, extended products for the gasoline, stationary,
time waveform recording, transient diesel and small engine markets.
data capture, UFF file export, Modal/ SEE DIRECTLINK @
ODS support and more. A WWW.DIESELGASTURBINE.COM
SEE DIRECTLINK @ continued on page 48
WWW.DIESELGASTURBINE.COM
 The Most Important Conference for
Turbomachinery Professionals

Presented by ASME International Gas Turbine Institute

c o p e n h a g e n
Photo by: Cees van Roeden
Wonderful Copenhagen

d e n m a r k

June 11-15, 2012 | Bella Center

www.turboexpo.org
ASME INTERNATIONAL GAS TURBINE INSTITUTE
phone +1-404-847-0072 | fax +1-404-847-0151 | igti@asme.org
Marine Propulsion Literature Library
1500 KW Thruster
In Operation In
Offshore Vessel
Drive technology combines electrical, mechanical
and hydrodynamic elements
Following the launch in 2011 of
its largest Voith Inline Thruster (VIT)
based on permanent magnet syn-
chronous machine technology (RIM
drives), Voith Turbo announced the
order of the 1500 kW inline thruster
for an offshore, wind farm jackup
vessel under construction by Chinese
shipbuilder Cosco Shipyard for the
Danish ship owner A2SEA.
The vessel will be equipped with a
VIT as well as three Voith Schneider
Propellers (VSPs), with the launch is
scheduled for early 2012.
Voith said the principle of a
thruster with a permanently excited
electric motor housed in the hollow
shaft and no maintenance require-
ments owing to sea water-lubricated
bearings has proven its worth. In
fact, since the start of series produc-
tion in 2008, Voith has sold more
than 55 units.
48 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
With an inner propeller diam-
eter of 2300 mm and a power
of 1500 kW, Voith Turbo’s cur-
rently largest inline thruster is
breaking through in the mar-
kets of offshore applications,
passenger vessels and yachts.
Voith Inline Thrusters and Voith
Inline Propulsors (VIPs) are so-called
RIM drives. This drive technology
combines electrical, mechanical and
hydrodynamic elements to obtain
low vibrations, extreme smoothness
of running and compact dimensions.
The Swing-Out Azimuth stern
thrusters are a particular type of
VIPs that can be extended from
the vessel hull and rotated through
360° without limitation. These
characteristics, as well as the advan-
tages of this propulsion concept for
dynamic positioning, are particu-
larly in demand for yachts and off-
shore applications.
Voith Turbo has confirmed recent
orders for offshore applications, pas-
senger vessels and yachts for these
propulsion systems. A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Turbomachinery
Education
Texas A&M University offers litera-
ture on its Turbomachinery Laborato-
ry, which helps educate students and
professionals on the turbomachinery
industry. The literature describes the
laboratory’s capabilities. The labora-
tory, which has 3251.6 m² of research
space, is for basic and applied re-
search, undergraduate and graduate
education and continuing education
and professional development.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Air Cooled Condensers
The Heat Exchange Institute (HEI)
has released the first edition of Stan-
dards for Air Cooled Condensers. The
brochure offers technical information
from members of the HEI Air Cooled
Condenser Section and includes typi-
cal purchaser requirements. It also
outlines the design criteria for air-
cooled condensers.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
continued on page 61
Power Generation
The Pueblo Airport Generation Station consists of four units: two Black Hills Energy – Colorado
Electric utility-owned, natural gas-fired GE LMS100 units; and two Black Hills Colorado IPP-
owned, high-efficiency, combined-cycle units.
Black Hills Corp. Power
Station Operational
GE’s LM6000 helping power Black Hills Corp.’s new generation station at
Pueblo, Colorado, U.S.A., airport
As part of its newly constructed
and commercially operational Pueblo
Airport Generation Station in Pueblo,
Colorado, U.S.A., Black Hills Corp. has
installed four GE LM6000 aeroderiva-
tive gas turbines at the facility.
The Pueblo Airport Generation Sta-
tion consists of four units: two Black
Hills Energy – Colorado Electric utility-
owned, natural gas-fired GE LMS100
units; and two Black Hills Colorado
IPP-owned, high-efficiency, combined-
cycle units. Each of the combined-cycle
units will consist of two 40 MW natural
gas-fired GE LM6000 turbines and one
20 MW steam turbine.
Based on the CF6-80C2 aircraft en-
gine, the LM6000 has grown through
technology developments like 15
ppm dry-low NOx combustion, spray
50 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
intercooling for power enhancement,
fiber optic distributed controls and
off-gas/liquid fuel flexibility, GE said.
Black Hills has GE’s LM6000-PF
and LMS100-PA technology at the
plant. According to GE, the LM6000-
PF offers 47 MW with up to 41%
efficiency, 99% fleet reliability and
dry-low emissions capabilities in a
package designed for utility, indus-
trial and oil and gas applications.
GE said the environmental benefits
of that unit were: reduced CO2 emis-
sions by 15 000 metric tons; reduced
gas consumption of over 264 000
MMBtu; and reduced NOx emissions
of 369 678 kg when compared with a
simple-cycle gas turbine in the 35 to 60
MW range with 35% efficiency operat-
ing 3000 hours at 25 ppm NOx.
The LMS100-PA provides 100 MW
of power generation and response to
load variations at a ramp rate of 50 MW
per minute. The unit takes compressed
air from the low-pressure compressor,
cools it to optimal temperature and
provides a near constant stream to the
high-pressure compressor, resulting in
a pressure ratio of 41:1 and increased
mass flow at 209 kg/sec.
The partnership marked the 1000th
shipment of GE’s LM6000 gas turbine.
“We have a long history with GE and
are excited to help them mark this
milestone of providing solutions that
help increase productivity and effi-
ciency,” said Mark Lux, vice president
and general manager, Power Delivery,
Black Hills Corp. The company’s non-
regulated businesses generate whole-
sale electricity; produce natural gas, oil
and coal; and market energy.
The LM6000 units are used in major
airports around the world, as well as for
backups for wind farms, grid support
for major cities, offshore installations,
mining operations, the food processing
industry and industrial applications.
“GE’s LM6000 aeroderivitive gas
turbines allow us to provide one of the
most efficient generation resources to
serve our customers,” Lux said. A
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Each of the combined-cycle units at the
Pueblo Airport Generation Station will
consist of two 40 MW natural gas-fired GE
LM6000 turbines (shown here) and one 20
MW steam turbine.
 Featured Products

