September – October 2014 · PDF fileSeptember – October 2014 Gas Turbine World (USPS 944760, ISSN 0746-4134) is published bimonthly in addition to the GTW Handbook annual by Pequot

Flow scaling key tohigher power output page 14

10% more power at high ambient tempspage 20

Flying high with newFT4000 gas turbine page 30

September – October 2014 www.gasturbineworld.com

Proven and proprietary technology from

Mitsubishi Hitachi Power Systems enables

the reliability, availability and cost effective

efficiency desired by power producers and

their customers across the Americas today.

Our M501J Series turbine in combined

cycle application at 942MW output and

61.7% efficiency exemplifies our

validated performance.

View our website to source your solutions

for existing and evolving energy needs.

NOW

INDUSTRYNEWS

1

World-Class Provider ofGas Turbine Technologyfor and in the Americas

Mitsubishi Hitachi Power Systems Americas, Inc. 100 Colonial Center Parkway Lake Mary, FL 32746 USA 1-407-688-6100www.mhpowersystems.com

Mitsubishi Hitachi Power Systems America – Energy and Environment, Ltd. 645 Martinsville Road Basking Ridge, NJ 079201-908-605-2800www.psa.mhps.com

INDUSTRYBRIEF

3

VISIT US AT POWER-GEN 2014 – BOOTH #2301

September – October 2014

Gas Turbine World (USPS 944760, ISSN 0746-4134) is published bimonthly in addition to the GTW Handbook annual by Pequot Publishing Inc. 654 Hillside Rd., Fairfield, CT 06824. Canada Post International Mail Product (Canadian Distribution) Sales Agreement No. 0747165. Printed in U.S.A. www.gasturbineworld.com

Gas Turbine World • Vol. 44 No. 5

On the Cover. Recently commissioned Panda 2x1 5000F combined cycle with ‘shaping power’ for 10% hot day power boost

2 Project development and industry news Thailand 12 cogen projects valued at $2.4B, China clean energy agreement, Turkey investing $1B for 950MW combined cycle, equity financing push for 1.8GW Trafford Power, Fuji Electric order for 8000H plant, Abu Dhabi 1600MW combined cycle

14 Exelon 7HA.02 combined cycle projects Company is building two 2x1 duct-fired combined cycle plants rated 1,000MW each to operate mainly as base load plants with the capability of fast startup for grid back-up dispatch

20 Panda is banking on Flex-plant versatility IPP’s newly commissioned 760MW fast-start combined cycle plant can be synchro-nized to the grid in 10 minutes and is capable of delivering 60% of its full load output in less than 25 minutes

26 Gas engine promises lowest owner costs New 2500kWe engine will have lower own-ing and operating costs than any engine in its class, says OEM, with up to 45% effi-ciency and flexibility for baseload, peaking or island operation

30 FT4000 rated 61MW and 40% efficiency New aeroderivative FT4000 gas turbine engine is being introduced with water injec-tion to reduce emissions and wet compres-sion option for a 15% boost in power output with improved efficiency

Steam is outNew air cooled H-class gas turbines with better than 61% net combined cycle efficiency are in final stage of verification testing prior to release, page 14

Double dutySome new baseload combined cycle designs are high up on the merit order of dispatch for short notice start-up and ramping flexibility, page 20

Flying highLatest 60MW sized aero-derivative gas turbine combining low $ per kW cost with high hot day efficiency and modular design for ‘overnight’ instal-lation, page 30

FT4000™ Gas Turbine Generator SWIFTPAC® Package

14 Export Classification EAR99 PWPS Proprietary Information

60 MW / 120 MW

Editor-in-Chief Robert Farmer

Managing Editor Bruno deBiasi

European Editor Junior Isles

Engineering Editor Harry Jaeger

Field Editor Michael Asquino

News Editor Margaret Cornett

Marketing Director James Janson

Publisher Victor deBiasi

Subscriptions Peggy Walker Facsimile +1 203 254 3431 [email protected]

Executive Office Gas Turbine World 654 Hillside Road Fairfield, CT 06824, USA Telephone +1 203 259 1812

Website www.gasturbineworld.com

Advertising Sales US & Canada – James Janson Telephone +1 203 226 0003 Facsimile +1 203 226 0061 [email protected]

Europe – Peter Gilmore Telephone +44 (0)207 834 5559 [email protected]

Japan – Victor deBiasi Telephone +1 203 259 1812 Facsimile +1 203 254 3431 [email protected]

© 2014 Pequot Publishing, Inc. All rights reserved. Reproduction without written permission strictly prohibited.

Postmaster, please send Form 3579 to PO Box 447, Southport, CT 06890

2 GAS TURBINE WORLD September – October 2014

INDUSTRY NEWS

ThailandGED-Mitsui venture to develop12 gas fired cogen projectsJapan’s Mitsui & Co., Ltd. has signed agreements with Gulf Energy Develop-ment (GED) Company Limited to build 12 gas fired cogeneration power projects in Thailand. Through a special purpose company, established as an investment vehicle, Mitsui will acquire 30% of the shares of the holding company it estab-lished with GED (70%) to own the 12 project companies. The projects, which will be executed under a build, own and operate basis will have a total capacity of 1470MW (120MW x 9 projects, 130MW x 3 proj-ects) and will be located at several in-dustrial estates around the country. In accordance with Thailand’s small power producer program (“SPP Pro-gram”), power from each plant will be sold to state utility Electricity Generat-ing Authority of Thailand (EGAT) under a 25-year contract. Any excess electric-ity and steam will be fed to industrial users around the site. Thai land’s SPP program was launched in 1992, with the aim of grow-ing its installed capacity through the use of high-efficiency cogeneration plants and renewable projects. The Thai government guarantees that developers can build plants of up to 90MW and sell the power to EGAT. They can also sell excess power and steam to neighboring industrial users. The total cost of the 12 plants new is expected to be approximately $2.4bil-lion (Yen280 billion). The project com-panies have individually entered into a construction contract with Toyo Engi-neering Corporation and a supply con-tract with one of its subsidiaries and a project finance agreement with several commercial banks in Thailand, Japan and Malaysia. Construction of the plants will be staggered, with the first plant expected to achieve commercial operation in May 2017 and the last in July 2019. Mitsui says it will contribute to the development and operation of the proj-ects by leveraging engineering, procure-ment and construction expertise.

USAStonewall is Siemens’ sixth contract for Panda PowerSiemens, in consortium with Bechtel, has been awarded the order for the turn-key supply for Panda Power Funds’ Stonewall Energy Project in Leesburg, Virginia, USA. This is the sixth order awarded to Siemens by Panda Power Funds, follow-ing the power projects Temple I and Temple II, Sherman, Liberty and Patriot. The natural-gas-fired Leesburg combined cycle power plant (CCPP) will have a gross installed electrical capacity of 778MW. Siemens will deliver the power island equipment for the Panda Stonewall CCPP, including two SGT6-5000F gas turbines, one SST6-5000 steam turbine with an SCon-4000 condenser, two SGen6-1000A generators, one SGen6-2000H generator and two NEM duct-fired heat recovery steam generators along with the complete electrical system and SPPA-T3000 instrumentation and control system. Bechtel will be responsible for the engineering and procurement for the balance of the plant, and the installation, construction and commissioning of the facility. In order to secure funds for the project, a finance package utilizing senior debt, mezzanine debt and equity has been obtained to cover the total project costs. In support of this package, the Financial Services Division of Siemens is also making a $75 million equity investment. “The fact that Stonewall is located in a high load-growth market and is be-ing managed by a highly experienced team means there is a strong investment case for the project. Siemens’ partnership with Panda Power Funds exempli-fies two strong contenders in the power generation market so we are very pleased to support the project on the financing side,” said Kirk Edelman, CEO of Siemens Financial Services Project and Structured Finance Power, Oil & Gas. The gas turbines, steam turbines and generators will be manufactured in the Siemens factory in Charlotte, North Carolina, which is the main production facility for Siemens 60 Hz power generation. Once built, Stonewall can supply the power for up to 778,000 households in Virginia and will make a significant contribution to the area’s economy. Commissioning of the plant is scheduled for spring 2017. In 2012, Siemens received the first two orders from Panda Power Funds for the turnkey supply of the Panda Temple Power Project in Temple I, Texas as well as the Panda Sherman Power Project in Sherman, Texas, also in consor-tium with Bechtel.

© Panda Power Funds

The order for Stonewall follows the recent commissioning of the Sher-man project in Texas

Follow GE Power & Water

@ge_powergen | @HArriet_GE©2014 GE Power & Water, a division of General Electric Company.

efficiency.gepower.com

We introduced H-class. So it’s only natural that we take it to the next level.A decade ago, GE built the industry’s first H-class gas turbine. Since then, our H-class gas turbines have logged more than 200,000 hours of operation and data monitoring. This experience, and data-driven insights, have led to performance improvements and smart innovation. Today, our 7HA and 9HA gas turbines lead the industry in total lifecycle value through strategic service solutions that enable our customers to adapt their operations and assets for cleaner, more reliable and cost-effective conversion of fuel to electricity.

Come see us at POWER-GEN International booth #2221.

80578 GE High Effi ciency Print ad Pub: Gas Turbine World November/Dec Bleed: 8.25inx10.75in Trim: 8inx10.5in Live: 7.5inx10in

80578_GE_HighEfficiency_HA_PGI_GTW.indd 1 10/22/14 4:59 PM


Industry News

ChinaGE signs clean energyagreements in ChinaGeneral Electric Co Ltd has signed agreements with two Chinese compa-nies in the natural gas and coal sectors, part of an effort to help China develop clean energy. A memorandum of understanding for a strategic partnership between GE and Chinese private company ENN En-ergy Holdings Ltd will see the compa-nies concentrate on areas including the development of gas-based distributed power. “As the world’s largest power gen-eration market, up to 30 percent of the global new energy supply will happen in China in the next 10 to 15 years,” said Steve Bolze, president of GE Power and Water. GE has estimated that power gener-ated by natural gas will reach the same level as oil and coal by 2030 globally. One-quarter of the world’s natural gas power generation increase will come from China, said Bolze. Separately, GE and the China Coal Resources Group signed a letter of in-tent to cooperate on a large-scale, effi-cient clean coal utilization. GE will pro-vide its third-generation Radiant Syngas Cooler gasification technology and re-lated services to China Coal. Xu Yaowu, deputy general manager of China Coal, said the cooperation with GE is a relatively short-term technology transfer, but the company hopes that it can be expanded. China is fast becoming a world lead-er in gasification. Robert Rigdon, head of Synthesis, which has developed ad-vanced coal-gasification projects at two plants in China recently said that China “will commercialize cleaner coal, prob-ably faster than any other country”. Gasification converts low-quality coal into relatively clean, synthetic natu-ral gas and has the ability to capture CO2. Such technologies are less eco-nomically viable in the US, where near-record levels of natural gas and oil pro-duction are putting downward pressure on domestic prices of those commodi-ties. “Because of the way their system

works… they can direct industry to go in certain directions, then the cleaner coal technologies will get built,” Rigdon said in an interview with Platts.

