GE Energy gas engines
2 0 1 1
I s s u ecogen 05
Two-stage turbochargingThe next gas engine generation
Eastern Europe and Russia special Major raw material reserves with enormous potential
24/7 serviceA 168-hour week in the service of our customers
editorial
president story 03Combining three powerful offerings
technology and product news 05The next gas engine generation
The J624 with two–stage turbocharging
Plant Maintenance 2.0 – the myPlantTM virtual service
GE’s Waukesha 275GL+ gas engines for power generation
industry news 13An imminent growth leap for decentralized energy supply
applications and solutions 15Heat Recovery Solutions Technology a perfect fit
South African industry booming; reliable power supply needed
Waukesha rich-burn engine delivers energy independence
distributors and service providers 21Holistic energy solutions for power generation in Eastern Europe
Complete solutions are the key to Filter´s success
region special 27Speeding up in Eastern Europe and Russia
Coal bed methane – a subterranean energy treasure
success story 33More power for the automotive industry
GE‘s Jenbacher gas engines cited for energy efficiency
GE’s Waukesha gas engine still going strong in Chile
service 3924/7 service
supply chain 41Area 53
personality story 43An interview with Scott Nolen,
product line leader of GE‘s gas engines business
feedback and masthead 45
cogen2.0 46
Dear Reader,
02
editorial cogen
This edition of our magazine bears
a new name, as “coJen” has become
“cogen.” This change reflects the fact that in
recent months, GE Energy’s gas engines
division has been enlarged considerably
with two acquisitions, and now stands for
cogeneration to an even more comprehensive
extent. In addition to electricity generation
with Jenbacher and Waukesha gas engines,
Heat Recovery Solutions provides efficient en-
ergy recovery from waste heat. It’s not just our
customer magazine that has a new face. We are
also pleased to introduce Rafael Santana, the new
leader of GE Energy’s gas engines division.
Highlights of this edition include a presentation of
two-stage turbocharging, representing yet another
genuine quantum leap in the history of Jenbacher
gas engines. In addition, we feature the new 275GL+
from Waukesha. By ensuring reliable operation in
the challenging oil and gas business with the addition
of Clean CycleTM, the 275GL+ showcases efficient
solutions for electricity generation from waste heat
for the low output area. Look for the Region Special,
dedicated to Eastern Europe and Russia. GE Energy
is already well-equipped to deal with the demands
of these important, high-potential
regions with a full coverage network
of 5,700 employees.
We would like to take this opportunity
to thank you for the extensive mail
that we receive following each issue of
the magazine. We welcome all letters
and, as a gesture of appreciation, will
enter your name into our super prize raf-
fle. On behalf of the entire editorial team, I
wish you exciting and instructive reading.
Yours sincerely,
Martina Streiter
Communications
PS: In this edition, for the first time, we are
thrilled to offer you an opportunity to experi-
ence “augmented reality” first-hand. Simply
hold the icons at the end of the individual
articles in front of your integrated web
camera. You can learn more about cogen2.0
on the inside back cover. _
cogen2.0
03 04
Changes are happening with GE’s gas engines business. First, GE is forming a new integrated
gas engines division after acquiring heat recovery technology from Calnetix Power Solutions
(CPS) and adding Dresser’s Waukesha gas engines business. And not only has GE placed these
units under one umbrella, along with the Jenbacher gas engines product line, it also has
appointed Rafael Santana, former CEO for GE Energy in Latin America, as the new president
for the gas engines business. He succeeds Prady Iyyanki, who leaves after five years leading
GE’s Jenbacher gas engines business to become vice president for turbomachinery within
GE Oil & Gas.
Combining three powerful offerings
COMMITED TO INVESTING IN TECHNOLOGY. After the economic
downturn, the gas engines industry is growing again, and
customers are looking for short delivery times and high-efficiency,
fuel-flexible offerings. GE Energy’s gas engines business emerged
from the downturn in a very good position, as GE made key busi-
ness investments during the last two years: It continued to invest
in the business even in the downturn, made the Heat Recovery
Solutions and Dresser acquisitions, and announced two major
technological milestones to the public.
“Our new expanded gas engines business is an ideal platform for taking these three
product lines to the next level.”
The first innovation was the updated J624, the first gas engine in
the world featuring the power boost of two-stage turbocharging
technology. Since it offers great performance in hot and humid
conditions or at high altitudes, the new J624 significantly improves
operating efficiency. The second innovation that GE invested
heavily in and, which soon will be fully launched commercially, is
GE Energy’s largest gas engine to date: the 9.5MW output J920 –
again featuring two-stage-turbocharging technology – gives GE a
more comprehensive offering targeting the growing Independent
Power Producer (IPP) segment. With the successful testing of the
first J920 units in Austria, the start of serial production of this new
flagship engine model is planned to start 2012.
The new ideas don’t end there, because a number of key
technological innovations for power generation – including a
strong expansion in service offerings – are under
way across all three gas engines business units.
INTEGRATING FOR GROWTH. Given their obvi-
ous synergies, it was a logical decision to bring
all three businesses together. Inherent in this new
structure is a strategy to accelerate and improve
technology developments and market penetra-
tion for the overall gas engines business. The
good news for customers is that this will make
more and better solutions available to them for
a wider variety of industrial applications.
By combining power generation offerings for the
gas engines business into one product line, GE
can expand its customer outreach and create a
unified and an even stronger services network
in that sphere. The integration will help make GE
a true one-stop-shop provider for all currently
relevant gas engines applications for power
generation and mechanical drive, and the Heat
Recovery Solutions technology enables GE to of-
fer comprehensive Organic Rankine Cycle (ORC)-
based solutions for the smaller output range.
From the former Dresser Waukesha business,
GE not only receives 600 additional employees
– including a highly experienced engineering
team – but also an installed base of more than
20,000 engines in the field. Rafael Santana sums
up the changes this way: “Our new expanded gas
engines business is an ideal platform for taking
these three product lines to the next level so that
we can serve our customers even better with
technology and services that meet their demand
for availability, reliability, fuel efficiency and low
emissions performance.” GE’s strong installed
combined fleet has coincided with the growing
global interest in gas engine technology to make
the new gas engines division a reality.
COMPLEMENTARY STRENGTHS. Because the
product, technology and expertise bases of the
Jenbacher and Waukesha segments mesh to-
gether so well, GE can be an even better player in
the gas engines sector globally. Santana asserts
that Waukesha’s compression expertise and the
complementary relationship between its power
generation capabilities and “the Jenbacher
domain knowledge and footprint” put both busi-
nesses in great shape for the future. More specifi-
cally, the Waukesha segment’s compression and
mechanical drive technologies and applications
add to GE’s gas engine offerings and allow GE
to achieve deeper penetration of its gas engine
technology into the oil and gas arena. Building on
president storyen cogenpresident storyencogen
Gas engines business is evolving
about Rafael Santana:
Current Position:
President – gas engines, GE Energy
Previous Positions:
· CEO for GE Energy Latin America
· President – Latin America, GE Transportation
· Product Manager - Off Highway Vehicle
Division, GE Transportation
· Marine and Stationary Power Regional
Manager – South America, GE Transportation
· Commercial Leader – GEVISA,
GE Transportation Systems
South America – GE Transportation
· Rafael spent another seven years at British
American Tobacco and Exxon Mobil in
various roles.
the Waukesha technologies will directly benefit
GE’s Oil & Gas customers, who need small-scale
compression as well as power generation solu-
tions. Now, GE can marry the Jenbacher product
line’s fuel flexibility and high efficiency with the
Waukesha line’s low emissions and reliability to
bring more gas engine solutions to petrochemi-
cal, mining and manufacturing customers. Also,
both the power generation and compression
segments have a strong service base and
continuously work to expand service offerings
so that customers are assured of getting the
quality and expertise that only the original equip-
ment manufacturer can offer. “This is what the
customer remembers,” Santana stresses. “We
need to provide a competitive quality product
with full services support. That will be key for our
business units to continue to be successful in
the long run.” The heavy involvement of GE’s gas
engines customers with renewable energy is a
major driver for the integration of Heat Recovery
Solutions into the gas engines business.
“We are now well-positioned to become the industry’s
waste-heat-to-power expert.”
Heat Recovery Solutions’ product development is
in an early stage, but the business brings a great
deal of innovative technology in a new space to
GE. By combining waste-heat-to-power tech-
nologies from Heat Recovery Solutions with the
technical and distribution capabilities of GE’s gas
engines business, GE can provide best-in-class,
comprehensive solutions to its power generation
customers engaged in waste heat recovery ap-
plications. With GE already boasting an array of
gas turbines and engines that use waste gases,
Santana believes the linkage with Heat Recovery
Solutions will bolster GE’s gas engines reach even
more. “We are now well-positioned to become
the industry’s waste-heat-to-power expert,” he
proclaims.
A LEGACY OF GROWTH. Santana is taking on
a gas engines business that has experienced
impressive growth. He observes, “We have grown
significantly through increased globalization,
services and product portfolio expansion, includ-
ing the recent acquisitions of Heat Recovery
Solutions and Waukesha gas engines.
We have a tremendous opportunity in front of
us to continue growing this business with unique
and flexible offerings.” _
Rafael Santana,
president of gas engines, GE Energy
Conceptualdesign Simulation
Single cylinderengines
Final designed multi cylinder test engineand pilot engines at customer sites
Component tests
J624 Two-stage turbochargedReleased product
J624 Single-stage turbocharged
0605
developed turbocharger unit consists of a low-
pressure compressor with subsequent intercool-
ing, a high-pressure compressor with charge-air
cooling and the corresponding high- and low-
pressure turbines on the exhaust gas side.
THE ADVANTAGES. Due to the new two-stage
turbocharging, gas engines will get a much bigger
role in the decentralized energy supply.
The applications are ranging from temperate
latitudes and Arctic regions to hot and humid
tropical climates. Two-stage turbocharging in
combination with the Miller cycle allows a charg-
ing air temperature of more than 158°F(70°C) at a
mean effective pressure of 24 bar. This prevents
mixture condensation even under tropical ambi-
ent conditions, and the engine can also provide
maximum performance even under extreme
climatic conditions.
In the case of the J624, the new technology also
facilitates a 10 percent increase in electrical
output, a 1 percent point rise in efficiency and a
simultaneous reduction in emissions. In combina-
tion with cogeneration, two-stage turbocharging
THE DEVELOPMENT. Jenbacher gas engines are characterized by
their extremely compact design and consist mainly of a basic en-
gine, a generator and an auxiliary unit including the turbocharger.
The engines of the type 6 series operate with an air/fuel mixture
provided by an external upstream mixer, turbocharging, a Miller
cycle, a lean combustion system and a scavenged pre-chamber.
“The new two-stage turbocharging advance constitutes a genuine quantum leap and will
enable us to continue to play a pioneering role in the creation of new technologies.”
– Volker Schulte, general manager engineering of GE´s gas engines division
Especially the Miller cycle and the lean combustion system are
reducing the knocking tendency and ensuring a stable engine
operation, but require a higher charging pressure.
With a Miller cycle, the inlet valve closes earlier, reducing the
filling time and causing incomplete filling of the combustion
chamber, which results in power loss. A higher charging pressure
allows filling the combustion chamber in a shorter time and even
with higher mass, resulting in further increased engine output
potential. Two-stage turbocharging was developed specifically to
achieve this higher charging pressure, and this technology is also
a strong contributor to increase engine efficiency.
Volker Schulte, general manager engineering of GE´s gas engines
division and responsible for the development, is highly enthusi-
astic: “We had progressed so far with the previous engines that
we had reached the development limits. The new two-stage
turbocharging advance constitutes a genuine
quantum leap and will enable us to continue
to play a pioneering role in the creation of
new technologies.”
