AIP.Front Cover.Autumn09.SpaceFINAL.qxd 20/11/2009 10:56 Page 1
P R O M O T I N G O N - S I T E P O W E R A N D C O G E N E R A T I O N
A M E R I C A N I N D E P E N D E N T P O W E R

If your business demands service support 24 hours a day, 7 days a week, BRUSH Aftermarket can give you 24 hour peace of mind.
We consistently deliver industry leading parts, service and training expertise to the world-wide power generation industry.
Our top class service provides:
• A 24 hour emergency hotline
• Support teams covering our generators across 130 countries world-wide
• An online parts ordering service
• A first class training programme
To find out more –
Americas
Call +1 281 580 1314
Email serviceus@brush.eu
EMEA
Call +44 1509 611511
Email serviceuk@brush.eu
Parts and Service for the Global Power Industry

AMENDED.AIP contents.Autumn.Nov23.qxd 23/11/2009 10:0
6
Page 1
Editor:
Aidan Turnbull powereditorial@gmp.uk.com
Sales Director:
Neb Saric nsaric@gmp.uk.com
Publisher:
Richard Teasdale rteasdale@gmp.uk.com
Journal Assistant:
Zoë Taylor ztaylor@gmp.uk.com
Accounts Division:
Ian Bain accounts@gmp.uk.com
Far East Sales:
C H Park,
Far East Marketing Inc femchp@unitec.co.kr
German/Danish/Swedish Sales :
Mario Dobresko mdobresko@gmp.uk.com
Russian Sales:
Sergy Stanovkin stanovkin@dars.ru
US Sales & Subscriptions:
Alex Carter acarter@gmp.uk.com
Asia-Pacific Correspondent:
John Goss john.goss@ceejay.com.hk
Contributors
Caterpillar, Cummins, Honda,
Environment One, Rotork, ABB,
GE Energy, Mitsubishi Heavy
Industries, Emerson Process
Management, SolvAir.
Published by:
Global Media Publishing Ltd
Global House, 13 Market Square,
Horsham, West Sussex, RH12 1EU,
UK. Tel: +44 (0)1403 220750
Fax: +44 (0)1403 220751
Website: ww.gmp.uk.com
© American Independent Power
(ISSN 1468-7100). Distributed by
UK Postings Ltd, Unit 18-19,
Wornal Park, Menmarsh Road,
Aylesbury, Bucks, UK.
Subscription price £180.00 per year. Periodicals Postage Paid at
MIddlesex, NJ. Postmaster:
Please send address changes to
Worldwide Independent Power,
544 Lincoln Blvd., Middlesex,
NJ 0886-2439
P R O M O T I N G O N - S I T E P O W E R A N D C O G E N E R A T I O N
A M E R I C A N I N D E P E N D E N T P O W E R
AUTUMN 2009
Powering the space station
Powering the space station
GMP
Global Media Publishing Ltd
A u t u m n 2 0 0 9
C O N T E N T S
Plus Contract News & Products on pages 25 & 26.
The International Space Station features a unique PV system based on eight solar arrays in permanent orbit. See p.11.
AIP looks at a unique power system which is out of this world.
The Titan 250 from Solar
Turbines. See page 12.
Solar Turbines’ Titan 250 represents an industry evolution.
Our focus is on the Rolls-Royce WLE dual-fuel gen-set.
A breakthrough by Huntingdon Fusion Techniques.
Avtron LoadBank’s Model LCV under the spotlight.
We look at Generac’s neat solution to airport backup power.
New from Rolls-Royce - a genset Down Under. See page 14.
If your boiler develops serious cracks maybe you need help?
The Marchwood Power Station
See page 23.
Steam turbines are being upgraded at Hattiesburg, Mississippi.
Our power portfolio includes
The Swagelock Photovoltaic Specification is an industry 1st.
8-10 June - NEC - Birmingham
2010
Independent Power & Energy Europe
AUMA provides actuators for the Marchwood Power Plant.
A look at Hawaii’s Kalaeloa Cogeneration Plant.
Official
Members of
AMPS
* Diesel/Gas Engines * Gas Turbines, * Emissions
* Gen-sets * Loadbanks *Alternators * UPS/Batteries
* Controls & Monitoring * Maintenance * Fuell cells
* Filtration * Power plants * Turnkey * North America
Power Review - and much more.
W O R L D W I D E I N D E P E N D E N T P O W E R
M I D D L E E A S T P O W E R

Page 29 Auma.qxd 10/11/2009 09:54 Page 1
■
■
■
■
■
■
AUMA Riester GmbH & Co. KG | P.O. Box 1362 | 79373 Muellheim, Germany
Tel. +49 7631 809-0 | www.auma.com

ed letter .AIP.qxd 16/11/2009 07:53 Page 1
WELCOME
A warm welcome to this month’s issue of Worldwide Independent
Power - as always bringing you closer to the stories and issues affecting on-site power and cogeneration around the world.
For editorial comments, please do not hesitate to contact the editor.
BIENVENUE
Soyez le bienvenu à cette issue de
Worldwide Independent Power.
Comme d'habitude, nous vous apportons toujours plus près des sujets qui affectent l'énergie et la co-generation sur place autour du monde.
N'hésitez pas contacter le rédacteur pour des commentaires
éditoriaux.
WILLKOMMEN
Herzlich Willkommen zur Ausgabe dieses Monates von Worldwide
Independent Power.
Wie immer bringen wir Sie näher heran an die
Ereignisse und Geschichten der
Stromerzeugungsindustrie rund um die Welt.
Für redaktionelle Kommentare und
Anregungen wenden Sie sich bitte an den Autor.
BIENVENIDO
Bienvenido a esta edición de
Worldwide Independent Power.
Como siempre, acercándolo a los temas que afectan a la energía y a la cogeneración in-situ. No dude en contactar con nuestro editor para cualquier cuestión editorial.
BENVENUTI
Benvenuti a questa nuova edizione di Worldwide Independent Power.
Come sempre cercheremo di offrirvi storie e questioni riguardanti on-site power e cogeneration a livello globale. Per commenti editoriali, si prega di contattare l'editore.
G lobal electricity networks could become Smart Grids designed to monitor and control our energy usage, if plans from US giant Cisco take off. The company, whose technology helps underpin the net, is building a two-way link into electricity grids. Smart Grids would allow devices to communicate with utility firms to give an accurate view of energy use that could cut
CO2 emissions by 211m tonnes.
Cisco is, essentially, creating the Cisco Smart Grid Ecosystem to facilitate the adoption of Internet
Protocol (IP)-based communications standards for smart grids which will benefit the energy industry as well as business and residential customers.
The members of the Cisco Smart Grid ecosystem include system integrators, technology vendors, power and utility integrators, service providers, and services and sales vendors who represent various elements of the Smart Grid infrastructure.
Ecosystem members will work with Cisco to support interoperability testing and enable industry migration to an IP-based infrastructure for Smart Grids and energy management applications. This effort will help reduce the cost and complexity of deploying multivendor Smart Grid communications infrastructure solutions for both utility companies and ecosystem members.
The initial list of companies who are part of this open ecosystem includes: Accenture, AeroScout,
Arcadian Networks, AREVA T&D, Cable&Wireless Worldwide, Capgemini, Coleman Technologies, EMC,
Echelon, EnergyHub, GE, GridPoint, Infosys Technologies, Itron, Landis + Gyr, OATI, Oracle, OSIsoft,
Pulse Energy, Proximetry, Science Applications International Corporation (SAIC), SecureLogix,
Schneider Electric, Siemens, Skyline-ATS, Telvent, Verizon, Watteco, Wipro, and World Wide
Technology, Inc. Cisco has formed a Smart Grid Technical Advisory Board (TAB) made up of leading innovative utility and energy companies from around the world.
The TAB will help Cisco align its service, support and product direction to its customers' specific business and mission requirements. It will give customers the opportunity to influence Cisco Smart
Grid product and solution development road maps through a technology-focused forum.
Marthin de Beer, senior vice president, Cisco Emerging Technologies Group, told AIP: "Cisco is making important strides toward enabling an end-to-end, highly secure Smart Grid communications infrastructure that will help utilities, business and consumers better manage and reduce energy consumption.”
A number of other companies are also making a bid to modernise the electrical networks.
IBM, for example, has launched a range of embedded software applications, although these communicate through the regular internet, rather than via the mains; General Electric and a number of new start-up firms are keen to be involved in a market worth up to US$20bn a year.
Cisco says its system is different, because it would send the IP data down the power lines themselves, rather than using the internet. Now we have to wait to see who wins in the end.
A
M E R I C A N
I
N D E P E N D E N T
P
O W E R
• A U T U M N 2 0 0 9
5

