59% net efficiency 100% CO2 capture page - Gas Turbine...

59% net efficiency100% CO2 capture

page 14

EV burner NOxreduced by 40%

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Optical probe formeasuring temps

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November – December 2014 www.gasturbineworld.com

For us, efficiency means generating the highest possible output without using additional fuel. The increasing de-mand for reliable base- and part-load supply, combined with environmental requirements, are all driving the need for greater efficiency and for reduced start-up times. That’s why we build a comprehensive range of steam turbines that make the best possible use of steam from diverse fuels and heat sources. Reheat technology and steam solutions for combined cycle conversion are both smart steps that boost efficiency.

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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. 6

On the Cover. Riyadh’s 2000 MW PP12 combined cycle plant in Saudi Arabia pow-ered by GE 7F.05 gas turbines, page 4

2 Project development and industry news MHPS 250 kW hybrid fuel cell, Duke Energy 2900 MW new capacity, China LNG-fueled 1075 MW combined cycle, 9HA German CHP plant, Saudi 600MW solar-CCGT proj-ect, 495MW M501J CC project

14 Gearing up for CO2 power cycle systems Toshiba has almost completed the detailed design of a turbine that will use CO2 as its working fluid to operate at high net effi-ciency with 100% capture

20 EV burner design: part-load NOx cut 40% Alstom has installed its new NOx-reducing premix burner, the EV-Alpha, on a GT13D combined heat and power unit where it has cut emissions by more than 40%

24 Corrosion and oxidation resistant coatings Chromium-free coatings for compressor and turbine components are entering in-service field test validation on gas turbines operating under severe environmental conditions

28 Thermal diagnostics prepares to go offline New ‘thermal history’ coatings enable R&D engineers to scan and precisely measure the max surface temperatures that parts have been exposed to during thermal testing

Oxy-plantNew Allam Cycle combines gas and steam turbine technologies for gas-fired plants with 59% net efficiency and 100% carbon capture, page 14

CF qualifiedChrome-free ceramic coatings for hot gas path parts protection are direct replacements for traditional coatings soon to be outlawed, page 24

Indelible dataThermal history coatings can record and store max component surface temperatures for offline digital read-out retrieval, page 28

Editor-in-Chief Junior Isles

Managing Editor Bruno deBiasi

Engineering Editor Harry Jaeger

Field Editor Michael Asquino

News Editor Margaret Cornett

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Publisher Victor deBiasi

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2 GAS TURBINE WORLD November - December 2014

INDUSTRY NEWS

JapanMHPS to deliver SOFC-microturbine hybrid power system Mitsubishi Hitachi Power Systems, Ltd. (MHPS) has received an order from Kyushu University for a pressurized hybrid power generation system inte-grating a solid oxide fuel cell (SOFC) stack and a micro gas turbine (MGT). The hybrid system is being jointly developed with Toyota Motor Corpo-ration, which has a group company, Toyota Turbine and Systems Inc. that markets MGTs. The system will be in-stalled at the Ito Campus of Kyushu University in Nishi-ku, Fukuoka City. With an output of 250 kW, the sys-tem size has been significantly reduced largely due to improved packing densi-ty of the cell stack. Kyushu University plans to use the system for verification of an industrial-use power generation fuel cell system, with verification op-eration to begin in spring 2015. SOFCs are ceramic fuel cells that operate at a high temperature of 900°Celsius (1650°F). In a pressurized hybrid system, power is generated di-rectly by chemical reaction between oxygen in the air and hydrogen and car-bon monoxide extracted from reformed city gas; residual fuel is then used to drive an MGT. This two-stage system achieves sig-nificantly higher power generation ef-ficiency and, as a result, saves sub-stantial energy. Air pressurized in the MGT’s compressor is supplied to the SOFCs for use as an oxidizing agent, and then high-temperature exhaust is fed to the MGT and the heat and pres-sure, together with the residual fuel, are used to generate power. The pressurized SOFCs, having significantly increased voltage as a result of pressurization, lead to enhanced power generation ef-ficiency. The pressurized SOFC-MGT hy-brid power generation system has been undergoing verification testing at the Senju Techno Station of Tokyo Gas Co., Ltd. since 2013. It will be used for carrying out basic research toward en-hancing the performance, longevity and reliability of SOFCs.

USAGE introduces 7F upgradesGE has introduced two new technologies for its 7F gas turbines. The Dry Low NOx (DLN) 2.6+ Combustion and Advanced Compressor upgrades will help existing 7F users to deliver power more profitably, flexibly and with a significantly lower emissions footprint. The DLN 2.6+ solution is designed to deliver broader operational flexibil-ity. With the capability to burn up to 25 percent ethane or propane from shale gas, plants operating with this technology have more options to purchase fuel based on composition, as well as price, to help save on fuel costs. According to GE, the technology also provides the option to burn up to 20 percent hy-drogen. All three fuels can be used while maintaining low emissions, says the company. The first 7F DLN 2.6+ upgrade will be installed at a Midwest U.S. power plant. The technology is being adopted to lower operational costs and better position the generator for current and future power capacity needs in the re-gion it serves. 7F DLN 2.6+ technology also enables operators to reduce NOx emissions by up to 40 percent and operate below 5 ppm NOx. The upgrade can also enable users to operate continuously for up to 32,000 hours or 1,250 starts between required maintenance intervals. This equates to approximately four years for typical continuous-duty plant operation. GE also is introducing the new Advanced Compressor upgrade to increase power output by as much as 12 percent while improving operational efficiency up to 2 percent. The upgrade is designed to help its users reduce outage frequency and durations for maintenance. With advancements including field replaceable compressor blades, operational downtime can be significantly compressed. The Advanced Compressor also features component innovations, including 3-D aero airfoils and variable stator vanes to improve efficiency and a reduced 14-stage rotor for better durability and lower maintenance costs. While new as an upgrade solution, the Advanced Compressor is proven technology already in operation on GE’s 7F.05 new gas turbine units.

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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, our H-class gas turbines have logged more than 200,000 hours of operation and data monitoring. This experience, and data-driven insights, have led to performance improvements and smart innovation. Today, our 7HA and 9HA gas turbines lead the industry in total lifecycle value through strategic service solutions that enable our customers to adapt their operations and assets for cleaner, more reliable and cost-effective conversion of fuel to electricity.

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Saudi ArabiaFirst 7F.05 gas turbines reach fulloperation in Saudi ArabiaThe first four highly efficient and flex-ible GE 7F.05 gas turbines in the field have successfully reached full commer-cial baseload operation at Saudi Elec-tricity Company’s (SEC) Power Plant (PP) 12 in Riyadh, Saudi Arabia. All eight units at PP12 are expected to be operating in combined cycle soon, add-ing nearly 2000 MW to support SEC in meeting its future electricity demands. PP12 is part of Saudi Arabia’s plans to add 33 GW of power generation capac-ity by 2020. “PP12 is one of the most important combined-cycle projects in Saudi Arabia and will enable us to provide the addi-tional electricity needed to support Sau-di Arabia’s ongoing economic growth,” said Eng. Ziyad M. Alshiha, president and CEO of SEC. “We are very pleased to be the first to operate GE’s latest F-class technology and expect GE’s advanced technology to provide reli-able power to residents and industries throughout the Kingdom for many years to come.” The first four of eight GE 7F.05 units (“Block One”) that SEC installed at PP12 began providing much-needed baseload power to the Kingdom at the end of last year. The four remaining units (“Block Two”) are in commission-ing. The four 7F.05 gas turbines are oper-ating in simple cycle at full baseload on distillate fuel. The plant is expected to be operating on natural gas and in com-bined-cycle mode in early 2015. Fuel flexibility is a significant advantage of the 7F.05 turbines, which can operate on natural gas, distillate fuel or Arabian Super Light crude. GE’s F-class gas tur-bines are the first to offer its customers the ability to operate on crude oil. “PP12 demonstrates the commitment of the Kingdom to adopt the newest technologies that promote operational efficiencies in the energy sector, under-lining Saudi Arabia’s status as a regional hub for cutting-edge technology,” said Mohammed Mohaisen, CEO, power generation products and services sales, Middle East and North Africa. “GE is

dedicated to being a technology partner for Saudi Arabia, and we take pride in delivering advanced technology solu-tions for the Saudi energy sector.” The eight units at PP12 are just the first of 20 GE 7F.05 units purchased in Saudi Arabia.

USAPSI launches gas engine JV with Doosan InfracorePower Solutions International, Inc. a leader in the design, engineering and manufacture of emissions-certified alter-native-fuel and conventional power sys-tems, has launched Doosan PSI, LLC, a joint venture with Doosan Infracore Co., Ltd the international construction and utility equipment manufacturer head-quartered in Incheon, South Korea. The JV, equally owned by both com-panies, will leverage the strengths of each to design, develop, produce, mar-ket and distribute industrial gas power systems to the global market. “This JV is the perfect vehicle to combine the production and develop-ment capabilities of Doosan with PSI’s engine technology, application and product support expertise,” said Gary Winemaster, Chairman and Chief Exec-utive Officer of PSI. “After seven years of successful cooperation with Doosan in North America, we’re ready to extend both companies’ global reach to new markets.” In terms of existing rights, the JV agreement adds a multi-year exten-sion to PSI’s exclusive rights to market power systems using Doosan engines in North America. Doosan Infracore will retain exclusive rights to market its products in South Korea under the Doo-san brand. The newly formed Doosan PSI JV will be the exclusive outlet for products for all other global markets.

USADuke investing in gas firedgeneration through 2018Duke Energy is planning to add more than 2,900 MW of new gas-fired gener-ating capacity to its Southeastern power fleet by the end of 2018. This represents an investment of around $2.45 billion.

Most of the capacity will be self-built by Duke although the North Carolina-based company also expects to purchase a gas unit from Calpine. In October a Duke utility subsidiary in Florida received Florida Public Ser-vice Commission approval for 1,640 MW of new combined cycle gas genera-tion at its Citrus County site in 2018. The Florida PSC has also approved a 220 MW power expansion at the Hines facility, which is expected to be online by the end of 2017. Duke is also negotiating the acquisi-tion of Calpine’s Osprey combined cy-cle unit or the addition of new combus-tion turbines at Suwanee in 2017. The Osprey purchase would need approval by the Federal Energy Regulatory Com-mission (FERC). In North Carolina, Duke expects to bring the 750 MW Lee combined cycle gas project online by the end of 2017. The North Carolina Utilities Commis-sion (NCUC) has already approved a certificate for the plant and Duke is starting to order long lead-time equip-ment for the project.