THE TECHNOLOGY. At present, turbocharger
suppliers offer single-stage charging up to a
pressure ratio of around 6. If higher pressure ra-
tios (charging pressures) are needed, the single
stage turbocharging system requires the use of
expensive compressor material and at the same
time the charging efficiency would significantly
drop below 60 percent.
For these reasons, GE decided to develop two-
stage turbocharging, which offers a charging
efficiency of more than 75 percent. The newly
· 10 percent increase in efficiency
· Enhanced electrical efficiency
· Far lower emission levels
· Improved engine use under
extreme climatic conditions
· CHP efficiency of 90 percent
· Excellent basis for further developments
technology and product news cogentechnology and product newscogen
The next gas engine generation GE’s gas engines division has once again demonstrated its leadership in the field of gas engine innovation. Because of
their efficiency, low emissions, fuel flexibility and natural gas availability, stationary gas engines are playing an increas-
ingly important role in the decentralized energy supply. These benefits have now been further enhanced by two-stage
turbocharging. Introduced by GE in 2010, two-stage turbocharging allows the new Jenbacher J624 and J920 gas engines
to reach electrical efficiencies of 46.5 percent and 48.7 percent, clearly demonstrating GE’s leadership in innovative gas
engine technology.
ILLuSTRATION OF SYSTEM ENGINEERING DEVELOPMENT
facts and figures:
can result in an improvement in overall efficiency
to as much as 90 percent.
THE FuTuRE. Despite continuous development
over many years, the potential of large, stationary
gas engines is far from being fully exploited.
The intelligent combination of innovative, tech-
nological elements and the new cornerstone of
two-stage turbocharging permits crossing of old
boundaries towards higher mean effective pres-
sures, improved efficiencies and extended areas
of application. However, this promise can first be
realized through the simultaneous optimization
of charge exchanges, valve timing, combustion
processes and control concepts.
The J624 is impressively demonstrating this
with an electrical efficiency of 46.5 percent at
4.4MW output and adherence to the Technical
Instructions on Air Quality Control (TA Luft), and
it forms the basis for a new GE engine genera-
tion. In fact, GE continuous to employ two-stage
turbocharging in the recently-developed new
J920. In the near future, efficiency levels close
to the 50 percent mark and NOx raw emissions
of less than 200 mg/Nm³ (5 percent O2) will be
possible. Moreover, these features will naturally
be combined with the same degree of robustness
and reliability that has for decades characterized
GE’s Jenbacher gas engines. _
FuNCTIONAL DIAGRAM OF THE TuRBOCHARGER
uNIT WITH SuBSEquENT INTERCOOLING
up to 40° C 50°-70° C 50°-70° C
cogen2.0
–> THE J920 IS ONE OF TWO GE GAS ENGINE MODELS FEATuRING TWO-STAGE TuRBOCHARGING
07
A LEADING INNOVATOR. For more than 50
years, GE has been a leading innovator in gas
engine technology. This tradition sparks a
desire in the Jenbacher team to always be on
the cutting edge in terms of in-house technol-
ogy, achieving quantum leaps and establishing
milestones in the history of gas engines.
For GE’s Jenbacher team, leadership in the innovation
field means pushing ahead with the ongoing optimization and
further development of energy solutions.
For the company leadership, innovation means
pushing ahead with the ongoing optimization
and further development of energy solutions.
J624 – uSED TO BEING THE FIRST. At the time
of its presentation in June 2007 as the world’s
first 24-cylinder gas engine, the J624 was the
most important new product of GE’s gas engines
division. Then and now, it amazes with its power
density. With an output of 4.4MW, a single gas
engine can now supply the electricity for almost
10,000 typical European households.
Moreover, upgrading with revolutionary two-
stage turbocharging has now helped the best-
selling J624 to once again play a pioneering role.
NOTHING BuT ADVANTAGES. For customers,
this further development of the J624 means
a tangible reduction in operating costs due
to a notable 10 percent increase in output to
4.4MW, and a 1 percent point pt improvement
in maximum electrical efficiency to 46.5 percent
(which, under hot, ambient conditions, improves
2 percentage points as compared to the original
version). Furthermore, not only the electrical,
but also the total efficiency could be improved
by about 3 to 4 percentage points, up to 90 per-
cent. The advantages as compared to standard,
single-stage turbocharging are clearly evident
and include higher total efficiency, an improved
specific output and environmental benefits as
well as enhanced flexibility with regard to ambi-
ent temperatures and gas fuel composition.
FROM THE MOuNTAINS TO THE TROPICS. GE’s
gas engines must be able to operate anywhere,
from the temperate zones and polar regions to
the tropics, running at 8,000 annual operating
hours throughout a long service life, mostly at
full load, and reaching availability levels of more
than 95 percent. These application conditions
08
In 2007, GE unveiled the Jenbacher J624, the world’s first 24-cylinder gas engine. The success of GE’s new flagship
quickly captured the hearts of our customer’s power plant stations. Moreover, in summer of 2010 the J624 became the
first gas engine to be equipped with revolutionary, two-stage turbocharging and has since occupied the international
spotlight, providing further evidence of GE’s innovative strengths.
The J624 with two–stage turbocharging
technology and product news cogentechnology and product newscogen
Successful customers, the best evidence of successmake massive demands on engine durability,
but represent a challenge that GE’s gas engines
division is gladly willing to face, just as it accepts
an obligation to meet strict emission limits, in
spite of fluctuating gas quality and composi-
tion. The new J624 offers exactly this flexibility
needed for applications in the different climate
zones, and is especially suited for operating
under hot and humid environments where
Gas engines must be ableto operate anywhere, from
the temperate zones and polar regions to the tropics.
gas engines already play an important role
in the decentralized energy supply. With an
electrical efficiency improvement of 2 percent-
age points under hot environments, the new
J624 is especially attractive in those countries. _
Another global first:
cogen2.0
“For us the new J624 offers still greater flexibility
for the combined generation of electricity and heat.”
JAAP NOORDAM,
one of the owners of the Dutch
greenhouse operator Red Harvest
GIL MARGuERAT,
the director of the power production
department at French plant
builder Forclum
WILLI GOLDSCHMIDT,
the CEO at Navigat Energy,
and authorized sales and services provider
for Jenbacher gas engines in Indonesia
“The J624 offers us an increased cogeneration efficiency in tandem with a reduction in NOx emissions
from 500 to 300 mg/Nm3 (at 5 percent O2)!“
“For us, the fact that even in our hot and humid climate
the new J624 with two-stage turbocharging provides top
performance is a huge plus.”
09 10
technology and product news cogentechnology and product newscogen
when an engine is running out of spec or is
stopped due to a failure.” The myPlant system,
which currently is being set up, “will promptly
notify the local service helpdesk for a pro-active
response,” adds Johan Brink, “so we can work
on the problem before the customer notices the
effect. This will increase plant availability and
save time and money.”
myPlant uses globallyinstalled references
to benchmarkindividual engines.
Customers can obtain detailed, advance
information about the myPlant system from the
Jenbacher gas engines service sales organiza-
tion and local sales providers. _
Apart from a completely redesigned inter-
face, myPlant provides numerous additional
advantages – chief among them the integration
of existing services, interface and operator stan-
dards into a centralized application character-
ized by uniform, user-friendly handling.
WEB-BASED SERVICES CREATE FLExIBLE
HANDLING. myPlant will enable customers
to monitor and control their global fleet of
Jenbacher gas engines from a single platform.
Moreover, GE’s centralized Web hosting will
reduce installation and servicing costs to a mini-
mum and make special hardware or software
unnecessary. Customers will be able to access
myPlant at any time and from anywhere through
a secured Internet link.
As a result of myPlant, in future, customers will only require
a single platform for the surveillance and control
of their Jenbacher gas engines installed around the world.
The system automatically collates the data from
all the connected Jenbacher gas engines around
the world either in real time or within defined
intervals, depending upon priority. Since custom-
ers will receive a picture of the entire fleet from
myPlant, they no longer will work directly with
the individual control systems of their engines.
EVERYTHING uNDER ONE uMBRELLA? NO
PROBLEM WITH MYPLANT! With myPlant,
customers will be able to do basically everything
they did before – and a great deal more besides.
For example, they still can conduct remote
monitoring of the installed fleet and access the
electronic control systems for targeted adjust-
ments in the running behavior of individual
engines. But myPlant not only will present the
relevant information clearly, it also will add role
management functionality that individually
adjusts the depth of displayed information to
match the respective user group.
SERVICE ExPERT SYSTEM SOLVES PROBLEMS.
The most outstanding of many myPlant innova-
tions is the Service Expert System (SES) – GE’s
knowledge database – which can provide
descriptions and solution scenarios for about
80 percent of all possible plant defects. Axel
Dancker, global service leader for Jenbacher
gas engines, puts the advantages of myPlant
in a nutshell: “myPlant offers our customers
myPlant is GE’s new, online service platform for customer-oriented fleet management. Customers with Jenbacher gas engines will have a marked
expansion in their remote plant monitoring capabilities in mid-2011, when the newly developed myPlant online services platform will be unveiled.
myPlant combines familiar, individual elements from services and remote applications into a single solution that will be augmented by attractive,
supplementary packages.
myPlantPlant Maintenance 2.0 - the myPlantTM virtual service
maximum flexibility, integrates existing systems
for plant surveillance and can be extended to
include other features such as the Service Expert
System. We see myPlant as intelligent service
that is available to our clients around the clock.”
The Service Expert System (SES) constitutes GE’s knowledge
database, which has been built up over the years.
myPlant also can use globally installed refer-
ences to benchmark individual engines, since all
the data gathered is evaluated through the cen-
tral server in Jenbach. This will help customers
optimize the operation of their in-house systems.
SuCCESSFuL TEST OPERATION HEIGHTENS
INTEREST. Pretests of the myPlant system, con-
ducted at various customer sites, demonstrated
its huge potential. One of the system’s strengths,
the free configuration of all parameters, allowed
the determination of appropriate actions to take
at the right times to prevent serious damage to
an engine during one of the pretests. As Johan
Brink, service leader for Belgium and the Nether-
lands, reports: “With myPlant, we will be able to
react immediately to fix performance problems
The advantages of myPlant™ at a glance
· Concentration of all existing elements
in a centrally hosted Web application
· Newly developed interface for
maximum operating comfort
· Customer access via a secured Internet link
· Enlargement options involving other systems
such as the SES knowledge database
· Benchmarking with comparable
reference plants
· Integrated role management
TM
Distributor HelpdeskService HelpdeskHermes portal to
DIA.NE RMCDIA.NE Win
HiDat
Common tools and pogramsCommon user interface
Common designEasy intallation
Benefits
myPlantTM
myPlantTM
–> MYPLANTTM uSES GLOBALLY INSTALLED REFERENCES TO BENCHMARk COMPARABLE PLANTS
11 12
technology and product newscogen technology and product news cogen
GE Energy’s $3 billion acquisition of Dresser, Inc. in February included Dresser’s compression business, Waukesha. Located in
Wisconsin, in the united States, Waukesha joins the Jenbacher power generation platform and Heat Recovery Solutions segment
to form the third segment of GE’s gas engines business. Now, Waukesha 275GL+ high-performance engines are available from GE
for power generation applications at oil and gas production sites.
GE’s Waukesha 275GL+ gas engines are pow-
erful units that operate reliably in the most chal-
lenging oilfield power generation applications. “At
highly demanding oil and gas production sites,
both the 12- and 16-cylinder models deliver high
performance on a wide range of fuels,” said Scott
Nolen, product line leader power generation of
GE’s gas engines business. “These engines are
designed specifically to deliver maximum perfor-
mance and to withstand the rugged conditions at
oil and gas production sites.”
GE’s Waukesha 275GL+ gas engines are
powerful units that operate reliably in the most challenging
oilfield power generation applications.