Sine Wave Inverters versions. All models feature an operating ber (ASTM D6450 and D7094) of the
temperature of -30° to 50°C, protection EraFlash provide safety and speed at min-
circuitry and a digital display to moni- imum costs, Ayalytical Instruments said.
tor low input voltage, short circuit, input
overvoltage, over temperature, overload
and low battery.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM

Schaefer Inc. introduced the AEP-5000
Series of 5000 W sine wave inverters.  The
pure sine wave output of the AEP-5000
Series, with less than 3% total harmonic
distortion, is suited for powering sensitive
loads and for improving AC equipment
performance, the company said. The in-
verters are designed for industrial, utility,
rail/transit, vehicle, marine and general
backup power applications.
The AEP-5000 Series, which measures
140 mm x 324 mm x 495 mm, is avail-
able in four standard input configura-
tions of 24, 48 and 110 Vdc, or 220 Vdc
input voltages. Outputs are available in
regulated 115 or 230 Vac (50/60 Hz)
Flashpoint Tester
Ayalytical Instruments, a provider of
instrumentation to the petroleum, bio-
fuels, lubricants and materials testing
industries, has added a flashpoint test-
ing product to its product line, known
as the EraFlash. Developed by eralytics,
a specialist in the testing of petroleum
and petrochemical products, EraFlash is a
flashpoint tester for petroleum and petro-
chemical testing.
The patented Peltier Boost Technology
(PBT) by eralytics opens a new dimen-
sion of flashpoint testing, the company
said. Measuring speed complements a
wide temperature range (-25° to 420°C).
The small sample size (1 to 2 ml) and the
continuously closed measuring cham-
The EraFlash is suitable for stationary
and mobile laboratories. It is also de-
signed for demanding tests, such as fresh
and used oil analysis (fuel dilution curve
measurement), product specifications,
transport classifications (D.O.T., ADR),
forensic analysis, FAME (biodiesel), re-
cycled fuels and hazardous waste (RCRA).
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
continued on page 57

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at www.electricpowerexpo.com
Power Generation

The South Bay International Wastewater Treatment Plant in San Ysidro, California, U.S.A., is designed to treat up to 95 million L of wastewater
a day. To ensure the plant’s discharge meets U.S. EPA standards, the plant operator added a secondary treatment process, which required the
installation of a second 2000 kW generator set system. Supplied by MTU Onsite Energy, the containerized gen-set (foreground) was designed to
physically match the plant’s existing gen-set that was installed in the late 1990s.

Clean Across The Border

South Bay International Wastewater Treatment Plant adds 2000 kW gen-set to help improve discharge water quality

