POWERgeneration

2015 Power Plants Of The World

Take a global tour of new power facilities

Alstom Banyan Combined-Cycle Cogeneration

Plant, Jurong Island, SingaporeCogeneration with sequential com-

bustion technology is at the heart of Sembcorp’s cogen facility located in Banyan area of Singapore’s Jurong Is-land. The 400 MW gas-fired combined-cycle cogeneration facility, built by Alstom for Sembcorp Industries, can supply around 200 T/hr of process steam to manufacturing industries in the area in addition to electricity. Sembcorp re-ports that fuel efficiency at the plant is up to 60%.

The GT26/KA26-based combined-cycle power plant (CCPP) operates at or above 60% all-around base-load efficiency with high efficiency maintained over the entire load range. The ecoHEAT solution maxi-mizes efficiency in both power generation and combined heat and power (CHP) gen-eration. Fuel is burned in two dry combus-

tion stages, producing NOx em levels that are 40% lower than th conventional systems, the compan

Along with the GT26 turbine, t stallation includes: an Alstom he covery steam generator of the hotal, triple-pressure reheat, drum type; a compact Alstom STF15C steam turbine with axial exhaust; a high-efficiency Al-stom TOPGAS hydrogen-cooled turbo-generator; a direct seawater cooling system; and an Alstom ALSPA Series 6 integrated control system.

These components are arranged in a single-shaft configuration, which saves capital cost. The gas turbine and gen-erator are coupled to the steam tur-bine through a self-synchronizing and shifting (SSS) clutch. This arrangement ensures lower maintenance expendi-ture associated with one less generator, transformer and high-voltage bay.

Because the plant was supplied in 11

modules, the need for on-site work was minimized and disruptions from weather and other site-related risks were reduced, helping to ensure timely completion.

The Banyan plant commenced com-mercial operations in October 2014.

Alstom is both an engineering, pro-curement and construction (EPC) con-tractor and an original equipment man-ufacturer (OEM), and was able to provide fully integrated turnkey solutions for the project, including initial design, con-struction, commissioning, operations and long-term maintenance.

www.alstom.com

Editor’s Note: Each year Diesel & Gas Turbine Worldwide invites prime-mover manufacturers to submit one specific power generation proj-ect they feel merits special attention due to advances in one or more of the following: efficiency increase, environmental aesthetics, op-erational characteristics, emissions improvements and construction principles. The coverage is limited to plants commissioned during the 2014 calendar year.

This long standing tradition has become a popular feature and this year’s edition once again highlights several noteworthy projects around the globe. Enjoy.

Alstom completed this 400 MW

combined-cycle cogeneration

plant, which began operating in

October 2014.

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POWERgeneration

Ansaldo EnergiaKocaeli-Gezbe Power Plant,

Istanbul, TurkeyAnsaldo Energia is responsible for the

construction and maintenance of an 825 MW combined-cycle power plant in Kocaeli-Gezbe, an industrial district in Istanbul. The natural gas-fired plant was designed to work on a cyclic and even daily basis, and satisfies the requirements stipulated by the Turkish electricity grid.

The plant consists of two AE94.3A F-class gas turbines with associated TRY-L56 electric generators, and an RT-30 steam turbine with a TRX-L56 generator, all manufactured by Ansaldo Energia. The other main components were pro-cured from third parties: two heat recov-ery steam generators, an air condenser, three step-up transformers, an electric substation, a gas-reduction station and auxiliary systems.

Ansaldo Energia was in charge not only of the construction of the main rotating machinery, but also of the design work, the purchase of plant components, trans-port, civil works and electromechanical erection, commissioning and testing. The civil works and erection activities were contracted out to local companies, which also were asked to supply components produced on the Turkish market.

Ansaldo Energia also helped finance the project, investing about €86 million for a 40% stake in the project company Yeni Elektrik Uretim AS on a joint basis with majority shareholder Unit Invest-ment N.V., an accredited operator on the Turkish electricity market.

Plant construction was completed on schedule and the main milestones included grid synchronization and the

synchronization of the second turbine. The steam turbine was synchronized a month later and the plant entered commercial service after receiving pro-visional acceptance from the Turkish Energy Ministry.

