July-August 2015www.dieselgasturbine.comWW_JulAug_C1.indd 1 7/17/15 3:20 PMwww.hilliardcorp.comElmira, New York Since 1905 Hilliard.indd 2 4/6/15 2:19 PMYou deliver more cargo per journey.Because we deliver more in every engine.Greater power density in a compact package. Flexible engine placement for a more efficient hull line. Clean-burning fuel for lower emissions. GEs marine gas turbines are a smart alternative to diesels. And a brilliantly designed solution for greater profitability and performance in the shipping industry.Learn more at ge.com/commercialmarine.GE.indd 1 3/23/15 2:53 PMheJuly-AugustissueofDiesel &GasTurbineWorldwidebrings thethirdinstallmentofouran-nual Order Survey. Each year, we producethreereportsbasedon data collected directly from OEMs which are designed to provide order details on large-horsepower prime movers used in power generation, mechanical drive and marine propulsion applications.ThePowerGenerationOrderSurvey (May2015D&GTW)examinesrecipro-catingengines,steamturbinesandgas turbinesforpowergenerationservice. The Mechanical Drive Order Survey (June 2015 D&GTW) is devoted to engine orders formechanicaldriveapplicationsinclud-ingpumps,compressors,oilexploration machinery, rail and other industrial appli-cations. The Marine Propulsion Order Sur-vey (July-August 2015 D&GTW) examines mechanicaldrive,auxiliaryanddiesel-electric marine propulsions systems.Each time a survey is published, we re-ceiveaflurryofquestionsfromreaders aboutthesurveyprocessandthedata thatispresented.Withtheconclusion ofthisyearsOrderSurvey,IthoughtId sharethefivemostcommonlyasked questions and their answers, for those of youwhomighthavealwayswondered, but never asked.How is the information gathered? Eachyearwesendthesurveydirectly toOEMs,whocompleteandreturn them to us. Order data from each OEM is combined to provide an overview of thespecificprime-mover/application. Each published report includes a list of participating OEMs.CanyousendmeindividualOEMor-der details? No. Our legal team has worked with the legal teams of myriad OEMs to produce documents that forbid the sharing, dis-closingordiscussionofspecificOEM orderdetails.Wehavelegallybinding policies, procedures and documents in Reader Mail Order Survey 2015DIESEL & GAS TURBINE PUBLICATIONSPresident & CEO ......................................... Michael J. OsengaExecutive Vice President .........................Michael J. BrezonickDIESEL & GAS TURBINE WORLDWIDEEditor & Publisher .............................................. Brent HaightExecutive Editor ........................................................DJ SlaterDeputy Editor ...................................................... Mark ThayerRegional Manager/Editor ....................................Ian CameronRegional Manager/Editor .............................. Roberto ChelliniRegional Manager/Editor ................................ Roberta PrandiField Editor/Business Manager ............................ Bo SvenssonAssociate Editor ...................................................... Jack BurkeAssociate Editor ...................................................Chad ElmoreAssociate Editor ........................................................Art AielloAssociate Editor ................................................. Angela JarrellCopy Editor .....................................................Jerry KarpowiczDigital Content Manager ...............................Catrina BoettnerAdvertising Manager............................................ Sarah YildizCirculation Manager .....................................Margaret PieperProduction Manager ....................................... Marisa RobertsGraphic Artist ................................................ Brenda BurbachGraphic Artist ...................................................... Carla LemkeGraphic Artist ..................................................... Alyssa LoopePUBLICATION HEADQUARTERS20855 Watertown Road, Suite 220 Waukesha, Wisconsin 53186-1873, U.S.A.Telephone: +1 (262) 754-4100 Telefax: +1 (262) 754-4175UNITED STATES - HOUSTONBrent Haight, Editor & PublisherMark Thayer, Deputy Editor12777 Jones Road, Suite 225Houston, Texas 77070, U.S.A.Telephone: +1 (281) 890-5310 Telefax: +1 (281) 890-4805GERMANYLisa Hochkofer, Advertising Manager Gabriele Dinsel, Advertising Manager Niemllerstr. 9 73760 Ostfldern, GermanyTelephone: +49 711 3416 74 0 Telefax: +49 711 3416 74 74UNITED KINGDOMIan Cameron, Regional Manager/Editor Linda Cameron, Advertising Manager 40 Premier Avenue, AshbourneDerbyshire, DE6 1LH, United KingdomTelephone: +44 20 31 79 29 79 Telefax: +44 20 31 79 29 70ITALYRoberto Chellini, Regional Manager/Editor 44, Via Delle Forbici I-50133 Firenze, ItalyTelephone: +39 055 50 59 861 Telefax: +39 055 57 11 55Roberta Prandi, Regional Manager/EditorVia Fitta, 21AI-38062 Arco, ItalyTelephone: +39 0464 014421Telefax: +39 0464 244529SWEDENBo Svensson, Field Editor/Business Manager Dunderbacksvagen 20 612-46 Finspong, SwedenTelephone: +46 70 2405369 Telefax: +46 122 14787JAPANAkiyoshi Ojima, Branch Manager 51-16-301 Honmoku Sannotani, Naka-kuYokohama, 231-0824 JapanTelephone: +81 45 624 3502 Telefax: +81 45 624 3503HONG KONGS.H. Mok, Branch Manager Rm 1903A, 19/F, Sunbeam Commercial Building 469-471 Nathan RoadKowloon, Hong KongTelephone: +852 31187930 Telefax: +852 23321565KOREAMyung-Shin Lee, Sales Manager 191-1, Pyungchang-dong, Chongno-kuSeoul, Korea 100-648Telephone: +82 2 391 4254 Telefax: +82 2 391 4255Reprints of all articles published in Diesel & Gas Turbine Worldwide are available. Please address inquiries to:mgraesing@dieselpub.comTel: +1 (262) 754-4147 Telefax: +1 (262) 754-4177Diesel & Gas Turbine Worldwide2July-August 2015NotesHAIGHTTBrent Haightbhaight@dieselpub.complacethatdonotallowustosharespe-cific OEM order data.Can you tell me how many units XYZ Co. reported? No.Sorry.Neitherwrittennorverbal,all data is confidential and cant be disclosed or discussed. Canyouprovideaspecificorderbreak-down by country? Theinformationthatispublishedineach order survey is all that is available. We have workedwithparticipatingOEMstocre-atearegionalbreakdownthatiswidely acceptedthroughouttheindustriesthat eachreportcovers.Wesendtheregional breakdowntoOEMsatthebeginningof the survey process and publish it with each reportsoreaderscanseewhichspecific countries fall into each geographic region.Ifyouadduptheregionalcodes/fuel type/enginespeedranges/etc.,they sometimesdontmatchthetotalnum-ber of units reported. Why? OEMsprovidethedatathatispresented in each report. From time to time an OEM willnotprovidespecificinformationfor acertaindatafieldor(inthecaseoffuel type) may double report a unit (diesel fuel andnaturalgas).Wemakeeveryeffort toclarifythedata,butultimatelywewill publish what is provided by the OEM rath-erthanattempttointerpret,predictor otherwise influence the data we receive.As a reminder, PDF versions of each Order Survey are available at our website. We continually re-evaluate the Order Sur-vey to ensure it is as detailed and compre-hensiveaspossiblewithoutintroducing transparenciesthatwouldlimitOEMpar-ticipation.Yourquestions,commentsand suggestions are always welcome. AWW163.indd 1 7/15/15 4:41 PMDiesel & Gas Turbine Worldwide is the leading authority for prime-mover products, technologies and news. www.dieselgasturbine.comMEMBER OF BPA WORLDWIDEDIESEL & GAS TURBINE WORLDWIDE (ISSN 0278-5994) Volume 47, Number 6. Published monthly except, Jan/Feb & July/Augissuescombined,byDiesel&GasTurbinePub lications,20855Water townRoad,Waukesha,WI53186-1873U.S.A. Subscription rates are $85.00 per year/$10.00 per copy worldwide. Periodicals postage paid at Waukesha, WI 53186 and at additional mailing offices. Copyright 2015 Diesel & Gas Turbine Publications. All Rights Reserved. Materials protected by U.S. and international copyright laws and treaties. Unauthorized duplication and publication is expressly prohibited. Canadian Publication Mail Agreement # 40035419. Return Undeliverable Canadian Addresses to: P.O. Box 456, Niagara Falls, ON L2E 6V2, Canada. E-mail: mpieper@dieselpub.com. POSTMASTER:Send address changes to: Circulation Man-ager, Diesel & Gas Turbine Worldwide, 20855 Watertown Road, Suite 220,Waukesha, WI 53186-1873 U.S.A. PRINTED IN THE U.S.A.Diesel & Gas Turbine Worldwide3July-August 2015Noise & Heat Reduction 6Quiet Piping10Take The HeatControls, Sensors & Instrumentation14Military Orders Rigorous Controls16 Cylinder Pressure-Based Controls In High Power Density Gas Engines21On The Level22Collaborative Concoction45ABB Expands Symphony Plus RangeMarine Propulsion24An Addition To The ABB Azipod Family40New Trend For Long-Haul Tugs?Marine Propulsion Order Survey26Hold FastIndustry News30Next-Generation Ignition38Liquid Gas InjectionPower Generation34Testing Clean EnergyCONTENTSFollow @dgtww on:In Every Issue2Haight Notes4PMO Report8Events & Meetings20Featured Products42Industry Drivers43Newsmakers44Literature Library46Index of Advertisers47Marketplace48World ViewpointCover Design: Alyssa Loope34Testing Clean Energy40New Trend For Long-Haul Tugs?38Liquid Gas Injection-august80celebratingyearsjulyWW_JulyAugust TOC.indd 1 7/20/15 10:07 AMWe Manufacture andRemanufacture theWorlds Largest EngineCrankshaftsEllwood Crankshaft GroupIrvine, PA, USA 16329Hermitage, PA, USA 161481-800-247-1326or 724-347-0250ecgsales@elwd.comwww.ellwoodcrankshaftgroup.comWe Manufacture andRemanufacture theWorlds Largest EngineCrankshaftsEllwood.qxp11/11/098:43 AMPage 1Diesel & Gas Turbine Worldwide4July-August 2015CATERPILLAR MARINECaterpillarMarinewillsupplyEdisonChouestOffshore fourCatC280-16generatorsets,eachrated5060bkWat 900 r/min for two new vessels being constructed at Edison Chouests La Ship shipyard in Houma, Louisiana, U.S.A.GEGEwillsupplya9HAgasturbinetoBouchain,France,fora new lectricit de France gas-fired power plant.GE MARINEGEMarinewillsupplyoneGELM2500gasturbineandtwo dieselenginesinacombineddieselandgasturbinepropul-sionsystemfortheUnitedStatesCoastGuardseighthNa-tional Security Cutter, Midgett. GE Marine will supply two LM2500 aeroderivative marine gas turbinesfortheJapaneseMaritimeSelfDefenseForcesnew 26DD destroyer.MAN DIESEL & TURBOMANDiesel&Turbowillsupplya7S50ME-B9.3-LGIengine foravesselcurrentlyunderconstructionbyMinaminippon Shipbuilding Co. Ltd. MITSUBISHI HITACHI POWERSYSTEMS AMERICAS INC.MitsubishiHitachiPowerSystemsAmericasInc.willsup-plythreeM501JgasturbinestoVirginiaElectricandPower CompanyfortheGreensvilleCountyPowerStationinVir-ginia, U.S.A.ROLLS-ROYCERolls-Roycewillsupplyfourelectricitygeneratingsetsfor twocombinedheatandpowerplantsoperatedbyP3Pfor BritishtomatogrowersAPSSalads.Thegen-setsarebased on medium speed 12-cylinder Type B35:40 gas engines from Bergen Engines.Rolls-Roycewillsupply589MTU8V199TE21dieselen-gines for use in the British armys new Scout armored fight-ing vehicle.SIEMENSSiemenswillsupplytwoSGT6-8000Hgasturbinesandtwo generators for the Empalme I combined cycle power plant in Sonora, Mexico. SiemenswillsupplyanSGT5-4000Fgasturbine,adualcas-ingSST-800/600steamturbine,anSGen-1200Agenerator,an SGen-100A generator and the related electrical and I&C equip-mentfortheCinerKazanSodacombinedcyclecogeneration power plant in Turkey. Siemenswillsupply24SiemensH-Classgasturbines,eight units for each of Egypts planned Beni Suef, Burullus and New Capital power plants.WRTSILWrtsilwillsupplytwoWrtsil9L46gensetstothePock-woodPondpowergeneratingstationintheBritishVirginIs-lands, owned by the British Islands Electricity Corp.Wrtsilwillsupplya12-cylinderWrtsil32mainen-gine for a fishing vessel being built by Simek AS in Norway onbehalfoftheU.K.operatorAntares(Whalsay)Fishing Company Ltd. AReport PMOAdditional information on these Prime-Mover Orders is available at www.dieselgasturbine.com/pmo-report/PrimeMover:Amachinethattransformsenergyfromachemical, thermal,electricalorpressureformintoamechanicalform.Electric motors, engines and turbines are examples of prime movers. Perez, Robert. 