The following are synopses of papers and working cost/operational reports published in the Power Engineer from 2009 to 2013.
GE’s integrated GTCC and fulfilment of grid code requirements
Maximum Buquet – Operability Systems Integration Leader and Christian Solacolu – Controls & Electrical Consulting Engineer, GE Power & Water
Frequency stability is one of the prevailing concerns of a Transmission System Operator (TSO) whose aim and duty is the reliable operation of the grid. Operation of the electrical grids must be reliable, handling future generation mix, whilst often being constrained by existing infrastructure. To help meet these challenges, TSOs have developed grid codes. Among other requirements, grid codes define minimum performance requirements of generating units connected to the grid.
This paper focuses on one important aspect of grid codes, which is grid frequency support.
Volume 17 Issue 3 (September 2013) – Paper 595
THE SGT-300 twin-shaft – the latest addition to Siemens’ GT portfolio
Christian Engelbert and Darrell Helas, Siemens Industrial Turbomachinery Ltd, Lincoln
Siemens Lincoln site has been designing and manufacturing industrial gas turbines since the late 1940’s.
With the introduction of its latest gas turbine, Siemens now proudly looks back at decades of engineering, manufacturing and operational expertise.
This paper looks at the heritage of Siemens’ small industrial turbines through to today’s business, the current product portfolio and typical applications. It examines how a ‘Product Family’ has been evolved via technology programmes. Scaled axial compressor technology is discussed as an example. An insight is given to how this ‘evolutionary technology’ approach has been applied to the latest SGT-300 twin shaft engine to ensure industry leading standards of reliability and availability.
Volume 17 Issue 2 (June 2013) – Paper 593
Ten years hard labour in Mombasa
Graham Dilliway, BSc CEng FIMechE FIET Hon FIPowerE
This paper examines all aspects of the work, skill and dedication that in the last twelve years have gone into the engineering, design, construction and operation of the Kipevu 2 diesel power plant in Mombasa. The plant is internationally recognised both by lenders and investors as a great success in terms of its operating reliability, power availability, energy dispatch and heat rate.
The paper also looks at some of the near-misses and incidents that have occurred during the first eleven operating years, and considers what might have happened if those near-misses had materialised into actual events. It also looks to the future of the plant, and considers what future events may occur which could impact heavily on its current excellent reputation and productivity.
Volume 17 Issue 1 (March 2013) – Paper 592
Narowal 213MW diesel combined cycle – overview of project from initial concept to commercial operation
Brian Kinsella and Stephen O’Gorman, Mott MacDonald Ireland Limited
Pakistan is a developing economy and its projected load growth in electrical power demand over the next ten years is expected to be at least 1,500MW per annum. There are many power plant technology alternatives being considered to meet this demand including hydro, open cycle gas turbine (OCGT), combined cycle gas turbine (CCGT), conventional steam turbine generation (STG) and diesel engine driven power plant. This power growth is located in the major cities of Pakistan, for example, in Lahore which is located in the Punjab region and has a population of circa 8.5 million. Power cuts during the Summer peak demand period are regular occurrences. This problem is compounded in certain less populated areas of the country where one such area is Narowal in the Punjab, a town which is located approximately 10km from the Indian border and 120km North East of Lahore.
Volume 16 Issue 4 (December 2012) – Paper 590
Implementing improvements to gas turbine air inlet filtration – an operator’s perspective
Scott Taylor and Stuart Lax, Sembcorp Utilities (UK) Ltd
This paper looks at an operator’s experiences and learning during the implementation of improvements to a gas turbine air inlet filtration system during the first few years of operation.
The operator, Sembcorp Utilities UK (Sembcorp), is a subsidiary of Singapore-based Sembcorp Industries, and is the leading industrial utilities and services business on Teesside and one of the largest in the UK, providing steam and electricity to the major manufacturers on the Wilton International site. As part of its combined heat and power operations Sembcorp now run two General Electric Frame 6B gas turbines at the Wilton International site.
Volume 16 Issue 3 (September 2012) – Paper 589
Gas processing, side stream alternative use
Stefan Falten, Wartsila Finland Oy
Gas conditioning produces different gas/liquid mixes that in the traditional downstream engineering process end up in defined products and by-products. Upstream gas, or gas and oil hydrocarbon fields do not necessarily turn up where the ethylene production is in its infancy or even well established, and even with access to modern supply chain management supply and demand techniques some of the by-products can be a challenge to find useful outlets. Gas processing intrinsically requires energy conversion in both forms of power and heat, therefore using by-products as free or minimum CapEx investment for a fuel source would maximise the main export sales gas amount produced. Full utilisation of all traditional downstream by-products, or even intermediate streams could dramatically simplify the gas conditioning plant design. A combustion gas engine with suitable properties to accept rich or lean fuel gas with wide variations is used to provide power and heat.