USABlack & Veatch to build OregonH-turbine combined cycle plantBlack & Veatch has been selected as prime contractor for the engineering, procurement, construction (EPC) and startup of the 869 MW Oregon Clean Energy Center (OCEC) in Oregon, Ohio. The OCEC will utilize two-high ef-ficiency Siemens SGT6-8000H combus-tion turbine generator (CTGs), two heat recovery steam generators (HRSGs) supplied by NEM, and a Siemens SST6-5000 steam turbine. The H-class gas tur-bines are being installed in a two-on-one combined cycle configuration. To increase power output, the HRSGs are equipped with supplemental firing and the gas turbines are equipped with evaporative coolers. The OCEC’s wet cooling system is optimized for the specific plant location. Siemens will engineer and deliver the thermodynamic cycle design and Power Island configuration as well as perform ongoing service at the plant un-der a long-term service and maintenance agreement. The plant will use the existing elec-trical transmission lines adjacent to the project site. Natural gas for the OCEC is delivered by a new pipeline from the Maumee hub, which provides reliable, economic gas supplies. Water for the facility will be provided from Lake Erie by the city of Oregon. The OCEC facility is being devel-oped by North America Project Devel-opment (NAPD) LLC, with equity fi-nancing from Energy Investors Funds and I Squared Capital. The new gas fired plant replaces generation from sev-eral aging coal-fired power plants in the region that are being retired. With their best-in-class efficiency the H-machines will significantly reduce air emissions while providing electricity for growing manufacturing and residential use. OCEC will be capable of supplying cost-efficient electricity to more than

800 000 homes in the northwest Ohio region. “This energy center will employ among the best quality technology that increases efficiency and emissions con-trol,” said Dean Oskvig, President and CEO of Black & Veatch’s energy busi-ness. “By implementing this project we are supporting NAPD’s goal to provide customers with cost-effective clean en-ergy.” The plant is expected to begin com-mercial operations by July 2017. More than 500 workers are expected to be at the project site during peak construc-tion.

IndiaBHEL commissions biggestcombined cycle in Northeast Indian engineering giant Bharat Heavy Electricals Ltd has commissioned the second unit of the 2x363.3 MW gas tur-bine combined cycle power plant in Tri-pura, located at Palatana, about 50 km from Agartala. This project, owned by ONGC Ther-mal Power Corporation (OTPC), is the biggest of its kind in the entire North East, according to BHEL. The first unit of the Palatana project was commis-sioned in January last year. BHEL has now commissioned nine GE Frame 9FA gas turbines in com-bined cycle made in India.

JapanKawasaki cogen system hasemergency power capabilitiesKawasaki Heavy Industries, Ltd. has launched a new PUC17D “ultra-effi-cient” cogeneration system that can also supply power in emergency situations. The system is powered by a 1.7MW M1A-17D gas turbine developed by Ka-wasaki. The system has been developed as a result of the huge East Japan Earth-quake, which dealt a severe blow to factories and other facilities. Businesses throughout Japan responded by estab-lishing a business continuity plan (BCP) in preparation for major disasters. This put an increasing focus on co-generation systems capable of supplying emergency power, primarily as a means

GE-4968_K3_FS_FClass_Gtw_v1a.indd KEYLINE 3

Saved: 11/18/14 Prepared by: Sarah Elwyn

312-970-5800

CLIENT GE Power Generation Services BLEED 8.375" x 11.125" CREATIVE DIR Elisa Ivany

DESCRIPTION Inside your F-Class gas turbine is an … TRIM 8.125" x 10.875" ART DIRECTOR

COLORS 4CP LIVE 7.625" x 10.375" COPYWRITER Mikey Ritto

DESTINATION Gas Turbine World LINE SCREEN N/A TRAFFIC

ROUTE SIGNOFF AS_________ AE__________ CD__________ COPY__________ AD__________ AAD__________ PROOF__________ PROD__________

GE-4968_K3_FS_FClass_Gtw_v1a.indd 1 11/19/14 9:17 AM


Industry News

of maintaining electricity supply during an outage and to assist in disaster recovery. Such systems are also suited to international markets where low-NOx, high-efficiency operation using gas fuel and the abil-ity to switch to liquid fuel when gas is in short supply are im-portant. During normal operation, the PUC17D relies on utility gas or other gas fuel to supply electricity. When the supply of gas fuel is cut off during an outage, the system automatically switches to liquid fuel and continues to generate electricity to run critical equipment, such as emergency lighting systems. Kawasaki claims it is a highly efficient system that elimi-nates the need to install a dedicated emergency power gen-erator. The company says this delivers savings in space, initial costs and maintenance costs through a more streamlined sys-tem. The M1A-17D gas turbine has a rated electrical efficiency of 26.5%, among the world’s highest level in its class. Some 22 units have been delivered since its launch in 2011. The newly developed system features dry low emission (DLE) combustion, which eliminates the need for water injec-tion to the combustor. This combustion method helps reduce NOx emissions to 50 ppm at 0% O2. In addition, improved per-formance of the waste heat boiler boosts overall efficiency by 5.3 percentage points. The DLE system is designed to respond to sudden fluc-tuations in load conditions while operating with low NOx emis-sions even during stand-alone operation. Further, the air intake duct is fitted with an optional variable blade mechanism. This allows the air-fuel ratio to be kept at a fixed level during partial load operation, allowing DLE com-bustion to be applied over a broader range of low-NOx opera-tion.

United Arab EmiratesAnsaldo Energia confirmsMirfa equipment orders A series of contracts worth a total of €350 million have come into force for Ansaldo Energia Group following financial clo-sure of the 1600 MW combined cycle power plant project in Mirfa, 200 km west of Abu Dhabi. The contracts were awarded by Mirfa International Power and Water Company (80% ADWEA Abu Dhabi Water & Elec-tricity Authority, wholly owned by the Government of the Emir-ate of Abu Dhabi, and 20% GDF Suez S.a). Ansaldo Energia, working in a consortium with HDEC (Hyundai Engineering & Construction), will supply three AE94.3A gas turbines, two MT20 steam turbines, five air-cooled turbogenerators and all the relevant auxiliary systems. Ansaldo Energia has also been awarded a 25-year Long Term Service Agreement (LTSA) for the gas turbines. Netherlands-based Ansaldo Thomassen, which specializes in servicing third-party gas turbines, signed a contract with HDEC for the refurbishment, conversion and commissioning of four existing GE Frame 9E gas turbines at the site. Ansaldo Thomassen also signed a Long Term Service (LTSA) with the project company to maintain the GE gas tur-

You have the POWER,

PROTECT...

TOMCO2 SystemsFire Systems Division

7619 Hamilton AvenueCincinnati, Ohio 45231 USA

Tel: 1.513.729.3473Email: [email protected]

www.TOMCOsystems.com

WEhave the

POWER to

www.gasturbineworld.com GAS TURBINE WORLD September – October 2014 7

Industry News

bines for 12 years. Ansaldo Energia and Ansaldo Thom-assen will use Ansaldo Thomassen Gulf’s Abu Dhabi facility to perform some of the service activities and the company will also act as a contractor to provide support for local work.

United KingdomFinance advisor for 1.8 GWTrafford Power stationCarlton Power, the Stokesley-based independent power producer (IPP), is pressing ahead with its 1.8 GW Traf-ford Power combined cycle gas turbine (CCGT) project in Greater Manchester, United Kingdom. It has now appointed Macquarie Capital as its exclusive fi-nancial advisor for the project. Macquarie Capital will be advising on raising debt and equity for what is one of the UK’s largest new power sta-tions. When complete, the project would generate enough electricity to power the equivalent of two million households.

Carlton Power will enter Trafford Power into the UK government’s new Capacity Market Auction that is to be held in December 2014. The Capacity Market will offer payment support for 15 years to new gas fired power stations in return for guarantees to provide ca-pacity when needed the electricity grid. Subject to the outcome of the auction and Carlton Power’s financing process, construction on the Trafford Power sta-tion is expected to start mid-2015 with operations commencing towards the end of 2018. Macquarie Capital has been appoint-ed to raise capital for the project and will be approaching potential equity in-vestors and debt providers to commence discussions leading up to the auction. Macquarie Capital is a leading infra-structure advisor globally, having ad-vised on over £100 billion worth of in-frastructure transactions in the last five years. Mark Dooley, Head of Development

Capital, Macquarie Capital said: “We are very pleased to have been appointed by Carlton Power to advise on raising capital for Trafford Power station. The upcoming Capacity Market Auction is an important milestone for the UK en-ergy sector and we believe that Carlton is extremely well positioned given its proven track record.”

USACosts mount at Kemper Construction and startup expenses add-ed another $30 million to the cost of Mississippi Power’s Kemper County integrated gasification combined cycle (IGCC) plant. In September, the plant’s total cost stood at $5.586 billion, com-pared with $5.556 billion month ear-lier. Originally the plant was expected to cost $2.5 billion. The latest increases are $63 million more than the company budgeted for pre-commercial operations for startup labor and materials, including costs of

Celebrating 15 Years of Proven PerformanceCOMPETITIVE, STRATEGIC, GLOBAL, GAS TURBINE SERVICE PROVIDER

www.psm.com

PSM – The Proven AlternativeImprove your plant’s reliability, fl exibility and profi tability.

Parts/Repair | Field Services | Long Term Agreements | Controls | Performance UpgradesPlant Solutions | Combustion Conversions | Monitoring & Diagnostics

• GT Upgrades • Long term service agreements

• Complete Power Plant Solutions - HRSG, ST, GEN


Industry News

training programs. The cost of engineer-ing, procurement and construction rose $3.68 million above what was expected, according to the monthly status report to the state Public Service Commission. Some of those costs were offset by $60 million less than estimated for schedule risks that cover the extended date of completion and $5 million less for contingency. Kemper began operation in August, when the combined cycle portion of the plant began running on natural gas. The lignite gasifier will begin opera-tion after it has gone through testing and startup, which is anticipated in the sec-ond quarter of 2015.