2013. Illustrated Dictionary Of Essential Process Machinery Terms; DGTP Inc., Waukesha, Wisconsin, U.S.A.WW159.indd 1 7/20/15 10:10 AMYOU HAVE TO DO IT LESS OFTEN THAN YOUSCHEDULE DOWNTIMEON EQUIPMENTDiesel & Gas Turbine Worldwide is the leading authority for prime-mover products, technologies and news.Still Free To Qualified Readerswww.dieselgasturbine.com/renew/RENEWING IS FREE!RENEW YOUR SUBSCRIPTION TO DIESEL & GAS TURBINE WORLDWIDEJUST ONCE PER YEARTO BE SURE YOU DONT MISS AN ISSUE the prime-mover magazine since 19691 2 37 8 9104 5 611 12 1314 15 1617 18 19 2021 22 2324 25 26 2728 29 3031SUNDAY MONDAY TUESDAY WEDNESDAY THURSDAY FRIDAY SATURDAYWW_Renew_Calendar.indd 1 7/16/15 2:12 PMNOISE & HEAT reductionDiesel & Gas Turbine Worldwide6July-August 2015tauffintroduceditsnewNRC clamps for noise- and vibration-reducedinstallationofpipes andtubeswithoutsidediam-eters between 6 and 88.9 mm. The company explained that the work-ing principle of the NRC clamps is based onpolyamideclampbodiesfollowing the design of its existing Standard Series thatcomplywiththeGermanIndustry StandardDIN3015,Part1.Theclamps featureaspeciallyshaped,two-part elastomerinsertthatmechanicallyab-sorbs vibrations in the pipe and, as a re-sult, reduces noise to a minimum. Theinsertisparticularlydistinguished byhowlittleofitssurfaceisincontact with the pipe and clamp body, and as a result is far more effective than the pre-viously known solutions, Stauff said.Thetongue-groovecontourofthein-sertandbody,whichisreversedand thusdivergesfromDIN3015,enables thesystemtobeusedforthewidest possiblerangeofpipediametersper clamp size, which contributes to flexibil-ity and versatility.Thispatentedsystempermitscom-biningtheabsorbingpropertiesofthe clamp,whicharesovitalforthisappli-cation, with the pipe-retaining forces re-quired, said Ulrich Knig, chief research anddevelopmentofficeroftheStauff Group. Thanks to the functional design, wehaveexpandedthepossibilitiesof theDIN3015standard,withoutdeviat-ingfromitinthedimensionsrelevant for the installation.The NRC clamps are completely compati-ble with commonly used steel or stainless-steel mounting hardware, and if necessary can simply be replaced or retrofitted.Stauffexplainedthat,particularlyin the field of civil shipping for example, oncruiseships,yachtsorportboats effectivenoisedampinghasbecome importantinrecentyearsasacriterion intheplanningofmachinery,devices andsystems,andselectingthecorre-sponding components, since it makes a great contribution to comfort and facili-tates communication on board. Further-more,itisknownthatnoiseemissions canhavegraveeffectsonawiderange of maritime animals.The International Maritime Organization hasalsodealtwiththedeterminationof noisethresholds,forexampleinengine and control rooms, in crew quarters, and for the reduction of underwater noise in order to protect the environment.Stauffaddedthatthereisarisingde-mandforthereductionofnoiseemis-sionsinmobileandstationaryapplica-tions,suchasinharborsandloading areas. This is sanctioned by the Europe-anCommunityaccordingtothecross-industryguidelinesoftheOutdoorDi-rective2000/14/EC(onnoiseemissions intheenvironmentbyequipmentfor use outdoors) and to the 2006/42/EC Di-rective on machinery.ApartfromtheregularNRCclamps, Stauffalsoprovidesanotherversiones-pecially meant for use on the high seas, which is manufactured completely with flame-resistantmaterialsaccordingto internationalstandardsanddirectives, and meets the demanding requirements for preventive fire protection.Inaddition,Stauffpointedoutthat all of the materials used in its products aredistinguishedbytheirdurability, asforexampleagainstcorrosionby seawater,mineraloilandotheroils, and by their wide operational temper-ature range. ASQuiet PipingNew clamps make pipe and tube installations less noisyWith a specially shaped, two-part elastomer insert, the new NRC clamps by Stauf are capable of mechanically absorbing vibrations in the pipe to reduce noise.Photo courtesy of Walter Staufenberg GmbH & Co. KGWW152.indd 1 7/15/15 4:47 PM*Weuseinnovativeinsulationsystems to keep energy where it belongs. As a leading company in the high tempera-turerange,ISOLITEproduceseffective solutions for both thermal and acoustic insulation. From heat protection to acoustic encap-sulation,fordieselaggregatesorgas turbines our products, including HeatCAP andNoiseCAP,arealwaystailoredto your precise requirements. ISOLITE managing energy.www.janus-wa.deISOLITE GmbH | Industriestrasse 125 | 67063 Ludwigshafen | Germany Phone: +49 (621) 91109-444 | info@isolite.de | www.isolite.deStop heatStop noise*ISOLITE HeatCAPThermal insulation system for a diesel marine engine ISOLITE NoiseCAPAcoustic package for a stationary gas turbineIsolite_StopHeat_AL.indd 1 7/14/15 8:58 AMConference & Exhibition1 3 September 2015IMPACT Exhibition & Convention CentreBangkok, ThailandMAKE PLANS TO BE PART OF ASIAS PREMIER POWER EVENT EVENT AND JOIN OVER 7,500 POWER INDUSTRY PROFESSIONALS UNDER ONE ROOFPOWER-GEN Asia, as part of ASEAN Power Week alongside Renewable Energy World Asia and the POWER-GEN AsiaFinancial Forum, has become the leading force in delivering a platform for the power industry to meet, share information on the challenges facing the power industry and discuss solutions for advancing Asias energy future. As part of ASEAN POWER WEEKINVESTING IN A SUSTAINABLE TOMORROWwww.powergenasia.comEARLY BIRD DISCOUNT SAVE OVER 10%Register yourself and your colleagues by 1 August 2015 as conference delegates and beneft from the Early Bird Discount Rate, plus free entry to the exhibition. There is no better place to meet the key decision makers in the power generation industry. REGISTER FOR ONE EVENT AND GAIN ACCESS TO ALL 3 CO-LOCATED EVENTS REGISTER NOW AT WWW.POWERGENASIA.COMOwned &Produced by:Presented by: Offcial Supporters:PowerGEN_Asia_PGA_JulAug_WW.indd 1 7/17/15 10:16 AMEngineering CongressOrlando, Florida, U.S.A.+1 (770) 271-7869www.energycongress.com 4-6Power-Gen Middle EastAbu Dhabi, United Arab Emirates+44 1992 656610www.power-gen-middleeast.com5-7Offshore Marine and Workboats - Middle EastAbu Dhabi, United Arab Emirates+44 1206 545121www.middleeastworkboats.com5-8Argentina Oil & Gas ExpoBuenos Aires, Argentina+54 11 4514 1400www.aogexpo.com.ar/en14-16EP Shanghai18-20Power-Gen Natural GasColumbus, Ohio, U.S.A.+1 (918) 831-9160www.power-gennaturalgas.com 1-3Power-Gen AsiaBangkok, Thailand+44 1992 656 634www.powergenasia.com14-17Turbomachinery SymposiumHouston, Texas, U.S.A.+1 (979) 845-7417http://turbolab.tamu.edu 22-25NEVASt. Petersburg, Russia+44 1449 741801http://neva.transtec-neva.com30 - Oct. 2World EnergyShanghai, China+852 2811 8897www.epchinashow.com19-21IAGT 2015 SymposiumBanff, Alberta, Canadawww.iagtcommittee.com20-23KormarineBusan, South Korea+1 (203) 840-5821www.kormarine.com 27-29High-Horsepower SummitDallas, Texas, U.S.A.+1 (888) 993-0302www.hhpsummit.com27-30GastechSingapore+44 203 615 2847www.gastechsingapore.com aug& Meetings EVENTSoctsepWW160.indd 1 7/17/15 10:32 AMBoldface indicates shows and conferences in which Diesel & Gas Turbine Worldwide is participating. A more complete listing of trade shows is available at www.dieselgasturbine.com/events/2-5 International Seminar Rotor Dynamics & BearingCologne, Germany+49 2267 6585 0www.arla-online.com 3-5Power NigeriaLagos, Nigeria+971 4 336 5161www.power-nigeria.com 3-6EuroportRotterdam, Netherlands+31 10 293 32 50www.europort.nl1-3International Workboat ShowNew Orleans, Louisiana, U.S.A.+1 (207) 842-5442www.workboatshow.com1-4Marintec ChinaShanghai, China+852 2827 6211www.marintecchina.com8-10Power-Gen InternationalLas Vegas, Nevada, U.S.A.+1 (918) 831-9160www.power-gen.com201622-25Asia Turbomachinery & Pump SymposiumSingapore+1 (979) 845-7417http://atps.tamu.edu1-3Middle East Electricity (M.E.E.)Dubai, United Arab Emirates+971 4 407 2472www.middleeastelectricity.com9-10GlobalConBoston, Massachusetts, U.S.A.+1 (770) 279-4392www.globalconevent.com15-16Power & Electricity World AfricaJohannesburg, South Africa+27 11 516 4031www.terrapinn.com/exhibition/power-electricity-world-africa/index.stm20-23Western Turbine Users GroupPalm Springs, California, U.S.A.+1 (513) 604-8018www.wtui.com21-23ShippingStamford, Connecticut, U.S.A.+1 (203) 406-0109 x3717www.cmashipping2016.comFollow dgtww on: Follow dgtww on:novdecfebmarEH70 Series Powerful,full-port, universal mount, pilot-assisted, direct operated valve 1/2 to 2 pipe sizes (2-way) Pressure ratings from0 - 1,500 PSIG Temps ranging from-350 to 400F Stainless steel valve body UL/CSA certified for hazardous locations ETL and CRN ListedFor more information, call 856-829-4580,E-mail: sales@clarkcooper.com or visitwww.clarkcooper.com.SOLENOI DVALVESFORADVANCEDAPPLI CATI ONSa Division of Magnatrol Valve941 Hamilton Avenue, Roebling, NJ 08554Clark Cooper EH70 and ER Series Valves are currently beinginstalled in new or overhauled gas turbines, and are available witha standard CRN or explosion-proof ETL certified coil for powergeneration applications such as gas turbine fuel plate (diesel orCNG) pollutant control, generator (trip valves) in hydrogen purgesystems for emergency shut down, and others.Need Rugged, Explosion-Proof Solenoid Valves forGas Turbine, Fuel Plate, or Generator Applications?ER Series Customizablerotary shaft, pilot or directoperated, 2 or 3-way valve 1/2 to 6 pipe sizes (2-way)and (3-way) options Temps ranging from -350 cryogenic to 550F Stainless steel, naval bronze, and other valve body materials Normally open or normally closed designs CRN ListedContinuous duty coils for all AC/DC voltagesWide range of options and accessories to suit any needEH70 SeriesER Series3340 Clark C ad_Layout 13/4/1511:03 AMPage 1ClarkCooper_Apr15_WW.indd 1 3/4/15 6:02 PMWW160.indd 2 7/17/15 10:32 AMNOISE & HEAT reductionTake The HeatBrazed-plate heat exchangers are efficient, compact and flexibleby Bo SvenssonDiesel & Gas Turbine Worldwide10July-August 2015continued on page 12The SWEP XXL-range, including the B633 and B649 BPHEs, ofers a heat transfer capacity above 11 NTU (heat transfer units) and fow capacities up to 435 m3/hr in the range of 10 to 50 kPa pressure drop when 90C water is cooled with 60C water. This graph is based on 25 to 100% of maximum number of plates.oralmostalltypesofengines,betheyreciprocating enginesorgasturbines,thereisaneedforreliable coolingofvariousfluids.Sometimesthereisalsoare-quirement for heating fluids. One manufacturer, SWEP, spoke about some of the advantages brazed-plate heat exchangers (BPHE) offer for many applications.The compactness of BPHEs is highly valued in oil-cooling ap-plicationsforenginesandotherapplicationswherespacefor theheatexchangerislimited.Sometimesaccessformainte-nance is restricted. The footprint of a BPHE unit is 60% smaller than for a plate heat exchanger (PHE) with gaskets, and around 75%smallerthanforashell-and-tubeheatexchanger(S&T), SWEP said.AnotheradvantageofferedbytheBPHEisthatitcanbelo-catedverticallyorhorizontallyaspreferred,integratedinthe enginearchitecture.Inanengineapplication,itcanbelying over the engine rather than placed alongside it.SWEPBPHEscovertheneedsofseveraldifferenttypesofoil cooling, e.g., hydraulic, engine and transmission oil cooling. The latest and most challenging technology introduction to theheatexchangermarkethasbeentheso-calledXXL-range, presentlymeaning6in.