Volume 16 Issue 3 (September 2012) – Paper 588
Addressing the cause of varnishing in gas turbine lubrication systems
John A Platt BSc(Hons) AIMechE FIPowerE, Global Technical Manager, Castrol Power, BP plc
Varnishing in modern gas turbine lubrication and control systems is an increasingly common problem which often results in serious impact on reliability and availably of the plant.
The problem of varnishing in lubrication systems is only too well known, but is generally not well understood. This paper seeks to impart an understanding of the lubricant properties and characteristics which affect its ability to resist varnish formation and, with reference to over 800,000 hours of successful operation under varying service conditions, to demonstrate that by careful formulation and appropriate selection of the lubricant, together with correct monitoring and control, it is possible to effectively address the root cause of varnishing thereby delivering a valuable contribution to reliability, availability and optimisation of the asset.
Volume 16 Issue 2 (June 2012) – Paper 587
Diesel power for UK rail traction
Trevor Owen CEng CMarEng MIPowerE FIMechE FIMarEST
One of the major applications of diesel power in the UK since the 1950s has been for rail traction purposes. This article traces the use of diesel power from the earliest shunting locomotive in the current main line locomotives, but excludes diesel multiple units (DMU).
Volume 16 Issue 2 (June 2012)
The influence of CO2 in fuel on engine parameters
Marcel Skarohlid, Josef Bozek Research Centre of Engine and Automotive Engineering, Faculty of Mechanical Engineering, Czech Technical University in Prague
The removing/clearing of CO2 from gaseous fuels as adulterant is a contemporary trend. To the contrary with this trend the presented paper describes benefits of CO2 fuel content on basic engine parameters like indicated mean effective pressure, indicated efficiency and NOx production. This paper analyses trade off between air excess, ignition timing and CO2 fuel mass fraction in detail.
Volume 16 Issue 1 (March 2012) – Paper 586
Protecting critical equipment, reducing operating costs and safeguarding against downtime through on-line oil condition monitoring
Dr Stuart Lunt, Kittiwake Developments Ltd, UK
Oil condition monitoring is a vital part of integrated asset health management. With an increasing impetus towards real-time decision making, delays incurred in offline laboratory oil analysis are becoming less acceptable. At present, several oil quality parameters can be monitored by commercially available sensors, and active research and development programmes are being pursued by both academic and industrial researchers to develop robust, cost effective sensors for the remaining key parameters.
Volume 16 Issue 1 (March 2012)
Technological and economic aspects of two years operation of the biogas co-generation set at the Warta SA waste treatment plant in Czestochowa, Poland
Adam Duzynski, Czestochowa University of Technology, Poland
As early as the 1970s, the Warta SA waste treatment plant in Czestochowa, and actually its predecessor – the Warta SA Commercial Water Company, undertook, on the initiative of Prof Karol Cupial from the Institute of Internal Combustion Engines and Control Technology (IMTiTS PCz) – presently the Institute of Thermal Machinery at the Czestochowa University of Technology – Poland’s first trials on the utilisation of biogas, a by-product of anaerobic sewage sludge fermentation, by using it for supplying piston engine-driven gas cogeneration sets. In the 1980s, the manufacture of a family of 100-300kW Wola Henschel gas engines was started up in co-operation with ZMiN Wola of Warsaw, and in the 90s, jointly with H Cegielski of Poznan, Poland’s largest and most modern heat and power-generating set with an 8A20G (600kW/1,000 min-1) engine with the recovery of engine, oil and blend cooling heat and exhaust gas heat was constructed and thoroughly tested. The cogeneration set complete with this engine had been commercially operated in the Warta SA waste treatment plant in Czestochowa by IMTiTS PCz employees up to 2006, and then, in 2008, it was sold and replaced with a cogeneration set driven by a larger-power GE Jenbacher engine.
Volume 15 Issue 5 (December 2011) – Paper 584
The propulsion of merchant ships: The case for LNG – the new era?
