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Continuing its commitment to invest in its mature gas turbine fleets to keep them competitive in today’s dynamic energy marketplace, GE has announced the launch order for its new GT26 HE (high efficiency) gas turbine upgrade with Uniper for the utility’s Enfield Power Station in greater London.

The GT26 HE upgrade also marks other GE firsts:

• First upgrade that takes the best technologies and capabilities from GE’s industry-leading F and H class fleets to create a robust solution for GT26 power plant operators.
• First upgrade that blends both GE and Alstom’s technology and expertise across all major components of a gas turbine solution.

Key performance benefits include:

• Higher efficiency for combined-cycle power plants:
– 2+ percent base load increased efficiency, translating to as much as $4 million in fuel savings annually per unit.
– Up to 1 percent increased efficiency in part load, yielding up to $1 million in fuel savings a year per unit.
• Increased plant output from 15 megawatts (MW) up to 55 MWs per unit, improving revenue opportunities.
• Extended inspection intervals up to 32,000 hours, reducing long-term maintenance costs.

Helping revitalize Uniper’s Enfield power station

Uniper’s Enfield power plant in London will be the first site to install the new GT26 HE technology in 2020 with several significant benefits that GE expects to exceed. These benefits will include increased megawatt output, improved plant and gas turbine efficiency, and extended maintenance intervals and operating hours to enable Enfield to consistently elevate its position on the dispatch curve in the highly competitive U.K. power market and ramp up its annual operating hours.

H-Class technology infusion drives high-efficiency performance

The GT26 HE upgrade provides a leap forward in efficiency, output and maintenance interval extensions. It’s powered partly through advanced technology from GE’s flagship HA gas turbine, the largest and most efficient in the industry, with additive manufactured parts and innovations in aerodynamics, material science and combustion dynamics. It embeds technology breakthroughs across every major component of the GT26 frame—turbine, compressor and combustor—to take turbine performance to a new level, significantly decreasing fuel costs while increasing full-load output and extending maintenance intervals.

The new upgrade also features the best of GE’s research and development centers in both the United States and Switzerland, including unique engineering elements:

• A low-pressure turbine used in GE’s H-class technology.
• High-pressure turbine improvements to increase efficiency, utilizing GE’s F-class technology.
• Advanced combustor engineering incorporating additive manufactured parts to deliver high performance, reduce cooling requirements by approximately 15 percent and lower relative emissions.
• A new 3D aero-profile compressor configuration to provide best-in-class base-load and part-load performance.

Source: GE

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GE’s Power Services business announced the completion of an aeroderivative gas turbine exchange at COMETA’s Talosa plant in Soria, Spain. COMETA, owned by Grupo LOSAN, is a major European producer of wood-based panels and faced the need to modernize its natural gas-fired plant to keep its industrial processes competitive globally.

“At our Talosa facility, we power our industrial process and sell the extra electricity produced by the turbine. Also, the exhaust gas is used to supply heat to the wood and chipboard factory and to a heat recovery steam generator that produces steam—delivering an additional 3,000 kilowatt-hours,” said José Luis Lázaro, deputy general manager, Losán Group, COMETA. “We needed an upgrade that provided us with more flexibility to balance the intermittent nature of the power grid. GE’s engine exchange with a new turbine was the best and most cost-effective solution for greater flexibility, reliability and performance to support our many industrial processes. Furthermore, the financing and leasing options included in GE’s exchange program met our requirements without impacting our own financing capacity.”

For the project, COMETA decided on a new GE LM2500 Base SAC aeroderivative gas turbine rather than a second overhaul of its existing engine, which had already reached 100,000 running hours. GE’s solution of a new engine rather than an overhaul for a third life cycle reduces the shutdown period and offsets the cost of a replacement engine. The new engine will result in an output increase of at least 2 percent, a heat rate improvement of at least 3 percent and increased electrical efficiency by at least 1 percent. The deal includes a multiyear service agreement through the end of 2023.

“This project marks our continuous commitment in supporting customers with holistic service solutions, whether it be maintenance, repair, overhaul or engine exchange,” said Martin O’Neill, general manager of Aeroderivative Gas Turbines and Gas Turbine Cross-Fleet solutions for GE’s Power Services business. “GE’s engine exchange program is vital for companies like Grupo LOSAN with aging fleets that have the need to increase efficiency and output. This program is crucial—especially in Europe where flexible power and reliability are needed to ensure continuous industrial operations and balance the intermittency of the grid.”

