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POWER ENGINEERING INTERNATIONAL
SEPTEMBER 2015/// VOLUME 23/// ISSUE 8
Contents
2 Industry Highlights
39 Ad Index
40 Diary
Features
24 Gas turbines in challenging conditions
4 How to unlock MENA power investment We highlight the technological developments for
The power sector investment opportunities in the Middle adapting gas turbines to operate in extreme heat,
East and North Africa are huge, but so too is the humidity or altitude.
challenge in releasing that finance. What is the solution?
On the cover
Picture: IPP3 power plant in Jordan. Courtesy of Wrtsil.
Tomorrows chimney
design: lighter, cheaper,
built to last
15c
23c
How to
How to unlock
unlock MENA
MENA
power investment
power investment
The power sector investment opportunities in the Middle East and North Africa are
huge, but so too is the challenge in releasing that finance. So what is the solution?,
asks Kelvin Ross
E
nergy demand in the Middle the scale of the task facing us all. But, for the provides evidence to convince financiers that
East is expected to increase region, it gives us the opportunity to create the investment opportunities in the regions
threefold in the next 15 years, far solutions for highly efficient energy systems power sector are real, large and happening
outstripping todays supply. that both supply our energy needs locally now.
The Middle East and North and connect to a growing world market in One key recent development being
Africa are forecast to account for energy technology. highlighted is the successful bid at the end
most of the worlds energy demand growth And he adds that since this will require of last year by the Dubai Electricity and Water
well into the 2030s and beyond. But many innovative approaches to financing energy, Authority (DEWA) for 200 MW of solar power
areas of the region face limited investments we believe it also presents real opportunities at $5.98/kWh, a game-changing price that
in new generation capacity and distribution, for the regions banking sector. has set a new world benchmark for utility-
and some countries have restricted or no The bank says that what at first appear scale solar PV costs, putting photovoltaic
supply of indigenous hydrocarbon resources. to be challenges as the region makes technologies on a competitive level with oil
In a report released this year called the transition to a new energy future can and gas.
Financing the Future of Energy, the National become the source of the opportunity, when
bank of Abu Dhabi states that to close the it is recognized that the situation will demand
gap will require huge levels of investment in innovative responses in technology, industry
The investment
projects that provide additional generation and infrastructure all of which need to be
capacity and improve the efficiency of our financed.
opportunities in the
energy use. NBAD believes that existing progress in
regions power sector
The banks chief executive Alex Thursby developing the Middle Easts energy mix are real, large and
stresses that we should not underestimate particularly with regard to renewables happening now
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It is widely agreed
that stable regulation
leads to lower
investment risks
and hence to larger
investments
discriminatory basis, thereby fostering further
investment in upstream resources.
to ensure security of consistent or stable policy regimes constitutes Expanding cross-border trade can indeed
a big barrier to investment. be a cost-effective way to increase reliability
supply Mobilization of financing requires a and affordability, but technical and political
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Project financing
barriers persist. To overcome such barriers, the required by banks. Cost transparency The MENA countries stand to benefit greatly
development of intense technical and political needs to be improved and organization from the EUs energy strategy, certainly with
co-operation is fundamental. Institutions questions regarding market integration the new momentum brought by the Energy
like MEDREG, MEDGRID and MEDTSO are need to be better answered. Union. Whereas most MENA countries were
increasingly involved in developing strong Due to the structure of the energy markets traditionally relevant to the EUs energy market
institutional partnerships at the regional in the region and because energy prices, because of their vast fossil fuel resources, they
and international levels, promoting effective including fuel oil and electricity, are subsidized have recently become increasingly relevant
exchange and leading to further integration for end users, there is an identifiable need because of their substantial renewable
of the regions countries. for well-designed and targeted government energy potential.
Synergy between these organizations is investment incentives and support Within the framework of the Energy Union,
crucial, notably to encourage the adoption of mechanisms in order to develop private there is now a clear opportunity for the EU to
compatible cross-border network codes. investment in renewable energy projects in become more aware of its role and influence
the region. A lack of clarity and coherence in the MENA region and to start thinking
Open market structures, in particular regarding available opportunities currently about long-term engagement. The European
for renewable energy-based generation undermines private sector participation and Commission (EC) has already envisaged
projects competition in most of the countries. the concept of a Mediterranean Energy
Competition should be introduced where MENA governments should therefore Community by 2020. The EC should continue
possible, notably in power generation, design incentives that drive private investment to develop ideas to open a credible window
trade, ancillary services and electricity to take advantage of the private sectors of opportunity for the integration of Southern
supply, provided that a level playing field is financing capacity, to profit from technology Mediterranean energy markets within the EU
established and that national markets are transfers, to optimize their oil and gas trades market.
sufficiently large, or that interconnections exist, and to benefit from positive environmental The main challenge for the EU will be to
giving room to larger regional markets. externalities (e.g., a lower carbon footprint). incentivize its neighbours to strive to adopt
Deregulation within national and regional The most meaningful public finance EU regulations without being able to rely on
energy markets is important to allow free entry programmes employ a package of financing a well-developed institutional framework for
and exit of new players and to create and mechanisms rather than relying on any single energy co-operation and without offering
facilitate competition among providers, in mechanism or fixed set of mechanisms. These them fully-fledged EU membership.