AIP.NEWS.Nov.09.qxd 17/11/2009 13:27 Page 1
N E W S
6
In brief...
New air preheaters upgrade for Brindisi
Sud Power Station
It's been 6 months since an upgrade contract for
Brindisi Sud Power Station was awarded to a consortium headed by STF
S.p.A. and BWE. Enel had asked for 8 Air Preheaters to be renovated at
Brindisi Sud. During the last 24 weeks the Air
Preheaters have been rebuilt to meet the newest BWE designs and also to incorporate BWE's advanced Active Leakage
Control system, new heating elements suitable for SCR operation, and new multi-fluid soot blowers. The work on the first two Air Preheaters at
Brindisi Sud unit 3 will be carried out during the outage period in the early
Spring of 2010.
Thermal Engineering International (USA) Inc. (TEi), located in Santa Fe Springs CA, is approaching the completion of a contract from Zachry Industrial,
Inc. to convert existing condensers. These had been used in a fossil-fuelled boiler application and will now form part of Topaz Power Groups’ new combined cycle power plants known as the Barney
Davis and Nueces Bay Energy Centers.
TEi has been involved in the modification of existing condensers by replacing titanium tubes, steam bypass lines, LP steam admission line, cathodic protection systems, and putting in new vacuum deaerators and main vacuum pumps.
The company says it has integrated the latest welding, engineering design, manufacturing, and testing techniques, to produce condensers with superior mechanical design which can offer maximum thermal efficiency and reliability.
The Barney Davis and Nueces Bay Energy Centers will replace existing fossil units, fired by natural gas and oil, at the Corpus Christi, Texas power stations with highly-efficient combined-cycle facilities. The facilities will be rated at 679 MW and 677 MW peak capacities, respectively. Both plants will begin commercial operations in 2010. Jon Koenig,
President of Thermal Engineering International (USA)
Inc., commented: “Heat transfer equipment
The Laredo power plant owned by Topaz.
conversions demand a high level of expertise in both thermal and mechanical design as well as extensive knowledge of condenser operational performance.
We were pleased when Zachry selected TEi for this project - it will provide clean, efficient, reliable power for the residents of south Texas.”
Zachry is a privately-held company founded in 1924.
The company’s expertise has led to more than 5,500 completed projects in the US and abroad. The San
Antonio-based organisation has grown to include nearly 20,000 employees and more than 30 million work hours per year.
Topaz Power Group is a Texas-based independent power producer owned by Carlyle/Riverstone.
Holdings. It was originally formed in 2004.
CMI sells to Lithuania
CMI Energy of Erie, PA, has been awarded a new order to provide a triplepressure with reheat, natural gas-fired horizontal HRSG for a combined cycle power station in Elektrenai,
Lithuania. The plant operator, Lietuvos
Elektrine, and Spanish utility Iberdrola, who will build the station, anticipate completion of the project by 2012. It will be an innovative facility, strategic for
Lithuania, guaranteeing security of supply. The country is currently in the process of upgrading its generation facilities following the closure at the end of last year of the
3,000 MW Ignalina nuclear plant.
Young & Franklin
Electric Fuel Control
Y&F has added the upgraded 3010 Series
Electro-Actuated (EMA)
Gas Fuel Control Valve to its product line of electric controls for gas turbine fuel control. The 3010
Series is part of Y&F's shipset of EMA products.
AREVA’s Transmission and
Distribution (T&D) division and
Bruker Energy & Supercon
Technologies (BEST) have successfully designed, built and tested a single module of a 13
MVA (2000 A, 6.4 kV) single-phase, shielded-type inductive superconducting fault current limiter (SFCL) at the AREVA T&D
Technology Centre. The design uses a proprietary cryogenic
A recent AREVA project: SOCATRI in France.
module incorporating BEST’s 2nd generation high-temperature superconductors.
Increasing demand for electricity and the restructuring of the power transmission system resulting from deregulation and the increased level of distributed and renewable energy generation can lead to fault current levels above the capability of existing switchgear. A viable solution is to install a current-limiting device which is self-triggering, rapidlyactivated within a few milliseconds and fail-safe.
The tests in Stafford showed positive results. The SFCL module limited a prospective 68.5 kApeak fault to 9 kApeak in five milliseconds (¼ cycle) Fault current after five cycles (before circuit breaker opening) was reduced by a factor of 10.
The SFCL exhibited fast recovery after a short circuit fault (less than 200 milliseconds) and is expected to withstand a large number of limitation sequences.
Commenting on the successful collaboration with BEST on these tests, Gerhard Seyrling,
Innovation & Performance
Improvement Senior Vice
President of AREVA T&D, told AIP:
“This product addresses issues with high fault currents which our customers are very concerned about in their networks. We intend to work with BEST to create an industrialised product which will make our customers’ grids smarter and allow integration of distributed generation. This breakthrough technology is set to play an increasingly important role in the development of smart grids.”
A U T U M N 2 0 0 9 • A
M E R I C A N
I
N D E P E N D E N T
P
O W E R

Page 7 Iberdrola.qxd 11/11/2009 15:22 Page 1
www.iberinco.com

AIP.NEWS.Nov.09.qxd 17/11/2009 13:28 Page 4
N E W S
8
In brief...
Boring work ahead for
Kingsbury
Kingsbury Inc., the inventor and manufacturer of a unique range of tilting-pad fluid-film bearings, is three months into an expansion project at its Philadelphia,
PA plant to accommodate very large turning machinery and a custom induction heat treating system. This new equipment will allow the company’s
Messinger Bearings brand to fabricate and repair rolling element bearings up to 25 feet in diameter, the largest size capacity of any
US bearing manufacturer.
For certain industries which use these giant bearings, such as tunnel boring equipment, slewing rings in the steel industry, stackers
& reclaimers, offshore cranes and others,
Messinger will be able to provide much faster lead times than were previously available from foreign providers, for both new bearings and repairs.
Foster Wheeler to
Supply Biomass-Fired
Boiler Island in Poland
A subsidiary of Foster
Wheeler has been awarded a contract by ZE PAK S.A.
for the design, supply and erection of a 55 MWe biomass-fired circulating fluidized-bed (CFB) boiler island for the Konin Power
Station in Poland.
Foster Wheeler has received a full notice to proceed on this contract.
Commercial operation of the new steam generator is scheduled for the first quarter of 2012.
Foster Wheeler will design and supply the steam generator and auxiliary equipment, and will carry out the erection and commissioning of the boiler island. The steam generator will be designed to burn wood biomass and up to
20% of agro- biomass.
The fuel flexibility of FW’s
CFB technology is said to provide an excellent solution for biomass power generation thanks to a wide range of fuels.
Woodward Governor
Company has already shipped its first seven
CONCYCLE® wind power converters produced in the US with more in the pipeline. The electric power converter units, shipped from
Woodward’s production facility in
Colorado, will be used with seven
REpower model MM92 wind turbines being installed for the second phase of the
Stoney Corners wind farm in Michigan. The wind turbines are rated 2 MW each.
US-based production is one element of
Woodward’s strategy to improve customer satisfaction. By producing converters in Colorado, it feels it can better serve the North American wind power industry.
OEM customers like
REpower, as well as local wind farm owners, benefit from local manufacturing with lower shipping costs, shorter lead times, local currency transactions and faster local support, says the company.
In addition to local production,
Woodward also provides US-based sales and service support for the estimated 600 CON-
CYCLE units already installed in North
America.
For North American customers, the converters are ETLcertified for use in the United States and
Canada.
To meet stringent utility grid code requirements in
North America and worldwide,
Woodward CONCYCLE converters are available with patented active Fault
Ride Through
(activeFRT) technology.
This allows wind turbines to stay connected to the grid even during large variations in the voltage or frequency of the transmission lines thanks to activeFRT.
Last month MAN Diesel celebrated the official opening of its latest service centre in
Seattle, Washington, to further expand its PrimeServ network in
North America. The Grand
Opening of MAN Diesel
PrimeServ Seattle took place in front of more than 100 customers, suppliers and business partners, including the local Honorary German and
Danish Consuls. The newly renovated, 1,800-m2 workshop and 400-m2 office space will handle customer requests for all basic repair and service requirements, and include complete overhaul facilities for fuel equipment and for the turbochargers. Plans are already in place to develop the facility in accordance with customer demand. This North West Pacific location is an important arena for MAN Diesel to reach customers on the West Coast.
TOP UK SHOW FOR 2010
Don’t miss the IP&EE Show
(Independent Power & Energy
Europe) which will be held on
8th - 10th June at the NEC
Birmingham, UK.
The exhibition will run concurrently with Electrex
2010, one of the UK's top industry trade shows.
Space is selling fast so book your stand now.
Both highly-regarded exhibitions are being organised by Global
Media Publishing Ltd.
More info? Visit: www.gmp.uk.com
----------------------------------------
.
DECEMBER 2009
* POWER-GEN International,
Las Vegas Convention Centre, NV,
USA, 8th-10th December, 2009.
* ENERGAIA - Europe’s premier
International Renewable Energies
Exhibition & Conference, Paris,
France, from 9th-12th December,
2009.
JANUARY 2010
India’s premier energy show -
ELECRAMA 2010 Conference &
Exhibition - will be held on 20th -
24th January, 2010, at the
Bombay Exhibition Centre.
FEBRUARY 2010
* Middle East Electricity, 9th-
11th February, Dubai International
Convention Centre, Dubai.
* Renewable Energy World North
America Conference & Exposition,
Austin, TX, USA. Held on the 23-
25th February, 2010. This latest
Photovoltaics World Conference &
Exposition will be co-located with this exhibition.
MARCH 2010
* Distributech, March 23rd-26th,
2010, Tampa Convention centre,
Tampa, Fl, USA.
* Russia Power to be held in
Moscow, Russia from March 24-26.
APRIL 2010
* POWER-GEN India & Central
Asia to be held on April 20-22,
2010, in New Delhi, India.
* ICAE 2010 International
Conference on Applied Energy, 21-
23rd April, 2010, organisaed by the National University of
Singapore.
MAY 2010
* 18th World Hydrogen Energy
Conference, May 16 - 21st, Essen.
* Windpower 2010 Conference &
Exhibition, Dallas, TX, USA, on
May 23rd-26th, 2010.
A U T U M N 2 0 0 9 • A
M E R I C A N
I
N D E P E N D E N T
P
O W E R