JapanSiemens receives firstJapanese H-Class order Two SGT5-8000H gas turbines will form the core of a new combined cycle power plant for Kobe Steel, Ltd. (KO-BELCO) in Moka City, Tochigi Prefec-ture in Japan. It marks the first order for Siemens H-Class machines from Japan. With an installed capacity of more than 1.2 GW and an efficiency level of more than 61 percent, the plant will be the most powerful and most efficient gas-fired power plant in the country. Siemens’ customer is Fuji Electric Co, Ltd., Japan, who will be erecting the plant on a turnkey basis for the end customer KOBELCO at its site. In addition to supplying two SGT5-8000H gas turbines, each with a capac-ity of 400 MW, Siemens will also pro-vide the associated auxiliary systems. As the plant is located inland, some 50 km west from the shore of the Pacific Ocean, it will be equipped with an air-cooled condenser. Approval of the environmental im-pact assessment for the power plant is expected to be granted in mid-2016 and commercial operation is scheduled to begin at the end of 2019. Commenting on the order, Roland Fischer, CEO of the Siemens Division Power and Gas, said: “We are pleased that we have now been able to enter the Japanese market with our innovative and yet extensively proven gas turbine after selling them in South Korea, Ma-laysia and the Philippines.”

AlgeriaOpen cycle gas turbinesfor Ain Djasser IIIAnsaldo Energia has been awarded a contract worth about €170 million for an open cycle power plant in the province of Batna in central Algeria, about 350 km south of the capital Algiers. The contract covers the supply of two gas turbines each with a capacity of about 170 MW (in ISO conditions) plus the associated generators. Ansaldo Energia Sociéte was award-ed the contract by Algérienne de Pro-duction de l’Electricité (SPE Spa), a Sonelgaz group company, following an international tender.

TurkeyAcwa to develop $1bnpower plant Acwa Power International, an indepen-dent developer of power projects based in Saudi Arabia, said its Turkish unit has inked a $1 billion deal to develop a combined cycle gas turbine power plant near the Turkish city of Kirikkale. The plant is being built by Acwa Guc Elektrik Isletme ve Yonetim Sanayi ve Ticaretower with a comprehensive long-term financing package arranged by the European Bank for Reconstruction and Development (EBRD). With a capacity of 950 MW, the proj-ect will be able to cover half the energy needs of a city the size of Ankara and will help meet Turkey’s growing de-mand for reliable energy. The EBRD has played a key role in securing long-term financing for the construction of the new plant by arrang-ing a syndicated loan of $250 million: $200 million for the EBRD’s own ac-count and $50 million syndicated to Banque Saudi Fransi, which is also pro-viding parallel financing of $100 mil-lion under a murabaha Islamic financial instrument. The International Finance Corpora-tion (IFC) is also providing a syndicated loan of $170 million, of which $45 mil-lion is syndicated to the Korea Develop-ment Bank. Korea Eximbank and Stan-dard Chartered Bank, with cover from Korea Eximbank, are joining as parallel lenders with $90 million and $60 mil-lion, respectively.

The investment being made in the plant, to be built in Central Anatolia, about 50 km east of Ankara, is the larg-est in the country in recent years. Highlighting the EBRD’s leading role in arranging financing for the proj-ect, Nandita Parshad, the director for power and energy said this was a land-mark transaction for many reasons. “First it brings together international financial institutions and commercial banks to lend on similar terms; it offers the longest tenure to date – 16 years – for a power project in Turkey and is also the first time in the country that an independent power producer is financed on a limited recourse basis,” explained Parshad. Acwa Power president and chief ex-ecutive Paddy Padmanathan said the Kirikkale power project was the com-pany’s first investment in Turkey. “It is a solid foundation for the multi-fuel power-generation portfolio we seek to establish in this thriving economy. The project represents yet another mile-stone in Acwa Power’s market expan-sion beyond the GCC countries,” he noted. Acwa is a major developer, investor, co-owner and operator of plants, with a portfolio of 15 000 MW across in-vestments in the Middle East and North Africa (Mena), Southern Africa and Tur-key. EBRD said, as an independent pow-er producer project, the Turkey plant will operate on a merchant basis, selling the electricity it generates on the power market. The power produced by this plant is expected to replace more carbon-inten-sive energy generation in Turkey and will lead to an annual carbon dioxide emissions reduction of over 1.825 mil-lion tonnes, EBRD added. Parshad noted that investment in sus-tainable energy has been a top priority for EBRD in Turkey.

USAMicroturbines to powerinnovation firmA technology innovation firm in South-ern California is to use two C1000 mi-croturbines supplied by Capstone Tur-bine Corporation to provide heat and

The continued growth of renewable energy generation puts power supply at nature‘s whim. The potential for rapid fluctuations in generation must be quickly balanced to maintain a reliable supply of power to the grid. With all of the flexibility and features of a peaker and the high efficiency of a combined cycle plant, proven Flex-Plants from Siemens work in harmony with renewables, providing efficient and reliable electricity when the wind stops blowing or the sun stops shining.

siemens.com/energy

We also offer unique Clean-Ramp™ technology that inte-grates the operation of the combined cycle to keep your emissions in compliance while ramping up and down.

As you tackle the challenge of ensuring a reliable power supply while remaining committed to using natural resources responsibly, Siemens has the solutions that help you do both. The journey to a new kind of energy system needs all types of answers. Answers today, and answers that last.

Siemens Flex-Plants™ - a trusted partner for renewablesFast, efficient and reliable Siemens Flex-Plant technology works in harmony with intermittent renewables to meet grid demand.

Answers for energy.

FlexPlant Ad Temple Gas Turbine World 8_125x10_875.indd 1 9/4/14 3:56 PM


Industry News

power for its business. Capstone’s dis-tributor in California, Regatta Solutions, secured the 2 MW order. Following an analysis of its energy usage the technology innovation firm decided to upgrade to a more efficient and reliable power generation solution. After comparing various technolo-gies, the company project engineers se-lected Capstone’s microturbines based on reliability, availability, cleanliness and cost savings. The two natural gas fired C1000 microturbines are dual mode, mean-ing they can operate independently of the grid or work with the grid in a load sharing capacity. This ensures the firm receives the lowest electricity cost avail-able at various times of the day and year. Additionally, heat from the exhaust of the microturbines will be captured via heat exchangers to provide hot air and hot water to the facility. This boosts the overall energy efficiency of the installa-tion to greater than 80%. “High system resiliency and inde-pendence of the grid for secure power were key drivers for this project,” stated Steven Acevedo, President and CEO of Regatta Solutions. USAFirst HRSG behind MitsubishiM501J gas turbineNooter/Eriksen has won an order from Grand River Dam Authority (GRDA) to design and supply a heat recovery steam generator (HRSG) to be installed be-hind the Mitsubishi M501J gas turbine ordered for the GRDA project in Chou-teau, Oklahoma. It will be the first custom-designed HRSG in North America behind Mit-subishi’s M501J. The three-pressure, reheat HRSG includes duct firing and the latest in emission control technology it will be part of the 1-on-1 combined cycle facility that has a nominal output of nearly 495 MW. The HRSG will recover heat from the 328 MW gas turbine to generate steam, which will be fed to a 167 MW steam turbine. The contract for the gas turbine was signed in March this year. The 495 MW plant will replace an old coal-fired unit.

JapanTokyo puts faith in IGCCA consortium led by Mitsubishi Hitachi Power Systems, Ltd. (MHPS) is design-ing a large-scale integrated coal gasifi-cation combined-cycle (IGCC) for To-kyo Electric Power Company, (TEPCO). The project plan calls for the con-struction of two 500 MW IGCC plants in Fukushima Prefecture to help local industrial recovery following the tsu-nami and earthquake of 2011. Following the recent award of the de-sign contract the consortium, which also includes Mitsubishi Heavy Industries, Ltd. (MHI), Mitsubishi Electric Corpo-ration and Mitsubishi Heavy Industries Mechatronics Systems, Ltd. (MHI-MS), has already begun the design work. One of the plants will be built at Tepco’s Hirono Power Station (Futaba-gun), and the other at the Nakoso Power Plant (Iwaki City) operated by Joban Joint Power Co., Ltd., a company partly owned by Tepco. MHPS is responsible primarily for designing the gasification and com-bined-cycle power generation equip-ment. This includes preparing the equip-ment specifications, layout design, ma-jor system diagrams, etc. MHI is in charge of gas refining equipment; Mitsubishi Electric will handle power generation and electrical equipment; and MHI-MS will design the wastewater treatment facilities.

USAGas plant additions downbut still dominantMore than of new utility-scale generat-ing capacity brought online in the first half of 2014 came from natural gas-fired power plants, according to data from the U.S. Energy Information Administration. The EIA also noted, however, that the 4350 MW of total new capacity add-ed in the first half of the year, was 40 percent less than the capacity additions in the same time period last year, with natural gas additions down by about half. Solar capacity was up 70 percent, ac-counting for more than a quarter of the new capacity. Wind capacity more than doubled compared with the first half of 2013 and accounted for about one-sixth

of the total. Most of the new capacity was added in Florida – 1210 MW, all from natu-ral gas. Other big gas users were Utah and Texas, which combined added 1000 MW, nearly all in the form of natural gas. Meanwhile, California added just un-der 1100 MW – 98 per cent coming from solar (77 percent) and wind (21 percent).

NigeriaAzura Power signs $890mfinancing for Azura-Edo IPPAzura Power Holdings Limited has signed the equity and loan financing documents for financing its Azura-Edo Independent Power Project (IPP) in Benin City, Edo State, Nigeria. The financing marks a milestone towards the beginning of construction work on the project, which will begin in January 2015. The Azura-Edo IPP comprises a 450 MW open cycle gas turbine power sta-tion; a short transmission line connect-ing the power plant to a local substation and a short underground gas pipeline connecting the power plant to the coun-try’s main gas supply. It represents the first phase of a 1500 MW power plant facility. The plant’s location on the outskirts of Benin City is ideal because of its close proximity to Nigeria’s biggest gas distribution pipeline (which makes gas feedstock easily available) and its unique accessibility to the country’s high voltage transmission network. The first phase of the plant is target-ed to come on stream in 2017. It is the first of a new wave of project-financed greenfield IPPs currently being devel-oped in Nigeria. The project is being developed by a consortium of local and international investors led by Amaya Capital Limited and American Capital Energy and Infrastructure. The other sponsors contributing eq-uity to the project are the Africa Infra-structure Investment Fund 2 (AIIF2), Aldwych International Limited, and the Asset and Resource Management Com-pany Limited (ARM). The debt financing is being provided by a consortium of 15 banks from nine

Client: PW - Power SystemsAd Title: Same Power. New OwnerPublication: Gas Turbine World - September/OctoberTrim: 8-1/8" x 10-7/8" • Bleed: 8-3/8" x 11-1/8" • Live: 7-7/8" x 10-5/8"

PW Power Systems continues to bring you advances in products and capabilities for the energy and power markets. Now an MHI group company, PWPS, with over 50 years of experience, is driven to provide the high-quality products and support you’ve always depended on. It’s the same trusted technology you know, always moving forward. Visit www.pwps.com or call 1.866.PowerALL (1.866.769.3725) to learn more.

Same power. Same products. New owner.

