2025 TRB Handbook Web
2025 TRB Handbook Web
HANDBOOK
TURBOMACHINERY INTERNATIONAL • HANDBOOK 2025 • VOL. 65 NO.6
2025
P.hone: +49 223696500
2025 Ushers in
ESTABLISHED IN 1959
FOUNDERS G. Renfrew Brighton and R. Tom Sawyer Uncertainty for the
VICE PRESIDENT, CONTENT
Alicia Bigica
[email protected]
EDITORIAL
EXECUTIVE CORRESPONDENTS
Amin Almasi
Klaus Brun
U.S. Power Industry
Mark Axford
ASSISTANT MANAGING EDITOR
T
Alissa Espinoza CUSTOM PROJECTS DIRECTOR
[email protected] Robert Alaburda he 2024 elections, including the presidency and Congress, weigh heavy on the
ASSISTANT EDITOR CUSTOM PROJECTS power industry and companies that own and operate power generation assets.
James Cook MANAGING EDITOR
[email protected] Jeanne Linke Northrop Although President Biden pushed many energy and environmental initiatives—
NATIONAL ACCOUNT CUSTOM PROJECTS including a zero-carbon power sector by 2035—Britt Burt and Brock Ramey, authors
ASSOCIATE SENIOR EDITORS
Gerard Onorata Megan Manzano of our cover story, U.S. Power Industry Outlook 2025, make a strong supporting case
Shannon Stolz
973-747-6070 that the United States is indeed not
[email protected]
on “a one-way trip to a carbon-free
CREATIVE SERVICES & PRODUCTION electric future.” The integration of digital
CREATIVE DIRECTOR
Melissa Feinen
CIRCULATION DIRECTOR
Jon Severn
The duo breaks down the power technologies is revolutionizing
industry sectors: coal, natural gas,
ART DIRECTOR
Wassana Techadilok
PRODUCTION SUPERVISOR
renewables, nuclear, microgrids,
the operation and maintenance
Charlton Prince
PRODUCTION COORDINATOR batteries, and beyond. With political of gas turbines. Utilizing
Amber Immordino uncertainty, delays in the planned
retirement of coal-fired generators,
sensors, data analytics, and
SALES & MARKETING
record summer temperatures, and AI artificial intelligence,
U.S.A. AND CANADA
Gerard Onorata
JAPAN
Yoshinori Ikeda
data centers skyrocketing electricity operators can gain valuable
demands, Burt and Ramey expect 2025
insights into turbine
485 F Suite 210, Rt. 1 South Pacific Business, Inc., Chuo-ku,
Iselin, NJ 08830 Tokyo, Japan
- 2029 to be “extraordinarily choppy for
performance and health.
T: 973-747-6070 T: 81-3-3661-6138
[email protected] F: 81-3-3661-6139 the new-build U.S. power industry and
[email protected]
GERMANY, AUSTRIA, those who service generators.” – Carter Palmer
SWITZERLAND INDIA, MIDDLE EAST
Sven Anacker Faredoon Kuka
Carter Palmer lays out the global
InterMediaPartners GmbH RMA media, Andheri (E), gas turbine market for 2025, which he says is stable and will remain so among factors
Beyeroehde 14 Mumbai-400059, India
Wuppertal, D-42389, Germany T: 91-22-6570-3081/82
such as hydrogen, digitalization, and renewable energy.
T: 49-202-271-690 F: 91-22-2925-3735 Giuseppe Tilocca, Scientific Officer at ETN Global, offers another perspective on
F: 49-202-271-6920 [email protected]
[email protected]
gas turbines. Our Q&A conversation examines the association’s global report on
KOREA, SOUTHEAST ASIA
UK, BENELUX, SCANDINAVIA, Leithen Francis decentralized energy systems. Tilocca highlights their advantages and dives into how
ITALY, FRANCE Francis and Low, Singapore gas turbines fit into these energy systems.
Ferruccio Silvera T: 65-6337-0818
Viale Monza 24 [email protected]
Among the listings and specifications, our handbook
20127 Milano, Italy also features Amin Almasi’s Turbo Tips column,
T: 39-022846716
F: 39-022893849
Challenges with Dry Gas Seals for Turbocompressors, in
[email protected] which he asserts that compressor seal systems are the
most common culprit of unscheduled shutdowns.
EXECUTIVE OFFICERS
Additionally, the Myth Busters close out their two-part
PRESIDENT AND CEO SENIOR VICE PRESIDENT,
Mike Hennessy Jr CONTENT series on compressor maps and address the two Alissa Espinoza
Silas Inman Assistant Managing Editor
CHIEF FINANCIAL OFFICER extremes: surge and choke.
Neil Glasser, CPA/CFE SENIOR VICE PRESIDENT,
HUMAN RESOURCES &
CHIEF OPERATING OFFICER
ADMINISTRATION
Beth Buehler
Shari Lundenberg
CHIEF DATA OFFICER
SVP, MERGERS & ACQUISITIONS,
Terric Townsend SUBSCRIPTIONS
STRATEGIC INNOVATION
EXECUTIVE VICE PRESIDENT, Phil Talamo For subscription/circulation inquiries,
GLOBAL MEDICAL AFFAIRS & email customerservice@
EXECUTIVE CREATIVE
CORPORATE DEVELOPMENT mjhlifesciences.com or send via Turbomachinery International (ISSN 0149-4147) is published bimonthly, plus an
DIRECTOR, CREATIVE SERVICES
Joe Petroziello mail to: Turbomachinery International, extra issue in October, by MutliMedia Pharma Sciences, LLC 2 Commerce Dr.
Jeff Brown
PO Box 457, Cranbury, NJ STE 100 Cranbury, NJ 08512. POSTMASTER: Please send address changes to
08512-0457 Turbomachinery International PO Box 457 Cranbury NJ 08512- 0457, USA.
CHAIRMAN AND FOUNDER, 1 9 6 0 - 2 0 2 1 Publications Mail Agreement No 40612608. Return Undeliverable Canadian
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485 F Suite 210, Rt. 1 South © 2024 MultiMedia Pharma Sciences LLC. All rights reserved. No part of this
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storage and retrieval without permission in writing from the publisher.
CATEGORY LISTINGS
68 Aftermarket
69 Analysis & Software
70 Auxiliary Equipment
72 Boilers — Suppliers
72 Cogeneration & Combined
Cycle
72 Compressors & Expanders
72 Electric Equipment
73 Energy Resources
73 Environmental Services
73 Gas Turbines
74 Instrumentation & Control
75 Manufacturing
75 Materials
75 Pumps
14
75 Renewable Energy
76 Safety Equipment
76 Services
77 Steam Turbines
77 Training & Education 03 From the Editor 30 Gas Turbines
Worldwide Gas Turbine Forecast 2025
06 New Products
The latest turbomachinery 34 Q&A
SPECIFICATIONS industry innovations Gas Turbines and Decentralized Energy
78 Combined Cycle Systems
81 Electrical Generation
10 Industry News
Recent news from the industry 38 Show Report
85 Mechanical Drive Turbomachinery & Pump Symposia
87 Steam Turbine 12 Turbo Tips 2024
90 Turbocompressors Challenges with Dry Gas Seals for
Turbocompressors 100 Myth Busters
96 Turboexpanders
Centrifugal Compressor Maps:
14 Cover Story Surge and Choke
U.S. Power Industry Outlook 2025
4 • www.turbomachinerymag.com
ADVANCED
AIR EMISSION SOLUTIONS
FOR GAS TURBINES
In the past three years, we have designed, manufactured and commissioned more SCR systems than
anyone else in the world… all with a 100% success rate of hitting performance targets.
EnergyLinkInternational.com
NEW
PRODUCTS
The latest turbomachinery industry innovations
MAN Energy:
CR 2.2 Injection System
The CR 2.2 contains an optimized and uniform
high-pressure pump, a newly developed injector,
the CR 1.6 valve group, and 35% fewer
high-pressure connections. It controls injection
pressure, timing, and duration throughout
complete operating ranges.
CR 2.2 common-rail fuel-injection system.
Credit: MAN Energy Solutions
6 • www.turbomachinerymag.com
TURNINGPOWER
INTOPERFORMANCE
We know the equipment. We understand the processes. We deliver the reliability, safety,
and value you need to succeed.
Rotoflow, an Air Products business, continues to transform the hydrocarbon, LNG,
petrochemical, industrial gas, and energy recovery markets with turbomachinery that
powers the world’s most efficient processing facilities.
Our world-class support is growing with the addition of new service facilities, capabilities,
and team members to support and service turbomachinery from nearly any manufacturer
while meeting the needs of customers around the world.
Whether you need new equipment, installation and commissioning, maintenance and
repair, or overhauls and upgrades, Rotoflow is here to help you keep your operations
running at their best.
8 • www.turbomachinerymag.com
Moving big things to zero
with five key technologies
www.man-es.com
Ebara Builds
Industry News
Hydrogen Testing,
Development
Center
The new center in Futtsu City,
Japan, will conduct equipment
performance tests and develop
elemental technologies using
liquid hydrogen. To guarantee
stable liquid hydrogen pump
operation and quality assurance
for customers, Ebara will
perform testing using liquid
hydrogen at -235° C.
10 • www.turbomachinerymag.com
Castellón refinery.
Credit: bp
Challenges with
Dry Gas Seals for
Turbocompressors
A compressor’s seal system is the culprit of most common unscheduled shutdowns.