It’s been said that water knows
no borders. But when you’re talking
wastewater treatment, what flows from
one place can have a great impact on
the quality of life in another. Thus it
was, that in the late 1990s, the United
States and Mexico jointly established
the South Bay International Wastewa-
ter Treatment Plant, San Ysidro, Cali-
fornia, U.S.A., to treat sewage from the
city of Tijuana, Mexico, and eliminate
health and environmental concerns in
the Tijuana River Valley just south of
San Diego, California.
When the International Border and
Water Commission (IBWC) — the
plant’s operator — decided to add sec-
ondary treatment to further improve
the quality of the discharge water,
it installed a 2000 kW generator set
from MTU Onsite Energy to provide
additional emergency standby power.
The South Bay plant can treat up
to 95 million L of wastewater a day,
which is discharged through a 7.2
km pipeline into the Pacific Ocean
near the Mexico-California border.
Recently, the quality of the water was
52 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
found to be below U.S. Environmental
Protection Agency (EPA) standards,
causing the IBWC to add a secondary
treatment process to the plant.
According to the IBWC, the addi-
tion of a second treatment process
would require additional power to
operate three 522 kW aeration blow-
ers, an activated sludge system and
other related equipment in the event
of a power outage. This led the IBWC
to employ MTU Onsite Energy to
help design a package to fit this new
demand, while mirroring the previ-
ously installed unit.
“The plant wanted the new power
system to physically match that of an
existing 2000 kW gen-set that was in-
stalled (by a different manufacturer)
during its original construction in the
late 1990s,” said Tim Oergel, critical
equipment sales professional, Facil-
ity Gateway Corp., formerly in power
systems sales at W.W. Williams, the
MTU Onsite Energy distributor in-
volved in the project. “Getting the
two units to fit into identical packages
was a challenge.”
Much of the installation challenge
stemmed from the more than 16-year
difference between the new system
and the existing one, Oergel said.
The new MTU Onsite Energy unit —
which has dimensions of 655 cm long
x 255.5 cm wide x 285.8 cm high and
a dry weight of 16 477 kg — is Tier
2 compliant, while the existing gen-
set is compliant with (but not certi-
fied to) Tier 1 standards. This meant
the company had to fit additional and
redesigned components into a space
that was not designed to hold them.
The new gen-set comprises an MTU
16V 4000 G43 engine rated 2250 kW
at 1800 r/min that drives a Marathon
brushless, four-pole rotating field gen-
erator with brushless pilot exciter.
While no aftertreatment was required
for compliance, an AMFCO silencer
was added to the new gen-set package.
According to Oergel, a specialized
heat transfer system was needed to
deal with the higher heat rejection
associated with the Tier 2 engine.
The radiator package was provided
through R.F. Partridge and AMFCO,
Power Generation
The new MTU gen-set incorporates an MTU 16V 4000 G43 engine rated 2250 kW at 1800
r/min, which drives a Marathon brushless, four-pole rotating field generator with brushless
pilot exciter. Each containerized set is mounted on a concrete pad supported by a seismically
reinforced mezzanine structure bolted to the pad to prevent damage to the generators in the
event of an earthquake.
and incorporates an IEA Radiator with
a fan provided by MTU and IEA that is
direct driven through a planetary gear
off of the engine’s crankshaft.
“Basically, what we had to do was
fit the new unit inside a standard ISO
container,” Oergel said. “Because of
that, the standard radiators used with
the existing unit wouldn’t fit, so we had
to omit the water-cooled option and
go with the air-cooled, mechanical-
driven one.”
Another issue that arose due to the
16-year gap between the existing and
new units centered on system com-
munication. The existing unit did not
possess an electronic governor or other
electronic controls that could help syn-
chronize its operation with the new unit,
Oergel said. MTU replaced the existing
governor control, while the switchgear
and automatic transfer switch upgrades
were handled by ASCO.
“The governor controller upgrade
to the old unit was procured in-house
through MTU,” Oergel said. “ASCO
took care of the switchgear upgrades.
Even though Cutler Hammer equip-
ment was used, the spec dictated that
it needed to match the existing unit
and ASCO helped with upgrades and
HMI control.”
The gen-sets are fueled through a
two-tank system. Packaged with the
sets are 1136 L Simplex day tanks,
which include pumps and monitoring
equipment. Each gen-set also draws
from 37 854 L ConVault tanks sup-
plied by Core Engineered Solutions.
Each containerized generator set is
mounted on a concrete pad outside of
the plant’s main building. Because the
plant is located in earthquake country,
both gen-set containers are supported
by a seismically reinforced mezzanine
structure consisting of I-beams con-
nected in crisscross patterns. These
structures support the weight of the
containers and are bolted to the con-
crete pad to prevent damage to the gen-
erators in the event of an earthquake.
The gen-sets at the South Bay International Wastewater Treatment Plant are fueled through a
two-tank system that includes day tanks as well as the 37 854 L ConVault tanks shown.
Diesel & Gas Turbine Worldwide M a r c h 2 0 1 2 53
“MTU Onsite Energy was success-
ful in winning the project due to a
combination of our EPA-certified
Tier 2 emissions rating, good pric-
ing and higher average load-factor
capabilities,” said Oergel. The MTU
generator set can supply an average
85% load factor over 24 hours, com-
pared with the existing unit’s in-
dustry-standard 70% average load-
factor capability. “That means dur-
ing extended outages, the MTU
generator set can supply 15% more
kW,” he said.
Installation, final commissioning
and load-bank testing were com-
pleted in midsummer of last year,
where the units demonstrated they
could carry the full plant’s load
while operating in parallel. “Get-
ting the different units to operate
together was a challenge,” said Oer-
gel. “There were many sequence-of-
operation changes that were needed
to make sure both units functioned
properly and could carry the load.
“But now the plant is assured of
having emergency power for all its
critical loads in the event of a util-
ity outage. That will allow this joint
U.S.-Mexico wastewater treatment
plant to continue to fulfill its mis-
sion of protecting the environment
throughout the Tijuana River Valley
and Southern California.” A
SEE DIRECTLINK @
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Marine Propulsion by ian cameron

The MTU-powered vessel will be operated by three crew members and able to transfer 12 wind farm technicians.

Austal Makes Waves In Wind Farm Sector

New fleet of boats enables wind farm personnel to be safely transferred greater distances and through
considerably higher sea states

The changing face of the offshore
wind farm industry is placing par-
ticular demands on the suppliers
of service vessels in terms of design
and propulsion needs.
Currently, many wind farms have
been generally positioned close to
land and serviced by traditional,
sometimes lower-tech and less pow-
erful, boats.
Such vessels had to contend with
relatively straightforward weather
conditions for the transfer of techni-
cians and equipment.
However, there is now a trend for
wind turbines to be placed farther
offshore and in areas subject to much
rougher seas and more hostile weather.
“There is clearly an increasing
desire in the industry for vessels
with enhanced capability, particu-
larly in terms of performance in
rough conditions,” said Austal CEO
Andrew Bellamy.
Shipbuilder Austal is based in Hen-
derson, south of Freemantle, West-
54 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
ern Australia, and also has shipyards
in Mobile, Alabama, U.S.A., and
Cebu, Philippines.
The company has established a
reputation in the renewable energy
market and recently secured a con-
tract for a fourth wind farm support
vessel for Turbine Transfers Ltd.
The order is the first for a new Aus-
tal design that will enable safer and
more efficient offshore wind turbine
service, the company said.
Turbine Transfers Ltd., based in
Anglesey, U.K., is a subsidiary of
Holyhead Towing Co. and operates
fast catamarans to transfer personnel
and equipment between the shore
and wind turbines.
It currently operates a fleet of more
than 20 fast boats. Its long-term cus-
tomers include Siemens, RWE NPow-
er, Van Oord, Dong Energy, EnBW
and Royal Boskalis Westminster.
Bellamy said the shipbuilder had
enhanced its Wind Express vessel
range following its launch in mid-
2010 as part of a strategy to pursue
new commercial vessel markets.
“This is a challenge that we have
already successfully addressed in the
ferry and naval markets with our
unique trimaran technology. We have
now applied that expertise to develop
and prove a new hullform that pro-
vides a step change in capability for
the offshore industry,” he said.
He said the new design combines the
seakeeping and fuel efficiency of Aus-
tal’s trimaran hull configuration with a
small waterplane area at rest to deliver
low vessel motions both in transit and
when alongside turbines. This enables
wind farm personnel to be successfully
transferred in considerably higher sea
states than is practical with catamarans
of similar size, he said.
The 27.4 m long, 10.5 m wide
vessel will be operated by three crew
members and able to transfer 12
wind farm technicians, their equip-
ment and over 4 tons of deck cargo,
stores and miscellaneous equipment.
Marine Propulsion