particular for the development of large-scale packages may include lines of credit to local Energy regulation diffusion to other regions
renewable energy generation projects. finance institutions; project debt financing; has, however, proved to be successful in the
loan softening programmes; guarantees to past, for instance with the enlargement of the
Design and implement the right financing mitigate lending risk; grants and contingent Energy Community to countries like Ukraine or
mechanisms to stimulate exploration of grants for project development costs; equity, Moldova.
renewable energy potential quasi-equity and venture capital; or carbon In order to persuade MENA countries to
Despite the substantial economic potential finance facilities. The programmes should join the Energy Community, the institution
of renewable energy across the MENA seek to leverage additional private financing should however be much more supportive
region, a number of factors currently make to the largest possible extent, and adopt to organizing a broad knowledge exchange
such projects economically unviable without a portfolio approach that avoids creating and having a closer look towards the barriers
targeted government support. The main path dependency on any specific set of and weaknesses in implementation of the
barriers include: technologies. Treaty, rather than focusing too much on the
l
Market risks: MENA economies generally legal enforcement aspects.
experience wider fluctuations of Improve education and technology transfer The right way forward for the South will most
macroeconomic indicators, making their Too few incentives exist to encourage the likely be a step-by-step approach that leads
investment climate harder to forecast private sector to hire and train local staff or to to better framework conditions for a possible
for investors. This in turn results in higher create business linkages with local SMEs.There set-up of a Southern Mediterranean Energy
borrowing costs, shorter loans, and higher is a need to shape strategy further by providing Community in the long run. Setting up industry
equity requirements for finance; dedicated training for key energy decision- and regulatory forums and workshops to
l
Technology and capacity risks: The limited makers within the MENA countries in order to enable necessary regulatory and market
expertise and experience (of the labour improve competence and share knowledge reforms and grid infrastructure is a priority first
force) can lead to misjudgments, decrease and information between EU member states step.
anticipated productivity, and unexpectedly and the region, e.g., on network codes, This could be followed by initiating the
increase costs. Relevant knowledge and technical standards, and renewable energy design of a centralized control centre to
capacity is often also limited among project financing. monitor the activities of electricity TSOs in the
relevant public administrations; Mediterranean region.
l
Access to finance: High up-front payment Enhance the EU-MENA Energy Cooperation:
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Fast-tracking in Egypt
Delivery of a major
U
ndertaken under the auspices 10, and first fire and commissioning took place
power project under of the new Egyptian during week 11, followed by the issuance of
governments Power Boost the construction completion certificate.
severe time constraints
programme, GEs 2.6 GW The unique thing about the TM2500s,
is a huge undertaking, fast-track power project was noted James Rusty Bonnett, EPC and gas
involving hundreds of designed to prepare the turbines project leader, is their ability to move
people, massive amounts country for the heat of the upcoming summer in fast.They are the workhorses of what we do.
of technology and months, as well as the increased energy use And it wasnt just the technology that moved
expected during the month of Ramadan, in fast the working teams did too. PEi visited
tremendous logistics.
beginning in mid-June. Under a contract several of GEs sites in Egypt and spoke with
Tildy Bayar visited the GE signed in mid-December 2014, GE was to the teams on the ground to find out what
Power & Water team as provide, install and commission a total of kinds of challenges they faced during the
they carried out a 46 gas turbines 34 aeroderivative turbines project, and how they dealt with them.
2.6 GW fast-track (14 LM6000 PCs, in the 4350 MW range,
and PFs, at 42-57 MW; and 20 TM2500+, at Working around the clock
project for the Egyptian
2530 MW), plus 12 E-class heavy duty According to GE, the first turbines were on their
government the turbines. These would be installed at multiple way to Egypt within hours of the contracts
businesss largest project sites throughout Egypt, and would need to signing. But even before the deal was finalized,
in Egypt to date. begin coming online in under six months. Bonnett said his team had begun working
For just the TM2500 sites, 500 MW would around the clock to make it happen.
need to be installed in 11 weeks. In GEs Gunnar Berg, LM6000 project director,
time-lapse video document, the customer noted that, in December 2014, a bunch of
selected 10 sites during week one. Week two teams GE, [Spanish EPC contractor] TSK
involved site preparation procedures such as and our other partners were virtually locked
debris clearing and levelling and preparing up in meeting rooms working out detailed
surface areas. During week three, the units equipment breakdown and configuration
were delivered after customs clearance, plans, which were presented to the customer
road assessments and transport logistics were within days of the contract signing. Of the
worked out.The foundations were then poured LM6000 [turbines], said Berg, some were
during week four, and the units arranged starting on liquid fuel, some on gas fuel,
on the foundations in week five. Balance some with water and some without quite a
of plant construction began in week seven configuration to match up. The key success
with the installation of the transformers, fuel factor in delivering the plans to the customer
tanks, cables and so on, and in week nine quickly was the teamwork between our
the turbine assembly began. The units were teams at GE and our partners, he said.
