Operate, maintain and upgrade for sustained efficiency

Operating efficiency is of vital importance to on-site power and cogeneration plants and, once a plant is commissioned, it’s down to operational patterns, service and maintenance practices ” and component upgrades where necessary ” to maximize and sustain efficiency. This article rounds up some recent accounts in this area.

A major ‘flange-to-flange’ upgrade of a Frame 6B gas turbine at a cogeneration plant was completed by GE within an industrial recycling paper mill in El Burgo de Ebro (Zaragoza), Spain, in just seven weeks earlier this year, says the company. Replacing the key components of the gas turbine with new, advanced design parts has resulted in increased operating efficiency, a significant reduction in emissions and a considerable life extension for the plant.

The project marked the world’s first flange-to-flange replacement for a GE 6B gas turbine.

The paper mill is owned by corrugated cardboard box manufacturer, SA Industrias Celulosa Aragonesa (SAICA). The gas turbine upgrade will enable the SAICA plant to continue to receive the total feed-in tariff from the Spanish government ” according to the Spanish legislation, cogeneration plants under 50 MW no longer qualify for the total feed-in tariff after 15 years of operation, unless they adopt more efficient and environmentally responsible technologies as specified in the legislation.

The upgraded Frame 6B at the SAICA cogeneration plant delivers approximately 38 MW of power, which is sold to the national power grid, and produces steam for use in the paper production process. The project included the installation of GE’s dry low NOx combustion technology to reduce NOx emissions from around 150 ppm to less than 15 ppm, without steam injection.

‘This type of upgrade brings significant results in a much shorter time than replacing the old gas turbine with a new unit would require,’ said Corinne de Bilbao, general manager of GE Energy Services, Western Europe and North West Africa.

Meanwhile, GE announced in March that it is expanding its global presence with the opening of a new US$3 million aeroderivative gas turbine service centre in Lincoln, UK, consolidating two sites in the UK to establish the company’s 17th aeroderivative gas turbine service centre and adding infrastructure and capabilities to support GE’s current and new onshore and offshore customers in the UK and Africa.

The Lincoln Service Centre allows maintenance of GE aeroderivative gas turbines operating in the region, as well as on-site, state-of-the-art training facilities for all LM engine types. Training courses can be customized to meet the specific needs of customers, adds the company.

‘GE is a local player with the experience of a large global company, and we are committed to providing solutions that drive customer success and productivity,’ said Ricardo Cordoba, president of GE Energy Western Europe, North Africa and Pakistan. ‘Europe and its customers are important to us ” this is the region where new technology is being tested, and we feel this region has potential to grow.’

More information at: www.ge.com

Wood Group GTS signed a five-year operation and maintenance (O&M) agreement in March with Australia’s largest gold producer, Newcrest Mining, under which Wood Group will provide mobilization and complete care, custody and control services for the primary and secondary power stations at Newcrest’s Telfer Gold Mine, located in the Pilbara district of Western Australia.

The primary plant is a 138 MW dual fuel (natural gas/diesel) fired electricity generation facility consisting of three GE LM6000 PC gas turbines. The secondary plant is a 13 MW single fuel (diesel) fired generation facility containing six reciprocating diesel engines.

‘The power facilities at Telfer Gold Mine are dedicated to supporting our operations and related activities at Telfer. Reliable, continuous power supply is critical to operations,’ said Glenn Ingram, Group Manager, Asset Management, of Newcrest.

Frank Avery from Wood Group GTS said, ‘This is a landmark contract for Wood Group GTS in Australia and we are delighted to be the first non-OEM power contractor appointed by Newcrest.’ More information at: www.woodgroupgts.com

In January this year, Alstom was awarded a contract, via its joint venture company NASL, worth €20 million from the National Aluminium Company (Nalco) of India to retrofit the electrostatic precipitators (ESPs) at five units of its captive power plant in Angul Orissa.

