may – june 2014 steam turbine, $1.2 billion 1500mw ... net rated at 826.1mw and 59.6% efficiency....

Making the move to small off-grid power page 14

5MW recip blocks fired on biomasspage 22

New OEM builderfor global powerpage 28

May – June 2014 www.gasturbineworld.com

May – June 2014

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

Gas Turbine World • Vol. 44 No. 3

On the Cover. MHPS 501J gas turbine rated at 475MW and 61.5% efficiency packaged as a combined cycle plant.

2 Project development and industry news Panda 820MW 8000H project, 501GAC replacements for retired coal units, 9HA with Toshiba steam turbine, $1.2 billion 1500MW KA24-2 station, 450MW Bangladesh SGT5-4000F project, Grand River M501J plant

14 Off-grid plants easier to finance and build Small distributed power generation plants have lower capital requirements, can be built and operational much faster with less risk than large plants

18 Gas pipeline sets retrofitted to reduce CO Key gas compression station in Germany has been retrofitted to reduce CO emissions of FT8 gas turbine compressor sets to 8 mg/m3 at 75% load

22 Straw feedstock to fuel 5MW recip plants CHP facility designed around two 5MW multi-unit recip plants will operate on syngas produced by the gasification of straw pellets and wood chips.

28 New OEM for global power plant projects Joint venture company formed by Mitsubishi and Hitachi merges their thermal power generation businesses and expands their gas turbine operations.

Overly efficientHighly efficient gas turbines are usu-ally not good candidates for combined cycle application but the LM6000 may prove otherwise, page 14

New directiveCompressor station has added CO catalyst to comply with new federal directives on gas turbine CO exhaust emissions at 75-100% load, page 18

Straw-to-powerGas engines modified to burn syngas will power combined heat and power plant operating at around 70-75% CHP efficiency, page 22

Editor-in-Chief Robert Farmer

Managing Editor Bruno deBiasi

European Editor Junior Isles

Engineering Editor Harry Jaeger

Field Editor Michael Asquino

News Editor Margaret Cornett

Marketing Director James Janson

Publisher Victor deBiasi

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

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

2 GAS TURBINE WORLD May – June 2014

INDUSTRY NEWS

That works out to an installed cost of ap-proximately $854 per kW. About 85 percent of the project was financed by China Exim Bank and US Exim Bank, with the balance financed by the Government of Pakistan.

Virginia Nominal 1400MW combined cyclereplacing retired coal-fired stationsDominion Virginia Power reports that con-struction of its 1,360MW Brunswick County combined cycle project which started last September is about 17 percent complete. It is on budget and scheduled to be generating electricity by the summer of 2016. Cost of the plant is estimated at around $1.3 billion. It was approved by the Virginia State Corporation Commission in August of 2013 to replace electricity from aging coal-fired power stations that are being retired for economic and environmental reasons. The three-on-one combined cycle plant configuration is designed around three 273.6MW Mitsubishi Hitachi M501GAC gas turbines, each equipped with a duct-fired HRSG supplied by Alstom providing steam to a common reheat condensing steam tur-bine generator. The gas turbines are designed to operate in dry low-NOx mode over a load range of 50-100 percent output. Operation at lower loads will only occur during start-up and shut-down. HRSG steam production will be aug-mented by the gas-fired duct burners which will have a firing rate of about 500 MMBtu/hr each. The steam turbine generator set is designed to produce up to approximately 610MW of electrical output at ISO condi-tions with duct firing. Selective catalytic reduction will be in-stalled to control NOx emissions, and oxida-tion catalysts will be installed to control CO and VOC emissions. Four mechanical draft cooling towers will also be incorporated to provide air inlet chilling for the gas turbines and enhance hot day power output and ef-ficiency. Design ratings for the plant’s 3x1 com-bined cycle configuration are not available. Relatively, however, a 1x1 M501GAS com-bined cycle module, without HRSG duct firing, is rated at 412.4MW net output and 59.5% efficiency – based on a 1.5 inch Hg condenser pressure. Comparable 2x1 plant is net rated at 826.1MW and 59.6% efficiency.

Japan 1x1 combined cycle rated at 569MW and 62% efficiencyToshiba has received an order for an ad-vanced next-generation 9HA combined cycle plant from Hokkaido Electric Power Co. for

PakistanNominal 750MW Fr 9FA combined cycle start-upPakistan Electric Power Co. (PEPCO) re-cently completed construction of a 2x1 natural gas-fired combined cycle project at the existing Guddu power plant complex in Sindh province, Southern Pakistan. The EPC contractor for the project was Harbin Power Engineering. The combined cycle plant is designed around two dual fuel General Electric PG-9331FA gas turbines rated 243MW each, two unfired triple pressure horizontal HRSGs and one 261MW steam turbine generator (from China). Plant will operate on gas as primary fuel with high speed diesel fuel for backup in

the event of a disruption in gas supply. At full load, on natural gas fuel, the plant is rated at 747MW gross output and 56.4% gross efficiency. With losses, the combined cycle plant is rated at 721MW net output and 6608 kJ/kWh heat rate (54.4% efficien-cy). For operation on diesel backup fuel, the plant is rated at 694MW net output. According to government officials, the project was initially approved in 2008 but delayed for various reasons and finally au-thorized in September 2009. Harbin Power Engineering of China was awarded a turn-key EPC contract at an estimated cost of US$616 million for equipment supply, con-struction and commissioning, to be com-pleted by mid-2014.

PennsylvaniaGroundbreaking for 820MW 8000H combined cycle plantPanda Power Funds has started ground work on the company’s 820MW gas-fired com-bined cycle Liberty generating station located in Bradford County, Pennsylvania. Pennsylvania’s Department of Environmental Protection said in April that it intends to issue an air permit approval for the project. Liberty is the first power plant delib-erately sited in the heart of the Marcellus Shale to take advantage of low natural gas prices and transportation costs. Siemens is supplying two power islands for the station, each consisting of one SGT6-8000H gas turbine, one SST6-5000 steam turbine, one hydrogen-cooled SGen6-2000H generator, and one heat recovery steam generator in addition to the complete electrical system and SPPA-T3000 instrumentation and control system. At 59°F ambient and sea level site conditions, each combined cycle power island is design rated at 410 net plant output with a heat rate of less than 5690 Btu/kWh – equiv-alent to more than 60% combined cycle efficiency. Siemens says it will also provide maintenance and service for the main components associated with the gas turbine under a long term service program. Parts, inspections, and scheduled service/maintenance, remote monitoring and diagnostics are included in the service agreement. Gemma Power Systems through a joint venture with Lane Construction is the engi-neering, procurement and construction contractor. Gemma-Lane will be responsible for installing the power island equipment and for engineering, procurement and instal-lation of the balance of plant equipment and commissioning. The generating station will be located in Asylum Township in Bradford County, ap-proximately 140 miles northwest of Philadelphia. Construction on the Liberty project began in August 2013 and is due for completion in January 2016.

76751 GE High Efficiency Print Ad Pub: Gas Turbine World Handbook Trim: 8.125” x 10.875” Live:7.625” x 10.375” Bleed: 8.375” x 11.125”

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We introduced H-class. So it’s only natural that we take it to the next level. A decade ago, GE built the industry’s first H-class gas turbine. Since then, GE’s H-class gas turbines have logged more than 200,000 operating hours. This experience has led to performance improvements and smart innovation. Today, our 7HA and 9HA gas turbines lead the industry with cleaner, reliable and cost-effective conversion of fuel to electricity.

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Industry News

the Ishikariwan Shinko Power Plant Unit 1. Construction is expected to start in October 2015. The 1x1 combined cycle configuration, which will combine General Electric’s latest high efficiency 9HA gas turbine with Toshi-ba’s most advanced steam turbine, is rated at 569.4MW net plant output and 62% thermal efficiency (LHV) on LNG fuel. Toshiba and GE have been cooperating on gas turbine combined cycle projects since 1982. In May 1996, the companies estab-lished Toshiba-GE Turbine Services Co. to provide maintenance services in Japan for high pressure components for gas turbines. In October 2011, they established an alli-ance to promote sales of 50-Hz systems in Japan and Asia which was enlarged in Sep-tember 2012 to include 60Hz systems. That was followed in October 2013 with a stra-tegic alliance agreement to reinforce joint marketing capabilities globally. More recently in a January 2013 memo-randum of understanding, Toshiba and GE agreed to work jointly on developing “next generation” combined cycle systems offering ever higher levels of thermal efficiency. Toshiba’s order from Hokkaido Electric is the first received since that agreement.

Thailand770MW combined cycle plant goes commercialElectricity Generating Authority of Thailand, (EGAT) announced that the 770MW Wang Noi 4 combined cycle power plant entered commercial operation in April 2014. The plant was built by Siemens and Marubeni. The multi-shaft unit, located in the vicinity of the Thai capital Bangkok, is an extension of a power plant complex that is already home to three units. For the new unit 4, Sie-mens supplied the main components, com-prising two model SGT5-4000F gas turbines, an SST5-5000 steam turbine, three SGen-1000A generators, and the SPPA-T3000 in-strumentation & control system. Siemens was also in charge of commis-sioning Unit 4. Marubeni supplied the heat recovery steam generators, the main trans-formers and the cooling tower. Marubeni was also responsible for the civil works and erection of the plant. Following Wang Noi 4, the Siemens and Marubeni consortium will be completing the 800MW Chana 2 combined cycle plant, two 1x1 single-shaft combined cycle units, scheduled for commercial operation in the summer of 2014.

West VirginiaIPP proposing 567MW$615 million CC plantIndependent power plant developer Mounds-ville Power plans on building an estimated $615 million gas-fired combined cycle plant nominally rated at 550MW output on a 37-acre site in Marshall County, West Virginia. Groundbreaking is expected to start early 2015. Moundsville Power says it is contracting with a consortium consisting of CH2M Hill and General Electric to design, engineer and construct the facility. GE will provide two 7F.04 gas turbines, a steam turbine and bal-ance-of-plant equipment for the 2x1 power island. In a 2x1 configuration GE’s combined cycle is rated at 567MW base load output (net of operating losses and auxiliary system power consumption) and 5790 Btu/kWh heat rate (59% efficiency) on natural gas. GE will also provide a long-term contrac-tual services agreement to ensure plant ef-ficiency and reliability.