LOWER FuEL CONSuMPTION, LOWER EMIS-
SIONS. GE’s Waukesha 275GL+ gas engines for
power generation have an improved turbo-
charger match, allowing for a leaner air-to-fuel
ratio. This, in turn, reduces fuel consumption
and emissions levels – and delivers more power.
Both the 12- and 16-cylinder 275GL+ units
are equipped with a NOx sensor that directly
measures NOx in the exhaust stream enabling
real-time, closed-loop control of the air-to-fuel
ratio to assure optimum performance. A display
panel mounted on the engine provides a read-out
of NOx emissions and other key engine operating
parameters. The statistics speak for themselves.
Both the 12V275GL+ and 16V275GL+ engines are
capable of 0.5 g/bhp-hr NOx and 1.8 g/bhp-hr CO
emissions levels without after treatment. These
emissions levels correspond to ½ TA Luft Europe-
an requirements for NOx emissions and also meet
2010 EPA Spark-Ignited New Source Performance
Standards (SI NSPS) without additional exhaust
treatment costs.
ADDED BENEFITS: MORE POWER, FuEL FLExI-
BILITY. When packaged as an Enginator® genera-
tor set, the 16-cylinder 16V275GL+ model is rated
3,480 kWe at 50 Hz (1,000 rpm) and 3,110 kWe
at 60 Hz (900 rpm). The 12-cylinder 12V275GL+ is
rated 2,600 kWe at 50 Hz and 2,330 kWe at 60Hz.
They have 1,000 rpm ratings of 4,835 bhp and
3,625 bhp, respectively. “GE’s Waukesha gas en-
gines are known for their fuel flexibility and 275GL
engines are no exception,” said Brian White, presi-
dent of Waukesha gas engines. “Because these
engines can operate reliably at higher power lev-
els on variable, low-quality gas pulled directly out
of the ground, they are particularly well-suited for
Designed to operate reliably in the most challenging oil and gas surroundings
facts and figures:
· Maintenance intervals
(oil/filter change,
spark plug maintenance,
valve adjustments) – 4,000 hours
· Turbocharger service – 25,000 hours
· Top end overhaul – 36,000 hours
· Major overhaul – 72,000 hours
President
of Waukesha gas engines
BRIAN WHITE
oil and gas production sites.” Both the 12V275GL+
and 16V275GL+ models have been designed to
operate at full power on fuels with heating values
down to 600 BTU/ft3 (23.6 MJ/m3) and at almost
70 percent load with fuels up to 2,350 BTU/ft3
(92.4 MJ/m3). In addition, 275GL Series engines
will operate at higher altitudes without derate –
the 12V275GL+ up to 4,000 feet (1,219 m) and the
16V275GL+ up to 3,000 feet (914 m).
uPTIME MAxIMIzED. All 275GL engines are
equipped with an enhanced version of Wauke-
sha’s ESM® engine control system to optimize
engine performance and maximize uptime.
The 275GL engines have long maintenance
intervals, allowing for high uptime and low
maintenance costs. “Waukesha has designed and
manufactured 275GL engines with an array of
benefits that make these engines an ideal choice
for oil and gas exploration and production sites in
remote and not-so-remote locations anywhere in
the world,” Brian White said. _
GE’s Waukesha 275GL+ gas engines for power generation
expansion during the period studied will be provided by renew-
able energy technologies, and in this regard wind energy will
demonstrate by far the largest growth. However, toward the end
of this decade, markedly stronger expansion is anticipated for
photovoltaics, and although bio-energy will also gain ground, it
will not be able to keep pace with the extremely dynamic advance
of wind and solar power. As a result of their ability to provide
demand-related power generation, fast reacting bio and natural
gas plants will assume an important function. That is because Eu-
ropean energy generation in 2030 will have a renewable energy
share of about 48 percent and will have to be far more flexible
than it is at present.
INVESTMENTS IN NEW CAPACITY WILL ALSO INVOLVE CONVEN-
TIONAL POWER PLANT TECHNOLOGIES. For this reason, in the
period up to 2030, roughly a third of investment in new capacity
will involve conventional power plant technologies. Apart from
the necessity of providing fluctuating renewable energies with
backup capacity that can be used flexibly, the obsolescence of
the power station park will constitute an important driving
Beginning in 2020, an increasing number of new, small-scale gasfired
power plants will be built.
force in this regard. Through the use of the large energy deficits
between existing power plants and new capacity, modernization
will create the preconditions required for a sizeable reduction in
INCREASING ENERGY CONVERSION EFFICIENCY. The energy sup-
ply system in Germany and the EU is currently facing fundamen-
tal change. The reduction of greenhouse gases and the accelerat-
ed depletion of fossil fuel reserves due to the rise in global energy
demand necessitate increasing energy conversion efficiency. A
number of studies describe this future development, in which a
diversity of electricity-generating technologies plays an important
role, although the producers are generally relegated to the status
of a supporting cast.
In the years up to 2030, Europe will require every energy source
and a drastic change in the energy mix will occur.
This is in spite of the fact that it is the latter who, through innova-
tions and investments in new technologies and the latest produc-
tion capacity, will exert a decisive influence on the restructuring
process. To make an active contribution to this debate within the
framework of the VDMA, the producers of differing electricity-
generating technologies have prepared a forecast regarding
development of the electricity mix in the EU 27 during the period
up to 2030.
A FOCuS ON RENEWABLE ENERGY TECHNOLOGIES. The most
significant conclusions of the expert report are that in the years
up to 2030, Europe will require every energy source and a drastic
change in the energy mix will occur. Almost two-thirds of capacity
The efficient use of renewable and fossil fuels in decentralized electricity and heat generation plants will be a major factor in the
restructuring of the European energy supply network in the coming decades. In fact, the VDMA (Verband Deutscher Maschinen-
und Anlagenbau – German Engineering Federation), one of the key association service providers in Europe and provider of the
largest engineering industry network in Europe, predicts in its expert outlook “Electricity Mix in the Eu 27” that – in the period up
to 2030 – some 86.5 GW will emanate from newly built and modernized decentralized engine power plants in Europe.
An article by Thorsten Herdan, VDMA Power Systems
the CO2 emissions from fossil fuel-fired power
plants. On the basis of a rapid update of the
fossil fuel-fired power plants, it will be possible
to attain the EU’s climate protection targets.
Beginning in 2020, an increasing number of
new, small-scale gas-fired power plants will be
built . In addition to flexible operation using heat
storage, these also offer the advantages of co-
generation, with fuel utilization levels in excess
of 90 percent.
THE IMPORTANCE OF DECENTRALIzED ENGINE
POWER PLANTS IS GROWING. The VDMA expert
forecast anticipates that by 2030, over 10 per-
cent of the 800 GW in additional capacity will be
provided by decentralized engine power plants.
In addition to new plants, it is also expected that
replacement capacity will play a central role,
meaning that by 2030, around 9.5 percent of
European electricity demand will be met on the
basis of decentralized engine power plants.
THIS TRANSITION IS ACHIEVABLE. With total
investments of well over EUR 1,000 billion in
new power plant capacity only, this transition
represents a colossal financial challenge.
Whether or not it takes place will depend to
a major extent on the political environment.
Jen industry newsco Jenindustry news co
13 14
Success will only be attainable when the politi-
cal sphere provides clear signals resulting in a
sustainable framework that permits planning.
A decisive factor in this connection will be the
creation of a trans-European electricity network
and the provision of power stores across the
continent.
With total investments of well over EUR 1,000 billion in new
power plant capacity only, this transition represents
a colossal financial challenge.
Industry can make an important contribution in
this regard through further technical innovations
such as improvements in the network compat-
ibility of power plants, new storage concept
research and testing, and the provision of manu-
facturing capacity. _
An imminent growth leap for decentralized energy supply
VDMA facts and figures:
· The largest association of capital goods
manufacturers in Europe
· Over 3,000 member companies, organized in
more than 40 branch associations
· 350 employees, with offices in Frankfurt and
Brussels as well as the capitals of other
important countries such as Beijing,
New Delhi and Moscow
· Assistance and secretarial management in
a large number of specialist bodies and
European branch associations
Further information is available under
www.vdma.org/powersystems (right-hand
column „Databases”, „Publications”).
VDMA Power Systems
Author
THORSTEN HERDAN
–> HEADquARTERS OF THE VDMA IS LOCATED IN FRANkFuRT AM MAIN, GERMANY
cogen2.0
CORE TECHNOLOGY. GE’s Heat Recovery Solutions product line
offers proven technology that recovers low temperature waste
heat from small-scale applications such as gas turbines, recip-
rocating engines, and biomass boilers and turns it into electric
power for onsite re-use or sale back to the grid.
GE’s Heat Recovery Solutions product line offers proven technology that recovers
low temperature waste heat from small-scale applications.
The core Heat Recovery Solutions technology is based on the
Organic Rankine Cycle (ORC), which is similar to the cycle that
a steam power plant uses except the working fluid has a much
lower boiling point. This allows the ORC to generate electricity
from much lower temperature heat. The heat is absorbed in the
evaporator, causing the working fluid to boil high pressure vapor
(like steam in a power plant). This high pressure vapor drives a
turbine, which generates electricity. While ORC has been applied
to large-scale industrial applications for a long time, small-scale
operations waste much more heat. It’s estimated that billions of
dollars worth of low-grade heat is wasted in this way every year.
Recycling even a tiny portion of that heat instead of dispers-
ing it into the atmosphere could cut down on fossil fuel usage
and significantly reduce CO2 emissions. A report published by
the American Council for an Energy-Efficient Economy in 2007
estimated that “waste heat recovery could substitute for 9
percent of total energy used by U.S. industry – or 1.4 quadrillion
Coming into the Fold
15 16
applications and solutionscogen applications and solutions cogen
GE’s Heat Recovery Solutions segment – part of GE Energy’s portfolio for more than eight months now – perfectly
complements the energy efficiency goals of GE‘s gas engines customers by providing them with advanced,
cleaner-technology solutions for generating power through waste heat recovery. Given the global potential that GE
projects for this industry sector, the integration of this business into GE’s gas engines division creates tremendous
opportunities for optimized energy delivery from an increasingly important alternative energy source. The initial
GE offering in this space already is yielding significant cost- and energy-savings paybacks.
Heat Recovery Solutions technology a perfect fit for GE Energy’s gas engines business
British thermal units (BTU).” To help salvage that
lost heat resource and meet the growing waste
heat-to-power demand, the Heat Recovery
Solutions team has developed Clean Cycle™, a
small-footprint, packaged ORC model that easily
integrates with machinery in the vast majority
of smaller-scale heat-wasting processes. Clean
Cycle takes waste heat from sources as low as
250°F (121°C) and transforms it into 125 kW
of electricity for the renewable and distributed
energy segments. Because it has satisfied a
rigorous third-party product review that proves
its ability to improve customer operating and
environmental benefits, Clean Cycle has just
received GE’s ecomagination approval.
MEETING CuSTOMER DEMANDS AND NEEDS.
Much of the activity in the small-scale, waste
heat recovery sector is concentrated in Europe,
where the European Union has set a goal of
generating 20 percent of the continent’s energy
from renewable sources by 2020. GE’s team
has responded to customer demand there by
starting pilot projects in Italy, Romania and
the United Kingdom. A pilot project using the
heat from two of GE’s Jenbacher type 3 biogas
engines in Dublovice, Czech Republic, is the
latest to come on line, starting up on April 20,
2011, at a power output of 125 kW. Recovering
waste heat from reciprocating engines, biomass
boilers, and microturbines and converting it into
electricity has become increasingly popular with
the global power industry, too, because it is a
highly efficient, clean-energy operation. GE is
very cognizant of that trend: by the end of 2011,
five independent third-party distributors will
help advance Heat Recovery Solutions products
globally. The introduction of Clean Cycle has
huge implications for renewable biogas projects,
which are especially attractive to countries that
have high electricity feed-in tariffs. Together
with Clean Cycle, GE’s Jenbacher gas engines
give onsite power plants the ability to generate
extra electricity without burning additional fuel
or producing more emissions. “Our technologies
mesh very well with Clean Cycle,” says Rafael
Santana, president of GE’s gas engines division.