GE’s aeroderivative engine exchange program is specifically made for customers that seek to reduce overall life cycle costs and provide a lower-cost method for maintaining unit availability. Customers can improve site availability by leasing equipment from GE when their own equipment is at a depot for repair or when their equipment is being repaired on-site.

GE can exchange existing engines with a new engine, a refurbished engine or a partial-life engine on-site, which would require only a two-to-three-day outage. As the original equipment manufacturer, GE not only has the largest engine exchange pool available, but also has a steady supply of new engines that provide the latest and greatest technology improvements. Additionally, GE can offer fully refurbished engines as a lower-cost alternative.

Source: GE

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Siemens received an award from the American Society of Mechanical Engineers (ASME) for its outstanding technological achievement with the first successfully 3D- printed and fully tested gas turbine blades.

The Mechanical Engineering magazine Emerging Technology Awards is the first in the 137-year history of the Society that Mechanical Engineering magazine has singled out such future-focused technologies for recognition. The goal is to recognize some outstanding examples of what ASME calls ascending technologies: new products and processes that have left the breakthrough stage, crossed the so- called commercialization valley of death, and are poised to reshape the industries where they compete. After exclusive vetting, ASME editors selected the technologies from each of five focus areas: advanced manufacturing, automation and robotics, bioengineering, clean energy, and pressure technology.

“The 3D-printed turbine blade places Siemens at the forefront of a technology trend that is spurring a global revolution in product design and production,” said Charla K. Wise, president of The American Society of Mechanical Engineers, ASME. “Mechanical Engineering magazine is pleased to present one of the five Emerging Technology Awards to a leader in manufacturing, and we thank the design team on the 3D-printed blade for advancing technology excellence.”

Earlier this year, Siemens has achieved a breakthrough by finishing its first full-load engine tests for gas turbine blades completely produced using Additive Manufacturing (AM) technology. The company successfully validated multiple 3D- printed turbine blades with a conventional blade design at full engine conditions.

This means the components were tested at 13,000 revolutions per minute and temperatures beyond 1,250 degrees Celsius. Furthermore, Siemens tested a new blade design with a completely revised and improved internal cooling geometry manufactured using the AM technology.

“We are especially proud to be honored by such a recognized organization as ASME,” says Jenny Nilsson, who led the team that realized the blade project. “The project objective was to try out and map this radical new way of working. The outcome is another confirmation that we are on the right path toward further improvements of our gas turbine technology,” Jenny continues.

The project team worked with blades manufactured at the Siemens 3D printing facility in Finspong, Sweden and at Materials Solutions, the recently acquired company in Worcester, UK. Materials Solutions has more than 10 years’ experience in additively manufacturing high performance parts for turbomachinery. Materials Solutions is AS 9100 certified and an approved vendor for Additive Manufacturing for leading customers in the aerospace industry. Applying its aerospace experience, Materials Solutions also supplies tooling to leading automotive companies and high performance parts in titanium and nickel super alloys for auto sports.

Additive Manufacturing has the potential to become a key technology in the production of gas turbine components. Siemens has been investing in this innovative technology right from its inception, and is now driving the industrialization and commercialization of these processes. Besides the awarded turbine blades, Siemens is using the innovative technology to produce burner tips, burner nozzles and to repair burner heads. “Additive Manufacturing is one of our main pillars in our digitalization strategy. With our combined know-how in 3D printing, we will continue to drive the technological development and application in this field,” says Christoph Haberland, Advisory Key Expert Additive Manufacturing, and member of the blade team.

The ASME distinction is the third award for this project, following the International 3D Printing Industry Award and the companywide Werner von Siemens Award. In addition to a 16-page special section of the December 2017 issue of Mechanical Engineering magazine, ASME has also produced a five-video series celebrating the technologies. Some of these videos were debuted at ASME’s largest annual event, the International Mechanical Engineering Congress and Exposition, held in Tampa in November.