synchronized to the customers grid in week Projects like this get a lot of attention for
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Fast-track power
their commercial and financial value, he How do we get [a project of this scale] And it wasnt just GEs team that worked
added, but probably even tougher is the done?, he asked, and answered his own flat-out. Berg said GEs Egyptian T&D EPC
executional intensity required to pull this question: Everyone works 24/7. partner, El Sewedy Electric, had completed
through. Progress updates on each Egyptian site its work on a TM2500 site in the greater Cairo
From the top-level project managers to the were posted for the entire company. In April, area in 1.5 months instead of the usual four
construction crews on the ground at each Berg announced in a video update from to six. The teams were competing to have
site, a significant aspect of their work seemed one LM6000 site that four units plus auxiliary their electrical stuff up first, he said, with the
to be keeping in mind at all times that the subsystems were placed on foundations winning group planting the Egyptian flag atop
clock was ticking. Bonnett, for example, set here just two months after breaking ground. the installation.
up a countdown clock for each project on Impressive progress! The fact that the units
his mobile devices, which he shared with were modular and quick-connect, he noted, Making it happen
everyone on his team. eliminated weeks of work. According to Bonnett, the project schedule
ran to some 24 pages, with 50 to 60 tasks listed
on each page, broken down into individual
components: systems, infrastructure, cable
laying, and so on.
Making all of it happen involved an
impressive amount of organization in a short
time, and one of the key steps was finding
the necessary equipment. Bonnett said that,
with multiple engine configurations with
all different systems we had to take stuff
meant for other projects. You cant deliver
14 complete units in 15 days. But he noted
that GEs strategic inventory process allows
for borrowing or allocating different parts
for different projects. For the Egyptian project
the equipment came from around the world:
according to Bonnett, on one LM6000 site
the stacks were from Mexico, the units from
Hungary and the transformers came from
Canada.
We do pride ourselves on having a strong
supply chain to make sure we have the right
parts to do what we need to do, he said,
Challenges included moving an entire plant 150 metres
Credit: GE Power & Water also noting that, in some cases such as the
Egyptian project, we can retrofit certain
The challenges
In addition to being the companys fastest, the Egypt project was also
the most technically complex in terms of engineering, Bonnett noted,
with all of the systems to piece together adding up to one very large
spreadsheet. For an example of the complexity, the LM6000s existed
in two versions for this project, and the auxiliary systems were designed
with different options, he said.
According to Bonnett, equipment configurations needed to be
HIGH PERFORMANCE
detailed with GEs suppliers so that the equipment arrived in Egypt in
the right order to facilitate the necessary work which sometimes
didnt happen, and work would be hung up as a result. Customs Electric actuators for the
clearance was also sometimes challenging, even though the process power plant industry
had been carefully planned and the Armament Authority officials
were ready, thanks to efforts by the government.
Reliable, powerful, precise control. AUMA
Sherif Abdel Moneim, construction co-ordinator for the LM6000 sites, offer a large portfolio of actuator and
said the biggest challenge for his team was getting the equipment
gearbox type ranges.
to the site in accordance with the schedule. He noted that, at times,
work was hung up while youre waiting for a piece of equipment you Automating all types of
need, and that the team eventually had to air-freight most of it on the industrial valves
Antonovs.
The number one issue and the biggest lesson learned, Bonnett
Standardised interface for
said, involved bringing in skilled people. Although he said the various site control systems
Egyptian government was very helpful, entry clearance inevitably took
Plant Asset
additional time. Nevertheless, he noted that the most important aspect
of any project is investing in people who can fix things when they go Management
wrong because they will. functions
Wade Cantwell, site manager for one of the LM6000 installations,
identified an initial challenge as all the equipment arriving within
Service
10 days of each other and having to be unloaded. But his biggest worldwide
challenge, he said, was managing a team that included 19 nationalities
on a single work site. The language, and fitting 19 nationalities into a
team, takes a little while, he said. Discover
The only accident Cantrell could recall at his site was a brake our solutions
failure on a crane.The driver drove it into a foundation to avoid hurting for the
anyone, and bruised his knee, he said. power plant
The need to make sometimes significant adjustments to each site on industry
the fly was another perennial issue. In general, Bonnett said,customers www.auma.com
make decisions very late in the process, so were always trying to set
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Moving forward
Work was completed ahead of time on the
TM2500 sites, in time to provide 440 MW for
Ramadan. Work on the LM6000 sites was
completed on schedule in July.