AIP.NEWS.Nov.09.qxd 17/11/2009 13:28 Page 5
N E W S
In brief...
Dresser-Rand Company recently designed and installed a complete waste heat recovery system at the
Greater New Haven Water
Pollution Control Authority
(GNHWPCA). The project included engineering, construction and testing of the waste heat boiler, steam turbine generator set and condenser, ducting and valves.
Through a long term service agreement with GNHWPCA,
Dresser-Rand will also maintain the facility, to achieve the guaranteed electrical production.
The system is expected to produce 4.4 million kW hours of electricity per year.
Providing wastewater treatment for the residents of New Haven,
Hamden, East Haven and
Woodbridge, Conn., the GNHWPCA wanted to reduce its electricity costs, minimise future rate increases, and pass those savings on to its customers. The Dresser-
Rand project uses waste heat from the wastewater treatment facility to produce steam, powering a Dresser-Rand 750 kW steam turbine generator at the
East Shore Water
Pollution Abatement
Facility. As a result of the project, GNHWPCA expects to reduce its electricity costs by one-third. The GNHWPCA has received financing for 50% of the capital cost of the project through the use of Clean
Renewable Energy Bonds (CREB's) at 0% interest for 16 years. The
GNHWPCA also received a
US$300,000 incentive grant from
CTDPUC, under Connecticut's legislation for distributed energy facilities.
"With the nation's focus on building renewable and alternative energy capabilities, there's a push to extract all economically viable energy, including energy at water treatment plants," Peter
Salvatore, Vice President, Global
Field Operations at Dresser-Rand, told AIP.
"This project is illustrative of
Dresser-Rand's 'turnkey' approach, providing single-point responsibility, offering an efficient and effective project delivery, and providing added value for our clients,” he said.
“We estimate this type of power recovery solution could be viable for 200 similar facilities in the
U.S. And while this project falls on the smaller end of the power scale, Dresser-Rand has equipment and capabilities exceeding 60MW."
The GNHWPCA water treatment process involves removing sludge, or sewer system waste, from the water, reducing the moisture content to a combustible level, and burning the dried sludge in a multiple hearth furnace. The exhaust gas is scrubbed to remove pollutants and released.
Tognum supplies power plant gen-sets
Two MTU Onsite Energy emergency gensets will be supplied by the propulsion and power solutions specialist Tognum to the
Unterweser power plant in early 2011. Awarded by Eon
Kernkraft GmbH, the contract is worth € 11.25
million. In the next few years, the replacement of emergency power systems in several German power plants will become a priority. The NPP
Unterweser is one of those requiring additional new emergency gensets.
Both emergency gensets are based on the MTU 16V
956 TB 33 engine and have a joint electric power output of 9,400kW.
This equals the energy consumption of a small town with a population of about 10,000.
Following the start signal, it takes the gensets less than
10 seconds to reach their operating speed so that electrical power can be generated.
5.2 MW
205-590-3505 Tel
205-590-3885 Fax
Wesley: wtuggle@maegen.com
Art: asigler@maegen.com
Greg: gposey@maegen.com
Keith: kcoleman@maegen.com
A
M E R I C A N
I
N D E P E N D E N T
P
O W E R
• A U T U M N 2 0 0 9
9

Page 10 Crestchic.qxd 11/11/2009 15:33 Page 1
W O R L D W I D E LO A D B A N K S P E C I A L I S T S
S A L E S R E N T A L
When power generation is vital, when backup systems must be fully tested to make sure they’re up to the job - you need a stable, continuous and variable power generation test to imitate real loads, in real time. You need a load test solution you can rely on.
No other company specialises in worldwide load test solutions like Crestchic.
Manufacturing loadbanks for sale and rental for over 20 years, we have delivered reliable and effective test solutions to all seven continents.
For more information, contact us on
(+44) 01283 531645
Or find us on the Internet at www.crestchic.co.uk
You can also email us: sales@crestchic.co.uk or hires@crestchic.co.uk

AIP.Space Station.p11.qxd 16/11/2009 08:10 Page 1
SPACE STATION
The SSI - not much atmosphere.
PV cells are mounted on 8 wing-like structures.
T he International Space Station (ISS) is an internationally-developed research facility currently being assembled in Low Earth Orbit. Orbital construction of the station began in 1998 and has development operations scheduled until at least 2015. The station can be seen from the Earth with the naked eye and is the largest artificial satellite in Earth orbit, with a mass larger than that of any previous space station.
In Earth orbit, the most practical source of power for the ISS is sunlight.
Fortunately, solar power is plentiful. The
Sun radiates 4 x 1023 kilowatts (kW) - if we could collect it all, the Sun's power output would be enough to supply the demands of 31,000 billion planet Earths, all consuming energy at 1999 levels.
In fact, our planet intercepts only about a billionth of the Sun's total output, but even such a small fraction represents a large dose of power.
"If we turned all the water in Lake Erie into fuel oil and burned it all in a single second, we'd produce about the same amount of energy as we get from the sunlight that strikes Earth in one day," explains Sheila Bailey, a research physicist at NASA's
Glenn Research Center (GRC) in Cleveland, Ohio.
The Glenn Research Center developed the highly-refined photovoltaic (PV) technology which is being used on the
ISS. These cells are mounted on eight large, wing-like structures called solar arrays, each measuring 34 m long and
11 m wide (112 ft. x 39 ft.).
The arrays together contain a total of 262,400 solar cells and cover an area of about
2,500 m2 (27,000 sq. ft.) - a computer-controlled gimbal rotates to keep the arrays tilted toward the Sun. But the up to 36 minutes of each 92-minute
The arrays contain a total of 262,400 solar cells.
In the dock: the Space Shuttle arrives.
Sun is not always ‘up’ because the ISS spends almost half its time in the shadow of Earth. The spacecraft is in eclipse for circuit around our planet. During the shadow phase the space station relies on banks of nickel-hydrogen rechargeable batteries to provide a continuous power source to draw on.
Those batteries consist of
38 cells connected in series and packaged together in
.
testing at GRC, according to David
McKissock, a power management systems analyst at Glenn. Switching back and forth between solar-generated power and stored battery power was a challenge for designers of the station's power system.
The entire electrical power supply has to be switched smoothly twice each orbit, distributing reliable glitch-free current flow to all outlets and devices.
"The result of this carefully managed process is 110 kW of power available for an enclosure which monitors temperature and pressure. The unit is designed to allow simple removal and replacement.
The batteries, which are recharged during the sunlit phase of each orbit, are expected to last more than
5 years based on extensive all uses," McKissock says. "After life support, battery charging, and other power management uses take their share,
46 kW of continuous electric power are left over for research work and science experiments. That's enough to run a small village of 50 to 55 houses."
AIP www.nasa.gov
A
M E R I C A N
I
N D E P E N D E N T
P
O W E R
• A U T U M N 2 0 0 9
11