Ghana340MW combined cycle IPP power plant projectCenpower Generation Company is develop-ing a site-rated 340MW dual fuel combined cycle power plant in the municipality of Kpone within the Tema industrial zone, to operate on natural gas and light crude oil back-up. The IPP project will provide urgently needed low cost and efficient thermal power to the deregulated Ghanaian power market. It is expected to become one of the main off-takers of the West African Gas Pipeline which links gas fields in Ghana and Nigeria to the Tema industrial zone. The combined cycle plant is designed around two GE 128.6MW Fr 9E gas tur-bines, two HRSGs and one 141MW steam turbine generator set. On natural gas fuel, the 1x1 combined cycle plant is rated at 392.5MW net plant output and 52.7% efficiency (net of auxiliary system losses) at 59°F sea level site condi-tions. Project timetable calls for construction to begin in the Q3 2014 for commercial startup by early 2016.

Ivory Coast400MW phased construction IPP combined cycle projectTelemenia IPP is developing a nominally rat-ed 400MW Songon combined cycle project on the Ivory Coast as a build, own and oper-ate (BOO) project whereby the IPP and part-

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Industry News

ners will design, build, operate and maintain the plant for a period of 35 years. Burns and Roe Enterprises has been awarded a contract to provide engineering services for the plant which is near Songon-Dagbe. As engineering contractor, they will be responsible for the mechanical, instru-mentation and controls, and field engineer-ing oversight. The combined cycle plant is designed around two GE Frame 9E gas turbines rat-ed 126MW each, two HRSGs and a single 135-150MW steam turbine generator set. Gas turbines will be installed first so that they can operate to generate power while the steam turbine bottoming cycle equipment is being installed. Timetable calls for the first gas turbine generator set to be delivered and in simple cycle commercial operation in 20 months, the second gas turbine to be delivered and in simple cycle service in 24 months, and the combined cycle balance of plant equipment installed for full combined cycle plant ser-vice in 36 months. The entire project should be completed by 2017.

TexasEPA permit for FGE Power1,500MW combined cycle The U.S. Environmental Protection Agency issued a final environmental Prevention of Significant Deterioration permit for FGE Power to proceed with its 1500MW com-bined cycle development project in Mitchell County, Texas. The generation station will be powered by two 747MW Alstom KA24-2 combined cycle plants, each designed around two 230.7MW GT24 gas turbines, two duct-fired HRSGs and one admission-condensing steam turbine. Without duct firing, the KA24-2 combined cycle plant is rated at 664MW net base load output and 59.5% efficiency (5843 Btu/kWh heat rate) at 59°F sea level site conditions. In combined cycle operation the plant has unprecedented part-load efficiency, project engineers claim, virtually consistent from 100% to 80% load. The gas turbines are also designed to idle in a “low load parking” mode at below 20% combined cycle plant load that enables plant operators to provide over 450MW of spin-ning reserve power in less than 10 minutes to firm the intermittent nature of wind pow-er year-round with high efficiency backup power. Turnkey equipment supply and construc-tion cost of both plants is estimated at around $1.2 billion. The first plant has been scheduled for start of commercial operation

by Q4 2016; phase 2 is scheduled for com-mercial startup by Q3 2017.

KoreaNominal 940 MW M501J 2x1 combined cycle plantDaewoo Engineering & Construction has awarded Mitsubishi Hitachi Power Systems a contract to supply two M501J gas turbines, one steam turbine and three generators for the 60-Hz Pocheon combined cycle project about 45 km northwest of Seoul, Korea. Daewoo Engineering will supply the bal-ance of plant equipment that make up the combined cycle including two heat recovery steam generators, condensers and cooling systems. Daewoo Energy, an affiliated special pur-pose company, will handle the construction. Timetable calls for commercial startup in November 2016. The 2x1 M501J combined cycle module is rated at 942,900kW net plant output with a 5531 Btu/kWh heat rate (61.7% efficiency) at base load output.

South CarolinaDuke Energy go-ahead to build 750MW combined cycle plantDuke Energy Carolinas announced it will build and operate a 750MW natural gas-fired combined cycle plant at the existing Lee Steam Station site in Anderson County, S.C. Following South Carolina’s Public Ser-vice Commission approval for the project in April, the company has finalized plans to move forward with construction starting mid-summer 2014. Reportedly, Duke is currently soliciting RFP bids for major plant equipment (gas turbines, generators, transformers, etc.) from major OEM equipment suppliers and con-struction contractors. Plant is scheduled for commercial startup in November 2017 to replace capacity that will be lost to retirement of old coal-fired plants between 2014 and 2017.

OmanFr-9E gas turbine generator successfully commissionedBharat Heavy Electricals reports that Petro-leum Development Oman has commissioned its latest 126MW Fr 9E gas turbine plant at Qarn Alam-3 power project. Two earlier units were commissioned in 2012. Like the earlier units, the gas turbine was engineered, manufactured and supplied by BHEL’s Hyderabad plant while the state-of-the-art control system was supplied by the company’s Bangalore works. BHEL says that since its first order in

Oman for the Wadi Al Jizzi power station project in 1995-96 that the company has se-cured and executed 14 major contracts which include the supply of 16 gas turbine sets.

JapanMitsubishi setting up global distributed power businessMitsubishi Heavy Industries says it is cre-ating a new “Distributed Power Business Development Department” within its Energy & Environment business domain to oversee business relating to small and medium-size power systems and equipment. New department will enable MHI to shift its business model for distributed power sys-tems from individual product sales to mar-keting and provision of solution packages, including servicing, matching market’s di-verse needs. As the market for distributed power sys-tems continues to expand on a global scale, MHI says it has opted to establish the new Distributed Power Business Development Department as a way of bringing together and manifesting comprehensive in-house capabilities in this area, with the aim of dy-namically developing new commercial ter-ritory. This will include aeroderivative gas tur-bines, small heavy frame gas turbines, or-ganic Rankine cycle (ORC) turbines, energy storage systems (from its Energy & Environ-ment group) plus reciprocating gas engines, diesel engines and district heating and cool-ing systems ( from its Machinery, Equipment & Infrastructure group). Previously, MHI’s power generation busi-ness has centered on high end, large-capacity offerings. More recently, however, the com-pany has added new small and medium-size distributed power systems through new mergers and acquisitions as well as business integration. The company has now positioned itself to supply a more diversified lineup of products that include gas turbines based on aircraft engines and ORC turbines which were added to the product lineup as an outgrowth of the acquisitions of Pratt & Whitney Power Sys-tems (PWPS) and Turboden in 2013. In addition, the power range of heavy frame gas turbines was further enhanced as a result of MHI merging its thermal power generation business with that of Hitachi (see feature article in this issue). Other areas of business to be handled by the new department are MHI’s pre-existing business fields. Although these all have solid track records, the company says it saw a need to create a new comprehensive organi-zation to further strengthen response capa-

INTRODUCING – HYPERION POWER SERVICES

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Industry News

bility in package type solutions for projects involving regional development, etc. Because the new department will require management capability enabling oversight of multiple business areas, it will launch with representatives in charge of sales, tech-nology, etc. for each product area. Sales operations will be carried out taking ad-vantage of MHI’s existing global networks, and cooperative relationships with trading houses, etc. When necessary, liaison will also be un-dertaken with business development depart-ments within the Energy & Environment domain that are already in the process of de-veloping distributed power system markets in specific countries or regions. Hiromichi Morimoto, Senior Vice President and Se-nior General Manager, Business Division of Energy & Environment, will simultaneously serve as Director of the new department.

JapanKyushu building 60-Hz M501J 470MW combined cycle plantKyushu Electric Power has awarded Mit-subishi Hitachi Power Systems an order for a 60-Hz 480MW M501J combined cycle power project at its existing Shin Oita ther-mal power station in Oita City, Japan. The combined cycle plant will be built at the existing station at the mouth of the Ono River. Project timetable calls for start of commercial operation by July 2016. It is designed around a 327MW M501J gas turbine (with 1320 lb/sec mass flow and 1176°F exhaust temperature) and an unfired HRSG, 148MW steam turbine and electric generator. In combined cycle base load operating mode, the 1x1 combined cycle module is rated at 470MW net plant output with a heat rate of 5549 Btu/kWh (61.5% efficiency). Once this plant is commissioned, Kyusho Electric will have a total of 14 gas turbine combined cycle plants in service with a col-lective installed capacity of 2,775MW.

Ghana Nominal 1100MW LNG-fired IPP combined cycle projectGeneral Electric and IPP developers, En-deavour Energy and Finagestion, are work-ing with Ghana’s Ministry for Energy and Petroleum on a project to add 1,080MW of LNG-fired gas turbine combined cycle pow-er to the country’s installed capacity within the next 5 years. In addition to supplying power generation equipment for the combined cycle station, which is to be built in western Ghana, GE is collaborating with the Government agen-cies to facilitate development, financing and

engineering partnerships for implementing project goals The first phase of the project, which will initially produce 360MW in simple cycle mode (two 180MW gas turbine generating sets) is expected to be operational by Sep-tember 2016. To be converted to combined cycle operation by June 2017 with the instal-lation of a 180MW steam turbine generating set and balance of plant equipment (540MW gross output). In parallel, the second phase of the project will see 360MW of simple cycle capacity installed by March 2018 for simple power generation followed by 180MW steam tur-bine bottoming cycle equipment installa-tion by December 2018 for combined cycle operation (540MW gross output). The com-bined completion of both phases will gener-ate 1,080MW of power. According to Jay Ireland, CEO and pres-ident of General Electric Africa, the first phase of the project alone will required more than US $20 million of development capital, over $200 million of equity from IPP proj-ect investors and over $600 million in debt financing. The project will combine having to im-port liquefied natural gas and a dedicated Floating Storage and Regasification unit to receive, store and regasify the LNG for land-based delivery to the combined cycle power station. The government will facilitate a long-term agreement with the Electricity Company of Ghana (ECG) and potentially other power off-takers that purchase power from the project. Access to a reliable LNG supply of fuel for the station as compared to light crude oil is expected to significantly reduce the cost of generation, says Sean Lang, CEO of Endeavour Energy, the company that will co-lead the project’s development. Current LNG prices are approximately 35 percent lower than the light crude oil that most thermal plants in the country burn.