T W Page, IEng, MIMarEST, FIPowerE, Wartsila UK Ltd
The fundamental changes in ship propulsion over the last century or more have been driven by economical pressures and resultant technological development. The first major change from coal firing to oil was a gradual process during the first half of the 20th century.
Volume 14 & 15 Issue 4
Operational Report (combined edition) 2009/2010 Data
Compiled by Tom Woodford, Guernsey Electricity
Volume 15 Issue 3 (September 2011) – Paper 583
Reducing fuel consumption on the field by continuously measuring fuel quality on electronically fuel injected engines
Mr Patrice Flot, CMR , France, Mr Alain Meslati, CMR, France and
Mr Thierry Delorme, Ecole Centrale Marseille, France
This paper describes the sensor’s hardware and software technologies as well as the expected engine combustion performance improvement resulting from the new control parameters. This sensor can also be used to protect the engine from poor quality fuel.
Volume 15 Issue 2 (June 2011) – Paper 582
The History of the Industrial Gas Turbine (Part 1 The First Fifty Years 1940-1990)
Ronald J Hunt CEng FIMechE FIPowerE , Thermal Power Consultant, Power + Energy Associates
This history of the industrial gas turbine documents the history of the development of gas turbines for land based, locomotive and marine applications. A key part of the history is the documentation of all manufacturers and gas turbine models produced each year since 1940. The aircraft engine is excluded from the scope of the work and only referred to in as far as it related to the development of industrial machines gas turbines. It has not been possible, up to the time of publication, to include every company who were active in the development of industrial gas turbine however the research work is continuing and it is planned to add to this history in due course.
This paper (Part 1) deals with the first fifty years of development of the industrial gas turbine from 1940 to 1990. It is planned that a second paper (Part 2) will be presented later in 2011 covering the period 1990 onwards.
Volume 15 Issue 1 (March 2011) – Paper 581
Efficient combustion of Glycerol and other low cetane fuels in the diesel engine
John McNeil Aquafuel Research, Kent Science Park
This paper covers the ultra efficient low exhaust emission burning of the bio-diesel by-product, and algae formed, pure Glycerine without chemical additives, or processing.
The paper specifically deals with the patented principle behind ignition and efficient combustion of glycerine and other low cetane fuels, together with the manner in which the process lends itself to CHP applications.
Volume 15 Issue 1 (March 2011) – Paper 580
Stationary MAN B&W MC-S engines for biofuel applications
Helle Gotfredsen, MAN B&W
In recent years, the stationary diesel engine market has seen a demand for units running on biofuel. The nature of this demand is driven by the desire to be CO2 neutral, based on reliable, fuel-efficient and environmentally friendly power generation for both public utilities and Independent Power Producers (IPPs).
This demand is being met by modern marine application derivative medium speed diesel gensets and two-stroke low speed crosshead uniflow diesel engines, capable of burning almost any mineral fuel available on the market, whether liquid or gaseous.
This paper deals with the application scenarios of such engines and their biofuel capability and describes the installation examples of such engines.
Volume 14 Issue 5 (December 2010) – Paper 578
Dhekelia ICE – a modern fast track low speed plant
Knud Hvidtfeldt Rasmussen, Burmeister & Wain Scandinavian Contract A/S
Dhekelia Internal Combustion Engines – ICE – is a 50 MW diesel power plant located on the east coast of Cyprus, north of Larnaka. The plant was contracted in November 2007 and handed over in May 2009. The Dhekelia plant is a conventional plant with 3 low speed diesel engines of type MAN-B&W Mitsui 12K50MC-S, each of 18 MW at 176.5 rpm. The plant is sea water cooled.
This paper describes the plant, the engine design with a single turbocharger, and the measures taken on design, logistics and construction for accomplishing the fast track execution.
At the time of ordering the plant, suppliers of large components were operating at peak load causing many difficulties resulting in long delivery time. This caused extreme demands for fast action during the erection on site. Due to the single turbocharger arrangement, the structural vibration condition deviates to some extent from well-known behaviour in former plants with similar engines. The “T-mode” vibrations of the engines are controlled by active force compensators.
The plant performance in terms of power and efficiency has been fully satisfactory. As the plant is operated in parallel with steam turbines, the engines are in most of the operation period used with daily start and stop, utilizing the optimal flexibility of the diesel engines. The performance of the engines has been closely monitored with regular port inspections. Very low wear rates of cylinders and piston rings have been demonstrated.