GasTurbines.p12.qxd 17/11/2009 13:13 Page 1
GAS TURBINES
12
A ccording to the manufacturer the
Titan 250 package features elements of a number of successful models. It includes combustion technology from the Mercury 50, hot section technology and turbine aerodynamics from the Taurus 65, and in-situ repairability and hot section durability from the Titan 130.
The Titan 250 gas turbine operates on a broad range of gaseous and liquid fuels and delivers 22MW of power in a highly compact package.
The manufacturer says it has been designed to give customers many years of productivity with low life-cycle cost.
Industry-exclusive SoLoNOx™ dry lean-premix combustion technology - proven on a wide range of Solar gas turbines to lower emissions - ensures compliance with stringent exhaust emissions regulations
The Titan 250 package.
worldwide. This technology cuts nitrous oxides by up to 90% of that of conventional combustors, says Solar. Solar gas turbines with SoLoNOx combustors have logged more than 66 million operating hours, avoiding more than 1 million tons of NOx emissions and improving air quality for millions of people around the world. According to the company: "The Titan 250 delivers the best performance in its class. You can be confident that it will support your own sustainable production and development through energy efficiency, low greenhouse gas emissions and low-pollutant emissions. No other turbine system gives you the power density, efficiency and low emissions, and costs
The Titan™ 250 gas turbine compressor rotor.
you less per kilowatt-hour."
Solar Turbine’s Titan 250 generator set can be used in a wide variety of applications including combined heat and
The Titan 250’s rail-mounted service system allows easy access. power (CHP), peaking power/load management, district heating and cooling, and base load power. For CHP applications the Titan 250 generator set can be coupled with heat recovery equipment to optimise an application by capturing otherwise waste heat energy to produce steam for space, water or process heating, thereby maximising energy efficiency and increasing sustainability.
The Titan’s rail-mounted service system allows easy access to inspect, repair or replace hot section components, bearings, blades and seals. Technicians can also remove and replace the gas producer independently of the power turbine, avoiding realignment of the power turbine and generator.
The company says: "Because the Titan
250 is highly reliable and efficient, utilities can benefit by using it to provide power to isolated communities, to commercial centres and to industries.
Utilities will also benefit by using the
Titan 250 in peaking applications to reduce the cost of additional generation."
The Titan 250 comes fully integrated and self-contained with lube oil, fuel and control systems on board. Solar Turbines says it can configure modular inlet, exhaust and ancillary systems to suit any application in enclosed or unenclosed packages. The Titan 250 package includes what the company calls the 'next evolution of Insight System' - said to be the industry's most advanced equipment health management system.
“InSight System,’ says Solar, “gives you a clear vision, focus and understanding of your machine operations.” www.solarturbines.com
AIP
A U T U M N 2 0 0 9 • A
M E R I C A N
I
N D E P E N D E N T
P
O W E R

AIP.GasEngines.p14.qxd 16/11/2009 08:15 Page 1
GAS ENGINES
14
T he year began well with a thumbsup for three Rolls-Royce Trent 60 gas turbines operating at two electric power stations in the cities of Lowell and
Braintree, Massachusetts, US.
All three units are Trent 60-powered Wet
Low Emissions (WLE) generating sets, capable of running on both gas and liquid fuel, with power outputs up to 58MW each.
Now the first Trent 60 gas turbine electrical generating package installed in
Australia has also officially begun service.
The announcement was made in conjunction with the formal opening of the Tamar Valley Power Station at Bell
Bay, near George Town, on the Tamar
River in Tasmania.
Operated by Aurora Energy (Tamar
Valley) Pty Ltd (trading as AETV Power), a wholly-owned subsidiary of Aurora Energy, the Trent 60 Wet Low Emissions (WLE) dual-fuel electrical generating set was ordered in 2007 and began operation in
March 2009.
The first Trent 60 power was supplied to the Tasmanian electric power grid in April.
Capable of providing up to 58MW of
[Below] The R-R factory in Derby (UK) features a Trent-powered cogen power station to supply electricity and steam.
power for back-up electricity when required, as well as peaking capacity to the Tasmanian grid, the Trent 60 package has recorded over 2,000 hours of operation.
Tony Davis, Regional
Director – Australia and New
Zealand for Rolls-Royce, told AIP: “The Trent 60 gas turbine power generation package will deliver an efficient and low emission source of electricity for the local community over the long term. The first Rolls-
Royce gas turbine electric generating sets in Australia were installed in 1968 here at the Bell Bay site, so we are very pleased that the first Trent 60 is installed close by.”
The Trent 60 WLE engine is designed to meet stringent environmental requirements, including reduction of carbon-dioxide and other greenhouse gas emissions, which is a particular focus of both the Australian federal and state governments.
The Tamar Valley installation continues to expand the installed fleet of Trent 60 power generation packages around the world. In addition to the Australia region, the Rolls-
Royce Trent 60 has been ordered for, or is installed in, new power stations in Belgium, Canada,
Chile, China, the Czech
Republic, Denmark, France,
Germany, Israel, New Caledonia,
Slovakia, Sharjah, and the UK.
The company already has energy customers in 120 countries.
Over 50 Rolls-Royce industrial gas turbines, including Avons,
501s, Olympus’ and RB211s,
A Trent 60 WLE unit is now operating at the Tarnar Valley Power Station in
Tasmania.
have been delivered to operators in
Australia to provide power for installations such as hospitals, factories, newsprint mills, mining companies and for operation offshore on oil and gas platforms.
The Trent 60 is the most powerful and efficient engine in the Rolls-Royce industrial gas turbines product range.
Capable of delivering up to 64MW of electric power in simple cycle service at
42 per cent efficiency, the engine has established a new benchmark for fuel economy and cost savings, says the company.
Rolls-Royce has other Trent 60 power generation successes in the Pacific Region, with units either installed or on order in
Western Australia and in the North
Province of New Caledonia in the South
Pacific.
AIP www.www.rolls-royce.com
A U T U M N 2 0 0 9 • A
M E R I C A N
I
N D E P E N D E N T
P
O W E R

AIP.Gensets.Welding.p15.qxd 16/11/2009 08:18 Page 1
GEN-SETS & WELDS
T o give additional argon gas shield coverage during welding, a ‘Trailing
Shield’ can be fitted to the welding torch, reports Huntingdon Fusion
Techniques Ltd (HFT).
This ensures that the hot weld zone is shielded with Argon for a longer period, than if it were shielded with the torch nozzle gas only, says the company.
The extra inert gas shielding gives time for the metal to cool, below the temperature at which it would oxidise.
According to reports, the improved shielding produces a brighter, shinier weld without any discolouration.
Leading British welding ancillaries manufacturer Huntingdon Fusion
Techniques Ltd (HFT) currently provide a wide range of trailing shields to fit any make of TIG (GTAW), MIG or Plasma (PAW) welding torch for manual or automatic welding.
Flat trailing shields are available for the welding of sheet metalwork or plate work. Radiussed trailing shields are manufactured for every diameter of tube pipe or vessel from 1-inch upwards.
As well as the popular ones radiused for outside welding, HFT also manufactures a version for inside welding.
Other trailing shield models are available for robotic welding where the shields are wider and longer for greater welding speeds that are possible with manual welding.
Other additional benefits are that gas consumption is reduced, faster welding times are obtained and the need to use a purge enclosure is eliminated. Argweld®
Trailing Shields can be used for welding stainless steel, duplexes and titanium.
The company has also developed a method of welding stainless steel pipes up to 12” diameter and has launched a new range of purging systems.
They allow the introduction of inert gas to reduce the oxygen content of pipes faster and allow welding to begin sooner than previously possible.
The new pipe purging system has been designed with multiple exhaust channels, to allow the oxygen in the weld space to be exhausted faster than before.
Furthermore, additional inert gas inlet channels have been provided to speed up the purging process for more time savings.
Called the ‘Multi Hole Pipe Purge
System’ this new Argweld® range is for pipes from 2 – 12” (50 – 300 mm) diameter and it replaces the previous range know as the MKIV System.
For pipes of 8” (200 mm) diameter up to
80”(2000 mm) the designer and manufacturer, HFT, has developed the
Argweld® Quick Purge range, with several other benefits. Recent news from the
[Above] To give additional argon gas shield coverage during welding, a ‘Trailing Shield’ can be fitted to the welding torch, reports
Huntingdon Fusion Techniques Ltd company reveals that a lead engineer for the Bechtel/Bioku Island LNG project in
Equatorial Guinea walked onto the stand of Cob Industries, HFT’s US exclusive distributor, at a recent exhibition.
The engineer subsequently placed a
US$95,000 order for equipment which included a large number of Argweld®
Quick Purge Systems.
Bechtel continues to be one of HFT’s largest and most regular customers having used Argweld® Quick Purge systems on the Sabine Pass LNG contract - and many other stainless steel pipework related projects, reports the company.
AIP huntingdonfusion.com
A
M E R I C A N
I
N D E P E N D E N T
P
O W E R
• A U T U M N 2 0 0 9
15