AustraliaAlstom to upgrade WesternAustralia’s largest gas-firedpower stationAlstom has been awarded a contract worth over A$30 million ($24 million) by NewGen Power Kwinana Pty Ltd to upgrade the 320 MW combined cycle Kwinana power station, south of Perth in Western Australia. The contract also incorporates an extension of the existing Long Term Parts Agreement (LTPA) to 2028. The Alstom GT13E2 gas turbine will be retrofitted with the multi-mode MXL2 upgrade package, which offers increased power output, substantial im-provements to operational efficiency and enhanced availability through in-creased maintenance intervals. This will be the first upgrade of its type in the Asia-Pacific region. The Kwinana power station, origi-nally supplied and commissioned by Alstom in 2008, will be the first gas turbine unit in the region to be upgrad-ed with this state-of-the-art technology,

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providing a more fuel efficient machine to compete in a market that has seen gas prices increase significantly since the plant was commissioned. The GT13E2 MXL2 upgrade fea-tures Alstom’s online switching concept, allowing operators to choose between two operational modes – for maximum power and efficiency, or for extended lifetime. In Kwinana, the upgrade will deliver an additional 7 MW of power and up to 1% combined cycle plant ef-ficiency increase whilst also extend-ing the time between scheduled out-ages from 36,000 Equivalent Operating Hours (EOH) to 48,000 EOH (approxi-mately 6 years) contributing to signifi-cantly lower operating costs. The upgrade will take place in late 2015 during a scheduled C inspection of the turbine. Under the contract, Alstom will provide all engineering, supervisory and labour staff to complete the imple-mentation and service outage, which in-cludes inspections on the steam turbine

and two generators. “The MXL2 upgrade at Kwinana will offer significant improvements in ef-ficiency and performance while pro-viding NewGen with greater flexibility when operating their plant,” said Russell Claxton, Managing Director of Alstom Thermal Service in Australia and New Zealand. “This upgrade will ensure that the plant is well placed to support the dy-namic market conditions of the power industry today, along with the flexibility to address market developments in the future.”

BangladeshChina to build MaheshkhaliLNG power plant Bangladesh is to build its first private power plant. MPC-Bangla Power, a joint venture of Meiya Power Company Limited and Trade Matrix Venture Lim-ited, will build a 1075 MW Liquefied Natural Gas (LNG)-based combined cy-

cle power plant at Maheshkhali in Cox’s Bazar. Construction of the plant will take 46 months. A Power Development Board official said the Prime Minister’s Office approved the proposal of the consortium to set up the power plant. He said it would likely be built under the Speedy Supply of Power and Energy (Special Provisions) (Amendment) Act. The government has been importing LNG for the country as it is suffering from an acute gas crisis due to the rapid depletion of current reserves and a lack of new discoveries. After the Chinese consortium sent a proposal to the Power Division to set up the plant late last year, the Power Division sought the opinion of the PD Board. “They have submitted a feasibility study to build the plant. We discussed their proposal at our board meeting and will send our opinion to the Power Divi-sion as soon as possible,” PDB Chair-man Shahinul Islam Khan told the Dha-ka Tribune. “The Power Division will take the final decision in this regard,” he said. The submitted report said the consor-tium would supply LNG to the proposed Power Division offshore LNG terminal from which it will obtain re-gasified LNG as fuel for the proposed plant. The power station is to be operated on a Build-Own-Operate (BOO) scheme for the 22 years. The consortium proposed that the cost per unit of electricity produced at the LNG plant would be around Tk12 (15.4 c/kWh) subject to the availability of LNG at $17 per million Btu (mmbtu). Currently, the cost of electricity per unit from a gas-run plant is less than Tk12 while the cost of electricity per unit produced from a diesel or oil-run plant is Tk14 to Tk18.

GermanyRepower contracts GE to supply 9HA to Leverkusen CHP plant Repower has signed contracts with GE and Spain’s Iberdrola, via its engineer-ing subsidiary, for the supply of GE’s high efficiency 9HA gas turbine, long-term services and turnkey installation

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for the new CHEMPARK Leverkusen combined cycle plant. The cogeneration or combined heat and power (CHP) facility is expected to help meet Germany’s carbon reduc-tion and energy efficiency requirements, while producing electricity and steam for CHEMPARK’s chemical businesses. GE plans to supply its 9HA gas tur-bine, the world’s most efficient at over 61 percent in combined cycle, and long-term maintenance services for the gas and steam turbines. Iberdrola will han-dle installation and balance of plant for the turnkey project. Repower chose GE and Iberdrola Engineering as preferred bidders back in the spring of 2014. The necessary agree-ments were subsequently drawn up and finalized, and were signed at the end of 2014. “While our business model is com-plex, GE and Iberdrola demonstrated a deep understanding of what Repower needs for a cogeneration facility that will be highly efficient, flexible, and reliable, and helps meet the necessary carbon reduction and energy efficien-cy targets,” said Dr. Daniel Fritsche, project manager at Repower and CEO of Repower GuD Leverkusen GmbH. “Their one-team approach and custom-ized solution supports our business plan and all required revenue streams.” Repower is now moving ahead with planning, and is in intensive discussions with a view to getting one or more proj-ect team members on board. Repower anticipates that once all the pieces are in place (results of the partnering negotia-tions, details of the set-up of the cogen-eration subsidy, and a reliable frame-work), it would be possible to make a final decision on construction of the project in the course of 2015. The CHEMPARK Leverkusen plant is expected to have an overall fuel ef-ficiency higher than 80 percent and steam extraction of more than 300 tons per hour, enabling companies on the CHEMPARK site to be supplied with process steam efficiently and cost-effec-tively. The 9HA plant should have a net output of more than 570 MW, and gen-erate the equivalent power that would be needed to supply approximately 600,000 German homes.

USAArizona RFP for peaking capacityArizona Public Service Co. (APS), the state’s largest and longest-serving elec-tricity utility, has announced a request for proposals (RFP) to provide dispatch-able capacity to meet peak power de-mands. The company is seeking approxi-mately 300 MW of peaking capacity, which may be bid as a power purchase agreement or a build, own, and transfer structure. Proposals should demonstrate that projects can reach commercial op-eration by summer 2018 or 2019. The deadline to submit bids is March 18, 2015. Proposals will be evaluated relative to an APS self-build option to expand the existing Ocotillo Power Plant site located in Temple, Arizona. The RFP process will be monitored by an independent third party.

RussiaAlstom commissions CCP units at Novogorkovskaya Alstom has commissioned two GT13E2 gas turbine-based combined cycle units at Novogorkovskaya thermal power plant in Russia. With a total capacity of 350 MW, the new units will nearly double the electrical capacity of No-vogorkovskaya power plant, which was commissioned in 1956. The construction of the new units started in December 2012. This proj-ect is part of the frame agreement signed in 2011, between Alstom and Renova Group regarding the supply of five 180 MW GT13E2 gas turbines for IES-Holding: for Novogorkovskaya (2 turbines) and Nizhneturinskaya (2 tur-bines) thermal power plants (TPP) and one turbine for Akademicheskaya power plant. In late November, the equipment in-stalled by Alstom at Novogorkovskaya TPP successfully passed the reliability run with 72-hours full-load tests. Andrey Lavrinenko, vice president Global Power Sales for Russia and CIS at Alstom, said: “The GT13E2 is one of Alstom’s largest equipment fleets, and has already achieved more than 10 mil-lion operating hours.” Alstom GT13E2 turbines are already in use in the CIS market. The first tur-

bine was commissioned in 2009 at Min-skaya TPP-3 in Belarus. Since 2010, two more turbines have been put into operation at Razdanskaya and Erevan-skaya TPPs in Armenia. In 2015 and 2016, Alstom equipment is scheduled for commissioning at two new CCP units at Nizhneturinskaya and one at Akademicheskaya TPP (Ekaterinburg).

TurkeyAlstom to supply the powerisland for KirikkaleAlstom has been awarded two con-tracts worth over €220 million ($246.5 million) in total for the supply and the maintenance of the power island of the 950 MW Kirikkale combined-cycle power plant located in the central Anatolia region in Turkey. The plant is expected to be commissioned in May 2017. The Kirikkale Independent Power Project (KIPP) is developed by Acwa Güç Elektrik Işletme ve Yönetim Sanayi ve Ticaret A.Ş. (“ACWA Guc”), a sub-sidiary of ACWA Power and which in-cludes Samsung C&T Corporation as a shareholder. KIPP is a greenfield project located within the municipality of Kiliclar in the Yahsihan District of the province of Kırıkkale, 9 miles (15 km) from Kirik-kale City Centre and 30 miles (50 km) east of Ankara. The project will be op-erating on a merchant basis selling the dependable power capacity and electric-ity dispatched via bilateral contracts and in the balancing/day-ahead market. Alstom will supply the main power train equipment components including two GT26 gas turbines, two heat re-covery steam generators (HRSGs), one steam turbine and three turbogenerators to Samsung Construction and Trading (SCT), which is responsible for the en-gineering, procurement and construction (EPC) on a turnkey basis. Alstom will also provide installa-tion and commissioning field advisory services to SCT during the construction phase and ensure long term maintenance services for up to 20 years after com-missioning. Alstom says that it has supplied key equipment for more than 25% of Tur-key’s installed power generation capacity.


