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combined cycle

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GE and EDF officially began operation of the first ever combined-cycle power plant equipped with GE’s HA turbine in Bouchain, France, launching a new era of power generation technology and digital integration. GE also announced that the company has been recognized by Guinness World Records for powering the world’s most efficient combined-cycle power plant based on an achieved efficiency rate of up to 62.22% at the Bouchain plant.

In addition to achieving unprecedented levels of efficiency, GE’s HA gas turbine delivers more flexibility than ever before, capable of reaching full power in less than 30 minutes. This helps pave the way for greater use of renewable energy by allowing partners to respond quickly to fluctuations in grid demand, integrate renewables onto the grid and adapt quickly to weather changes. These advances support the recent Paris COP21 agreement, where 195 countries pledged to reduce greenhouse gas emissions, placing more emphasis on cleaner electric power opportunities.

The Bouchain plant is also an important demonstration of GE’s Digital Power Plant capabilities, which have helped drive the record-breaking levels of efficiency by unlocking power that was previously inaccessible. Capabilities, including the digital control system, use real-time data to deliver better plant outcomes with stable and efficient operations, while providing valuable predictive insights for higher reliability and optimization.

With a generating capability of more than 605 MW, the Bouchain plant will generate the equivalent power needed to supply more than 680,000 homes. In addition, the HA compressor flows air at a rate that could pump up the Goodyear blimp in 10 seconds, and the tip of the last blade in the 9HA.01 moves at 1200 mph/1931 kph — 1.5 times the speed of sound.

 

Source: General Electric

Siemens has signed binding agreements for a substantial expansion of three existing thermal power plants with Ende Andina SAM of Bolivia. These contracts follow a Memorandum of Understanding (MoU) from November 2015 and were signed in the presence of Bolivia’s President, Evo Morales and Joe Kaeser, President and CEO of Siemens AG. Total power generation capacity of the combined cycle power plants Termoelectrica del Sur, Termoelectrica de Warnes and Termoelectrica Entre Rios, owned and operated by ENDE ANDINA, is set to increase by more than one Gigawatt (GW).

“Siemens is supporting Bolivia’s ongoing efforts to improve access to electric power of its growing population and developing economy,” said Willi Meixner, CEO of Siemens’ Division Power and Gas. “With these binding agreements for three combined cycle power plants we have taken another important step in this direction and help Bolivia to protect its energy sovereignty,” Meixner added.

The Siemens scope of supply comprises 14 SGT-800 gas turbines, 11 SST-400 steam turbines with condensers, 22 steam generators and the instrumentation and control system SPPA-T3000. TSK, a Spanish industrial group, will be responsible for civil works, balance of plant, delivery of high-voltage substations as well as for the mechanical and electrical erection of the projects.

Termoelectrica del Sur thermal power plant in the south of Bolivia near the border to Argentina will be equipped with additional four SGT-800 gas turbines, four steam turbines and eight steam generators.

The second plant, Termoelectrica de Warnes is located in the province Warnes in Bolivia’s Santa Cruz department. It will be expanded by four SGT-800 gas turbines, four SST-400 steam turbines and eight steam generators.

For the Termoelectrica Entre Rios power plant located in Cochabamba, 220 kilometers southeast of La Paz, Siemens will supply six SGT-800 gas turbines, three SST-400 steam turbines and six steam generators.

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The Siemens gas turbine factory in Berlin has shipped its 1,000th gas turbine manufactured at the plant. The SGT5-4000F gas turbine, which has a capacity of 300 MW, weighs 300 metric tons and is destined for the Umm Al Houl combined cycle power plant in Qatar. The total installed capacity of the 1,000 gas turbines produced in Berlin, amounting to nearly 220 GW, would be sufficient to theoretically supply approximately one billion people* with electricity. The total capacity of the 1,000 gas turbines is thus equivalent to the installed power generating capacity of Spain and Italy. More than 90 percent of the 1,000 gas turbines produced in Berlin have been exported.

“1,000 Siemens gas turbines from Berlin for customers in 65 countries around the world – we have good reason to be proud of this achievement,” said Willi Meixner, CEO of the Siemens Power and Gas Division. “This huge volume is only possible because Siemens supplies the global market and continuously drives the competitive further development of its products forward.” Ever since it shipped its first gas turbine in 1972, the Berlin gas turbine factory has been a reliable partner with extensive expertise and today continues to provide its customers with the right solutions for their needs.