“The combination will create more compre-
hensive waste heat-to-power solutions and
enhances our global leadership in the renewable
energy segment.” Clean Cycle’s flexibility caters
to varying customer requirements because it is
compatible with Jenbacher Type 3, 4, and 6 gas
engines, it can operate in small spaces, and it
can be moved from site to site.
“Our technologies mesh very well with Clean Cycle, the combination will create more comprehensive waste heat-to-power solutions
and enhances our global leadership in the renewable
energy segment.”- Rafael Santana, president of GE’s gas engines division
It also will accommodate applications in a broad
range of facilities, including factories, foundries
and cement plants. Heat Recovery Solutions
president Brad Garner describes the essential
value of Clean Cycle in this way: “We have cre-
ated the first commercially viable, ORC-based
waste heat recovery system that harvests
heat at the lower temperatures generated by
reciprocating engines, biomass boilers and
microturbines and then turns it into electricity
without creating additional environmental emis-
sions. Waste heat-to-electrical power generation
really is about the most environmentally friendly
technology there is, and that’s very attractive
to our customers. But their major incentive for
using Clean Cycle is economic, because if you’re
wasting heat, you’re wasting money. Our system
saves that heat from being wasted.” _
IS THE CLEAN CYCLE 125kW FEASIBLE FOR MY INSTALLATION?
Thermal Input required to reach 125 kW grid output 1,02MW @ 302°F (150°C) 0,27 kW can be replaced by lower temperature heat @ 201.2°F (94°C) from engine cooling water
Thermal Input required to reach 75 kW grid output0,65MW @ 302°F (150°C) 0,19MW can be replaced by lower temperature heat @ 201.2°F (94°C) from engine cooling water
Engine and Clean Cycle combinations 1 engine – 1 or 2 Clean Cycle, 2 engines – 1 Clean Cycle
Maximum Distance (from gas engines)Minimum possible distance between Clean Cycle and engines, to reduce heat losses. Distance from exhaust duct to heat exchanger should be less than 65.6 feet (20 meters). Water pipes can be longer.
Available Space 90.4 square foot (84 square meters), including clearances for container
Rate of Feed in Tariff Variable by country. High feed in tariffs yield better ROI.
Brad Garner,
president of Heat Recovery Solutions
cogen2.0
the company is a respected partner in the South African mining
industry, specializing in chrome-manganese steel and copper
castings which, above all, are intended for export. The foundry’s
highly complex special furnaces must be provided with an
uninterrupted supply of energy. A standstill that leads to cooling
means plant damage and serious financial losses.
SECuRITY THROuGH IN-HOuSE POWER SuPPLY. Because the
South African public grid is subject to the constant risk of power
outages, the Thos Begbie management decided in 2007 that the
company should generate its own electricity.
In an initial step in 2008, four of GE’s Jenbacher J620 gas engines
with a total output of 11.6MW were installed. Additional expan-
sion with another 20MW is planned for 2011 and 2012.Explains
Gert van Zyl, the managing director of ADC (PTY) Ltd, a private
project management company specializing in electricity solutions
and a long-term GE partner in South Africa, “Following Thos
Begbie’s decision to install an autonomous energy supply, it
evaluated a number of alternatives for on-the-spot generation.
Jenbacher gas engines from GE represented the final choice, as
these could already refer to a notable track record with regard
to similar applications and, above all, were able to offer the flex-
ibility, reliability and high levels of efficiency that constitute vital
competitive factors for the company.”
THE ECOLOGICAL FOOTPRINT – SMALL IS BEAuTIFuL! Apart from
security of supply, environmental protection is also an important
reason for the adoption of Jenbacher gas engines. With low emis-
Especially rich in resources, South Africa numbers among the
world’s leading exporters of raw materials. With manufactured
goods also gaining in importance, South African industry is be-
coming increasingly competitive on an international level, result-
ing in the rise of production locations throughout the country.
FROM uNCERTAINTY TO AuTONOMY. In recent years, South
Africa has embarked on an extensive program aimed at providing
the entire population with electricity. However, this undertak-
ing, along with rapid industrial growth, has pushed the country’s
outdated power supply network to its limits. Frequent power
outages can
South African industry is becoming increasingly competitive on an
international level.
result in production losses – a serious problem for the nation’s
budding industry, which is not only confronted with the prob-
lem of security of supply, but also with rising prices due to the
increased demand for electricity. Production costs are naturally
a major factor in business competitiveness and, as a result,
autonomy in the energy field – especially for heavy industry –
is a decisive advantage.
THOS BEGBIE – LONG TRADITIONS AND A PROMISING FuTuRE.
The Thos Begbie company is a foundry in Middleburg, a center
of South Africa’s metal processing industry. Founded in 1887,
17 18
sions and the cogeneration of electricity and heat, which provides
overall efficiency of almost 90 percent, they make a considerable
contribution to a reduced ecological footprint.
MuLTIFACETED PROJECTS FOR THE FuTuRE. GE’s success in
South Africa is ongoing. In 2008, the first power plant fueled
by landfill gas went into operation near Durban. This not only
allows the use of renewable energy and raises markedly the
reliability levels of the local energy supply, but also cuts carbon
Apart from security of supply, environmental protection is also
an important reason for the adoption of Jenbacher gas engines.
dioxide emissions. In addition, a contract was signed in 2010 with
Transnet Limited, a state-owned South African infrastructure
company, which foresees the constant supply of power to a new
fuel pipeline running between Durban and Johannesburg by GE
diesel generators. Once installed, these generators, with a total
output of 34MW, will provide emergency power for the pipeline’s
pumping stations and terminals. The new pipeline is intended
to furnish South Africa’s domestic market with a secure flow of
diesel, gasoline and aviation gasoline.
As a result of the successful projects completed to date, GE has
established an outstanding position in the South African energy
segment and is a strong partner to industry, commerce and
government in this up and coming industrial nation. _
applications and solutionscogen applications and solutions cogen
South African industry is in top gear, but local enterprises are faced with numerous uncertainties, including the
reliability of the electricity supply system. Because outages and shortages are a repeated occurrence, many
companies are looking for reliable and innovative possibilities with low environmental impact. South Africa
has more than sufficient resources for alternative energy production, and the innovative plants from Jenbach
constitute an optimal solution in achieving autonomy from the fault-prone public grid.
South African industry booming; reliable power supply needed
–> INSTALLATION OF THE FIRST FOuR GE’S JENBACHER J620 GAS ENGINES IN 2008
cogen2.0
–> CAPE TOWN, SOuTHAFRICA
2019
ENERGY SuPPLY DILEMMA. BBARWA’s waste-
water treatment plant could not count on a
secure, dependable, uninterrupted supply of
electricity. The local community is susceptible
to rolling blackouts during peak demand hours,
and energy prices are some of the highest in
the United States. Moreover, the plant is located
in a resort area that experiences sharp fluctua-
tions in demand because of the seasonal ebb
and flow of the population. Further complicating
things, BBARWA operates the plant at ultra-low
emissions levels – specifically, 11 parts per mil-
lion (PPM) of nitrogen oxide (NOx) and 72 PPM of
carbon monoxide (CO).
RICH BuRN VERSuS LEAN BuRN. Plant officials
decided to confront these challenges by generat-
ing all of the plant’s power onsite and cutting its
dependence upon the local utility. With an ex-
tremely high altitude capability available in a gas
engine, the rich-burn F3524GSI generator-set,
paired with a three-way catalyst, made the most
sense because it provided full-rated power – even
at the facility’s 6,700-foot altitude (2,046-meter
altitude) – and a low-cost option for satisfy-
ing those exacting emissions limits. Lean-burn
engines made less sense because they sustain
a significant power derate at high altitudes and
have selective catalyst reduction (SCR) systems
that require urea injections, which add an extra
operating cost and present environmental
concerns.“We needed a high-performance en-
gine that made us completely energy-independ-
ent, kept our costs down and let us pass cost
savings on to our ratepayers,” said Joe Hanford,
the plant superintendent at BBARWA.
With the Waukesha engine, BBARWA can retrieve peak usage
electrical power to treat 5.4 million gallons.
“The Waukesha engine made it possible for us
to achieve each of those goals.” Engineered for
dependability and durability, the robust feature
set of the F3524GSI includes the fuel flexibility to
operate at rated output on a wide range of fuel
qualities, and an ESM® engine system manager
that monitors and controls vital engine functions
for optimal performance and maximum uptime.
MAJOR CHANGE IN OPERATIONS AND COSTS.
Seven years after the engine became opera-
tional, BBARWA has gone from being one of
the community’s largest energy consumers
to being a surplus energy generator. Being its
own power plant has left BBARWA immune to
local service problems – a particularly critical
advantage in winter, when its electricity usage
is highest. With the Waukesha engine, BBARWA
can retrieve peak usage electrical power to treat
5.4 million gallons per day (mgd) (20.44 million
liters) of wastewater – at a 40 percent lower
cost than what the utility would charge. That’s
not the only way the plant cuts its costs. It also
saves money by purchasing large amounts of
natural gas at reduced rates, avoiding the util-
ity’s $6,500 charges for on-peak demand – and
diverting the excess power it generates to the
agency’s administration building, a measure that
saves more than $1,200 per month. As if all that
weren’t enough, BBARWA even got some help
paying for the engine, as it took advantage of a
state government rebate that covered half the
cost. To illustrate how economical the F3524GSI
engine is, Joe Hanford makes a comparison with
diesel fuel. “At today’s prices, if we were using
diesel-powered engines, it would be at six times
the cost per kilowatt hour, which we’d have to
pass on to our ratepayers.” _
applications and solutionscogen applications and solutions cogen
Off Grid Power Solution
Waukesha rich-burn engine delivers energy independence By investing in a Waukesha F3524GSI gas engine, the Big Bear Area Wastewater Agency (BBARWA)
in Southern California has become independent from the local utility’s high energy prices and uncertain
power supply. BBARWA installed a self-sufficient solution delivering power at considerably less cost
while meeting local emissions regulations that are among the strictest in the united States.
facts and figures:
· Cylinders: Inline 6, turbocharged and
intercooled
· Compression Ratio: 8:1
· Control System: Waukesha Engine System
Manager (ESM®), which integrates spark
timing control, speed governing, air/fuel
ratio control, detonation protection, start-
stop control, diagnostic tools, fault logging
and engine safeties.
· Starting System: 125-150 psi air/gas
24V electric
· Fuel System: One natural gas, 4” (102 mm)
updraft carburetor and one mounted Fisher
99, 2” (51 mm) gas regulator, 30-60 psi (207-
414 kPa) fuel inlet pressure required. 10 ft.
(3 m) harness provided for ESM® control of
customer supplied fuel shutoff valve.
· Bore and stroke: 9.375” x 8.5” (238 x 216 mm)
· Piston Displacement: 3520 cu. in. (58 L)
–> THE WASTEWATER TREATMENT PLANT COuNTS ON A SECuRE, DEPENDABLE, uNINTERRuPTED SuPPLY OF ELECTRICITY.
–> BIG BEAR LAkE, SOuTHERN CALIFORNIA
Considered one of Eastern Europe’s “Baltic
Tigers,” Estonia’s strongly expanding economy
has led to higher energy requirements and grow-
ing environmental awareness. FILTER, headquar-
tered in Harjumaa, Estonia with a workforce of
320 employees, operates in the water treatment
and energy generation plant segments, as well as
in the field of boiler facilities designed to generate
steam for industrial purposes. In addition to plant
construction, FILTER also offers comprehensive
consulting, maintenance and training services.
Customer-oriented services and a dense network
of branch offices are further important success factors.