30016-1_SamePower_GasTurbineWorld.indd 1 9/9/14 11:34 AM


Industry News

countries led by Standard Chartered Bank (SCB) as Global Mandated Lead Arranger for the project, IFC, a mem-ber of the World Bank Group, Neder-landse Financierings-Maatschappij voor Ontwikkelingslanden (FMO) and Rand Merchant Bank (RMB), a division of FirstRand Bank Limited. FCMB Capital Markets was the Lo-cal Loan Arranger for the Central Bank of Nigeria’s Power and Aviation Infra-structure Facility (BOI-PAIF) through the Bank of Industry. The Azura-Edo IPP is the first Ni-gerian power project to benefit from the World Bank’s ‘Partial Risk Guarantee’ structure, specifically created to meet the developing needs of emerging mar-kets world-wide, and political risk in-surance for equity and commercial debt from the Multilateral Investment Guar-antee Agency, also part of the World Bank group. Significantly, the overall transaction will be underpinned by financial support

provided by the Federal Government of Nigeria. The United Nations estimates that Nigeria’s population will reach 230 mil-lion within the next 20 years, and the to-tal grid-based power generation capacity must rise, during this period, by at least tenfold to meet the demand.

PolandSiemens sells first H-Classgas turbine in PolandSiemens has won a contract for its ad-vanced H-Class gas turbine in Poland. It is the first time the company will build a turnkey H-Class combined cycle plant in Central Europe outside of Germany. The 596 MW CCGT plant is being built for PKN Orlen, Eastern Europe’s largest mineral oil refinery company. The plant located in Płock, about 100 km northwest of the capital city of War-saw is designed to feed electricity into the national power grid, and also supply the refinery with electricity and process

steam. Commissioning of the plant is scheduled for the end of 2017. The turnkey contract will see Sie-mens erect the combined cycle with a single-shaft configuration, and supply the main components: an SGT5-8000H gas turbine, the heat recovery steam generator, an SST5-5000 steam turbine with an SCon-2000PF condenser, an SGen5-3000W generator, the electrical systems and the SPPA-T3000 I&C sys-tem. Siemens will also be responsible for plant maintenance and service for a period of around 12 years.

Submit News Articles & ImagesEmail news articles, contact information and high-resolution image files to [email protected].

Gas Turbine World reserves the right to edit printed submissions for clarity and context. Please accompany image files with copyright/credit information and written permissions for use.

Additional Test and Finishing Equipment Available Including:

Liechti 5-Axis Machining Center Model: go-Mill 350, Installed New 2010Work Range: Recommended max blade dia. 250 mm / 9.8” Distance A rotary table to B-axis 150 mm / 5.90” Distance A-axis to B-axis 90 mm / 3.54”Heidenhain iTNC 530 Control w/ Heidenhain scales & encoders 20,000 RPM Spindle for HSK-A63 Tooling w/ tool and work changers

Surplus to the needs of a world class manufacturer of turbine generatorsLate Model 5-Axis CNC Turbine Blade Machining Centers

All machines available for inspection under power

(2) Liechti 5-Axis Machining Centers Model: Turbomill 2600xl, Installed 2010Work Range: Max distance between centers 102.3” / 2600 mm Max part diameter 25.6” / 650 mm Siemens 840D Control w/ Heidenhain Scales15,000 RPM Spindle, HSK-A63 Tooling w/ 32 position tool changer

(17) Starrag Heckert 5-Axis Machining Centers Model: LX-151, Installed 2007-2011Work Range: Max distance between centers 33.7” / 855 mm Swing diameter 15.7” / 400 mm Siemens 840D Control 18,000 RPM Spindle, HSK-A63 Tooling w/ 24 position tool changer, Automatic work piece changer, Main drive 28 kw/38 hp

Be sure to ask for a complete copy of our Terms & Conditions.

• Rosler Drag Finishing Equipment complete with 2 finishing bowls w/ spinners, media systems and automation controls

• Brand new equipment never installed - Vision Robotics Polishing and Innovative Peening Systems for finishing blades.

• (4) Centrifugal Barrel Finishing Model VFC40F

• Gould Bass MP and MagnaFlux testing equipment

Contact: Casey Mulqueen Call: 203-247-3991 [email protected]

Strategic Solutionsfor Industry

Available for delivery January 2015

Seller reserves the right to withdraw rejecting offers to purchase and or inspections at any time during this process including rescinding any form of previous acceptance.

Access Handbook Performance Specs (from 1976) and Gas Turbine Plant Prices (from 1982) to current year in a searchable online database.The database presents OEM gas turbine design ratings by model, year and power output for simple cycle, combined cycle and mechanical drive applications.

Common Searches • See price and performance changes by specific models over time • Compare OEM offerings by price, type, frequency, footprint, weight • Track power, pressure ratio and efficiency upgrades of specific models • Review industry pricing and gas turbine design performance trending

Performance Specs & Plant Prices Online...

Simple Cycle Electric Power Plants • Combined Cycle Electric Power Plants • Mechanical Drive Gas Turbines

Ask a Sales Rep for a Live DemonstrationToll Free: 1.800.762.3361 International: 1.713.783.5147

Key Search Fields • Handbook Year • OEM Company Name • Gas Turbine Series • Gas Turbine Model • 1st Year Unit Available• 50/60 Hz Frequency • ISO Base Rating kW • Heat Rate Btu/kWh • Pressure Ratio • Flow lb/sec • Exhaust Temperature • Turbine Speed rpm • Weight • Size LxWxH

Searchable Online Database

Industrial InfoResources &

NEW: Gas Turbine World Online Database

GET INSTANT ACCESS TO


In late September of this year, GE announced orders for four of its

new 60Hz 7HA.02 units from US generation utility Exelon. All four gas turbines are to be shipped in 2016 together with steam turbines and generators for two 2x1 combined cycle power blocks nomi-nally rated 1000MW each without supplementary firing. Aside from offering close to 20% more power and exhaust flow than the 7HA.01 engine, the design rat-ings for efficiency, pressure ratio and exhaust temperature are identical to those for the 7HA.01. Major performance and design characteristics:

o7HA.02 GT. Gross output of 330MW (vs. 275MW for the 7HA.01) with 1522 lb/sec exhaust flow (vs. 1269 lb) and same 41.4% simple cy-cle efficiency, 21.5 to 1 pressure ratio, 1145°F exhaust.

oCombined cycle. Without HRSG supplementary firing, 2x1 configu-ration is rated at 976MW net com-bined cycle plant output (vs. 405MW) and 61.2% net efficiency (same as the 7HA.01).

oCC load change. Deliver full combined cycle plant output within 30 minutes of start command, capable

of 60 MW/min ramp rate and turn-down to 40% of plant load (same as the 7HA.01). Exelon Generation is building the two 2x1 duct fired 7HA.02 combined cycle plants on existing company sites: one at the 498MW Colorado Bend natural gas plant in Wharton County and the other at the 704MW Wolf Hollow natural gas plant in Granbury. Each combined cycle will be pow-ered by two 330MW natural gas-fired General Electric 7HA.02 gas turbines, two duct-fired Alstom Power heat recovery steam generators and one nominally rated 500MW GE steam turbine. Without supplementary duct fir-ing, the 2x1 combined cycle is rated at 976MW net plant output and 5570

Btu/kWh heat rate (61.2% net effi-ciency) at 59°F ambient and sea level site conditions. With supplementary duct burner firing, the additional steam generated will increase total maximum electric power output to around 1,160MW with a corresponding increase in heat rate to around 5910 Btu/kWh (57.7% efficiency). It is expected that the two new 7HA.02 combined cycle plants will operate base load to produce electric-ity for sale to the Electric Reliabil-ity Council of Texas (ERCOT). But the units may also be called upon to operate at reduced load in response to changes in electric grid power re-quirements and/or stability. Perhaps most impressive about the 7HA.02 is the ability to provide

Exelon will be first to debutGE’s new 7HA.02 gas turbine By Tim Probert

Order for 7HA.02 gas turbines is a milestone in the evolutionary shift of GE’s H-class machines from steam to air cooledunits that will operate at over 61% combined cycle efficiency.

Design parameter 7HA.02 7HA.01Net base load *330 MW *275 MWHeat rate (per kWh) 8240 Btu (8694 kJ) 8240 Btu (8694 kJ)Net efficiency *41.4% *41.4%Pressure ratio 21.5 to 1 21.5 to 1Exhaust flow (per sec) 1522 lb (826 kg) 1269 lb (575 kg)Exhaust temperature 1145°F (619°C) 1145°F (619°C)Approximate weight 660 tons 600 tonsApproximate size 90 x 17 x 20 feet 81 x 15 x 23 feet

Simple Cycle specs. The 7HA.02 gas turbine has 20 per cent more power and 20 per cent higher mass flow than its 7HA.01 predecessor.

*rating at 59°F and sea level net of inlet, exhaust and auxiliary system losses.


20% more power than its predeces-sor at the same efficiency due to a 20% increase in compressor air flow and 21.5:1 pressure ratio. “It’s called flow scaling,” says Guy DeLeonardo, who leads the product strategy for ad-vanced gas turbines. “It still has a 14-stage compressor and we held all the same nozzle and blade counts across the four stages of the turbine. To get more output out of the same architecture you need more flow,” he explains. “We opened the first five stages of the compressor blading, nominally four inches, and in the back of the turbine radially moved the blade tips a shade less than four inches to hold the exit Mach speed.” The 7HA.02 engine is 19 inches longer than the 7HA.01. Increasing the engine length only 5% to obtain a 20% increase in output was a techni-cal challenge, says DeLeonardo. “It took us a while to figure out how to do this. We wanted to preserve as much of the architecture as pos-sible, and shorten the development cycle of the HA.02, but we never fig-ured the change between the two en-gines would be that small to get a 20% increase in output and torque.” GE says the increased power den-sity of the new design has no effect on maintenance schedules. Becuase the firing temperatures are identical; intervals for combustion inspection, hot gas path inspection do not change. One of the reasons Exelon selected the 7HA.02 is due to the increased ca-pex productivity. “But it’s not only the gas turbine where we get this kind of capital efficiency, it’s also the steam turbine, the HRSG and the heat rejec-tion systems of the plant,” says De-Leonardo.

Exelon referenceAs Exelon’s four 7HA.02 units rep-resent the first orders for the new turbine, Wolf Hollow and Colorado Bend are very much reference plants. “Being able to partner with a com-pany as well respected as Exelon is a

big deal,” notes DeLeonardo. Initially, Exelon was looking at Wolf Hollow being 800MW and Col-orado Bend being 1000MW. When Exelon analysed the economics at 1000MW for Wolf Hollow they saw a much better prospect because it dis-places less efficient generation, such

as F class and even coal power. DeLeonardo explains: “Customers with mixed assets will look at what’s the better generating asset and we’re getting to the point with low cost natural gas where you have a lower variable cost with natural gas-based generation than coal.”