AsiaShanghai Electric proposing to buy 40% ownership in AnsaldoChinese power company Shanghai Electric is negotiating to buy a 40 percent stake in Ansaldo Energia of Italy for US $551 mil-lion. The transaction is expected to close by the end of this year. If the deal goes through, as expected, the companies may form joint ventures to open a research and development center in Shang-hai and establish a factory in the region to manufacture gas turbines for Asian markets. The agreement opens the door for Ansaldo to enter rapidly expanding Chinese gas tur-bine markets which the Italian firm says

represents 50 percent of the global market. Ansaldo’s simple cycle gas turbine prod-uct line currently ranges from 75MW (AE64.3A) to 310MW (AE94.3A) in out-put. Combined cycle 1x1 plants range from 112MW net output and 53.8% efficiency to 456MW net output and 58.9% efficiency in performance.

Florida Duke Energy proposing to build 1,640MW combined cycle plantDuke Energy Florida announced plans to construct a combined cycle natural gas-fired plant in Citrus County and two 160MW simple cycle gas turbine plants at the Su-wannee plant, near Live Oak, pending ap-proval by the Florida Public Service Com-mission. After a months-long request for proposals process, Duke Energy Florida has selected its self-build option to construct a 1,640MW combined cycle plant for commercial op-eration in 2018. The anticipated cost to build the new plant is approximately $1.5 billion, including financing costs. The new plant will be located on 400 acres adjacent to the existing Crystal River Energy Complex. Company officials also announced the retirement timeline for two coal-fired units at that site. If all regulatory approvals are received, construction is expected to start in early 2016. The plant’s first 820MW are expected to come online in spring 2018, and the sec-ond 820MW are expected to be available by December 2018. InternationalRolls-Royce selling its industrial gas turbine business to SiemensIn a $1.3 billion deal, Siemens has agreed to buy Rolls-Royce’s aeroderivative gas turbine and compressor business (including after-market replacement parts and service) to bol-ster its position in the oil and gas industry. On completion of the transaction, Rolls-Royce’s shareholding in the Rolls Wood Group joint venture which provides mainte-nance, repair and overhaul services will be transferred to Siemens. The transaction has been approved by the boards of directors of Rolls-Royce and Siemens. It is expected to be finalized be-fore the end of December 2014, subject to closing conditions including regulatory ap-provals. As part of the deal, Siemens will pay Rolls Royce an additional $340 million over 25 years for exclusive access to R-R’s advanced aero jet engine technology for application to new generation industrial gas turbine de-signs.

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Industry News

Indiana Cost of 650MW combined cycle project limited to $636 millionIndianapolis Power and Light has received approval from the Indiana Utility Regulatory Commission to spend $636 million for con-struction of a new 650MW combined cycle power station at its Eagle Valley generating station near Martinsville, Indiana. The Utility Regulatory Commission also signed off on IPL’s proposal to spend $36 million to convert two coal-burning units totaling 200MW at its Harding Street plant to operating on natural gas fuel. Construction on the CCGT project is scheduled to begin in the third quarter of this year for commercial operation in 2017. Conversion of Harding Street Units 5 and 6 to begin in the fall of 2015 and be completed by early 2016.

IndiaFr 9E combined cycle plant commissionedBharat Heavy Electricals Limited (BHEL) recently commissioned a site-rated 160MW 1x1 Fr 9E combined cycle power plant in Rajasthan, India’s largest state. With commissioning of the steam turbine on May 1, the plant, which was operating simple cycle, is now at full power combined cycle mode. BHEL’s scope of work included design, engineering, manufacture, supply, erection and commissioning of the main plant and as-sociated systems. The equipment supplied by BHEL includ-ed one Fr 9E gas turbine with generator, one HRSG, one steam turbine generator, auxil-iaries and plant controls & instrumentation. The equipment for the project was sup-plied by BHEL’s Hyderabad, Trichy and Bangalore plants, while the company’s northern region Power Sector undertook erection and commissioning,

Virginia Panda Power cleared to build 750MW combined cycle plantVirginia regulators have approved construc-tion of Panda Power’s proposed 750MW Stonewall natural gas-fired combined cycle project to be located in an industrial-zoned area south of Leesburg. Proposed 2x1 combined cycle plant will be powered by two gas turbine plants, two HRSGs, and one steam turbine generator. Not known if Panda’s design will go with General Electric’s 227MW 7FA.05 or Sie-mens’ 232MW SGT6-5000F5 gas turbines. Bechtel Development will be responsible for the engineering, procurement and con-struction of the Stonewall facility. Construc-

tion start date has not been specified but the plant will take approximately 30 months to complete, subject to financing, regulatory approvals and other conditions. If all goes well, it could be ready for com-mercial combined cycle operation by Q3 2017. Project development cost has been quoted at around $500 million – which in-dustry observers suspect is understated. GE rates its 2x1 7F-05 combined cycle plant at 688MW net plant output and 59.0% efficiency in full base load operation – with-out a duct-fired HRSG. Siemens’ 2x1 SCC6-5000F combined cycle is rated at 690MW net plant output and 58.0% efficiency. Project will reduce Virginia’s reliance on imported power to fill the gap between in-state production and load growth. De-mand is projected to increase by more than 7,000MW by 2020.

BangladeshTurnkey 450MW Ashuganjcombined cycle North plant Ashuganj Power Station Co. has awarded two Spanish construction companies, Tech-nicas Reunidas and TSK Group, the turnkey engineering, procurement and construction contract for the nominally rated 450MW combined cycle (North) plant being built in Ashuganj in eastern Bangladesh about 100 km northeast of the capital city Dhaka. The EPC consortium’s proposal was based on providing a single-shaft combined cycle plant powered by a 307MW Siemens SGT5-4000F gas turbine, SST-3000 steam turbine, and SGen5-2000H generator (to be supplied by Siemens) and unfired HRSG. Siemens rates its SCC5-4000F-1S refer-ence plant combined cycle design at 445MW net plant output and 58.7% efficiency at 15°C sea level site conditions. In this case, at specified site design conditions (35°C, 1.013 bar and 98% relative humidity), the Ashuganj North installation will have a net base load output of 380.7MW on natural gas fuel. Reportedly the winning bid submitted by the EPC team came to around US $286.8 million total, which works out to $753 per kW installed based on the plant’s site rating. Commissioning is scheduled for mid-2016 allowing 20 months for the simple cycle gas turbine installation and 30 months for the balance of plant to complete the combined cycle installation.

Oregon M501GAC combined cycle duct fired to 440MWoutputAbengoa Engineering and Construction, the EPC contractor for Portland General Elec-tric’s new 440MW combined cycle project,

has awarded Mitsubishi a contract to supply the power block equipment. Includes a M501GAC gas turbine, SRT-50 reheat steam turbine and duct-fired heat re-covery steam generator for the $450 million Carty Generating station being built near Boardman, Oregon. In base load operation at 59°F sea level site conditions, the M501GAC combined cycle is rated at 412.4MW net plant output and 59.5% efficiency – without supplemen-tary duct firing. Under average annual site conditions, duct firing can increase base load output to 440MW. Under a separate long term service agree-ment MPSA will provide the Carty Generat-ing Station with turbine maintenance, repair and outage services, replacement parts sup-ply, and dedicated remote monitoring for its gas turbine. Construction of the Carty combined cycle plant is scheduled for completion in the sum-mer of 2016.

England Multi-unit 300MW peaking plant for wind power backupWatt Power has proposed building a simple cycle gas turbine power station capable of providing up to 299MW of electricity in-corporating five gas turbine gensets on the site of a former World War II USAF base in Suffolk. The gas turbines are designed to operate as peaking plants that can respond quickly and efficiently to short-term variations in de-mand and intermittent output from onshore and offshore wind power. The station will require a substation and underground cable connection to the grid in addition to a gas pipeline connection to a nearby transmission pipeline for fuel. Subject to consultation, planning and fi-nancing, the natural gas-fired power station would enter commercial operation in 2018.

RussiaChina to invest billions in Russian energy projectsChinese power giant Dongfang Electric an-nounced plans to invest up to $2.3 billion in the energy projects of Russian power hold-ing RAO EES Vostoka in Russia’s Far East. The companies have also agreed to col-laborate in repairing, technically upgrading and renovating the existing generating units in the Far Eastern power service complex. They also will work together to develop so-lar energy in the Yakutia region. RAO EES Vostoka has four construction projects in progress in the Far East, includ-ing plants in Yakutia, Blagoveshchensk, on Sakhalin island and in the city of Sovetskaya

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Industry News

Gavan. The company’s power plants have a total capacity of more than 9,000MW.

Michigan Controls upgrade to improvePlant versatility and reliabilityTurbine Technology Services recently completed a turbine control system retro-fit modernizing two GE MS6001B gas tur-bines owned by the Holland Board of Public Works, with a TMS-1000 series turbine con-trol system. The retrofit control consists of a program-mable automation controller (PAC) system using Allen Bradley’s ControLogix platform to replace the obsolete original equipment manufacturer control system. They also employed generator control sys-tems by Basler Electric and digital generator protection relays by Schweitzer Electric Co. In addition, TTS incorporated a black start system to one of the units which will allow it to start automatically in the event of a black-out to the electrical system. “Upgrading from the GE Speedtronic MK IV control system to a modern redundant PAC control system has greatly improved our ability to find, troubleshoot and fix issues that come up when minutes matter,” said Carl Thorwall, project engineer for Holland.

ArkansasControl system retrofits for2x1 combined cycle blocksUnion Power Partners has awarded Emerson Process Management a contract to replace turbine controls at Union Power Station lo-cated in southern Arkansas. Union Station has a generating capacity of 2,200MW and comprises four individual 2x1 combined cycle power blocks. Emerson will replace legacy controls on the power block’s GE Frame 7FA gas tur-bines and GE D11 steam turbine with Ova-tion control technology, and the GE EX2000 systems with its Ovation generator excitation technology. Equipment delivery will take place in Oc-tober, and the first retrofitted power block is expected to be back online in December 2014.