AIP.Loadbanks.p16.qxd 16/11/2009 08:23 Page 1
LOADBANKS
16
A ccording to its manufacturer, the
Avtron Model LCV allows testing of
AC power systems at less than unity power factor, typically 0.8 p.f. lagging.
To achieve a 0.8 power factor, the LCV combines resistive load (KW) with reactive load (KVAR). This combination is said to provide a ‘true test’ of the actual generator or UPS nameplate rating (KVA) and simulates a ‘real world’ load.
The unit is available in three different capacities 3750, 5000, and 6250 KVA at
480 VAC, 3 phase, 60 Hz. The unit is PLC controlled with a convenient hand-held remote controller. Laptop computer control with data logging is also available as an option.
The Avtron Model LCV load bank is designed to provide high capacity resistive and reactive loading of AC power systems such as diesel generator sets, turbines, or
Uninterruptible Power Supplies (UPS).
The loadbank itself consists of a rugged
ISO-style container housing the resistive and reactive components, blowers, associated controls, and interconnections.
The container features air intakes on the sides of the container with vertical exhaust through the roof.
The resistive elements are manufactured from corrosion-resistant chromium alloy wire and are fully supported on stainlesssteel rods for long life.
The reactive elements are of nonsaturating single and three-phase ironcore construction impregnated with high dielectric varnish.
The control power - 120 VAC, 1-Phase,
60 Hz – is provided by an integral control
T provided to measure voltage, current, frequency, KW, KVAR, and power factor.
Schematic: essentials of the Model LCV container.
M OD LC V
Remote Hand Held Controller
The Avtron Model LCV.
The resistive elements are cooled by integrally-mounted blower motors each rated 10 HP, 460 VAC, 3-Phase, 60 Hz.
The LCV Load Bank features both local and remote load control. The remote hand held controller is rugged and compact (7"x7"x2"). The controller is easy to operate and load values are activated by pressing a membrane style keypad. All resistive and reactive functions are displayed on a LCD display. A hard wired
E-Stop push button is also provided.
The remote controller communicates with the Load Bank PLC via 200 feet of control cable in two 100' increments with
MS style connectors.
There is branch-circuit fusing on all load steps and over-temperature protection.
Air switches on the blowers are all electrically interlocked to remove the load if the airflow is not sufficient to provide proper cooling.
According to Avtron ‘the Model LCV loadbank is ideal for high power resistive a reactive testing of AC generating systems in factory production lines or in the field after installation’.
AIP www.load-bank.com
A U T U M N 2 0 0 9 • A
M E R I C A N
I
N D E P E N D E N T
P
O W E R

Page 7 Marellit.qxd 22/06/2009 11:33 Page 1
Marelli Motori S.p.A. - Via Sabbionara 1 - 36071 Arzignano (VI) - Italy
Tel. +39 0444 479 711 - Fax +39 0444 479 888 - Web: www.marellimotori.com - E-mail: sales@marellimotori.com
®

Page 18 Wabash Teksan Giro Interpower.qxd 18/11/2009 09:45 Page 1
5.2 MW MOBILE GEN SETS
CALL: 800-704-2002
WITH OVER 25 YEARS EXPERIENCE,
INTERPOWER HAVE THE KNOWLEDGE
AND EXPERTISE TO MEET YOUR
POWER REQUIREMENTS.
EVERY SYSTEM IS BUILT TO THE
CUSTOMERS SPECIFICATION. FROM
2500kVA 65dBA @ 1m CONTAINER
SETS, THROUGH TO OIL & GAS
SPECIFICATION EQUIPMENT.
INTERPOWER HAVE THE SOLUTION TO
YOUR POWER PROBLEM.
INTERPOWER MARINE SETS ARE BUILT
AND TESTED TO THE HIGHEST MARINE
CLASSIFICATION SOCIETIES, INCLUDING
LLOYDS, DNV, ABS AND BV.
OUR DISTRIBUTOR NETWORK OFFERS
SUPPORT IN MANY COUNTRIES AROUND
THE WORLD.
FOR MORE INFORMATION PLEASE
CONTACT US ON DETAILS BELOW.
INTERPOWER INTERNATIONAL LTD
PO BOX 70, PICKERING,
NORTH YORKSHIRE,
YO18 7XU
ENGLAND
Tel: +44(0)1751 474034
Fax: +44(0)1751 476103
Web : www.interpower.co.uk
Email : info@interpower.co.uk

AIP.Controls&Monitoring.p19.qxd 17/11/2009 12:56 Page 1
CONTROLS & MONITORING
C abarrus County is an area of gently rolling hills northeast of Charlotte, in North Carolina, USA. This is a rapidly-growing region which is bustling with business activity. It’s also renowned as a centre of stock car racing activity, and is home to almost a dozen NASCAR racing teams and the world famous Lowe’s
Motor Speedway.
With its location along Interstate 85 just fifteen minutes north-east of Charlotte’s central business district, the airport is in the heart of the highest-impact growth corridor in North Carolina. The airport averages over 5,500 arrivals and departures per month, peaking at over
7,000 during May in conjunction with major events at the Speedway.
The sprawling airport grounds encompass
750 acres, and include a 5,500-foot allweather runway, a main terminal building, numerous hangars, a fuelling facility, a
City of Concord fire station, and a business park. To keep aviation activities going in the event of a power outage the Concord Regional Airport relies upon three standby generators from
Generac Power Systems. Each one
[Below] 100kW diesel unit from Generac. The runway lights, instrumentlanding system and navigational equipment are backed-up up by this unit.
supports a critical part of the airport operation, ready to supply backup power whenever necessary to keep the facility operational during power outages.
“Concord Regional Airport is open
24-hours-a-day, seven-days-aweek,” says Richard Lewis, Interim
Aviation Director. “With the
Generac Power Systems equipment, our terminal building, fuel operations, and airport lighting systems will operate when others are not. Dependability is the key to our success, and
Generac is part of that commitment to our customers.”
The 18,000 square foot terminal building is the nerve centre of the airport operation. Providing backup power for the terminal building is a 250-kilowatt diesel generator
[Above] 250kW diesel gen-set developed by Generac.
[Left]45kW gen-set powered by LPG.
set with a 450 gallon fuel tank and
Generac automatic transfer switch, with enough fuel to run for more than 20 hours at full load, if necessary.
Not far away is a 100-kilowatt diesel gen-set, dedicated to providing backup power for the airport’s instrument landing system, navigational equipment, and runway lights. This generator ensures that the airport can continue handling incoming flights in the event of severe weather, when normal power may be interrupted.
The third Generac unit is a 45-kilowatt
LP gas-fuelled gen-set, which provides standby power for the airport’s 'fuel farm'.
In the event of an outage, this unit will keep the fueling facility fully operational until utility power is restored.
The Generac units were all installed by
Premium Power Systems of Concord in conjunction with a local electrical contractor. AIP www.generac.com
A
M E R I C A N
I
N D E P E N D E N T
P
O W E R
• A U T U M N 2 0 0 9
19