Two 900 kW MTU 10V2000 M72 number of vessels and personnel livery scheduled for May this year,
diesel engines coupled to Kamewa required to support a given site, re- said Austal.
waterjets will provide a service ducing capital and operating costs The new vessel is designed to op-
speed of 23 knots, with the direc- without sacrificing power genera- erate in ocean areas of all European
tional thrust of the waterjets being tion reliability,” he added. countries, including the demand-
supplemented by a bow thruster The latest order is part of Turbine ing conditions of the North, Irish
for low-speed maneuvering and Transfers’ fleet expansion plans, and Baltic Seas. It is designed to
station keeping. With an operat- which already include three 21 m operate in up to 3.0 m significant
ing range in excess of 360 nautical catamarans ordered from Austal in wave height. A
miles, the vessel can operate up to July 2011. Construction of those SEE DIRECTLINK @
75 nautical miles offshore, well be- vessels is progressing well, with de- WWW.DIESELGASTURBINE.COM
yond the distances of current wind
farms, Austal said.
The vessel will initially be char-
tered to Turbine Transfers for up to
five years. It is scheduled for com-
pletion in November.
Turbine Transfers Managing Di-
rector, Captain Mark Meade, said
his company was using Austal
technology to support the next
phase of wind farm development,
which would see a much larger
number of turbines installed far-
ther offshore and in other areas
with rougher sea conditions.
“To do that, we need to be able to
transfer farther, and in larger waves,
while still providing the technicians
we carry with comfortable transits
and safe turbine step-offs,” he said.
Bellamy said the new design
would improve the viability of off-
shore wind farms by overcoming
the seakeeping limitations of the
support vessels currently used in
the industry.
“To date, most wind farms have
been relatively close to the coast
and serviceable with fairly basic
boats. Now, as they move farther
offshore there is a need for a second
generation of vessels that can ad-
dress the significant challenges this
brings,” he said.
“As well as minimizing seasick-
ness among personnel and provid-
ing safer transfer conditions, the
new design’s enhanced seakeeping
performance can improve the eco-
nomics of offshore wind farms,”
said Bellamy.
“Being able to operate in a broader
spectrum of sea conditions increases
overall operability, which means
there is the potential to reduce the
Diesel & Gas Turbine Worldwide M a r c h 2 0 1 2 55

SeaJapan.indd 1 1/16/12 9:58 AM

Turbomachinery Controls by roberta prandi
The Unitrol 1000 series of automatic voltage regulators by ABB are used to control synchronous
machines up to 50 MW in a wide range of applications such as power plants, marine and rail.
Unitrol 1000 Family Gets
First Pilot Installation
Rudolf Moeckli, product manager of Unitrol 1000 at ABB Switzerland,
reports on the first pilot installation of Unitrol 1020 automatic voltage
regulator (AVR)
It all started in Baden, a picturesque
thermal town in the middle of Swit-
zerland: In 1891, two partners came
together there and founded the Brown
Boveri Co. for the production of exci-
tation systems for power plants.
Their very first project was the Kap-
pelerhof hydro power plant that pro-
vides power to the town of Baden. After
that, the company soon established it-
self as a leader in excitation technology.
Today, over 120 years later, the
company — now known as ABB —
is heading back to its roots at that
same first power plant constructed
by Brown Bovery Co. in 1891 with
the installation of an automatic volt-
age regulator (AVR) for machines
with exciters. The Kappelerhof hydro
power plant has taken delivery of the
first pilot Unitrol 1020.
56 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
“The products are showing excel-
lent performance, where reactive load
sharing and fast synchronization are
required,” said Moeckli. “The range
— known as Unitrol 1000 — is able
to manage fault ride through (FRT)
conditions imposed by demanding
grid codes. Fast detection of network
short circuit as well as boost function-
ality keeps the machine online. Power
system stabilizer (PSS) functionality
is equipped with injection points as
well as test points to verify PSS trans-
fer function.”
The Unitrol 1000 family is used to
control synchronous machines with ex-
citers up to 50 MW in a wide range of
industries such as power plants, marine
and rail. (Read more about the launch of
the Unitrol 1000 series in Diesel & Gas
Turbine Worldwide, December 2010.)
“There are two AVRs in the range.
The Unitrol 1010 is capable of 10
Amp dc excitation current. The light
version covers essential functional-
ity for cost-sensitive applications
including all voltage, field current,
power factor and VAR regulation, as
well as limiters to keep the machine
in the safe operational area and volt-
age matching for pre-synchroniza-
tion,” said Moeckli.
The basic version covers fieldbus
interface, rotating diode monitoring,
load sharing with constant bus bar
voltage, and extensive monitor and
protection functions for building up re-
liable dual-channel systems. An auto-
synchronization function is available
as an option.
“The Unitrol 1020 is capable of 20
Amp dc excitation current and comes
with a local human machine interface.
The units cover higher excitation cur-
rent and feature extended integrated
software for more demanding appli-
cations,” added Moeckli. “The basic
version has the same software func-
tionality as the Unitrol 1010. The full
version offers auto-synchronization,
event and data logger, and time syn-
chronization via simple network time
protocol (SNTP) signal. PSS is avail-
able on request.”
Unitrol 1010 and Unitrol 1020 are
certified according to CE regulations,
DNV class society regulations and
cUL (CSA compliant UL). The prod-
uct successfully passed extensive type
tests and can be operated in an ambi-
ent temperature of -40° to 70°C.
All Unitrol 1000 products are de-
livered with the user-friendly com-
missioning and measurement tool
CMT1000. The tool is used to set up
parameters and tune the PID to guar-
antee stable operation. CMT1000
software allows an extensive supervi-
sion of the system that helps the user
to identify and locate problems dur-
ing on-site commissioning.
ABB’s global excitation service net-
work guarantees local professional
technical support as well as commis-
sioning service. A
SEE DIRECTLINK @
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Featured Products