The products of GE’s gas engines division com-
prise an important component of innovative, total
energy technology solutions. As a result of its
large-scale success in Estonia, FILTER has already
set up subsidiaries in Latvia, Lithuania, Russia,
Belarus, Bulgaria and Finland.
RELIABLE PARTNER. Many FILTER customers in
industry, commerce and public administration
rely on the competence of this Jenbacher gas
engine distribution and service provider. FILTER
takes advantage of the mature Jenbacher gas
engine technology to complement its intelligent
and environmentally-friendly power and heat
generation product offerings. As a result, holistic
energy solutions are offered, enabling the pro-
duction of heat, cold and electricity.
In its cooperation with GE, FILTER has gained
extensive expertise concerning the Jenbacher
gas engine products and their manifold applica-
tions and combination possibilities. This depth of
knowledge is a key to FILTER’s success.
PERFECT SERVICE. Customer-oriented services
and a dense network of branch offices are further
important success factors. In line with the phi-
losophy of Jenbacher’s gas engines team, FILTER
also strives to extend the useful life of its facilities
through optimal service and the replacement
of individual parts. The modular construction
of the Jenbacher engines allows customers to
perform upgrades rather than having to acquire
completely new aggregates. Even older motors
are always up-to-date in terms of efficiency and
eco-friendliness, serving as the basis for a longer
and trouble-free operating life. FILTER’s service
portfolio also includes the turn-key, ready-to-op-
erate handover of all facilities, including training
and education for optimal operation.
THREE-FOLD STRENGTH. At present FILTER is
installing a major project in Belarus at a com-
bined heat and power plant facility. Joint Stock
Company Grodnochimvolokno in Grodno, one
of the largest chemical companies in Belarus,
manufactures polyamide and polyester yarns,
polyamide 6 granulate and composite materials.
Three engines were delivered in 2004, and now
the facility has twelve J620 gas engines with a
capacity of 36MW, enabling the simultaneous
generation of electricity, heat and cold. All are
required for production and processing work.
The trigeneration plant at Grodnochimvolokno
thus serves as an important reference project in
this region. Grodnochimvolokno is both FILTER’s
first customer in Belarus, but also its largest
single contract order. _
21 22
distributors and service providerscogen distributors and service providers cogen
Holistic energy solutions for power generation in Eastern EuropeSince 1992, Estonia’s FILTER AS has positioned itself as a successful and reliable business associate for
power generation and water treatment technologies. GE’s Jenbacher gas engines have long been bestsellers
in FILTER’s product portfolio. They offer optimal complete energy generation solutions in combination with
other technologies.
facts and figures:
Founded: 1992
Cooperation with GE: Since 1998
Employees: 320 at 22 locations
Installed units: 197
Total electrical output: 298MW
Total thermal output: 250MW –> TALLINN, ESTONIA
distributors and service providerscogen distributors and service providers cogen
eight heat recovery generators, manufactured
at the FILTER production facilities in Finland, this
plant represents an optimum and complete en-
ergy technology solution for Joint Stock Company
Grodnochimvolokno.
How important to you is the cooperation with
GE’s Jenbacher gas engines team? It is difficult
for me to imagine our business without GE. Over
the years, we have become strong partners with
excellent synergies derived from our respective
corporate strategies.
“For our customers, perfectly functioning, efficient and
complete solutions in combination with a professional, local service provided by our team are of the
greatest importance.”
What business objectives do you have for
the future? We are looking for stable growth in
Eastern Europe, and we see the greatest poten-
tial in Russia. The main target is further market
development per se and the further expansion
of the customer base in those regions where we
are active.
What makes FILTER so special? We seek to
be a specialist in our various business areas
such as energy (electricity, heating, steam,
hot oil, bio-energy), water treatment, pump
technology, automation, etc. For our customers,
perfectly functioning, efficient and complete
solutions in combination with a professional,
local service provided by our team are of the
greatest importance.
How has your business changed since you
became a distributor and service provider
for GE? The initial contacts with the Jenbacher
gas engines team date back 13 years, and we
sold the first engine in 1999. For us, GE’s
significance grows year by year and the busi-
ness with engines from Jenbach has become
FILTER’s most important business segment. _
Many thanks for the interview.
cogen: Over the years, you have expanded successfully beyond
Estonia’s borders, and you now occupy an excellent position in
six countries. What is the secret of FILTER’s success?
Antti Toppi: FILTER was founded in 1992, and from the outset
we endeavored to achieve geographical growth. The second
important success factor was cooperation with leading technol-
ogy suppliers such as GE.
“For us, it is especially important that we serve our customers as a long-term partner.”
One of your focal points is customer service. Why do you
invest so heavily in this area? For us, it is especially important
that we serve our customers as a long-term partner. Any machine
downtime we can prevent means hard cash and faster ROI for our
customers. Outstanding performance also enables us to generate
additional service contracts, which today already constitute over
50 percent of our total business.
In your opinion, what has been your most important project up
to now involving a plant equipped with Jenbacher engines?
The modern trigeneration plant for Joint Stock Company Grodno-
chimvolokno in Grodno is certainly our most important project in
Belarus to date for several reasons. First, this is the first customer
in the region for whom we have delivered a gas engine, and the
contract thus constitutes a very important reference for potential
clients. Second, this is the biggest CHP plant order yet placed in
Belarus. Twelve Jenbacher J620 gas engines provide a combined
output of 36MW and, together with the absorption coolers and
23 24
Complete solutions are the key to FILTER´S success
–> HEADquARTERS OF FILTER AS IN HARJuMAA, ESTONIA.
–> INSIDE A MODERN TRIGENERATION PLANT IN GRODNO
An interview with ANTTI TOPPI, CEO at FILTER AS,
and authorized sales and services provider for
Jenbacher gas engines in Estonia.
2625
region specialregion specialcogen cogen
JENBACHER SALES AND SERVICE PROVIDERS
IN EASTERN EuROPE AND RuSSIA
01. BuLGARIA
Filter EOOD
02. MOLDOVA
Vipropat S.R.L
03. POLAND
kWE - Technika Energetyczna Sp.z o.o.
04. ROMANIA
SC Total Energy Business SA
05. RuSSIA
GE Russia
Max Motors LLC (South Region)
Intma CJSC (South ural Region)
Vapor CJSC (North West Region)
06. SLOVAkIA
EMES s.r.o
07. SLOVENIA
IMP Inzeniring d.d.
TES d.o.o.
08.CzECH REPuBLIC
klor GmbH
JMP (Service)
09. ukRAINE
PS&IC Sinapse
10. HuNGARY
GE Energy Jenbacher Hungary (Service)
11. BELARuS
Filter SzAO
For additional information, please contact [email protected], [email protected],
[email protected], [email protected], [email protected]–> MOSCOW, RuSSIA
2827
region specialregion specialcogen cogen
The countries of Eastern Europe and Russia are referred to repeatedly as Europe’s most important trade and
growth territory, and without doubt, the region continues to offer great promise for commerce and industry.
However, since Russia is recognized as Western Europe’s most significant supplier of raw materials, this creates
dependencies, as underlined by massive supply projects such as the new “Nabucco” gas pipeline. Moreover, a
general tendency towards a cross-border closing of ranks in the energy sector is already apparent. under these
circumstances, GE has identified the major potential for modern power generation with low environmental
impact and has moved into an ideal position as a supplier.
Speeding up in
Eastern Europe and Russia
>
E
astern European countries remain important growth drivers
for the European economy as a whole. Despite a slowdown dur-
ing the past few difficult years, growth continued in some coun-
tries, and the need to catch up has coincided with an improve-
ment in living standards to significantly increase energy demand.
However, some of the modern, technical possibilities for power
generation have not been fully exploited – particularly, innovative
solutions from GE Energy’s gas engines division. Consequently,
sizeable opportunities are still available.
COAL AND OIL ARE PREDOMINANT BuT PROBLEMATIC. Eastern
Europe and Russia currently depend heavily on the fossil fuels
of coal, oil and gas. But coal and oil in particular have major
negative environmental impact and oil has extremely limited
availability in the long-term. At present, coal accounts for 40 to
50 percent of the total energy requirement in Europe, and that
creates an enormous ecological burden. But the push to counter
the growing greenhouse effect by sharply reducing global CO2
emissions within the framework of the Kyoto protocols will inspire
and accelerate a trend away from coal and gas and towards
largely-untapped environment-friendly and renewable forms of
energy.
uNCONVENTIONAL AND ExTREMELY ATTRACTIVE “NEW”
GASES. In its “World Energy Outlook” for 2010, the International
Energy Agency (IEA) predicted an even greater role in energy sup-
ply for gas – especially natural gas, which already is the world’s
third most important energy source. Indeed, gas-generated
electricity could double by 2035. That bodes very well for the use
of Jenbacher gas engines, along with the fact that coal – the
world’s second biggest energy source after oil – will become more
important in the near future despite its serious environmental
consequences. Above all, unconventional gases such as coal bed
Eastern Europe and Russia currently depend heavily on the fossil
fuels of coal, oil and gas.
methane (CBM), landfill and biogas will become more impor-
tant in power generation on a regional level during the coming
decades. Today, these gases are relatively underused because
extracting and transporting them is somewhat complex and
inefficient. However, it is anticipated that optimal and therefore
extremely cost-effective ways to obtain and exploit these gases
will be developed in the years ahead. International Energy Agency
estimates that up to 35 percent of total power generation could
come from unconventional gases. The future will see a growing
number of low-emission, high-efficiency solutions that generate
more than one form of energy. In fact, GE’s gas engines division
already is meeting the existing, considerable industrial sector
demand for this by offering customers cogeneration and even
trigeneration systems.
MAJOR RAW MATERIAL RESERVES... The bulk of the world’s raw
materials deposits are found in countries belonging to the so-
called “strategic ellipse”. Indeed, one half of global natural –> MOSCOW, RuSSIA
region specialregion specialcogen cogen
their extensive performance range and applica-
tions flexibility in serving this business. JMP,
Poland’s largest flower growing company, is a
case in point. With one of the biggest green-
house facilities in Europe (around 27 acres, or
11 hectares) and a workforce of over 100
employees, company management decided to
generate its own electricity and heat production.
After a precise analysis of what their competi-
tors in the Netherlands were doing, JMP chose
GE’s Jenbacher gas engines primarily because
they also produce CO2 for fertilizer – which is a
very expensive process otherwise. The system
JMP installed at its facility in Stezyca has three
J420 engines for combined heat and power
(CHP) and downstream CO2-fertilizer production.
The resulting electricity output of 5.6MW com-
bines with thermal energy production of
Prevailing climatic conditions have boosted the Polish
horticultural industry and made Poland the third most important
flower supplier in Europe.
4.5MW for an overall efficiency level in excess of
80 percent. Since the GE system is so efficient,
and there is no need for offsite production and
gas reserves are located in three nations
within this region: Russia, Iran and Qatar – and
this does not include unconventional gases and
flare gas.1 Russia is the European Union’s most
important natural gas trading partner, while
countries belonging to the Commonwealth of
Independent States (CIS) account for more than
40 percent of gas requirements. In 2009, Russia
was the world’s second largest gas producer be-
hind the USA and in the preceding years, it com-
pletely dominated global exports.2 Two-thirds of
the Russian gas produced has to meet domestic
needs, while the remainder is exported. The gas
volumes extracted are increasing steadily from
year to year and the nation’s reserves of brown
and hard coal also are among the largest in the
world.
...MEAN ENORMOuS POTENTIAL! The vast
quantities of gas available, in the form of natural
and alternative gases, present GE with an excel-
lent opportunity to provide its high-performance
gas engines for electricity generation. Russia
currently generates approximately 67 percent of
its energy from coal, oil and gas. Part of the ex-
isting installed plant capacity for this dates from
the Soviet period and must be replaced. The
government also is planning the liberalization
and regionalization of the electricity segment.