Industry News

IndiaBHEL bags $196 million orderfor 370 MW CCPP Bharat Heavy Electricals Limited (BHEL) has bagged an engineering, procurement and construction (EPC) contract for a combined cycle power plant (CCPP) in Karnataka. Valued at Rs.12,020 million ($196 million), the order for the 370 MW gas turbine-based CCPP to be installed at Yelahanka on the outskirts of Bengaluru city, was awarded by Karanataka Power Corporation Limited (KPCL). Significantly, it will be the first gas-based utility power project for KPCL. The plant will replace an old 128 MW diesel generator-based power plant, which has not been operating for some time due to environmental issues. Yela-hanka CCPP will not only address en-vironmental concerns but will also im-prove the power supply in Karnataka and specifically Bengaluru city. BHEL’s scope of work includes de-sign, engineering, manufacture, sup-ply, construction, erection, testing and commissioning of the plant. The key equipment for the contract will be man-ufactured at BHEL’s Hyderabad, Trichy, Haridwar, Bhopal and Jhansi plants, while the company’s Power Sector – Southern Region will be responsible for civil works, erection and commissioning of the equipment. The gas-based power plant is capable of fast start-up for peaking power and has low emissions. With the recent gas price revision and proposal for gas price pooling, gas availability is likely to im-prove which will result in setting up of more gas-based power plants in the country.

MexicoAbengoa to develop 924 MWplant for CFESpain’s Abengoa has been chosen by Mexico’s Federal Electricity Commis-sion (CFE) to build the 924 MW Norte III combined cycle plant in Ciudad Juárez (Mexico). The project is part of the National Investment Plan 2014-2018 recently announced by the Mexican government. Abengoa will be responsible for the engineering, design and construction

of the project, as well as its subsequent operation and maintenance for a 25-year period. The total contract is worth $1550 million, including construction, operation and maintenance of the plant. Norte III, which is expected to be completed within 30 months, will create up to 2000 direct and indirect jobs dur-ing the construction phase. The invest-ment during the construction phase will total around $700 million, which will be financed with a mix of equity and non-recourse debt. Abengoa will take an equity stake in the project. This latest contract will bring the estimated backlog for Abengoa’s en-gineering and construction division to around €9300 million, based on the fig-ure from the end of 2014. The plant will produce enough power to supply more than 500,000 homes ev-ery year, improving the country’s energy independence while reducing green-house gas emissions and the end cost of electricity to consumers. The Norte III project is the largest combined cycle plant in Mexico and the second that Abengoa will have con-structed for the CFE, after the 640 MW Centro Morelos plant currently under construction. Abengoa is also carrying out two power transmission projects for the CFE.

USAIberdrola to build CCGTplant in SalemIberdrola, through its engineering sub-sidiary Iberdrola Ingeniería, has been awarded a contract for the construc-tion of a combined cycle power plant (CCGT) in Salem (Massachusetts) with an installed capacity of 674 MW. The contract was awarded by Foot-print Power, a U.S. project company specialising in the replacement of old-er and less efficient coal- and oil-fired plants with more efficient and modern power generation facilities. This contract is one of Iberdrola In-geniería’s largest ever in terms of scale, and represents a key milestone in estab-lishing itself in one of the most competi-tive markets in the global energy indus-try. Located some 19 miles (30 km) from Boston, the Salem CCGT plant will be

able to supply electricity to 280,000 people. The state-of-the-art facil-ity, which will use GE’s Flex-efficiency technology, will be housed in a modern, environmentally friendly building de-signed by the U.S. firm Cookfox Archi-tects. The new quick start plant will use the most advanced technology and will replace the 63-year old coal-fired Salem Harbor Station, which is being decom-missioned. In addition to reducing emis-sions, the new gas fired plant will free-up space at the current site.

Saudi ArabiaSEC launches integrated solar-CCGT project Saudi Electricity Company (SEC) has selected GE for a project that marks Saudi Arabia’s first integration of a solar field with a combined cycle plant and the first introduction of condensate as a gas turbine fuel. The landmark project, the ‘Green Duba’ Integrated Solar Combined Cycle Plant, will be built in northwest Saudi Arabia, along the Red Sea coast. “This part of Saudi Arabia is a devel-oping region with limited grid intercon-nection, so the additional power gener-ated by the Green Duba project will be tremendously important in supporting growth,” said Ziyad M. Alshiha, presi-dent and CEO of SEC. The plant will have the capacity to generate the equivalent power needed to supply around 600,000 homes for a year. It is designed to generate up to 550 MW from the combined cycle plant, while the solar field will supply steam for an additional 50 MW. The SEC order includes a 7F.05 and a 7F.03 gas turbine; one steam turbine; generators; heat recovery steam gen-erators (HRSGs); condenser; boiler feed pumps; Mark VIe distributed control system and a long-term service agree-ment. “We expect the plant to provide cost-efficiencies over its lifecycle, along with the fuel flexibility and solar capabilities needed to support the Kingdom’s fuel conservation and renewable technology initiatives.” In terms of fuel flexibility, the 7F.05 gas turbine will operate on condensate

www.gasturbineworld.com GAS TURBINE WORLD November - December 2014 11

Industry News

while the 7F.03 will operate on natural gas, with Arabian Super Light (ASL) crude oil as backup. GE’s F-class gas turbines are the first to offer customers the ability to operate on ASL. “The contract is another testament to our committed partnership with SEC to further enhance the efficiency and flex-ibility of its plants,” said Hisham Albah-kali, GE’s president and CEO for Saudi Arabia and Bahrain. “The integration of solar power and the introduction of condensate fuel at the Green Duba project is a true mile-stone for the Kingdom, and supports the government’s vision to promote energy sector efficiency with a focus on renew-ables,” said the CEO. The first four 7F.05 gas turbines in the field recently achieved full commer-cial baseload operation at SEC Power Plant (PP) 12 in Riyadh.

PeruSiemens delivers threeF-class gas turbines to PeruSiemens has received an order for three SGT6-5000F gas turbines from Peru. The turbines will be used in the project Nodo Energético del Sur - Planta N° 2 Región Moquegua, which consists of three simple cycle power plants. The customer is the power utility EnerSur, the contractor being Técnicas Reunidas and JJC. The commercial operation date is scheduled for March 2017. The three new plants will be in-stalled in Ilo, which is a seaport in the Moquegua region, the southern part of Peru. The SGT6-5000F dual fuel gas turbines will run on fuel oil for the first five years, then they will be operated on natural gas. The three simple cycle plants will to-gether have a capacity of 600 MW when fired with fuel oil. “We are happy to have received this order from Técnicas Reunidas and JJC, and are committed to deliver first class technology for the Nodo Energético del Sur project,” said Thierry Toupin, CEO of the Business Unit Large Gas Tur-bines/Generators at Siemens Power and Gas division. “The SGT6-5000F gas turbine of-fers economical power generation for peak-, intermediate-, or base-load duty.

It is an environmentally friendly gas turbine technology with low water in-jection requirements, and equipped with Shaping Power, a feature that enables higher power output on higher tempera-ture days.” The SGT6-5000F units will be manu-factured in the Siemens factory in Char-lotte, North Carolina, which is the main production facility for 60 Hz power gen-eration projects.

USAGas engines help Oregon wind integrationThe Port Westward Unit 2 power plant owned by Portland General Electric (PGE) has reached commercial opera-tion. The 220 MW near Clatskanie, Or-egon is using engines supplied by Wärt-silä to balance wind and solar energy, as well as provide load-following and peaking services. “With the growing amount of vari-able renewable power coming online, this type of flexible resource is essential in helping us continue to provide reli-able service to our customers in an in-creasingly complex environment,” said Jim Piro, PGE’s President and CEO. The power station includes 12 Wärt-silä 50SG engines, running on natu-ral gas. With an output of 18 MW, the Wärtsilä 50SG is the largest commer-cially operating gas engine in the world. Wärtsilä’s contract with PGE includes a long-term maintenance agreement of ten years. Fast-reacting capacity is needed to balance sudden fluctuations in the re-newable energy supply in real-time. “Port Westward Unit 2’s advanced technology and unique configuration allows PGE to ramp the plant up to full load in less than 10 minutes,” said Rick Tetzloff, PGE’s project manager for the new plant. “This flexibility allows us to adjust quickly when renewable energy – like wind and solar – rise and fall with natu-ral variability. And it also means that on peak demand days, our customers ben-efit from increased reliability.”

South KoreaAnsan completed in record timeSiemens and its partner South Korean

POSCO Engineering & Construction Co. Ltd. (POSCO E&C), an affiliate of POSCO, one of the largest steel com-panies in the world, have completed the Ansan combined cycle power plant in a record time of 24 months from ground-breaking to first commercial operation date (COD). The Ansan combined heat and power (CHP) plant is located in the city of the same name in Gyeonggi-do province southwest of the capital Seoul. This liq-uefied natural gas (LNG) fired plant is the first H-class 2+1 multi-shaft power plant in Korea and has an electrical ca-pacity of 834 MW. Siemens delivered the power island main equipment: two gas turbines of type SGT6-8000H, an SST6-5000 steam turbine, three hydrogen-cooled genera-tors of type SGen6-2000H, and two heat recovery steam generators from BHI, South Korea, as well as the entire instru-mentation and control technology, SP-PA-T3000. Siemens will also supply the long-term service for the gas turbines. It is the fourth Siemens H-class-based combined-cycle power plant in commercial operation in Asia with an electrical efficiency of more than 60 percent. In addition to generating elec-tricity, the plant will also provide district heating for the inhabitants of the city of Ansan. CHP production raises the overall fuel utilization factor to over 75 percent. NOx emissions from the plant are 7 ppm, the lowest in Korea. This makes the plant one of the most efficient and eco-friendly fossil-fuel-fired electric-ity generating plants in the country. The owner and operator of the plant is S-Power, headquartered in Ansan. “The trustful relationship developed with POSCO E&C made it possible to execute this highly efficient H-class power plant in a record time. Thus we are making an important contribution towards cost-efficient and environ-mentally friendly power supply in the Gyeonggi-do Province at the right time to support the winter peak,” said Lothar Balling, head of the Business Unit Proj-ect Management Energy Solutions in the Siemens Energy Power Generation Division. “Ansan CHP project was developed


Industry News

by POSCO E&C, reflecting the long term electric power supply plans of the Korean Government. Further emphasis was put into selecting the most environ-mentally suitable technologies with the local environmental authorities of Ansan City in a process covering a period of two years,” said Mr. Sung-Taek Seo, POSCO E&C´s Project Manager. “We selected the Siemens H-Class gas turbine technology and Siemens in-house basic engineering and proj-ect management capabilities in order to construct one of the most competitive power plants in Korea. As the results have shown, the Ansan power plant and the partnership with Siemens have prov-en to be a great success and a bench-mark in the IPP market.” Siemens has now sold 15 SGT6-8000H gas turbines to South Korea for eight projects totalling over 6.3 GW installed CCPP capacity. Four H-class projects have been completed while four projects are still under construction. They are scheduled to commence opera-tion in 2015 and 2017.