The plant satisfied the requirements of the Turkish grid code. According to the code, every gas turbine must be able to deliver a 15 MW increase in power in one minute in response to primary demand (i.e., to support the grid in the event of unbalanced power conditions). In the case of secondary demand, a ser-vice sold by the plant operator to the grid operator, the plant showed that it had the capacity to supply 260 MW in five minutes.

www.ansaldoenergia.it

Caterpillar Energy Solutions GmbH

Crossness and Beckton Sewage Treatment Works, London

In order to meet the requirements of the growing population in greater Lon-don and to improve the water quality of the River Thames, the Thames Water utility expanded the wastewater treat-ment plants Crossness and Beckton in Newham and Greenwich in a major ex-pansion project involving an investment of some £410 million.

The operator commissioned the Edina Group, the official dealer of MWM en-gines in the U.K. and Ireland, for the energy conversion of the naturally oc-curring wastewater treatment gas by means of combined heat and power plants. Edina installed MWM TCG 2020 V20 series gen-sets with an output of 2 MW each for the on-site combined

heat and power (CHP) plants. Corre-sponding to the project requirements, the gen-sets are equipped with medi-um-voltage alternators. This allows the output to be fed directly into the respec-tive plant grid, with 11 kV at Crossness and 6.6 kV at Beckton.

A total of six containerized cogenera-tion systems were installed for the ex-pansions of both wastewater treatment plants. With a total site output of 12 MW, they could theoretically supply up to 24 000 households with renewable elec-tricity. The power generated by the con-version of sewage gas, however, is used to cover the site demand of both waste-water treatment plants resulting in high savings of the plant electricity cost.

The heat created as a byproduct of the combustion is applied to the fermen-tation process of the sewage sludge. In the CHP container module, roughly 170 m³/hr of water is heated to 80°C and made available for further plant processing, by using the engine coolant and exhaust heat of the gen-sets.

As result, the cogeneration systems op-erate at a continuous overall efficiency in excess of 85%, having an electrical effi-ciency of nearly 43%, the company said.

Moreover, the container gen-sets are designed for low noise emissions, rated under 65 dB(A) in a 10 m radius from the units.

All engines and peripheral devices were built into containers and tested by Edina, allowing for a smooth “plug-and-play” installation of the CHP plant on-site in Newham and Greenwich with adherence to British and European stan-dards and requirements.

The Crossness plant treats the waste-

The 825 MW Kocaeli-Gazbe power plant was constructed in

two-and-a-half years under the direction of Ansaldo Energia.

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water of up to 2 million inhabitants. Ac-cording to the company, the Beckton fa-cility was already one of Europe’s largest wastewater treatment plants, and after the expansion, it will handle the waste-water of nearly 4 million people, com-pared to the previous 3.5 million.

www.mwm.net

Dresser-RandQualtia Alimentos Food Processing

Plant, Tepotzotlán, MexicoQualtia Alimentos selected Dresser-

Rand to develop a 5.5 MW cogeneration project at its food processing plant in Tepotzotlán, Mexico. The main objective was to generate reliable power using steam and hot water and to reduce the cost of making meat products, which re-quires intensive energy consumption of both electricity and heat.

Dresser-Rand carried out the entire proj-ect, including engineering, equipment supply, civil works, electromechanical in-stallation and plant commissioning.

The plant required six Guascor SFGM560 natural gas generator sets and auxiliary systems, including two heat-recovery steam boilers for the use of hot water, and a control system for the cogenera-tion plant and engines.

Plant engineering was managed us-ing a multidisciplinary team of Dresser-Rand employees and other external col-laborators, who designed, procured and implemented the project within the six-month timeframe requested by Qualtia.

The result was a cogeneration plant with a total power capacity of 5520 kW, a site altitude of 2280 m, steam heat-recovery generation capacity of 5348 kg/hr and a thermal power recovery (in the form of hot water) of 3144 kW.

The lift system and interconnecting power plant were developed using equipment manufactured in Mexico ac-cording to appropriate project engineer-ing standards and installed with a total capacity of 7725 kVA.

Equipped with control architecture for both Dresser-Rand engines to other peripherals via a distributed system consisting of multiple control panels, the cogeneration plant also allows for optimal monitoring of plant variables through SCADA system acquisition and data processing.

Qualtia Alimentos, a subsidiary of the Xignus group, took advantage of recent legislation that allows businesses to develop generation plants that use co-generation and other renewable energy sources to improve their energy costs. Qualtia Alimentos met its key objective to cut costs by 45%.

www. dresser-rand.com

GE Power & WaterEstre Ambiental landfill,

Guatapara City, Sao Paulo, BrazilThree of GE’s Jenbacher reciprocating

gas engines have been commissioned at Estre Ambiental’s landfill in Guatapara City, Sao Paulo, Brazil, representing the

first waste-to-energy project at an Es-tre landfill, one of the largest municipal solid waste operations in Latin America, GE said.