From H to HA and beyond

GE refers, almost apologetically, to its steam-cooled H turbines as “historical sites”. Introduced in the early 2000s, when the industry standard for gas turbine combined cycle efficiency was closer to 55%, it was a big leap and a big deal to get to 60%.

Back in the 1990s, GE believed the only way to get to these levels of efficiency was via steam cooling. It turned out that the technology works but is very complicated and expensive. While GE’s six H-class gas turbines at Baglan Bay, Wales; Futtsu, Japan and Inland Empire, California USA have amassed around 200,000 operating hours, their days could be numbered.

GE’s 7HA and 9HA units (the ‘A’ stands for air-cooled) are now the US manufacturer’s flagship turbines. The 9HA combined cycle plant is one and the same as the 50Hz FlexEfficiency50 launched in June 2011, when marketing decided to capitalise on the fashionable idea of flexible generation to support renewables.

GE defines H-class as a firing temperature in excess of 2600°F and up to 2900°F, superseding E class firing temperatures of 2000-2200°F and F-class temperatures of 2300-2600°F.

The 9HA.01 has been joined by a 9HA.02 unit that offers 41.5% sim-ple cycle efficiency and 61.4% combined cycle efficiency. The 9HA.02 gas turbine has a simple cycle rating of 470MW net base load output compared to 397MW rating of the .01 model.

In a 1x1 configuration the 9HA.02, combined cycle performance is rated at 701MW net plant output, compared to 592MW rating of the 9HA.01 plant, and 61.4% net efficiency. In a 2x1 configuration, com-bined cycle output of the 9HA.02 plant reaches 1398MW.

For 60Hz markets, GE offers the 7HA.01 gas turbine rated at 275MW net base load output and 41.4% simple cycle efficiency. In 1x1 com-bined-cycle configuration, the 7HA.01 plant – initially launched as the FlexEfficiency60 in September 2012 - is rated at 405MW net plant output and 61.1% efficiency, while 2x1 7HA.01 gas turbines are rated at 813MW and 61.2% efficiency.

The 7HA.01 also sits alongside a brand new 7HA.02 machine which is rated at 330MW and has a net combined cycle efficiency of more than 61%. In a 1x1 combined-cycle configuration, the 7HA.02 is rated at 486MW and 61.1% efficiency, the 2x1 configuration is rated at 976MW and 61.2% efficiency.


Due to the 12GW of wind on the ER-COT grid, Exelon wanted a flexible plant. Low turndown and fast ramping while maintaining efficiency and low emissions are highly valuable on the ERCOT grid. Despite the large volume of wind on the ERCOT grid, the 7HA.02 gas turbines were evaluated based on an operating profile of 7000 hours baseload operation and 150 starts per year, starting three times a week for 47 hours at a time. However, the units were also evaluated on a differ-ent mission mix, which included low turndown and fast ramping. Jimmy Porch, a spokesman for Ex-elon, said the units are expected to come on line near the projected need date identified by ERCOT to meet re-serve requirements. “Therefore these units will have similar impact on

Exelon 2x1 7HA.02 layout. Drawing shows arrangement of the gas turbines, HRSGs, steam turbine and cooling towers.

2x1 7HA.02 combined cycle. Gas turbines and steam turbine can reach full load output within 30 minutes of start command.

100%

80

60

40

20

0

0 5 10 15 20 25 30

PlantOutput

2x1 7HA.02Combined cycle

30% load in 7 minutes

66% load in 10 minutes

Full load in 30 minutes

Minutes to Full Load


prices (and therefore existing assets – ours or competitors) as any other new build that would have otherwise been built to maintain the ERCOT reserve requirement,” he said. “We’re looking to expand in Tex-as due to the increasing demand for electricity in the state, projected fu-ture load growth and excellent market conditions. The new units will add more than 2000MW of operational capacity to our fleet, 1104MW and 1085MW at Colorado Bend and Wolf Hollow, respectively, and will provide reliable sources of generation to help the state meet its future energy de-mands.”

Steam cooling is deadGE’s ability to achieve thermal ef-ficiency with air cooling comes from: improved blade aerodynamics im-ported from its aircraft engines busi-ness; better thermal barrier coatings; improved hot gas path components

to reduce stress and temperature; heat transfer improvements; and last but not least, improved cooling flows. The latter is achieved by the use of thousands of tear-drop shaped holes, as opposed to the hundreds of circular holes used in previous designs. So, does the vorsprung durch tech-nik (progress through engineering) achieved in air cooling mean steam cooling is dead forever? “We have no plans to offer a new steam-cooled tur-bine for the foreseeable future,” says DeLeonardo, who suggests GE could readily retrofit its “historical” steam-cooled 7H/9H turbines to air-cooled 7/9HA units. “When you have a fleet of only six machines, spare parts and O&M productivity is not high, although GE supports all our units in the field. One can understand that as both units are within 1% of the output of each other, that if the customer wanted to flip from the original steam cooled H-

class to the new HA.01, it would be relatively straightforward.” The original H-class models fa-mously incorporated steam cooling on rotating parts, which was noth-ing if not technologically advanced. GE is also incorporating some eye-catching technology in the new HA class gas turbines, namely additive manufacturing, popularly known as 3D printing.

3D printingCurrently additive manufacturing ex-tends to factory tooling and fixtures. However, General Electric has a two-fold plan for extending the application of 3D printing to the HA gas turbine series. One is printed parts, says De-Leonardo. “The challenge here is to be able to print an alloy that can withstand the high temperatures, but we have made some major strides in the past 18 months; the second part is to fab-

ElectricGenerator

ElectricGenerator

ElectricGenerator

SteamCondenser Dry Fin

Fan Cooler

Compressor

Dew PointHeaters

Steam Turbine

Ammonia Storage and Distribution

Natural Gas from Pipeline

Water

Water

Air

Air

Water Steam

Exhaust

Exhaust

Steam

Steam

Combustor

Combustor

TurbineHRSG including SCR

and Oxidation Catalyst

HRSG including SCRand Oxidation Catalyst Turbine

Compressor

Exelon 2x1 7HA.02 combined cycle. Plant will be powered by two natural gas-fired 330MW 7HA.02 turbines equipped for dry low NOx combustion, two HRSGs with SCR and oxidation catalyst, single steam turbine generator nominally rated at 500MW for HRSG operation with supplementary duct firing.


ricate blades that have hollow cored passages.) “Today’s standard blade core re-quires a split die that comes apart in a very linear fashion. Once I man-age to print that kind of part, I can do

whatever I want with the airflow. In the long run it amounts to flow sav-ings and better turbine efficiencies, enabling higher temperatures.” DeLeonardo says the name of the game today to achieve these type of ef-

ficiencies is the ability to cool more ef-fectively as you run hotter. “Additive printing will lead to advances in the types of geometries in cooling, which is crucial to improving efficiency.” The most crucial issue with addi-tive manufacturing is getting the right alloys. “We use nickel superalloys to be able to withstand the effects of ageing and creep, so a lot of our focus with printing is on being able to get the right alloys. “When you are heating and layer-ing powder in thin layers, you do not get forging type properties. We must be able to rely on suitable properties to tolerate the environments in which a gas turbine operates.” DeLeonardo says GE is in the process of facilitating capabilities to use additive manufacturing for both printed parts as well as the intermedi-ate step for hot gas path blading and nozzles. What would additive manufactur-ing do to costs? “It can reduce the cost depending on how you use it. “The beauty of 3-D printing is we can do it anywhere, as long as you have the printer and the right material. To increase capacity all we have to do is add printers. We would expect cost productivity with the move to additive manufacturing and replacing things that were built up from piece parts and printing them wholesale.”

Testing, testing While additive manufacturing is something very much to keep an eye on, GE has also spent big on testing facilities to ensure the reliability of its latest H-class machines. At its $200m facility in Green-ville, South Carolina, GE can test 50Hz or 60Hz machines in a non-grid connected testbed, replicating real-world plant conditions with the required accessories to run a fully loaded gas turbine on natural gas and liquid fuel. For each of its first new engines, GE runs tests for three months on variable speed, stalling and straining

Design Parameter 1x1 7HA.02 1x1 7HA.01Net plant output *486 MW *405 MWHeat rate (LHV) 5580 Btu/kWh 5580 Btu/kWh 5892 kJ/kWh 5892 kJ/kWh Net plant efficiency *61.1% *61.1%Gas turbine power 328.1 MW 273.4 MWSteam turbine power 164.1 MW 136.8 MWNominal gross output 492 MW 410 MW

Design Parameter 2x1 7HA.02 2x1 7HA.01Net plant output *976 MW *813 MWHeat rate (LHV) 5570 Btu/kWh 5570 Btu/kWh 5878 kJ/kWh 5878 kJ/kWhNet plant efficiency *61.2% *61.2%Gas turbine power 656.2 MW 546.8 MWSteam turbine power 331.2 MW 276.0 MWNominal gross output 987 MW 823 MW

1x1 Combined Cycle specs. Design ratings for both plants are calculated for 1.2 inch Hg condenser pressure and air cooling tower.

2x1 Combined Cycle specs. Design ratings for both plants are calculated for 1.2 inch Hg condenser pressure and air cooling tower.

*Net of gas turbine, HRSG, steam turbine and CC plant auxiliary system losses.

*Net of gas turbine, HRSG, steam turbine and CC plant auxiliary system losses.

7HA.02 gas turbine model. Air-cooled H-class gas turbine is ISO rated at 330MW base load output and 41.4% simple cycle efficiency with an exhaust flow of 1522 lb/sec and 1146°F temperature.


it to its limits (which requires around 4000 sensors on the engine under test. “The ability to fully test the full system as opposed to building a pro-totype, putting it on site and running a field test has been a very different approach for us, and it’s greatly ap-preciated not just by customers but also financiers and insurers,” says De-

Leonardo. “It’s been through that in-vestment in validation capability and the ability to put our turbines through the mill beyond what they would see in the field which has enhanced prod-uct acceptance. “That’s a huge part of making sure our products are reliable. There is no point in jamming up efficiency for the sake of it – it has to be reliable.”

Potential usersIt would be expected that the HA machines are best suited for utility-scale and high fuel hour markets be-cause of the efficiency advantage. But as GE points out: “Here we have Exelon with an IPP type project in a low fuel hour market as the launch for the 7HA.02. “So it’s both IPP and utility-scale power and it’s low and high fuel hour markets. Recent orders and commit-ments bear out this value in places like the US, Mexico, Brazil, the Mid-dle East and also Asia, where you ab-solutely must have over 60% efficien-cy to use an LNG fuel that costs $16/MBTU. “When you put together capital and fuel productivity with higher efficien-cy, HA gas turbines can compete all the way down to $2 fuel.” n

Power Block 7HA.02 7HA.01GT simple cycle plant 330 MW 275 MW1x1 combined cycle 500 MW 400 MW2x1 combined cycle 1,000 MW 800 MW3x1 combined cycle 1,500 MW 1,200 MW

60Hz power blocks. Between them, the 7HA.01 and .02 gas turbine platforms blanket industry project requirements ranging from 275MW to 1,500MW of base load power.