USATIC to build first J-Seriespower plantThe Industrial Company (TIC), a wholly owned subsidiary of Kiewit Corpora-tion, has been awarded an engineering, procurement and construction (EPC) contract to build the 495 MW Grand River Energy Center Unit 3. The plant owned by Grand River Dam Authority (GRDA), Oklahoma’s state-owned electric utility will feature the nation’s first installed Mitsubishi Hitachi Power Systems Americas, Inc. (MHPSA) M501 J-series engine. Construction on the plant will be-gin in early 2015 at GRDA’s facility in Chouteau, Oklahoma, just 35 miles east of Tulsa. The new power plant will help GRDA meet new emissions regulations by reducing its dependence on coal-fired power generation. The project is scheduled to become operational in May 2017. TIC will execute the project using its own workforce and capabilities, starting with engineering and procurement, and extending to all key craft disciplines in the field.

USAWaukesha-Pearce Industriesbroadens distributionGE’s Distributed Power business has announced that Waukesha-Pearce In-dustries (WPI), a long-time Waukesha gas engines distributor in the U.S., is expanding its 30-state territory to now include the 48 states in the lower United States. Customers utilizing Waukesha equip-ment in the United States often oper-ate in multiple areas across the country. This expansion provides a single dis-tributor point of contact in the U.S. for genuine Waukesha parts and a consis-tent, high standard in expert aftermarket support. “WPI has enjoyed a 90-year history as a partner with Waukesha gas engines. We are looking forward to the expanded territory relationship and the opportunity to support new customers as well as con-tinuing the support of our existing cus-tomer base,” said Mr. Louis Pearce III, president of Waukesha Pearce Industries. With more than 20 genuine Wauke-sha parts and service centers around the country and a skilled team of factory-trained engine technicians, WPI says it is committed to providing the same high level of customer support in its new territory. This will be further enhanced through WPI’s new investments in per-sonnel and service infrastructure and by partnering with GE-approved regional service companies to ensure immediate, local customer support in remote areas. WPI also will provide genuine parts and service support to gas compression packagers in GE’s new Gas Compres-sion Power Packager Program. MexicoCapstone Turbine securesmajor Mexico orderCapstone Turbine has received a sig-nificant order from Mexico for fourteen C1000 microturbines for multiple com-bined heat and power (CHP) projects in Mexico. This substantial order was received just weeks after an order for six C800 microturbines and sixteen C30 micro-turbines for the second phase of the Los Ramones pipeline project in Mexico. Darren Jamison, President and Chief

Executive Officer at Capstone Turbine, said: “These two orders have a com-bined total of approximately $17 mil-lion and should make Mexico a top-five market for calendar year 2015.” USASiemens long term services for Blythe Energy CenterSiemens has been awarded a long-term service agreement for the Blythe Energy Center’s gas-fired 507 MW combined cycle plant located in California. The customer is AltaGas Ltd, headquartered in Alberta, Canada. The new agreement covers sched-uled maintenance activities, program management, spare parts, power diag-nostics and performance monitoring for the plant’s two Siemens V84.3A (now named SGT6-4000F) gas turbines for the next 25 years or 116,000 equivalent operating hours (EOH). The agreement will enable the Blythe Energy Center to take advantage of Sie-mens modernization and unit enhance-ments, such as thermal performance optimization, low-load turn down, and rotor exchanges, all designed to help ex-tend scheduled inspection intervals and improve the operational flexibility of the two combustion turbines at the facility. Siemens offers the turn down op-timization as part of its “Flex-Power Services” portfolio. The optimization is designed to reduce carbon monoxide emissions during part-load operation. “The Blythe Energy Center has been providing reliable electricity for the past 11 years, and this continued service agreement and gas turbine performance enhancing upgrades will enhance the units’ ability to continue to operate op-timally for many years to come,” said Craig Weeks, CEO, Siemens Power & Gas Services Business Unit.

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INDUSTRYBRIEF

4


The case for building new coal fired plants or back-fitting exist-

ing coal plants with carbon capture technology is economically unattract-ive. The case for equipping gas-fired plants with carbon capture and stor-age (CCS) is even more difficult to justify. High capital cost, combined with the penalty in efficiency that the capture process places on the power plant, has so far proved to be a ma-jor stumbling block in the commer-cial deployment of power plants with CCS. A solution that has been under seri-ous development for the last 5 or 6 years, however, has now reached the stage where the key component – a new type of turbine and combustor – is close to the start of manufacturing. The turbine and combustor, being designed and built by Toshiba, essen-tially combine gas turbine and steam turbine technologies, with the poten-tial to deliver a power plant with:

● Efficiency of about 59% (LHV) when running on natural gas

● Efficiency of 51-52% (LHV) when running on gasified coal (syngas)

● Full 100% carbon capture at 300 bar without any efficiency penalty.

Since 2012, Toshiba has been devel-oping a new turbine and combustor for the new CO2 power cycle together with NET Power, CB&I, Exelon and 8 Rivers Capital. The five companies have now completed major agree-ments to build a 25MW gross elec-

tric (50MWt) demonstration plant in Texas. Through the successful completion of operating tests, the demonstration plant is intended to provide the basis for construction of the first 295MWe full-scale commercial plant.

CO2 power cycleNET Power LLC was formed almost six years ago by 8 Rivers Capital, a technology commercialization firm based in North Carolina (and inventor of the supercritical CO2 power cycle) with a clear and different approach to tackling the problem of burning fossil fuels more cleanly. Instead of trying to “fix” super-critical coal, IGGC (integrated gasifi-

cation combined cycle) or natural gas combined cycle power plants, 8 Riv-ers looked at designing a fossil based system from scratch that achieves the desired end result. The cycle produces pipeline-ready CO2 and no air emis-sions without reducing plant efficien-cy or increasing costs. In 2009, Rodney Allam, a former head of technology development at Air Products, joined the company to work on a new thermodynamic cycle so all the emissions are controlled from the outset.

Process descriptionThe cycle is not a combined cycle. Instead, it exploits the special thermo-dynamic properties of carbon dioxide

Gearing up for a new supercritical CO2 power cycle system By Junior Isles

Toshiba has almost completed detailed design in preparation for a turbine that will use carbon dioxide as the working fluid.

25MWe Demo Plant. Design features a single can-type combustor and double-shell turbine structure, scaled-down model of a 250-300MWe turbine design for a commercial plant.


as a working fluid by eliminating the energy losses that steam-based cycles encounter due to the heat of vaporiza-tion and condensation. According to the company, the Al-lam Cycle (named after its lead in-ventor) removes the steam Rankine Cycle from the process and improves upon the simpler, more efficient Bray-ton Cycle. The Allam Cycle combusts natural gas or synthetic gas (derived from a coal gasification system) with pure oxygen (oxyfiring), as opposed to burning gas with air. Following a Brayton Cycle-like ex-pansion across its turbine, CO2 is re-circulated back to the beginning of the cycle in a highly recuperative process. The system eliminates the expensive steam cycle components and avoids the inefficiencies of traditional Ran-kine cycles. This process generates a relatively pure stream of high pressure carbon dioxide and some water while signifi-cantly reducing or eliminating other pollutants such as NOx. At very high pressures, CO2 exhibits a greater ener-gy density and work output, enabling the cycle to reach extremely high ef-ficiencies. The working fluid is expanded through a turbine that has an inlet pressure in the range of 200 bar to 400 bar and a pressure ratio between 6 and 12. It is then cooled through a heat exchanger, and H2O is separated from it to create a CO2 stream. The CO2 stream is pressurized and a ma-jor part of this flow is fed back to the combustor to begin the cycle anew. This novel cycle separates almost all of the CO2 from the other combus-tion products, producing a seques-tration-ready CO2 byproduct that is at pipeline quality and pressure. The need for a separate CO2-capture sys-tem is thus eliminated. There is there-fore no efficiency penalty of adding a capture process, which can typically result in a loss of around 10 per cent in overall electrical efficiency. An important factor in achieving high net cycle efficiency is to use a

high turbine inlet temperature. This temperature, however, is limited by the maximum allowable temperature of turbine exhaust that flows directly into the heat exchanger. The operating temperature at the hot end of the heat exchanger is thus in the range of 700°C to 750°C. This leads to a typical turbine inlet tem-perature constraint in the range of 1100°C to 1200°C.

Turbine and combustorThe turbine and combustor are new pieces of equipment for this cycle, and their development includes com-bining gas turbine and steam turbine technologies. The turbine inlet temperature of the cycle is not high for gas turbines, but it is very high for steam turbines. Similarly, the pressure of this cycle

does not surpass that of advanced steam turbines, but it is extremely high for gas turbines. The combustor has been designed to cope with a gas pressure of 300 bar, which is more than 10 times the gas pressure utilized in conventional gas turbines. Turbine: In developing the tur-bine, Toshiba has set out to use prov-en technology as much as possible. It has also designed a commercial scale turbine in the 250-300MWe (500MWt) size range and scaled it down to build a 25MWe (50MWt) demonstration unit. This, it says, will mitigate risks and shorten develop-ment time of the full-scale machine. Hideo Nomoto, Chief Fellow, Toshiba said: “Our plan is to construct the first commercial plant having two turbines and common BOP (balance of plant) for some part, and the to-

CO2 Power Plant Project Partners

Toshiba, NET Power, CB&I, Exelon and 8 Rivers Capital are working together to develop and commercialize the application of supercritical carbon dioxide power cycle technology for efficient emissions-free electric power generation. They have completed major agreements to build a 25MWe gross electric (50MWt) demonstration plant in the U.S. for test and evalua-tion that will provide the basis for the design and construction of a full-scale 295MWe commercial plant.

● Toshiba is to provide a first-of-a-kind turbine that will utilize super-critical CO2 as a working fluid to produce low-cost electricity while eliminating NOx, CO2 and other pollutants.