BY AMIN ALMASI
12 • www.turbomachinerymag.com
TURBO TIPS
COMMISSIONING OF DRY GAS SEALS turbocompressor from rest to maximum Monitor these parameters for indications
Liquid can cause problems for dry gas seals. operating speed. Monitor and record gas of the dry gas seal’s operational condition and
Inspect all parts in a seal system/skid, seal leakage during acceleration and health. A rise in seal gas consumption can
including low-point drains in the primary compare it to the guaranteed leakage rate. indicate an increasing internal clearance of
and secondary seal vents and seal gas filters Operate the turbocompressor for four the seal due to wear. An increase in the
for the liquid. Low-point drains should be hours and monitor/record leakage rates and primary-vent gas leakage could show an
closed and plugged before commissioning. other important seal parameters every 10 increased running gap of the primary seal.
The sources of all utilities, including the - 15 minutes. The dynamic leakage rates The most common reasons for a
separation gas (usually N2) and seal gas should be within acceptable limits as turbocompressor unscheduled shutdown
should be operational and available for specified by the manufacturer. are related to the seal system. Reviewing
commissioning. key seal system parameters such as seal gas
Step one is to static test the dry gas seal. flows, differential pressures, and gas
During static testing, the gas seal is slowly OPERATION AND KEY PARAMETERS leakages is important to turbocompressor
pressurized by ~10% incremental increases The following operational parameters are reliability and performance.
up to the maximum operating pressure. The critical for the dry gas seal and seal
actual static leakage is compared to the seal system/skid: Amin Almasi is a Chartered Professional
Engineer in Australia and the U.K.
manufacturer’s guaranteed static leakage seal gas supply flow
(M.Sc. and B.Sc. in mechanical
rate. If the static leakage rate is acceptable, seal gas differential pressure engineering). He is a senior consultant
specializing in rotating equipment,
perform the seal dynamic test. During the primary and secondary vent gas
condition monitoring and reliability.
seal dynamic test, accelerate the leakage rates
Clean Air
Engineering
Ensure optimal performance with Camil’s clean
air solutions for turbomachinery. Our advanced
filters enhance efficiency, protect equipment
and improve your carbon footprint.
[email protected]
www.camfil.com
Air inlet filters and housings • Weather protection • Ducting and acoustics • Air sampling and site surveys • Test & Learn training events
Predictive analytics services • Full air inlet system inspection • Filter installation and support • In-depth filter testing
U.S. POWER
INDUSTRY OUTLOOK
2025
Presidential elections are typically important for the power industry, but few in
recent memory stack up to the potential consequences of the 2024 election.
BY BRITT BURT AND BROCK RAMEY
his spring, near the end of a momentous Republican National Committee platform,
term, the U.S. Supreme Court overturned adopted in July, included planks calling for
a four-decade-old bedrock regulatory the abolition of the electric vehicle (EV)
precedent that granted deference to sub- “mandate,” cutting burdensome regula-
ject-matter experts at regulatory agencies. tions, and “making America the dominant
In deciding Ohio v. E.P.A., the high court energy producer in the world, by far.”
upended the process by which future, and Then, over the summer, as Biden’s
potentially past, regulations would be support fell apart, he bowed out of the race
determined for energy, the environment, and endorsed Vice President Kamala Harris
vehicle safety, and food and drug safety— as the candidate to succeed him, creating a
indeed the broader economy. The over- completely different electoral dynamic
turned case was one of the most-cited cases for November.
in federal regulatory law: Chevron U.S.A., The results of the November elections—
Inc. v. Natural Resources Defense Council. for the presidency, one-third of the Senate,
Well before the high court’s July 1 and all 435 members of the House of
ruling, Republican presidential candidate Representatives—will likely have an outsize
Donald Trump had repeatedly vowed to impact on companies that own and operate
reverse, block, or at least defund many if electrical generation assets in the United
not most of President Joe Biden’s energy States as well as those who build or service
and environmental initiatives. The those generators.
14 • www.turbomachinerymag.com
U.S. Power Generation Capacity: Under Development with Construction Kick-off Scheduled During 2024 - 2028
West
North
Coast 0.8% U.S. POWER GEN
EastUNDER DEVELOPMENT
348 mw WITH CONSTRUCT
103,654 mw
45,280
1.4%
FUEL OIL 4.0%mw 0.3% 0.5%
NATURAL GAS
742 MW NATURAL GAS NUCLEAR
519 MW 809 MW
2,103 MW
0.7%
1.5% 2.3%
WEST ROCKY
COAST MOUNTAINS
720 mw 52,228 MW
94.6%
150,321 MW
99.1%
1,532 mw 2,345 mw RENEWABLE
49,384 MW
RENEWABLE
148,988 MW
14.1%
6,039 mw
88% LEGEND
5.3%
LEGEND 225,918 mw
11.8% 21.4% Mid
Fuel Oil
>1%
2,269 mw
6,928 mw 11.7%
Natural Gas
0.3%
Nuclear
3,798 mw
0.1%
>1%
80.3%
WEST 4,947 MW
Renewable Energy 91% 95.9% 130,576 MW 0.2% 0
Project Locations 320 mw 65.8% 32,425 mw 366 mw 34,300 mw
RENEWABLE
125,206 MW
NUCLEAR
320 MW
NA
However the elections conclude, events in energy consumption of their data agency to question its own ability to
MW
the months preceding them should give pauseRM centers effectively erasedGL years of their NE provide reliable electricity to Texans.
to those who thought the United States was on use of renewable electricity. Biden’s EPA finalized a suite of Clean
a one-way trip to a carbon-free electric future: Power plant CO2 emissions grew in the Air Act regulations, sure to be chal-
The U.S. Supreme Court ruling in Ohio developing world more than offsetting lenged by Republicans, sharply
v. E.P.A. overturned a 40-year-old prece- reductions in developed economies. lowering emission standards from
dent in which experts in regulatory WC In a highly unusual move, the Supreme
NE
existing coal-fired power plants as well
agencies were granted deference in crafting Court stayed the EPA’s “Good Neighbor as future gas-fired generators. A
regulations when Congressional intent was Rule” on air emissions, even as it was separate rule, covering emissions from
ambiguous or unclear. still being litigated by the lower courts. existing gas-fired generators, is
FirstEnergy became the latest electric SW
2023 went down in SEthe record booksMAas expected later this year. That, too, is
utility to delay the planned retirement the hottest in recorded history, and 2024 expected to draw legal challenge.
of coal-fired generators, joining appeared on track to break that record. Another executive-level agency, the
PacifiCorp, WEC Energy Group, Alliant Extreme weather events—fueled, experts Council on Environmental Quality,
Energy, Dominion, Santee Cooper, say, by global warming—are becoming finalized changes to reform, update, and
Omaha Public Power District, and more extreme, more frequent, more streamline the environmental review
Evergy. TheIllustrator
list may grow longer as
graphs - original destructive, and more expensive. process in the National Environmental
utilities grapple with the soaring The Texas grid operator Electric Policy Act (NEPA), another foundational
electric demand growth coming from Reliability Council of Texas (ERCOT) piece of federal environmental regula-
data centers, particularly those powered estimated there was a 12% probability of tion. Again, this final rule is almost
by artificial intelligence (AI). rolling blackouts this summer, as certain to be challenged by GOP
Google, Microsoft, and other tech dramatically faster electric demand attorneys general and other parties,
companies disclosed that they no longer growth coupled with a shortfall of regardless of how power is apportioned
were on a net-zero trajectory, as the dispatchable generation caused the in Washington, D.C., in 2025.
94 % 94 % 91%
88 %
82% may also significantly impact new-build
80 % 72%
67%
generation. At press time, the EV initiative
65 % 61%
60 %
60 %
58 % 55 % 57% 55 % 57% appeared to be falling short of initial
43% estimates, but results vary from state to
39 % 41% 41% 41%
40 % 36 %
state. California is still expecting a jolt to
26 %
20 % 19 % 18 % 21% 18 % electric demand from electric transporta-
11%
5% 5% 7% tion, but other states seem to be scaling
0%
back expectations.
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16 • www.turbomachinerymag.com
TURBOMACHINERY MARKET
What are the key drivers shaping the current and future
industrial market?
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expand their distribution networks. Scheduled Five-Year Kickoff Construction Period
But offsetting this trend is the sharp
growth in demand from data centers, But in recent years, those plans have Another factor influencing types of
particularly those equipped with AI. Several sharply accelerated. In IIR’s most recent new-build generation construction is the
utilities with data center clusters in their analysis of U.S. planned generation construc- continued influence of “sustainable”
service areas, such as Dominion, Georgia tion starts, covering 2025 - 2029, about 875 investing among institutional investors,
Power, American Electric Power, and GW of new-build generation is scheduled to pension funds, and other types of financial
Public Service Electric & Gas, have been begin turning dirt, roughly four times the asset managers. A growing number of
forced to increase their projection of prior five-year period. This data includes all asset managers have pledged to abide by
electric demand growth, and thus CAPEX to types of electric generation. the U.N. Principles for Responsible
build new generation. IIR does not expect all these planned Investment (PRI), which rules out
Some, but not all, of this new generation generation projects will begin construction investing in new coal generators and
is slated to burn natural gas, but because as slated. Many will be deferred, and some frowns on new-build gas generation.
many data center owners have signed will be canceled outright. However, Through March 31 of this year, organiza-
sustainability commitments, IIR expects a tracking power plant development suggests tions that managed over $128 trillion in
good bit of this new generation will be that many new projects will be added over funds have signed onto the UN PRI,
renewables plus storage. the next five years. continuing a yearslong rise (FIGURE 3).