Measuring Flange can be recorded online to correct the

Manner Sensortelemetrie has devel-
oped a torque measuring flange with 24-
bit resolution, especially meant for meas-
uring friction power.
Manner said torque values are already
recorded in the measuring flange with a
high-precision measuring amplifier. They
are then digitized in the rotor and trans-
ferred to the measuring computer via
CAN or Ethernet.
A reconversion into an analog value
is not necessary due to the high exact-
ness of the recording, the company said.
The temperature of the testing object
zero-point and gain the changes at the
measuring computer — changes that
are conditioned by the environmental
temperature changes.
Friction moments can be measured
with high precision and without changing
the measuring flange, despite operating
load resistance. Manner said the measur-
ing flange can be used for test benches as
well as for vehicle field testing.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Torque Multiplier
Advanced Torque Products (ATP) has
introduced its compact, high-capacity,
ATP 40000 mechanical torque multi-
plier. This digitally controlled wrench
produces up to 54 233 Nm, yet is accu-
rate to ±1%, even in extreme tempera-
tures, the company said. It is suited for
automatic motor drives, MRO appli-
cations and a variety of high-torque
applications.
The ATP 40000 employs all-mechan-
ical operation, which eliminates the
need for heavy pumps, tubes and bleed-
off. A Smartchip and electronic bridge
circuit in the wrench’s outer casing pro-
vide traceability and permit any control
box to be used with the calibrated hub.
An eprom within the wrench stores
calibration data. The digital controller
is equipped with peak and track mode
and an over-torque alarm, and has up
to eight programmable scales, such as
in lb.ft., lb.in., Nm, kg-cm or other
custom units.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM

Diesel & Gas Turbine Worldwide M a r c h 2 0 1 2 57

SmallerHorsepowerHalfH.indd 1 2/7/12 9:14 AM
Marine Propulsion by bo svensson

(Left) Each of the two multifunctional icebreaking supply vessels (MIBSVs) will be equipped with four diesel generators providing a total
power output of 18 MW. The electric propulsion system alone will consume up to 13 MW. (Right) The two MIBSVs will be capable of operating
year-round, either on rough seas or in the middle of 1.7 m thick ice fields in the harsh environmental conditions in the Sakhalin area where
temperatures reach as low as -35°C.

Metso Looks To Break The Ice

Company receives contracts for supply, cargo vessels

Metso has received multiple auto-
mation system contracts for three ad-
vanced vessels that will be construct-
ed in Finland. One contract is for two
multifunctional icebreaking supply
vessels (MIBSVs) from Arctech Hel-
sinki Shipyard Oy, a joint venture
company owned by STX Finland and
United Shipbuilding Corp., for the
Russian maritime shipping company
Sovcomflot. The second contract calls
for a multipurpose deck cargo car-
rier (MDCC) from STX Finland Oy
for Finnish Gaiamare Ltd., which
belongs to the Turku, Finland-based
Meriaura Group.
The two MIBSVs are designated for
the Sakhalin-1 Arkutun-Dagi gas field
and will be used as supply vessels for
the Exxon Neftegas Ltd. gas platform.
The vessels are designed for the harsh
environmental conditions in the
Sakhalin area — conditions that con-
sist of drifting ice and temperatures
that can reach as low as -35°C.
The vessels’ main task is to trans-
port personnel, supplies and storage
materials to the platform. Other tasks
include protecting the platform from
ice, escorting ships in icy conditions,
58 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
oil spill containment operations, fire
fighting and ocean towage of plat-
forms and other large installations.
The project combines the arctic
expertise of Russia and the West,
providing vessels capable of operat-
ing year-round, either on rough seas
or in the middle of 1.7 m thick ice
fields. The Vitus Bering and her sister
ship will be ideal vessels for the tasks
at hand, according to the company.
Both vessels will measure 99.2 m in
length and 21.7 m in width, with a
deadweight of 3950 tons. Four diesel
generators will provide a total power
output of 18 MW, 13 MW of which
will be consumed by the electric pro-
pulsion system. The first vessel is
scheduled for delivery at the end of
2012 and into early 2013.
The Metso DNA Integrated Auto-
mation System (IAS) handles con-
trol, alarm and monitoring functions
in the vessels’ machinery and liquid/
bulk cargo spaces. The vessels’ power
plants are fully managed by the Metso
DNA Power Management System.
The Finnish MDCC, which will also
contain a Metso-supplied automation
system, is a vessel designed for trans-
porting large steel fabrications such as
offshore and wind farm structures. It
is also suitable for transporting energy
wood in the Baltic Sea region. The vessel
is A1 ice classed and includes double-
acting ship mode, meaning it will run
ahead in open waters and astern in ice.
Another important design feature
of the carrier is the ability to oper-
ate as an oil spill recovery vessel.
The ship has a 2700 m3 oil spill tank
and can carry versatile oil spill recov-
ery equipment on its deck. The ves-
sel also has an efficient, low-carbon,
diesel-electric propulsion system and
is designed to use bio oils as alterna-
tive fuel. The ship, which will be de-
livered to its owner in May 2012, will
measures 105 m long and 19 m wide.
For this vessel, the Metso automa-
tion system handles control, alarm
and monitoring of the machinery
plant including controller loops, con-
trol and standby functions for pumps,
fan controls and the management of
the diesel-electric power plant.
For all three vessels, Metso’s au-
tomation system includes the DNA
Operate multifunctional operator sta-
tions, which enhance system reliabil-
Marine Propulsion