● CB&I to provide engineering, procurement and construction ser-vices including pre-FEED (front-end engineering design) and FEED studies for the demo plant and pre-FEED study of a commercial 500MWt power plant.

● Exelon, one of the leading competitive energy providers in the US, will be responsible for siting, permitting and commissioning the demo plant facility.

● NET Power will be responsible for project management, overall sys-tem engineering and integration, coordination between the partners.

● 8 Rivers Capital , inventor of the supercritical CO2 cycle, will provide ongoing engineering and technology development services.

Timetable calls for Toshiba to begin delivery of key equipment to the demo plant site in August 2016. The completed plant is expected to enter the commissioning stage before the end of 2016.


tal plant size will be 500-600MWe range. The turbine for the demonstra-tion plant is 25MWe and it is intended to be a scale-down of the commercial turbine as much as possible. “It is difficult to quantify how much we can speed up the develop-ment. However, the scaled-down tur-bine is a necessary step to mitigate

R&D risk and to demonstrate to our future customers that this technology is realistic and promising.” Describing the fundamentals of the turbine design, Nomoto said: “The easiest way to describe the turbine is that we need only a single HP turbine for this cycle. Since the pressure at the exhaust end of the turbine is 30

bar, we don’t need an IP or LP. In a coal-fired plant, the steam turbine consists of HP, IP and LP sections. In a combined cycle plant, there’s a gas turbine and a steam turbine with HP, IP and LP sections.” The new machine has a double shell structure (outer casing and in-ner casing), which is steam turbine technology that serves to contain the system’s high pressure. The space be-tween the inner casing and outer cas-ing will be filled with a carbon diox-ide cooling flow extracted from the lower temperature end of the plant. The cooling technology enables the outer casing and larger inner casings to be designed using CrMoV cast-ing. Ni-based material is used for the smaller, inner casing that encloses the

Natural gas fired CO2 cycle. Allam Cycle is expected to deliver 58-59% net efficiency (LHV) on natural gas fuel including 100% CO2 capture at 300 bar.

Design Parameter Gas HHV Gas LHVGross efficiency 74.65% 82.70%CO2 compressor power -10.47% -11.60%Plant parasitic power -11.01% -12.20%Net Efficiency 53.170% 58.90%

Source: Toshiba, December 2014

Supercritical CO2 Allam Cycle (Natural Gas Fuel). The CO2 working fluid is expanded through a turbine, cooled through a heat exchanger, followed by water separation to create a CO2 stream which is then pressurized. A major part of the flow is fed back to the combustor to begin the cycle anew.

ASUAir

Oxygen

Natural Gas

CO2 Recycle Flow

ASUIntercooling

PowerCooling

Heat Exchanger

Water Separator

H2O

CO2 Pump

High PressureCO2 for Pipeline

ZeusCombustor

Turbine

CO2 Compressor

Fuel Combustion

CO2 Turbine

Heat Rejection

Water

Compression, and

Additional Heat Input

Heat Recuperation


exhaust area, where temperatures are higher than 700°C and moderate cool-ing is applied. In addition to using a welded ro-tor, the turbine design calls for the use of cooling technology. Cooling CO2 is supplied to the rotor. This cool-ing flow is distributed to each stage

through the rotor, which protects both the blade fixation and the moving blade. Film cooling (which is generally used for high temperature gas tur-bines) is not needed because the inlet temperature is not extremely high, as compared to existing gas turbines, and

because the heat transfer coefficient of the cooling flow is very high, mak-ing simple convection cooling very effective. Combustor: The combustion pro-cess in this cycle is of critical im-portance because the working fluid and pressure is different from typical heavy-duty gas turbines. Major char-acteristics of this combustor are:

● Negligible NOx emissions because of the use of oxygen as opposed to air.

● Temperature is not as high as exist-ing combustors for heavy frame gas turbines.

● Pressure is much higher than exist-ing combustors.

Recent developments in combus-

Coal based syngas fired CO2 cycle. Allam Cycle is expected to deliver 51-52% net efficiency (LHV) on coal gasification fuel including 100% CO2 capture at 300 bar.

Design Parameter Syngas HHV Syngas LHVGross efficiency 71.12% 74.91%CO2 compressor power -10.25% -10.78%Plant parasitic power -11.99% -12.69%Net efficiency 48.88% 51.44%

Source: Toshiba, December 2014

Supercritical CO2 Allam Cycle (Coal Syngas Fuel). The coal is gasified using a conventional partial oxidation gasifier.After going through several clean-up stages the clean syngas can be sent directly into the supercritical CO2 combustor.

ASU

Gasifier

Syngas Compressor

ZeusCombustor

Turbine

Power

CO2 Compressor

CoalCoal Dryer

N2

N2

Air

Oxygen

H2O w/Impuritiesfor Blackwater Treatment

H2OScrub

H2O

HX

GAC

ModeratingH2O or CO2

Low-GradeHeat Recovery Heat

Exchanger

Cooling

Water Separator

H2OH2SO4HNO3 CO2

Drive Gas

PumpHigh Pressure

CO2 for Pipeline

Lock Hopper

CO2 Recycle

Flow

H20


tors for heavy frame gas turbines have been focused on decreasing NOx emissions. This effort has led to the use of pre-mix combustion, in which fuel is mixed with air before com-bustion to enable lower temperature combustion. The disadvantage of pre-mixed combustion, however, is that it causes system vibrations, called dy-namics, due to flame instability. The Allam Cycle has an advantage in this respect because it eliminates NOx while enabling adoption of sim-pler and more stable diffusion com-bustion. The system is also able to use proven cooling technology, such as back side convection cooling, due to the moderate temperature of combus-tion and the high cooling capability and availability of carbon dioxide. Toshiba has been conducting a high-pressure rig test of an Allam Cy-cle combustor, scaled down by 1:5. Rig testing achieved its rated pressure of 300 bar in 2013. Since then, the company says it has continued the testing in order to get wide range of operational data.

PerformanceA big advantage of the cycle com-pared to supercritical coal fired plant and combined cycle plants, is the ef-ficiency – especially when taking into account the carbon capture. NET Power and its partners have carried out cycle efficiency calcula-tions that demonstrate that its targeted natural gas efficiency is competitive with current CCGT technologies that do not employ carbon capture. The coal-fired Allam Cycle calcu-lations demonstrate superior efficien-cies to that of traditional supercritical pulverized coal and IGCC technolo-gies that do not employ carbon cap-ture. Nomoto noted: “Ultra-supercritical coal plant efficiency is in the region of 42-43% (HHV). Present IGCC plants have almost the same efficien-cy, with future IGCC plants targeting 49%, although that would pose some technical difficulties. That’s without

carbon capture in all cases. This new cycle will achieve 51-52% on coal with 100% capture. “The most advanced combined cycles are projected to achieve 62% efficiency (LHV) but this is without carbon capture. We will achieve 59%, with capture. Also, the efficiency is likely to increase as the technology matures.” There are also expected to be fur-ther efficiency gains as turbine inlet and therefore outlet temperature is increased beyond the current level of 1150°C. “The heat exchanger inlet is the temperature limitation point for NET Power’s cycle designs. This tempera-ture is not very high since we have taken a conservative approach and don’t want to use new materials for the heat exchanger,” said Nomoto. “But we can enhance the inlet tem-perature, and raise the efficiency, if we want to use new materials in the future.” Efficiency gains for the air separa-tion plant and compressors, the two largest parasitic loads for the system which have been included in all ef-ficiency calculations, will further in-crease overall system efficiency. Sev-eral technologies are in development that can dramatically improve this as-pect of plant performance.

EconomicsThe consortium suggests that the new cycle will have comparable or low-er capital costs compared to CCGT, pulverized coal and IGCC plants, as much of the equipment associated with conventional technology can be eliminated. For example, all of the steam ele-ments of a combined cycle system can be eliminated, including the heat recovery steam generator, main steam piping, reheat steam piping, steam headers, and the entire three-stage (HP, IP, LP) steam turbine block. In substitution, NET Power’s sys-tem does include components that are not included in standard combined

cycle plants, though, including most notably heat exchanger and air sepa-ration unit. Because of its high pressure, the system is able to utilize smaller com-ponents and will thus have a smaller overall footprint than plants with a similar power output. Additionally, because of its closed-loop, oxy-fuel characteristics, the NET Power cycle is able to avoid many of the emis-sions control systems and components required by conventional fossil fuel plants. Major components of a full-scale commercial NET Power natural gas plant can be prefabricated, leading to lower site erection costs and a shorter construction schedule compared to existing systems of a similar size. NET Power argues that the econom-ics of such a plant will be even more attractive when the CO2 is used for enhanced oil recovery, gas recovery, or in a variety of industrial processes.

CommercializationThe project is now entering what is the third of four phases i.e. construc-tion of the demonstration plant. After this, Phase 4 will see construction of a 295MWe plant. The demonstration plant construc-tion will be completed in 2016, and commissioning and testing will occur in 2017. Nomoto noted: “We have almost finished fundamental design of the turbine and will do some more design work before starting actual manufac-ture. The date for shipping the turbine from our factory is September 2016.” Internal discussions are ongoing regarding when a commercial plant will be offered. However, Toshiba re-mains confident in the future of the technology. “A lot of our customers around the world are watching this technology to see how things are progressing.” Nomoto said. “If we did not think this technology was very promising, we would not have spent such a large amount of money to develop it.” n

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It has been almost a quarter-century since Alstom launched its first-gen-

eration EV premix burner. Initially developed by ABB, whose power generation assets Alstom acquired in 2000, the EV was a second-gener-ation dry low NOx burner with the novel addition of premix technology. Initial validation tests of that EV burner, carried out on a GT11N gas turbine back in 1991, achieved NOx values between 15-25ppm at 15% O2 for base load and high part-load out-put (compared to 35ppm for the first-generation dry low NOx burner tech-nology ABB introduced commercially in 1984 on a GT13C engine). The EV burner design has been installed on most other Alstom ma-chines including the GT11N2, 13D, 13E1 and GT8 models as well as GT13E2, 8C2, GT24 and 26 annular combustor engines. In 2010, Alstom embarked upon a new dry low NOx combustor R&D project – the EV-Alpha burner – tar-geted at achieving <10ppm NOx at base load output. Operational test re-sults for a GT11N gas turbine instal-lation of the EV-Alpha burner demon-strated:● NOx emissions at base load down to <10ppm● NOx emissions reduced by 40% at upper part-load output● Significant emissions reductions down to 30% gas turbine relative loads.Alstom says in principle the EV-Al-pha is the second generation of its successful premix burner. But in re-

ality there is no major jump in tech-nology, it is more an evolutional improvement. The original premix burner concept remains inherent in the design, i.e. producing a ‘swirl’ of air in which natural gas is injected to homogeneously mix with the air so as to avoid high flame temperatures.