AIP.Boilers.p20.qxd 16/11/2009 08:27 Page 1
BOILERS
20
T he story behind Thermbond Formula
Castable really begins with Stellar
Materials Incorporated, a company headquartered in Boca Raton, Florida
USA. Stellar Materials Incorporated is the manufacturer of Thermbond® Refractories and Phoscrete® Concretes. It is probably best-known as the inventor of the patented Stellar Binder System™, an advanced binder technology used in both
Thermbond and Phoscrete.
Its major product - Thermbond® - is regarded as being superior to traditional refractory materials. Thermbond is a family of engineered castable refractories. Thermbond uses the Stellar
Binder System™, a patented two-part system which incorporates a blended dry aggregate and a liquid activator. When mixed, the two-part product forms a unique 'Ionically-bonded' refractory.
Stellar’s Director for the Power Industry,
Brendan Gallagher, told AIP: "Thermbond sets very quickly. Thermbond's binder system initiates an exothermic reaction that causes the refractory to set very hard at ambient temperatures very quickly. It is excellent for casting shapes, since molds can be turned over eight times or more per shift. Thermbond is ideal for fast installations and fast repairs."
When one of Australia's major power stations had a problem with its Unit 2 boiler, a Penthouse Refractory Repair
(PRR) was diagnosed. The refractory in the B2 Penthouse around the tube penetrations proved in poor condition and needed repair to minimise the ingress of fly ash and hence reduce the clean-out time for the Penthouse in future outages.
Australia-based Refractech Pty. Ltd was brought in to supply Thermbond Formula
Castable using a paddle mixer, vibrator and concrete finishing tools. The contractor team used mullite-based
Thermbond Formula
Castable to provide a solution to the damaged conventional refractory which surrounded 137 tubes, 48mm in diameter. The contractor applied Thermbond to areas of existing damaged conventional refractory, creating a permanent repair which rapidly cured and dried within hours so the unit could go back into service.
According to Stellar, the permanent
Thermbond repair to existing fired refractory reduces the potential for burns to cleaning operators. The dust can flow through cracked conventional refractory and burn personnel something the plant has experienced in the past.
An industrial vacuum cleaned out fly-ash and any loose existing refractory material. Next, a 2mm thermal
Schematic of a typical PTWM-
50 boiler.
Thermal cracks in the walls can impair efficiency and increase the risk of cleaning crews suffering burns while cleaning out hot ash and other dust residues. insulating paper was glued around the steel tube penetrations to allow for some expansion and contraction during temperature fluctuations. The repair averaged 60mm in depth and some exposed anchors were evident. Whenever possible an insulation blanket was laid down and the Thermbond refractory was cast and vibrated into place.
Folowing the installation the plant engineer commented: “The Thermbond repair work was complete, the refractory went in quite well and there were no problems at all. All damaged refractory was removed down to the super wool layer. The super wool was replaced and ceramic paper was wrapped around the tubes. The contractors were very professional in their work. If the product performs well in these conditions, I will look at doing the rest of the penetration repairs with Thermbond.”
Special thanks go to John Pulbrook,
Sales Manager, Refractech Pty. Ltd. for this application report. John and
Refractech have been successful Stellar
Materials International Strategic
Partners for over 10 years.
AIP www.thermbond.com
A U T U M N 2 0 0 9 • A
M E R I C A N
I
N D E P E N D E N T
P
O W E R

AIP.SteamTurbine.p21.qxd 16/11/2009 14:12 Page 1
STEAM TURBINES
G
E Energy’s gas turbine technology has been selected by South
Mississippi Electric Power
Association (SMEPA) to expand the capacity of its Moselle Generating Station near Hattiesburg, Miss. The project will add 150 megawatts of output, helping
SMEPA meet the growing requirements of its cooperative members for reliable and efficient power with low emissions.
South Mississippi Electric, a generation and transmission cooperative, has been in business for more than 40 years and today provides wholesale electric power for more than 400,000 homes and businesses served by 11 member systems.
GE will supply two Frame 7EA gas turbines, technical advisory services and customer training for the Moselle project.
With 780 units in service, the GE 7E/7EA gas turbine fleet has accumulated millions of hours of service while demonstrating high levels of reliability and availability.
“South Mississippi Electric sees a need to increase its supply of reliable, efficient power to meet the requirements of its member cooperatives,” said John Reinker, general manager of heavy duty and combined-cycle gas turbines for GE Energy.
“With a proven track record spanning millions of hours of commercial service, GE 7EA gas turbines offer a reliable and efficient solution for meeting those growing energy needs.”
GE’s 7EA gas turbines are workhorses of the industry and have been used in a wide variety of power generation, industrial and
GE’s Frame 7 turbines will be augmenting existing steam turbines at Moselle.
cogeneration applications. The new machines for SMEPA will be installed behind boilers that currently provide steam for units 1 and 2 at the Moselle site. They will be equipped with GE’s dry low NOx combustion technology, restricting NOx emissions to 9 parts per million to help SMEPA meet the latest emissions standards.
When the new gas turbines are coupled with the existing steam turbines at the site, each of the new combined-cycle units will generate 134 megawatts and will be 30 percent more efficient than the existing Unit 1 and Unit 2 steam units.
It is expected that both of the new GE units will be commissioned by the spring of 2012.
www.ge.com/energy
AIP
®
ComRent /ŶƚĞƌŶĂƟŽŶĂů͕>> ͕ǁŝůůďĞƚŚĞƌĞǁŚĞŶŝƚĐŽŵĞƐƟŵĞƚŽ
put your systems to the test. We provide a full range of power test
ƐŽůƵƟŽŶƐ͗ůŽĂĚďĂŶŬƐͶ͕͕ƌĞƐŝƐƟǀĞ͕ƌĞĂĐƟǀĞ͕ĐĂƉĂĐŝƟǀĞ͕ŵĞĚŝƵŵ
ǀŽůƚĂŐĞΛϱͬϭϱŬs͘tĞĂůƐŽƉƌŽǀŝĚĞƚƌĂŶƐĨŽƌŵĞƌƐ͕ƐǁŝƚĐŚŐĞĂƌ͕ƉŽǁĞƌ
ĐĂďůĞƐ͕ĐŽƌŽŶĂĐĂŵĞƌĂƐ͕ĂŶĚŵŽƌĞ͘tŝƚŚϭϰ/ŶǀĞŶƚŽƌLJĞŶƚĞƌƐůŽĐĂƚĞĚ
ĂĐƌŽƐƐEŽƌƚŚŵĞƌŝĐĂ͕ǁĞĂƌĞLJŽƵƌƌŝŐŚƚ͕ƌĞĂĚLJĂŶĚƌĞůŝĂďůĞƉŽǁĞƌ
®
LLC ƚĞƐƟŶŐƐŽůƵƟŽŶƐƉƌŽǀŝĚĞƌ͘ www.comrent.com
888.881.7118
A
M E R I C A N
I
N D E P E N D E N T
P
O W E R
• A U T U M N 2 0 0 9
21

AIP.Test&Measurement.p22.qxd 16/11/2009 08:29 Page 1
TEST & MEASUREMENT
22
T he Ohio-based Swagelok Company unveiled a new process specification designed to meet the needs of the photovoltaic (PV) market, aimed at helping to ensure quality and reduce cost of ownership for the growing industry.
The Swagelok Photovoltaic Process
Specification (SC-06) outlines testing, cleaning, and packaging steps for stainless steel components for use in PV applications. The specification illustrates the company’s continued leadership in process-specific cleaning, which began in the 1980s with ultra-high-purity components.
“The photovoltaic industry presents unique challenges for solar cell manufacturers, who have to balance the need for ultrahigh-purity processing with the cost containment that will help them achieve grid parity,” John Baxter, manager, products and technology,
Swagelok Company told AIP.
“The SC-06 specification defines a set of baseline requirements so that products can be processed at a level appropriate for the industry and its goals.”
The baseline requirements include specifying the high-quality surface finish,
The VCR group.
The Swagelock range.
visual inspection criteria and particle counts the PV industry needs to maintain reliability and process control for improved uptime, while identifying areas
(such as work area classification, analytics, and packaging) where costs can be contained. Swagelok® products are designed to provide reliable, leak-tight performance in critical PV manufacturing processes, such as Plasma Enhanced
Chemical Vapor Deposition (PECVD) and diffusion. These and other processes require low leak rates for safety, control of process gas purity, as well as precise delivery of gases to maintain cell integrity and reduce scrap.
The Swagelok Photovoltaic
Process Specification (SC-06) is an available option for many
Swagelok high-purity products, in place of the company’s other specifications: SC-01 (Ultrahighpurity Process), SC-10 (Standard
Cleaning and Packaging), and
SC-11 (Special Cleaning and
Packaging).
The Microfits group.
The products currently available with
SC-06 processing include DP and DPH springless diaphragm valves, HB and BN series bellows valves, CW series check valves, VCR® metal gasket face seal fittings, and Micro-Fit® miniature tube butt weld fittings.
AIP www.swagelock.com
A U T U M N 2 0 0 9 • A
M E R I C A N
I
N D E P E N D E N T
P
O W E R