The milestone machine is an SGT5-4000F gas turbine. The first one of its kind was shipped in 1996 and had a capacity of 240 MW. Over the past 20 years, Siemens has sold approximately 400 gas turbines of this type in 40 countries around the world. This turbine model now has a capacity of 300 MW.

The gas turbine is one of a total of six SGT5-4000F turbines for the Umm Al Houl combined csiemens_eventoycle power plant. Siemens is supplying ten SGen5-1200A generators and four SST-4000 steam turbines as additional key components for this plant with a total capacity of 2.5 GW. In addition to electricity, the integrated seawater desalinization plant produces up to 618 million liters of drinking water per day for the people of Qatar. Siemens has also signed a 25-year service agreement for the plant’s maintenance and servicing. The power plant is scheduled to go into operation in mid-2018.

“We are very pleased to be cooperating with Siemens for this important new power plant. With proven technology and Siemens as our trusted service partner, we are looking forward to the reliable operation of the power plant for many years to come,” said Jamal Al Khalaf, CEO of Umm Al Houl Power Q.S.C. “We are proud that the anniversary gas turbine is destined for our power plant in Qatar. This history of 1,000 gas turbines from Berlin is a sign of the reliability, quality, and continuous improvement inherent in Siemens technology. Congratulations! And we look forward to welcoming Siemens’ 1,000th gas turbine to Qatar.”

As it embarks on its journey to Qatar, the gas turbine will first be shipped from the factory to Berlin’s Westhafen port. From there, it will travel by barge to Rotterdam. Upon arriving at the seaport, the gas turbine will be loaded onto a heavy cargo vessel. It will pass through the Atlantic Ocean to the Mediterranean Sea via Gibraltar. The machine will then enter the Red Sea through the Suez Canal, round the Arabian Peninsula, and finally reach Qatar.

Primera turbina Siemens ETSA 1 Primera turbina Siemens ETSA 1

The Berlin turbine factory was founded in 1904. Initially producing steam turbines, the factory shipped its first gas turbine for power plants in 1972, which was delivered to Electricity Trust of South Australia. The first Siemens ETSA 1 gas turbine from Berlin had a capacity of 62.5 MW. It is still in standby operation today and has its original turbine and compressor blades. Since then, gas turbine technology has undergone rapid development. Gas turbines uniquely combine classic heavy machinery construction with ultramodern production technology, such as additive manufacturing, for example. Components – from extremely heavy to tiny – are assembled using the most advanced methods and with clockwork precision. It takes the engineers and technicians several months to produce one gas turbine. The result, in the case of H-class turbines, is a machine with a capacity in the 400 MW range. This power is sufficient to supply a city of 2.4 million people with electricity. The capacity of a single H-class gas turbine is equal to that of 1,300 Porsche 911 turbos or ten Airbus 380 aircraft.

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DF Services, by means of its companies DF Mompresa and Turbogeneradores del Perú, has signed a new contract for 33 million Euros together with Siemens for the construction of the final phase of the Santo Domingo combined cycle power station in Chilca (Peru).

Thanks to this project, the plant, owned by Termochilca SA, will increase its current power of 201.5 MW by a further 100 MW, by means of a heat recovery steam generator (HRSG) and a steam turbine.

The scope of the project will include civil works, procurement, electromechanical assembly and support for commissioning. Work will start in August and the estimated delivery period is 21 months.

With this new contract the Group has reinforced its position in the market in Peru, where DF has already delivered over 15 electricity generation projects through its subsidiary TGP, and has installed over 2.5 GW. We could highlight the Groups work at the three largest power plants in the country (Kallpa, Chilca and Ventanilla). DF is currently executing the Chilca Plus turnkey project in the country, a 110 MW combined cycle plant which is estimated to start working in the second half of 2016.

DF boasts a traditional presence in Peru, especially in the Oil & Gas business division. For this important business, our company has carried out various projects for Petroperú over the last decade. The company has also taken part in successive expansions at the LPG and oil plants for the Talara refinery, and at the Pluspetrol terminal in Pisco.

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The fleet of Siemens H-class high-efficiency gas turbines achieved more than 200,000 operating hours in January 2016. There are currently 19 turbines in the SGT-8000H series in commercial operation, and they are setting the standard for efficiency, reliability, and availability. Siemens has sold a total of 76 H-class gas turbines worldwide to date: This makes it the most successful gas turbine in this efficiency category on today’s world market.