Optimised designThe EV-Alpha burner is materially the same, but optimised, with deep-er penetration of gas injection due to fewer but larger gas holes. This design enriches the lean burner cen-tre, distributes the fuel more homog-enously and thereby achieves a better mixing compared to the baseline. But to get to that improvement is no simple task. The core element of the development program was an im-provement in fuel/air mixing quality of the burner by modifying the pat-tern of gas holes in the EV burner. In the first step, CFD calculations were used to select the most promis-ing hole patterns for gas injection, which has a crucial impact on fuel and air mixing within the burner and hence determines local flame temper-ature and emissions. This entails ana-lysing the ‘unmixedness’ of the burn-er fuel and the hottest flame zones. Firstly, isothermal flow of each variant was simulated to investigate the mixing within the burner and combustor. Fuel distributions were displayed on the burner cross-section plane and at the burner exit as well as on a cone surface, which was defined in the standard baseline case to repre-

sent the flame front. In principal, says Alstom, it would be more accurate to get unmixedness from a real flame front. However the flame front shape changes from case to case so heavily, especially between the standard and shifted patterns, that no reasonable trend can be derived to help better understand the mixing. Therefore, unmixedness was calculat-ed at the burner exit and on the fixed cone surface.

Atmospheric combustion testsAlstom processed several variants from these CFD calculations to opti-mise the position and diameter for gas injection. The two most suitable were chosen for atmospheric burner tests, where the NOx reduction was con-firmed by a one-to-one comparison with the older version of the burner. Testing these two variants in a test rig gave Alstom the criteria for choos-ing a final, single variant for an en-gine test. The plenum and the com-bustion chamber were equipped with water-cooled flanges for measure-ment equipment such as thermocou-ples, emission probe, microphones, cameras and pressure instrumentation. Air flow temperature and velocity were kept at a level corresponding to real engine conditions, although both temperature and velocity were var-ied in order to investigate sensitivity. Lean blowout was examined, as well as flashback behaviour, burner pres-sure drop and supply gas pressure. Furthermore, Alstom’s laboratory al-lowed for testing different gas mix-

EV-Alpha: A burning desire to reduce NOx emissions Tim Probert looks at the

technology in depth.

For the first time, Alstom has installed its latest NOx-reducing premix burner, the EV-Alpha, on a GT13D gas turbine.


tures (natural gas from the Swiss grid was used for the tests). Ultimately, both variants showed lower NOx emissions during the tests compared to the old design. At rel-evant flame temperatures a 30 percent reduction in NOx was achieved, while CO and UHC (unburned hydrocar-bon) emissions were measured; all variants showed the same emissions under chosen operating conditions. After analysis of all data from the test rig, Alstom selected one variant of the final gas hole pattern for the EV-Alpha burner. Alstom says the new EV-Alpha burner has improved the fuel gas mixing and produces an even more stable flame, while pul-sation is reduced in both steady and transient states (which lowers the risk of flameout failures). Furthermore, improved fuel gas mixing reduced the NOx levels without the need for water or steam injection.

Reference plantThe next step was to install the new burner in a reference plant. In May 2011, an EV-Alpha upgrade package was implemented in a GT11NM en-gine in Tung Hsiao, Taiwan during a scheduled outage where the old burn-er set was removed from the combus-tor and replaced by a new set of EV-Alpha burners. Six of the burners were fitted with thermocouples and pressure taps. The test program included pre-test mea-surements, an engine shutdown and A-inspection, installation of the EV-Alpha burners and an EV-Alpha test program. Emissions of all gases were mea-sured during commercial operations over the full load range. Both oil and gas firing were verified. Three burn-ers of the variable group and three main burners were instrumented to calculate the flame temperature and to validate the air distribution models. The burner thermocouple and pres-sure lines were run out of the enclo-sure to the instrumentation rack and finally to the data acquisition system.

The instrumented EV-alpha burn-ers allowed for more thorough test-ing. During the EV-Alpha tests, the FDS (fuel distribution system) pres-sures were measured, along with the pressure loss over the burners and the air temperature at the burners. These measurements were necessary for the accurate calculation of burner flame temperatures in order to validate Al-stom’s models. Several tests at base load and part-load output were performed during validation of the EV-alpha burner. Variable group mappings were carried out at base load. These mappings in-volved fixing the engine at base load and varying the variable group valve stroke. This varied the equivalence ra-tio and flame temperature of the main burners allowing at the same time a characterization of the burner NOx and pulsation sensitivity. At part-load the burner switch points were measured and retuned for the operation with the EV-alpha burn-ers. Similar tests were performed dur-ing the pre-measurements with EV and during the main validation tests with the EV-alpha burners for com-parison. Transient validation measure-ments were also recorded. NOx emissions were reduced by 40% in upper part-load and baseload. The project target of less than 10ppm NOx @15% O2 at base load was met with CO emissions < 1 ppm. Between 90-100% relative load the operation concept was adjusted in order to keep NOx below 10ppm. Between 40-90% relative load the NOx emissions were within 12-25ppm @15% O2. Further, pulsations at part-load with the EV-Alpha burner are never higher than with the standard EV burner. The results confirmed emissions reduction specifications and im-proved pulsation behaviour. After eight months of improved operation (at lower ambient temperature) the customer, Taiwan Power Company, ordered five additional EV-alpha sets for the remaining gas turbines to fur-ther reduce total plant emissions.

Lucky 13?Alstom originally developed the EV-Alpha burner for the GT11N gas tur-bine. But based on its success, Al-stom began a development program to look at the benefits of installing it in a GT13D unit. In mid-2013 an interested util-ity customer was found, Germany’s Mainova AG, which owns the Heiz-kraftwerk West combined heat and power plant located in Frankfurt. Implementation was planned for the next possible regular service out-age, a C inspection scheduled for au-tumn 2014, meaning a wait of one year for the validation. The power plant outage and the installation of the new burner were completed on sched-ule in September 2014 by engineers from Alstom’s Mannheim and Baden sites. The Frankfurt turbines previously had EV premix burners but an older version, the EV 17. Stefano Tartoni, Alstom’s General Manager for Base Fleet Management, says the outage was approximately ten weeks. “This specific upgrade can be done much faster, but we usually combine it with a larger inspection in order to avoid additional downtime. Cleaning and installing takes a couple of days.” Frank Grimm, Alstom’s R&D pro-

EV-Alpha burner. Deeper penetration of gas injection, due to fewer but larger gas holes, enriches the lean burner cen-tre and distributes fuel more homog-enously.


gram manager, Emission Reduction Program, says there was a three-day test. “We started with measurements on base load, i.e. 100 percent load, then measured the entire load range down to 0 percent load. On the third day we did a transient test. “We had an even bigger NOx re-duction [than the reference plant in Tung Hsiao, Taiwan], however part of the reduction was due to the re-covery effect of the C inspection. We also achieved excellent results in part-load, where you want to achieve a high flame temperature in order to keep CO at acceptable levels.”

Bigger potential Alstom sees an EV-Alpha upgrade as suitable for both base load and peaker plants over their entire load range. The EV-Alpha is also suitable for dual fuel turbines, says Tartoni. “We see the potential for EV Al-pha burners to be installed on a fur-ther 60 units around the world cover-ing three different engine types: the GT11N, the GT13D and the GT8. It’s a mature engine upgrade for Alstom’s

so-called base fleet gas turbines. On average these units have been run-ning for 30 years. Alstom has some units running more than 45 years.” Tartoni also notes that the EV-Alpha is fully-retrofittable – compatible with all available upgrade packages during standard C-inspection or slightly ex-tended A or B-inspections. Alstom says the EV-Alpha bears out the company’s commitment to service-oriented R&D, something it believes it puts more effort into than other gas turbine manufacturers. So, are there any plans to further devel-op the EV-Alpha? “The new prod-uct fulfils the current requirements of our customers and regulators,” Tar-toni says, and therefore no further im-provements are currently planned. “Of course, if the market require-ments change, then we will evaluate how we can leverage our technology to react. Our motivation is to sup-port customers with ageing units bet-ter cope with more stringent emis-sions regulations and keep their units running. With the EV-Alpha burner, emissions are significantly below reg-

ulator levels, helping to ensure further operation of such plants. What better return on investment for the customer, and for us, can there be?” Tartoni sees the most potential for the EV-Alpha in North America and Europe, and to a lesser extent the Middle East and Asia. Alstom is cur-rently in the process of developing an EV Alpha Project for the GT8 Fleet and is planning the first implementa-tion in spring 2015 in Wesseling, Ger-many near Düsseldorf. Another ver-sion of the burner is being developed for gas turbines in the Middle East which now operate on diluted natural gas. Alstom is targeting to have this ready by mid-2015. Of course, there are other ways and companies to upgrade burners to reduce NOx emissions. So why use Alstom and not a third-party, such as RJM International of the United Kingdom and others, to upgrade an ageing gas turbine? “It would be very hard for a third-party to offer similar results given the huge investment and know-how in R&D behind this solu-tion,” says Tartoni. n

Mainova CHP plant. GT13D combined heat and power plant in Frankfurt was retrofitted with Alstom’s new extra-low NOx EV-Alpha burner design in September 2014, during the gas turbine’s regularly scheduled C-inspection maintenance interval.

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Knowledge = Power


Praxair Surface Technologies is introducing a new line of chro-

mium-free ceramic aluminum coat-ings for gas turbines that match the performance of its legacy coatings (superior in some features) without the environmental toxicity associated with hexavalent chromium content. These new chromium-free (CF) coatings have been developed to pro-vide the same high performance of chrome-containing coatings under the same extreme conditions typical of gas compressor and turbine operation. Primary uses:

oSermeTel CF. Chrome-free re-placement for 5380 DP, 2F-1 and 6F-1 legacy coatings designed to pro-tect compressor components against corrosion, heat degradation and foul-ing at temperatures up to 1100°F.

oSermaLoy J CF. Hexavalent chrome-free replacement for J legacy diffusion slurry coatings designed to protect hot gas path turbine compo-nents against corrosion and oxidation at temperatures up to 1800-1900°F.