South America Kobelco expanding the scope of itsnon-standard compressor operationsKobe Steel recently announced that its sub-sidiary company, Kobelco Machinery do Brasil (KMB), based in Sao Paulo, has be-gun full-scale marketing of non-standard compressors used to compress and transport gases in oil and gas processing facilities. Kobelco says it has a high record of supply for screw compressors used on FPSO (Float-

ing Production, Storage and Offloading) ves-sels that process oil and gas, and temporar-ily store them onboard, after which they are transferred to tankers. The company has also supplied numerous centrifugal and reciprocating compressors operating in South America, increasing the need for after-sales services in the region that KMB now provides. Established in November 2013, KMB has already begun strengthening its marketing, sales and after-sales service operations, with aims to expand Kobelco’s compressor busi-ness in South America. Kobe Steel has previously set up locations in China, Southeast Asia, the Middle East, North America and Europe. The addition of KMB operations in South America will increase the global competitiveness of its non-standard compressor business.

Oklahoma M501J to power 495MW combined cycle plantGrand River Dam Authority awarded Mit-subishi Hitachi Power Systems Americas a contract to supply M501J power island equipment for a gas-fired combined cycle plant to be built adjacent to an existing two-unit (Unit 1 and 2) GRDA coal-fired com-plex at Chouteau, Oklahoma. The new unit (Unit 3) is to be a com-bined cycle, capable of producing 495MW of electricity at over 60% combined cycle efficiency, powered by a 328MW M501J gas turbine generator and 167MW SRT-50 steam turbine generator. The M501J gas turbine generator has an estimated capital cost of $50,500,000 ($154/kW) and the SRT-50 steam turbine generator $27,340,000 ($164/kW). Total costs for the entire Unit 3 combined cycle plant are esti-mated at around $372,000,000 ($752/kW). This M501J gas turbine installation will be the first of its kind in North America. Construction of Unit 3 is scheduled to begin in 2015 and be completed in time for com-mercial operation in 2017. Black & Veatch has been appointed by GRDA to provide engineering services as “owner’s engineer” during the project’s development, construc-tion and commissioning. MHPS says it has now received orders for 30 J-series gas turbines worldwide. There are currently 10 of the 60-Hz M501J tur-bines in service with more than 44,000 hours of operation accumulated to date. Singapore800MW turnkey combined cycle plants commissioned Siemens Energy and its consortium partner Samsung C&T designed, erected and com-

missioned Pacific Light Power’s combined cycle plant on Jurong Island in Singapore on a full turnkey basis. With an installed electrical generating capacity of approximately 800MWs, and an efficiency of over 58 percent (based on site conditions), the two new power plant units will contribute toward meeting the country’s significant rise in demand for reliable power. Siemens scope of supply included two SGT5-4000F gas turbines, two SST5-5000 HIL steam turbines and two SGen5-2000H-hydrogen-cooled generators (for single-shaft arrangement) as well as an SPPA-T3000 instrumentation and controls system. Siemens and Samsung were also respon-sible for full erection and commissioning the power plant. According to company project engineers, the plant topped the contractually guaranteed figures for power output, NOx and CO2 emissions.

MalaysiaH-class cogen facility rated at1220MW and 1480 tph steamSiemens in a consortium with MMC Engi-neering Services of Malaysia has received an order from Malaysia’s state-owned petro-leum corporation, Petronas, for the turnkey construction of the Pengerang cogeneration plant in Malaysia. The order requires Siemens to undertake the turnkey construction of the PCP, which comprises four cogeneration units along with a long-term maintenance and services con-tract. Each unit comes with an H class gas turbine, waste heat recovery steam generator, steam turbine, associated mechanical and electrical systems, and the instrumentation and control system. The plant will be able to produce approxi-mately 1,220MW of power and up to 1,480 tons per hour of steam for the Pengerang integrated complex, a mega development in southern Johor, Malaysia. The first cogeneration unit is expected to go online by mid-2017, and it will also supply power to the national grid for public consumption. The remaining cogeneration units will supply electricity and steam to PIC’s facilities.

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GE has launched a Distributed Power business unit that com-

bines three product lines – aeroderiv-ative gas turbines, Jenbacher gas en-gines, Waukesha gas engines – into an umbrella organization totally focused on meeting a growing global demand for on-site power systems. Target areas of strength will in-clude smaller power plants located near their point of use, especially in remote areas with poor or non-exis-tent electric grids. When announcing the consolida-tion earlier this year, GE said that it has been working on four key areas of development:

o LM6000 gas turbine. Major engi-neering program planned to make the LM6000 more suitable for combined cycle power than current design.

o Jenbacher J920 gas engine. New 60-Hz/900 rpm unit is being intro-duced at 8.5MWe and 49% simple cycle efficiency.

o High speed diesel. GE is currently offering a prototype engine for field evaluation prior to introduction of a new production unit in 2016.

o Dual fuel technology. Engineering development and test program is un-der way to allow the reciprocating en-gines to operate on gas or diesel fuel.

GE company executives met with In-donesian business leaders and gov-ernment officials in February to de-fine the scope and goals of the opera-

tion, national and regional project ap-plications, and the global importance of distributed power to future growth of emerging economies. Lorraine Bolsinger, president and CEO of GE’s Distributed Power busi-ness unit, says that GE plans to invest $1.4 billion on product development over the next four years – with a big slice going to new engine designs and technologies. Bringing the three busi-nesses together gives the new busi-ness economies of scale. In the past, there were three busi-nesses all fighting for investment in technology and market share. “We now have a global commercial foot-print,” she says. Before, there were three indepen-dent sales forces, each going in with their one product to sell. Now they have a broad array of technologies from which to choose the product that best fills customer needs.

LM6000 gas turbine upgrade Since commercial introduction 20 years ago, the LM6000 has logged more than 26 million hours, with more than 1,000 units operating in utility, industrial and oil & gas service around the world. In September of 2011, GE intro-duced an enhanced LM6000-PG de-sign, with a single annular combustor, rated at around 54MW and 40% effi-ciency for simple cycle power genera-tion. The same gas turbine packaged for combined cycle operation is rated at around 70MW and 51% efficiency. Changes in the LM6000 design are needed to improve combined cy-

cle performance, says Bolsinger, but made no reference to scope, goals or timing – or how design parameters will differ from the 30 to 1 pressure ratio, 317 lb/sec exhaust flow and 862°F temperature of the LM6000-PG current production model. In comparison, the typical heavy frame industrial gas turbine will have a pressure ratio closer to 20-to-1 and an exhaust temperature of around 1100°F. Steam turbine bottoming cycle of such plants typically contributes about one-third of overall plant power (or about 50% of the gas turbine’s contribution). Today’s combined cy-cle plants based on these gas turbines are achieving plant efficiencies on the order of 58% or higher. Basically, anything you do to in-crease gas turbine exhaust energy - flow and/or temperature - will in-crease steam turbine output and bet-ter optimize combined cycle perfor-mance. More fundamentally, however, ad-vances in hot gas path materials, coat-ings, cooling techniques, component (compressor and turbine) aero-ther-modynamic efficiencies can all en-hance potential performance improve-ment. Industry gas turbine design engi-neers speculate modifications might involve a combination of mechanical and thermodynamic design changes. For example, using ceramic matrix composites for hot gas path compo-nents plus advanced thermal barrier coatings (developed for next gen-eration aircraft propulsion engines)

Distributed power easier tofinance and faster to build By Junior Isles and

Victor deBiasi

GE plans to invest $1.4 billion over the next four years on its portfolio of distributed power generation equipment to capitalize on expected growth in the sector.

GAS TURBINE WORLD May – June 2014 15

would allow operation at higher firing temperatures without more cooling (efficiency increase). Modifying the compressor to in-crease air flow (more power) and us-ing off-engine compressor intercool-ing to reduce turbine power require-ment for compression would also in-crease power output. Another less obvious option may be to reduce engine pressure ratio. This would tend to compromise the LM6000 gas turbine simple cycle ef-ficiency but it would contribute to optimization of combined cycle per-formance.

J920 gas engine GE’s Distributed Power business un-veiled a new 10MW class Jenbach-er J920 Flextra gas engine this June for 60Hz generation that features a 5-minute start-up time and 49% ef-ficiency, more than 90% for combined heat and power applications. Thanks to its 2-stage turbocharg-ing design feature, project engineers report that the J920 gas engine genset can attain up to 2 percentage points better electrical efficiency when com-pared to gas engines with single-stage turbocharging. It is also said to offer faster re-sponse to peaks in demand with ex-cellent load-following capabilities.Bolsinger says the J920 offers a “very viable block of power” around which to build plants ranging from 10MW to 100MW and more in capacity. The technology is easily scaled. By putting several engines together, she explains, you can build a plant with fast start capability and maintain its high overall plant efficiency at part-load by taking off 10MW increments at a time.

High-speed diesel This June, GE also announced it is currently testing its first high-speed diesel engine offering for distributed power generation. The 2.6MW 616 diesel engine model, which GE plans to start ship-

ping later this year, is a derivative of the Jenbacher J616 gas engine design and the P616 locomotive diesel en-gine design from GE Transportation. The 616 high-speed diesel brings together medium-speed engine fuel economy with high-speed engine CA-PEX, aiming to improve total life cy-cle cost for on-site power generation applications.

White paper GE has released a white paper on “The Rise of Distributed Power” which makes the case for what the company says is a wave of decentral-ization sweeping across the globe. The move is away from solely cen-tralized systems and toward integrated networks that include both distributed and centralized elements. In this sce-nario distributed power technologies create a decentralized power system within which generators meet local power demand throughout the net-work. According to the paper, distrib-uted power will grow 40 percent faster than global electricity demand between now and 2020. It also re-ports that distributed generation (up to about 100 MW in unit output) repre-sents 33% of today’s global power ca-pacity additions and will rise to about 42% in 2020. Distributed power technologies can stand alone, the paper says, or work together within that network of inte-grated technologies to meet the needs of both large and small energy users. The rise of distributed power is being driven in part by its ability to overcome the constraints that typi-cally inhibit the development of large capital intensive power plant proj-ects and transmission and distribution (T&D) grids. Because they are small, they have lower capital requirements and can be built and become operational faster, with less risk, than large power plants; they can also be incrementally ex-panded to meet growing needs. And the growth of unconventional

natural gas production (shale gas) as well as expansion of land and seabed gas networks is making gas fuel more available.