(152.4mm)ports,saidHenrikBjerre, project manager at SWEP. Increasing the size of a BPHE, and in particular the port diameter, carries many technical challenges. Manufacturingoftheseunitsfullydependsonthecapillary forcestogetthebrazingmaterialtotherightlocationinthe right amount, which in turn requires extremely tight tolerances overalargesurface,forhundredsofstackedplatescarrying each others weight.SWEPs XXL-range models B633 and B649 are suitable for ap-plications such as engine-oil cooler, condenser and evaporator in steam and Organic Rankine Cycle (ORC) plants, and heat re-covery in chillers. The company said these heat exchangers are FThe asymmetric plate pattern used by SWEP makes it possible to optimize the channel geometry according to the application area, and thereby combine excellent heat transfer with a low-pressure drop and a reduced fluid charge.The plate design of a symmetric BPHE is always a compromise, where thermal performance is balanced against pressure loss of fuids. Improving heat transfer too much would result in excessive pressure loss.WW151.indd 1 7/15/15 4:54 PMYou have unique energy generation goals. And we have the technology and expertise to ensure you achieve them with a broad portfolio of solutions that can be combined to meet your specic challenges. And now our portfolio is even bigger, and even better with the introduction of the MAN V35/44G TS and MAN V51/60G TS gas engines with two-stage tur-bocharging and a power output range of 7.4 to 20.7 MW. Your benet: maximum performance, lower emissions, greater exibility and greater efciency. Discover the power of turbocharged MAN gas technology at www.mandieselturbo.comBoosting Your Energy OptionsNew gas engines with two-stage turbochargingEngine and Marine SystemsPower PlantsTurbomachineryAfter SalesMAN_BoostingEnergy_AL.indd 1 6/25/15 1:13 PMNOISE & HEAT reductionDiesel & Gas Turbine Worldwide12July-August 2015the first BPHEs on the market with DN150 (152.4 mm) connec-tions and offer capacities at high temperature and pressure on par with PHE products without the wear and tear of parts. The workingpressureoftheB633/B649at155Cis25barforthe inner and outer circuits of the exchanger. BPHEscanbeveryefficient. Upto95%ofthematerialina brazed-plateheatexchangerisusedtotransferheat,asop-posed to other technologies, which use much of their material forsupportequipment,shell,orframes,saidAndreasMller, segment manager, Engines & Energy. The benefit of this is sav-ings in energy consumption, space, spare parts and transporta-tion and installation.AsyMatrixisSWEPsasymmetricplatedesigntechnologyfor BPHEs. The asymmetric channel configuration combines maxi-mum heat transfer on the oil side with minimum pressure drop onthesecondaryside.Theincreasedenergyefficiencyand better use of the structural material delivers a more sustainable solution in suitable applications.BPHEs offer the best performance-to-size ratio of heat trans-fertechnologiesavailabletoday,thecompanysaid. Theself-supporting plate geometry of a BPHE delivers high performance with less weight, footprint and internal volume than technolo-gies like shell and tube, coaxial and plate-type heat exchangers.SWEPsaidtheplatedesignofasymmetricBPHEisacom-promise,wherethermalperformanceisbalancedagainst pressurelossoffluids.Improvingheattransfertoomuch wouldresultinexcessivepressureloss,whichwouldreduce the systems performance.Theasymmetricplatepatternweusemakesitpossibleto optimizethechannelgeometryaccordingtotheapplication area,therebycombiningexcellentheattransferwithalow pressuredropandareducedfluidcharge,Mllersaid. The result is a powerful improvement of system efficiency and sus-tainability, taking into consideration both thermal and hydrau-licperformanceaswellasareducedrefrigerantcharge.And there is no need to do compromises.MllersaidSWEPsportfolioofproductsofferssolutionsto copewithchallengesrangingfromextremelyviscoustrans-missionoiltocopper-freealternativesforsensitiveoilorag-gressive water.AThe B633 is a high capacity BPHE, suitable for a diversity of applications. Together with the larger B649, these are the frst heat exchangers on the market with 152.4 mm connections.The working pressure of the B649 at 155C is 25 bar for the inner as well as for the outer circuit of the exchanger. The same is valid for the smaller B633 BPHE.Up to 95% of the material in a brazed-plate heat exchanger is used to transfer heat.Andreas Mller, segment manager, Engines & Energy, SWEPWW151.indd 2 7/15/15 4:55 PMMTU_JA15_WW.indd 1 6/10/15 10:15 AMMilitary Orders Rigorous ControlsPerformance, reliability are key factorsby Ian CameronDiesel & Gas Turbine Worldwide14July-August 2015echnologysuppliedbycom-panies for use in military appli-cations must be designed and manufacturedtothehighest standardstoensurethatit performscorrectlyandreli-ably.Equipmentandcomponentshave tomeetstringentstandardsofperfor-mance to comply with what is known as MIL-SPEC(UnitedStatesdefensestan-dard) standards.CMRGroup(ControleMesureRegula-tion) supplies MIL-SPEC-grade marine en-gine control equipment, instrumentation, controlsandpowermanagementforoff-shore, marine, engine and industrial appli-cations. Core product groups include elec-tronics and software, custom engineering solutions, fuel systems, industrial sensors, switchboards and wiring systems.Three critical areas for military applica-tionsofmarineenginecontrolequip-ment are as follows:vibrationtestingofshipboardequip-ment for electromagnetic compatibil-ity (MIL-S-167, rev. 1A) electromagneticinterference(MIL-S-461, rev. F) high-impactmechanicalshocktest-ingrequirementsforshipboardma-chinery (MIL-S-901, rev. D)WhileMIL-STD461isthebasisfor electromagneticcomplianceformost naviesaroundtheworld,mostcivilian organizations,includingCMRGroup anditscustomers,usethesespecifica-tionstotestcomponentrobustnessin harshenvironmentswithhighelectro-magneticpollution,whichcanbeap-pliedtononmilitaryorientedproducts, said Flavio Massariello, deputy technical manager,enginecontrolsdepartment atCMRGroupFrance.Thisisbecause MIL-STD461effectivelyestablishes verificationrequirementsforimmunity fromelectromagneticinterference emissionsandsusceptibilityapplied toelectronic,electricalandelectrome-chanicalequipmentandsubsystems, which may be designed or procured for theNorthAtlanticTreatyOrganization (NATO)naviesandotherinternational naval organizations and agencies.HeaddedthatallCMRGroupMIL-SPEC equipment is designed and clas-sifiedasessentialtothesafetyand continuedcombatcapabilityofend usersandprovidecontinuousperfor-mance throughout the product opera-tional life. Massariellosaidthatinadditionto compliancewithpreviouslymentioned critical performance criteria, equipment isalsocompliantwiththefollowing,in which compliance is maintained by con-tinuous review and analysis: MIL-STD-108E,DefinitionsofBasic Requirements for Enclosures for Elec-tric and Electronic Equipment MIL-DTL-2212 J, Contactors and Con-trollers,ElectricMotorACorDC,and Associated Switching DevicesTHigh-voltage MIL-SPEC panel protection.WW150.indd 1 7/15/15 4:58 PMCONTROLS, SENSORS & instrumentationDiesel & Gas Turbine Worldwide15July-August 2015MIL-E-2036D,EnclosureforElec-tricandElectronicEquipment,Naval ShipboardDOD-STD-2143,MagneticSilencing RequirementsMIL-E-917E,ElectricPowerEquip-ment Basic RequirementsMIL-P-15024E,Plates,Tags,and Bands for Identification of EquipmentMIL-STD-454 N, Standard General Re-quirements for Electronic EquipmentCMRGroupcandeliverhigh-per-formanceproductsforthenavalfleet environmentoneoftheharshest andmostdemandinginthemarine sector,Massariellosaid.Withourde-tailedknowledgeofmilitarystandards, CMRGroupbringsrealaddedvalueas atechnicalpartnerinconsultingorigi-nalequipmentmanufacturers(OEMs) toguidethemthroughthelabyrinthof military standards, evaluating the appro-priate solutions and identifying the most robust and cost-effective solutions.This is an approach thats proven suc-cessfulforCMRGroupintheworkun-dertakenforcustomersinthemarine sector,reflectedincontractsforthe provisionfor,amongothers,propul-sion and power generation control sys-tems for engines that need specifically engineeredMIL-SPECtechnologyfor applicationsbaseduponCMRGroups CLARINUXLocalControlPanel(LCP) systemandfeaturingthelatestSCM-2 Resilient MIL-SPEC panel mounts.module technology (signal acquisition).These developments deliver added value,givingtheCLARINUXsystem theabilitytohandlemultiplesen-sorinterfacesforthemonitoring, managementandcontrolofawide rangeofengineperformancesand functions.CMRGroupsClarine-121 304.3mmdisplayunitcanbeinte-gratedwithinthecontrolpanelfor full graphic display, and is compatible withenginecontrolunitselectronic controllerparameters(high-pressure commonrailsengines,gasengines, dual-fuelengines,electronicfuelin-jection engines).Stainless-steelcontrolpanelscanbe designedandbuiltincompliancewith militarystandardsofshock,vibration andelectromagneticinterferenceand lowmagneticsignature.Evidenceof the compatibility of the system to these specialist standards has been confirmed by testing in French and other European government laboratories." AShinkawa_June14_WW.indd 1 5/12/14 10:43 AMWW150.indd 2 7/15/15 4:58 PMCylinder Pressure-Based Controls In High Power Density Gas EnginesPrechamber control loop based on miniaturized cylinder pressureDiesel & Gas Turbine Worldwide16July-August 2015Es10MWJenbacherJ920 FleXtragasengineoffers oneofthebestelectrical efficienciesinitsclassand isdesignedfordurability, simpleinstallation,andmaintainability. Itconsistsofthreemodules,including agenerator,engineandturbocharger auxiliarymodule,inaprefabricated, standardized generator-set module.BasedontheexperienceofGEstype 6gasenginecombustionsystems,the J920 Jenbacher FleXtra unit is equipped with an advanced prechamber combus-tionsystemwithsparkignition.Indi-vidualgasmixingisachievedbyport injectionincombinationwithcylinder specificsensorstoalloweachcylinder tobecontrolledtooperateatoptimal performance. The J920 FleXtra mechani-calstructureisdesignedtoallowpeak firing pressure well above 200 bar.TheJ920FleXtraisequippedwiththe nextgenerationofGEsJenbachergas enginemanagementsystemwithcyl-inderindividualoptimization,adaptive