Chromium coating materials have al-ways performed well in service says Tom Lewis, vice president for appli-cations research and development for Praxair Surface Technologies, but the chromium content poses an environ-mental risk while being applied as a liquid slurry coating. During the coat-ing process the hexavalent chromium

(VI) compounds undergo transfor-mation into environmentally benign chromium III substances. Europe has already approved leg-islation that prohibits the import of hexavalent chromium coating materi-als after 2017 under a new EU regu-lation for the Registration, Evalua-tion, Authorization and Restriction of Chemicals (REACH). In the United States there is increasing pressure from OSHA to minimize exposure to hexavalent chromium. The driver behind Praxair’s intro-duction of chromium-free coatings

was this looming environmental re-quirement, says Lewis. The biggest engineering challenge was to devel-op a system that would maintain the same performance as today’s chrome coatings for gas turbines in oil & gas and power generation operation.

Testing and validationHe notes that with all research projects of this type the emphasis is always on developing and testing that meet or exceed existing gas turbine OEM requirements -- in this case to develop the same protection with new hexava-

New aluminum ceramic coatings for hot gas path component protection By Victor deBiasi

Chromium-free coatings for compressor and turbine application are entering final field testing on gas turbines operating under severe environmental conditions.

Cyclic oxidation resistanceUncoated and coated Inconel 738 alloy at 2010°F (1100°C) in air showing equivalent protection of SermaLoy J and J CF against high temperature oxidation attack.

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Sermaloy J


lent chromium-free formulations. Another major goal was to devel-op a “drop-in” solution for direct sub-stitution for coating applications and processing currently in use. Maintain-ing the coating application process in-cludes curing and burnishing steps sim-ilar to existing chromium-containing coatings with comparable finish data and thicknesses results (or superior). During the development phase, ex-perimental specimen tests include per-formance under high temperature heat cycling, salt fog exposure, durability, plasticity and predictable load stress characteristics. This is done in the lab routinely using in-house test equip-ment to confirm the ability to meet extreme heat cycle and salt spray tests prescribed by OEMs. Praxair has already supplied the new CF coating material to gas tur-bine OEMs for their own indepen-dent testing. Currently, says Lewis, the focus is on long term field test programs on a variety of aeroderiva-tive and heavy frame industrial gas

turbine OEM installations to evaluate in-service performance under extreme operating conditions.

In-service testsPraxair is also working with major gas turbine OEMs to enlist gas turbine owner-operators to evaluate coating performance under different site con-ditions in oil & gas and power genera-tion. The goal is to accumulate 15,000 to 20,000 hours of field experience under a broad range of operating con-ditions on different fuels, site and duty cycles.

Chrome-free coating SermeTel CF coatings systems are multi-layer inorganic coatings de-signed to provide corrosion protection of compressor components at tem-peratures up to 1100°F (595°C). The basecoats for those coatings consist of an aqueous inorganic binder combined with aluminum particles that provide galvanically-sacrificial

corrosion protection. Corrosion re-sistance may be imparted by a stand-alone basecoat or in combination with newly formulated topcoats. Topcoats used for SermeTel CF coatings contain an inorganic binder filled with various insoluble, thermal-ly and chemically stable functional pigments. Operationally they perform as chemically inert and heat resistant sealants that produce a smooth sur-face finish and retard corrodents from penetrating the base metal. They can significantly extend the service life of coatings in harsh en-vironments, Lewis claims. Serme-Tel 2F-1 CF coating, for example, is designed to provide protection from severely corrosive conditions (see table). Suitable applications include steel compressor blades, vanes, shafts, cases and bearing supports. Another formulation, SermeTel 6F-1 CF, has demonstrated what he refers to as “excellent” anti-corrosion performance in high temperature con-ditions up to 1100°F (595°C).

Operating Range 2F-1 CF Coating 6F-1 CF Coating 5380 CF coatingMax operating temp 1100°F (595°C) 1100°F (595°C) 1100°F (595°C)Max peak temperature 1150°F (621°C) 1150°F (621°C) 1150°F (621°C)Operating pH range 3.5 to 8.5 3.5 to 8.5 3.5 to 8.5

Properties 2F-1 CF Coating 6F-1 CF Coating 5380 CF coatingThickness of coating 1.2-2.0 mils (30-50 µm) 1.2-2.0 mils (30-50 µm) 1.2-2.5 mils (30-64 µm)Surface roughness Ra < 40 µin @ 0.03” cutoff < 30 µin < 25 µinAdhesion tape test ASTM 5B excellent 5B excellent 5B excellentBend adhesion ASTM No edge chipping at 0.22 inch mandrel, 90° bend for all three coatings

PerformanceSalt spray (B117) No red rust in scribe for all three coatings after 2500 hoursCyclic heat corrosion No red rust for all three after 10 cycles 850°F (450°C) Heat/salt fog/humidity No red rust for all three after 10 cyclesBoiling water immersion No chalking, blistering or spallation for all three after 10 minutesDry heat resistance No spallation for all three after 1000 hours at 1100°F (595°C)

Source: Praxair data sheet

SermeTel CF Properties and Performance. These chromium-free coatings can be customized for thick-ness and processing temperature to meet specific application requirements.


It is able to meet stringent gas tur-bine OEM specifications including cycle heat combined with salt fog, dry heat stability, boiling water resistance and humidity testing. A variation on this coating, Serme-Tel 5380 CF, offers that same perfor-mance (above) plus smoother surface finish. According to Lewis, proven re-sults in cyclic corrosion plus heat tests show that it meets all requirements to preserve surface finish in severe envi-ronments.

Diffusion aluminide coatingSermaLoy J CF diffusion aluminide coating is a slurry formulation free of hexavalent chromium compounds which, Lewis says, has a “unique” silicon- and chromium-enriched outer layer that offers equivalent perfor-mance to that of conventional Ser-maLoy J coating. It provides turbine rotors “excel-

lent” protection against both high- and low-temperature hot corrosion and oxidation for superior protection of hot gas path components in ma-rine and industrial gas turbines at tem-peratures up to 1800-1900°F (982-1028°C). Like SermeTel CF the new diffu-sion aluminide coating is REACH-compliant. It is also compatible with austenitic stainless steel and nickel- and cobalt-based superalloys. SermaLoy J CF is applied by spray-ing or brushing the coating onto the component surface to deposit a uni-form layer of aluminum- and silicon-containing slurry. This is followed by heating the component in a protective atmosphere in which the slurry diffus-es into the substrate to form a silicon-modified aluminide coating. The outer portion of the coating comprises chromium silicide phase and aluminide phase. Chromium sili-

cide is particularly resistant to acidic and basic hot corrosion, Lewis notes, while aluminide offers superior pro-tection against high-temperature oxi-dation (see table). The slurry application process sim-plifies masking and allows for selec-tive coating on localized regions of turbine blades and vanes. Alternative-ly, he points out, the coating can be produced on all external surfaces of the components. Diffusion treatment can be tailored to each alloy and application. Dif-fusion temperatures can be as low as 1600°F (870°C) for nickel-based superalloys and 1800°F (980°C) for cobalt-based superalloys. Such relatively low diffusion tem-peratures eliminate the need for any post-coating heat treatment process. They also allow brazed components to be refurbished without risking damage to the brazed joints. n

Properties Uncoated SermaLoy J SermaLoy J CFCoating thickness N/A 1-4 mils (25-100 µm) 1-4 mils (25-100 µm)

Diffusion temperaturesNickel-based alloys N/A ≥ 1600°F (870°C) ≥ 1600°F (870°C)Cobalt-based alloys N/A ≥ 1800°F (980°C) ≥ 1800°F (980°C)Austenitic steels N/A ≥ 1800°F (980°C) ≥ 1800°F (980°C)

Performance Uncoated IN738 SermaLoy J SermaLoy J CFCyclic oxidation at 2010°F (1100°C) mass change after 198 hours – 23.7 mg/cm2 + 0.7 mg/cm2 + 0.7 mg/cm2

Hot corrosion at 1650°F (900°C) depth of penetration after 500 hours 11 µm 7 µm 5 µmHot corrosion at 1290°F (700°C) depth of penetration after 500 hours 68 µm 17 µm 19 µm

Performance Uncoated MarM002 SermaLoy J SermaLoy J CFHot corrosion at 1650°F (900°C) depth of penetration after 500 hours 500 µm 11 µm 5 µmHot corrosion at 1290°F (700°C) depth of penetration after 500 hours 99 µm 26 µm 29 µm

Source: Praxair data sheet

SermaLoy J CF Properties and Performance. Chromium-free diffusion treatment for nickel-based and cobalt-based super alloys can be tailored to the alloy and application.

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Traditional thermal paints can be used on hot gas path components

to provide information on their tem-perature. Typically, however, temper-ature measurements must be carried out online. UK-based company Sensor Coat-ing Systems (SCS) has developed what it calls a Thermal History Coat-ing (THC) which allows engineers and turbine developers to take tem-perature measurements offline. It is compliant with Europe’s REACH legislation (in contrast to ex-isting thermochromic paints) and also acts as a thermal barrier coating. Op-erational advantages of the new coat-ing over existing technology include:

● Accurate, objective 2D temperature profiling on critical components for enhanced thermal management.

● Ability of a single coating to deliver continuous data over a wide tempera-ture range

● Permanent record that can be used as a warranty tool to identify compo-nents subjected to excessive and non-regulatory operating temperatures.