According to analysis firm the Oxford
Business Group, Egypts power generation
capacity needs to be scaled up to 50 GW
by 2025, nearly double todays capacity, to
The team on one work site included 19 nationalities
meet a demand growth of 1012 per cent
Credit: GE Power & Water
per year. In addition to GEs contribution,
Egypt has recently added or contracted
a speed record and he added that any in additional workload and a quick rethinking power capacity using multiple technologies
construction project is a bit of a push-pull. of the site preparation. In addition, the team from a number of companies, including a
Among the adjustments noted by Bonnett and had to change one plant over from gas to $266 million deal signed in June with Ansaldo
Berg were moving the entire Cairo-area plant liquid fuel because gas was unavailable Energia to upgrade two gas-fired power plants
150 metres at the customers request, resulting resulting in three weeks of extra work, Berg with three 265 MW steam turbines; a $9 billion
5NVEILINGOUR
next generation products
deal with Siemens, also signed in June, for energy projects for its inaugural feed-in tariff mobile GEs team will now be on to other
16.4 GW in gas-fired plants and wind power; scheme. projects elsewhere.
a $30 million contract in July with APR Energy With such large-scale infrastructure Bonnett, for one, has worked on large-
for a gas-fired power plant; a memorandum projects in the works and an immediate need scale power projects in a number of countries
of understanding signed last year for the for power, fast-track power is a logical first step. including Algeria, Turkey and Mexico, and
countrys first coal-fired power plant, to be Governments like the TM2500s, says Bonnett, looks forward to finding out where his next
built by an Abu Dhabi-based consortium; a because they can come online quickly and assignment will take him.
preliminary agreement with Russia on building they are mobile they can move further out
a nuclear power plant, signed in February; as theyre replaced with permanent plants. Visit www.PowerEngineeringInt.com
and in January Egypt picked 109 renewable And its not only the technology which is for more information
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Round table panellists debate the future of gas engines running on alternative fuels
Gas engines
T
he use of gas engines is continually energy sufficiency/efficiency will in future drive In India, she said the needs and
increasing as the capabilities of the market for alternative fuels, the current requirements are very basic: They need
these machines become more biogas market has somewhat slowed down. energy, and they just want to meet demand.
cutting edge. There was talk three to four years ago There is a growing rise in interest in clean
In the new energy landscape about renewables and alternative fuels taking fuels the Indian government is focused on
the buzzword is flexibility, and gas over the market, but the recession put a brake renewable energy.
engines are fulfilling that need, winning new on that. She said that for an emerging market like
devotees because of the speed at which they She said Frost & Sullivan believes that, India which has a desperate need for power,
can be transported and installed compared for the European market, there is 40 GW of the reason for looking to waste gas was
to their gas turbine counterparts. installed capacity, and added that globally a obvious:There is a lot of waste, and they need
One of the key trends of recent years is few pockets are growing Germany, central to use it.
the development of gas engines running on and Eastern Europe, India and China. But she cautioned that the availability of
alternative fuels. Gunjan said that the key drivers of the waste-to-fuel technology comes at a cost. If
I recently moderated a round table market were cost/benefit, regulations, enough subsidies are not provided to help,
discussion which assessed the current and political stability and energy consciousness. they are not going to meet their needs.
future challenges and opportunities that the Of those developing pockets, she said Energy and engine consultant Jacob
alternative fuel gas engine market is facing. Germany is taking a lead because it is a very Klimstra said that the market potential of
Pritil Gunjan, Energy & Environment Industry open-minded country. They are aware that biogas rather depends on just what you
Analyst for Europe at consultancy Frost & greenhouse gases will cause huge havoc mean by biogas: AD, syngas, landfill gas all
Sullivan, began the session by setting the for future generations it is a commendable have different qualities and problems and
scene. She said that while clean energy and thing that the country is doing. challenges.
Gunjan: waste-to-fuel technology Boom: highlighted increasing Grtz: spoke about trends
comes at a price maintenance costs for the future
Looking at low electricity prices in Europe lubricant. The stop-start nature of flexible batch that is relatively clean and then the next
at the moment, its very difficult to compete. operations puts more pressure on the lubricant batch could have high levels of impurities
He said that in the Netherlands there were to protect the engine during startup. As the such as siloxanes and sulphides. Its important
a lot of big farmers using biogas from their engine starts up, it takes time for the lubricant to protect engines against these impurities
manure and waste, but the problem was that to be pumped through the system, which can and lubricants are now available which can
the scale was too small only 350500 kW. leave moving parts operating without suitable help mitigate the negative effects to reduce
When you look at the processing of gas to protection. Its therefore important to select scuffing and wear and keep engines running
get it clean enough to put into an engine, it is a lubricant that can enable quick start-ups, for longer.
too expensive. Biogas may be possible on the while offering optimum protection, even when Its also important to make regular
municipal level, but on a smaller scale its very, aggressive gases are being used. maintenance checks used oil analysis is
very difficult to compete in the long run. A key issue for all the panellists was the even more important for engines running on
Dr Tilman Ttken, vice-president of MAN quality of gas from differing sources. aggressive gases such as those from landfill
Diesel & Turbo, was keen to highlight the Andreas Grtz, Director of Sales for Power or farming waste where engine wear can be
German success story of 4000 MW of biogas. Generation at Rolls-Royce Power Systems, accelerated. Developing products that have
We have subsidies, political will, a believes it makes no sense to use farmland to the potential to offer energy efficiencies can
clear environment for subsidies, and it was grow plants for producing biogas or biofuel. I also help extend oil drain intervals and reduce
decentralized, with a lot of smaller engines. spoke to a farmer a couple of days ago and waste. With a thorough process it is possible
But he cautioned that around the world it hes invested in a biogas power station. His to improve the productivity of gas engines
is difficult to get subsidies or financing and the price for corn was 70 ($81) now its 36. running on biogas.