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Siemens is now offering its SGT-800 industrial gas turbine with a power output of 57 MW and an electrical efficiency of more than 40% in simple cycle application. In a combined cycle configuration the power output is 163 MW at a net efficiency of more than 58.5%. The SGT-800 is now available with power output from 47.5 MW to 57 MW thanks to this upgrade, which will be offered onto the market in addition to the current ratings.

The most powerful SGT-800 to date is aimed primarily at industrial power producers and oil and gas companies that have a particularly high energy demand.

 

The 57 MW upgrade follows the design philosophy of taking small evolutionary fine tuning steps, while staying close to the commercially proven and reliable design of the SGT-800 industrial gas turbine. Only improvements of gas turbine parts using Siemens existing and mature core engine technologies have been made. The improved performance of the 57 MW rating has also been achieved through improved gear box and outlet casing/diffuser efficiencies. A reduced footprint of the gas turbine package has been achieved thanks to a shorter design, as well as a higher degree of preassembly for shorter installation time at site.

To date, more than 325 SGT-800 turbines have been sold worldwide. The Asia Pacific region is an especially important market for the machine, with more than 100 units sold, 71 of them in Thailand alone. Over the last five years the SGT-800 has been the market-leading gas turbine for combined cycle applications in its power range. The installed SGT-800 fleet has currently reached more than five million operating hours. The turbine, which was originally known under the product name GTX100, began development in 1994 and was launched in 1997.

Source: Siemens

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On March 23, at exactly 11:19 in the morning, the combined output of California’s copious solar panels and wind farms briefly supplied 49.2 percent of the state’s power demand for the first time. The record was a good omen for America’s most populous state, which is striving to use renewables for half of its electricity consumption by 2030.

But this laudable goal comes with a few hurdles. Customers want their electricity always on, but the wind can weaken and, even in California, the sun hides behind a cloud. “It’s not always possible to meet the full demand with renewables in the mix,” says Selma Kivran, a general manager for aeroderivatives at GE Power Services. “You need something else to fill the gap.”

 

In the absence of grid-scale batteries to bridge supply gaps (batteries remain expensive and limited in use) natural-gas-burning turbines can quickly ramp up and pick up the slack when renewables drop off. But even the fastest machines take several minutes to reach full power, forcing operators to run them at minimum load to keep them ready, burn gas and put more wear on the machines. “This is inefficient combustion that needs extra fuel, costs money and generates unnecessary greenhouse emissions,” Kivran says. “It’s not the ideal, and not the only possible solution.”

That’s why Kivran and her colleagues at GE Energy Connections decided to bring peakers and batteries together and wrap them in a single, efficient package with sophisticated power management software. With this hybrid system, the gas turbine can be turned off, and the battery will respond instantly.

Southern California Edison (SCE) is deploying the solution — the first of its kind in the world — at two sites near Los Angeles. “The battery is quick and clean, and the gas turbine is giving you the power you need. It’s reliable power because it’s always there, and you also get the environmental benefits,” says Mirko Molinari, general manager for digital grid at Grid Solutions from GE Energy Connections.

Under the hood of GE’s California grid-scale hybrid, there’s the company’s LM6000 gas turbine — a nimble peaker with jet engine technology at its core that can reach 50 MW in just 5 minutes — and a 10 MW battery assembled from lithium-ion cells that lasts up to 30 minutes. When a wind farm output drops, the battery can kick in immediately and give the turbine the time to start up without cutting off from the grid.

GE engineers developed software that allows the utility to manage in the most optimal way how fast the battery discharges and how quickly the turbine needs to ramp up from full stop. “Anybody can put a battery next to a turbine,” Molinari says. “The magic is in integrating the controls.”

The California Independent System Operator (CAISO) already has software that is always listening to what’s happening on the grid. When it detects that the power line frequency is dropping, it will send a signal to the battery-turbine hybrid to get ready and also the utility’s central control room. It will keep the amount of power racing through the lines the same even after the renewable source drops off.

Besides fighting dips in renewables production, the solution could be also useful in fighting the dreaded California duck — the nickname for the duck-like curve that describes the sharp difference between power supply and demand after the sun sets and the state’s plentiful solar panels stop producing electricity. “This solution is scalable,” Kivran says. “We’ve optimized the energy storage to meet desired cost proforma, but given its design is modular, there is no reason why we could not go to 100 MW or more.”

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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

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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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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.

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