The ESPs at Angul were originally supplied by BHEL and commissioned between 1985 and 1989. The upgrade will reduce particulate emissions from the plant to well below the 150 mg/Nm3 requested by the Environment Pollution Control Board, allowing Nalco to conform to India’s environmental requirements.

The contract scope includes the design, supply and commissioning of the mechanical and electrical components of the ESPs, including the control system and the ash handling system. The contract will be executed through Nalco’s local services partner, NASL, a joint venture company of Alstom and National Thermal Power Corporation. The first unit is expected to be commissioned in 2012, with the fifth one being completed in 2014.

Meanwhile, Alstom signed in March the renewal of a long-term service agreement (LTSA) with Phu My Thermal Power, a subsidiary of Electricity of Vietnam (EVN). The agreement came into force at the beginning of April and covers the gas turbines, steam turbines and the generators installed in the Phu My 2.1 and Phu My 4 gas-fired power plants. Under this LTSA, Alstom will provide over a term of eight years, maintenance services and supply parts for the main equipment installed.

In the Phu My 2.1 and Phu My 4 gas-fired power plants, Alstom delivered four GT13E2 units. The first two units, in Phu My 2.1, entered commercial operation in December 1997 while the two units in Phu My 4 entered operation in August 2004. In 2003, Alstom signed a LTSA with Phu My Thermal Power Company for both Phu My 2.1 and Phu My 4 power plants. Phu My Thermal Power decided to renew this LTSA based on an excellent experience and cooperation between the parties, it was reported.

Through the LTSA, EVN’s Phu My power plant will benefit from the sustainable high efficiency of Alstom’s combined cycle technology which delivers lower carbon dioxide emissions, as well as feedback from the global experience of Alstom’s worldwide installed base.

More information at: www.power.alstom.com

Turbine Technology Services Corporation (TTS), a full-service gas turbine engineering services firm based in Orlando, Florida, US, announced the development of a Strategic Gas Turbine Parts Sourcing Service in March, enhancing its product offerings for power generation clients.

The company is already seen as a knowledgeable service provider in the power generation industry and this, says the company, has prompted it to offer its extensive knowledge of the aftermarket parts business to its international customers.

In recent years, gas turbine spare parts have been in high demand in the energy industry as power plants continue to age and their operators look for ways to extend the lifetime of their equipment.

‘TTS has been in the business of managing gas turbine retrofit and upgrade projects for over 25 years,’ said Rudy Taylor, parts support specialist at Turbine Technology Services Corporation. ‘Offering spare parts is a natural progression for us to offer this knowledge to our international customers and give them better options to meet their spare parts needs.’

Given its international scope, TTS is enhancing this strategic initiative with support in a wide number of languages to include Arabic, French, Spanish, Italian, and Portuguese ” reflecting the company’s ability to meet the demand for gas turbine parts and services across the globe. Under its spare parts initiative, the company plans to make its multilingual customer support team available to customers to provide a complete sourcing and procurement service for gas turbine packages from all the major OEMs.

Gas turbine operators requiring inventory spares or parts in support of any maintenance activity will now have access to on-base devices and equipment; pumps and valves; electrical, electronic and instrumentation; turbine and generator control systems; and capital and hot section spares ” all from one single provider. Through its network of suppliers, TTS is also capable of providing used or refurbished parts, OEM and non-OEM systems, consumables, application engineering and parts identification, as well as international shipping and logistics.

More information at: www.turbinetech.com/parts

Independent provider of repairs and services for industrial gas turbine and aeroderivative engines, Chromalloy, has opened a new office in Beijing, China, to better serve customers in the region.

The new office expands the company’s staff to a group of sales leaders with deep industry expertise in each key segment. During the past 18 months, Chromalloy has announced other growth and expansion in its worldwide manufacturing, service and sales network.

The company completed the expansion and doubled capacity recently at its turbine component repair and manufacturing centre in Bangkok, Thailand. And, last year, the company invested more than $27 million to expand its turbine engine component casting operation in Tampa, Florida, US ” at a new facility that now serves customers around the world.

To better serve customers in China, Chromalloy also launched its website in Chinese.