Volume 14 Issue 3 (September/October 2010) – Paper 577
An analysis of micro gas turbines for UK domestic combined heat and power
A Clay and G D Tansley, School of Engineering and Applied Science, Aston University, Birmingham
For Domestic Combined Heat and Power (DCHP) applications, large component losses are inevitable when using a Micro Gas Turbine (MGT) prime mover of 1kW or less due to low mass flows and high operating speeds. MGT research has developed advanced technological strategies to address the particular issues of bearing platform, impeller design and impeller manufacture. This paper seeks to establish the performance criteria for an alternative, low cost MGT DCHP machine via an analytical discussion based on adiabatic, air standard cycle analysis.
Break-even DCHP system efficiencies were derived for various operating strategies; a target prime mover efficiency of 15% was established. The detrimental effect of low component efficiencies on the Brayton cycle made the DCHP performance targets a significant challenge. As a result, a simple cycle machine was considered unsuitable for DCHP application.
A competitive recuperated MGT was deemed suitable only when slightly optimistic turbomachinery efficiencies were considered. The introduction of pressure drops from heat exchange combined with poor component performance produced shallow inflection points on a system efficiency vs. pressure ratio curve. Selecting a pressure ratio below that which corresponded with maximal efficiency reduced shaft speed with some compromise in system efficiency. Both the use of efficient turbomachinery components (at low cost) and an effective heat exchanger with low pressure drops are essential for a successful MGT DCHP unit.
Volume 14 Issue 3 (September/October 2010) – Paper 576
The evolution of gas turbine compressor cleaning
Russ Gordon, R-MC Power Recovery Ltd
This paper looks at the evolution of gas turbine compressor cleaning, and relates it to the various technical advances in the development of gas turbines. It starts with a reminder of how fouling affects the aerodynamics of the compressor and hence the necessity for compressor washing.
The early days of cleaning compressors with very basic materials and methods are described, as used on the relatively unsophisticated types of gas turbines of the time. Moving on through the 60s and 70s and the introduction of single crystal blades and super-alloys, it goes into the move from hand cleaning to cleaning at crank speeds, and so on to the latest cleaning technology employed today.
The development of wash fluids is also presented, from tap water up to the latest sophisticated blends of chemicals.
Evolving nozzle design and positions in the intake plenum is examined in some detail. Increasing air flows, and developments in compressor blade design, have influenced the importance of droplet formation and hence nozzle design.
Environmental legislation is covered briefly, with its influence on gas turbine development and hence cleaning methods.
The degree of automating wash systems is discussed as the efficiency demands on the industry become greater.
Volume 14 Issue 2 (June 2010) – Paper 575
Carbon capture and storage implications for CCGT development
K Foy, Parsons Brinckerhoff
This paper describes the various methods of Carbon Capture and Storage (CCS) applicable to Gas Turbines (GT) and CCGT plant, focusing on the three most advanced technologies: post-combustion chemical capture of CO2 from GT exhaust; gasification of coal with pre-combustion CO2 capture followed by combustion of low carbon fuel in a GT; and oxyfuel technology, or combustion of gas with oxygen rather than air. The current status of each technology is described and possible future developments are considered.
The technical issues involved in both CCS equipped new-build thermal plant and retrofit of CCS to existing and future thermal plant are described, including both space requirements and design implications. The meaning of Carbon Capture Ready is discussed and the impacts of the new EU and UK consenting regime for thermal plant are presented.
The impact of the different types of CCS on operation of CCGT and SCGT is discussed.
The cost of power generation from thermal plant fitted with CCS is presented in comparison with other power generation options.
The paper also includes a discussion of possible developments in the future CCS industry, including transportation and storage networks.
Volume 14 Issue 1 (March 2010) – Paper 573
Biomass – going that extra mile!
A McMurtrie, AIM Energy Ltd
Biomass is seen as being an important renewable energy resource and a key component in helping to deliver the Government’s greenhouse gas emission reduction targets as set out in the Climate Change Act 2008, ie a 34% reduction in the UK’s net carbon account by 2020, rising to 80% by 2050 (versus a 1990 baseline) and, the UK’s target under EU legislation to produce 15% of its energy requirement from renewable sources by 2020.
This article primarily refers to combustible biomass material typically categorised as ‘plant biomass’, although many of the challenges faced with utilising this fuel source equally apply to other biomass materials. To date, viable, medium sized industrial and commercial scale biomass has proven challenging to implement due to the added complexity and cost, versus say traditional fossil fuel heat/steam production, power or CHP plant. Increased complexity typically arises out of fuel; its availability, storage and handling, the physical plant size and duty, environmental compliance, capital cost, etc. This has meant that the number of developments delivered to date has fallen short of what might have been expected.