This year, electric reliability organiza-
tions, such as the North American Electric Figure 3: Surge in Cumulative Investments in “Responsible” Companies and Funds
Reliability Corp. (NERC) and ERCOT, sounded
alarms about whether electric generation will $160
Cumulative Assets Under Management (Trillions)
struction of about 200 GW of new generation Dollars Invested According to U.N. Principles of Responsible Investment
in the United States over successive five-year Source: United Nations Principles for Responsible Investment
periods starting in 2011 (FIGURE 2).
18 • www.turbomachinerymag.com
COAL OUTLOOK non-negotiable element of their mission. It’s
In mid-2024, when FirstEnergy CEO Brian the reason electric utilities exist. Everything
Tierney told the Financial Times the else—safety, affordability, economic
multistate utility holding company was development, and, more recently, sustain-
abandoning the planned 2030 phaseout of ability—comes after reliability. To meet
coal-fired generation, he observed, “Some soaring electric demand, they will use any
people think we were bad people for doing and all resources at their disposal, starting
that. I think … we’re just honest.” with the most economical ones first.
FirstEnergy operates 10 electric As the cost of renewables has fallen
distribution companies that provide steadily in recent years, utilities have
electricity to six million customers in five embraced wind and solar. The hundreds of
states in the Midwest and Mid-Atlantic billions of dollars in federal support for
regions. It also operates two coal-fired renewables contained in the 2022 Inflation
power stations in West Virginia with about Reduction Act didn’t hurt, but the embrace
3,082 MW of combined generating capacity. of wind and solar was well underway before
FirstEnergy’s operating utilities operate that law was passed.
in the PJM Interconnection, a power Even as they embraced intermittent,
market that includes northern Virginia, the non-emitting generation like wind and
world’s largest data center hub. Electricity solar, some utility leaders did so grudgingly,
demand in the PJM region is one of the mindful that the wind doesn’t always blow,
fastest growing in the country, the Financial and the sun doesn’t always shine. But
Times reported, with the operator this year regulators supported renewables, and what
more than tripling its growth forecast for regulators want, they usually get.
the next decade. One other trend we noticed this year:
“When we were looking at emissions More asset owners were deferring the
reduction, it was based on running our planned closure of coal-fired generators. At
coal-fired power plants less at the end of the the start of 2024, IIR tracked nearly 5 GW of
decade,” Tierney said. “We don’t see a planned retirements for U.S. coal-fired
pathway for that now.” generators, but by midyear, that slipped to Turbo Part Specialist
He cited exceptionally strong electric about 3 GW. It may fall faster in the last Gas Turbine / Steam Turbine
demand growth, driven by existing and months of the year. Turbo Compressor / Rotor
planned data centers in the Old Dominion We expect the decision to close, or defer Diaphragm / Blade / Vane
Bolt / Nut / Labyrinth Seal
state and elsewhere. closing, coal-fired generation may lead to Packing Ring / Impeller
“The things that are bumping up against questions from regulators, lawmakers, and Blisk / Diffuser
each other are people’s growing demand consumer groups. If that comes to pass, we
and desire for reliability, what’s affordable expect utility leaders to say, in effect,
Reverse Engineering
Retrofit
for most customers, and then what’s “Increased CO2 emissions were preferable Upgrade
sustainable. It’s easier to make two of those to rolling blackouts.” Overhaul
three things congruent with one another. Since 2010, over 150 GW of U.S. coal-
It’s harder to get all three solved at the same fired generation has been retired, forced by
time,” Tierney told the Financial Times. tightening environmental regulations,
Tierney’s not the only utility chief increasingly competitive natural gas prices,
struggling to balance the energy trilemma: and the declining cost of renewables.
reliability, affordability, and sustainability. Looking out over the next five years, IIR is
But forced to make a choice, it appears he is tracking the planned closure of about 56
willing to sacrifice sustainability to deliver GW of coal generation (FIGURE 4).
reliability and affordability. But those numbers are not set in stone. www.flowdy.co.kr
Those who lead electric utilities hold In fact, as we have seen in 2024, they are [email protected]
electric reliability as a foundational, subject to change.
75
70
65
Thousands of Persons
60
55
50
45
40
35
2015 2016 2017 2018 2019 2020 2021 2022 2023 2024
Shaded areas indicate U.S. recessions. Source: U.S. Bureau of Labor Statistics fred.stlouisfed.org
20 • www.turbomachinerymag.com
CUSTOM BOILER
SOLUTIONS.
Rentech knows the conditions, demands and specifications of your boiler application
are unique—and critical to your success. Our expert engineers analyze your specific
needs and design an integrated, cost-effective, tailored solution. Then we construct
and deliver a boiler that’s durable, energy efficient, and clean running.
Always the best and never off the shelf.
WWW.RENTECHBOILERS.COM
COVER STORY
1,200,000,000
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Year
Louisiana, where developers have been
Source: U.S. Energy Information Administration
busily constructing LNG export terminals
as well as petrochemical plants and other
NATURAL GAS OUTLOOK Southwest, anchored by Texas, plans to industrial facilities that are reliant on
Last year, 2023, may go down as an inflec- build far more gas-fired generation during natural gas.
tion point in the fortunes of new-build 2025 - 2029, slightly over 30,000 MW than This mini-trend to revive new-build
gas-fired generation. After falling steadily the Southeast at about 7,000 MW. natural gas generation will likely be decried
from 41% of all new-build generation over IIR is tracking developers’ plans to build by environmental organizations and others
2019 - 2023 to 5% for 2024 - 2028, developers eight billion-dollar-plus gas-burning who want to keep gas “in the ground.” But
planned to build many more new gas-fired generators in the Southwestern region over state utility regulators, whether appointed
power plants over the 2025 - 2029 period: the next five years. By contrast, only four or elected, can’t afford to let the lights go
approximately 65,000 MW or 7% of all billion-dollar-plus mega plants are sched- out. When in doubt, given the penalties for
new-build generation. uled to begin construction in the Southeast getting it wrong, the incentive is to build.
The regions turning most sharply to over that timeframe. Therefore, while developers and regula-
new-build gas-fired generation over the next Developers plan to install CCUS at some tors have been circumspect about new gas
five years are the Southeast (where 21% of all of those big-ticket planned gas plants. generation, generally preferring to comment
new-build generation will be gas-fired), The resurgence of new-built gas narrowly rather than globally, we expect to
Mid-Atlantic (14%), and Great Lakes (11%). generators in the nation’s largest gas-pro- see new-build gas generation rise throughout
In recent years, the Mid-Atlantic and ducing state has been aided by Texas’ $10 the next five years—particularly if electric
Great Lakes regions have had the greatest billion state fund, created in 2023 to demand comes close to overwhelming electric
preference for new-build gas generation. support the construction or refurbishing of supply, leading to blackouts.
This year, they are joined by the Southeast, dispatchable (mostly gas-fired) generation. Any move to boost the construction of
where plans to build new gas-fired genera- In less than a year, about 125 companies new-build gas-fired generation in the
tion have soared from less than 1% from have reportedly applied for approximately United States will be helped by fuel’s low
2024 - 2028 to about 21% for 2025 - 2029. IIR $39 billion in grants and low-cost loans cost, widespread abundance, and relative
defines the Southeast region as Florida, from the Texas Energy Fund to construct a price stability. Though gas prices for
Georgia, Alabama, Mississippi, proposed 55,800 MW of new natural electric generation briefly shot up in early
and Tennessee. gas-generating capacity. 2021, driven by the bitter cold, they quickly
And, in the Southwest, developers It’s anyone’s guess whether Texas returned to normal, only to have that brief
tripled earlier plans to build gas generation, lawmakers will add more money to the period of normalcy upended by Russia’s
rising to 12% for 2025 - 2029 compared to Texas Energy Fund to capture developer invasion of Ukraine in early 2022. Shortly
3.8% for 2024 - 2028. IIR defines the enthusiasm for gas-fired generation. Much thereafter, market forces of supply and
Southwest region as Texas, Oklahoma, may depend on whether the lights, and air demand displaced panic, causing prices to
Arkansas, and Louisiana. Switching from conditioners, go out this summer. The fall as new supply continued to outstrip new
percentages to raw numbers, the Texas legislature only operates in demand (FIGURE 7).
22 • www.turbomachinerymag.com
2025 – 2029, more than nine in 10 planned
Figure 7: Gas Prices Paid by Electric Generators Since 2008
megawatts of new-generating capacity will
Dollars per Average cost of fossil fuels for electricity generation (per Btu) be solar, wind, or other
million Btu for natural gas, monthly non-emitting resources.
20 Although nuclear is a non-emitting
resource, IIR does not include it in its tally
15 of renewable generation.
On a percentage basis, the regions with
10
the greatest appetite for renewables in their
5
planned construction kickoffs for 2025 - 2029
include New England and the Northeast (tied
0 with 99% of all planned generation), followed
2010 2012 2014 2016 2018 2020 2022 2024
by the Rocky Mountain states (97%), and
— United States: Electric Power
West Coast (96%).
Data source: U.S. Energy Information Administration Source: EIA Short-Term Energy Outlook (July 2024)
But on a raw-numbers level, the amount
of renewable generation to be built in the
With the prospect of brighter days RENEWABLES OUTLOOK Southwest region dwarfs all other regions.
ahead, natural gas power developers may Whether or not natural gas storms back The Southwest has about 226 GW of
soon echo then-president Gerald Ford, who into the new-build power generation renewable generation slated to begin
after pardoning disgraced President market, renewable energy developers are construction over the next five years,
Richard Nixon proclaimed, “Our long expected to continue dominating the roughly 88% of all planned new-build power
national nightmare is over.” market for the foreseeable future: From plant construction activity in that region.