The multipurpose deck cargo carrier (MDCC) to be built by STX Finland Oy for Finnish Gaiamare Ltd. is A1 ice classed and includes double-acting
ship mode, meaning it will run ahead in open waters and astern in ice.

ity and availability, the company said.
Other equipment includes redundant
fiber optic communication network
and process controllers with main
and reserve in different locations. The
Metso DNA Historian information
management system that provides an-
alyzing and reporting tools for optimi-
zation of machinery performance and
fuel consumption, for example, is also
provided. Other accommodations are
LCD touch panels for the unattended
machinery sailing (UMS) mode alarm
announcement and a dead man alarm
system for machinery spaces.
“The Metso marine group is estab-
lished in Norway to further develop
and execute Metso’s strategic focus and
services in the ship automation mar-
ket,” said Jarle Nilsen, director, sales
and marketing, Metso Automation AS.
“The group has engineering resources
with broad automation competence
for machinery, power plant and air-
conditioning systems onboard ships.” A
SEE DIRECTLINK @
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 Oil & Gas

Paradox Engineering For

The Oil And Gas Market
PE.WSNi wireless sensor network features ultra-low power technology
and can withstand very harsh conditions

Paradox Engineering, a Swiss specialist in wireless sen-

sor networks, global virtual networks and smart metering,
recently sealed two important partnerships for the oil and
gas industry.
The company is joining forces with Harris CapRock
Communications, a global provider of fully managed com-
munications for remote and harsh environments, to offer
telemetry systems for site performance and production-
efficiency monitoring.
Paradox Engineering will provide its PE.WSNi wireless The PE.WSNi wireless sensor network system by Switzerland-based
sensor network system to be integrated in Harris Cap- Paradox Engineering is increasingly being used for applications in the
Rock’s TConnect platform. oil and gas industry.
TConnect is for oil and gas companies that need to
develop a dedicated telemetry network with robust data pooling capabilities. It is based on Harris CapRock’s
VSAT satellite technology.
“The integration of PE.WSNi will enable the develop-
ment of a fully bidirectional network,” said Gianni Mi-
netti, president and CEO of Paradox Engineering.
PE.WSNi is based on IETF open standard on sub-

Did you
GHz ISM band for higher penetration and noise im-
munity, and it is the first wireless sensor network on

? the market to be based on the new 6LoWPAN proto-

col, Paradox said. Certified with IP67 and ATEX, it fea-
tures ultra-low power technology and can withstand
very harsh conditions.
• February 1865 is the only month in “PE.WSNi is a fault-tolerant, self-organizing, self-healing
recorded history not to have a full moon. and adaptive solution with over 99% data reliability,” Mi-
netti said. “It can be easily interfaced with any type of exist-
ing sensor or infrastructure.”
• In most advertisements, including The second partnership for Paradox Engineering was sealed
newspapers, the time displayed on with Tormatic AS, a Norwegian distributor of automation,
a watch is 10:10. processing, instrumentation and calibration technologies.
Under the agreement, Tormatic will distribute and im-
plement Paradox Engineering systems in Norway. The ini-
• You must renew your subscription tial focus will be the PE.WSNi and the PE.AMI platform for
to Diesel & Gas Turbine Worldwide smart metering and smart grid.
each and every year. Of course, the strong presence of the oil and gas industry
in Norway will already provide a large potential basin for
these applications. But Norway has also recently passed a
law for the introduction of smart meters across the country
by 2016, which is going to create another key market for
DEDICATED TO ENGINE ROOM PRODUCTS, TECHNOLOGIES & NEWS these products. A
www.dieselgasturbine.com SEE DIRECTLINK @ WWW.DIESELGASTURBINE.COM

60 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide

DidYouKnow.indd 1 2/10/12 1:42 PM
Literature Library
Industrial Gas
Turbines
Siemens has published a bro-
chure on its line of industrial
gas turbines. The turbines
listed, which range from 4
to 47 MW, include the SGT-
100, SGT-400, SGT-600 and
SGT-800. A technical data
sheet accompanies each tur-
bine model in the brochure.
SEE DIRECTLINK @
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PwrChina2012_JF12_WW.indd 1
Marine Industry
Power
Depco, specializing in new,
used and rebuilt power gen-
eration equipment, presents a
catalog to highlight its servic-
es. It provides detailed charts
on generator sets, marine en-
gines and marine transmis-
sion, as well as quantity and
condition of available units.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Fasteners, Gaskets
And Seals
A brochure from Lone Star
highlights its products and ser-
vices: high-performance fas-
tener capacities, materials and
products; specialty coatings,
epoxies and plating technolo-
gies; and sealing technologies
and gaskets. A facility break-
down is included.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Multiphase
Production Systems
The multiphase production
systems of Leistritz in the Gulf
of Mexico’s Ku-Maloob-Zaap
Field are featured in literature
from the company. Specs and
requirements for increased pro-
duction from three platform re-
quirements are included.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
continued on page 62
12/1/11 9:43 AM
 Literature Library