GE delivered three 1.4 MW Ecomag-ination-qualified J420 Jenbacher gas engines for an estimated total output of 4.2 MW, with the potential to be ex-panded to 10 MW in the next five years. According to the company, the current configuration may produce enough energy to support about 13 000 aver-age Brazilian homes. GE’s fuel-flexible gas engines are powered by landfill gas, which is created from solid waste decomposition and then recovered as a valuable renewable fuel.

GE’s Jenbacher landfill gas engines use the gas — consisting of methane, CO2

and nitrogen — created during the de-composition of organic substances in a landfill. Methane has a global warming factor 21 times greater than CO2, the most widely recognized greenhouse gas affecting climate change.

The new Estre Ambiental landfill project supports the initiatives of the Brazilian government to increase the production of electricity from re-newable sources and may reduce the country’s greenhouse gas emissions by between 36.1 and 38.9% from pro-jected amounts in 2020, the company said. It may reduce the equivalent of about 70 000 tonnes of CO2 emissions into the atmosphere.

www.gepower.com

Six Guascor natural gas gen-sets power the Qualti

Alimentos meat processing plant.

Methane from a Sao Paulo landfill fuels three Jenbacher

reciprocating engines to provide energy for thousands

of homes.

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GE Power & WaterSaudi Electric Company Power Plant 12, Riyadh, Saudi Arabia

Saudi Electricity Company (SEC) in late 2014 began commissioning its new Power Plant 12 (PP 12) outside Riyadh, Saudi Arabia, as part of the Kingdom’s broader plans to add 33 GW of power generation capacity by 2020 while pro-moting greater energy efficiency and fuel conservation.

The first four 7F.05 gas turbines that GE has deployed in the field successfully reached full commercial baseload opera-tion at PP 12 as “Block One” in 2014. The four remaining units (“Block Two”) began final commissioning in September 2014 and were expected to begin operating by early 2015. PP 12 is located adjacent to the PP 11 facility, about 100 km west of Riyadh.

By early 2015, all eight of PP 12’s units were scheduled to be operating in com-bined cycle mode to add nearly 2,000 MW — enough to power approximately 2 million homes — to support SEC in meeting its future electricity demands.

The 7F.05 gas turbine technology at the heart of PP12 offers highly ef-ficient baseload power and flexibility, helping PP 12 become the most effi-cient air-cooled, combined-cycle pow-er plant in Saudi Arabia, said the com-pany. This is particularly important for extreme climates like Saudi Arabia, where the ability to cycle up or down

to respond to dramatic daily changes in power demand while also maintain-ing high levels of fuel efficiency are critical capabilities.

The first four 7F.05 gas turbines began operating in simple cycle at full baseload on distillate fuel. However, the plant is ex-pected to shift to natural gas in combined-cycle mode in early-to-mid 2015.

GE 7F.05 turbine engines can oper-ate, can operate on natural gas, distil-late fuel or Arabian Super Light (ASL) crude. The company says it’s F-class gas turbines are the first to offer custom-ers the ability to operate on crude oil. Saudi Arabia has substantial quantities of ASL crude readily available. As SEC transitions the plant to gas from distil-late, ASL will serve as a backup fuel.

In addition to offering significant fuel savings and lower emissions to meet today’s needs, SEC’s PP12 plant will sup-port the Kingdom’s plan to expand the role of renewable energy technologies in the future.

www.gepower.com

Hyundai Heavy IndustriesMiraflores Power Plant Expansion,

Panama Canal, PanamaThe Engine and Machinery Division of

Hyundai Heavy Industries Co. Ltd. (HHI-EMD) successfully constructed and completed the 70 MW Miraflores Power Plant expansion. The electric power produced from the plant is used to

operate the waterways in the Panama Canal, with surplus energy sold to the national grid.

HHI-EMD received the turnkey con-tract for expanding the Miraflores Power Plant by Autoridad del Canal de Panama (ACP), a state-owned enterprise that manages the Panama Canal. HHI-EMD supplied two sets of Hyundai-MAN B&W 12K80MC-S two-stroke, low-speed en-gines operated by heavy fuel oil (HFO) as the prime movers. It also provided engineering, procurement and con-struction (EPC) solutions to complete the plant, along with technical support for operation and maintenance.

www.hyundai-engine.com

MAN Diesel & Turbo220 MW Power Plant,

Bellefontaine, MartiniqueLeading a consortium on the Caribbe-

an island of Martinique, MAN Diesel & Turbo completed the second of a total of three power plants the company is building for the French energy supplier Électricité de France (EDF). MAN Diesel & Turbo has been responsible for en-gineering, procurement and construc-tion (EPC) as well as for commissioning of the engines.

