Gas turbine upgrade kit knocks the socks off NOX

GE Oil & Gas has announced that its DLN-1 IBH emissions technology, which enables Frame 5-2 gas turbines running at partial load to meet new NOX emission standards, has been self-certified as a GE Ecomagination service offering.

The DLN-1 IBH upgrade kit for the Frame 5-2 recently completed a rigorous environmental and operational evaluation to meet the requirements of Ecomagination, which is GE’s commitment to address the need for cleaner, more efficient sources of energy and reduced emissions.

“Developing technologies to help customers meet their environmental challenges is a central focus of our business,” said Jeff Nagel, vice-president Global Services for GE Oil & Gas.

“We foresee that within the next 3-5 years, emission regulations similar to those already in place in the USA and the EU will be applied in the Middle East and North Africa, where much of our Frame 5-2 fleet is installed. A GE DLN-1 IBH upgrade for Frame 5-2 gas turbines will allow operators to meet NOX emission standards of 42 ppm without purchasing a new turbine”.

The GE Oil & Gas DLN-1 IBH technology enables a Frame 5-2 gas turbine to operate at 50 per cent rather than 80 per cent partial load, saving about 12.3m kg of natural gas, or approximately the amount used by more than 8500 typical US households in a year.

Installed on a Frame 5-2 gas turbine running at 50 per cent load, the new technology also lowers emissions from 80 to 42 ppm, which translates to 570 tonnes per year on a turbine running full time – the equivalent of taking more than 30 000 US cars off the road each year.

GE’s Frame 5-2 gas turbines typically are used for mechanical drive applications in the oil and gas industry. These heavy-duty machines are designed for direct coupling with centrifugal compressors over a wide operating range, including variable loads and extreme environmental conditions.

GE’s DLN (Dry Low NOX) combustion system combines hardware solutions for fuel and air stream regulation with closed-loop monitoring and controls to fine tune emissions throughout the combustion process. Since its introduction in 1980, the technology has continued to evolve and has been proven in millions of hours of operation on a wide variety of gas turbines worldwide.

The DLN-1 IBH is the fifth GE Oil & Gas product to receive Ecomagination certification, joining the recently certified integrated motor compressor (ICL) designed to help compression plant operators meet their growing operational and environmental challenges.

Next-gen lube set to ease the pain of servo-valves

Shell lubricants companies have reformulated their Shell Turbo Oils CC range of turbine oils so that they now offer improved deposit resistance for increased turbine reliability and availability.

Shell Turbo Oils CC meet the severe demands imposed by modern heavy-duty turbine applications including combined-cycle, gas and steam turbines.

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The Shell Turbo Oils CC range will help tackle the longstanding problem of lacquer or varnish formation in servo-valves, which causes the valves to stick or seize. Formation of varnish on thrust or journal bearings can cause increased wear rates, while other problems caused by varnish in turbine oil systems include reduction of cooler performance, increased bulk oil temperatures, prematurely plugged filters and strainers, and plugging of small oil orifices.

William Stein, project leader – turbine oils at Westhollow Technology Centre for Shell Lubricants, said: “Our Shell Turbo Oils CC range was introduced in 1997-98 specifically for combined-cycle systems and has performed well.

“However, we felt that we could further improve our original formulation to help reduce lube oil varnishing in turbines and hence improve reliability in today’s demanding conditions.”

The next generation Shell Turbo Oil CC series combines the traditional strengths of the previous formulation, is fully compatible with the current formulation, and shows improvement in its long-term deposit resistance performance. Also, the new formulation has excellent RPVOT (Rotating Pressure Vessel Oxidation Test) retention and outstanding thermal and oxidative performance.

The new products also provide extra protection and improved component life in turbine applications through their rapid air release, high resistance to foaming and excellent water-shedding properties.

The Shell Turbo Oils CC range also boasts good load carrying capacity, making the products suitable for use in turbines with highly loaded gears.

The next generation Shell Turbo Oil CC series has been approved or meets and exceeds the requirements of many major OE manufacturers.

The Turbo family of products has proven experience in a broad range of turbine applications, including gas, steam, heavy industry and water turbines and is designed to deliver outstanding performance and value.

Stein concludes: “The problems attributable to lacquering can prove costly in terms of maintenance hours, unscheduled stoppages, component wear and failure.

“Next Generation Shell Turbo Oils CC’s, excellent ability to prevent varnishing will help operators to overcome this longstanding problem, thereby helping to extend component life, reduce running costs and improve the reliability of turbines.”

Offshore oil extractor gets into the Brotherhood habit

Fred Olsen Production ASA has chosen UK engineering company Peter Brotherhood Ltd to supply two condensing steam turbine driven generator sets for the Knock Allan floating production, storage and offloading (FPSO) vessel for the Olowi field off the coast of Gabon.

The turbines are the world’s most powerful to be installed on an FPSO vessel.