Since introducing this turbine onto the market in 2010, Siemens has sold 39 of the turbines on the 50-Hertz (Hz) market worldwide. The largest single order to date for the SGT5-8000H turbine has come from Egypt, where a total of 24 H-class engines are being installed in the Beni Suef, Burullus, and New Capital power plant projects. Siemens has also sold 37 turbines worldwide on the 60-Hz market. The most recent order for two H-class turbines came from Mexico in January 2016 for the CFE Empalme II combined cycle plant. The SGT-8000H turbines are manufactured in Berlin, Germany, and Charlotte, U.S. and shipped from these locations to sites around the globe.

The first SGT5-8000H gas turbine entered commercial operation in 2011 in Irsching near Ingolstadt, Germany, with the next SGT6-8000H units for the 60-Hz market following in 2013 at the Cape Canaveral power plant in Florida, U.S. and the Dangjin 3 plant in South Korea. Siemens is investing its expertise acquired from 200,000 operating hours, or roughly 23 years of operation, in the continuous development of the H-class machines.

“The SGT-8000H achieves a very high degree of efficiency and is marked by short startup times and fast load-changing capabilities,” said Theo Maas, head of Large Gas Turbines and Generators in the Siemens Power and Gas Division. “The turbines have proven themselves extensively in daily power plant operation after more than 200,000 hours of operation: The reliability of the SGT-8000H fleet is over 99 percent, and availability is over 96 percent.”

Combined cycle power plants equipped with SGT-8000H gas turbines achieve an efficiency level of over 60 percent. The Lausward combined cycle plant at the Düsseldorf port has set three new world records at once: The power plant with the SGT5-8000H gas turbine as its key component achieved a net efficiency level of about 61.5 percent, with a maximum net electrical generating capacity of 603.8 megawatts (MW). The plant is also able to provide 300 MW(th) of heat for the city of Düsseldorf’s district heating network. The installation of an H-class gas turbine in this kind of combined heat and power plant (CHP) has proven to be one of the most efficient ways to convert fuel into usable energy. The high fuel efficiency of the plant plays an important role in meeting economic requirements and reducing the environmental impact.

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Designed to operate with five MAN 18V48/60 engines and a MAN MARC® steam turbine, the new power plant has a production capacity of up to 96 MW. It is the second plant in Africa to make use of MAN’s diesel combined cycle product package. The waste heat from the engines powers a steam turbine, which in turn generates 6.6 MW of electricity.

The power plant, which is located in Tobène in the region of Thiès, 90 km north of Dakar, will supply to the national grid that is operated by Senegal’s national electricity company, SENELEC. It will generate the equivalent of 15 percent of the country’s current electricity consumption. This electricity will be used to power businesses, shops, universities and houses, thus providing a whole host of new opportunities for growth within Senegal, which currently experiences recurring power outages.

“The new plant uses our diesel combined cycle product package, which offers outstanding performance and excellent environmental standards. Thanks to the second cycle using a MARC® steam turbine, fuel consumption is lowered by 6 percent and CO2 emissions are also reduced for any kWh produced,” says Mesut Yentur, CEO of MAN Diesel & Turbo France and Head of Power Plant Sales in the French-speaking regions of Western Africa.MAN-1

Thanks to its effective partnership with MATELEC, a Lebanese company specialising in electricity infrastructures, MAN has managed to get the plant commissioned in record time. “We are very happy with this project,” says Sami Soughayar, CEO of MATELEC. “Our collaboration with MAN Diesel & Turbo proved to be highly professional and a great success. With project teams being perfectly coordinated, it only took just over 15 months for the power plant to be able to deliver its first MW to the Senegalese national grid.”

With the existing plant having now been taken over by MAN PrimeServ, MAN Diesel & Turbo’s service brand, to ensure best-in-class maintenance is provided, an expansion is already planned.

By adding a diesel engine, the plant’s generation capacity will be increased from 96 MW to 115 MW by the end of the second working phase.

MAN Diesel & Turbo is witnessing a rise in its activities in Africa. Having had a presence in South Africa since 2008 and in Dakar since 2010, the company opened a new Sales & Service office in Lagos, Nigeria in 2015 and is currently building plants in Gambia, Eritrea, Niger and Burkina Faso. These successes are based on more than 50 years of doing business in Africa. During that time, over 3.2 GW of generation capacity have been installed in 37 African countries.