$0 $25 $50 $75 $100 $125 $150 $175 $200 $225 $250 $275 $300
The regions with the lowest percentage The numbers get more bunched with about 47% of all new-build project
of renewables in their new-build portfolio together when storage is added to solar or kickoffs during the 2025 - 2029 period,
include the Southeast (66% of all new-build wind. Even then, onshore wind and storage followed by battery energy storage systems
projects), the Mid-Atlantic (80%), the generally pencils out to a lower cost per (BESS; 31%), wind (16%), and hydro (6%)
Midwest (87%), and the Great Lakes (88%). So megawatt-hour than gas-fired com- (FIGURE 9).
even in the lowest green regions, developers bined-cycle generation. The states with the largest dollar value
have plans to build a lot of non-emitting A large and growing proportion of of solar projects scheduled to begin
generation over the next five years. planned renewable generation includes construction during this timeframe are
Overall, developers plan to begin turning some form of energy storage, which boosts Texas, Nevada, and Arizona. The states
dirt on slightly over 796 GW of U.S. renew- the construction cost. Right now, over 170 with the biggest dollar value of wind-
able generation over the next five years, proposed renewable-generation projects power projects scheduled to begin
significantly higher than earlier years. include an energy storage component. Five construction over the next five years are
Again, it bears mentioning that IIR does years ago, storage projects were attached to Texas, Illinois, Iowa, Wyoming, and
not expect all these announced projects will less than three dozen renewable elec- North Dakota.
be constructed according to their original tric-generation projects. Today, stand-
timelines. This is particularly true for alone renewable generation is giving way to Figure 9: U.S. Renewable Energy Project
Kickoffs, 2025 - 2029
renewable generation, which has a higher combined generation + storage.
rate of delays and cancellations compared Something else that has changed in the
Hydro
to gas-fired generation. Still, the size of the renewable energy world: Offshore wind
renewable electric pipeline is notable. As generation continues to blossom, with 6%
Wind
interest rates come down, more projects about two dozen projects under develop-
may be deemed economically viable. ment, with the combined asset value (TIV) 16%
Lazard’s 17th annual Levelized Cost of of those projects exceeding $55 billion. Solar
Energy study, released in summer 2024, Several put steel in the water in 2023 and 47%
BESS
showed utility-scale solar and wind being 2024, and we expect that will continue, even Battery Energy
lower-cost resources, on average, than accelerate over the next five years. That is Storage System
conventional generation, even when unless Donald Trump is elected president. 31%
excluding the effect of federal renewable According to project-development data
tax credits (FIGURE 8). This continues a tracked by IIR, solar is keeping its lead in
Source: Industrial Info Resources
lengthy trend. the new-build renewable market share,
24 • www.turbomachinerymag.com
Renewable power development has been Unit 4 of the Alvin W. Vogtle Nuclear As the curtain was coming down on the
particularly hamstrung in recent years by Power Station began commercial opera- Vogtle project, another curtain began a
yearslong interconnection queues in organized tions in April 2024. Unit 3 began operating slow potential rise. In June 2024, the
wholesale markets. Steps taken in 2024 by the commercially in July 2023. owners and off-takers of a next-generation
Federal Energy Regulatory Commission (Order Principal owner Georgia Power nuclear project, Natrium, began prelimi-
1920) and the U.S. Department of Energy Company will likely spend lots of time in nary site development activities on the
(National Transmission Corridors) could prudence hearings before Georgia utility project in Wyoming.
expedite the construction of transmission regulators as it seeks to recover the costs That 345-MW sodium-cooled nuclear
lines to carry green kilowatts to load centers, of, and make a profit on, the 2,228 MW of project, backed by Microsoft founder Bill
but that’s unlikely to happen in the near new nuclear capacity represented by units Gates’ extraordinarily deep pockets,
future. There are too many entrenched 3 and 4. The utility has already taken hefty originally was scheduled to begin operating
interests eager for litigation to be optimistic asset write-offs and absorbed incremental in 2028. Shortly after that in-service date
that a tangle that took decades to develop financial penalties. was announced, Russia—the world’s only
can be sorted out quickly. The all-in costs to build the two nuclear supplier of high-assay, low-enriched
units hovers around $35 billion, less a uranium (HALEU) fuel for the project—
multibillion-dollar payment from Hitachi invaded Ukraine, and the fuel contract was
NUCLEAR OUTLOOK after Westinghouse bailed on the project in scuttled. A replacement HALEU supply
During a few weeks in 2024, the “old” 2017. Years late in coming online, and with a chain is trying to be assembled in the
nuclear renaissance wrapped up and one of ghastly price tag, Vogtle units 3 and 4 brought United States. Stay tuned.
the technologies that could spur a “new” the curtain down on the much-hyped circa The Natrium project has been selected
nuclear renaissance began to take shape. 2010 version of the “nuclear renaissance.” to receive up to $2 billion in federal grants,
REACH US AT
413.267.0590 [email protected] www.sohreturbo.com
26 • www.turbomachinerymag.com
WE WERE
ALREADY
THERE
28 • www.turbomachinerymag.com
C
CM
MY
CY
CMY
K
GAS TURBINES
WORLDWIDE GAS
TURBINE FORECAST
2025
The gas turbine market is stable and will remain so among factors such as
hydrogen, digitalization, and renewable energy.
BY CARTER PALMER
he gas turbine market for to hydrogen fuel. However, the transition necessary. Digitalization also has a role in
electrical generation has been and involves significant challenges, including: the future of gas turbine technology.
will continue to be stable barring adjustments to control systems
any unforeseen circumstances, such as the safety concerns
2020 pandemic, that affected many economic considerations DIGITALIZATION
markets. That said, the major players such The integration of digital technologies is
as Siemens Energy, Mitsubishi Power, and While existing turbines can be retrofit- revolutionizing the operation and mainte-
GE Vernova still hold the majority of the ted with hydrogen-compatible burners, the nance of gas turbines. Utilizing sensors,
market value. Major trends will likely not combustion characteristics of hydrogen data analytics, and artificial intelligence,
affect turbine production itself, as produc- differ significantly from natural gas, operators can gain valuable insights into
tion rates remain stable for now. Forces like necessitating modifications to ensure turbine performance and health. Predictive
hydrogen use, digitalization, and renewable efficient and stable operation. The eco- maintenance algorithms can anticipate
energy have the potential to be market-al- nomic viability of hydrogen-fueled gas potential failures, allowing for proactive
tering, but to what degree is uncertain. turbines is also influenced by the initial maintenance and minimizing downtime.
investment in retrofitting or purchasing Digitalization also enables remote
new units, in addition to the cost of monitoring and control, reducing the need
HYDROGEN READY? hydrogen itself. Transporting hydrogen will for onsite personnel and improving
Gas turbines offer a promising avenue for be a factor as well, either pipelines or an operational efficiency. Furthermore, digital
decarbonization through their adaptability on-site hydrogen production facility will be twin technologies can create virtual
30 • www.turbomachinerymag.com
FIGURE 1. Gas Turbine Electrical Power Generation
$14B
$12.82B $12.77B $12.94B $12.66B
$12.41B $12.33B $12.32B $12.39B $12.18B
$12B $11.68B
$10B
$8B
$6B
$4B
$2B
$0
2024 2025 2026 2027 2028 2029 2030 2031 2032 2033
replicas of gas turbines, providing a popularity than currently, but will that
platform for testing different operating
conditions and optimizing performance.
offset the unused capacity already installed
worldwide? The Irsching Power Station in
Flexware
Gas turbines can also be leveraged for use in Germany, for example, is reportedly Turbomachinery Engineers
conjunction with renewable resources. running only one out of three units at the
plant. Hydrogen, too, has its opponents: Compressors - Turbines
A recent report from the Institute for ❖ Engineering Design
TURBINES + RENEWABLES Energy Economics and Financial Analysis ❖ Remote Monitoring
Hybrid systems—gas turbines combined suggests that hydrogen might not be the ❖ Training
with renewable energy sources such as solar best way forward for gas turbines. ❖ Inspections & Repairs
or wind power—offer a powerful solution to Therefore, balancing the potential gain ❖ Installations & Start-ups
address the challenges associated with in popularity among energy companies and ❖ Rerates & Mods
energy production. These systems leverage the public with the unknowns of hydrogen’s ❖ Overhauls
❖ Software
the complementary strengths of both future in this market and the issue that
❖ Spare Parts
technologies, providing reliable baseload many turbines are not being fully utilized
power from gas turbines and intermittent translates to a stable market in this
clean energy from renewable sources. analyst’s eyes. No massive swings in the
market are foreseen at this time.
As displayed in FIGURE 1, the value of
HYBRID SYSTEMS: the gas turbine market for electrical
enhance grid stability power generation will remain stable
optimize energy efficiency moving forward. The most popular
reduce reliance on fossil fuels, contrib- turbines will fall in the 250 - 500 MW
uting to a cleaner energy future output range (FIGURE 2), with GE
Vernova, Siemens Energy, and Mitsubishi
[email protected]
What does all this mean? Gas turbines Power holding the position of top-three
www.flexwareinc.com
have the potential to gain even more manufacturers (FIGURE 3).