Projected growth The net result is an increase in distrib-uted power investment and capacity installations that is expected to con-tinue over the next decade. In 2012, an estimated $150 bil-lion was invested in distributed power technologies including gas turbines, reciprocating engines and solar photo-voltaic cell projects globally. Approxi-mately 142GW of distributed power capacity was ordered and installed, according to the paper. During the same year, GE esti-mates that 218GW of central power capacity was ordered and installed – which means that distributed pow-er capacity additions accounted for about 39% of total global capacity ad-ditions. By 2020, GE figures, distributed power will grow to 200GW from 142GW in 2012. That represents an average annual growth rate of 4.4 per-cent.

Distributed power Indonesia When company executives met with Indonesian business and government officials, they did so in the context of what GE now has to offer and is doing to support the growth of dis-tributed power in Southeast Asia and, more specifically, Indonesia. Some of the more interesting proj-ects and alliances:

Lorraine Bolsinger, president and CEO


● separate MOUs with Clean Power Indonesia and with PLN for develop-ment and deployment of its integrated biomass gasification power system in Indonesia, with potential to further diversify Indonesia’s fuel mix by cre-ating power from sustainable local

bamboo and wood sources.● contract agreement with project developer Navigant Energy to sup-ply and service 100 Jenbacher gas engines that will generate a total of 330MW at a number of IPP sites in Indonesia and Thailand. And a sepa-

rate 10-year agreement under which Navigant will provide maintenance on GE’s installed fleet of 100 Jenbacher J620 gas engines that are driving on-site power projects in Singapore, In-donesia and Thailand.● an agreement between GE and Ma-laysian company Green & Smart to jointly provide a waste-to-power plant using Green’s patented technology in anaerobic digesters and GE’s Jen-bacher gas engine technology to pro-duce and supply power to the Malay-sian electricity grid.● an MOU between PLN Enjinirng and GE Distributed Power in partner-ship with GE Oil & Gas to develop an integrated “virtual pipeline” power generation pilot project for remote islands of Indonesia. They will com-bine Oil & Gas’ small-scale regasified LNG gas fueling technology with Distributed Power’s gas turbine and engine technologies to provide the islands onsite gas-to-power capability without building a network of inter-connecting pipelines. n

Municipal CHP installation. This 50Hz/1,000 rpm J920 gas engine is rated at 9.5MWe and 48.7% simple cycle efficiency.

LM6000 gas turbine. The latest LM6000PG model is rated at 53.5MW and 39.8% simple cycle efficiency.

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Open Grid Europe in Germany recently retrofitted two FT8

gas turbine compressor units at its Werne gas compressor station, ME7 and ME8, to comply with the national directive on emissions effective Octo-ber 2015 and also to reduce noise. The directive limits exhaust emis-sions for all existing gas turbine in-stallations to less than 75 mg/m3 NOx and 100 mg/m3 CO over a 70-100% load range – 50 mg/m3 NOx for new units. Both FT8 gas turbines at Werne al-ready meet NOx for old units thanks to dry low NOx combustion which produces around 50 mg/m3 NOx per gas turbine. However, their exhaust systems were modified to reduce CO emissions as well as noise. Key changes:

o Catalyst. Addition of carbon monoxide catalytic oxidation section within the gas turbine exhaust duct-ing.

o Silencer. Addition of a resonator-absorber and silencing system mount-ed inside the inner stack exhaust.

o Power. Slight loss in power out-put due to exhaust gas pressure drop across catalyst and silencer.

Gas turbine project supervisor, Athanasios Pechlivanis, reports that the CO catalyst has limited ex-haust gas turbine emissions to 8 mg/m3 CO at full load. And the si-lencer has reduced the gas turbine noise to around 90 dB(A) at full load.

Performance testing of the ME7 gas turbine verified a maximum ex-haust gas pressure drop of 21 mbar with an associated 133kW loss in power output at full load output (see test results table). Comparable shaft loss on the ME8’s gas turbine is not available be-cause the gas turbine’s power turbine was out for overhaul service during the exhaust stack retrofit period.

Compressor sets The ME7 gas turbine compressor set was commissioned in 1995 and retro-fitted in 2012-13; the ME8 was com-missioned in 1996 and retrofitted in 2013-14. Each gas turbine engine consists of a Pratt & Whitney 25MW FT8-55 dry low NOx gas generator and MAN 3-stage power turbine. The en-gines are coupled to 3-stage RV090

Werne gas compression station retrofitted to cut CO and noise By Michael Asquino

Key station in North Germany has been retrofitted to meet federal directive on allowable emissions for existing gas turbine installations.

Werne gas turbine compressor station project

Open Grid Europe is Germany’s leading natural gas carrier with a transportation network of around 12,000 km in length.

Werne, a key station in that network, is powered by eight gas turbine compressor units with a total ISO rated capacity of 110MW.

It has a maximum flow rate of 6 million cubic meters per hour and an-nual gas capacity of 25 billion cubic meters (25% of the entire German capacity).

As required by German Federal Emission Protection Directive regula-tions, all existing gas turbine plants over 50MW thermal heat input must reduce emissions to less than 75 mg/Nm³ NOx and 100 mg/Nm³ CO by October 1st, 2015.

The NOx emission limit for new gas turbines is 50 mg/Nm³.

Performance parameter ME7 FT8 ME8 FT8 NOx concentration 51.1 mg/m³ 41.0 mg/m³CO concentration 7.0 mg/m³ 8.0 mg/m³Max noise level 90.9 dB(A) 90.4 dB(A)Added pressure drop 21.0 mbar 23.3 mbarShaft power loss 133.0 kW * N/A

*Note: ME8 gas turbine shaft power loss data not available.

Test results. Operational tests were conducted before and after the retrofits to document emission levels and shaft loss at full load output.


pipeline compressors with an intake pressure of 60 bar and 1.45 compres-sor ratio, also manufactured by MAN Diesel & Turbo. The German Federal Emission Protection Directive (13. BImSchV) requires all gas plants over 50MW thermal input to limit NOx and CO emissions within a load range of 70-100% output at 15°C ambient and sea level ISO conditions. This may require retrofitting old gas turbine units for dry low NOx combustion (if not already equipped with DLN combustors like the FT8s at Werne) or selective catalytic reduc-tion to limit NOx and carbon monox-ide catalyst to limit CO.

CO catalystThe units at Werne only needed to reduce carbon monoxide emissions. The CO catalytic converter unit de-signed for the application consists of a special stainless steel foil that forms a honeycomb core encased in a stainless steel enclosure, shaping a so-

called “module”. The CO catalyst arrangement is made up as an array of five x eight (5x8) modules with a rectangular cross section fitted into an internal carbon steel support frame (see draw-ing). Expansion seals on the outside assure the exhaust gas passage.

The sidewall of that section of the exhaust stack in which the CO con-verter unit is installed has also been fitted with a new manhole for installa-tion and removal access.

Silencer design The silencer system is constructed of

rain deflector

resonator panel

silencer

CO catalyst

expansion joint

GT collector box

platform

Exhaust stack retrofit. The CO catalyst, resonator panels and silencer in-stallation did not increase the height of the ME7 or ME8 gas turbine exhaust stacks (circa 27.5 meters).

CO catalyst. The CO converter unit consists of modular catalyst assemblies fitted into an internal carbon steel support frame for mounting inside the exhaust duct.


single resonator-absorber panels bun-dled and mounted in the inner pipe of the existing exhaust stack. The panels are calculated to react at the relevant disturbance frequency of the gas turbine exhaust flow to ab-sorb and reduce noise. The panels consist mainly of a steel frame encasing mineral wool, covered by a resonator steel vibratory membrane. This membrane serves to convert the acoustic energy into vibrational energy, Pechlivanis explains, which is converted by the absorbing mineral wool into heat energy.

Testing goals A series of operational tests were ex-ecuted on the retrofitted gas turbines in order to verify design performance. Primarily to confirm that the new total exhaust gas pressure losses (re-sulting from the addition of catalyst and new silencer) did not exceed a val-ue of around 25 mbar. (This pressure drop corresponds to an estimated shaft power loss of approximately 240kW). Values for both pressure drop and associated power loss of the FT8 gas turbines were also calculated at full load output corrected for ISO condi-tions, says Pechlivanis.

The tests were conducted to offi-cially confirm that emissions did not exceed 75 mg/m3 NOx and 100 mg/m3 CO, and that noise levels do not exceed 89 ± 2 dB(A).

Test procedures NOx and CO emission levels were measured via a gas analyzer, includ-ing a sample probe equipped with a pump, drain separator unit and an electronic cooler unit. Measured and evaluated in ac-cordance with DIN EN 15058 to de-termine the mass concentration of carbon monoxide and EN 14211 to measure the concentration of nitrogen dioxide and nitrogen monoxide in the ambient air. Noise emissions levels were sam-pled at different measuring points (ac-cording to DIN EN 45635-47 stan-dards) via a sound level meter under-neath the mouth of the exhaust stack rain deflector, which registered 90.9 dB(A) as the highest noise level. The reduction in shaft power out-put due to the pressure drop of the catalytic section and exhaust stack silencer were measured (according to ISO 2314 and VDI 2045) before and after the retrofit to evaluate the power loss (see schematic).

Performance tests Operational shaft power output per-formance was recorded by the sta-tion’s torque meter. Gas turbine power output before retrofit was thermodynamically de-rived through the gas compressor’s performance to verify reliability of test torque meter measurements. Mass flow of the fuel gas was cal-culated via a pressure differential ori-fice plate inserted in the fuel gas sup-ply line. Fuel gas composition and thermodynamic properties were ana-lyzed by gas chromatographic meth-ods. To assure the best possible test re-sults, says Pechlivanis, all of the in-strumentation was calibrated in ad-vance of the operational test runs. Before testing began, the gas tur-bine inlet air filters were inspected to make sure they were clean. In ad-dition, the gas turbines were water washed to clean any compressor blade fouling that might throw off test re-sults. All of the ambient (and other rel-evant) parameters were also corrected (via manufacturer’s correction curves) to ISO standard reference conditions.