This paper seeks to outline some of the key challenges and considerations to be addressed in assessing whether biomass offers a sustainable and viable option to companies and in doing so may offer some insight into why many organisations in the UK have so far rejected or ‘parked’ a potential biomass solution. However, whilst highlighting these challenges, I also hope that some additional guidance may allow interested parties to also consider the ‘positives’ and thus encourage them to give some serious thought to the opportunity that biomass may have to offer them in their specific situation.
Volume 13 Issue 5 (December 2009) – Paper 572
Product Development and test program for aggressive gas engines
V Carey, K Tellier, G Delafargue and D Squirrell, Exxon Mobil
Engine designs, operating conditions, and environmental factors place increasingly higher demands on lubricants for all gas engines, but even more so those operating on the aggressive gas applications associated with sewage and landfill gases. This paper will focus on the product developed specifically for such applications, and where the fuel contains high amounts of silicon along with other contaminants, presenting an especially difficult lubricating environment.
Increased engine reliability, extended time between engine overhauls, and reduced operating costs were the primary objectives of the development program. This paper will cover general aspects of the laboratory development program and present documentation on the excellent field performance achieved.
Volume 13 Issue 3 (September 2009) – Paper 571
Industry-University collaboration: a case study between Manx Electricity Authority and Cranfield University
Y G Li, P Pilidis and E Tsoutsanis, Cranfield University and M Newby, Manx Electricity Authority
In the volatile energy market effective use of the available technological, energy and financial resources is now, more than ever, highly pursued. In a combined cycle power plant, gas turbines are the prime mover of power generation. Therefore, detailed understanding and monitoring of gas turbine performance, health condition and associated costs have a deep impact on the decision making process concerning the plant’s operational and maintenance strategy.
In this context, research collaboration between Manx Electricity Authority (MEA) and Cranfield University has been carried out since 2001 and a series of technologies and software have been and are still being developed at Cranfield University and some of them have been integrated into MEA’s Combined Cycle Gas Turbine Power Plant in Pulrose, Isle of Man. During this constructive and successful collaboration period, the University has been fortunate to acknowledge the industrial needs and make significant academic contributions through ongoing research projects jointly supported by both MEA and EPSRC. On the other hand, MEA has valued the complexity of asset management concerning the gas turbine and the combined cycle, therefore enhancing its trading and operational capabilities through the application of developed performance, diagnostic, trading and economic analysis software.
This paper presents the main framework of this collaboration by emphasising the research undertaken on the gas turbine performance simulation and diagnostics, combined cycle performance analysis, trading and economic analysis to support MEA in their decision making process.
Volume 13 Issue 4 (November 2009) – Paper 570
Operational Report 2009
Compiled by Tom Woodford, Guernsey Electricity
Volume 13 Issue 2 (June 2009) – Paper 568
Barking Power Station generator core failure and repair process
G Smith, Thames Power Services
Core failures on running turbo-generators are rare, however when such failures occur they are often sudden and usually lead to major equipment damage which will need significant specialist engineering to repair. Repair durations can be lengthy and arduous which often relate to substantial loss of revenue for the business. This paper discusses the tools available to carry out the diagnosis and subsequent cause of the fault and the Engineering and risk management processes adopted to return the generator unit back to reliable service in the shortest possible time.
Volume 13 Issue 1 (March 2009) – Paper 567
The Tri-O-Gen Organic Rankine Cycle: Development and perspectives
J P van Buijtenen, TriO-Gen BV
The principle of the ORC (Organic Rankine Cycle) is well known already for decades. However, most of the present ORC-plants are based on conventional turbine technology, which includes shaft seals, a reduction gear and a lubricating oil system. A new turbo-generator concept has been developed, using Toluene as a working fluid and lubricant. This concept allows a completely hermetic design, with no need for shaft seals or a separate lubrication system. Toluene is a combustible solvent, but it has a high thermal stability and is not marked as poisonous.
The ORC process demands a very high expansion ratio, at moderate turbine inlet temperature. A standard 175 kW (gross power) unit is able to run at optimum speed for turbine and pump on the same shaft as the high-speed generator.
This paper will describe the novel turbo-generator as well as the total packaged system, as it recently has been introduced on the market.