condition-basedcontrols,protectionof core components and an intelligent safe operation mode.ThemostimportantaimintheJ920 FleXtradesignwastoensureasupe-riorefficiencyathighbrakemeanef-fectivepressurelevels,whichongas enginesimpliesusingalean-burn combustion concept. This is due to the factthattheoperatingrangeofthe engine narrows down.Thelimittowardarichercombustion withoutEGRisthetendencyofagas enginetoknockandmisfire.Misfiring happenswhenthein-cylindermixture becomesleaner.Inthiscase,itisnot possibletoproperlyignitethemixture any more, and it is scavenged to the ex-haust. This leads not only to an obvious dropinefficiency,butrepresentsasig-nificantincreaseinhydrocarbonemis-sions as well.GGEs J920 Jenbacher FleXtra gas engine has been designed based on the experience of GEs type 6 gas engine combustion systems, and is equipped with an advanced prechamber combustion system with spark ignition and individual-cylinder gas mixing. This engine features the next generation of GEs Jenbacher gas engine management system with cylinder individual optimization.This technical paper by GEs Jenbacher gas engines product line was presented at the Dessau Gas Engine Conference 2015. Authors are: H. Kopecek, N. Spyra, A. Birgel, K. Spreitzer, C. Trapp. Special contributions regarding software auto-coding and engine controller implementation led by Michael Waldhart is well appreciated by the authors.WW161.indd 1 7/16/15 1:14 PMthe prime-mover magazine since 1969COMING ONLINETHE EVOLUTION OF GAS TURBINES FOR POWER GENERATION BY DR. RAKESH K. BHARGAVAWW_GT_Poster_GTxcel.indd 1 7/23/15 11:19 AMCOMING ONLINETHE EVOLUTION OF GAS TURBINES FOR POWER GENERATIONJune 1903December 1936Worlds First Gas Turbine With Net Power OutputJens William gidius Elling in Norway designed and constructed a gas turbine with a net power output of 8.1 kW. The design included intercool-ing and use of steam injection.Design Features: P: 8.1 kW; TIT: 400C; PR: 7; Compressor: six stages (centrifugal); Turbine: one stage (radial)First Large Commercial Gas Turbine Became Operational The frst large commercial gas turbine was a BBC (now Alstom) unit driven by fue gases from a Houdry Cracking process at Marcus Hook Refnery in Philadelphia, Pennsylvania, U.S.A. Design Features: P: 900 kW; TIT: 510C; PR: 3.1July 1939Worlds First Utility-Type Gas Turbine Became OperationalThe frst utility-type gas turbine supplied by BBC (now Alstom) became operational at Neuchatel power station in Neuchatel, Switzerland.After more than 60 years of service, it was moved to a museum at Alstoms facility in Birr, Switzerland, in 2002. It became one of ASMEs Mechanical Engineering Landmarks in 1988.Design Features: P: 4 MW; TIT: 547C; PR: 4.4; sc: 17.4%; Compressor: 23 stages; Turbine: seven stages1946June 1949U.S. Entered Gas Turbine Power Generation MarketA GE Model 3001A installed at the Belle Isle station of Oklahoma Gas & Electric Co. in Oklahoma City, Oklahoma, U.S.A., was the frst gas turbine used for utility power generation in the United States. The gas turbine was declared an ASME National Historic Mechanical Engineering Landmark in 1984.Design Features: P: 3.5 MW; TIT: 760C; PR: 6; Compressor: 15 stages; Turbine: two stages1961Worlds First Combined-Cycle PlantThe plant built by Austrian utility NEWAG at Korneuburg A power station in Austria consisted of two BBC (now Alstom) gas turbines (Type 12), each rated at 25 MW with 26% simple-cycle thermal efciency and one steam turbine rated at 25 MW. The gas turbines were designed with intercooling.Design Features: Pnet (cc): 75 MW; TIT: 625C; PR: 12; cc: 32%First Gas Turbine With Intercooling, Reheat And RecuperationUsing an intercooled, reheat and recuperated Brayton cycle, the gas turbine supplied by BBC (now Alstom) and installed at a power plant in Beznau, Switzerland, became the most efcient gas turbine at the time. Design Features: P: 27 MW; TIT: 650C; PR: 8; sc: 34%AAir IntakeB Compressor, Three Stages Double-Entry Centrifugal Impellers + Three Stages Single-Entry Impellers, Water Injection Between The Stages, h = 70+%CCompressed Air Bleed D Combustion Chamber With InsulationEFuel FeedFWater CoolerWWater SupplySSteam DuctGExhaustT Turbine, Centripetal Type, Dia 275 mm, h = 70+%April 1963First Industrial Aeroderivative Gas Turbine Introduced For Power GenerationPratt and Whitneys frst FT4 two-spool gas turbine, derived from its J75 aircraft engine, became operational at Edgemoore power station of Delmarva Power & Light Co. Design Features: P: 15 MW; LPT: two stages; HPT: one stage; PT: three stages1968First Commercialized Complete Radial Design Gas TurbineThe frst complete radial design gas turbine, the Kongsberg Vapenfabrikk AS (now Dresser-Rand) Model KG2, became op-erational at the Norwegian Water & Electricity Board in a standby power generation service in Lofoten, Norway. Design Features: P: 1.2 MW; sc: 15.4%; Compressor: one stage; Turbine: one stageJune 1980GTCC Plant Achieved Record Net Thermal Efciency Of 47%An Austrian utility, NEWAG, commissioned a 125 MW plant in a 1x1 combined-cycle confguration using one BBC (now Alstom) GT13D gas turbine at the Korneuburg B plant near Vienna, Austria, and achieved the highest combined-cycle thermal efciency of the time, 47%.Design Features: P: 81 MW; TIT: 990C, PR: 9.3; sc: 31.8%; Compressor: 17 stages; Turbine: fve stagesJune 1990First F-Class Gas TurbineGE introduced the frst F-class gas turbine (TIT range of 1200 to 1300C). The frst Frame 7F (model PG7191F became operational at Virginia Electric & Powers Chesterfield power station) was also GEs frst implementation of cold-end drive instead of hot-end drive.Design Features: P: 150 MW; TIT: 1260C class; PR: 13.5; sc: 34.5%; Compressor: 18 stages; Turbine: three stages1993-1994Horizontal-Silo Combustor Confguration IntroducedSiemens changed its combustor design on the 60 Hz V84.3 gas turbine from the vertical-silo confguration used on the V84.2 and earlier models to a horizontal-silo confguration, resulting in reduced cooling-air requirements.1995-1996Annular Hybrid Burner Ring Combustor Technology IntroducedSiemens 60 Hz V84.3A (new designation SGT6-4000F), an upgrade to the V84.3, used annular hybrid burner ring combustor technology instead of the twin-silo combustor design. The unit also utilized Pratt and Whitneys aero-engine technology in the compressor and turbine sections to enhance performance.February 1997Worlds First Closed-Loop, Steam Cooling Of Stationary HGP ComponentsMHIs M501G, installed at the T-Point plant in a 1x1 combined-cycle confguration in Takasago, Japan, was the worlds frst closed-loop, steam-cooled gas turbine (only for combustors transitions and stage-one blade ring). Design Features: P: 254 MW; TIT: 1500C class; PR: 20; sc: 38.7%; Compressor: 17 stages; Turbine: four stagesSponsored By:WW_GT_Poster_GTxcel.indd 2 7/23/15 11:20 AMCOMING ONLINETHE EVOLUTION OF GAS TURBINES FOR POWER GENERATIONBY DR. RAKESH K. BHARGAVAJune 1903December 1936Worlds First Gas Turbine With Net Power OutputJens William gidius Elling in Norway designed and constructed a gas turbine with a net power output of 8.1 kW. The design included intercool-ing and use of steam injection.Design Features: P: 8.1 kW; TIT: 400C; PR: 7; Compressor: six stages (centrifugal); Turbine: one stage (radial)First Large Commercial Gas Turbine Became Operational The frst large commercial gas turbine was a BBC (now Alstom) unit driven by fue gases from a Houdry Cracking process at Marcus Hook Refnery in Philadelphia, Pennsylvania, U.S.A. Design Features: P: 900 kW; TIT: 510C; PR: 3.1July 1939Worlds First Utility-Type Gas Turbine Became OperationalThe frst utility-type gas turbine supplied by BBC (now Alstom) became operational at Neuchatel power station in Neuchatel, Switzerland.After more than 60 years of service, it was moved to a museum at Alstoms facility in Birr, Switzerland, in 2002. It became one of ASMEs Mechanical Engineering Landmarks in 1988.Design Features: P: 4 MW; TIT: 547C; PR: 4.4; sc: 17.4%; Compressor: 23 stages; Turbine: seven stages1946June 1949U.S. Entered Gas Turbine Power Generation MarketA GE Model 3001A installed at the Belle Isle station of Oklahoma Gas & Electric Co. in Oklahoma City, Oklahoma, U.S.A., was the frst gas turbine used for utility power generation in the United States. The gas turbine was declared an ASME National Historic Mechanical Engineering Landmark in 1984.Design Features: P: 3.5 MW; TIT: 760C; PR: 6; Compressor: 15 stages; Turbine: two stages1961Worlds First Combined-Cycle PlantThe plant built by Austrian utility NEWAG at Korneuburg A power station in Austria consisted of two BBC (now Alstom) gas turbines (Type 12), each rated at 25 MW with 26% simple-cycle thermal efciency and one steam turbine rated at 25 MW. The gas turbines were designed with intercooling.Design Features: Pnet (cc): 75 MW; TIT: 625C; PR: 12; cc: 32%First Gas Turbine With Intercooling, Reheat And RecuperationUsing an intercooled, reheat and recuperated Brayton cycle, the gas turbine supplied by BBC (now Alstom) and installed at a power plant in Beznau, Switzerland, became the most efcient gas turbine at the time. Design Features: P: 27 MW; TIT: 650C; PR: 8; sc: 34%AAir IntakeB Compressor, Three Stages Double-Entry Centrifugal Impellers + Three Stages Single-Entry Impellers, Water Injection Between The Stages, h = 70+%CCompressed Air Bleed D Combustion Chamber With InsulationEFuel FeedFWater CoolerWWater SupplySSteam DuctGExhaustT Turbine, Centripetal Type, Dia 275 mm, h = 70+%April 1963First Industrial Aeroderivative Gas Turbine Introduced For Power GenerationPratt and Whitneys frst FT4 two-spool gas turbine, derived from its J75 aircraft engine, became operational at Edgemoore power station of Delmarva Power & Light Co. Design Features: P: 15 MW; LPT: two stages; HPT: one stage; PT: three stages1968First Commercialized Complete Radial Design Gas TurbineThe frst complete radial design gas turbine, the Kongsberg Vapenfabrikk AS (now Dresser-Rand) Model KG2, became op-erational at the Norwegian Water & Electricity Board in a standby power generation service in Lofoten, Norway. Design Features: P: 1.2 MW; sc: 15.4%; Compressor: one stage; Turbine: one stageJune 1980GTCC Plant Achieved Record Net Thermal Efciency Of 47%An Austrian utility, NEWAG, commissioned a 125 MW plant in a 1x1 combined-cycle confguration using one BBC (now Alstom) GT13D gas turbine at the Korneuburg B plant near Vienna, Austria, and achieved the highest combined-cycle thermal efciency of the time, 47%.Design Features: P: 81 MW; TIT: 990C, PR: 9.3; sc: 31.8%; Compressor: 17 stages; Turbine: fve stagesJune 1990First F-Class Gas TurbineGE introduced the frst F-class gas turbine (TIT range of 1200 to 1300C). The frst Frame 7F (model PG7191F became operational at Virginia Electric & Powers Chesterfield power station) was also GEs frst implementation of cold-end drive instead of hot-end drive.Design Features: P: 150 MW; TIT: 1260C class; PR: 13.5; sc: 34.5%; Compressor: 18 stages; Turbine: three stages1993-1994Horizontal-Silo Combustor Confguration IntroducedSiemens changed its combustor design on the 60 Hz V84.3 gas