technology challenge of cleaning waste gas However, he said gas from waste makes Klimstra said that gas quality has to be
is very costly. However he is mildly optimistic sense: In Asia theres a huge amount of determined by customers and not by suppliers.
there is a lot of waste were still developing waste, so use it. But he does not believe that By now gas companies have completely
technologies to make it commercially feasible in Germany you can use biogas as backup changed their position. If the gas quality is
but it will take a lot of time. for renewables its not sufficient, you have to variable, you cant guarantee flexibility.
use natural gas. With poor quality you have to start the
Flexibility Paul Jordan, Global Market Sector Head of engine very slowly; with good gas quality,
Frank Grewe, Managing Director at 2G Clean Energy & Power Generation at Ricardo, engines perform very well. With poor quality
Energietechnik, said that currently we see said that landfill feedstock is changing as well, they cant respond so quickly, so the engine
that its getting more and more important as recycling and composting is improved. cant deliver ancillary services.
for us to be flexible with our CHP and power Feedstock is going into scrubbers pre- I asked the panel what is the biggest
generation. pipeline, so there will be challenges around constraint to the growth of gas engines fuelled
2G Energietechnik specializes in heat, not how you standardize that its difficult. Industry by alternative gas policy or technology?
just power generation, especially in the small will have to be aware that what we set today Both, said Gunjan, while Rick Boom,
power range, and here Grewe said that may not be the same as in 20 years time. Director of Product Marketing of Large Engines
flexibility becomes more important. He said it will require flexibility in whatever at Woodward Nederland, said that while the
He listed three main requirements for process, whether pre-pipeline or with a gas technology has to deal with different gas
todays gas engines: To be reliable so theyre engine. qualities, that can be done. Most engines
there if needed, low maintenance costs, and Jarmo Vihersalo, Europe, Africa and Middle today are tuned for a certain gas quality, but
to fit the emissions regulations. East Industrial Marketing Advisor for Energy at with direct feedback from the combustion
Thorsten Hamm, Field Testing Co-ordinator ExxonMobil, said the fluctuation of gas quality chamber you can adapt that, so the
for Europe, Africa and Middle East at has an effect on engine maintenance. technology is available but not on every
ExxonMobil, said that flexible energy supply Variable gas quality puts more pressure engine installed today. But it should not be a
presents unique challenges in terms of the on engine performance. You could have one hurdle.
for island use but not a big market and Boom and Grewe also
conceded that it is a niche market.
Gunjan said that the problem with landfill is that nobody wants it in
their back yard. Waste-to-energy, if that can be sent out to consumers
at the same cost, there would be support for it. Whether utilities are
YOUR GLOBAL
able to meet that kind of cost demand is something else.
But even the developing countries have their own barriers to
growth. Gunjan said India is too diverse, too decentralized. She said
POWER GENERATION
the key drivers for the sector to grow are proper grid infrastructure and
support mechanisms, not the fact that there is a lot of waste available.
Hamm explained how ExxonMobil keeps pace with, and even
PARTNER
anticipates, future demand and challenges.
We keep in close contact with major OEMs, keep our ear on the
rail to find out whats going on what is the next trend or challenge,
and this feeds into the next product development wed like to do.
Our design department comes up with a new formulation, and
then it goes to lab testing. The variation in gas quality is sometimes
challenging you need 600010,000 hours before you can say the oil
has been proven, so it can take 18 months. Product development is
three years, so we have to be really early on the market.
He said that now everybody is crazy about the efficiency rate, so
we have to manage the oxidation challenge.
Mechanical oil consumption is something everybody is trying
to get down. Making sure the heat exchanger does not receive too High performance components
much ash; we have to find a really good solution, thats whats really
driving development.
Complete lter cleaning systems
Finally, I asked the panellists what would be the best and the worst Advanced lter cleaning controls
thing that could happen to the sector in the near future.
Hamm said the best thing would be having a solid gas standard Membrane air dryer technology
and quality so that we know what we can expect for the engine.
Lubrication protection systems
Grtz said a real boost would be if there is a solution for power-
to-gas. Im not sure its really feasible, but this would change it a lot
and would be a real economic way of having power with storage to
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Taking
the heat
Adapting gas turbines for heat, humidity and altitude is a complex equation with
no single solution, writes Penny Hitchin
L
ocation, site and climate can all This reduces the output of the gas turbine and temperature reduces the work of compression
have a substantial impact on the decreases efficiency. and there is more power available at the
efficiency and power output of gas Gas turbine manufacturers specify turbine output shaft.
turbines. In hot climates and or at performance at standard conditions called Three main types of system are available:
high altitude, gas turbines operating ISO ratings. The three standard conditions evaporative cooling, overspray techniques
in single or combined cycle generate specified in the ratings are Ambient (high fogging or wet compression) and chiller
less power than their equivalent counterparts Temperature 15oC, Relative Humidity 60 per technology. In evaporative cooling, water is
operating in a cooler climate or near sea level. cent, and Ambient Pressure at Sea Level. Gas trickled through a porous medium to cool
Seasonal and diurnal weather variations turbine efficiency deteriorates by 1 per cent the air. Evaporative cooling is not effective
also affect turbine performance. With the for every 10-degree rise in temperature above in conditions of high humidity. Water is not
demand for power in the Middle East and ISO conditions. Depending on the gas turbine, injected into the system.