New engine test regime. Three-month long schedule of testing the first of a new design models subjects the engine to dynamic loads in excess of operational performance limits to insure engine reliability and flexibility.


US independent power producer Panda Power Funds recently

started up its Temple I combined cy-cle power plant near Austin, Texas. The 758 MW combined cycle gas tur-bine (CCGT) power plant is:

oThe first Flex-Plant in Texas, ad-dressing the need for fast start and ramping.

oFirst use of ‘Shaping Power’ in the US, allowing 10 per cent more power at high ambient temperature.

oCapable of delivering 60 percent of full load in less than 25 minutes.

Texas is one of the fastest growing states in the US, with four of the fastest growing cities in the country. With a population that is expanding at more than 1,000 people per day, de-mand growth is projected to outpace growth in supply. The target reserve margin in the ERCOT transmission system region serving Texas is 13.75 per cent. How-ever, at a load growth rate of 2-3 per cent, Panda predicts that margins will fall to about 5 per cent by 2023. At the same time, the state has a considerable amount of wind power, which calls for flexible conventional power generation to provide support when the wind is not blowing. The scenario creates a perfect op-portunity for investing in gas fired

generation in the Lone Star state. “There’s a big need for power. With reserve margins declining and coal challenged as a generating fuel, we see a great opportunity to capture a first-mover advantage in Texas,” says Bill Pentak, Vice President of Investor Relations and Public Affairs, Panda Power Funds. With ERCOT essentially being an island, unable to import power, Pen-tak believes that its high efficiency CCGT units are the “perfect solu-tion”. Not only will they be high up the dispatch merit order, due to their high efficiency, they will also be able to dispatch power at short notice and ramp up and down. Satisfying the market conditions dictated the choice of technology for Temple I. The plant, being built by a consortium of Siemens and Bechtel, uses Siemens’ Flex-Plant technology. It is the first time the technology is being deployed in Texas and only the third time in the US. Siemens provided the thermody-namic cycle design and power island engineering, delivered the main plant equipment and also has a long-term service agreement for the main gen-eration components.

Plant configurationThe power island includes two SGT6-5000F gas turbines, one SST6-5000 steam turbine, two SGen6-1000A generators, one SGen6-2000H gen-

erator and an SPPA-T3000 instrumen-tation and control system. Siemens also supplied two Ben-son duct-fired heat recovery steam generators (HRSGs) manufactured by NEM USA Corp. The steam turbine produces about a third of the power of the facility with two-thirds from the gas turbines. Each gas turbine has a 13-stage ax-ial flow compressor with can-annular combustors and a 4-stage turbine. The plant has a multi-shaft 2-on-1 con-figuration, where exhaust gas from the turbines enters the HRSGs to gen-erate steam that is then fed to a single steam turbine. The steam turbine, which has a combined HP/IP section with a dou-ble-flow LP section, is designed to use steam at temperatures of approxi-mately 1050°F (565.5°C) and pres-sures of approximately 2400 psi (165 bar). Like each of the gas turbines, the steam turbine, has its own genera-tor. This configuration has the flex-ibility to run the gas turbines without powering the steam turbine (if less power is needed), run only one gas turbine, or run both gas turbines and the steam turbine for full plant output.

Highly flexibleThe Temple I power station is capa-ble of being synchronised to the grid in 10 minutes, making it suitable for complementing Texas’ considerable

Temple I power plant has now started commercial operation By Junior Isles

In addition to being the first Siemens Flex-Plant in Texas, it is the first in the USA to feature Shaping Power for increased power production on hot days.


wind power generation. Baseload is reached in less than 60 minutes. Jacki Engel, Product Line Manag-er, Siemens Energy Solutions Ameri-cas comments: “The plant is really designed with the end user in mind. It will allow Panda to optimize profit-ability and provide reliable, flexible, clean generation for the Texas mar-ket.” The HRSGs are an integral part of the Flex-Plant as they allow un-restricted gas turbine ramping. They are horizontal, three- pressure natural circulation once-through boilers with reheat. Each of the HRSGs is capable of delivering 99.5 kg/s of high-pressure steam at 159 bar and 567°C. The boil-ers are also equipped with supple-mentary firing to help optimize plant performance. The Benson boiler technology es-sentially replaces the thick-walled drum in the HP section of a conven-tional boiler. Eliminating thick-walled components enables the boiler to warm faster, allowing it to receive en-ergy faster from the gas turbine. “We talk a lot about integration and the major components are critical, but maximizing the value of these compo-nents through the bottoming cycle de-sign is what sets the Flex-Plant apart,” says Engel. “Some of the key features of this

integration include a two-stage attem-peration scheme, steam turbine piping warm-up strategy, and an auxiliary boiler that allows the plant to main-tain high metal temperatures over a longer shutdown period so the plant can be started quickly. These are all brought together and controlled by the SPPA-T3000 control system.” Such integration enables Temple I to achieve 60 per cent of its 758 MW baseload power output in less than 25 minutes. In addition to allowing Panda to deliver power to the grid faster, the shorter start time helps to reduce the plant’s emissions footprint. Temple I is able to maintain air compliance standards i.e. carbon monoxide (CO) emissions less than 10 ppm and nitro-gen oxide (NOx) emissions less than 2 ppm. Engel explains: “In a conventional [CCGT] plant, from the start of the gas turbine, you will come up to, say, 25 per cent [of full load] and hold, so you can bring some of your big met-als up to temperature. “But that is not the most efficient place for a gas turbine to hold – not only are you burning fuel but you are also loading up on your start-up emis-sions. The fast start capability brings about an 85% reduction in CO and close to 90% on NOx.” Another attribute that makes the

plant so flexible is the inclusion of Shaping Power in the gas turbine. Ac-cording to Siemens, Shaping Power can boost turbine output by 10 per cent on hot days. “You start to see the benefits of Shaping Power above 70°F,” said Engel. It is the first time the technology is being used in the US. Gas turbines suffer significant de-rating at high ambient tempera-tures. Siemens’ Shaping Power tech-nology allows the gas turbine’s inlet guide vanes (IGVs) to be opened on hot days. This increases mass flow through the engine, and also contrib-utes additional exhaust gas flow for the bottoming cycle, resulting in over-all higher plant output. “Historically this was done only with slow-moving duct firing in the HRSGs, says Engel. “With Shaping Power, the fast-moving gas turbine is filled up first so the topping cycle generates power more efficiently and exhaust energy is also increased since you have more mass flow through the turbine. “On top of that you still have the ability to duct fire, as needed. The result is a lower heat rate for a given megawatt level, with the ability to generate more power output.” Station Site Manager Sean Haus-man points out that “we can gain 1.5-2% of efficiency by sliding in to this

Figure 1. Temple I is online and ready to feed power into the ERCOT grid on demand.


power shaping mode. It leans-out the engine a bit and sure, it shaves [off] a few megawatts of our net capability, but there is an overall improvement in efficiency. “And as demand grows we can eas-ily transition out of this mode within minutes into a typical combined cycle mode and fire our duct burners.”

Steam water cycleCooling for the plant is provided by cooling towers supplied by Interna-tional Cooling Tower Inc. These re-move heat from the cycle through wa-ter vaporization and air circulation. Hotter water from the steam tur-bine condenser is pumped to the top of the cooling tower where it then runs down the ‘fill material’ (essen-tially corrugated plastic). Air in turn is pulled up through the fill material by the large fans and cools the water. The water collects in the cooling tow-er basin where it is then pumped back to the condenser to repeat the process. These cooling towers have twelve (12) individual cells with fans each measuring more than 30 ft. in diam-eter. A Steam and Water Analysis Sys-tem (SWAS) helps control the puri-ty of water and steam in the HRSGs and steam turbine, which is required to be ultra-pure. The plant operators and chemists use the SWAS to verify proper operation of the condensate polisher system and chemical injec-tion systems. There are two main SWAS shel-ters at the facility with a total of 27 sample streams from both HRSGs and the steam turbine. Some 51 analyz-ers measure the chemical properties of the steam and water. For example, they measure pH, conductivity, dis-solved oxygen, sodium, and silica. These elements prevent rust, oxida-tion and/or fouling, or the unwanted material on solid surfaces. The analyzers are extremely ac-curate. For example, the dissolved oxygen analyzer can measure 1 part of oxygen per 1 billion parts of water.

The Temple Plant is permitted as a Zero Liquid Discharge (ZLD) facility, which means no process or wastewa-ter is permitted to leave the site. Most of the water for this plant

is supplied from the City of Temple Waste Water Treatment Plant Facility. It is reclaimed water that would oth-erwise be lost and discharged into the local water streams. This water con-

Figure 2. The once-through HRSGs are central to the plant’s flexible performance.

Figure 3. The SPPA-T3000 control system manages the integrated operation of all of the major equipment in the plant.

CLARCORindustrialair.com | +1-800-821-2222 | +44 (0) 1420 541188

©2014 BHA Altair, LLC. All rights reserved. altair is a registered trademark of BHA Altair, LLC.

And so is our fi ltration expertise.For nearly 50 years, we’ve provided enhanced protection against corrosives and moisture that threaten your gas turbine’s performance. And today, our expertise, fi ltration systems, products and upgrade capabilities are still here to help ensure that your gas turbine not only runs longer, but also runs when you need it to. Salt and sand aren’t going away anytime soon. And neither are we.

Register for our free webinar, High-Velocity Air Filtration Systems, and learn more about altair solutions at CLARCORindustrialair.com.

High-Velocity Air Filtration Systems, and learn

79139 Clarcor Altair O+G Print Ad Pub: Gas Turbine World | Trim: 8.125 x 10.875 Live: 7x10in Bleed: 8.375 x 11.125

79139_CLAR_Altair_PrintAd_O&G_GTW.indd 1 7/15/14 5:21 PM


servation measure helps to conserve a valuable natural resource. The high water quality required to run the plant is met by further treating the reclaimed water through the onsite clarifiers, purification filters and re-verse osmosis units. All process wastewater streams are treated through the ZLD wastewater treatment equipment. Here the waste-water is treated and separated into two process streams. Clean water is recycled back into the process systems for further reuse and the reject water is discharged to the site evaporation pond.