AIP.Turnkey.p23.qxd 16/11/2009 08:33 Page 1
TURNKEY
A new US$634 million natural gas combined cycle (CCGT) power station in Hampshire, UK, is adopting modular actuation technology to operate valves vital to the station’s final control processes.
The 842MW Marchwood Power facility is due to start commercial operations by the end of 2009. State-of-the-art technology, including AUMA actuators, is being adopted to ensure maximum energy efficiency with minimal impact on the environment. AUMA’s main contract for this order has been placed by Siemens.
Located adjacent to Southampton Water,
Marchwood Power is designed to generate enough electricity to supply the needs of nearly one million homes and will be one of the most efficient electricity generators in the UK. AUMA’s modular actuator design was recognised as providing the necessary adaptability to enable the scheme to continue to meet its objective of optimising energy
AUMA’s modular actuator.
Computer-generated view of
Marchwood Power Station.
production. With a track record supplying power plant applications dating back over
40 years, AUMA met requirements for a reliable and flexible actuation solution.
The company’s lightweight, ergonomically styled actuators also impressed as they are designed to be a straightforward solution for efficient valve control.
Products and services provided by AUMA include the SA electric actuator, which is capable of accepting up to 450,000 pounds (2,000 kN) thrust and of providing an output torque from 7 to 23,600 ft-lb.
(10 to 32,000 Nm). Combined with the
AUMA Matic integral motor control, the actuator enables automated valves to be integrated into a wide variety of control systems. For this application, the ‘Matics’ have been configured to integrate into a bespoke operating system designed by
Siemens for the Marchwood power plant.
Additionally, specific educational needs have been met for the station’s engineers through AUMA’s bespoke training programme. With a focus on practical guidance, the courses have been tailored to meet the needs of the power station’s staff giving engineers the necessary skills to assess, and address, on-site maintenance requirements.
Marchwood Power (www.marchwoodpower.com) is jointly owned by ESB
International and Scottish & Southern
Energy. The facility has been built under an EPC contract by a consortium of
Siemens PLC and Siemens AG.
AIP www.auma.co.uk
A
M E R I C A N
I
N D E P E N D E N T
P
O W E R
• A U T U M N 2 0 0 9
23

AIP.Cogen.p24.qxd 16/11/2009 08:38 Page 1
COGENERATION
24
K alaeloa is a 209 megawatt combined-cycle cogeneration plant which uses low-sulphur fuel oil. The facility sells all of its electric power to the island utility, Hawaiian Electric
Company, under a long-term power purchase agreement.
Combined cycle is characteristic of a power producing engine or plant which employs more than one thermodynamic cycle.
The Kalaeloa plant supplies steam energy to a local refinery, Tesoro Hawaii, one of only two refineries on the island.
Kalaeloa provides 90% of the refinery’s thermal requirements and supplies approximately 20% of the entire island electrical generating capacity.
The plant’s output is critical for meeting the energy needs of Oahu, the third largest and chief island of Hawaii.
In these times of growing awareness of energy efficiency, Hawaii businesses and residences have both the electric energy they need and the emphasis on conservation with Kalaeloa Partners, L.P.
“We are a service-oriented company committed to providing energy to our customers reliably, safely and as inexpensively as possible, with minimal adverse impact on the environment,” says
General Manager Hans (Ruedi) Tobler of
KPLP. KPLP provides 26% of Oahu’s annual electrical energy as a provider and partner with HECO.
The Kapolei-based 208-Megawatt
Combined Cycle Cogeneration Power Plant is at the forefront of conservation and pollution reduction technologies in the process of generating electrical and thermal energy.
It is the only one in the US which burns residual fuel oil, a ‘waste product’ called
LSFO (low sulphur fuel oil) remaining after extracting gas and diesel from crude oil by Tesoro Hawaii’s local refinery.
The plant recaptures much of the waste heat from its combustion turbines’ exhaust generated in that process to produce steam, which is used to produce 50 Megawatts of additional pollutionfree electrical energy and process steam for
Tesoro.
“In simple terms, like
H-Power converts garbage to energy, KPLP converts ‘waste oil’ to energy,” says Tobler who emphasises the alternative is to ship
LSFO off-island.
Compared to a
Conventional Power
Plant’s 25 to 32% efficiency, KPLP’s efficiencies approach
45%, which means less fuel and less pollution for same energy output, says Tobler.
In fact, KPLP is operating the most efficient plant in
Hawaii. Tobler credits KPLP owners, PSEG and Harbert Power, for the many costly plant modifications and improvements over the years which have resulted in the plant’s excellent efficiency - a 15% increase without increasing fuel or pollution. It is Hawaii’s first power plant to replace city water with treated waste water for steam production, saving
500,000 gallons of Oahu’s drinking water daily. A leader in pollution reduction and renewable energy generation, the New
Jersey-based PSEG can provide its expertise in photovoltaic-generated energy to KPLP’s future plans to explore the possibility of building solar plants.
“As a good neighbor and community member, our highest priority is to gear up to a meaningful transition from conventional ways of producing electricity to even more environmentally-friendly ways, while continuing to provide reliable and affordable electric energy to the businesses and residents of Hawaii,” says
Tobler. AIP www.pseg.com
A U T U M N 2 0 0 9 • A
M E R I C A N
I
N D E P E N D E N T
P
O W E R

Contracts.AIP.p25.qxd 17/11/2009 13:23 Page 1
C O N T R A C T S & A P P L I C A T I O N S
FG Wilson genset contract for Brazil
The Brazilian town of
Igarassu, Pernambuco, has installed more than 500 FG
Wilson diesel gensets in one of the world's largest generating unit installations. FG Wilson
Dealer, Aruanã Energia SA, has installed 576 generating sets supplying a total power output of 236
MW of standby power to the Brazilian national grid.
The power plant is expected to operate between 1,000 and 2,000 hours each year during times of peak demand.
SSC gets US$75m
Seattle Steam Company has been awarded a US$75m grant to build a CHP plant at Post Street in downtown
Seattle, which is integrated into the existing electrical and thermal energy distribution networks. Seattle Steam
CEO Stan Gent told AIp:
“This facility will generate
50 MW of electrical power and 35 MW of heat to offset existing, less efficient steam and electricity production systems.”
The renovated plant at
Post Street - along with the recently-installed biomass boiler at the company's Western Avenue plant - will reduce greenhouse gas emissions by 80% from its current level, says the company.
CHP for Houston
TECO is building a new CHP project at the Texas
Medical Center, Houston,
TX, where the company provides district heating and cooling service to 18 institutions. Now under construction, the 45 MW
CHP system will increase the company's heating and cooling systems.
Capstone’s contract
The Capstone Turbine
Corporation has received a
US$2m+ order for three
C800 microturbine systems for a large wastewater treatment plant in Brazil.
This is the first sale of
Capstone C800 units in
South America.
GE and E.ON Climate & Renewables (EC&R) North
America have signed a seven-year operation and maintenance (O&M) agreement covering EC&R’s complete fleet of 529 GE wind turbines installed in the United States. The O&M deal is one of the largest wind services agreements ever signed by GE.
The agreement is designed to maximise turbine availability and energy production across EC&R’s
U.S. installed base of GE wind turbines. In addition, the agreement reflects GE and EC&R’s shared goal of maintaining peak performance and reliability and building the world’s best running fleet.
Under the milestone agreement, GE will provide
24/7 remote monitoring and diagnostics from GE’s
Schenectady, N.Y.-based Renewable Operations
Center; flow and capital parts support; as well as complete site services for all GE 1.5-megawattb wind turbines installed at five EC&R project sites: the Pyron phase of Roscoe, Panther Creek I & II and
Panther Creek III in Texas, Munnsville in New York and Stony Creek in Pennsylvania. The O&M contract includes an availability guarantee, ensuring turbine performance.
Working closely with EC&R’s global team in the
United States and Germany, GE developed a services agreement which addresses EC&R’s need for predictable and competitive service costs, while maintaining operational excellence at the multiple sites. As the original equipment manufacturer, GE’s extensive product expertise, coupled with its ability to deliver customised service solutions, will help maximise revenue generation for EC&R.
“By teaming with GE on this comprehensive agreement, we will have greater capability to control our O&M costs over the long term, which will help us cut our total operating costs,” Steve
Trenholm, CEO of E.ON Climate & Renewables North
America told AIP. “In addition, the agreement ensures that our wind turbines will continue to operate at high availability and overall energy production.”
A single point of availability across E.ON’s fleet of
529 GE wind turbines can equate to more than
25,000 MW-hours of additional energy produced annually. That’s enough electricity to power more than 2,600 average American homes for an entire year.
“We look forward to working with EC&R in continuing their commitment to the ongoing development of renewable energy,” comments
Victor Abate, vice president—renewables for GE
Power & Water. “This landmark agreement is the start of a long-term services relationship. With one of the industry’s largest fleets of installed wind turbines, we have accumulated the technology expertise and experience to really help customers.”
The Philippines is looking at wave energy to generate part of its
379MW target.
Renewable energy (RE) contracts worth around US$1bn and with a total capacity of 379MW have been confirmed by the Philippine
Department of Energy (DOE).
The Energy Secretary of
Philippines confirmed the signing of service and certificates contracts with seven US-based RE companies engaged in the development of wind power.
The P-DOE signed four new wind energy service contracts with three companies. A combined investment of US$983 will be made by 6 companies in the
Philippines renewable energy sector. Around 70 renewable energy projects are in the pipeline, of which 50 are related to mini-hydro power, 20 related to wind energy and one with ocean energy.
Filipino Angelo T. Reyes, Energy
Secretary, commented:
“With these projects renewable energy is really coming on strong this year. I am very keen to see how these projects will turn out in the coming years.”
The investment in Philippines wind power projects is expected to rise to nearly US$2.5m per megawatt.
Meanwhile, Oriental Energy and
Power Generation Corp. has signed a contract for a 18 MW project in Madalag, Aklan.
This project is likely to cost
US$2m for each megawatt of hydropower.
A
M E R I C A N
I
N D E P E N D E N T
P
O W E R
• A U T U M N 2 0 0 9
25