Southeast Asia growing, turbine experts have this translates into a power output reduction of In a fogging system, water droplets are
focused on developing techniques to improve 5 to 10 per cent. sprayed in the air to artificially create colder
the efficiency of turbines operating in hot and conditions. The water evaporates in the air
humid climates. Inlet air cooling systems inlet before reaching the compressor. In wet
Gas turbines are air-breathing machines In the last 20 years in an attempt to compression or inlet fogging, a fine spray of
whose power output is dependent on the compensate for the lower air mass at high demineralized water enters the compressor,
air mass through the compressor. Ambient temperatures, gas turbine (GT) manufacturers where it evaporates. Fogging and overspray
temperature, altitude and humidity all affect have introduced techniques to cool inlet air, systems require more water than evaporative
the density of air. On hot days, when air is thus boosting turbine output in single and cooling. In areas where water is in short supply,
less dense, power output falls off. Hot and combined cycle operations. Feeding cooler other techniques may be more appropriate.
humid air is less dense than dry, cooler air air into the turbine increases mass flow, Air inlet chilling cools the air by refrigeration.
and the density is thinner at high altitudes. resulting in higher output. The power required It is power-hungry but may be economic in
As the density of air decreases, more power to compress air is directly proportional to the cases where off-peak or cheap power can be
is required to compress the same mass of air. temperature of the air, so reducing the inlet air used.
Each has advantages and disadvantages lower specific costs than buying or building plant (for example, coating compressors
and it takes site-specific analysis of a number of new capacity. It is important to look at all these with advanced coatings), but it enables
factors to determine the optimum technology details before making a recommendation. the addition of capacity without civil work
or combination of technologies. In the Middle East, ambient temperature is such as adding generators and additional
Turbine expert Sasha Savic of SS&A very high in summer at the time when peak transformers. Once in place, the inputs for wet
Power Consultancy draws on wide-ranging demand (notably for air conditioning) is compression are demineralized water and
experience to carry out the complex process. at its highest. Wet compression is one of the power to run the forwarding pumps. The water
He starts by studying conditions at the site, available techniques for inlet air cooling. It evaporates in the compressor and cannot
including weather patterns and the availability can be retrofitted to existing frames as well be recovered, so the technique is particularly
of water. The next step is to consider the as supplied with new systems. It works best in suited to power plants running alongside
technology installed as, for example, some a very hot dry climate, but is effective in high desalination facilities.
GT technology is more prone to compressor humidity. Zaid Al-Sati specializes in wet compression
erosion than others, in which case it might Wet compression increases the power systems for Siemens Power Generation Services
be necessary to limit the amount of water output of the gas turbine by reducing in Dubai. He says that wet compression is
injected. Then the all-important economic compressor inlet temperatures, inter-cooling perfectly suited to upgrade capacity for
aspects, such as capital investment and the compressor and increasing mass flow baseload machines, especially in Middle East
the added value from investment, must throughout the turbine. areas close to the sea where humidity is high.
be evaluated. It is important to look at the Demineralized water is injected into the The system has many benefits here in the
payback as customers have different tariffs, compressor. It evaporates in the air intake Gulf region. It is very sustainable technology
boundary conditions, capacity and payback and increases the saturation of air, which which is independent of ambient temperature
times. increases the mass flow, leading to additional and of humidity, he says.
Savic says that it is a complex equation capacity. Wet compression systems can be The company performed its first upgrade in
with no one solution. easily switched on and off, enabling a rapid North America in the late 1990s, followed by
You have to understand the behaviour increase of output peak demand. the ME region in 2004.
and ambient conditions for the operating Retrofitting wet compression to existing Operators decisions about plant upgrades
period. Normally cooling technologies have turbines requires some adaptations to the will be based on economic, financial and
www.vaisala.com/power
Improving designs
During the design of a new or upgraded GEs 7HA gas turbine
gas turbine model, the major OEMs take Credit: GE
+1 804.743.0982
e-mail: power@sealeze.com
GEs 9HA gas turbine going into the test stand www.sealeze.com
Credit: GE ISO 9001 Certifed
Take this opportunity to represent your company and network with the power elite.