50kMW
40kMW
30kMW
20kMW
10kMW
$0
2024 2025 2026 2027 2028 2029 2030 2031 2032 2033
32 • www.turbomachinerymag.com
Powering Precision:
Your Go-To Database for
Industrial & Marine Gas Turbine
Installations
[email protected] | 203.426.0800
www.forecastinternational.com
Q&A
Giuseppe Tilocca
Scientific Officer at
ETN Global
34 • www.turbomachinerymag.com
Read this case study at www.MDAturbines.com/AGP
MD&A’s experts repaired 7FA.04 advanced gas path (AGP) components, with over 15 years
of experience in repairing single crystal gas turbine blades. Significant savings can be
realized by opting for lower-cost repaired spares instead of new parts.
36 • www.turbomachinerymag.com
remote locations offshore. They’re fuel gas turbines, hydrogen, and biogas, onto an turbines change rapidly in decentralized
flexibility means they are often used with island near Norway. energy systems—moving from 8,000
waste fuels that other technologies may Gas turbines’ carbon neutrality is not a operating hours per year to about 1,000 and
struggle to run, such as flare gas from oil matter of technology but fuel. Gas turbines from two to three cycles per year to two to
and gas, biofuels, etc. Gas turbines also can already use fuels like hydrogen, but the three per day. This operational change will
have the potential to provide waste heat for infrastructure for these fuels is missing. impact energy systems both economically
residential, commercial, and indus- and technically.
trial cogeneration applications. On the technical side, new market
Small turbines can help in remote
locations with no access to the grid or access
to an unstable grid. They’re expected to play
Q What are the advantages and
struggles of gas turbines in
these systems? What solutions
requirements will affect maintenance and
operations. The R&D community is
working on fuel flexibility to minimize
a significant role in emerging economies like and applications are addressing emissions like NOx, which will position
Africa, where natural gas will drive indus- these issues? dispatchable, affordable gas turbines as
trial growth. Standalone generation will sustainable and clean technologies for the
provide cost-effective electricity access for Tilocca: Gas turbines enable flexibility. In energy trilemma.
nearly one-third of Africa by 2030. Here, decentralized energy systems, clean and
smart grids and microgrids present signifi- dispatchable solutions such as gas turbines Listen to the full podcast with Giuseppe
cant opportunities. An EU-funded project enable the energy transition—in fact, there Tilocca by scanning the QR code or visting
studied the impact of integrating decentral- is no energy transition without turbomachinerymag.com/podcast.
ized energy systems, including solar, wind, dispatchable solutions. We’re now seeing
the role of gas
Turbomachinery &
Pump Symposia 2024:
Emerging Technologies in
the Spotlight
TPS 2024 tackled the latest challenges, solutions, and technologies in the turbomachinery industry.
BY JAMES COOK AND ALISSA ESPINOZA
he 2024 Turbomachinery & Pump According to Fabio Jacinto Zanetti De FPSO Compressor Challenges
Symposia (TPS), held Aug. 20 - 22 at Souza, Brownfield Account Manager at CCC: Pedro Barbosa, Turbomachinery Advisor at
the George R. Brown Convention “The primary function of the anti-surge Petrobras laid out several challenges with
Center in Houston, boasted over 4,500 control system is to prevent the centrifugal running a gas compressor on a floating
attendees and more than 300 exhibitors. compressor from operating under surge production, storage, and offloading (FPSO)
Organized by Texas A&M’s Turbomachinery conditions, which is a potentially damaging vessel in the Brazilian pre-salt fields:
Laboratory, attendees from over 50 countries phenomenon for the compressor. However, Gas compressors are the largest power
gathered to hear engineers, directors, and the secondary functions of an anti-surge consumers and greenhouse gas emitters
managers discuss optimizing compressor control system are often overlooked or aboard an FPSO vessel
anti-surge control systems, integrating CO2 unaddressed by many providers. It can help FPSOs have highly variable operating
capture plants, bottoming cycles, and more. maintain specific suction pressure in conditions over unit lifecycle
centrifugal compressors through a Ps limit Following startup, gas compressors are
loop or prevent reaching a high discharge difficult to tune
ANTI-SURGE CONTROL SYSTEMS pressure through a Pd limit loop. The system Pre-salt FPSOs contain complex plants
Presenters from Compressor Controls also avoids high discharge temperature that with high CO2 content
Corp. (CCC) and Petrobras hosted a paper could lead to a trip due to high Td or Gas reinjection increases CO2 content,
presentation, Optimizing Compressors manipulate the anti-surge valve for periodic affecting compressor curves and
Anti-Surge Control to Reduce Power stroke tests and send operators an alarm if surge lines
Consumption and Greenhouse Gases the valve demonstrates some level of
Emissions in Oil Production Units, analyzing stickiness. The anti-surge control can also be Barbosa addressed further compressor
the energy and carbon performance of used to avoid critical speeds during startup difficulties that could be assisted by
compressor anti-surge control systems on of an expander-recompressor arrangement anti-surge control. “When the unit is
existing offshore platforms in the Brazilian in natural gas liquids plants or even treating gas for exportation, it passes
pre-salt fields. prevent overspeed.” through a CO2 removal plant to the export
38 • www.turbomachinerymag.com
BEARING TECHNOLOGY
FOR THE HYDROGEN
TRANSITION
optimize compressor operation by main- use and carbon emissions in real-time. This He outlined several considerations for
taining their most efficient point, thus integrated approach allows for continuous choosing carbon-capture technologies,
reducing energy consumption. Minimizing adjustments and improvements, ensuring including:
unnecessary power output keeps gas that operations remain as efficient and Desired capture rate
compressors from emitting large amounts low-emission as possible, ultimately CO2 capture amount
of CO2 from FPSOs. leading to significant reductions in the Available space at location
40 • www.turbomachinerymag.com
Energy and water availability Hot Potassium Carbonate: Unlike Membranes: These are also proven for gas
Impact of NOx and SOx on solvent life typical potassium carbonate, it operates processing but struggle when applied to gas
and replacement rate at high flue gas temperatures in a turbines, as multiple modules are required
pressurized process. It can generate its to achieve the desired capture rate and
According to Welch, carbon capture is a own electricity and gas turbine supple- purity. Membrane contactor modules are a
difficult process when using gas turbines: mentary firing can increase CO2 hybrid solution combined with
“The only certain thing about CO2 capture is concentration. amine solvents.
that you’ll need a lot of space, and it’ll cost
you a lot of money—it’s not a cheap
solution. Most processes are designed to
operate at low ambient temperatures, so
you become limited to the available
technologies when operating with a gas
turbine. There are only a few that don’t
require cooling of the gas turbine exhaust
and most of the emerging technologies can’t
support large-scale turbines.”
Available Systems
Despite the inherent challenges of running
current carbon-capture technologies in
conjunction with gas turbines, there are
many available systems in use today. The
most common are amine-based systems,
which utilize proven solvents to absorb CO2
with low toxicity and low energy demand for
desorption. However, these solutions have
large footprints and long construction times,
with higher energy demand for absorption.
42 • www.turbomachinerymag.com
COMPANY DIRECTORY
A&A COATINGS ACCUSHIM, INC. ADVANCED DESIGN TECHNOLOGY LTD. AGIS, LLC
thermalspray.com accushim.com adtechnology.com agismfg.com
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Tel: +1 888-679-5460 Tel: +1 708-442-6448 Tel: +44 (0) 20 7299 1170 Contact: Robert Freese
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A&A Coatings - Thermal spray coatings, Tollfree: +1 800-435-4485 [email protected] Fax: +1 215-646-8013
thermal coating applications. Contact: George Hurtado, General Manager Advanced Turbomachinery Design Software and [email protected]
Coatings [email protected] Services using 3D Inverse Design. Manufacturer/distributor of high-temperature,
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AB TECH GROUP Alignment equipment manufacturer. Maintenance - Boilers
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CHINA GENSET GENERATOR CAMFIL POWER SYSTEMS Cincinnati OH USA MAGTYPE COMPUTER RESOURCES
MANUFACTURERS CO., LTD. Boras Sweden GREAT RIVER ENERGY Stratford CT USA
Xiamen Fujian China ENERGYLINK INTERNATIONAL Elk River AL USA
IDEAL ELECTRIC COMPANY (FORMERLY Calgary AB Canada GT SAS DI TUZI GABRIELE Gas Turbines - Mechanical Drive
HYUNDAI IDEAL ELECTRIC CO.) MANTOVA Lombardia Italy MAGTYPE COMPUTER RESOURCES
Mansfield OH USA Catalysts IBRAHIM & ASSOCIATES LLC Stratford CT USA
KATO ENGINEERING, A NIDEC BRAND EMERACHEM Los Angeles CA USA MUC OIL & GAS ENGINEERING
North Mankato MN USA Knoxville TN USA IMP ENERGY SYSTEMS & SOLUTIONS LLC CONSULTANCY
MEGA-WATT CONSULTING, LLC ENERGYLINK INTERNATIONAL Sugar Land TX USA Sharjah United Arab Emirates
Klein TX USA Calgary AB Canada KALE RESEARCH & DEVELOPMENT INC.
Gas Turbines - Packagers
PHILADELPHIA GEAR, POWER SYSTEMS Istanbul Turkey
BY TIMKEN Continuous Emission Monitoring AFGLOBAL CORPORATION
MAGTYPE COMPUTER RESOURCES
King of Prussia PA USA Systems Houston TX USA
Stratford CT USA
LOCCIONI ALTURDYNE INTERNATIONAL
Motors - Electric MEGGITT CONTROL SYSTEMS
Angeli di Rosora Ancona Italy El Cajon CA USA
North Hollywood CA USA
ATB LAURENCE SCOTT (WOLONG GROUP) GREENGOLD ENERGY LTD.