In years to come, decentralized power genera-
tion in Russia will become even more important,
as the sheer size of the country and the supply
The vast quantities of gas available, in the form of natural
and alternative gases, present GE with an
excellent opportunity.
of its widely-dispersed population would other-
wise involve excessively long transport routes.
This can drive an enormous amount of business
growth for GE’s efficient generating systems,
which have the additional advantage of gen-
erating energy from a diverse range of gases –
including coal gases that have remained unused
because of their (problematic) waste emissions.
For example, the Russian government has
stipulated that over 90 percent of flare gas must
be utilized from 2012 onwards.
Even thin gas mixtures with a low calorific value
can be burned for electricity generation by GE’s
products. Although Russia contains climatic
zones ranging from Siberia to the subtropical
Black Sea coast, Jenbacher gas engines can be
optimally used in any of them because they fea-
ture innovative technologies such as two-stage
turbocharging. GE’s advanced power generation
plants are ideal for handling the extreme tem-
perature variations found in this country.
POLAND SHOWS RAPID DEVELOPMENT. Since
1990, the Polish economy has demonstrated im-
pressive performance while the energy industry
has restructured. In 2008, Poland responded to
the Kyoto targets and the problem of resource
availability by releasing the “Energy Policy Strat-
egy up to 2030”. Besides emphasizing increased
energy efficiency and fewer CO2 emissions,
this document also focused on the combined
generation of differing forms of energy such as
electricity, heat and cold. Poland also intends
to move away from coal, its primary source of
energy to date, and towards renewable energy
sources with a smaller environmental footprint.
THE POLISH FLOWER INDuSTRY IS IN FuLL
BLOOM. Prevailing climatic conditions have
boosted the Polish horticultural industry and
made Poland the third most important flower
supplier in Europe, after Germany and the Neth-
erlands. GE’s gas engines have demonstrated
transport of power or CO2 fertilizer, JMP has been able to save
40 percent of its primary energy requirements. Now, JMP is
planning to install additional Jenbacher engines for even greater
production. The JMP CEO, Jaroslaw Ptaszek, is highly enthusiastic
about this investment: “As a result of the cogeneration system,
we have been able to slash our liquid CO2 fertilizer costs, since
today we quite simply produce it ourselves. The installation of the
GE system has made a tangible contribution to our positive busi-
ness development and our greenhouses currently are among the
most modern in the world.” The whole Lublelskie region of Poland
where Stezyca is located possesses major resources which could
be converted into energy on the spot.
Though gas now supplies a mere 0.4 percent of the local energy
requirement, biogas, landfill and coal mine gas are available in
sizeable quantities. Therefore, the JMP system will serve as an
important reference project for GE in the area.
EMPLOYEES POISED FOR THE FuTuRE OF EASTERN EuROPE.
Eastern Europe not only is an important region for plant produc-
ers, but also independent power producers (IPPs). GE Energy is
well positioned to serve this significant customer group through
a full coverage network of almost 5,700 employees located in 11
production and service operations. Gas engines already produce
more than 450 GW of energy in Eastern Europe.
GE Energy has more than 300 employees in Russia, and one of
its key facilities in the country is the Kaluga Power Technology
Center, which is located 112 miles (180 km) from Moscow and
opened in 2010. This location specializes in the repair, servicing
and maintenance of existing capacity, as well as the installation
of new and innovative systems. Further expansion is planned.
GE Energy is well positioned to serve this significant customer group
through a full coverage network of almost 5,700 employees located in
11 production and service operations.
GE’s largest heavy-duty gas turbine parts manufacturing plant in
Central and Eastern Europe is in Veresegyház, Hungary, while the
Engineering Design Center (EDC) in Poland is a state-of-the-art
technology incubator with more than 1,000 engineers collabo-
rating in the development of world-class aviation, energy and
oil & gas technologies. Decentralized power generation should
continue to grow throughout the entire region, and GE’s gas
engines division is perfectly suited to support it .
Thomas Achrainer, regional sales leader Eastern Europe for GE
Energy’s gas engines division, is optimistic: “Given the geographi-
cal conditions and the resources available in Eastern Europe, we
expect that the regionalization of power generation will continue.
Our modern systems represent ideal, complete solutions, and
they are enhanced with strong customer service. In the future,
we must remain focused and aggressive on innovations and
product development. By doing that, I am convinced that we will
remain the pacesetter in this field in the years to come.” _
1 http://www.bgr.bund.de/cln_160/nn_331084/DE/Themen/Energie/Erdgas/
erdgas__inhalt.html2 http://de.wikipedia.org/wiki/Erdgas/Tabellen_und_Grafiken#Nach_
L.C3.A4ndern
sources:
facts and figures:
Nations: 28
Inhabitants: 360 million
Average, annual per capita electricity consumption: 2,500 kWh
GE Energy’s employees in the region: 5,700
Total gas engine capacity installed: 450 GW
>
3029
–> MAJOR BROWN AND HARD COAL RESERVES ARE FOuND IN RuSSIA
–> WARSAW, POLAND
3231
In the search for new energy sources and low-cost alternatives to natural gas, a previously little-used gas has
moved into the spotlight. With major reserves found all over the world, coal bed methane (CBM) is already being
used as an energy source in the united States, Canada and Australia. In addition, Russia is beginning to take an
interest in this subterranean treasure. In fact, the first CBM-powered Jenbacher gas engine supplied to Russia
by GE recently went online in kusbass/Siberia, and it is already clear that this will by no means be the last ...
(ALMOST) PuRE METHANE. As opposed to the mine gas that is ex-
tracted from active and closed pits, CBM can be obtained directly
by drilling into unused coal deposits (beds). CBM is a free gas that
exists in cracks, fissures and pores and as an adsorbed gas on the
inner, upper surface of the coal and the surrounding rock. Above
all, it can be obtained from coal beds that, due to their location or
characteristics, are unsuitable for mining.
Apart from the possibilities for its efficient exploitation in many
parts of the world, the prime reason CBM is a suitable alternative
to natural gas is its high methane content of over 95 percent,
which makes it an excellent fuel.
A SINGLE GAS FROM MANY PARTS OF THE WORLD. Large re-
serves of CBM can be found all over the world. These are already
being exploited successfully and employed as an energy source,
especially in the U.S., Canada and Australia.
An outstanding example of the use of CBM for decentralized
energy supply is in the Australian state of Queensland, which in
recent years has installed a gas-fired, electricity generating plant
with a capacity of over 150MW and has thus covered a consider-
able part of its local power needs from this new energy source.
NEW, SAFER CHANCES FOR COALFIELDS. The extraction of CBM
in the vicinity of active collieries not only offers the potential of a
local energy source, but also the advantage of pre-degassing of
the methane in the coal. As a result, safety is increased during
subsequent mining operations.
DOuBLE CLIMATIC BENEFITS. In such cases, the use of CBM
also demonstrates its value through a two-pronged reduction
in greenhouse gases. First, with CBM, the highly active green-
house gas methane is transformed into less harmful CO2 even
prior to its release during coal mining (methane released into the
atmosphere has a 21-fold greater climate relevance than does
CO2). Second, CO2 emissions per kWh can be reduced markedly
by substituting fossil fuels. In addition to the ecological benefits,
this also results in an economic advantage, since related projects
qualify for carbon credits.
NEW ENERGY FOR kuSBASS. The province of Kemerovo in the
Kusbass is a Siberian coalfield with an area of around 59,651
miles² (96,000 km2) with a history of over 300 years and major re-
serves of CBM. To date, these resources were generally neglected
in Russia, but that is now likely to change. Following recent test
drilling by Gazprom, the first plant in the country for the energetic
use of CBM recently went online near Kemerovo, which is located
some 124 miles (200 kilometers) east of Novosibirsk and is the ad-
ministrative center of the Kusbass region. For this operation, the
local mine operator, Kuzbasskaya Energosetevaya, is using a J320
gas engine from the Jenbacher product line that converts the
extracted gas into electricity, which is then fed into the public grid.
In such cases, the use of CBM also demonstrates its value through a two-pronged
reduction in greenhouse gases.
Peter Kuruch, the Kuzbasskaya Energosetevaya CEO: “The in-
novative technology of the Jenbacher gas engines from GE has
enabled us to put a gas that constitutes an environmental prob-
lem into cost-efficient use as a valuable fuel for reliable energy
generation. Apart from enormous specialist competence, the fact
that installation and startup were possible in just two and a half
months was decisive in our decision to choose GE.”
THESE FIGuRES SPEAk FOR THEMSELVES. At present, Jenbacher
gas engines with a capacity in excess of 400MW are being oper-
ated with mine gas and CBM. These provide an annual production
capacity of over 3 million MWh of electricity, thus saving 30,000
billion foot³ (830 million m3) of natural gas equivalents and pre-
venting methane emissions equating to over 8 million metric tons
of CO2. Once again, these figures provide confirmation of the en-
vironmental advantages of the Jenbacher gas engines from GE,
which demonstrate great flexibility with regard to fuel and – apart
from natural gas – can also be operated with a large number of
biological and special gases. _
region specialregion specialcogen cogen
Coal bed methane – a subterranean energy treasure
VALuABLE POTENTIAL – GLOBAL CBM RESERVES
Country CBM reserves in TCF1 CBM ultilization in BCF1
u.S. 9702 2009: 1,7002
Canada 1,7502 2009: 2702
Australia 3502 2009: 1402
China 5002 2009: 292
India 922 2010: 92
Russia 2,3002 2010: 12
Indonesia 1122 2010: 23
ukraine 1,4002 2009: 0
Further CBM reserves and/or initial test drillings in Germany, uk, Poland, kazakhstan, Bulgaria, Turkey, South Africa, Vietnam, Thailand and Colombia.
1 TCF = Trillion Cubic Feet, BCF = Billion Cubic Feet, 1 m³ = 35.3 Cubic Feet2 ifm RWTH Aachen, Alternative Geogene Lagerstätten, Lecture 2009 3 IHS, Recent CBM Developments in Asia, March 2010
CSM
(CO
AL S
EAM
MET
HAN
E)
CBM CBM
(Coal Bed Methane)
Gas from unexploided
coal deposits
> 90%
mehtane content
Min
e ga
s
CMM
(Coal Mine Methane)
Gas from
active collieries
25-60%
mehtane content
AMM
(Abandoned Mine Methane)
Gas from
closed collieries
60-80%
mehtane content
–> THE kuSBASS IN SIBERIA HAS MAJOR RESERVES OF COAL BED METHANE
cogen2.0
–> THE J320 AT THE MINE OPERATOR kuzBASSkAYA ENERGOSETEVAYA
33 34
success storycogen success story cogen
The automotive industry is subject to stringent regulations. Both production and emission targets must be attained. Furthermore, vehicle
production standstills are to be avoided at all costs. Therefore, with Jenbacher gas engines, GE offers optimum solutions for energy supply
in this industry, not only furnishing the electricity required, but also heat that can be used for the manufacturing process and plant heating.
Accordingly, the cooperation between GE in Jenbach and the automotive sector is a genuine success story.
In the automotive industry, reliability, simple operation, high ef-
ficiency levels and low emissions are all critical aspects of energy
technology. Moreover an island operation that is completely
independent of the public grid must be possible at any time and at
the individual location. Jenbacher gas engines, which are designed
for combined heat and power generation, constitute an ideal and
complete solution in this regard. CHP power plants can thus pro-
vide both the necessary electricity output and heat at overall
Island operation that is completely independent of the public grid
must be possible at any time and at any individual location.
efficiency levels of up to 90 percent. The advantages of Jenbacher
gas engines are clear: Due to the product’s flexibility, the solu-
tions can be adapted to specific construction conditions and to
specific customer needs. In addition, Jenbacher gas engines can
be integrated directly into the existing plant capacity. GE is also ex-
perienced at project management, which can be a challenge since
the exchange of the existing gas engine often needs to take place
without any interruptions to the backup power supply.