Plant controlThe SPPA-T3000 control system manages the integrated operation of all of the major equipment in the plant to enable fast, flexible operation while assuring all components are operating within their individual design enve-lopes. The control system monitors and processes approximately 9000 data points for the core power island and approximately 2500 more for the rest of the plant. According to Siemens, the control system is designed with a database set up like the worldwide web, which enables the hardware to be easily up-graded as technology changes without needing to change out the whole con-trol system. The logic programmed into this integrated system monitors conditions throughout the plant and provides op-erators with real-time information on equipment status. This information from the control system is remotely monitored at the Siemens Power Diagnostic Center in Orlando, where experts track trends throughout the fleet. A dedicated en-gineer tracks the behaviour of this particular plant and looks for changes over time, which enables early warn-ing of potential problems before they happen. The control room is manned 24/7. Temple 2 will also be controlled from

this same control room. Should there be a need, this plant can be started and stopped from the Power Diagnos-tics Center in Orlando.

Safe constructionBechtel was responsible for the bal-ance-of-plant engineering, overall plant construction, procurement, and led the commissioning of the facility. The plant, which was completed two weeks ahead of schedule, was built on a short time schedule – just two years from ground-breaking in September 2012. Describing the early work, Mike Robinson, Project Manager for Bechtel recalls that “we had about 80,000 cubic yards of excavation. There were about 24,000 cubic yards of concrete and over 1,000 tons of steel that went in across the plant. Construction, basically took place al-most around the clock. We were lit-erally making concrete pours in the middle of the night.” Notably, all the work including some complex heavy lifts of the gas turbine was performed without inci-dent. “For the entire duration of the project [more than 2 million man-hours] there was not a single lost-time accident… There were no injuries and

no incidents around the heavy lifts – and there were some significant lifts. A jack and slide system was used to lift and position the gas turbines. The heaviest lift performed onsite was the steam turbine-generator weighing 375 tons.” In addition to completing the proj-ect without incident and two weeks ahead of guaranteed schedule, Robin-son noted that the plant performance was also better than its guarantees. “We got through performance test-ing in one shot and the reliability and availability were close to 100% dur-ing testing.”

More flexible plantsJust two weeks after the start-up of Temple I, Panda Power also fired up what is essentially a sister project in Sherman, Texas. With Temple I and Sherman up and running, work is now firmly focused on Temple II. This plant is expected to start commercial operation next summer, to add another 758 MW to the site. The projects are part of a growing Panda portfolio of combined cycle projects that demonstrate the impor-tance of flexibility in many parts of the US. n

Figure 4. Steam and Water Analysis System (SWAS) helps control the purity of water.

METKA is a leading EPC (Engineering-Procurement-Con-

struction) contractor for large-scale power generation plants,

well-known for its ability to reliably deliver complex projects

throughout Europe, the Middle East and Africa, often on very

demanding project schedules.

The company has significant experience in gas turbine based

power generation, including combined cycle, co-generation and

simple cycle technology, providing world-class solutions and

optimal performance.

Strong project management skills, together with a complete

range of functional expertise and understanding of interna-

tional markets, give METKA the advantage in meeting cus-

tomer needs. The company excels in fast-track execution,

bringing critically needed power to growing markets.

With over 50 years of experience, METKA is a reliable partner

for utilities, independent power plant developers and local

communities around the world.

E N E R G Y

www.metka.com

Over 6,5GW of natural gas fired plant capacity

is currently under execution by METKA,

in 5 different countries

Empowering the future

206x276_2014.indd 1 25/4/14 2:47 μ.μ.


In July 2014 Caterpillar Inc. intro-duced the latest addition to its new

series of Cat generator sets. Known as the G3520H, this engine is the sec-ond of the H-Series product line now available for operation on natural gas.

The engine, currently offered at 2500 kWe power output at 50 Hz and 60 Hz, is designed to deliver the low-est owning and operating costs in the market in its class and rating. It of-fers:

oElectrical efficiency of 45.3%

oMajor overhaul at 80 000 hours

oOperational flexibility for basel-oad, peaking or island operation

The Cat G3520H was developed to meet customer demands for improved return on investment, extended-duty combined heat and power (CHP) and continuous electric power applica-tions. According to Caterpillar, the G3520H achieves the lowest owning and operating costs through an elec-trical efficiency of up to 45.3% (ISO, 1.0 p.f.) and decreased maintenance costs. Mike Yohe, a Product Line Man-ager responsible for Gaseous Fuelled Generator Sets said: “As you go into medium speed engines obviously you get higher electrical efficiency but you also realize higher initial costs.

At this power range, high-speed engines typically make the most eco-nomical sense and this engine real-izes the lowest owning and operating costs in its class. This comes from increased electrical efficiency but in addition, we took a real look at the overall maintenance and overhaul costs. I haven’t seen any other prod-uct on the market in this power range with break oil consumption as low as the G3520H.” New product developments – in-cluding cuffed cylinder liners, updat-ed valve stem sealing, and increased valve train lubrication – have min-imized the number of maintenance events and reduced oil consumption over previous levels. Caterpillar targets an oil change interval of roughly 2000 hours . Yohe notes: “This is about average for what you would see from other manufac-turers but what you often don’t see is the amount of oil they use to get to that 2000h limit.” The standard G3520H has a low volumetric sump capacity – roughly 605 litres, which, according to Cat-erpillar, is “very competitive” in the marketplace. Caterpillar says it also takes a con-servative view of overhaul and main-tenance schedules. Yohe commented: “We look at our overhaul and mainte-nance schedule in terms of their ‘B10 life’. Basically, this means that when you look at a field population, 10% of the equipment needs to be overhauled at or before the published interval.

A lot of the industry represents their product at a B50 life, meaning that half their fleet requires an overhaul of some kind at or before the published interval. For us, we look at a top-end maintenance schedule of about 20 000 hours, in-frame at 40 000 hours and major overhaul at 80 000 hours at B10 life. I haven’t really seen anyone else achieve an 80 000 h overhaul schedule for a high speed engine of this size.” Yohe points out that the engine’s top-end and in-frame overhauls can be done on site, without the need for an engine swap-out.

Building on a platformThe new engine is the latest mile-stone in more than three decades of engine evolution. Caterpillar’s 3500 series engine platform has been in existence since the early 1980s and has been improved as new technology has become available. The H Series has accumulated more than 100 000 hours and is built on the legacy of the proven G3500 generator set platform, which has over 10 000 MWe of pow-er installed worldwide. The main focus for technology de-velopment over the years has been on improving power density and con-trolling emissions. Each new series in the platform has therefore looked to improve power density and effi-ciency compared with its predecessor in these two key areas. “With the electronics and controls that we can put on these engines also

Gas engine promises lowest owning and operating costs By Junior Isles

Caterpillar’s latest gas engine is claimed to offer the lowest cost of ownership and operation for a gas engine in the 2.5 MW power range


gives us the ability to decrease the cost per kilowatt-hour of the lifecycle cost,” said Yohe. The new engine fills a market gap for Caterpillar, which prior to this did not have a gas product in the 2.5 MW size range. “As for the rest of the H series platform – there is a 16 cylinder en-gine and a 12-cylinder is being de-veloped – we are really going after the best-in-class life cycle cost,” said Yohe.

V20 DesignDevelopment of the H series began in late 2009. Work on this latest V20 en-gine began late 2012/early 2013 and it was released in July 2014 for both the 50 and 60 Hz markets. “The basic recipe for the platform is what takes time,” said Yohe. “And once we have developed the recipe, we have to validate it – not only in the lab but also in the field.” According to Caterpillar, the 16 cylinder version accumulated over 80 000 hours of operation to validate the platform. Yohe added: “To validate the 20-cylinder version, we only had to essentially validate the other four cylinders, so it required less hours but you are still in the 15-20 000 hour range for validation of the lower own-ing and operating cost and service maintenance intervals.” While this is ongoing, technical data work is being undertaken in the lab to verify parameters such as emis-sion levels when using different fuels, altitude and ambient temperature ca-pabilities, etc. The G3520H has been designed for increased power density. The in-creased power density of the genera-tor sets provides a compact size that helps reduce installation costs. The V20-cylinder engine has a 170 mm bore and stroke of 215 mm. Cat-erpillar notes that there have been a number of improvements that enable the increased electrical efficiencies and better operational cost. It has a new long-stroke engine de-

sign that features higher-compression ratio steel pistons, and a high-efficien-cy turbocharger and electrical genera-tor. Another major theme was reduc-ing the amount of unburned hydro-carbons. “There is legislation on un-burned hydrocarbons in Holland that we meet with this product,” notes Yohe. The G3520H is a spark-ignited with a traditional lean-burn type de-sign. Multiple NOx emissions settings are available, including 500 mg/Nm3 (1.1 gm/bhp-hr) NOx and 250 mg/Nm3 (0.55 g/bhp-hr) (50 Hz). As is common in many spark-ig-nited, lean burn engines, Miller tim-ing is used to control combustion and NOx formation. The Miller cycle dif-fers from the more traditional Otto cycle in that the intake valves close not when the piston reaches bottom dead centre but at typically 10 to 15° before bottom dead centre. This ad-justment in the combustion cycle by itself can increase fuel efficiency by about one per cent. The Miller cycle can be configured as early inlet valve close (EIC) or a late inlet valve close (LIC) version. The EIC camshaft configuration is used on most gaseous-fuelled heavy-duty engines. As the piston contin-

ues downward with the intake valves closed, the air/fuel mixture expands and thus cools, increasing the detona-tion margin. When detonation (‘knocking’ caused by uncontrolled combustion) occurs, the flame front begins to spread from the spark plug, but as the fuel oxidizes and pressure builds up, “end gases,” typically at the outside edges of the cylinder, combust sponta-neously. Depending upon the level of detonation, this can greatly increase the cylinder pressure, possibly to the level of damaging cylinder compo-nents. A greater detonation margin in turn enables a higher compression ratio of 14:1 or 15:1, versus 11:1 or 12:1 for the Otto cycle. The higher com-pression ratio allows for a higher ex-pansion coefficient in the cylinder, making better use of fuel and increas-ing fuel efficiency. Delivering a full air-fuel charge in a shortened intake interval requires more efficient turbo-chargers that deliver rapid airflow. The new engine features an open combustion chamber design, which allows use of a low-pressure fuel sys-tem (0.5 to 5 psi/ 10 to 35 kPa) that facilitates maximum performance on pipeline natural gas. “It is designed as a pipeline natu-

G3520H engine. The 2.5 MW G3520H was launched in July this year for the 50 and 60 Hz markets.


ral gas engine,” said Yohe. “Methane numbers are typically between 55 and 100.” In gases where there might be higher hydrogen sulphide (H2S) there are stainless steel after-cooler core options to mitigate the corrosion ef-fects. “When you get up into the 15-30 ppm hydrogen sulphide range, you can build in the capability to absorb some of that acid that could be cre-ated. This, however, is likely to have an effect on oil change intervals… but it would be manageable.”