turbine from the vertical-silo confguration used on the V84.2 and earlier models to a horizontal-silo confguration, resulting in reduced cooling-air requirements.1995-1996Annular Hybrid Burner Ring Combustor Technology IntroducedSiemens 60 Hz V84.3A (new designation SGT6-4000F), an upgrade to the V84.3, used annular hybrid burner ring combustor technology instead of the twin-silo combustor design. The unit also utilized Pratt and Whitneys aero-engine technology in the compressor and turbine sections to enhance performance.February 1997Worlds First Closed-Loop, Steam Cooling Of Stationary HGP ComponentsMHIs M501G, installed at the T-Point plant in a 1x1 combined-cycle confguration in Takasago, Japan, was the worlds frst closed-loop, steam-cooled gas turbine (only for combustors transitions and stage-one blade ring). Design Features: P: 254 MW; TIT: 1500C class; PR: 20; sc: 38.7%; Compressor: 17 stages; Turbine: four stagesSponsored By:WW_GT_Poster_GTxcel.indd 3 7/23/15 11:28 AMJune 1997First Use Of Single-Crystal CastingRotor Blades In Industrial Gas TurbinesSiemens used single-crystal technology in heavy-duty machines (frst two stages of its V84.3A gas turbine) to increase the TIT range and improve material strength and other mechanical properties of rotor blades. The frst V84.3A (new designation SGT6-4000F) was installed at Kansas City Power & Lights Hawthorn station in Kansas City, Missouri, U.S.A.Design Features: P: 167 MW; TIT: 1300C class; PR: 17; sc: 38%; Compressor: 15 stages; Turbine: four stagesDecember 1997September 1998Only Industrial Aeroderivative Gas Turbine With Three Spools First Introduced For Power GenerationRolls-Royces three-spool Trent-60 gas turbine, derived from its Trent 800 aircraft engine, became operational at Whitby cogeneration plant in Whitby, Ontario, Canada, in a cogeneration application. The machine can operate in 50/60 Hz application without using a gearbox.Design Features: P: 51.2 MW; PR: 35; sc: 42%; LPC: two stages; IPC: eight stages; HPC: six stages; LPT: fve stages; IPT: one stage; HPT: one stageSeptember 2003First Closed-Loop Steam Cooling Of Stationary And Rotating HGP ComponentsGE was frst to use closed-loop steam cooling of both rotating and stationary hot gas path components on its 50 Hz 9H gas turbine in a single-shaft combined-cycle confguration at Baglan Bay power station in South Wales, U.K. The unit featured a four-stage turbine com-pared to three stages in previous GE models.Design Features: Pnet (cc): 480 MW; TRIT: 1400C class; PR: 23; cc: ~60%; Compressor: 18 stages; Turbine: four stagesJune 200460 m Long Single-Shaft BFG-Fired GTCC The worlds largest BFG-fred plant used MHIs M701F gas turbine in a single-shaft combined-cycle arrangement with total shaft length of about 60 m. The gas turbine was installed at Kimitsu Cooperative Thermal Power Co.s Unit No. 5 in Chiba Prefecture in Japan. The gas turbine, with TIT of 1300C, produced net plant output of 300 MW at 50% net thermal efciency.Annular Sequential Combustion System IntroducedABB (now Alstom) introduced the annular sequential combustion system in its GT24 gas turbine, which frst became operational at Jersey Central Power & Light Co.s Gilbert power station in Milford, New Jersey, U.S.A. The annular combustion system included two annular combustion chambers, called EV (EnVironmental) and SEV (Sequential EnVironmen-tal), respectively. The system allowed increasing gas turbine thermal efciency without increasing TIT value, and also resulted in lower NOX emissions.Design Features: P: 166 MW; TIT: 1260C class; PR: 30; sc: 37.9%; Compressor: 22 stages; HPT: one stage; LPT: four stagesDecember 2004Small Gas Turbine Reached 38.5% EfciencySolar Turbines achieved high efciency (38.5%) and low NOx emissions (5 ppmv) in a unit with a power rating less than 5 MW. The frst Mercury 50 gas turbine, developed as a part of the U.S. Department of Energys ATS program and installed at San Diego Veterans Administration hospital in La Jolla, Cali-fornia, U.S.A., was a single-shaft machine utilizing recuperated Brayton cycle and implemented with ultra-lean pre-mix combustion technology.Design Features: P: 4.6 MW; TIT: 1093C; PR: 9.9; sc: 38.5%; Compressor: 10 stages; Turbine: two stagesMay 2005Downgrade Achieves Higher EfciencySiemensV94.2A gas turbine (new designation SGT5-3000E) was designed by downgrading the V94.3A (new designation SGT5-4000F) to achieve higher efciency than its predecessor, the V94.2 (new designation SGT5-2000E). While improve-ments are typically achieved through upgrades, the downgrade of the later model improved efciency from 34.7% to 36.8%. The frst modifed unit became operational at BASF Ludwigshafen chemical complex in a cogeneration application.July 2006Worlds Highest- Efciency Gas TurbineGEs frst LMS-100PA gas turbine with inter-cooled Brayton cycle entered commercial operation in a simple cycle peaking service at Basin Electric Power Cooperatives Groton Generation Station near Groton, South Dakota, U.S.A. This two-spool aeroderivative gas turbine was derived from GEs CF6 class aircraft engine and heavy duty machine MS6001FA.Design Features: P: 103 MW; TIT: 1380C; PR: 42; sc: 44%; LPC: six stages; HPC: 14 stages; HPT: two stages; IPT: two stages and PT: fve stagesJanuary 2010100 MW Class Simple Brayton Cycle GT Exceeded 38% EfciencyThe frst Hitachi (now MHPS) H-80 50 Hz dual-shaft gas turbine, developed for drop-in repowering of existing 100 MW class CCPP and installed at Shin Oita Power Station of Kyushu Electric Power in Aosaki, Japan, exceeded 38% efciency. Design Features: P: 112.4 MW; TRIT: 1488C; PR: 19.3; sc: 38.2%; GGC: 17 stages; GGT: two stages; PT: two stagesJuly 2011 First Operating Air-Cooled H-Class Gas Turbine Siemens frst air-cooled 50 Hz H-class gas tur-bine, the SGT5-8000H, installed in a single-shaft combined-cycle confguration, became opera-tional at E.ONs Irsching-4 plant (now called Ul-rich Hartman). During testing, the plant achieved 578 MW and 60.75% net efciency.Design Features: P: 375 MW; TIT: 1488C class; PR: 19.2; sc: 40%; Compressor: 13 stages; Turbine: four stages July 2011First GTCC Plant To Surpass 61% Efciency MHIs (now MHPS) frst 501J gas turbine using a steam-cooled combustor and frst-stage turbine blade ring, installed in a 1x1 combined-cycle arrangement at T-Point plant in Takasago, Japan, surpassed 61% efciency.Design Features: P: 327 MW; TIT: 1600C class; PR: 23; sc: 41%; Compressor: 15 stages; Turbine: four stagesDecember 201350 MW Class Gas Turbine Achieves 39.5% EfciencySiemens twin-shaft gas turbine, the SGT-750, achieved 39.5% efciency in a cogeneration appli-cation at Wingas Oil & Gas Co.s landfall station of Nord Stream pipeline in Lubmin, Germany. Design Features: P: 37.03 MW; TIT: 1260C; PR: 23.8; sc: 39.5%; GGC: 13 stages: GGT: two stages; PT: two stagesJune 2014GT Combustion Technology Achieved Less Than 1 ppm NOXOxidation combustion, developed by Ener-Core, was implemented with Flex Energys microturbine (Model MT250 rated at 250 kW) burning low-calorie landfll gas and successfully demonstrated NOX emissions less than 1 ppm. The unit was installed at Atteros landfll facility located in Schin-nen, Netherlands.Sponsored By:WW_GT_Poster_GTxcel.indd 4 7/23/15 11:28 AMJune 1997First Use Of Single-Crystal CastingRotor Blades In Industrial Gas TurbinesSiemens used single-crystal technology in heavy-duty machines (frst two stages of its V84.3A gas turbine) to increase the TIT range and improve material strength and other mechanical properties of rotor blades. The frst V84.3A (new designation SGT6-4000F) was installed at Kansas City Power & Lights Hawthorn station in Kansas City, Missouri, U.S.A.Design Features: P: 167 MW; TIT: 1300C class; PR: 17; sc: 38%; Compressor: 15 stages; Turbine: four stagesDecember 1997September 1998Only Industrial Aeroderivative Gas Turbine With Three Spools First Introduced For Power GenerationRolls-Royces three-spool Trent-60 gas turbine, derived from its Trent 800 aircraft engine, became operational at Whitby cogeneration plant in Whitby, Ontario, Canada, in a cogeneration application. The machine can operate in 50/60 Hz application without using a gearbox.Design Features: P: 51.2 MW; PR: 35; sc: 42%; LPC: two stages; IPC: eight stages; HPC: six stages; LPT: fve stages; IPT: one stage; HPT: one stageSeptember 2003First Closed-Loop Steam Cooling Of Stationary And Rotating HGP ComponentsGE was frst to use closed-loop steam cooling of both rotating and stationary hot gas path components on its 50 Hz 9H gas turbine in a single-shaft combined-cycle confguration at Baglan Bay power station in South Wales, U.K. The unit featured a four-stage turbine com-pared to three stages in previous GE models.Design Features: Pnet (cc): 480 MW; TRIT: 1400C class; PR: 23; cc: ~60%; Compressor: 18 stages; Turbine: four stagesJune 200460 m Long Single-Shaft BFG-Fired GTCC The worlds largest BFG-fred plant used MHIs M701F gas turbine in a single-shaft combined-cycle arrangement with total shaft length of about 60 m. The gas turbine was installed at Kimitsu Cooperative Thermal Power Co.s Unit No. 5 in Chiba Prefecture in Japan. The gas turbine, with TIT of 1300C, produced net plant output of 300 MW at 50% net thermal efciency.Annular Sequential Combustion System IntroducedABB (now Alstom) introduced the annular sequential combustion system in its GT24 gas turbine, which frst became operational at Jersey Central Power & Light Co.s Gilbert power station in Milford, New Jersey, U.S.A. The annular combustion system included two annular combustion chambers, called EV (EnVironmental) and SEV (Sequential EnVironmen-tal), respectively. The system allowed increasing gas turbine thermal efciency without increasing TIT value, and also resulted in lower NOX emissions.Design Features: P: 166 MW; TIT: 1260C class; PR: 30; sc: 37.9%; Compressor: 22 stages; HPT: one stage; LPT: four stagesDecember 2004Small Gas Turbine Reached 38.5% EfciencySolar Turbines achieved high efciency (38.5%) and low NOx emissions (5 ppmv) in a unit with a power rating less than 5 MW. The frst Mercury 50 gas turbine, developed as a part of the U.S. Department of Energys ATS program and installed at San Diego Veterans Administration hospital in La Jolla, Cali-fornia, U.S.A., was a single-shaft machine utilizing recuperated Brayton cycle and implemented with ultra-lean pre-mix combustion technology.Design Features: P: 4.6 MW; TIT: 1093C; PR: 9.9; sc: 38.5%; Compressor: 10 stages; Turbine: two stagesMay 2005Downgrade Achieves Higher EfciencySiemensV94.2A gas turbine (new designation SGT5-3000E) was designed by downgrading the V94.3A (new designation SGT5-4000F) to achieve higher efciency than its predecessor, the V94.2 (new designation SGT5-2000E). While improve-ments are typically achieved through upgrades, the downgrade of the later model improved efciency from 34.7% to 36.8%. The frst modifed unit became operational at BASF Ludwigshafen chemical complex in a cogeneration application.July 2006Worlds Highest- Efciency Gas TurbineGEs frst LMS-100PA gas turbine with inter-cooled Brayton cycle entered commercial operation in a simple cycle peaking service