Norwich UK Emissions Reductions MITSUBISHI POWER AMERICAS
Kuala Lumpur WP Malaysia
Lake Mary FL USA
ATB MOTORS COOK COMPRESSION MAGTYPE COMPUTER RESOURCES
The Woodlands TX USA Houston TX USA ROTATION SOLUTIONS
Stratford CT USA
Perth WA Australia
BROOK CROMPTON USA, INC. COOK COMPRESSION - SUZHOU
Cleveland OH USA Suzhou China SHIN NIPPON MACHINERY CO., LTD. Gas Turbines - Power Generation
Tokyo Japan
PHASE USA INC. COOK COMPRESSION LTD. ANSALDO ENERGIA S.P.A.
Lombard IL USA Ellesmere Port UK SIEMENS ENERGY GLOBAL GMBH & CO. KG Genoa Italy
Munich Germany
PHILADELPHIA GEAR, POWER SYSTEMS CORMETECH, INC. BRAYTON ENERGY
BY TIMKEN Durham NC USA SKYLINE TURBINE SERVICES B.V. Hampton NH USA
King of Prussia PA USA Poeldijk Selecteer een gebied, St Netherlands
DOVER PRECISION COMPONENTS ENERGY EXPERTS NOW
THE SWITCH The Woodlands TX USA TECHNIPFMC Juan Dolio Dominican Republic
Helsinki Finland Zoetermeer Netherlands
ENERGYLINK INTERNATIONAL FLOWDY
WOLONG AMERICAS, LLC Calgary AB Canada U.S. BOLT MANUFACTURING, INC. Changwon-si Gyeongsangnamdo Korea
Chicago IL USA Houston TX USA South
FRANKE-FILTER GMBH
WOLONG GROUP Bad Salzdetfurth Germany INDUSTRIAL MOTOR POWER
Gas Turbines - Aeroderivatives
Norwich Norfolk UK HAUG SAUER KOMPRESSOREN AG CORPORATION
AIR NEW ZEALAND - GAS TURBINES Los Angeles CA USA
St. Gallen Switzerland
Variable Frequency Drives Manukau Auckland New Zealand
UT 99 AG OIL MIST ELIMINATORS MAGTYPE COMPUTER RESOURCES
PHILADELPHIA GEAR, POWER SYSTEMS MAGTYPE COMPUTER RESOURCES Stratford CT USA
Andelfingen Switzerland
BY TIMKEN Stratford CT USA
MAJOR TOOL & MACHINE, INC.
King of Prussia PA USA NOx Control MITSUBISHI POWER AERO LLC Indianapolis IN USA
THE SWITCH Glastonbury CT USA
ENERGYLINK INTERNATIONAL METIS POWER INC
Helsinki Finland Calgary AB Canada VERICOR POWER SYSTEMS Anaheim CA USA
Alpharetta GA USA
PRECISION AIR & LIQUID SOLUTIONS, LLC
ENERGY RESOURCES Pollution Controls
ENERGYLINK INTERNATIONAL
Gas Turbines - Auxiliary Power Units
Hammond LA USA
74 • www.turbomachinerymag.com
M A NUFAC TURING | M AT ERI AL S | PUMPS | RENE WA BL E ENERGY
MAGTYPE COMPUTER RESOURCES Stratford CT USA USHERS MACHINE & TOOL GORMAN-RUPP COMPANY
Stratford CT USA MITSUBISHI HEAVY INDUSTRIES Greenville SC USA Mansfield OH USA
76 • www.turbomachinerymag.com
ST E A M TURB INES | TR A INING & EDUC AT ION
THE BALANCING COMPANY POWER ELECTRIC SP. Z O.O. Steam Turbines - Packagers TURBOMACHINERY INTERNATIONAL
Vandalia OH USA 43-384 Jaworze Poland COBEY, INC. Iselin NJ USA
TST-TURBO SERVICE & TRADING GMBH ROTATING MACHINERY SERVICES, INC. Buffalo NY USA
Moers NRW Germany Bethlehem PA USA Education
EBARA ELLIOTT ENERGY
SKINNER POWER SYSTEMS Jeannette PA USA CAMFIL POWER SYSTEMS
Turbomachinery Shipping & Storage Erie PA USA Boras Sweden
Containers MITSUBISHI HEAVY INDUSTRIES
TGM STEAM TURBINES COMPRESSOR INTERNATIONAL (MCO-I) INTERNATIONAL GENERATOR
CROWLEY LOGISTICS INC. Sertaozinho - SP Sao Paulo Brazil Houston TX USA TECHNICAL COMMUNITY
HoustonTX USA Columbus OH USA
DIXIE CULLEN INTERESTS, INC. Steam Turbines - Electrical, Steam Turbines - Refurbished
HoustonTX USA Industrial Training
DE PRETTO INDUSTRIE SRL
EBARA ELLIOTT ENERGY Schio Italy ATLAS COPCO GAS AND PROCESS
DIVISION
STEAM TURBINES Jeannette PA USA
TRIVENI TURBINE LIMITED
DOOSAN ŠKODA POWER
Plzen Czech Republic
Cologne NRW Germany
Bengaluru Karnataka India CAMFIL POWER SYSTEMS
Generator Sets - Steam Turbines EBARA ELLIOTT ENERGY Boras Sweden
Jeannette PA USA
DE PRETTO INDUSTRIE SRL CCC BY HONEYWELL
Schio Italy Steam Turbines - Electrical, Nuclear MITSUBISHI HEAVY INDUSTRIES Des Moines IA USA
COMPRESSOR INTERNATIONAL (MCO-I)
DOOSAN ŠKODA POWER RELADYNE RELIABILITY SERVICES CONCEPTS NREC
Houston TX USA
Plzen Czech Republic Cincinnati OH USA White River Junction VT USA
ROTATING MACHINERY SERVICES, INC.
EBARA ELLIOTT ENERGY EBARA ELLIOTT ENERGY
Bethlehem PA USA
Jeannette PA USA Steam Turbines - Mechanical Jeannette PA USA
WEG STEAM TURBINES EBARA ELLIOTT ENERGY GLOBAL TRAINING SOLUTIONS INC.
Duluth Georgia Jeannettem PA USA
TRAINING & Mississauga ON Canada
Steam Turbines
FRONTKEN (SINGAPORE) PTE. LTD.
Singapore EDUCATION ROTATING MACHINERY SERVICES, INC.
Bethlehem PA USA
ANSALDO ENERGIA S.P.A. ROTATING MACHINERY SERVICES, INC.
ASME Certification VIBRATION INSTITUTE
Genoa Italy Bethlehemm PA USA Oakbrook IL USA
DE PRETTO INDUSTRIE SRL OPTIMISTIC
Schio Italy Steam Turbines - Mechanical, Lisbon Portugal
DOOSAN ŠKODA POWER Process
Books & Magazines
Plzen Czech Republic EBARA ELLIOTT ENERGY
Jeannette PA USA COMPRESSORTECH2 - KHL GROUP
EBARA ELLIOTT ENERGY
Waukesha WI USA
Jeannette PA USA MITSUBISHI HEAVY INDUSTRIES
COMPRESSOR INTERNATIONAL (MCO-I) CONCEPTS NREC
FRANCO TOSI MECCANICA S.P.A.