Operational performanceThe engine is capable of fast starts and can operate in island mode. In terms of ramping, it can accept load steps of around 30%. For applications isolated from a primary electric utility, Caterpillar says the G3520H offers “industry-leading” load acceptance capability. “These engines can typically be on line in 30 seconds and near full load in that time if ramping load.” notes Yohe. This makes it suitable for support-ing wind generation. “We have seen interest in this from the peaking in-dustry – either at the end-use level or at the utility level. In fact one of the first applications for the engine is at a utility in Utah, USA. It is being utilized as a peaking unit that is pro-viding online power to the grid most of the time but is capable of being isolated and running in parallel with other gensets to basically create a lo-cal grid,” said Yohe. In the Utah utility application, the engine is installed at about 5400 ft (1646 m) but notably performance is not compromised at higher altitudes and ambient conditions. The engine has updated turbocharger trim options making it capable of running at alti-tude with similar operating charac-teristics. “There is a version that is designed to run at high altitudes with minimal power derates and a loss of only a couple tenths of a per cent in efficiency,” noted Yohe.

Essentially the engine is available in three configurations – a high re-sponse, high efficiency and high al-titude version – providing the flex-ibility for the engine to be applied in multiple locations and varying operat-ing conditions.

Easy integrationReduced time for commissioning and the associated costs has been a focus of the design. According to Caterpil-lar, the plug and play design enables users to integrate it more easily with their balance-of-plant. “Customers say they have noticed a big difference in the amount of time it took to get the unit up and running,” said Yohe. The G3520H generator set is easily tailored to specific applications with a wide selection of Cat SR5 generators and attachments, premium controls, exhaust options, remote annunciator modules and battery chargers. With these features, the new gen-erator set provides a robust power source that is also easy to install and commission. The G3520H also features easy in-tegration with building management systems, using a non-proprietary com-munication infrastructure from Cater-pillar’s new EMCP4.3 generator set controller. The expanded set of fea-tures from Caterpillar also includes a complete gas train, package-mount-ed air cleaners and simplified wiring connections. The new generator set as well as the associated electrical and mechani-cal equipment required to complete a fully functional CHP plant are being sold and supported through the global Cat Dealer network.

ApplicationsSo far, interest in the new engine has been for a mix of peaking and cogen-eration applications. Caterpillar notes that a number of H series products are also being used in standby applica-tions, where they can also be run in island mode. Caterpillar notes that the unit in Utah can be used in peak-

ing mode or for “storm avoidance”, whereby if the grid goes down in a storm, the engine can operate in is-land mode to provide power. The engine, however, is primarily targeted at high-hour, baseload appli-cations and is therefore designed to be effective in continuous-duty ap-plications. It can be used in indus-trial and commercial facilities such as hospitals, data centres, manufacturing plants and greenhouses, as well as in distributed generation power plants. Michael Devine, Gas Product Mar-keting Manager said: “We do a lot of CHP work with these products in many different markets, it just de-pends what the applications are. It could be heating and/or cooling – co-gen/trigen. It could even be quadgen where you take the CO2 from the unit for greenhouse applications, for ex-ample, or where the CO2 is used for improving plant growth.” The temperature of the heat recov-ered from the engine for CHP depends on the application. “Basically you would have different temperatures be-cause of the lean burn design. You can reduce NOx by reducing the tem-perature in the exhaust so an engine operating at 500 mg/Nm3 would have a higher exhaust temperature than one running at 250 mg/Nm3,” explained Devine. Currently there are a total of five 20-cylinder installations in the field to assess and validate the engines. Caterpillar currently has “an endur-ance unit” running at its offices in La-fayette that not only helps offset some of its energy costs but also allows the company to collect running data on the engine. “We have a G3520H at our facility which runs 24/7. We col-lect data and it reduces our cost of operation by providing us with lower cost electricity,” said Devine. There are also a number of addi-tional units on order. Caterpillar says it is running ahead of schedule in terms of the number of units being ordered and therefore expects to see “ a lot more activity in the 6-8 months”. n

Software companies come and go, sometimes in the middle of a project. They change ownership, outsource development and support, or just disappear.

Thermoflow, by contrast, has always been a group you can rely upon. Independent, under the same ownership for 25 years, responsible only to you, the customer.

Our philosophy is old-fashioned. Just make high quality software products, keep maintaining them well, and keep supporting our customers well.

Nearly every year since 1987 a new version of the Thermoflow suite has been created with ever increasing capabilities and user-friendliness. About 300,000 hours of top engineering talent have been invested in the process. Yet, despite the vast enhancements in scope and capability over 25 years, new versions are back-compatible with older ones. For example, the latest release of GT PRO can read a file saved in 1992. How many software products show this level of stability and respect for their customers’ legacy?

No matter if your interest is combined cycle, conventional coal gasification or solar thermal, no matter if your application is district heating, cogeneration or desalination, Thermoflow’s heat balance design and cost estimation software suite offers you the stable solution!

+1 508 303 5033 [email protected] www.thermoflow.com

Knowledge = Power


PW Power Systems recently com-pleted design validation and ac-

ceptance testing of its first production FT4000 gas turbine engine in prepa-ration for start of shipments next year. At its initial introductory rating, the FT4000 delivers roughly twice the unit output of the FT8 engine series and almost 15% better fuel efficiency. Key design and performance features of the FT4000 SP 60 and 120 pack-aged plants:

oIntro ratings. Single and twin gas generator genset packages nominally rated at 61.2MW and 122.4MW re-spectively and 40.4% simple cycle efficiency.

oSpinning reserve. Normal starts of less than 10 minutes to full gas tur-bine output with the ability to change load up or down at >30 MW/min ramp rate.

oTurndown range. Operational part-load capability down to 50% output for the SP 60 genset package and 25% plant output for the SP 120 genset.

oWet compression. With power boost option the SP 60 and SP 120 plants are nominally rated at 70MW and 140MW respectively and 41.3% efficiency.

The new FT4000 gas turbine en-gine is leveraging its advanced aero design efficiency, power density (kW per lb of air), compact footprint as well as operating flexibility to com-

pete for 50/60-Hz electric utility and industrial cogeneration markets for replacement and new capacity instal-lations. PWPS is also promoting its pre-as-sembled and factory inspected modu-lar plant design which has adopted a similar module arrangement and in-stallation template developed for the proven FT8 SP 30 and 60 gas turbine plant series. It allows simple cycle plants to be erected (on waiting concrete founda-tions), commissioned and operational within 10-12 weeks of on-site delivery. The FT4000 SP gensets will have a lower $ per kW installed price than the FT8 units, says PWPS Vice Presi-dent Charles Levey, while providing higher efficiency and lowering cost of

electricity.

Active project orders To date, PW Power Systems has se-cured two firm orders for the FT4000 gas turbine engines. One is for a SP 60 generator pack-age (equipment only) to power a base load plant located in Argentina; the second is for a SP 120 peaking plant (turnkey contract) located in the Unit-ed States. Both plants are currently under construction with commercial opera-tion planned in 2015. The FT4000 SP 60 plant is being built in Santiago del Estero by Gener-acion Frias, a subsidiary of the Alba-nesi Group, while the FT4000 SP 120 plant is being developed as a turnkey

Introductory FT4000 SP 60 rated at 61.2MW and 40.4% efficiency By Michael Asquino

PW Power Systems is introducing its new aero-derivative FT4000 gas turbine with water injection to reduce emissions and wet compression option for a 15% boost in power output.

FT4000 gas turbine engine. The aeroderivative FT4000 delivers about twice the unit output of the FT8 and close to 15 percent better fuel efficiency.


project by Constellation Energy in Aberdeen, Maryland. Energy Services Inc., a group company of PW Power Systems, was awarded the engineering, design and construction management and com-missioning contract for the project. Successful completion of initial verification testing conducted at Pratt and Whitney jet test facilities in Q3 of this year have paved the way for com-mercial operation at both customer launch sites, the earliest of which is anticipated in June 2015.

Operation and maintenance One major operational advantage of dual engine FT4000 SP 120 plants is that one gas generator can be shut down for maintenance while the paired gas generator remains opera-tional, allowing continued plant gen-

erating capacity at power levels equal to 50%. By the same measure, either of the gas generators can be readily removed

for major overhaul and a spare unit installed in its place in a short time, without having to shut down the en-tire plant. n

Swiftpac power plant package. Pre-assembled and tested modules can be quickly installed on concrete foundations and inter-connected. Entire plant can be erected, commissioned and operational within 10-12 weeks of on-site delivery.

Nominal Performance FT4000 SP 60 WC OptionWet compression option Off OnGross output 61,236 kW 70,005 kWHeat rate (LHV) 8450 Btu/kWh 8265 Btu/kWhEfficiency 40.4% 41.3%Exhaust flow 361 lb/sec 391 lb/secExhaust temperature 805°F 797°FWater flow 57 gpm 75 gpm

Simple cycle FT4000 SP 60. Genset package for 50/60-Hz operation has an introductory rating of 61.2MW and 40.4% efficiency on natural gas fuel. Wet compression option offers close to a 15% boost in power output.

One Screw Compressor.Two Ways to Save.

Ask Kobelco! The Best Solution for Any Gas Compression.

Kobelco Compressors America, Inc.Houston, [email protected]

Kobe Steel, Ltd.Tokyo +81-3-5739-6771Munich +49-89-242-1842

www.kobelcocompressors.com

No Standby RequiredStill thinking about recip or centrifugal compressors for fuelgas boosting? A Kobelco screwcompressor is so reliable, you won’tneed to buy a spare. What’s more, thescrew design is inherently more economical to maintain. You’ll get around six years of continuous operation between overhauls. Plusyou’ll have only one machine to maintain.

Save on PowerKobelco screw compressors

feature an innovative slide valvethat substantially reduces power

consumption – without steps – tohandle fluctuations in turbine load

(turndown range: 100% to 20%) and suction pressures (up to 1,500 psig/100 barg).So you’ll continue to conserve power andreduce costs every day.

FUEL GAS BOOSTING COMPRESSORS FOR GAS TURBINES

2WaysToSave_Ad_GasTurbine_Full Page Ad 1/16/12 5:17 PM Page 1

INTRODUCING – HYPERION POWER SERVICES

The new year brought the launch of Hyperion Power Services (HPS), a unique consulting group dedicated to serving the global power industry.

As a U.S. subsidiary of Hyperion Systems Engineering Ltd., HPS has emerged with a cadre of experienced industry veterans and key strategic alliances to offer clients a wide spectrum of solutions including owner’s engineer services, project management and control, engineering analysis, permitting support, plant testing and commissioning, and other specialized power-related capabilities.

Hyperion Power Services...new solutions for rising power challenges.

Contact: George Kassianides, President | +1 407 878 0018 | [email protected] | hyperionsystems.net

Look to future issues of Gas Turbine World for more information.

A New Day Has Dawned...

Documents

September – October 2014 · PDF fileSeptember – October 2014 Gas Turbine World (USPS 944760, ISSN 0746-4134) is published bimonthly in addition to the GTW Handbook annual by Pequot