at Basin Electric Power Cooperatives Groton Generation Station near Groton, South Dakota, U.S.A. This two-spool aeroderivative gas turbine was derived from GEs CF6 class aircraft engine and heavy duty machine MS6001FA.Design Features: P: 103 MW; TIT: 1380C; PR: 42; sc: 44%; LPC: six stages; HPC: 14 stages; HPT: two stages; IPT: two stages and PT: fve stagesJanuary 2010100 MW Class Simple Brayton Cycle GT Exceeded 38% EfciencyThe frst Hitachi (now MHPS) H-80 50 Hz dual-shaft gas turbine, developed for drop-in repowering of existing 100 MW class CCPP and installed at Shin Oita Power Station of Kyushu Electric Power in Aosaki, Japan, exceeded 38% efciency. Design Features: P: 112.4 MW; TRIT: 1488C; PR: 19.3; sc: 38.2%; GGC: 17 stages; GGT: two stages; PT: two stagesJuly 2011 First Operating Air-Cooled H-Class Gas Turbine Siemens frst air-cooled 50 Hz H-class gas tur-bine, the SGT5-8000H, installed in a single-shaft combined-cycle confguration, became opera-tional at E.ONs Irsching-4 plant (now called Ul-rich Hartman). During testing, the plant achieved 578 MW and 60.75% net efciency.Design Features: P: 375 MW; TIT: 1488C class; PR: 19.2; sc: 40%; Compressor: 13 stages; Turbine: four stages July 2011First GTCC Plant To Surpass 61% Efciency MHIs (now MHPS) frst 501J gas turbine using a steam-cooled combustor and frst-stage turbine blade ring, installed in a 1x1 combined-cycle arrangement at T-Point plant in Takasago, Japan, surpassed 61% efciency.Design Features: P: 327 MW; TIT: 1600C class; PR: 23; sc: 41%; Compressor: 15 stages; Turbine: four stagesDecember 201350 MW Class Gas Turbine Achieves 39.5% EfciencySiemens twin-shaft gas turbine, the SGT-750, achieved 39.5% efciency in a cogeneration appli-cation at Wingas Oil & Gas Co.s landfall station of Nord Stream pipeline in Lubmin, Germany. Design Features: P: 37.03 MW; TIT: 1260C; PR: 23.8; sc: 39.5%; GGC: 13 stages: GGT: two stages; PT: two stagesJune 2014GT Combustion Technology Achieved Less Than 1 ppm NOXOxidation combustion, developed by Ener-Core, was implemented with Flex Energys microturbine (Model MT250 rated at 250 kW) burning low-calorie landfll gas and successfully demonstrated NOX emissions less than 1 ppm. The unit was installed at Atteros landfll facility located in Schin-nen, Netherlands.Sponsored By:WW_GT_Poster_GTxcel.indd 5 7/23/15 11:29 AMGas Turbine Order Trends (1977-2014) 02004006008001000120014001600180077-7878-7979-8080-8181-8282-8383-8484-8585-8686-8787-8888-8989-9090-9191-9292-9393-9494-9595-9696-9797-9898-9999-0000-0101-0202-0303-0404-0505-0606-0707-0808-09200920102011201220132014Year020406080100120140Capacity(Data Courtesy Of Diesel & Gas Turbine Worldwide Order Survey) Gas Turbine Units (Qty)Yearly Capacity (GW)Gas Turbine OrderedRakesh BhargavaApril 2015Thermal Efficiency Power Generation Application (1939-2014)0102030405060701930 1940 1950 1960 1970 1980 1990 2000 2010 2020YearEfficiency (%)Heavy-DutyAeroderivativeHeavy-Duty (CC)Aeroderivative (CC)NeuchtalBeznauBelle IsleLMS-100LM6000PGL-30AM501JRakesh BhargavaApril 2015Diesel & Gas Turbine Sourcing GuideSponsored By:WW_GT_Poster_GTxcel.indd 6 7/23/15 11:29 AMGlobal Gas Turbine Orders History By Power Range (1977-2014) 02040608010077-7878-7979-8080-8181-8282-8383-8484-8585-8686-8787-8888-8989-9090-9191-9292-9393-9494-9595-9696-9797-9898-9999-0000-0101-0202-0303-0404-0505-0606-0707-0808-09200920102011201220132014Year1-2 MW 2-10 MW 10-30 MW 30-60 MW 60-120 MW 120-180 MW >180 MW(Data Courtesy Of Diesel & Gas Turbine Worldwide Order Survey) Rakesh BhargavaApril 2015% Of Yearly Total Global Gas Turbine Orders History By Region (1977-2014) Year0 20 40 60 80 100 77-78 78-79 79-80 80-81 81-82 82-83 83-84 84-85 85-86 86-87 87-88 88-89 89-90 90-91 91-92 92-93 93-94 94-95 95-96 96-97 97-98 98-99 99-00 00-01 01-02 02-03 03-04 04-05 05-06 06-07 07-08 08-09 2009 2010 2011 2012 2013 2014 % Of Yearly Total North AmericaCentral & South AmericaAfricaWestern Europe Central, South East Asia & Australia Far EastMiddle EastEastern Europe & Russia (Data Courtesy Of Diesel & Gas Turbine Worldwide Order Survey) Rakesh BhargavaApril 2015the prime-mover magazine since 1969WW_GT_Poster_GTxcel.indd 7 7/23/15 11:29 AMThisposterwasdevelopedbyDr.Rakesh Bhargava,founderandpresidentofIn-novativeTurbomachineryTechnologies. Dr.BhargavaisaFellowofASMEandan activememberoftheAPICommittee onStandardsonMechanicalEquipment (SOME). He has more than 35 years of ex-periencewithgasturbines,rotatingand reciprocatingmachinesandpackaged process equipment, and delivers lectures, papers and training on gas turbine and ro-tatingequipmenttechnologyandissues. He would like to thank Dr. Carlos Koeneke, RonNatole,SeptimusVanDerLinden, John Mcllvoy and gas turbine manufactur-ers for sharing the requested information.Nomenclature & AcronymsATSAdvanced Turbine SystemBFGBlast Furnace GasCCPPCombined-Cycle Power PlantGGCGas Generator CompressorGGTGas Generator TurbineGTCCGas Turbine Combined CycleHPCHigh-Pressure Compressor HPTHigh-Pressure TurbineIPCIntermediate-Pressure CompressorIPTIntermediate-Pressure TurbineLPCLow-Pressure CompressorLPTLow-Pressure TurbineMPCMedium-Pressure CompressorPPower (MW)Pnet(cc)Net Output of CCPPPRPressure Ratio (-)PTPower TurbineTITTurbine Inlet Temperature (C)TRITTurbine Rotor Inlet Temperature (C)cc Thermal Efciency Combined Cycle (%)scThermal Efciency Simple Cycle (%)For a complete list of references, visit dgtww.co/GTPower 2015 Diesel & Gas Turbine PublicationsDelivered10timesperyeartomorethan21000 globalsubscribers,Diesel&GasTurbineWorldwideis the leading authority for prime-mover products, tech-nologies and news. Available in print and digital form, youcansubscribeforfreeatwww.dieselgasturbine.com/subscribe/.the prime-mover magazine since 1969WW_GT_Poster_GTxcel.indd 8 7/23/15 11:30 AMDiesel & Gas Turbine Worldwide17July-August 2015To move this limit to higher lambda ra-tios, an innovative prechamber design is used on the J920 FleXtra, with the spark plugplacedinachamberseparated fromthemaincombustionchamber. Thisprechamberisconnectedtothe maincombustionchamberviaseveral bores.Afterignition,theflametorches fromthecombustionreachintothe maincombustionchamberandensure the very lean mixture is ignited.Themisfirelimitcanthereforebe shiftedandtheoperationrangeofthe enginecanbeextended.Lowerhydro-carbonemissionsareproduceddueto less flame quenching effects.Toachievehighlambdacombustion incombinationwithadvancedMiller valve timing, very high boosting pres-suresarenecessary.Forthis,GEisus-ingatwo-stageturbocharginglayout thatachievesincreasedpressureratio at efficiencies higher than 75%.TochargetheJ920FleXtrawithmix-turewouldleadtobigvolumescon-taininganignitablemixture.Hence thedesignoftheenginehasseparate pipes for air and fuel gas. The gas is fed toeachindividualcylinderjustinfront of the intake ports by means of port in-jection(PI)valves.Withthisseparated approach,safetyisincreasedandad-ditionalbenefitswithrespecttocon-trolsareachieved.However,duetothe knocking tendency of gas engines, a ho-mogenous mixture in the cylinder has to be achieved through the advanced port design of the J920 FleXtra.Centrallow-pressuregasadmission, widelyusedingasengineswithless than5MWel,offersarobustandcost efficient solution for mixing gas with air. Forlargergasenginesinthe10MWel range,portinjectionistheinnovative mixingconcept.Theadvantagesof higherefficiency,bettertransientbe-haviorandeliminatingtheriskofdef-lagrationcompensatethehighereffort compared to central gas mixing. Themainchallengeforport-injection continued on page 18CONTROLS, SENSORS & instrumentationgas mixing is the short time for mixture preparation.Iffuelgasisadmittedtoo earlyintotheintakeport,thegascan potentiallyflowtothenextcylinders downstreamofthePIvalveorthegas canslipthroughthecylinderintothe exhaustductduringvalveoverlap.Ad-mitting the gas too late would not allow allthegastoenterthecylinderwithin thenextcycle.Residualgasisaccumu-latedattheintakeportanditispoten-tiallypurgedintotheexhaustductas hydrocarbonslipduringthenextgas exchange cycle.EspeciallyforengineswithearlyMiller cycle, valve overlap and two-stage turbo-chargedengineswithhighscavenging differentialpressure,thetimeframefor proper gas admission is less than 20 m/s.Usingportinjectioninsteadofacen-tral gas mixer adds challenges as well as opportunitiestothecontrolstrategyof theengine.Cylinder-individualgasad-mission valves close to the intake valves offerthepossibilitytoactonthegas WW161.indd 2 7/16/15 1:14 PMThe chart displays the results of diferent engine operation, in terms of air mass fow versus indicated mean efective pressure.Diesel & Gas Turbine Worldwide18July-August 2015amountofthecylinderwithinthenext cycle.Foridlespeedcontrol,fastload rejectionlikeinisolatedmode,orgrid codecompliance,thegasadmission toindividualcylinderscanbestopped, and the engines power output reduced from one cycle to another.On the J920 FleXtra engine, the overall gas amount of all PI valves is controlled byGEsJenbacherLeanoxconcept.But havingagasadmissionvalveforeach cylinderrequiresastrategytocontrol andadjustthegasamountandtheig-nitiontimingforeachcylinder.EachPI valvehasflowtolerances,agingeffects anddifferentboundaryconditionsat the inlet and outlet due to oscillations in the gas and in the air rail.TheJ920FleXtraclosedloopcontrol conceptwithcylinder-pressure-based combustion feedback makes the gas ad-missionnotonlyrobustagainstdiffer-entboundaryconditionsandchanges overthelifetime,butitalsooptimizes each cylinder individually.Closed-loop, pressure-based control al-lows not only operating the J920 engine inanoptimummodewhentheengine is new, but also to react on degradation of the engine during its lifetime.To be robust over the engines lifetime, the controller is set up in steps: in a first stepthesignalsarecheckedforplau-sibility,andthestatusoftheengineas well as the status of each cylinder is as-sessed.Inanextsteptheenginecon-troller decides how to operate each cyl-inder based on the signals.If abnormal combustion like knock oc-cursonacylinder,theenginecontrol-lerstabilizesthecombustion.Incase asignalofasensorisinaccurateor showssignificantnoise,thecylinderis operated in a safe mode, which is based on the settings of the latest cycles with proper signals.The port injection valves are key compo-nents for the J920 FleXtra engine as they impacttheengineperformancecycle-by-cycle. The requirement on accuracy is high; the flow of the valves has to be very precisefromcycle-to-cycle,andtight-nessiskeytogoodcontrollability.For longserviceintervalsandshortengine downtime,thevalveshavetowithstand several hundred million cycles without a significant decrease in performance.Besidestraditionalbenchmarkcrite-rialikehighestfull-loadefficiencyand lowestemissions,gasenginesarecon-tiunuallyfacingadditionalchallenges Typical start-up behavior of the J920 FleXtra. The gas engine is able to reach full load in less than fve minutes after the request under preheated conditions.WW161.indd 3 7/16/15 1:15 PMDiesel & Gas Turbine Worldwide19July-August 2015CONTROLS, SENSORS & instrumentation on transient performance and grid code compliance.Fast-raisingsegmentslike peaking or other applications