PuTTING POWER INTO BMW. Quality is a convincing argument.
Today, leading German automotive manufacturers rely upon Jen-
bacher technology. As early as 1982, an initial plant was installed
at the BMW engine plant in Steyr, Upper Austria. Since then, the
company’s plants in Leipzig, Regensburg and Landshut have all
More power for the automotive industry
>
CuTTING CARBON EMISSIONS WITH CHP. Cogeneration, or com-
bined heat and power (CHP), dependably generates onsite electric
power while capturing excess thermal energy to produce heat. This
makes CHP a much more efficient process than dual-source heat
and power generation. In addition, using CHP is a critical anti-pol-
lution strategy in a world where two-thirds of all fuel is wasted and
global energy requirements will grow by 44 percent within the next
20 years – along with demands to cut greenhouse gases.
In Europe, where the European Union has set a goal of reducing
CO2 emissions by 20 percent by the year 2020, cogeneration is pro-
viding eleven percent of total electricity and saving an estimated 35
million tons of oil equivalent per year. The Coca-Cola Hellenic
Bottling Company for example has supported the goal by installing
15 CHP plants featuring GE’s Jenbacher units in twelve countries.
With this GE technology, each plant can eliminate more than 40
percent of its annual CO2 emissions.
FuEL FLExIBILITY. Jenbacher gas engines can run on almost any
gaseous fuel. Besides operating at top efficiency on natural gas,
they can generate power while safely disposing of environmentally
harmful gases from landfill, agricultural, coal mining, chemical
processing and other industrial applications.
THE LATEST GENERATION. The newest development in the
Jenbacher product line is the J920, which can provide enough
energy to power 18,500 average European households. With an
electrical efficiency of 48.7 percent, the J920 can reduce annual
CO2 emissions by about 1,500 tons per year. _
Low Carbon Technology Innovation
36
success story cogen
World Finance magazine has honored GE’s ground-breaking cogeneration technology by naming
Jenbacher gas engines the Best Carbon Markets Energy Efficiency Pioneer for Western Europe
in 2011. “This award recognizes companies whose development of and investment in innovative
carbon-efficiency methodologies create the deep reductions in carbon output needed to protect
the environment,” said Alexander Redcliffe, Editor of World Finance magazine.
success storycogen
35
GE‘s Jenbacher gas engines cited for energy efficiency
“This award recognizes companies whose development of and investment in innovative carbon-efficiency methodologies create the deep reductions in carbon output needed to
protect the environment” - Alexander Redcliffe, Editor of World Finance magazine
facts and figures:
Engines in operation: 16
Plants: 7
Total electricity output: 29.6MW
Total heat output: 27.6MW
been equipped with CHP plants from GE. In 2007, two Jenbacher
CHP plant modules with J420 engines and an electricity output
of 2.8MW and heating output of 3MW were installed at the BMW
plant in Landshut. The BMW engine plant in Steyr has had four
Jenbacher J420 engines with a total capacity of 5.6MW in opera-
tion since 2007. The BMW plant in Leipzig, which is regarded as
the most modern car plant with the highest level of sustainability
in the world, also uses a Jenbacher J620 gas engine with a capac-
ity of more than 3MW for the production of electricity and heat.
Finally, the largest project of this kind can be found at the BMW
plant in Regensburg, where four Jenbacher J616 engines with a
total output of almost 11MW are supporting the uninterrupted
production as of 2011.
MERCEDES-BENz LuDWIGSFELDE AND GE – A STARRY
CONSTELLATION. Mercedes-Benz is a major German automotive
manufacturer in the premium classification to rely on the perfor-
mance and operational possibilities offered by Jenbacher CHP
plants. GE and Mercedes-Benz have maintained a cooperative
relationship for more than 10 years. The first plant was installed in
Rastatt in 1997. Today, the Mercedes-Benz works has two
Jenbacher J412 and J416 gas engines, generating a combined to-
tal of 2MW of electricity. In 2011, a new plant consisting of a J412
and a J416 with a total output of 2MW began supplying the
Ludwigsfelde commercial vehicle plant with its power require-
ments. Matthias Westermann, the project manager of the CHP
plant at Mercedes-Benz in Ludwigsfelde: “Our plants number
among the most modern in the world and with the help of Jen-
bacher gas engines, this also applies to our electricity generation.
Above all, the performance and efficiency of the engines are highly
impressive and were decisive in our decision to purchase.”
STEPPING ON THE GAS WITH JENBACHER ENGINES. Apart from
BMW and Mercedes-Benz, a leading German sports car manu-
facturer is also already using Jenbacher engines. In 2010, the
company installed two J612s with a total output of around 4MW.
CO2 EMISSIONS HEADING FOR zERO. The automotive industry
is continuing its efforts to minimize its CO2 emissions. On the one
hand, these endeavors relate to the specific CO2 emissions from
vehicles and on the other, to the aim of turning production centers
into zero emission locations by means of low energy construc-
tion methods and modern energy solutions. Within this context,
due to their low emissions and high efficiency levels derived from
the combined production of electricity and heat, Jenbacher gas
engines are already making a sizeable contribution to a reduction
in the ecological footprint of the automotive industry. _
>
“Our plants number among the most modern in the world and with the help of
Jenbacher gas engines, this also applies to our electricity generation.
Above all, the performance and efficiency of the engines are highly impressive and
were decisive in our decision to purchase.”- Matthias Westermann,
the project manager of the CHP plant at Mercedes-Benz in Ludwigsfelde, Germany
37
success storycogen success story cogen
38
GE Energy recently acquired Dresser, Inc.,
the parent company for Waukesha, to augment
GE’s global technology offerings across the en-
ergy spectrum. The Waukesha product portfolio,
which stocks a fleet of top-in-class, durable,
low-emissions, rich-burn mechanical drive
engines, complements the clean-burning, fuel
flexibility and high efficiency expertise GE has
developed with its Jenbacher gas engines –
some of which also are part of EDELMAG’s
installed fleet. The merged capabilities of the
Jenbacher and Waukesha offerings are expect-
ed to generate additional gas-engine technology
The merged capabilities of the Jenbacher and Waukesha
offerings are expected to generate additional
gas-engine technology solutions.
solutions that will serve petrochemical, mining
and manufacturing applications, as well as the
power generation industry.
That EDELMAG has had an ongoing customer
relationship with both product lines underscores
the strategic common sense that brought them
together within GE.
RuGGED DuRABILITY. Since its installation in 1982, the Waukesha
gas engine has been shut down solely for regularly scheduled
maintenance, including top-end overhauls at 22,000-hour inter-
vals and bottom-end overhauls at 44,000-hour intervals.
An automotive analogy is a good way to assess
the durability and reliability.
Aside from a new control system upgrade in 2002, the unit always
has operated – smoothly and continuously – as original equip-
ment, “It’s a relatively simple, open system, and it’s easy for our
technicians to work on the engine, so we handle the maintenance
ourselves,” Wurth said. An automotive analogy is a good way to
assess the durability and reliability of the VHP7100GSI:
Operating this stationary engine for 200,000 hours is equivalent
to driving a car at 35 mph (56.3 km/h) for 7 million miles (11.3
million kilometers). The VHP7100GSI is part of the product line of
gaseous-fueled, VHP 12-cylinder generator sets built for longev-
ity and dependable performance in a wide range of operating
conditions. It is particularly suitable for isolated sites and mission-
critical power generation facilities. Porvenir, a town of more than
5,000 people on the southernmost tip of South America that still
lacks access to a central power grid, fits both of those criteria.
The engine has continuous power ratings of 840-920 kWe at
50 Hz (1000 rpm) and 1000-1100 kWe at 60 Hz (1200 rpm).
VHP GSI series engines also have good fuel tolerance and excel-
lent load response.
A REWARD FOR PERFORMANCE. When the Porvenir station
needed to boost its generating capacity within the last decade to
meet the growing local electricity demand, EDELMAG’s positive
experience with the Waukesha gas engine prompted its decision
to buy two Waukesha VHP9500GSI generator sets. The additions
increased total gas-fueled electrical output to 3.275MW. “The
performance of the VHP7100 at Porvenir has been spectacular! It
is a strong, robust engine. Its impressive reliability – along with the
responsiveness of the distributor and factory technicians – were
key factors in our decision to select two more Waukesha units
to accommodate the growing power needs of this community,”
Wurth said. “I expect that GE will continue to develop gas engines
that are robust, durable and highly efficient. For all of those rea-
sons, we always consider GE and its Waukesha gas engines any
time we need to add more power generation units.” _
200,000+ Hours and Counting…
GE’s Waukesha gas engine still going strong in ChileAfter more than 200,000 hours contiuos opperation, a Waukesha gas engine still supplies electrical powert ot the town of Proventir, Chile. For
two decades, the generator set was the sole – and indispensable – primary power source for Porvenir, whose location in a region with abundant
natural gas supplies made it a good fit for the Waukesha product. “If the engine turned off, the town turned off,” declared Juan Carlos Wurth,
the maintenance chief for EDELMAG, the Chilean utility that owns and operates the Porvenir power station.
facts and figures:Edelmag, Punta arenas, Chile
· Business Area – Punta Arenas, Puerto
Natales, Puerto Williams, Porvenir
· Region – xII Region of Magallanes
and Chilean Antarctica
· Porvenir Power Generating Station Installed
Capacity – 3.275MW (As of Dec. 31, 2009)
· Porvenir Population Served – 5,465
–> THE VHP7100GSI IS BuILT FOR LONGEVITY AND DuRABILITY
–> ONGOING CuSTOMER RELATIONSHIP WITH WAukESHA AND JENBACHER PRODuCT LINES
39 40
servicecogen service cogen
24/7 service means that GE’s Jenbacher gas engine team is on call around the clock. Saturday, March 5, 2011. At 3 a.m.,
Jochen Duell, an employee of Bioenergie Rottenbauer GmbH & Co. kG in Reichenberg, Germany, called the 24/7 hotline for
Jenbacher gas engines. A few minutes before, a J312 engine had shut down, and urgent action was vital. For Bioenergie
Rottenbauer, which operates a biogas-fired heating power plant in Germany, every minute lost costs hard cash.
F
ortunately, Bioenergie Rottenbauer has a long-term mainte-
nance contract – also known as a customer service agreement
– with GE’s Gas Engine service team. As a result, the company
automatically benefits from the new 24/7 service, complete with
a global hotline, which appropriately enough became operational
on 7/24/2010. Since then, a team of 37 highly qualified service
engineers have been stationed at locations across Europe to pro-
vide Jenbacher customers all over the world with telephone sup-
port 24 hours a day, seven days a week. In the first nine months
of operation, the hotline helped more than 400 customers, with
more than half the inquiries dealt with purely by phone.
The new 24/7 service hotline is thus far more than just
a simple call center.
SHORT REACTION TIMES THANkS TO THE NEW 24/7 SERVICE
HOTLINE. Axel Dancker, global service leader for Jenbacher gas
engines, says the new service provides customers with increased
benefits. “Very often it’s the case that a plant shutdown is caused
by difficulties which can be quickly corrected,” he expresses.
“However, this is only possible due to the precondition that a
qualified Jenbacher service hotline expert is connected to the
customer and the engine in case on demand, whenever needed.”
The 24/7 service team possesses the required competence; team
members average 13 years of experience in dealing with the
company’s gas engines. The new 24/7 service hotline is thus far
more than just a simple call center, where calls are received and
transferred, but a place where customer problems are solved by
qualified specialists.