Tooling and Field Gas Turbine Subsea

Technicians Service Rotors Compression

A booklet shows the numer-
ous products and services of-
fered by Bolttech Mannings.
Features, benefits and speci-
fications are detailed for a va-
riety of standard and custom
tool applications. Bolttech-
Mannings specializes in on-
site plant services.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Turbo Components & En-
gineering announces a new
field service division, Ind
Services, offering technical
and mechanical personnel
for on-site repair and mainte-
nance applications. Services
provided include: steam, gas
turbine and compressor.
SEE DIRECTLINK @
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Turbine Energy Solutions
offers a folder containing re-
movable literature featuring
its inventory of refurbished
and new OEM surplus gas
turbine rotors. Model listings
are provided for combuster,
rotating, stationary and com-
pressor parts.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM
Literature is available that
highlights MAN Turbo AG’s
development of integrated
turbocompression systems
using high-frequency motor
drives and magnetic bearings.
MAN Diesel & Turbo details
its foray into the depths of the
North Sea.
SEE DIRECTLINK @
WWW.DIESELGASTURBINE.COM

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Please send Marine & naval technical support organization
Function is:
me Diesel & 35 Shipbuilder or Naval Architect 91 Consulting Engineer or Contractor EN Engineering
36 Operator or Owner of Marine or Naval Vessels 92 Project Developer or Investment Company
Gas Turbine 37 Government or Military Naval Authority 95 Research & Development Organization PR Production/
Worldwide 38 Manufacturer or Packager of Marine Propulsion Systems — 54 Engine Overhaul/Service Facility Purchasing
50 Engine Distributor or Agent
Magazine Main and/or Auxiliary
OP Operating/
Free of electric power generation
81 Electric Power Utility
ManuFacturer: engines or related coMponents Maintenance
40 Manufacturer of Diesel, Natural Gas, Dual Fuel Engines
any charges 82 Industrial/Commercial Firm Producing Own Power 41 Manufacturer of Gas Turbine Engines AD Administrative/
65 Manufacturer of Power Generating, Compression or 62 Manufacturer of Industrial & Marine Power Transmission Products, Marketing
yes Pumping Sets and Systems
63
Engine Components & Accessories, and Control Systems
Manufacturer of Driven Machinery including Generators, Pumps
oil & gas industry OT Other (describe)
m Digital 71 Oil & Gas Exploration or Drilling Company, Oilfield Contractor
and Compressors
or 72 Gas or Petroleum Pipeline and/or Storage Company other
Check this box
m Print 73 Petrochemical, Hydrocarbon and/or Gas Processing Company 99 None of the above. My Company’s Business is
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no 79 Railroad/Rail Transportation Company

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Address: 20855 Watertown Road, Suite 220 • Waukesha, WI • 53186-1873
 Marketplace see directlink @ www.dieselgasturbine.com

FOR SALE
15.1MW G.E. GAS TURBINE
Improve your Engine’s FR5LA GEN. UNIT 3/60/13,800V
#2 OIL: (GAS) 1840 HOURS
Performance!
Electronic
Indicator for
Diesel Engines

.Clean
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.Made in Germany
CALL: 800-704-2002
Contact us today: sales@imes.de
FAX: 847-541-5600
www.imes.de WEB SITE: www.wabashpower.com

PRE-OWNED CAT POWER SYSTEMS

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• LARGEST USED INVENTORY

wabash POWER
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444 Carpenter Avenue, Wheeling, IL 60090
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HEAT EXCHANGERS & DIESEL 
ENGINE CHARGE AIR COOLERS 
INTERNATIONAL & DOMESTIC INQUIRIES
Lyndon.Schultz@ringpower.com ...... 904.494.1278
Steve.Ferlita@ringpower.com........... 904.494.1268
Victor.Flores@ringpower.com ............904.494.7311
U.S. Energy Corp 1k x 1" 3/11/03 11:06 AM Page 1

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EXPLOSION PROOF Marine or power genera�on 

AC&DC ENGINE STARTING SYSTEMS OEM approved                 
• STARTER 1MOTORS • ALTERNATORS
RingPower_JF12_WW.indd 12/6/11 2:16 PM World‐Wide service 
• SWITCHES • CLASS I, DIV. 1&2, GROUP D
UNITED STATES ENERGY CORPORATION
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(714) 871-8185 • (714) 871-9229 FAX
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ADVERTISERS’ INDEX Need Fast Answers? Go To