NEWPRODUCTS.AIP.NOV09.p26.qxd 16/11/2009 08:41 Page 1
PRODUCTS AND SERVICES
26
Sensonics in transducer upgrade
In an upgrade of the Uskmouth Power Station in Newport, South
Wales, UK, Sensonics has supplied and fitted its Aegis VME
(Vibration) and Sentry turbine monitoring systems to a turbine and alternator. The vibration sensors fitted included Sensonics PZV2 piezo-electric velocity transducers which were selected, rather than accelerometers, based on their superior noise performance in heavy industrial environments and unique internal signal processing.
www.sensonics.co.uk
Avtron Minuteman loadbank
The Avtron Minuteman Load Bank is a portable, self-contained AC resistive loadbank designed for indoor use. The loadbank sets the new standard in ultra compact loadbanks, says the manufacturer. The loadbank provides up to 100 KW resistive load at 480 VAC or 240 VAC,
3-phase, 60 Hz. Weighing only 65 pounds, this versatile loadbank is said to be 20% lighter than competitive units.
The loadbank is also rated for continuous operation, unlike competitive units. The Minuteman Load Bank features horizontal air discharge to provide a low profile design. Fully-rated, quick-connect load terminals and simple operation allow the loadbank to be set up and operated by a single technician, saving valuable time in the field. www.load-bank.com
Saft’s new generation Tel.X telecom network batteries
Saft’s new generation of batteries have been widely accepted for use with telecom network backup power applications. Less than a year after Saft opened a dedicated US$9 million production line at its US manufacturing facility in
Valdosta, Georgia, the new
Tel.X battery has been adopted by a number of leading telecom operators in North America, the
Middle East and Europe.
“Extreme temperatures and high levels of humidity are a particular challenge for outdoor telecom installations, so with
Tel.X we focused on developing a battery capable of delivering high performance, reliability and low TCO,” says Xavier Delacroix, the
General Manager of Saft’s IBG division. “The early success of Tel.X
has come from wireline and wireless operators working in locations where outdoor cabinets are subjected to very high or very low temperatures. They have recognised the opportunity to make a switch from troublesome VRLA batteries to totally reliable, long-life, compact and maintenance-free nickel-based technology.” www.saftbatteries.com
New windfarm resins from Ashland
Ashland Performance Materials, a commercial unit of Ashland Inc.
will join a consortium of companies and university experts to develop, deploy and test three wind turbines off the Maine coastline.
A recent announcement by the U.S. Department of Energy awarded
$8m to the University of Maine for offshore, deepwater wind energy research, and Ashland was selected as a partner in this program. “We are looking forward to this collaborative effort. As the sole resin supplier to this project, we were pleased to have our efforts in resin science and development recognised by the
University of Maine,” said Ruben Bake, global marketing director, Ashland
Performance Materials. The consortium’s research and development plan will optimise materials and designs for deep-water floating platforms. The group will investigate options for using lighter, corrosion-resistant hybrid composite materials, evaluate the ease of making various turbine components, and explore how best to deploy such platforms.
www.ashland.com
Onan Introduces RV Generator Wireless Remote-Start Control
Onan has launched its newest power generation management tool,
Energy Command-15W (EC-15W), a remote-start tool for RV generators. Available to consumers this fall through authorised Onan dealers and compatible with all current Onan generators, the new
EC-15W features a wireless on/off switch on a fob that can be wall mounted or attached to a key chain and an easily installed receiver unit that attaches to the genset remote harness and works off of the existing battery terminal. The new EC-15W can be easily installed by the RV owner on RVs with an installed genset and can even be used in conjunction with existing wired on/off switches in the RV. The EC-
15W will retail for approximately $150.
Three versions of the EC-15W will be offered to coincide with various generator sizes including, one for diesel gensets, one for 3.5kW to
7.0kW gensets and a third for 2.5kW
to 2.8kW gensets. The units will also feature an additional hour meter that can be use with generators that do not already have one and additional fobs will be available for purchase. www.cumminsonan.com
AUMA to be used in new powerplant development
A new £380 million natural gas combined cycle (CCGT) power station
- the Marchwood power plant in Hampshire, UK - is adopting modular actuation technology to operate AUMA valves vital to the station’s final control processes. The 842MW Marchwood Power facility chose
AUMA's SA electric actuators; each is capable of accepting up to
450,000 pounds (2,000 kN) thrust and of providing an output torque from 7 to 23,600 ft-lb. (10 to 32,000
Nm). Combined with the AUMA Matic integral motor control, each actuator enables automated valves to be integrated into a wide variety of control systems. [see page 23 for more info.] www.auma.com
A U T U M N 2 0 0 9 • A
M E R I C A N
I
N D E P E N D E N T
P
O W E R

IPEE Front Cover 16.06.09.qxd 19/06/2009 09:55 Page 1
2010
8-10 JUNE 2 010
HALL 2 - BIRMINGHAM NE C , UK
C o l o c a t e d w i t h : S p o n s o r e d B y : M e d i a P a r t n e r :
W O R L D W I D E I N D E P E N D E N T P O W E R

SOLVAir® Select 200 trona is a naturally occurring mineral mined in Green River, Wyoming by Solvay
Chemicals, Inc. When used to treat acid pollutants occurring in flue gases, this underground mineral helps clean the air. Utilizing simple chemistry, Select 200 efficiently and cost-effectively removes a variety of acid gases such as SO
2
, SO
3
or HCl.
Used in a low capital cost injection system, Select 200 has shown the ability to remove over 90% of the acid gases present. Power plants, both large and small, have turned to the SOLVAir Group and its line of products to fight for cleaner air.
For more detailed information on SOLVAir Select 200 trona and how it cleans acid gas in the stacks, go to www.solvair.us
, or e-mail michael.wood@solvay.com.
Solvay Chemicals, Inc.
1.800.SOLVAY C (800.765.8292) www.solvair.us
Copyright 2009, Solvay Chemicals, Inc. All Rights Reserved
SOLVAir Whats Trona Oct AIP MagA1 1
Chemical and Phamaceutical Group
9/23/2009 12:04:50 PM