A NEW SPARE PART SERVICE FOR ON-THE-SPOT CuSTOMER
ASSISTANCE. In addition to the 24/7 service hotline, GE has been
working intensively since last year on the implementation of
another special global customer service, the 24/7 express supply
of emergency spare parts. This development required a complete
overhaul of the existing logistics structure. Explains Axel Dancker:
“In 2010, we had to deal with problems regarding the availability
of our spare parts, and thanks are due to all our customers and
partners for their understanding and patience. With the new 24/7
service, in future we will be able to react to customer problems
with greater speed.” In January 2011, the first of three new logis-
tics centers was opened in Duisburg, Germany, and two more are
to follow this year. From the third quarter of 2011 on, following the
24/7 service A 168-hour week in the service of our customers
receipt of an order, emergency components will
be supplied to customers in Germany, the
Benelux nations and Denmark in an ensured
time of four hours. Deliveries will be completed in
close cooperation with an international hauling
company.
GE has been working intensively since last year on
the implementation of another special global customer service,
the 24/7 express supply of emergency spare parts.
Moreover, additional locations in Southern Eu-
rope are planned for next year with the medium-
term aim of extending the ensured supply time
to all of Western Europe and extending the
actual delivery period to a 24/7 level.
ExTENSIVE AVAILABILITY OF THE NEW 24/7
SERVICE. Although any customer can use the
new service, GE’s Jenbacher customers with
long-term maintenance contracts can call on
the 24/7 service at no extra charge, according to
Stefaan Verbanck, service operations manager
for the Jenbacher gas engines: “With the 24/7
service we have taken a further step forward
in the direction of best-in-class service and
wish to provide a large number of customers
with access to this offer. However, as a result of
remote-controlled plant access, customers with
long-term maintenance contracts have an ad-
ditional advantage.” With the 24/7 service,
GE’s Jenbacher gas engines team has signifi-
cantly increased its reliability, benefiting plant
owners and customers. _
facts and figures:
· A team of qualified service hotline experts
with an average of 13 years of experience
in dealing with Jenbacher gas engines
· Service support in English, German, Italian,
Spanish and Danish
· Over 400 customers helped successfully
since July 2010
· More than 50 percent of all inquiries dealt
with by phone (without an onsite service
engineer visit)
· Spare part deliveries within four to eight
hours in Germany (in future,
throughout Europe)
41 42
supply chaincogen supply chain cogen
Test stands have a long tradition in GE’s gas engines division, as they are vital to the new and further development of efficient
engines. 2009 saw the completion of the largest test stand yet installed at the Jenbach location. In recent months, this test
stand has been used to subject the new J920 engine to intense scrutiny in order to bring it up to serial production maturity.
Moreover, in the newly completed building 53, the stage is being set for the engine classes of the next generation.
Before a new GE engine is launched, it has already been sub-
jected to numerous test runs on in-company test stands.
The examinations carried out are comparable with the functional
tests used in the automotive industry. Engines intended for future
serial production are subjected to the most rigorous checks. Vari-
ous gas compositions and a number of possible defect sources
and numerous load situations, right up to overloads, can all be
quickly and simply simulated on the test stands.
Engines intended for future serial production are subjected to the most
rigorous checks.
Moreover, the stands can also simulate the conditions in hot and
tropical regions to perfection. This is vital, as countries in these
climatic zones constitute a major future business segment for
GE’s gas engines division.
TWO TEST STANDS WITH A SINGLE OBJECTIVE – THE PERFECT
ENGINE. A company team looks after the completion of the indi-
vidual tests while, internally, a differentiation is made between a
development and a serial production test stand. The former is em-
ployed primarily for pilot series production and the validation of
new engine design. Engine reliability is examined and conclusions
drawn concerning the functionality of the engine throughout its
service life. The development test stand is also employed for the
simulation of various operating conditions likely to be encoun-
tered in customer plants. In this manner, possible sources of
faults in the pre-series models can be corrected at an early
stage. Volker Schulte, general manager engineering of GE’s gas
engines division: “The development test stand plays a critical role
in the design of engines of the next generation and therefore is
equipped with a more comprehensive range of measurement
technology systems than its serial production counterpart. We
can use it to investigate completely new technologies. As a rule,
Jenbacher engines are tested on the development stand for three
years prior to serial maturity.” Finally, the development test stand
establishes all the parameters for the finished product, including
the key parameters for testing on the serial production test stand.
These checks include engine operation at levels far in excess of
standard running, as part of a process that eventually results in a
control strategy and limits for the shutdown of serial production
The development test stand is also employed for the simulation of various operating
conditions likely to be encountered in customer plants.
engines. Lastly, the final examination of the functionality of the
finished product takes place on the serial production test stand
using various key parameters. Only when these are fulfilled is the
engine delivered to the customer.
GE’S TEST STAND OF THE FuTuRE FOR SPECIAL CLASS ENGINES.
The fact that a test stand cannot be employed for every type of
engine does not serve to make things simpler. In 2009, the largest
test stand yet installed in Jenbach was complet-
ed. Building 53 contains two test cabins which,
due to their dimensions and the simulation pos-
sibilities they offer, constitute a milestone in
Jenbacher test stand development. Last
autumn, the first J920 engine to be built was
transferred to building 53 for assembly and serial
testing. In addition, the training of the installa-
tion crew for the first pilot project in Rosenheim,
Germany, was carried out on the Jenbacher test
stand.
TEST STANDS WILL ALSO BE NEEDED IN
FuTuRE. In the past, new engines were checked
almost entirely on tests stands. And, although
in recent years simulation software has found
increasing employment, test stands will continue
to be essential in the future – simulation can
never entirely emulate reality. A test stand is an
ideal tool to simulate the service life of an engine
at short intervals and to carry out numerous test
procedures that go far beyond everyday opera-
tion. Test stands not only assist the development
of new engines, they can also aid the ongoing
improvement of existing products. This is evi-
denced by the fact that the performance of the
type 6 Jenbacher engines has been more than
doubled during the past 20 years. _
Working at full speed on the gas engines of the future
Area 53–> LAST AuTuMN, THE FIRST J920 ENGINE WAS TRANSFERRED TO BuILDING 53
–> IN BuILDING 53 THE STAGE HAS BEEN SET FOR THE GAS ENGINES CLASSES FOR THE NExT GENERATION
cogen2.0
43
cogen: As Product Line Leader, what do you see
as your basic mission?
Scott Nolen: We want to coordinate develop-
ment and maximize the marketplace solutions
capabilities for power generation segment. It’s
really a cradle-to-grave responsibility for all these
products: making sure they’re competitive in
the field and that we do smart development of
new products, reduce costs on existing products,
increase our supply chain capability and develop
strong aftermarket solutions for our products in
the field.
How does your function reflect the integration
focus for the Jenbacher and Waukesha product
lines and Heat Recovery Solutions segment?
The intention is to create synergies so that the
products we develop can be used across all
the business units. Previously, when all three
businesses were separate, some research and
development activities – especially within
Waukesha gas engines and GE’s Jenbacher gas
engines businesses – focused on the same areas.
But now, we can optimize R&D (research and
development) work and obtain better efficiency,
higher power density, better fuel flexibility and a
greater capability to hold power and efficiencies
at higher ambient temperatures and altitudes.
We’ll optimize our R&D dollars and, more im-
portant, our R&D resources to the benefit of our
customers.
What are your short- and long-term business
goals?
In time, there will be a multi-generation product
plan that incorporates all the gas engines product
lines. An integrated offering combining gas
engines and the products supplied by the Heat
Recovery Solutions segment, currently in the early
development phase, will be created over the com-
ing months and years as those products mature.
The commercial launch of the J920 gas engine is
the major priority for 2011. That involves what I
call a “macro-sale” and a “micro-sale”. The
macro-sale is well under way, and included the
formal introduction of the J920 last fall at series of
launch events at the Jenbacher headquarters.
“The intention is to create synergies so that the products
we develop can be used across all the business units.”
The next step is the micro-sale, which really is the
key to launching a new product. It requires sitting
with customers, listening to their concerns and
priorities and developing solutions that emphasize
the products’ superior attributes and mitigate any
In March, Scott Nolen became product line leader for the entire power generation product line within GE’s gas engines business. He’ll be based
in Jenbach, so it helps that skiing is his favorite sport. “They’ve already taken me out on the slopes and made sure I’m good at that.” Actually,
Nolen has a wealth of other qualifications for his new position, including leading the power generation and compression product line managers
for the Waukesha product line, which GE recently acquired. He discussed his new role and its major challenges with cogen.
Scott Nolen, product line leaderpower generation of GE’s gas engines business:
profile:
Age: 43 years
Education: B.S. in mechanical engineering,
university of Vermont; M.B.A. in business
administration, university of Rochester
Married, one son
Scott’s leisure activities are skiing,
hiking and bicycling
His dream job as a child was airline pilot
“because I always wanted to travel when I
was young, so I guess it all worked out.”
Previous position: Vice President,
Power Generation, Waukesha gas engines
44
issues that may arise in support of the units.
What are the major challenges and opportuni-
ties that you will confront?
I think our significant investment in natural gas
products strongly positions GE’s gas engines
business for a future where there will be few other
power generation options using fuels that are
going to be acceptable in a carbon-constrained
world. In a world with a growing concern around
the production of CO2, natural gas is the best
“The challenge, though, is to generate the
most power possible with the fewest emissions, because
many power generation gas engines will be installed
near population centers.”
hydrocarbon-based fuel available, and the interest
in biogas continues to expand, too. Both of those
fuels promise a strong future for our gas engines
business. The challenge, though, is to generate the
most power possible with the fewest emissions,
because many power generation gas engines will
be installed near population centers. So there will
be two main drivers of technology development –
maximizing efficiencies and minimizing emissions.
personality storycogen personality story cogen
Integrating and optimizingPower Generation resources
As the fuel of the future, natural gas will power
formats ranging from big-baseload power plants
using gas turbines in combined-cycle service to
gas engines in cogeneration applications. GE has
been spending a significant amount of R&D effort
to maximize
efficiency for both electrical and heat genera-
tion. Now, with emissions, whether they’re from
exhaust, noise or vibration, it’s going to be very
critical to control them to very low numbers in
order to locate engines next to populated areas
where the waste heat can be used to maximize
the overall efficiency.
How has your career prepared you for your new
position?
What was so important was my previous sales ex-
perience, both in the field and in the home office. It
gave me a real strong focus on looking at project
applications from the customer viewpoint and ap-
preciating what customers value. That translates
well into how we develop products and how GE
competes – on solutions rather than price. Our ef-
forts go well beyond just ‘here’s a one-page quote
with a price at the bottom’. We’re about under-
standing and delivering efficiency, maintenance,
availability and numerous other attributes that go
well beyond the dollars at the bottom of the sheet.
Thank you for talking to us.
Publisher
GE Jenbacher GmbH & Co OHG
Achenseestr. 1-3, 6200 Jenbach, Austria
Editorial team:
Thomas Achrainer, Nancy Deptolla,
Andreas Eberharter, Sheila Gailloreto,
Ekaterina Goron, Christof Harrasser,
Petra Kalaskova, Claire Kelly, Stephan Laiminger,
Eugen Laner, Thomas Misch, Debra Murphy,
Scott Nolen, Klaus Payrhuber, Ray Pelosi,
Gerhard Pirker, Susanne Reichelt, Martina Streiter,
Chuck Taylor, Tatijana Uzelac, Stefaan Verbanck,
Michael Wagner, be.public Werbung Finanz-
kommunikation GmbH, KronthalerWaltl GmbH,
Texterei Theiner
Guest writers in this issue:
Gerd Krieger, VDMA Power Systems
Thorsten Herdan, VDMA Power Systems
Design and Layout:
Zimmermann Pupp Werbeagentur
Printer:
Alpina Druck GmbH, 6020 Innsbruck, Austria
Printed on paper free from chlorine.
Feedback:
We value your opinion and welcome your
comments or questions. Please send them to the
editorial team at [email protected]
Picture credits:
GE Energy
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