The plant, located in Bellefontaine, in the west part of the island, has 12 type 18V48/60 engines with a capacity of 220 MW and covers around 60% of the island’s power needs. It replaces the

Power Plant 12’s eight GE 7F.05 turbines can operate on

natural gas, distillate fuel or ASL crude, producing nearly

2000 MW of electricity.

Hyundai Heavy Industries’ Miraflores Plant powers the waterways of the Panama Canal and contributes to the national power grid.

POWERgeneration

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former power plant, which is around 30 years old.

Particular attention was paid to the plant’s environmental compatibility and energy efficiency. Fuel consumption was reduced by 15% and nitrous oxide emissions by 85% compared to the pre-vious plant.

Water resources are also spared, since the power plant can cover its require-ments using desalinated seawater instead of ground water. Dry coolers also allow annual water savings of 700 000 m3. This is the equivalent of the annual consump-tion of around 10 000 households. The heat from the engines is also used to gen-erate the hot water required at the site.

With its 110 m chimney, which was custom-made for the plant, the new power plant is the island’s tallest build-ing and complies with particularly strin-gent safety standards. “Martinique lies in a danger zone for earthquakes and hurricanes,” said Dr. Hermann Kröger, senior vice president and project direc-tor for EDF at MAN Diesel & Turbo. “In its dimension and design the chimney has been constructed to sway at its high-est point by only one meter even in the event of magnitude-7 earthquake and a simultaneous hurricane.”

www.mandieselturbo.com

Rolls-Royce Power Systems – MTU Friedrichshafen

Unterweser CHP Plant, Northern Germany

An MTU modular combined heat and power (CHP) plant was installed at the

Unterweser nuclear power station to provide heat and electricity for the fa-cility. The station, located near Bremen in northern Germany and operated by E.ON Kernkraft GmbH, was taken off the German power grid as a result of the political decision to opt out of nuclear power.

The station first came on stream in September 1978 with a net output of 1345 MW but has been in “continuous zero output mode” since March 2011. It has not been decommissioned yet as the owner E.ON is legally contesting the withdrawal of its operating license, for which it received no compensation. Thus the plant still has quite a big powerrequirement, to operate things like pumps, fuel-rod cooling and the normal building infrastructure. In total, the pres-ent internal energy demand is around 3.5 MW of electrical power and — de-pending on the outside temperature — up to 4 MW of heat.

Since the beginning of 2014, a good proportion of that energy has been de-livered by a CHP module from MTU On-site Energy. Based on a Series 4000 gas engine and housed in a shipping con-tainer standing on a solid foundation in the outer part of the grounds, the mod-ule produces just under 2 MW of electri-cal power and 2.2 MW of heat, achieving an efficiency of roughly 86%, MTU said.

It is only in the coldest few weeks of the year that the CHP module cannot entirely cover demands. When that hap-pens, one of the two auxiliary boilers comes into action. In the past, the oil-

fired 12.7 MW-rated boilers were there to bridge the brief downtimes that oc-curred about once a year when the fuel rods were replaced. To further reduce costs and also lessen the impact on the environment, one of them is currently being converted from oil to gas and si-multaneously rerated to an output of 4 5 MW. That is possible because a gas sup-ply line was laid to the facility when the CHP module was being installed.

Another reason the auxiliary boilers are needed is because they produce steam, which is necessary for the water treat-ment of the nuclear power plant, that is to evaporate water that is contaminated because it has been use, for example, to cool the fuel rods.

MTU Onsite Energy had already been a supplier for the Unterweser plant, de-livering the emergency generator sets years before, which are still in working order. There are seven gen-sets spread across the site — four for the safety-related systems, two emergency back-up gen-sets (in case the emergency die-sels should fail) and one for nonsafety-related systems.

The CHP module will play a key role in supplying power to the nuclear plant for at least another 10 years. As soon as the decommissioning starts, more electri-cal power will again be needed simply because there will be more equipment in use. In the decommissioning of a nuclear power plant, everything has to be individually dismantled and, where necessary, decontaminated.

www.mtu-online.com

A 2 MW MTU combined heat and power plant helps

sustain the Unterweser nuclear power station while it

awaits decommissioning.