Advertiser Page Number
ABB AB.......................................................................... 31
*ABB Turbo Systems....................................................... 21
Altronic, Inc. .................................................................. 1
ASME Turbo Expo 2012................................................ 47
China (Shanghai) International Boat Show 2012.......... 49
Chromalloy.................................................................... 13
*Dresser-Rand................................................................. 11
Electric Power 2012...................................................... 51
*Ellwood Crankshaft Group............................................ 39
*GE Oil & Gas............................................... Fourth Cover
HARCO......................................................................... 29
HYTORC................................................................. 25, 27
Industrial Gas Turbine Institute................................... 45
Kobelco/Kobe Steel Ltd. ............................. Second Cover
*Further information on this company’s products can be found in the Diesel and Gas Turbine Publications 2011­Global Sourcing Guide and at www.GSGnet.net.
www.dieselgasturbine.com
Advertiser Page Number
*MAN Diesel & Turbo SE................................................. 5
Manner Sensortelemetrie GmbH................................... 43
MIRATECH Corporation................................................. 9
*MOTORTECH GmbH.............................................. 32, 33
*MTU Maintenance Berlin-Brandenburg GmbH............. 19
*OPRA Turbines...............................................Third Cover
Power China 2012......................................................... 61
Sea Japan....................................................................... 55
*Siemens AG Energy......................................................... 7
Switch Filtration........................................................... 17
*Thermal Structures, Inc. ............................................... 37
Thermamax Hochtemperaturdämmungen GmbH......... 15
12th China International Petroleum & Petrochemical
Technology & Equipment Exhibition (CIPPE)............. 59

Fractured Relationships
The controversial technique of gas
drilling called hydraulic fracturing
— or fracking — continues to stir up
strong emotions and reactions.
The process has been around for
many years and involves a fluid of
water, sand and small amounts of
chemical additives being pumped
down a well at high pressure, often
over a few hours. This forms cracks in
the rock, which enables imprisoned
gas to flow to the well.
It is a technique which has been used
widely in the United States and Canada.
It sounds like a relatively earth-
friendly process and not one which
would normally cause outrage from
local populations and prompt gov-
ernment bans.
Supporters of fracking claim it en-
larges global gas supplies, thus reduc-
ing market costs, offers gas security
to some countries, limiting their de-
pendence on imports, and generates
electricity at half the carbon dioxide
emissions produced by coal.
In the United States, one of the big-
gest producers of natural gas from
shale rock is energy company Chev-
ron, following its acquisition last year
of Pittsburgh, Pennsylvania, U.S.A.-
based Atlas Energy, a move the for-
mer said complemented its “global
64 M a r c h 2 0 1 2 Diesel & Gas Turbine Worldwide
position in developing unconvention-
al gas resources.”
And complement it certainly did.
Chevron is now one of the largest lease-
holders in Pennsylvania with more than
700 000 net acres of leases in the Mar-
cellus Shale — one of North America’s
largest shale gas resources.
According to Chevron, such is the
vast scale of the Marcellus — it runs
beneath huge parts of Pennsylvania,
West Virginia, New York, Ohio and
other states — that it offers potential
resources of 396 billion cubic meters,
which the company said is enough to
supply all of the United States’ natural
gas requirements for seven months.
The company added that it plans
what it calls “a robust drilling program”
to grow its Marcellus production.
Given the many benefits of natural
gas, it sounds too good to be true.
While fracking has attracted some
criticism in the United States, opposi-
tion to the process seems to be step-
ping up to a new level in Europe.
It recently became apparent that
the relationship between frackers and
legislators had deteriorated when Bul-
garia became the second European
country after France to ban the prac-
tice following large-scale, country-
wide protests by environmentalists.
by ian cameron, ashbourne, england
Bulgaria is also said to have revoked a
shale gas permit awarded to Chevron.
The Bulgarian ruling is backed up
by threats of multimillion-pound fines
for anyone ignoring the ban.
Perhaps the most chilling allega-
tions to be leveled against the fracking
procedure concerned earth tremors
which were felt in northwest England
in May last year.
Cuadrilla Resources, the British
company exploring for natural shale
gas in the area, subsequently released
details of a report which found that,
“It is highly probable that the hydrau-
lic fracturing of Cuadrilla’s Preese
Hall-1 well did trigger a number of
minor seismic events.”
Furthermore, the report added, “The
seismic events were due to an unusual
combination of geology at the well site
coupled with the pressure exerted by
water injection as part of operations.”
Although the study said the com-
bination of geological factors was ex-
tremely rare and would be unlikely
to occur together again at future well
sites, the episode has handed ammu-
nition to anti-fracking groups.
This is particularly true of the U.K.-
based pressure group Greenpeace,
which claims the practice “is wreak-
ing havoc on communities all over the
country, as well as on our climate.”
So, do we accept the risks because
of the huge natural gas reserves to be
exploited, or should we conclude that
there are too many unattractive angles
to the technique? The argument is set
to run and run. A
OPRA Turbines is hiring.
Please see our website for details.
Gas Turbine Power
COMPACT CLEAN EFFICIENT RELIABLE

OP16 gensets in a multiple installation

at an oil & gas field in Siberia

OP16 GENSETS The 2 MW class OP16 gas turbine is APPLICATIONS

sophisticated simplicity at its best,
resulting in a robust design for high
reliability and dependability. Its unique
all radial configuration, efficient flow path
and advanced metallurgy provides
the following characteristics:
• Compact and low weight
• Ultra low emissions and multi fuel
• Highest efficiency in its power class
• High temperature clean exhaust gas
• Simple, robust and reliable
The OP16 is availible in single
and multiple installations, suitable
for continuous and standby duty in
a number of applications including:
• Oil & Gas: Onshore and offshore
power generation
• Marine: Auxiliary and
standby power
• Green energy: Cogeneration,
bio fuels, flare elimination

SOPHISTICATED www.opraturbines.com,
info @ opraturbines.com
SIMPLICITY +31 (0)74 245 21 21
T U R B I N E S

see directlink @ www.dieselgasturbine.com

Powering
We’re developing oil and gas
technologies to power the world.
At GE, the future is at work.

see directlink @ www.dieselgasturbine.com