related to ancillaryservicesrequirepowerplants with fast load-tracking capabilities with-outanytradeoffinplantefficiencyor start-upreliability.Besidesarobust andatthesametimeversatileme-chanicalandthermodynamicdesignof theengine,thecontrolstrategyplaysa key role here.Keytechnologytobeabletomeetall theserequirementsistheJ920FleXtra cylinderindividualcombustioncontrol systemmakinguseofin-cylinderpres-sure sensing, distributed controllers with embeddedsoftwarearchitecture,the main controller and the cylinder individ-ual gas supply via port injection valves.Thein-cylinderpressuresensorsare speciallydesignedtowithstandthe harshconditionsregardingpeakfiring pressuresandtemperaturesinsidethe cylinders.Atthesametime,thesesen-sors,togetherwiththecorresponding signal conditioning units, must maintain an accuracy of less than 1% of full scale over the whole operation range.Besides a robust sensor design, it is im-portanttodevelopadequatesoftware featuresthatimmediatelydetectany sensor failures before any subsequent controlactiononthatill-conditioned signalcouldtakeplace.Awholesetof such algorithms is implemented on the J920FleXtraenginecontrollertoreli-ably detect and classify any fault of the pressure signal.Basedonthefaultclassificationper-formed by the main controller, the engine is either intended to stop or can be further operated under limited conditions.Theenginecontrollerusesthecycle-basedcombustioninformationtocal-culatetheoptimumamountofgasas wellastheoptimumignitiontimingfor each cylinder individually. Hence, engine operationatmaximizedefficiencyisen-suredunderdifferentboundarycondi-tionslikerequestedload,gasquality, intake air temperature or ambient condi-tions. Thesystemespeciallyreducesthe spreadofpeakfiringpressuresamong Harco_May15_WW.indd 1 2/19/15 9:43 AMdifferentcylinders,tryingtolocatethe cylinder-individualoptimumfordiffer-ent operation conditions.Under transient load events, the control-ler immediately adapts the existing con-troloptimizationalgorithmsforhighest steadystateefficiencyautomaticallyto maintain fast load response of the engine.Besidesitsveryhighefficiencylevel andlowemissions,theJ920engineis abletorampupanddowninpowerat 80 kW/s, and takes about 100 from zero to full load and reverse. Further, this en-gine is capable of operating as the single power-generation unit in isolated grids, ensuringhighstabilityandlowimpact on grid frequency and voltage in case of fast load steps. AWW161.indd 4 7/20/15 10:32 AMYOUR SOURCE FOR THE ONLY USCG APPROVED MARINE THERMOPLASTIC PIPING SYSTEM W&O is the proud North American distributor for the groundbreaking SeaCor piping systems from Georg Fischer the rst and only commercially available United States Coast Guard-Approved (USCG) marine thermoplastic piping system in the world. SeaCor is also the only thermoplastic piping system that meets the requirements of Transport of Canada. Light in weight and long-lasting, the corrosion-resistant SeaCor piping system is a unique, cost-saving solution to optimize vessel performance.Pipe|Valves|Fittings|Actuation|Engineered SolutionsW&O INTRODUCESby GF Piping Systems800.962.9696wosupply.comNo. 164.141/36/0TransportCanadaW&O.indd 1 4/10/15 1:58 PMFEATURED PRODUCTSHortonInc.introducedthefrstgen-eration of its line of complete fan and fan drive upgrade packages available for towable generator sets.Currently available for a number of Cat-erpillarandMultiquipgen-sets,theup-grade packages are designed to improve the performance of units operating with frst-ft direct drive fans, Horton said. The packages key component, Hortons vari-ablespeedfandrive,ensuresthatthe unitsfanturnsattheoptimalspeedto provide proper engine cooling.Inadditiontoenginecooling,theup-grade packages provide decreased radi-atorclogging,reducedoperatingnoise and potential fuel savings up to 10%.www.hortonww.comFAN DRIVE UPGRADEEmersonProcessManagementhas introducedtheFisherZ500lineof metal-seated ball valves.Thevalvesareengineeredtowith-standhighertemperatures,pressures, and erosive conditions than a standard on/ofballvalve,thecompanysaid.A bi-directionalsealingdesignofersa solutiontoprocessbackpressureand shutofrequirementsinbothfowdi-rections,safeguardingcontrolvalves and other equipment in the line.Fisher Z500 valves are designed with anintegralmetalseatandself-ener-gized metal body gasket to help elimi-nate leak paths and withstand extreme temperature changes, Emerson said. www.emersonprocess.comBALL VALVESBinsfeld Engineering Inc. has released the TorqueTrak TPM2 torque and pow-er monitoring system for marine, ener-gy and power generation applications. TheTPM2modelfeaturesadigital RS422fullduplex,serialinterfacewith userselectablesampleratesranging from10to4800samplespersecond. Signalresolutionis15bitsforeightin-put ranges from 0 to 32 mV/V down to 0 to 0.25 mV/V.The TPM2 uses strain gage technology anddoesnotrequireshaftmodifca-tionormachinedisassembly,Binsfeld said. The system is ideal for continuous long-termmeasurementandavailable for shaft diameters from 19 to 1016 mm.www.binsfeld.com TORQUE MONITORING SYSTEMWW_JulyAugust_Products.indd 1 7/17/15 12:15 PMCONTROLS, SENSORS & instrumentationOn The LevelDiesel & Gas Turbine Worldwide21July-August 2015ariohmEuroSensorintroduceditsSST300series singleordualaxisinclinometerswithacombined absolute accuracy of 0.01. The sensor is available in six measurement ranges up to 60 and offers optional temperature drift accuracy of 0.05 at ambient temper-atures between -40 and 85C.ThecompanysaidtheSST300seriesoffershighprecisionfor otherimportantmeasurementparameters,includingcross-axis sensitivity, offset, repeatability and hysteresis.The compact cylindrical sensor measures just 50 mm in diame-ter with a nominal height of around 50 mm. Three fixing slots on the base flange and a generous installation misalignment factor makes for a straightforward setup of the sensor, Variohm said.The inclinometer is approved for IP67 protection and has a high resilience to shock and vibration. The company said it also has a mean time between failures rating from 25 000 hours up.ThenewSST300seriesissuitedtodemandingtiltmonitoring applications,includingdrillingplatformsandstructuralmoni-toring.Theseriesincludesawiderangeofoptionsforoutput, mechanicalinstallationandelectricalconnection.Achoiceof interfacesisavailable,asforexampleRS232,RS485,CANopen, as well as integrated mil-spec connectors.VariohmEuroSensordesigns,manufacturesandsourcesa comprehensiverangeofsensortechnologiesforlinearand rotaryposition,load,force,vibrationandtemperature,forap-plications in agriculture, construction, and research markets. AVVariohm EuroSensors new SST300 single- or dual-axis inclinometers offer high precision in a small package just 50 mm in diameter and about 50 mm in height.Variohm EuroSensor rolls out new inclinometerKIENE Cylinder Pressure Indicators for measuring diesel engine firing pressures... Easy to use simple and reliable. Reduce maintenance costs. Improve engine availability. Use to balance cylinders. Pinpoint engine problems. Optimize fuel consumption. Fits any standard indicator valve. Recommended and used by major engine builders. Minimal investment to monitor engine condition. Contact us now for more information.KIENEDIESEL ACCESSORIES, INC.Phone: 1-800-264-5950Fax: 630-543-5953www.kienediesel.comE-mail: info@kienediesel.comSIMPLE.RUGGED.RELIABLE.Kiene7/7/043:33 PMPage 1WW154.indd 1 7/16/15 1:23 PMCONTROLS, SENSORS & instrumentationCollaborative ConcoctionAltronic, Enbase Energy Technology introduce the Altronic Telematics SystemDiesel & Gas Turbine Worldwide22July-August 2015ltronic and Enbase Energy Tech-nologyhavecollaboratedto createtheAltronicTeematics System(ATS).Thesystem isanengineandcompres-sorautomationplatformwithbuilt-in telematicsforremotediagnosticsand set point control. ATS also includes a mo-bile application and analytics dashboard that drives engine and compressor opti-mization and uptime performance.Thereisnothird-partyhardwareand nofieldsupervisorycontrolanddata acquisition(SCADA)wiringrequired, accordingtoAltronic,allowingopera-tors and packagers to receive critical in-formationwirelessly. Withtheabilityto remotelyconfiguresetpointsoncom-patibleAltroniccontrollers,fieldtech-niciansnolongerneedtoperformthis work on-site. A small staff of centralized personnelcanremotelyperformthese functions for an entire fleet.According to Altronic, the ATS provides the industrys first Wi-Fi human-machine interface,makingsecurereadingsat-tainable on Wi-Fi enabled smartphones, tabletsandotherdevices,allowingfor integrationwithoperatorSCADAsys-tems without running cable or installing additional gateways.TheTelematicsSystemjointlydevel-opedwithEnbasechangesthegame entirelybyeffectivelyblurringtheline betweenthelocalcontrolpanelandthe remotemonitoring/dataanalysisfunc-tions,saidDavidBell,seniorvicepresi-dentofsalesandserviceatAltronic. By providingaccesstotheoperatingdata and system configuration away from the panel 10 feet, 10 miles, or 10,000 miles away the user retains full confidence in operating a proven set of controller hard-ware, including Altronic DE-3000 systems, whilesimultaneouslytappingintonew web/browser-baseddatacollectionand analysistoolswithoutregardtophysical locationallserveduptotheuseron smart phones, tablets and/or laptop PCs.EnbaseEnergy Technology,headquar-teredinHouston, Texas,U.S.A.,isanoil andgastechnologycompanyfocused onfieldautomation,mobileapplica-tionsandpredictiveanalytics,serving E&P, midstream and energy service com-panies world-wide.Altronic is the lead plant for Hoerbiger EngineSolutions,partoftheCompres-sionTechnologyBusinessUnit.Hoer-bigerisactivethroughouttheworldas a leading player in the fields of compres-siontechnology,drivetechnologyand automation technology. AAThe Altronic Telematics System is an engine and compressor automation platform with built-in telematics for remote diagnostics and set point control.WW158.indd 1 7/16/15 1:27 PMHItachi_OurFoundation_AL.indd 1 7/7/15 3:58 PMAn Addition To The ABB Azipod FamilyLatest model could appeal to new shipping sectorsby Ian CameronDiesel & Gas Turbine Worldwide24 July-August 2015BB has unveiled a new addition to its family of Azipod electric propulsion products in a move the company said makes the technology suitable to a wider range of vessel types.TheAzipodsystemwasfirstdevelopedsome28 years ago, but ABB has developed a new version the Azipod D with power ranges from 1.6 to 7 MW. The Azipod electric propulsionsystemisastreamlined,steerablepodmotor mounted below the ship with the propeller connected di-rectly to the motor shaft.ABBsaiditsgearlessAzipodsystemisalreadywidelyin servicewithcruisevessels,icebreakers,ice-goingcargo vessels and accommodation ships. With the Azipod D, ship-pingsegmentssuchasoffshoredrilling,constructionand AABB said that with its new Azipod D, shipping segments such as ofshore drilling, construction and support vessels and ferries could beneft from the higher fexibility, reliabil-ity and energy efciency provided by Azipod technology.WW155.indd 1 7/17/15 1:51 PM MARINE propulson supportvesselsandferriescouldbenefitfromtheflex-ibility,reliabilityandenergyefficiencyprovidedbyAzi-pod