Filtering out
the problems
Self-cleaning filters can
T
o operate efficiently, gas turbines of sand, dust and hydrocarbons that require
optimize power output require the cleanest possible air, filters to have a long life and be self-cleaning.
yet at the same time consume No filter is 100 per cent efficient, so some
and heat rate for gas
vast amounts of it. dust will get through. When a filter is used
turbines operating in Any contaminants within in an environment that is much dustier, a
harsh, dusty environments, this air stream will result in proportionate amount more dust will get
writes Jim Lenox degradation in operating efficiency (output), through the filter, leading to an increased
fuel consumption (heat rate) and differential rate of compressor fouling and a greater
pressure. need for downtime to off-line wash when
The resulting lower MW output and compared to using the same filter in a lower-
increased heat rate come at a huge cost to dust environment.
the power generation sector. Selecting filters designed for optimized
In recent years operators have become efficiency to remove from the airstream those
far more aware of the cost associated with particulates that lead to higher operational
operational compressor degradation and, compressor degradation is critical to the
therefore, solutions to minimize this effect have performance of the turbine.
become essential. An inadequate solution will carry a
Proper air filtration is critical to the overall heavy cost for power plant operators with
health of the compressor and reliability of gas a significant loss in revenue due to lower
turbines. Significant gains in output and heat MW output, increased heat rate and shorter
rate are achieved through the proper use of intervals between water washes.
air filters. These gains, combined with reduced Another environmental element that
maintenance costs of filters and the engine negatively impacts gas turbine performance
itself, mean that selecting the correct air filter is salt. Many gas turbines are located in
solution is a vital decision. coastal regions where salt, mist and fog are
A prime example of the importance of a problem. Sodium in salt will combine with
proper filter selection is dealing with the sulphur in the fuel within the hot section of the
climatic conditions in the Middle East, which turbine to cause accelerated corrosion known
add challenges not experienced in many as sulphidation.
other power generation regions around the There are two types of sulphidation
world. These challenges include high volumes corrosion: Type I takes place where
temperatures are above the melting point This can then leave a sticky salt residue advanced media over the past decade.These
of the sulphate (825C950C) and Type II on the compressor blades, which makes advanced media filters have been selected
corrosion occurs between 700C and 800C. them more likely to foul with fine particulate in preference to ePTFE filters on various new
The chemical reaction between the that has passed through the filters and, more unit coastal systems for power generation
sodium sulphate and turbine metal at these importantly, leads to accelerated corrosion. applications.
temperatures attacks the base metal of the The sticky salt will also compromise the Clearcurrent Pro and clearcurrent BP
turbine blades and can cause catastrophic blade aerodynamics, leading to operational NanoPleat are new gas turbine inlet air
turbine failure. degradation including lower MW output and filtration products from Clarcor Industrial Air,
The lower-temperature Type II hot corrosion increased heat rate. specifically designed for power generation
is characterized by pitting, but the higher- Some suppliers are introducing new, applications, which offer two solutions for
temperature Type I sulphidation corrosion high-efficiency technology such as ePTFE varying harsh environmental conditions.
produces a devastating accelerated attack membrane filters into power generation The clearcurrent Pro filters are engineered
on turbine metals. applications, but those filters have been to remove particulates from the air
This is a particular concern in coastal developed for installation environments stream that are most likely to adhere to a
Middle East regions where much of the found in areas such as HVAC and the compressor blade. BP NanoPleat is nanofibre
fuel used is sour fuel that has high sulphur pharmaceutical sector. technology engineered through optimized
content. The mean time between failures in Therefore, the robustness of ePTFE in-house nanofibre capabilities specifically
these conditions is highly dependent on the solutions has proved unsuitable for the harsh for the power generation sector. The resulting
corrosion level, which is directly related to the environments and demanding operating proprietary nanofibre medium has smaller
protection that is provided to prevent salt from conditions of the power generation sector, pores for more efficient filtration and is more
entering the gas turbine inlet. where hydrocarbon contaminants and durable than ordinary nanofibre media. These
Salt can freely change between dry moisture are real challenges that lead to improvements lead to better filter cleaning
particulate and liquid depending upon the unexpectedly high pressure losses and and longer life compared with traditional
relative humidity. In the Middle East, airborne unplanned turbine shutdowns. alternatives.
salt will most often be in dry particulate form This industry sector requires filters with Clarcor Industrial Airs comprehensive
and, therefore, will be filtered by traditional dust proven media technology that are very robust, range of final filters covers efficiency ratings from
filters. However, when the humidity is high, such very strong in terms of rated airflow, and are F8 to E12. Extensive field trials of clearcurrent
as during the frequent fogs that are present assembled in such a way that will last for years technology show significant reductions in gas
in many Middle Eastern coastal locations, salt despite harsh conditions. turbine degradation between compressor
can turn to liquid and migrate through the Advanced glass-fibre media and properly washes, leading to significant operational
filter and into the engine of the turbine. engineered nanofibre which has been utilized benefits with greater overall generated output
within the industry for many years provides and increased time between offline washes.
efficiency, proven-through-life performance Comprehensive studies with several of these
and hydrophobic properties equivalent to, new filters in high-moisture, high-salt coastal
and in many instances better than, ePTFE sites also show significant improvements in
membrane without sensitivity to moisture, mist, turbine output and heat rate compared to
fog and hydrocarbon fouling. using conventional filters on the same sites.
Clarcor Industrial Air has supplied in The variance in the requirements and
excess of 200,000 gas turbine operating conditions of each gas turbine
filters with this installation means that one filtration solution
does not fit all. In many power generation
installations a mixture of dust, salt and moisture
leaves turbines vulnerable to degradation
that will reduce efficiency and availability
while increasing risk of failure.