SCS was officially formed in 2012 but its work on a new type of ther-mal paint dates back to 2008/2009 through a team at Imperial College, London, working under the auspices of Southside Thermal Sciences. Dr Jörg Feist, Managing Direc-tor, Sensor Coating Systems, recalls: “Although the focus at the time was on online temperature measurements, one client expressed an interest in

thermal paint that could enable offline measurement.” Having a new paint technology would not only allow SCS’ client to measure temperatures offline, it would allow it to become independent of its existing thermal paint supplier, which was also one of its competitors. This coincided with upcoming EU rules on the removal of hazardous chemicals in paint. The Registra-tion, Evaluation and Authorisation of Chemicals (REACH) places new responsibilities on many sectors of industry – manufacturers and users – to ensure that raw materials are safe to use. The new rules are being intro-

duced progressively between now and 2018, by which time coating suppliers must demonstrate that their products are risk-free both for users and the environment. Dr Feist added: “REACH also says if there’s an alternative more environ-mentally safe technology, it has to be used. Since the client said he wanted to be independent of his competitor, we have been looking into developing the new offline technology.” The possibility that an alternative to thermal paints could enable of-fline temperature measurement was first realised on the back of a test at Didcot power station in the UK. The

Thermal diagnostics prepares to go offline By Junior Isles

Thermal paints are used extensively in various industrial sectors but a new thermal history coating has the potential to significantly improve component design diagnostics.

Figure 1. THC technology allows an operator to scan a surface and get a temperature at a specific point.


company’s team, based at Imperial College London, had been running tests on a paint that was being used as a TBC on three tiles inside a gas tur-bine. After 4,500 equivalent operating hours, researchers found that the new paint had remained intact, unlike the standard reference coating. “Lab results had shown our coating to be more robust than standard coat-ings, so we decided to test it at Did-cot,” said Dr Feist. PhD students ana-lysed the tiles using two techniques. One of them produced a luminescent temperature map; this gave us the idea of other ways in which the coating could be used. “Essentially we had a TBC that could be used as an online tool but when manufactured slightly differ-ent it offered the possibility of offline diagnostics, which is what one of our clients was asking for.”

Robust technologySCS has spent the last five years de-veloping the technology. In April 2012, shortly after it was spun out of Southside Thermal Sciences, SCS was awarded a grant under the Innovate UK’s SMART programme to aid de-velopment of the paint. The new THCs give the opera-tor reliable temperature profiles in harsh environments. The coatings are deposited using standard industrial processes so that they survive where other techniques fail, says SCS. The THC stores the thermal exposure in-formation and later – after operation – can be read out by using an optical probe. The THC will replace current in-dustry standard thermal paints and offers very significant advantages to companies engaged in the develop-ment of aero engines and industrial gas turbines. The technology is ro-bust and non-destructive, thereby en-abling multiple tests of components used in the development process without the time and cost penalties of repeatedly dismantling the engine for analysis.

“It can show up hotspots in en-gines, which could indicate cracks. Therefore it will be a tool for diagnos-tics and maintenance,” noted Dr Feist. “Valve manufacturers, for example, could use it to locate and therefore avoid overheating in valves.” SCS’ THC is based on the light emitting properties of a class of ce-ramic materials, which, when exposed to particular levels of temperature, undergo irreversible changes in the material structure or chemistry. When excited with a probing light the mate-rial starts to phosphoresce and this can be observed with specialised opti-cal components to establish a correla-tion between the observed light and the past temperature. The ceramic material can be ap-plied as a robust coating (THC) onto a component using standard manufac-turing techniques such as atmospheric air plasma spraying or, for low tem-perature regimes, as a paint (Ther-mal History Paint) giving the end-user greater flexibility over the coating ap-plication. The readout device can be bench-based or hand held, the latter enabling in-situ temperature profiling on a com-

ponent. Unlike existing solutions in the market, the reading of temperature does not require human subjectivity. “Thermal paints change colour at a certain temperature; our technology is different. It’s not dependent on an operator looking at a colour – which is subjective – and calibrating,” said Dr Feist. “Our technology allows an operator to scan a surface and get a temperature at a specific point.” SCS’s novel technology will be beneficial in all industrial sectors where temperature information is es-sential. The technology development programme covers a range of 100-1400°C to a precision of ±5-10°C. Dr Feist said: “Along with the THCs and the THPs, we are also able to provide the instrumentation and support required to take measure-ments. Based on discussions with one of our OEM customers, this innova-tive technique could save them £1.5-3 million ($2.5-5 million) per product development programme.”

CommercialisationAccording to Dr Feist, temperature sensing in gas turbines is the main driver and SCS is now working to

Figure 2. Ceramic THC materials can be applied using standard pro-cedures such as atmospheric air plasma spraying.


bring the technology to “TRL5” i.e. a tool that can be applied to industry. “TRL1-TRL5 is the pre-competitive stage,” noted Dr Feist. TRL stands for Technology Readi-ness Level and originates from NASA and has been adopted widely in the gas turbine industry to evaluate the readiness level of new technologies. Commercialisation of the technolo-gy received a boost in February 2013, when SCS announced the success-ful formation and launch of a ‘User Club’. The club launched with five members, including Alstom (Switzer-land), MAN Diesel & Turbo (Ger-many), SNECMA (France) and SCS. With representatives from the US and Europe, and both the aero en-gine and industrial gas turbine sec-tors, the User Club’s objective is to generically develop the technology in a way that it can be applied in modern engine development programmes to significantly lower development costs and accelerate the introduction of new low-emission engines. According to SCS, this exclu-sive User Club arrangement gives its members particular rights to future use of the technology and also se-cures a first mover advantage over non-members. Additionally, the club’s development roadmap is aligned with two existing programmes financed by both UK and US governmental agen-cies, giving the club an advantageous starting position. The programme was planned to run to the middle of 2015. Dr Feist commented: “The SCS team is extremely proud of bringing this unique and exceptional club of leading industrial organisations to-gether. Under this club arrangement the members are developing confi-dence in the technology and assist-ing SCS in defining a new industrial standard for temperature profiling and temperature indicating sensors.” The next stage is to bring the tech-nology to TL6, where the application is used regularly on a competitive ba-sis. “This,” said Dr Feist, “has to be done with individual clients”.

With the various members of the User Club planning different uses for the technology, SCS wants to start consultancy services in the next 10 months. “We will be helping compa-nies to solve specific issues for tem-peratures up to 900°C,” said Dr Feist. “One customer is looking to use the technology for design, whereas others are looking more at long term applications for service and main-tenance. We will be covering gas turbines, diesel engines for marine drives, turbochargers, diesel injector

nozzles, etc.” He concluded: “In the long term we want users in the power indus-try. Paints go currently up to 900°C (1650°F) and are not as robust as TBCs, although we have launched the programme NATEP co-financed by the UK National Aerospace Technol-ogy Programme (NATEP). For gas turbines, we need to go beyond this. The Users Club’s target is therefore 1400°C (2550°F) and we hope to get to TRL5 for this tempera-ture by summer 2015.” n

The science behind the technology

Essentially, in the technology’s applications, phosphorescence is a process whereby light is used to excite the material and as a result light of a different wavelength (colour) is emitted. The emitted light which comes from atoms within the material can be analysed to provide information on the state of the material itself such as temperature, pressure or crystallinity. Such interrogation can all happen remotely by detecting the light through cameras and glass fibres and without wiring electronics to the component. SCS has developed smart coatings for multiple applications. The wide range of technology offered by SCS is based on the funda-mental concept of using luminescent ceramic materials for sensing purposes. The design and manufacture of the coating is tailored to requirements of both the sensing and substrate application. As such, several different physical properties can be measured and, important-ly, the coating will survive for as long as the underlying material. Sensor coating technology is based on phosphor materials. Opti-cally active components within the phosphor are either rare earth or transition metal elements. When excited with UV-light, these dopants absorb the energy (directly or indirectly) which promotes their elec-trons to higher energetic states. These higher energetic states are unstable, and the electrons eventually fall back to their stable ground state. In doing so, they emit visible light which is called luminescence. The time it takes for the luminescence to cease depends on various factors, but can have fundamentally different meanings. Phosphorescence light shows slow emission rates, while fluorescence shows very fast emission times. When manufactured in a certain way, the coating material has the capability of changing irreversibly when exposed to high tem-peratures. After cooling, the state changes in the coatings remain and can be interrogated at room temperature. The physical or chemical changes are reflected in the luminescence properties and can thus be used as a measure of the thermal history. The material acts as a tool that remembers the thermal conditions it has been exposed to. The measurement device can then interpret the luminescence changes and provide temperature information.

Stay Ahead of the Curve

Reference copies of the 2014 Performance Specs available at:

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Most emissions control systems drain your profits. CLN® pays you back.

These days, turbine operators are under more pressure than ever to reduce emissions and make their operations more “green”, all while keeping costs down. Easier said than done – nearly all emissions control systems are expensive, slow to implement, and degrade performance, which increases operating costs.

That’s where the CLN system* comes in. It’s the only emissions control technology that actually improves efficiency, increasing saleable power while reducing fuel consumption and carbon emissions. It’s simple and fast to implement, and offers a positive return on investment within 12 months. Cheng Power Systems’ technologies (including CLN and ACS) are proven, with a track record of over 2 million operating hours across more than 200 global installations.

Contact us to learn how we can quickly help your turbine generate more power — and more profits.

*See Gas Turbine World, May/June 2009 v.39, pp. 12-17

www.chengpower.com480 San Antonio Road, Suite #120 Mountain View, CA 94040Email: [email protected]

ppm

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

ansaldoenergia.com

Proud to be here

WHEN YOU ASK FOR A 60–120 MEGAWATT

AERO-DERIVATIVE DESIGN, PROVEN WITH OVER

34 MILLION HOURS IN THE AIR, LESS THAN

10 MINUTES TO FULL POWER, OPERATIONAL

FLEXIBILITY WITH LOW LIFE CYCLE COST AND

THE ROBUSTNESS OF A HEAVY- DUTY ENGINE,

THAT ONLY LEAVES ROOM FOR

THE FT4000® GAS TURBINEpowered by Pratt & Whitney® PW4000™ aero engine technology

We’ve really just about said it all, except, go to pwps.com to find the power system in a class by itself.

Pratt & Whitney® and PW4000™ are trademarks of United Technologies Corporation, used with permission.

Client: PW - Power SystemsAd Title: FT4000Publication: Gas Turbine World - Nov/DecTrim: 8-1/8" x 10-7/8" • Bleed: 8-3/8" x 11-1/8" • Live: 7-7/8" x 10-5/8"

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