Conclusion In summary, says Pechlivanis, test results verified that the strict federal limits on gas turbine emissions and shaft power loss were kept within de-fined values. n

Performance test. Gas turbine shaft output was indirectly calculated through the gas compressor’s performance before retrofit to verify torque meter reli-ability. Gas turbine rotational speeds were recorded by the station’s distributed control system.

LP turbine

HP turbine

gas-probe

torquemeter

CO-catalystfuel-gas line

combustionchamber

m_fuel gas

∆p_air inlet

axial aircompressor

air inlet and fi lter

gas compressor

∆p_exhaust gas

Athanasios D. Pechlivanis is a gradu-ate of the Aachen University of Applied Sciences in Mechanical Engineering and Energy Systems. He has worked on diverse power plant and gas field proj-ects in Germany, Middle East, Asia and South America.

Stay Ahead of the Curve

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issues that impact utility, oil & gas, industrial and marine turbine operators around the globe. (Bi-monthly)

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A biomass gasification cogenera-tion plant being built in Bulgaria

will demonstrate the technical and economic case for using reciprocating engines in this application. As part of an ongoing drive to re-duce Bulgaria’s heavy dependence on imported energy, an innovative 10MW biomass-to-energy plant pow-ered by GE Jenbacher gas engines is being built in the village of Stroevo, in Plovdiv province. The 10MW Karlovo plant will gas-ify straw and wood chip feedstock to produce low-Btu syngas to fuel the reciprocating gas engines. Project de-sign and performance highlights:

o Power island. Two 5MW blocks each comprised of one J612 and two J620 gas engines with heat recovery to produce electricity and hot water for industrial heating.

o Efficiency. Plant is expected to have an overall combined heat and power efficiency of 70-75% based on 30-35% efficiency for electrical and 40-45% for thermal output.

o Project cost. Investment cost is estimated at around €20 million for each of the two 5MW units, including land and permitting costs as well as the capital cost of the plants.

The plant is being built by EQTEC Iberia, part of Spanish holding com-pany EBIOSS Energy AD. It is the latest development in a strategy to ap-ply its integrated biomass gasification cogeneration power plant technology throughout Europe. This will help countries reduce their dependence on foreign energy supplies and increase the proportion of energy generated from renewable sources. Bulgaria’s economy has been de-veloping quickly since joining the EU in 2007, which in turn has been driv-ing electricity demand. One of the government’s goals outlined in its en-ergy plan is to reduce dependence on imported fossil fuels. At present more than 70 percent of its energy is from imported natural gas, mainly from Russia, and oil. The country’s target is for 16 percent of its energy demand to be met by domestic renewable sources by 2020. Although the country plans to in-vest in wind and solar, biomass is seen as a particularly important source of renewable energy in the country. Luis Sanchez Angrill, CEO of EBIOSS, commented: “The Bulgari-an authorities encouraged us to invest in biomass generation as it has social benefits, mainly to farmers. The straw

in Bulgaria is not well utilized; most of it is just spread on the land and burned. Selling the straw for power generation gives the farmers an in-come.”

Choice of prime moverThere are two main options for con-verting gas from the gasifier to elec-tricity: either use its heat to gener-ate steam which can be utilized in a steam turbine (Rankine cycle) or burn the gas in a gas turbine or reciprocat-ing gas engine. The conventional Rankine cycle approach uses mature, simpler tech-nology but has low efficiency, typi-cally about 20 percent electrical ef-ficiency from biomass to grid. Gas-ification in combination with gas en-gines or gas turbines can offer much higher electrical efficiency. With a gasification efficiency of 78+ percent and a gas engine effi-ciency running on syngas of typically 39+ percent, an overall biomass to grid efficiency of 30 percent in simple cycle or 35 percent in combined cycle mode is possible. The choice of whether to use a gas turbine or gas engine depends on several factors, the key ones being the quality of gas and the required power output of the plant. “We explored the possibility of us-

Biomass gasifier to fuel recip engine CHP plant By Junior Isles

Straw and wood chip feedstock will fuel 10MW combined heat and power facility designed around bubbling bed gasifiers and reciprocating gas engines modified to burn syngas.


ing GE’s gas turbines but the heating value of the syngas at the Karlovo plant is too low for gas turbines,” said Sanchez. Gas turbines require syngas gas with a minimum heating value of about 12-15 MJ/m3, whereas the heat-ing value of syngas from our gasifier is about 5-6 MJ/m3.” GE has dedicated Jenbacher gas engines for burning these “special” gases which are predominantly a hy-drogen and carbon monoxide mixture. According to EBIOSS, the choice of Jenbacher gas engines versus oth-er engine manufacturers was due to GE’s Jenbacher gas engines “very long experience” with these types of gases and the high efficiency of the engines. “They also offer reliable ser-vice, which is particularly important when running with these special gas-es,” added Sanchez. The engines chosen for the proj-ect are the J620 and J612 – the same models used for the Movialsa project, a similar project built by EQTEC in Spain. The Jenbacher Type 6 engines are GE’s largest engines for burning syn-

gas and are well-suited for EQTEC’s projects, which are typically in the 1-10MW size range.

Suitable for strawThe Karlovo plant will use straw and wood chips to produce the syngas. Modifications are also being made to the fuel feed system to allow the plant to use chipped straw. Straw will be bought from local farmers as standard bales, from which EBIOSS will produce pellets. The pellets will be stored in a bunker with a storage capacity of up to 10 days. “This provides a kind of safety buf-fer in case straw cannot be delivered in the event of problems with trans-port due to bad weather, which can happen during winter in this area of Bulgaria,” noted Sanchez. Using syngas as a fuel is uncom-mon in such plants and represents an innovative solution to the energy chal-lenges Bulgaria and many other na-tions face. However, it is challenging to develop an integrated gasification design that does not produce syngas containing impurities that can foul engines.

Straw is a very difficult fuel. It has a high ash content containing a num-ber of alkali metals, mainly potassium which forms potassium chloride. This salt is difficult to handle in a combus-tion chamber or gasifier. Sanchez explained: “The ash has a very low melting point of around 750°C compared to wood chips which melt at about 1100°C. We are able to run on straw because our gasifier runs at a very low temperature, ap-proximately 740-750°C. Combustion boilers have to operate at about 1100-1200°C.” This ability to run on a wide range of fuels, says EBIOSS, was one of the key reasons for choosing gasifica-tion technology instead of combustion technology.

Gasification islandFeedstock is fed to the gasification is-land, which consists of a reactor ves-sel and gas cleaning equipment. The pressure in the gasifier de-pends on the plant. According to EBIOSS it can be designed to run slightly under pressure or just above atmospheric pressure.

Karlovo plant site. Civil works are now completed along with a 9 km line connection to the substation. The 10MW plant powered by the first of two 5MW blocks should be commissioned and ready for commercial startup on syngas fuel by mid-December 2014.


In the Karlovo plant, the gasifier runs at 1.5 bar. This, noted Sanchez, “is very low compared to a steam boiler, where the steam usually reach-es 40-60 bar.” Once inside the gasification reactor vessel, straw pellets and wood chips are converted to syngas at a tempera-ture of about 750°C. The syngas con-tains about 12-18 percent hydrogen (H2), 15-20 percent carbon monoxide (CO) and about 5 percent methane (CH4). The remainder is mostly nitrogen and 1-2 percent hydrocarbons such as ethane, butane, propane, etc. Impor-tantly for the engines, the gasifier is able to deliver a syngas that has very stable composition, temperature and pressure. Syngas is then passed to the cleanup system for removal of pollut-ants. The first stage of gas cleaning is done in a cyclone for ash removal. This is composed of a tar-cracker to crack long molecular chain hydrocar-bons i.e. oils and tars to produce more hydrogen and CO. After the tar-crack-er there is an ash filter for removing ash not captured by the cyclone. The final cleaning stage is a wet syngas cleaning system. This com-prises a wet scrubber. Syngas is cooled and then heated. The cleaned syngas leaves the gasification at a temperature of 50-60°C and is fed to the engine. “This syngas can be fed to the en-gine without causing any problems in terms of pollutants that could dam-age the engine or produce exhaust gas emissions,” said Sanchez.

Power islandThe power island plant in Karlovo consists of two 5MW blocks each comprising one 1.1MW J612 and two 1.95MW J620 gas engines. The difference in composition be-tween syngas and natural gas requires modifications to the standard Type 6 engine platforms. Their gas supply systems must be adapted to operate on syngas which has a low heating

Biomass gasifier. Korlovo will gasify straw pellets and wood chip feedstock at about 750°C temperature and 1.5 bar to produce syngas with a lower heating value of about 5-6 MJ/m3 for gas engine fuel.

Gas engine. Jenbacher gas engines, like this unit at a biomass plant in Italy, must be modified for fuel-air mixing and combustion system operation on low-Btu syngas.


value, somewhere between 15 and 20 percent that of natural gas. Martin Schneider, Product Line Manager, GE Power & Water Dis-tributed Power explained: “You need about five times more gas volume than with a natural gas engine for the same output. At the same time you also need less air per cubic meter of gas with syngas.” Both the gas-air mixing system and combustion system have been modi-fied. Piping and surfaces have been altered and the fuel mixing system has also been modified, with the inclu-sion of special gas dosing valves. The combustion concept has been changed so that only low-pressure gas of 120-150 mbar is required for the entire syngas flow. Although the syngas is cleaned of condensates and hydrocarbons in the gasification island, there is a special gas filter in front of the engine gas train in case the gas cleaning system is not working properly. The combustion system has been changed to an “open combustion chamber design”. On the Type 6 en-gine, there is usually a pre-chamber combustion system, where the spark plugs ignite a small amount of gas in a small pre-chamber. In the modified syngas engine, this pre-chamber is not needed as the syn-gas has a high H2 content. This means the spark plugs can be located directly in the main combustion chamber. The entire turbocharger mixing unit has been modified and tuned for the specified operating points. Since H2 is very reactive and CO is very poisonous, special safety systems are built-in to satisfy envi-ronmental health and safety require-ments. These safety systems include flame arresters to inhibit unintended H2 combustion and a nitrogen flush-ing system to eliminate CO. GE’s Jenbacher gas engines have very low emission levels and are able to meet the German TA Luft emis-sion requirements adopted in Bulgar-ia, without any additional emission

abatement equipment. NOx levels are expected to be less than 300 mg/Nm3. At Movialsa, for example, concentrations have been measured at less than 300 mg/Nm3 of NOx in the exhaust.