 

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Combined-cycle plants are arguably the least well-known electrical plants, but in Spain they account for 25% of the country’s installed capacity. There are ten units based on this technology, manufactured by Siemens: two in Campo de Gibraltar (Cádiz), three in Palos de la Frontera (Huelva), two in Arrúbal (La Rioja) and three more in Sagunto (Valencia). Today, these plants continue to work as the most useful safeguard to guarantee Europe’s energy generation system, counted among the least contaminant fossil fuel combustion plants in the world. Their thermodynamic efficiency, in other words, the percentage of energy that can be obtained from the fuel, is around 60% (much higher than that generated by a coal-fired plant).

The key lies in its operation. This technology generates electricity from the rotation of a turbine propelled by the combustion of natural gas. Apart from the electrical energy generated by the gas turbine itself, the resultant heat from this combustion is used to heat water, converting it into steam
to be used in a second turbine that also produces electricity. Moreover, the application of Siemens technology improves these ratios, by reducing CO2 emissions by one third. Siemens’ SGT5-8000H gas turbine has broken a world record by exceeding 60.75% efficiency at the Irsching plant in Germany.

Despite the advantages of combined-cycle plants, they only covered 8.5% of electricity demand in 2015, at the same time as playing a leading role in complementing renewable energy sources; as clean and they are unpredictable as they only produce where there is sun and wind. As such, combined-cycle plants, that were originally designed to mainly operate at full load, are able to handle difficult market conditions: fewer operating hours, a reduction in megawatts generated, a higher number of start-ups and greater market control as regards gas reserves. And they are achieving this in a scenario in which energy demand is once again on the up, at the same time as the ageing of the plants is becoming more pronounced. Read more…

Laurent Dendrael
Head of Service for Combined Cycle Power Plants, Siemens Spain

Article published in: FuturENERGY January-February 2016

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An opening ceremony on January 19, 2016, saw a new gas-fired combined heat and power plant being put into operation at SAIC VOLKSWAGEN AUTOMOTIVE COMPANY LIMITED— a joint venture between Chinese SAIC and German Volkswagen Group. The plant contains four sets of MGT 6200, the latest range of gas turbines by MAN Diesel & Turbo.

Attending the ceremony were Prof. Jochen Heizmann, President and CEO of Volkswagen Group China, and Dr. Uwe Lauber, CEO of MAN Diesel & Turbo.

“The inauguration of this combined heat and power system is a landmark for our car production in China. The new plant not only provides steam and electricity for our Car Plant 3 here at SAIC Volkswagen, it also means we no longer use coal boilers so CO2 emissions will be reduced by 59,000 tons each year,” explained Prof. Heizmann during the ceremony.

The plant also marks the premiere of MAN Diesel & Turbo’s latest gas turbine series in China, with the order dating back to December 2014. Each of the four turbine sets delivers electrical power by driving a generator. Additional use of the waste heat for producing process steam increases the plant’s overall efficiency to more than 80 percent. The steam is used at the production works of the Volkswagen Joint Venture in China.Antin-Plant-Turbine-House-01_prev-baja

“We are elated to be involved in this project,” said Dr. Lauber after the ceremony. “Today, we have inaugurated a gas-fired power plant that covers almost 25 percent of the energy needs of one of the biggest car production sites in the country, which is low in greenhouse gas emissions and utilises more than 80 percent of the invested fuel energy. MAN and the Chinese industry look back at a decades-long tradition of partnership in many technological fields. Now that the Chinese government has set ambitious goals to reduce the country’s carbon footprint, our gas turbines and engine technology can help to reach these goals and reduce CO2 emissions.”

With awareness of air pollution in China increasing, the government is pursuing an active program to lower emission levels and increase energy efficiency. The new CHP plant fulfills this objective by producing electricity to cover 100 percent of the annual demand in Car Plant 3 and the neighbouring gearbox plant in Anting, thereby reducing CO2 emissions by approximately 23 percent.

According to the National Energy Administration, the gas supply in China is expected to reach 400 billion cubic metres in 2020, and natural gas will increase to represent 10 percent of primary energy consumption. Natural gas as a clean, efficient energy source is receiving increasing attention from the government and will gradually become one of the backbones of China’s energy supply.