The cost of an ideal gas turbine inlet
filtration solution needs to be assessed against
all lifetime operational and maintenance costs
as well as lost power output from reduced
efficiency and unscheduled downtime.
Utilizing clearcurrent Pro and BP NanoPleat technology, cartridge filters from Clarcor
Clarcor Industrial Air
Industrial Air help ensure proper gas turbine filtration in harsh environmental conditions for increased
power output and heat rate
Visit www.PowerEngineeringInt.com
Credit: Clarcor
for more information
Advancing solar
technology in the
Middle East
UAE-based renewable
R
ecently launched in Masdar City testing for PV modules, coatings and related
energy research and in Abu Dhabi, UAE, the Masdar equipment; a concentrating photovoltaic
Solar Hub is a state-of-the art (CPV) test centre, which is a joint initiative with
development firm Masdar
solar testing and R&D hub for Spains Instituto de Sistemas Fotovoltaicos de
has launched a new photovoltaic (PV) and solar Concentracin (ISFOC) and offers testing of
test facility for solar thermal technology, and the first CPV systems under Abu Dhabis environmental
technologies, with the facility of its kind in the region. conditions; and the research, development
aim of increasing the The Solar Hub will offer testing, evaluation and demonstration-focused Masdar Institute
and certification of solar technologies and Solar Platform (MISP), which will explore
adoption of solar power
systems, Masdar says, as well as consulting solar thermal technologies such as CSP and
in the Middle East, and information services. It is a key addition thermal energy storage.
writes Tildy Bayar to Masdars growing solar portfolio, which The Hubs planned activities include long-
includes the worlds largest concentrating term outdoor exposure testing of PV and CPV
solar power (CSP) plant, the 100 MW Shams modules and CSP components; testing of
1 in Abu Dhabi; Mauritanias first utility-scale solar thermal equipment and solar receivers;
PV plant, at 15 MW; a microgrid-connected PV indoor testing of PV modules, and testing
plant on the Tongan island of Vavau; and a of thermal energy storage systems. Testing
500 kW PV plant on Murawah Island off the UAE facilities are also planned for battery, flywheel
coast. Torresol Energy, Masdars joint venture and other types of energy storage solutions.
with Spanish engineering and construction The MISP is built around a 100 kWth solar
firm Sener, has resulted in three CSP plants in thermal plant, which features a beam down
Spain: the 20 MW Gemasolar plant and Valle concentrating tower and its solar field, a hot-
1 and 2, each 50 MW. oil loop and thermal energy storage system,
Alexander Ritschel, senior manager a solar irradiometer platform, a compact
at Masdars Special Projects project linear Fresnel reflector and other solar thermal
management and consulting arm, plays a systems connected to a double effect
key role in managing the Solar Hub project. PEi absorption chiller.
spoke with him about the facility, why it was The beam down concentrating tower is
necessary, and what it aims to accomplish. a pretty unique thing its not the only one
in the world, but for sure there are not more
The facility than 10 globally, Ritschel says. The 20-metre
The Solar Hub is made up of three main high tower is surrounded by a parabolic field
facilities: a photovoltaic test centre, which of 22 heliostat mirrors in three concentric
offers performance, reliability and durability rings, which adjust their angle to track the
CONFERENCE&EXHIBITION
4-6OCT2015
ABU DHABI NATIONAL EXHIBITION CENTRE
SHARING TECHNOLOGY INNOVATION
Under the Patronage of
H.E. Suhail Mohamed Al Mazrouei, Minister of Energy, UAE
Joint opening ceremony featuring change to honoured speakers: HE. Suhail Al Mazrouei, Minister of Energy, UAE; Dr. Matar Hamed
Al Neyadi, Undersecretary of Ministry of Energy, UAE and Eng. Jamila Youssef Matar, Director of Energy Management, League of Arab
States, Egypt and Mr. Glenn Ensor, Managing Director, PennWell International Power Group, UK
World-class conference programme comprising 24 sessions delivered by 90 eminent global speakers from around 20 countries
Exhibition floor showcasing 80+ leading companies
New business matchmaking service to connect you with influential players
Exhibitor presentation theatre with live demonstrations
Expand your companys presence in the Abu Dhabi and wider Middle East marketplace and hear about the latest technology innovations
and developments.
Ad Index
ANSALDO ENERGIA 13 POWERGEN MIDDLE EAST 35
AUMA RIESTER GMBH & CO. KG 17 POWERGEN EUROPE 29
DR THIEDIG GMBH & CO KG 19 PENTAIR ENVIRONMENTAL SYSTEMS LTD 23
HADEK PROTECTIVE SYSTEMS BV 3 SEALEZE, A UNIT OF JASON, INC. 27
HX HOLDING GMBH C2 SIEMENS AG 5
INSTITUTION OF MECHANICAL ENGINEERS 15 SOUTHERN ENVIRONMENTAL INC. 16
LUCY MIDDLE EAST, FZE 18 SULZER MANAGEMENT LTD 11
MAPNA INTERNATIONAL FZE C3 TURBOMACH SA C4
MERSEN 7 VAISALA OYJ 25
METKA SA 9
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