Heat recoveryIn addition to producing electricity, engines in this application can pro-vide either low-temperature heat as hot water or high-grade heat in the form of steam. At the Karlovo plant, the engines produce hot water, mainly for heating greenhouses to be built nearby. Heat is essentially delivered to a common hot water circuit from three sources. Firstly, it is recovered when cool-ing the syngas from 750°C to 300°C, before the syngas is fed to the gas cleanup system. A heat exchanger uses thermal oil to transfer this heat to a hot water circuit to heat water to a temperature of about 90°C. Exhaust gas from the engine pro-vides the second source of heat. Gas temperature at the engine exhaust is about 470°C. Cooling exhaust gas to about 180°C and the use of another heat exchanger also allows the pro-duction of hot water at about 90°C.

The third heat source is the en-gine’s two cooling circuits. The cir-cuit cooling the engine’s jacket water, oil and the first stage of the inter-cooler uses water at a temperature of about 85°C, which can also be used for heating purposes. Most of the electricity will be fed into the grid. “We have our own sub-station, where we increase the voltage for the plant to 20 kV for feeding into the public grid,” noted Sanchez. In combined heat and power mode of operation, the plant will have a pre-dicted overall efficiency of 70-75 per-cent (30 percent electricity and 40 percent heat). According to EBIOSS, one advantage of the configuration is that the plant can run the whole year round for maximum electricity pro-duction. Sanchez commented: “For a co-generation plant employing a Rankine cycle, i.e. using a conventional steam boiler, you would have to reduce the electrical power in order to maintain high heat output. In our case, you al-ways produce 100 percent of your power at 30 percent efficiency, with no reduction in heat. This would be a big advantage in a district heating ap-plication.”

Plant in Italy. First of four biomass gasification power plant projects that EBIOSS is developing in Italy. The other three are due to start construction later this year.


Project progressThe project has been long in the mak-ing. The permitting process was start-ed about three years ago. Sanchez re-calls that permitting was a time-con-suming procedure that lasted about two years. All the key permits needed to be-gin plant construction were secured about a year ago. EBIOSS signed the EPC contract with EQTEC Iberia for construction of the plant in July 2013 and site construction began in No-vember. Civil works are now complet-ed as well as the 9 km line to connect the power plant to the substation. Engines arrived at the site on June 5. Other main components such as the gasifier and syngas cleanup equip-ment are scheduled for delivery in July. When all the equipment is de-livered, there will be roughly two months of electro-mechanical instal-lations. Cold commissioning will start in mid-August and hot commissioning i.e. first syngas production will kick off in October this year. “Testing and fine tuning of the plant’s operation will take place dur-ing October and November, first for the gasifier island and then for the engines. Final commissioning and the test run will take place in mid-Decem-ber 2014.”

EconomicsWhen the plant comes on line, it will be a boost for a technology that has been slow to catch on, largely due to uncompetitive economics. Overall plant costs indicate, however, that un-der the right circumstances gasifica-tion can be a competitive solution. The two 5MW units represent an investment of €20 million each; this includes land and permitting costs as well as the capital cost of the plants. Due to the length of the process, per-mitting costs were quite high. The EPC contract, equipment and commissioning costs are about €16.5-17 million. This also includes the ap-proximately €2 million system needed

to produce the pellets. The Karlovo plant has been fi-nanced using 40 percent equity, with the remaining 60 percent in the form of project financing from a Bulgarian bank. Under the legal framework in Bulgaria, EBIOSS expects a return on investment of 15-16 percent, and a payback period of 7-8 years. “Biomass gasification is becom-ing more competitive compared to combustion,” said Sanchez. “Maybe it is a little more expensive but if you consider the opex, which is linked to the efficiency of the plant and the ability to run on low value feedstock, the IRR for the gasification plant is higher. “Capex is important but at the end of the day the return on investment is more important to investors than the investment itself.”

Future project potentialEBIOSS is confident iabout the fu-ture of EQTEC gasifier technology coupled with GE’s Jenbacher engine technology. “It has a promising future due to the many technical advantages. These plants also have a much smaller foot-print than [conventional boiler] com-bustion plants,” said Sanchez. “The stacks are similar to those used in a natural gas fired power plant, so the visual impact is very low.” EBIOSS currently has more than 25MW of projects in the pipeline, mainly in Bulgaria and Italy, where it has a subsidiary company with four projects. “One is already running and the other three are due to start con-struction in the coming months. “Another 25MW are also in the permitting process. This gives a total of 50MW in the EBIOSS Holding Group. We are also quoting on an-other 40-50MW in Europe and North Africa,” noted Sanchez. The company is continuing to de-velop its gasification technology in order to build plants that can run on municipal solid waste. A contract has already been signed with a solids treat-

ment plant in Osnabrück, Germany. Explaining the significance of this development, Sanchez said: “This will be our first plant to run on waste, which is much more abundant than biomass. Running on waste would not only help solve a problem for society, it would also allow us to develop more projects on a larger scale.” Meanwhile, GE’s Jenbacher gas engines team is continuing to work with potential partners in further de-veloping its engines for this type of application. Schneider said: “There is definitely further potential regarding output and efficiency. This will help make proj-ects more economically feasible, and reduce the footprint of the plant.” The team is also looking to devel-op more dedicated products in order to have “a sort of tool-kit” for differ-ent gasification concepts. “We con-tinue to work on dedicated engines for gases with low H2 content or high H2 content,” noted Schneider.

Syngas combustionAt the same time, the gas turbine divi-sion of GE is also looking to develop its gas turbines to allow them to han-dle syngas from the EQTEC gasifier. Current work includes exploring how to modify the combustion cham-ber of its turbines to enable them to run on low Btu gases. EQTEC is also running an R&D program to see how its gasifiers can produce syngas with a higher heating value. Sanchez summed up: “Both we and GE are working towards being able to have projects that are based on gas turbines. The biggest engine that Jenbacher has for this type of plant today is 2MW; the ability to use gas turbines would open up the market for bigger projects. “With projects on the table of 20-30MW, we would have to install 10-15 engines; this may be too much. Having a 10MW gas turbine for these would be excellent.” n

Kapaia Power Station, commissioned in 2002, supplies over 50% of the power required by the island of Kuai using Cheng Power Systems’ technology.

1

10

100

1000

0 0.5 1.0 1.5 2.0 2.5 3.0

NOx Emissions

Steam to Fuel Ratio

-40%

-30%

-20%

-10%

0%

10%

20%

30%

40%

0 0.5 1.0 1.5 2.0 2.5 3.0 3.5 4.0 4.5 5.0

Power and Heat Rate

Steam to Fuel Ratio

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Heat RateKapaia Power Station, commissioned in 2002, supplies over 50% of the power required by the island of Kauai using Cheng Power Systems’ technology.

Power


Mitsubishi Hitachi Power Sys-tems (MHPS) officially com-

menced operation on February 1, 2014 as a joint venture company combining the global thermal power generation operations of MHI and Hi-tachi. The announced arrangement has MHI holding the majority share of the new company, with 65% of the equity versus 35% for Hitachi. The two companies’ operations are said to be a “perfect match” that complement one another in terms of technologies, product lines, markets and international project activity. In power generation, MHI is better known for its large advanced gas tur-bine accomplishments, while Hitachi has been more focused on steam gen-erators, air quality, control systems, steam turbines and smaller gas tur-bines. As joint venture partners, they can now draw on their collective pool of new-unit power project capabilities, service and maintenance assets, in-dustry alliances and a combined cus-tomer base to better grow their busi-nesses on a global scale. The MHPS gas turbine product mix covers a full spectrum of unit ratings ranging from about 17MW to 330MW, and consisting of indus-trial and advanced heavy frame de-signs that will enable MHPS to fulfill a broadened approach to the North American and South American mar-kets:

o MHPS joint venture. Gas turbine lineup includes the proven Hitachi H-15, H-25 series and relatively new

H-80 gas turbine as a complement to MHI’s D-, F-, G-, and J-class product mix.

o The Americas market. Initially, the merged power generation system businesses in The Americas will con-tinue to maintain their separate orga-nizations and support facilities while working together within the MHPS framework to deliver a combined mix of products and services.

The merged power generation system

businesses in The Americas continue to do business in the US, Canada, Mexico and South America. Com-bined, their full product mix includes gas turbines, combined cycles, steam turbines, coal-fired boilers, coal gas-ification (IGCC) power plants, geo-thermal, SCR systems (for gas turbine and coal-fired plants), fuel cell tech-nology and expanded EPC and main-tenance services. David M. Walsh has assumed responsibility for the largest of the MHPS North American businesses,

MHI and Hitachi combining thermal power businesses By Victor deBiasi

The new joint venture company formed by Mitsubishi and Hitachi integrates their thermal power generation businesses to compete more effectively in the global marketplace.