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On January 22, 2016, Siemens handed over the combined cycle power plant equipped with a Siemens H-class gas turbine at the Lausward location in the Düsseldorf (Germany) harbor area to the customer and operator, the utility company Stadtwerke Düsseldorf AG. The turnkey plant sets three new records in world-wide comparison. During the test run before acceptance, unit “Fortuna” achieved a maximum electrical net output of 603.8 megawatts (MW), which is a new record for a combined cycle plant of this type in a single-shaft configuration. A new world record of around 61.5 percent for net power-generating efficiency was also achieved, enabling Siemens to beat its own efficiency record of 60.75 percent set in May 2011 at the Ulrich Hartmann power plant located in Irsching in the south of Germany.

The high efficiency level makes the power plant especially environmentally friendly. In addition, unit “Fortuna” can also deliver up to around 300 MW for the district heating system of Düsseldorf – a further international peak value for a power plant equipped with only one gas and steam turbine. This boosts the plant’s fuel utilization up to 85 percent, while reducing CO2 emissions to a mere 230 gram per kilowatt-hour. The increase in the capacity and efficiency levels is the result of consistent ongoing developments, for example in the design of components, in the materials used, in the overall construction of the plant, and in the perfect interworking of all plant components. “We optimized the power plant to enable it to be ideally positioned in one of the world’s most demanding power markets. Together with the Stadtwerke Düsseldorf we are therefore very pleased that this plant set the new efficiency world record,” stated Willi Meixner, CEO of the Power and Gas Division within Siemens AG.

The gas turbine can run at full load in less than 25 minutes after a hot start, enabling it to also be used as a backup for renewables-based power production. This flexibility supports the operator in efforts to achieve economical operations in a challenging environment for conventional power plants.

Unit “Fortuna” was handed over to the customer 19 days ahead of the date set in the contract. The project on the bank of the Rhine was additionally a huge success with regard to occupational safety for everyone involved. More than two million hours of work in total were performed without a single accident. Because of the plant’s close proximity to the downtown area of the city, special importance was attached to minimum emissions, optical integration into the cityscape, and lowest achievable noise levels: On the opposite shore of the Rhine, across from the plant, the noise level is less than 25 decibels – quieter than a whisper.

To date Siemens has 76 H-class gas turbines under contract worldwide. With 17 units in commercial operation, the SGT-8000H fleet has already reached more than 195,000 hours of operation.

What an efficiency level of 61.5 percent means for the climate

In terms of the average emissions of power generation for all coal-fired power plants throughout the European Union, a natural-gas-fired combined cycle power plant such as this one, with an electrical efficiency of 61.5 percent, theoretically saves approximately 2.5 million tons of carbon dioxide (CO2) annually. This corresponds to the amount of CO2 emitted by 1.25 million passenger cars, each driving 15,000 kilometers a year.

Siemens hat seit dem Frühjahr 2015 Aufträge über insgesamt sechs SGT6-8000H-Gasturbinen aus Mexiko erhalten. Since the spring of 2015, Siemens has received orders for six model SGT6-8000H gas turbines from Mexico.

Siemens has received an order to supply two SGT6-8000H gas turbines and two SGen6-2000H generators for the Empalme II combined cycle power plant in Sonora, Mexico. The plant will have an installed electrical capacity of 791 megawatts (MW). The customer is a consortium consisting of the Spanish engineering and construction companies Duro Felguera and Elecnor and the Mexican subsidiary Elecnor Mexico. The operator of the plant will be the state-owned power provider Comisión Federal de Electricidad (CFE). Commercial operation is scheduled for April 2018. Additionally, Siemens will provide technical assistance during construction and commissioning of the plant. Since the spring of 2015, Siemens has received orders for six H-class gas turbines from Mexico.

“CFE is becoming a pioneer in the integration of environmentally-compatible and resource-saving power generation solutions in Latin America. With these steps, Mexico will become an energy hub in the region and a reference for other similar projects”, declared José Aparicio, Vice President of the Siemens Power and Gas Division for Latin America.

A total of six model SGT6-8000H gas turbines are to be installed in the Empalme I (770 MW), Empalme II (791 MW) and Valle de México II (615 MW) combined cycle power plants. Siemens is also supplying two SGT6-5000F gas turbines for the Tula plant located in Hidalgo, Mexico. These four power plants have a combined electrical capacity of 2,727 MW, enough to supply one million households in Mexico with electricity. Siemens has sold 76 H-class gas turbines worldwide to date. The SGT-8000H fleet, with 16 units currently in successful commercial operation, has already achieved more than 195,000 fired hours.

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