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Siemens EnergyH-Class Combined Cycle Power Plants,

Andong and Ansan, South KoreaSiemens Energy, together with its Ko-

rean partners GS E&C and POSCO Engi-neering & Construction Co. Ltd. (POSCO E&C), erected the Andong and Ansan combined-cycle power plants (CCPP) in Gyeonggi-do province, South Korea. Siemens said the plants, completed in just 24 months, feature electrical effi-ciencies of more than 60%.

Andong CCPP, a liquefied natural gas (LNG)-fired plant with an electrical ca-pacity of 417 MW, is owned and oper-ated by Korea Southern Power Co. Ltd. (KOSPO), a power supply utility in Korea and Asia. Designed for 250 starts per year, with a startup time of 30 minutes from standstill to full load, the Andong CCPP is flexible, able to react to rapid changes in the Korean power market.

The Ansan Combined Heat and Power Plant, also an LNG-fired plant, is owned and operated by S-Power, headquar-tered in Ansan. Siemens said the plant is the first H-class 2+1 multishaft pow-er plant in Korea and has an electrical capacity of 834 MW. In addition to gen-erating electricity, it will also provide district heating for the inhabitants of the city of Ansan. The combined heat and power production can raise the overall fuel utilization factor to over 75%, and NOx emissions are 7 ppm, the company said.

Siemens delivered the power island main equipment: two SGT6-8000H gas turbines, an SST6-5000 steam turbine, three hydrogen-cooled SGen6-2000H generators, as well as the entire instru-mentation and controls system, SPPA-

T3000. Siemens will also supply the long-term service for the gas turbines.

www.energy.siemens.com

WärtsiläKiisa Emergency Reserve Power

Station, Tallinn, EstoniaAn emergency reserve power station has

been built and inaugurated near Kiisa in the outskirts of Tallinn, Estonia. The station is actually two plants consisting 27 Wärt-silä 34DF engines with a total capacity of 250 MW. The first 110 MW plant was com-pleted in 2013, and the second 140 MW plant came into operation in July 2014.

Wärtsilä has been responsible for the engineering, procurement and construc-tion (EPC) delivery of the plants and also for the project management. The owner of the plants is Elering, the Estonian transmission system operator. The total cost of the project was around €135 mil-lion and the investments in the develop-ment of the network and security of sup-ply were funded through network tariffs.

Elering’s Kiisa power plants will provide emergency power in case of sudden drops in the electricity supply, as in the case of a failure in the interconnections or in other power plants serving the grid. The plants’ capacity is sufficient to cover one-sixth of Estonia’s peak elec-tricity consumption in the winter, a sig-nificant improvement of the country’s energy security, Wärtsilä said.

An emergency-reserve power plant needs to be able to start up as rapidly as possible to avoid blackouts. The company said that its emergency re-serve power plants can be started and ramped to its full load of 250 MW in less than 10 minutes.

“The Wärtsilä 34DF engines will oper-ate mainly on natural gas but can switch to light fuel oil as a backup fuel,” said Vesa Riihimäki, vice president, Qual-ity, Wärtsilä. “A fuel efficiency of 45% is exceptionally high for an emergency plant, and this will result in more energy being produced from the same amount of fuel, and with less carbon emissions.”

Built for emergency use, the plants will typically operate for only about 200 hours per year. In standby mode, the en-ergy consumption of the plants is only 200 kW, which is achieved by using heat pump technology to keep the engines warm. Wärtsilä said that this is the first plant in the world with such a solution.

“This is an important EPC project for Wärtsilä in the European context. We are also proud of the fact that these are the first dynamic grid stability plants to have been primary tested to fulfill the new re-liability requirements by the European Network of Transmission System Op-erators (ENTSO-E),” Riihimäki said. “The ENTSO-E requirements include criteria for maintaining frequency stability in case of short circuits and other disturbances.”

For Elering’s emergency reserve pow-er plants in Kiisa, the requirements of ENTSO-E meant 24 different tests, for example, the fault ride-through (FRT) test, which required the plant to con-tinue to operate through a transient low grid voltage without disconnecting from the grid.

The two power plants are fully automatic and require no on-site personnel, Wärtsilä said. The contract with Elering includes a two-year maintenance agreement, with an extension option of 10 years.

www.wartsila.com

Aerial view of Wärtsilä’s 250 MW Elering emergency-

reserve power (ERP) plants in Kiisa, Estonia.

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