technology.ABBhopesAzipodcharacteristicswillmakethetech-nologyparticularlyappealingtotheoffshoreshipping sectorwheremostvesselsoperateinadynamicposi-tioning mode and require high reliability.The new thruster gives designers and ship builders in-creased design flexibility to accommodate a wide range ofhullshapesandpropellersizesandofferssimplein-stallation, the company said.The Azipod D requires up to 25% less installed power, partly due to the new hybrid cooling that increases the performanceoftheelectricmotorbyupto45%,ABB said.Thereareopenpropellerandductedversionsof thenewAzipodcoveringtheneedsofhigh-thrustand high-speed applications.Thegearlessconstruction,highmotorefficiencyand advanced hydrodynamic design result in fuel consump-tionthatistypically10to15%lowerthanwithgeared thrusters, ABB said.Technicalsolutionsonthelatestversionhavebeen tested and proven in either Azipod C or Azipod X thrust-ers.Introducedin2000,thegearlessAzipodCisavail-able as an open propeller version, Azipod CO for typical ship applications, and as a nozzled version, Azipod CZ.The power range of the C series varies from 1 to 4.7 MW, andaccordingtoABB,thethrusterimprovesthreeas-pectsofoperationalprofitabilityoveravesselslifetime efficiency, reliability and cargo capacity.Asconventionalgearedpropulsorsarepoweredwith an inboard induction motor, an advanced feature of the gearlessthrusteristhepermanentmagnetpropulsion motor, said ABB.The company added that unlike normal electric motor types,therotorofapermanentmagnetmotorisnatu-rally magnetized thus saving the additional power con-sumption for magnetizing.In a separate move, ABB announced it recieved a US$60 millioncontracttodeliverAzipodXOpropulsionand powersystemstotwoNorwegianCruiseLinevessels built by Meyer Werft of Germany and due for delivery in 2018 and 2019.ABB also announced it had received record levels of or-dersforthemarinepartofthegroupsbusiness,driven bygrowthindemandforelectricalpropulsionsystems especially in the cruise and ice-going segments.In2014,thecompanywonordersworthUS$200mil-lion to deliver power plants and Azipod propulsion sys-tems to cruise customers and US$900 million to deliver solutions to ice-going and icebreaking projects. Aengineering for a better worldGEA Westfalia Separator Group GmbHWerner-Habig-Strae 1, 59302 Oelde, GermanyPhone: +49 2522 77-2118, Fax: +49 2522 77-32118ws.info@gea.com, www.gea.comTechnology from GEA Westfalia Separator Group protects the performance, safety and economy of your power generator systems worldwide.Our separators shield your diesel engines and gas turbines from all aggressive by-products in fuel oils, reducing service downtimes and failures. Diesel engines are safe from destructive cat fines in low-sulphur residual oils. Gas turbines are protected from corrosion caused by sodium and potassium in untreated oils.High-Performance SeparatorsSafeguarding your diesel engines and gas turbinesEN-01-004GEA_Safeguarding_JulAug_WW.indd 1 7/7/15 1:12 PMDiesel & Gas Turbine Worldwide25 July-August 2015WW155.indd 2 7/17/15 1:54 PMHold Fastby Brent HaightDiesel & Gas Turbine Worldwide26July-August 2015iesel&GasTurbineWorldwidesMarinePropulsion OrderSurveyisthelastofthreereportsdesigned to provide details on the markets of large recipro-catingengines,steamturbinesandgasturbines usedinpowergeneration,mechanicaldriveand marine propulsion applications.Wedividethedataintothreereportsinordertoprovidea more in-depth look at key market segments for prime movers. The Power Generation Order Survey (see May D&GTW 2015, p. 28)examinesreciprocatingengines,steamturbinesandgas turbinesforpowergenerationservice.TheMechanicalDrive OrderSurvey(seeJuneD&GTW2015,p.26)isdevotedtoen-gine orders for mechanical drive applications including pumps, compressors, oil exploration machinery, rail and other industri-al applications. The Marine Propulsion Order Survey examines mechanicaldrive,auxiliaryanddiesel-electricmarinepropul-sions systems.ProceduresTheMarinePropulsionOrderSurveyincludesprimemovers beginning at 500 kW (0.5 MW). New orders are broken into die-sel-electric,mechanicaldriveandauxiliarygeneratingsetor-ders. Fuel types include diesel fuel, heavy fuel and natural gas.Alldatafoundinthesurveywasprovidedbyparticipating originalequipmentmanufacturers(OEMs).Anaccompanying table identifies those companies that participated in the 2015 survey. Every effort is made to ensure this survey is as complete andcomprehensiveaspossibleandwouldnothavethelevel of detail it contains without the generous contributions of the participating companies.Data in this survey does not represent units shipped, but only the total orders received during calendar-year 2014.Geographic location is the ship-building site.For reference, the geographic breakdown that was presented to participating OEMs along with the survey forms is included in this report.Itisimportanttonote,someunitsreportedinthe2015Ma-rinePropulsionOrderSurveydidnothavecompleteinforma-tion. In some cases OEMs chose not to provide engine output, fuel type or geography for some of their reported orders.OverviewThe 2015 Marine Propulsion Order Survey echoes the theme of the 2015 Power Generation Order Survey Hold Fast.LastyearsMarinePropulsionOrderSurveyrevealedthebe-ginning of a turnaround for an industry plagued by years of de-cline. The 2015 survey shows an industry holding fast, despite myriad challenges that have little to do with shipbuilding and are affecting most industries worldwide.Total units reported in the 2015 Marine Propulsion Order Sur-vey (2014 data) equaled 12 123, a decrease of only 0.3% com-pared to last years report. Good news considering it could have been much worse. Low oil prices, economic uncertainties and geopolitical concerns continue to influence business decisions around the globe.TheFarEastwasonceagainthetopgeographiclocation(all reporteddrivertypes).With6198unitsdestinedfortheFar East, the region claimed 51% of all orders last year.The Far East continues to set the tone for the global shipbuild-ingmarket,butthelandscapeisshifting.Ordersdestinedfor the Far East, which includes China, Japan and South Korea (the wordsthreelargestshipbuildingnations)fell13%compared to last years survey.DMECHANICAL DRIVE MARINE PROPULSION ORDERS, January December 2014Output Range (MW)Number Of UnitsTotal Engine Output ForEach OutputRange (MW)Engine Operating Speed Ranges(r/min)Fuel Regions/Regional CodesBelow 300300 to 600720 to 1000Above 1000Diesel FuelHeavy FuelNatural GasWestern EuropeEastern Europe, Russia & CISMiddleEastFar EastSoutheast Asia &AustraliaCentralAsiaNorthAfricaCentral, West, East & South AfricaNorth AmericaCentral America & CaribbeanSouth America0.50 to 1.00 2637 1633 0 0 1 2636 2637 0 0 531 10 101 833 483 2 0 2 649 8 181.01 to 2.00 2403 3289 14 8 446 1935 2268 129 4 628 52 152 646 453 4 0 8 381 1 782.01 to 3.50 525 1359 18 3 222 282 490 30 5 142 14 36 136 126 41 0 0 12 0 183.51 to 5.00 155 680 45 1 48 61 102 49 4 27 2 8 61 38 9 0 0 18 0 05.01 to 7.50 196 1259 176 0 12 8 18 178 0 9 2 1 181 0 0 1 0 2 0 07.51 to 15.00 735 7570 717 2 0 16 16 717 2 10 7 0 669 29 4 5 0 4 0 715.01 to 30.00 244 4607 244 0 0 0 0 214 30 0 6 0 234 4 0 0 0 0 0 030.01 to 50.00 76 3300 76 0 0 0 0 76 0 0 1 0 73 2 0 0 0 0 0 050.01 and above19 1171 19 0 0 0 0 19 0 0 0 0 19 0 0 0 0 0 0 0Totals 6990 24 868 1309 14 729 4938 5531 1412 45 1347 94 298 2852 1135 60 6 10 1066 9 1212015MARINE PROPULSIONorder surveyWW164.indd 1 7/17/15 5:18 PMDiesel & Gas Turbine Worldwide27July-August 2015That trend may continue. Orders at Chinese shipyards (ranked thirdintheword)havefallen77%infirst-quarter2015com-pared to last year.WesternEuropeandNorthAmericaonceagaincameinsec-ond and third respectively. Western Europe logged 16% of the total orders reported, while North America received 12% of all orders reported.TheregiontowatchisSoutheastAsia&Australia,which claimed the number four spot with 11% of 2014 orders, a 39% growthcomparedtolastyear.SoutheastAsia&Australiais poised to take over the number three spot in our survey, as the Philippines continues its rise as a shipbuilding world leader and the outlook for North American shipyards remains cautious.While North America posted 18% growth in orders compared tolastyear,lowoilpricescontinuetoimpactinvestmentsin explorationanddevelopment,limitingdemandforoffshore drilling and support vessels, which will impact orders in 2015. Mechanical Drive OrdersTotalreportedmechanicaldriveordersreportedthisyear were 6990 units, a 2% decrease compared to last years survey. Units sized 0.50 to 1.00 MW accounted for 39% of the mechani-cal drive orders.Engineoperatingspeedsabove1000r/mincomprised74% of the total mechanical drive units ordered in 2014. Diesel fuel continued on page 28MARINE AUXILIARY GENERATING SET ORDERS, January December 2014Output Range (MW)Number Of UnitsTotal Engine Output ForEach Output Range (Mwe)Engine Operating Speed Ranges (r/min)Fuel Regions/Regional Codes300 to 600720 to1000Above1000Diesel FuelHeavy FuelNatural GasWestern EuropeEastern Europe, Russia & CISMiddleEastFar EastSoutheast Asia &AustraliaCentralAsiaNorthAfricaCentral, West, East & South AfricaNorthAmericaCentral America & CaribbeanSouthAmerica0.50 to 1.00 2560 1497 0 1640 808 686 1762 0 163 26 5 2091 102 53 0 1 88 4 271.01 to 2.00 1390 1441 0 608 374 386 586 10 190 6 16 673 68 296 0 3 92 0 462.01 to 3.50 352 791 0 194 158 169 173 10 38 16 0 181 3 0 0 0 97 1 163.51 to 5.00 200 738 0 200 0 6 158 36 13 0 0 185 0 0 0 0 0 2 05.01 and above7 40 0 7 0 2 5 0 0 0 0 5 0 0 0 0 2 0 0Totals 4509 4507 0 2649 1340 1249 2684 56 404 48 21 3135 173 349 0 4 279 7 89DIESEL-ELECTRIC MARINE PROPULSION ORDERS, January December 2014Output Range (MW)Number Of UnitsTotal Engine Output ForEach Output Range (Mwe)Engine Operating Speed Ranges (r/min)Fuel Regions/Regional Codes300 to600720 to1000Above1000Diesel FuelHeavy FuelWestern EuropeEastern Europe, Russia & CISMiddleEastFar EastSoutheast Asia &AustraliaCentralAsiaNorthAfricaCentral, West, East & South AfricaNorth AmericaCentral America & CaribbeanSouth America0.50 to 1.00 4 3 0 4 0 2 2 0 0 0 4 0 0 0 0 0 0 01.01 to 2.00 97 103 0 92 5 93 1 57 0 0 24 8 1 0 0 7 0 02.01 to 3.50 298 638 0 102 196 291 7 119 8 3 60 16 0 0 0 88 4 03.51 to 5.00 56 247 0 56 0 40 12 4 12 0 28 8 0 0 0 4 0 05.01 to 7.50 50 231 12 38 0 30 8 24 0 0 22 0 0 0 0 4 0 07.51 and above 111 903 79 32 0 36 26 26 0 0 73 12 0 0 0 0 0 0Totals 616 2125 91 324 201 492 56 230 20 3 211 44 1 0 0 103 4 0Country Information For Regions/Regional Codes, D&GTW Annual Market SurveysWestern EuropeAndorraAustriaBelgiumDenmarkFinlandFranceGermanyGreeceIcelandLiechtensteinLuxembourgItalyIrelandMaltaNetherlandsNorwayPortugalSan MarinoSloveniaSpainSwedenSwitzerlandUnited KingdomEastern Europe,Russia & CISAlbaniaArmeniaAzerbaijanBelarusBosnia andHerzegovinaBulgariaCroatiaCzech RepublicEstoniaGeorgiaHungaryKazakhstanKyrgyzstanLatviaLithuaniaMoldovaPolandRepublic of MacedoniaRomaniaRussiaSerbiaSlovac RepublicTajikistanTurkmenistanUkraineUzbekistanMiddle EastBahrainCyprusEgyptIranIraqIsraelJordanKuwaitLebanonOmanQatarSaudi Arabiacontinuedon page 28WW164.indd 2 7/17/15 5:19 PMDiesel & Gas Turbine Worldwide28July-Au