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Each of the two 27 MW sets consists of a turbine, gearbox and generator, all mounted on a common bedplate which incorporates the oil system. The turbines will accept steam from gas fired boilers on the vessel and will exhaust to a separate condenser, also supplied by Peter Brotherhood.

The generator sets have recently been tested on steam at Peter Brotherhood’s manufacturing facility and will be delivered to Dubai Drydocks for installation on the top deck of the Knock Allan FPSO vessel. Engineers from Peter Brotherhood will be employed to commission the machines on board the vessel.

The vessel is currently being converted from a trading tanker to an FPSO at Dubai Drydocks. Once operational, it will be able to store 1m barrels of oil and produce 22 000 barrels per day.

Fred Olsen Production said that it chose Peter Brotherhood because of the company’s extensive experience in manufacturing steam turbine driven generator sets for installation on FPSO vessels.

These sets have to incorporate features to enable them to operate reliably in a floating environment, where they can be affected by, for example, the pitch and roll of a ship.

Peter Brotherhood’s managing director, Stephen Fitzpatrick, said: “Winning this order has strengthened the company’s position as a world-class supplier of steam turbines for FPSO vessels worldwide. The combination of Peter Brotherhood technologies and FPSO experience provide an exclusive and superior solution for our customers.”

The company has been designing and manufacturing steam turbine driven generator sets for FPSOs since 1981, having installed turbines moored off the coast of West Africa, Indonesia, Thailand, Brazil and Australia and in the North Sea.

Latest Volvo Penta diesel engine hits top gear

Volvo Penta has launched the TAD1650VE diesel engine, the company’s latest and most powerful engine for off-road and stationary applications.

The Swedish company says that the engine combines impressive power and torque with exhaust emissions that comply with the world’s most stringent regulations: EPA/CARB Tier 3 and EU Stage 3.

The TAD1650VE is based on Volvo Penta’s successful state-of-the-art concept of the Volvo 9 and 12 litre engines. The design features Volvo Advanced Combustion Technology (V-ACT), which results in low exhaust emission levels.

With a swept volume of 16.1 litres, the TAD1650VE delivers tremendous power and impressive torque, while giving excellent fuel economy, high reliability and durability.

The Volvo electronic system (EMS2) has been further upgraded for this engine with increased processing power.

Together with improvements in air and fuel management this gives extremely fast response to throttle opening but with very low transient smoke, easily meeting the overall EPA/CARB Tier 3 and EU Stage 3 off-highway emission regulations.

As part of the V-ACT system, the engine is equipped with internal exhaust gas recirculation. An electro hydraulic control system regulates valve actuation to allow a small amount of exhaust gas to be fed back into the cylinder, thereby lowering peak temperatures and reducing the formation of NOX.

Fuel quality can sometimes prove to have harmful effects on certain designs of emissions certified engines. Despite being designed to meet EU and US emission standards, the TAD1650VE is manufactured with a worldwide specification and is designed to operate using all commercially available fuel qualities.

The engine is a direct-injected, four-stroke, turbocharged, charge-air-cooled diesel with mechanically actuated, electronically controlled unit injectors. It has a rear timing gear train, giving it a shorter length and improved noise characteristics.

The TAD1650VE produces 400 kW at 1800 rpm with a virtually flat torque curve of 2500 Nm over the speed band 950-1500 rpm and peaking at 2550 Nm at 1400 rpm.

Yorpower celebrates first anniversary of Kenya operation

Yorkshire-based generator supplier Yorpower Manufacturing Limited is celebrating the first anniversary of its operation in Kenya.

The UK company took the decision to set-up an operation in Nairobi owing to the increasing demand for generators in East Africa. The facility has now been operating for a year and is fully staffed with sales, operations and engineering staff. There is also a large stock of generators and spare parts available at the facility.

Local manager Tim Wanjau said: “We are delighted to be celebrating our first year of operation. The availability of stock locally has proved crucial in the success of the operation.

“Customers are less willing to wait for generators to be dispatched from the United Kingdom, preferring immediate availability. The location of the facility, adjacent to the international airport, has also proved to be very popular for its ease of access.”

A spokesman for Yorpower’s sister company Techknol Power said that its Nairobi facility was operating very much as usual despite the recent hostilities in the African nation following a disputed general election result.

He said: “All of our local staff and their families have been unaffected by the recent political difficulties, and generator sales have continued as usual. We would like to thank our customers for their continued support during this difficult time.”

Meanwhile, Yorpower has announced an order for its 2 MVA generator sets. Two MTU-based generators are to be supplied by Yorpower to a data centre in London, UK

Yorpower will also be responsible for the supply and installation of the generators as well as all plant room equipment.

Formed in 1989, Yorpower Manufacturing Limited, based in York, has grown to be one of the most recognized and successful suppliers of power generation equipment in the world.

Around half of Yorpower’s annual turnover is exported, and the UK organisation has supplied customers in over 55 countries to date.