More information at: www.chromalloy.com

Finland’s Wärtsilä was awarded an operation and maintenance contract by the Al Badia Cement JSC for its captive power plant within the company’s cement factory grounds in the Abu Al Shamat area in Syria in November last year. The contract is valid for three years.

The power plant will be the sole source of electrical supply to this new cement works facility, and is currently in the process of being commissioned for operation. It is powered by five Wärtsilä 20V32 and one Wärtsilä 9L32 generating sets, and produces a total output of more than 45 MW. The plant is also fitted with exhaust gas-fired boilers for its auxiliary heating system.

Under the terms of the agreement, Wärtsilä will take responsibility for operating and maintaining the power plant so that it runs cost-effectively and with optimal efficiency. In this way the customer is able to focus entirely on the company’s core business of producing 1.4 million tonnes of cement annually in the first line.

More information at: www.wàƒ¤rtsilàƒ¤.com

In November last year, Veolia Energy North America celebrated the fifth anniversary of its acquisition of the Cambridge, Massachusetts steam distribution network, which serves 15 customers, including global leaders in biotechnology, pharma-ceuticals, and manufacturing, with 240,000 pounds per hour of steam production.

Since 2005, Veolia Energy has invested more than $10 million to enhance the Cambridge system, replacing old boilers, converting the heavy oil-fired operation into a natural gas-fired steam heating plant, and upgrading the distribution system, which is now monitored by a state-of-the-art control room.

Upgrades made to the Cambridge system by Veolia Energy include the replacement of two old boilers that burned heavy oil, devoid of add-on emission controls. Today, the system utilizes state-of-the-art boilers fired by natural gas as the primary fuel, and ultra low sulphur diesel as a secondary fuel. The plant also utilizes ultra low nitrogen oxide burners, and is equipped with superheaters and economizers to optimize fuel efficiency and minimize emissions.

Another environmental benefit is the utilization of cogenerated steam from Mirant’s Kendall Station, which would otherwise be forced to discharge waste heat to the environment. Over the past five years, cogenerated steam, clean fuels, combustion controls, and advanced burner technology have combined to deliver clean energy to customers in Cambridge and Boston.

More information at: www.veoliaenergyna.com

Finland’s Metso is supplying advanced combustion management systems for cutting emissions at the 225 MW Jaworzno III CHP plant in southern Poland. The project will be carried out in close cooperation with Fortum Power and Heat Oy, Power Solutions, a company responsible for modernizing six coal-fired boilers at the plant.

Metso’s delivery scope includes an advanced process control (APC) solution running on the metsoDNA CR automation and information platform. Based on a fuzzy logic controller, it will coordinate, supervise and optimize the combustion process efficiently in real time.

More information at: www.metso.com

A waste-to-district energy scheme on the Shetland Islands in Scotland, which serves the UK’s most northerly town of Lerwick, is now fit for future expansion following installation of a new distributed control system from Siemens.

The Lerwick DHS scheme pumps hot water around the clock to 1100 homes and other buildings in the Shetland Islands’ capital. The heat is supplied by the local energy recovery plant, which incinerates 22,000 tonnes of waste each year from Shetland, Orkney and the Highlands.

A distributed control system (DCS) manages the entire process, from regulating the ERP’s huge 1100à‚°C furnace, to ensuring that pressure and temperature levels are correct as the water is pumped around Lerwick.

After 12 years’ operation of the previous distributed control system, the Shetland teams was concerned that the system was fast becoming obsolete and would be unable to support ambitious plans for planned expansion. After a tender process, Shetland selected Digital Applications International (DAI) to build a control and reporting solution based on the Siemens SIMATIC PCS 7 platform, for which DAI is an approved integrator.

DAI and Siemens ensured that migration to the SIMATIC PCS 7 platform was smooth and on schedule. Thanks to the flexibility of the Siemens technology, the DAI project team built several features into their changeover strategy that kept risk of operational disruption to a minimum. More information at: www.siemens.co.uk

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