Houston TX USA White River Junction VT USA
Legnano Milano Italy
M+M TURBINEN-TECHNIK GMBH
Bielefeld Germany
TRADEMARKS
AeroBlock Standardized integrally- FSR Full Solution Rejuvenation PNEUTRIP Highest performing pneumatic TurboLink Digital connectivity solution for
geared main air compressor for industrial Proprietary heat treatments to restore trip valve solution 1oo2 and 2oo3 • Drake operating data analysis • Atlas Copco Gas
gas applications • Atlas Copco Gas and turbine blades/buckets to as-new Controls, LLC, Houston, TX, USA and Process Division, Cologne, Germany
Process Division, Cologne, Germany strength • Liburdi Turbine Services, Inc.,
Dundas, Canada PolyBlock Standardized direct-driven TurboPulse New pulse filtration with
BoostToReduce Upgrading GT-filtration centrifugal compressor for PP/PE superior performance, longevity, and
is the easiest way to reduce carbon Gas Connectivity Suite of digital applications • Atlas Copco Gas and reliability • Camfil Power Systems,
emissions • Camfil Power Systems, connectivity solutions for turbomachinery Process Division, Cologne, Germany Boras, Sweden
Boras, Sweden service • Atlas Copco Gas and Process
Division, Cologne, Germany PowerEye Real-time monitoring of key
CamGT 3V-600 Game-changing inlet system and GT metrics • Camfil Power
high-efficiency filter for non-stop MSG® Centac ® Multi-stage geared Systems, Boras, Sweden
performance • Camfil Power Systems, (MSG) centrifugal air compressors •
Boras, Sweden Ingersoll Rand Inc., Davidson, NC, USA TurboBlock Standardized integrally-
geared centrifugal compressor for the
COMS® - Contec Oil Mist Separators MSG® TURBO-AIR® Multi-stage power generation market • Atlas Copco Gas
Separators and high-performance filter system geared (MSG) centrifugal air & gas and Process Division, Cologne, Germany
• Contec GmbH Industrieausrüstungen, compressors • Ingersoll Rand Inc.,
Bad Honnef, Germany Davidson, NC, USA
78 • www.turbomachinerymag.com
Combined Cycle Plant Specifications
SIEMENS ENERGY
Heat Rate
Model and configuration Total Power (mw) [kJ/kWh] [BTU/kWh] Number of GT Pressure / Reheat
SGT5-9000HL CC 1x1 (50Hz) 870 <5,714 <5,416 1 Triple/Yes
SGT5-9000HL CC 2x1 (50Hz) 1,740 <5,714 <5,416 2 Triple/Yes
SGT6-9000HL CC 1x1/1S (60Hz) 647 <5,714 <5,416 1 Triple/Yes
SGT6-9000HL CC 2x1 ( 60Hz) 1,294 <5,714 <5,416 2 Triple/Yes
SCC5-8000H 1S / 1x1 (50Hz) 665 5,850 5,545 1 Triple/Yes
SCC5-8000H 2x1 (50Hz) 1,335 5,850 5,545 2 Triple/Yes
SCC6-8000H 1S / 1x1 (60Hz) 465 5,895 5,587 1 Triple/Yes
SCC6-8000H 2x1 (60Hz) 935 5,875 5,568 2 Triple/Yes
SCC6-5000F (260 MW) 1x1 (60Hz) 387 6,040 5,706 1 Triple/Yes
SCC6-5000F (260 MW) 2x1 (60Hz) 780 6,000 5,687 2 Triple/Yes
SCC5-4000F (329 MW) 1S (50Hz) 480 5,980 5,668 1 Triple/Yes
SCC5-4000F (329 MW) 2x1 (50Hz) 960 5,980 5,668 2 Triple/Yes
SCC5-4000F (385 MW) 1S (50Hz) 565 5,807 5,503 1 Triple/Yes
SCC5-4000F (385 MW) 2x1 (50Hz) 1,130 5,807 5,503 2 Triple/Yes
SCC5-2000E 1x1 (50Hz) 286 6,569 6,226 1 Dual/ No
SCC5-2000E 2x1 (50Hz) 572 6,545 6,203 2 Dual/ No
SCC6-2000E 1x1 (60Hz) 174 6,818 6,462 1 Dual/ No
SCC6-2000E 2x1 (60Hz) 350 6,818 6,462 2 Dual/ No
SCC-800 (45 MW) 1x1 72 6,305 5,976 1 Triple/No
SCC-800 (45 MW) 2x1 144 6,239 5,914 2 Triple/No
SCC-800 (45 MW) 3x1 216 6,239 5,914 3 Triple/No
SCC-800 (50 MW) 1x1 79 6,283 5,955 1 Triple/No
SCC-800 (50 MW) 2x1 160 6,207 5,883 2 Triple/No
SCC-800 (50 MW) 3x1 240 6,207 5,883 3 Triple/No
SCC-800 (56 MW) 1x1 81 6,218 5,893 1 Triple/No
SCC-800 (56 MW) 2x1 163 6,154 5,833 2 Triple/No
SCC-800 (56 MW) 3x1 243 6,154 5,833 3 Triple/No
SCC-800 (57 MW) 1x1 88 6,154 5,833 1 Triple/No
SCC-800 (57 MW) 2x1 163 6,091 5,774 2 Triple/No
SCC-800 (57 MW) 3x1 245 6,091 5,774 3 Triple/No
SCC-800 (62 MW) 1x1 88 6,100 5,782 1 Triple/No
SCC-800 (62 MW) 2x1 180 6,000 5,687 2 Triple/No
SCC-800 (62 MW) 3x1 270 6,000 5,687 3 Triple/No
SGT-A65 DLE 66 8,300 7,124 1 Dual/ No
SGT-A35 (GT62) DLE 40 7,005 6,639 1 Dual/ No
SGT-A35 (GT61 34MW) DLE 43 6,820 6,464 1 Dual/ No
SCC-750 1X1 53 6,797 6,442 1 Dual/ No
SCC-750 2X1 106 6,774 6,421 2 Dual/ No
SCC-700 1x1 46 6,806 6,451 1 Dual/ No
SCC-700 2x1 92 6,786 6,432 2 Dual/ No
SCC-700 1x1 49 6,684 6,335 1 Dual/ No
SCC-700 2x1 99 6,644 6,297 2 Dual/ No
SCC-600 1x1 36 7,220 6,843 1 Dual/ No
SCC-600 2x1 74 7,071 6,702 2 Dual/ No
Conditions= 59 oF, 14.7 psia, 60% RH (15oC, 1.013 bar).Plant performance includes aux power. Ratings on LHV natural gas.
80 • www.turbomachinerymag.com
Electrical Generation Specifications
BAKER HUGHES
BAKER HUGHES
82 • www.turbomachinerymag.com
Electrical Generation Specifications
SIEMENS ENERGY
Heat rate Turbine Exhaust mass flow Exhaust temp
Power Frequency Efficiency Pressure
Turbine Model speed
(MW e) (Hz) (%) (Btu/kWh) (kJ/kWh) ratio (lb/s) (kg/s) (F) (C)
(rpm)
SGT5-9000HL 593 50 >43 <7,938 <8,375 3,000 24 2,315 1,050 1,238 670
SGT6-9000HL 440 60 >43.2 <7,898 <8,333 3,600 24.0 1,598 725 1,238 670
SGT5-8000H 450 50 41.2 8,284 8,740 3,000 21 2,061 935 1,166 630
SGT6-8000H 310 60 40.4 8,455 8,920 3,600 21.0 1,433 650 1,193 645
SGT6-4000F 385 60 41.5 8,455 8,675 3,600 17 1,054 800 1,134 619
SGT6-5000F 260 60 40 8,530 9,000 3,600 19.5 1,292 586 1,098 592
SGT5-2000E 198 50 37.6 9,082 9,582 3,000 12.8 1,230 558 997 536
SGT6-2000E 119 60 35.5 9,611 10,140 3,600 12.0 811 368 990 532
SGT-800 (DLE) 62.5 50/60 41 8,302 8,759 6,600 21.1 298.7 135.5 1,104 596
SGT-750 (DLE) 39.8 50/60 40.3 8,456 8,922 6,100 24.3 254.4 115.4 874 468
SGT-700 (DLE) 35.2 50/60 37.2 9,170 9,675 6,500 18.7 209.4 95 991 533
SGT-600 (DLE) 24.5 50/60 33.6 10,161 10,720 7,700 14 179.2 81.3 1,009 543
SGT-400 (DLE) 14.3 50/60 35.6 9,572 10,103 9,500 18.5 98.1 44.5 984 529
SGT-300 (DLE) 7.9 50/60 30.8 11,094 11,704 14,045 14 66.6 30.2 993 534
SGT-100 (DLE) 5.4 50/60 30.1 11,322 11,945 17,384 14 43 19.5 1,011 544
SGT-A65 66 50/60 41.5 8,147 8,670 3,000 38 397 180 799 426
SGT-A35 (GT61 ) 37.2 50/60 40.4 8,445 8,910 4,850 25 232.4 105.4 903 484
SGT-A35 (GT62) DLE 31.3 50/60 38.3 8,910 9,400 4,800 22 215.6 97.7 905 485
SGT-A05 KB7HE 5.8 50/60 33.2 10,281 10,888 14,600 14.4 47.2 21.4 965 518
Site Conditions= 59 oF, 14.7 psia, 60% RH (15 oC, 1.013 bar).Ratings at generator terminals. Specifications for Natural Gas Fuel
84 • www.turbomachinerymag.com
Mechanical Drive Specifications
BAKER HUGHES
SIEMENS ENERGY
Turbine Power ISO Efficiency Heat rate Turbine speed Pressure Exhaust Mass Flow Exhaust Temp
Model (Dry Low emissions) hp mw (%) (btu/hp-hr) (kJ/kWh) (rpm) Ratio (lb/s) (kg/s) °F °C
SGT-750 (DLE ) 56,591 42 41.7 6,136 8,642 6,100 24.9 255.7 116.0 855 457
SGT-700 (DLE ) 48,511 36 39.0 6,542 9,230 6,500 20.4 217.6 98.7 988 531
SGT-600(DLE ) 33,847 25 34.6 7,344 10,390 7,700 14.0 179.2 81.3 1009 543
SGT-400 (DLE ) 19,905 15 37.1 6,876 9,702 9,500 18.5 98.1 44.5 984 529
SGT-300 (DLE ) 12,296 9 36.0 7,082 10,003 11,500 14.1 65 30.4 939 504
SGT-100 (DLE ) 7,486 6 33.3 7,675 10,195 13,000 14.4 42.7 19.4 1013 545
SGT-A65 (DLE) 83,143 62 44 8,147 9,943 3,000 38 330 150 799 426
SGT-A35 (GT61 ) 51,616 39 42 6,079 8,601 4,850 25 232.4 105.4 903 484
Site Conditions= 59 ºF, 14.7 psia, 60% RH (15 oC, 1.013 bar). Values based on Natural Gas Fuel
Power Rating ISO Boosted Power Heat Rate Power Shaft Speed Pressure Number of ISO Base Load Exhaust Exhaust
Model
Base Load (hp) (hp) LHV (btu/kWh) (rpm) Ratio Combustors Flow (lbs/sec) Temp (°F)
ASE40 4.3 4.7 12,105 16,000 8.8 1 28.2 1,081
AE50B 4.9 5.4 11,305 16,000 10.1 1 30.3 1,077
TF40F 4.1 4.5 12,229 16,000 8.5 1 27.7 1,072
TF50F 5.3 5.8 11,253 16,000 10.5 1 31.1 1,122
86 • www.turbomachinerymag.com
Steam Turbine Specifications
Model Power Rating (mw) Thermal Cycle Type Application Configuration Grid Freq. (Hz) Inlet Temp. (°C) Inlet Pressure (bar)
GT series 15–150 — Geothermal 1 to 2 cylinder 50/60 Up to 240 Up to 20
MT10 40–250 Non-Reheat Combined Cycle, Fossil, Solar 1-cylinder 50/60 Up to 565 Up to 140
Combined Cycle, Fossil,
MT20 100–350 Non-Reheat 2 to 3 cylinder 50/60 Up to 565 Up to 140
Cogeneration
MT15 100–300 Reheat Combined Cycle, Fossil, Solar 2-cylinder 50/60 Up to 600/585 Up to 170
Combined Cycle, Fossil,
RT30 150–1000 Reheat 3 to 5 cylinder 50/60 Up to 600/620 Up to 280
Cogeneration
1 shp base. Note: Estimates are for natural gas fuel
Power Rating Speed Range Rated Inlet Pressure Rated Inlet Controlled
Model (mw) (rpm) (bar A) Temperature (°C) Inlet Control Type Extractions (#) Exhaust
MP 2–30 3,000–13,000 140 525 Sliding/Fixed Pressure 0–1 Radial
MC 2–45 3,000–13,000 140 525 Sliding/Fixed Pressure 0–1 Radial/Axial
BFPT 5–45 4,000–15,000 170–280 565–575 Sliding/Fixed Pressure — Radial
P 1–6 5,000–13,000 90 480 Sliding/Fixed Pressure 0–1 Radial, Max 20 BARA
C 1–6 5,000–13,000 90 480 Sliding/Fixed Pressure 0–1 Radial
MP = Multivalves—Backpressure Type, MC = Multivalves—Condensing Type, BFPT = Boiler Feed Pump Turbine,
P = Single valve—Backpressure Type, C = Single valve—Condensing Type
Power Rating Speed Range Rated Inlet Pressure Rated Inlet Controlled
Model (mw) (rpm) (bar A) Temperature (°C) Inlet Control Type Extractions (#) Exhaust
SC/SAC 2 - 150 3,000–15,000 140 565 Sliding/Fixed Pressure 0–2 Radial/Axial
SNC/SANC 2–100 3,000–15,000 140 565 Sliding/Fixed Pressure 0–2 Radial, Max 60 BARA
Power range Speed range Rated inlet pressure Rated inlet Controlled
Model (mw) (rpm) (bar A) temperature (°C) Inlet control type extractions (#) Exhaust
DPRA 0.2-5 5,000-15,000 100 510 Sliding/Fixed Pressure 0–1 Radial
DRPG 0.2-5 5,000-15,000 100 510 Sliding/Fixed Pressure 0–1 Radial
De Pretto Industrie is an Italian turbomachinery manufacturer. The company was established in 1885 and for more than 80 years has been part of leading global organizations.