First M501J gas turbine order for the United States

Grand River Dam Authority awarded MHPSA an equipment contract earlier this year to supply a M501J gas turbine, SRT-50 steam turbine and associated electric generators for a 1x1 combined cycle plant to be built at an existing power station in Chouteau, Oklahoma. GRDA is said to have entered into a separate long term service agreement with the company to provide comprehensive maintenance for the gas turbine and its associated electric generator once the plant is in commercial service. M501J combined cycle plant efficiency and price factored highly in the competitively bid order, according to utility documents. At full base load output the M501J will provide over 61% combined cycle efficiency. Even at 50% part-load output, says MHPSA vice president Bill Newsom, “you’re still above 55% combined cycle efficiency.” Construction of the combined cycle plant is scheduled to begin in 2015 and be completed in time for commercial startup by April 2017. This will be the first installation of an M501J gas turbine plant in North America. MHPSA reports that ten 60-Hz M501J gas turbines currently in operation have accumulated more than 42,000 hours of operation to date (as of May 2014). MHPS in Japan reports orders have been booked for another ten units in South Korea for a total of 28 units worldwide. The M501J gas turbine to be installed at the GRDA power gen-eration facility will be manufactured at MHPSA’s Savannah Machinery Works facility located in Georgia.


after recently being appointed Presi-dent and Chief Executive Officer of Mitsubishi Hitachi Power Systems Americas, Inc. (MHPSA). In his previous position within the MHI organization, he served as senior vice president of sales & marketing, projects and services for Mitsubishi Power Systems Americas. Mr. Walsh has also been named as a Corporate Officer of the new parent joint com-pany, Mitsubishi Hitachi Power Sys-tems, Ltd. in Japan.

The vision for MHPSARecently we spoke with Mr. Walsh briefly about his vision for MHPSA, what the joint venture merger might mean for customers – both electric utility and project developers – and how owner-operators already doing business with Mitsubishi and Hitachi stand to benefit. He says that his main task and pri-orities will focus on harnessing the synergies generated by the merger and on growing the business to increase the company’s share of the market

throughout the Americas relative to its main rivals, General Electric and Sie-mens. He will also pursue develop-ment of niche markets that capitalize on MHPSA’s unique engineering and technology strengths. Mr. Walsh is very bullish on the gas turbine market in North Ameri-ca for both large and small machines over the next 15 years. He predicts that gas-fired intermediate and base load combined cycle power genera-tion will dominate new capacity addi-tions and replacements, at the expense of both coal and nuclear, which will experience net retirements over the period.

Collaborative process With respect to ultimately integrat-ing the partners’ separate sales, engi-neering, manufacturing and service operations in the US, Mr. Walsh said that they are actively collaborating on both business unit and depart-ment levels to optimize combined capabilities into the new MHPSA framework.

Similar functions and business pro-cesses will eventually be integrated as appropriate, he noted, with the end goal being to “provide our custom-ers with a single-source provider of power generation solutions.” I questioned the extent to which comparably rated gas turbines and steam turbines might continue to be

David M. Walsh

Unit OutputMW

– 400

–

– 300

–

– 200

–

– 100

–

– 0

60-Hz MHPS gas turbine portolio. The integrated Mitsubishi Hitachi Power Systems gas turbine product line for the North America market ranges from about 17MW net unit output for the H-15 at the low end of the power spectrum to a high of 327MW net power output for the M501J.

H-15

17 MW

H-25 Series

32

42 MW

H-80

111 MW114 MW

M501DA M501F3

185 MW

276 MW

M501GSeries

268

327 MW

M501JSeries

310

Hitachi Models

Mitsubishi Models

Source: Gas Turbine World, 2014 Performance Specs annual


offered in parallel. For instance, the Hitachi H-80 gas turbine is rated at 112MW and Mitsubishi’s M501DA at 110MW; will both models continue in production? Mr. Walsh pointed out that each of the products now available under the MHPSA umbrella will be marketed on the basis of its own attributes rela-tive to specific project requirements. Although some units may have simi-lar ratings, he stated, they are being marketed for different applications. In this case, the H-80 is seen as ideal for retrofitting and upgrading (repowering) older and less efficient combined cycle plants without hav-ing to change the existing bottoming cycle.

Continuing evaluationWe also asked about the extent, if any, that MHI advanced G and J-Series technology might be retrofitted or in-corporated into Hitachi gas turbine designs. And, conversely, whether there is any Hitachi technology that might be applied to MHI designs. The parent organizations bring a significant history of technology, products and services to the new joint venture, Mr. Walsh stated. And, as part of an ongoing integration pro-cess, MHPSA will continue to evalu-ate all technology options so as to choose the best solution for each ap-plication. All products and services in the portfolio will be evaluated, he empha-sized, to provide the optimum prod-uct lineup and service capability for the North and South American power markets. In closing, he observed: “This is the key synergistic benefit of having two technology leaders [Hitachi and Mitsubishi] combining their comple-mentary products and services for MHPSA.”

Replacement marketMr. Walsh’s optimism about the future for MHPSA business stems largely from continued robust shale gas de-

velopment in North America, and the stable low price of shale gas relative to the highly volatile cost of natural gas fuel in the past. This, bolstered by the new regula-tory emphasis on cleaner power gen-

eration technology, will extend the trend that has made gas turbine com-bined cycle power plants the most at-tractive choice for new thermal power plant projects. However, with annual electric load

Large 60-Hz combined cycle blocks. Design ratings range from 285MW net base load output and 57.1% combined cycle efficiency for a 1x1 M501F plant to 943MW and 61.7% efficiency for a 2x1 M501J configuration.

CCGT Power Block Net Output Net Heat Rate Efficiency

1x1 M501F3 285,100 kW 5976 Btu/kWh 57.1% 2x1 572,200 5955 57.3

1x1 M501G 398,900 kW 5843 Btu/kWh 58.4% 2x1 800,500 5823 58.6

1x1 M501GAC 412,400 kW 5735 Btu/kWh 59.5% 2x1 826,100 5726 59.6

1x1 M501JAC 450,000 kW <5594 Btu/kWh >61%

1x1 M501J 470,000 kW 5549 Btu/kWh 61.5% 2x1 942,900 5531 61.7

Note: All ratings across generator terminals net of inlet and exhaust losses, based on 1.5 inch Hg condenser pressure design assumption.

Net OutputMW

– 1,000

–

– 800

–

– 600

–

– 400

–

– 200

–

– 0

60-Hz MHPS combined cycle portfolio. The integrated combined cycle prod-uct line ranges from 157MW net power block output (1x1 plant) and 321MW (2x1 plant) for the H-80 at the low end of the power spectrum to a high of 450MW (1x1 plant) and 943MW net power block output (2x1 plant) for the M501J.

1x1 combined cycle 2x1 combined cycle

Hitachi Models

Mitsubishi Models

Hitachi Models

Mitsubishi Models

H-80

321 MW

157

336 MW

M501DSeries

167

572 MW

M501FSeries

285

826 MW

M501GSeries

399

Source: Gas Turbine World, 2014 Performance Specs annual

M501JSeries

943 MW

450

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growth expected to stay below 1% in North America for the near future, the retirement of old coal- and oil-fired plants, as well as of older nucle-ar plants (see chart) represents a key factor to market growth, amounting to almost 50GW over the next several years. Industry analysts note that 50GW is on the conservative side and does not include the replacement market for the large population of older co-generation gas turbines still in base load service. Nor does it account for potential retrofitting or “repowering” of the population of 1970s-1990s vintage combined cycle plants by replacing their gas turbines with new high ef-ficiency, low emissions units. Whether for replacement or up-grade applications, MHPSA now of-fers an operationally proven family of high-efficiency, high capacity gas turbines for 60Hz power generation. Specifically, the advanced large gas turbines available from MHP-SA range from around 185MW unit output for the M501F3 to around 330MW for the M501J. The smaller gas turbines at the other end of the power spectrum range from around 17MW unit output for the H-15 to 111MW for the H-80.

Combined cycle niche Combined cycle plants are offered in

both single and multiple gas turbine configurations. Rated output of advanced 1x1 combined cycle blocks in the MHPSA portfolio range from around 160MW and 53.8% efficiency for the H-80 to rating of 470MW and 61.5% for a plant based on the M501J. In a 2x1 configuration, powered by those same gas turbine models, combined cycle output ranges from around 320MW and 55.2% efficiency for the H-80 to more than 940MW and 61.7% efficiency for the M501J plant. With this broadened product mix,

Mr. Walsh sees MHPSA as being well positioned for a full range of power generation solutions, either maintain-ing and retrofitting old coal plants with environmental cleanup systems or, where that isn’t deemed economi-cal, replacing them altogether with gas-fired combined cycle power plants. For the longer term, when the cost of natural gas increases to the point where turning to clean coal tech-nologies is economically justifiable, MHPSA offers a range of IGCC solu-tions based on MHI’s demonstrated air-blown coal gasification system. n

US and Canada power industry retirements (2014-2017) More than 47GW of coal, fuel oil. natural gas and nuclear capacity scheduled for retirement between 2014 and 2017 represents a strong market for the develop-ment of new intermediate and base load gas turbine combined cycle plants.

Year

– 2017

– 2016

– 2015

– 2014

0|

Coal Fuel Oil Natural Gas Nuclear

5,000|

10,000|

15,000|

20,000MW|

Source: Industrial Info Resources, 2014 Power Outlook Report, S. Mullins

7GW

6GW

12GW

22GW

Current Model Base Load Heat Rate Units Units onGT Model Year Output* (Btu/kWh) Efficiency Shipped Order

M501G1 2009 267,500 kW 8730 Btu 39.1% 35 2

M501GAC 2011 276,000 kW 8574 Btu 39.8% 1 15

M501J 2011 327,000 kW 8325 Btu 41.0% 10 18

M501JAC 2015 310,000 kW <8325 Btu >41.0% N/A N/A

*Note: Ratings on natural gas fuel and 59°F sea level site conditions, with inlet and exhaust losses

Global M501G and J Series sales and orders (as of April 2014). Steam-cooled combustor and air-cooled (AC) designs for the M501G -Series and M501J-Series are being sold in North America and 60-Hz regions of the world market. An air-cooled M501JAC gas turbine design is scheduled for 2015 introduction.

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

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

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

Knowledge = Power

siemens.com/energy

Siemens’ SGT-8000H series gas turbines are capable of performing at efficiency levels of more than 60 percent. That means a 85,000-ton reduction in CO2 emissions every year compared with today’s conventional combined cycle plants. But the story of the most powerful commercially operating gas

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may – june 2014 steam turbine, $1.2 billion 1500mw ... net rated at 826.1mw and 59.6% efficiency....

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