De Pretto Industrie is today an Independent company acting as an Original Equipment Manufacturer (OEM) for new steam turbine generator sets up to 50mw but also as an Independent
Service Provider (ISP) of any rotating equipment manufactured by any OEMs in the market, thanks to its reverse engineering capabilities and its broad team of qualified engineers covering
all key domains (thermodynamic/construction/instrumentation&control/electrical/auxiliaries).
De Pretto Industrie has extensive competences and references in repair, conversions, modifications and upgrades (CMUs) of turbomachinery and is able to develop customized solutions
for each product and make. One stop solution provider for any rotating equipment, repair in emergency situations, OEM-equivalent warranties as well as cost and lead time advantages are
the main benefits we can provide our customers with. Innovative thinking is applied to manufacturing and upgrading of turbomachinery control systems according to the highest market
standards, latest normatives and best practices.
De Pretto Industrie always applies a customized and tailor-made approach on all its projects minimizing at the same time capital and operating expenditures for the end-users.
Power Range Speed Range Rated Inlet Pressure Rated Inlet Controlled
Model (mw) (rpm) (bar A) Temperature (°C) Inlet Control Type Extractions (#) Exhaust
DK 3-50 4,500-13,000 120 530 Sliding/Fixed Pressure 0–2 Radial/Axial
DG 1, 5-50 4,500-15,000 120 530 Sliding/Fixed Pressure 0–2 Radial
EBARA ELLIOTT ENERGY, JEANNETTE, PENNSYLVANIA, U.S.A. AND SODEGAURA, CHIBA, JAPAN
88 • www.turbomachinerymag.com
Steam Turbine Specifications
Power Rating Speed Range Rated Inlet Pressure Rated Inlet Controlled
Model (mw) (rpm) (bar A) Temperature (°C) Inlet Control Type Extractions (#) Exhaust
3 Up to 5 Up to 20,000 145 575 Sliding/Fixed Pressure — Radial
4 Up to 25 Up to 15,500 145 575 Sliding/Fixed Pressure 0–1 Radial
5 Up to 50 Up to 14,000 145 575 Sliding/Fixed Pressure 0–1 Radial
7 Up to 60 Up to 8,500 145 575 Sliding/Fixed Pressure 0-2 Radial, Axial
8 Up to 80 Up to 6,500 145 575 Sliding/Fixed Pressure 0-2 Radial, Axial
9 Up to 120 Up to 4,500 145 575 Sliding/Fixed Pressure 0-2 Radial, Axial
SIEMENS ENERGY
Controlled Uncontrolled
Model Power Output Speed (Rpm) Inlet Pressure Inlet Temperature Back Pressure Condensing Extraction Extraction
3,000 / 3,600 165 bar / 72 bar / up to 1.2 bar /
SST-800 up to 250 mw 565°C / 1,050°F up to 2 up to 7
- up to 7,100 2,393 psi 1,044 psi 16 psi
180 bar / 0.7 bar / 10.1
SST-700/900 up to 250 mw 3,000 / 3,600 565°C / 1,050°F up to 3 up to 7
2,611 psi psi
3,000 / 3,600 165 bar / 72 bar / up to 1.2 bar /
SST-600 up to 200 mw 565°C / 1,050°F up to 2 up to 6
- up to 18,000 2,393 psi 1,044 psi 16 psi
3,000 / 3,600 30 bar / 435 up to 3.0 bar 0.7 bar / 10.1
SST-500 up to 150 mw 400°C / 750°F up to 4
- up to 15,000 psi / 43.5 psi psi
140 bar / 25 bar / 365 0.5 bar / 7.1
SST-400 up to 65 mw up to 7,100 540°C / 1,004°F up to 2 up to 5
2,030 psi psi psi
140 bar / 20 bar / 290 0.7 bar / 10.2
SST-300 up to 60 mw up to 12,000 540°C / 1,004°F up to 2 up to 5
2,030 psi psi psi
120 bar / 20 bar / 290 0.7 bar / 10.2
SST-200 up to 25 mw up to 13,500 540°C / 1,004°F up to 1 up to 4
1,740 psi psi psi
Centrifugal Compressors
Max. Inlet Volume Discharge Power Number of Maximum Type of Type of Type of Gas Compressor Type of
Model (m3/hr) Pressure P2 (bar) Requirement (hp) Stages rpm Casing Split Seals Can Handle Design
GT Up to 500,000 up to 205 46,500 1 to 8 52,000 V all all gases C,I
Inlet Volume Discharge Power Number of Maximum Type of Type of Type of Gas Compressor Type of
Model (m3/hr) Pressure P2 (bar) Requirement (hp) Stages rpm Casing Split Seals Can Handle Design
BCL, 2BCL 125,000 900 — 2–10 20,000 V D,L,O 2 C
MCL, 2MCL 600,000 60 — 2–10 20,000 H D,L,O 3 C
DMCL 700,000 25 — 2–8 10,000 H D,L,O 3 C
3MCL 400,000 60 — 2–10 15,000 H D,L,O 3 C
SRL 450,000 200 — 1–8 40,000 V D,L,O 2 C
DBCL 250,000 100 — 2–8 18,000 V D,L,O 3 C
PCL 100,000 130 — 1–4 18,000 V D,L,O natural gas C
AN 600,000 25 — up to 20 10,000 H D,L,O 3 A+C
AX 600,000 15 — up to 20 10,000 H D,L,O 3 A
BlueC 400 180,000 205 16,763 3–5 10,670 V — natural gas C
RA 4,500 220 10,700 1–7 20,000 V D,L,O process gas C
Reciprocating Compressors
Model Number of Throws Max Power (@Max Speed) (kW) Rod Load (lbs) Maximum (rpm) Application Type of Design
OA 1 435 26,325 800 Process (1) / Natural Gas Horizontal
HA 2 TO 4 2,120 32,557 1,000 Process (1) / Natural Gas Horizontal
HB 2 TO 6 5,520 53,055 800 Process (1) / Natural Gas Horizontal
HD 2 TO 8 10,400 72,562 700 Process (1) / Natural Gas Horizontal
HE 2 TO 10 28,700 136,466 800 Process (1) / Natural Gas Horizontal
HF 2 TO 10 34,600 256,500 514 Process (1) / Natural Gas Horizontal
HG 2 TO 10 66,820 445,500 400 Process (1) / Natural Gas Horizontal
SHM 2 TO 6 7,980 80,565 1,200 Natural Gas Horizontal
SHM-B 2 TO 4 5,320 80,565 1,200 Natural Gas Horizontal
PH 4 TO 24* 36,000 326,250 310 LDPE Horizontal
PK 4 TO 24* 72,000 652,500 310 LDPE Horizontal
* # of cylinders 1 Refinery & Petrochemical
90 • www.turbomachinerymag.com
Turbocompressor Specifications
EBARA ELLIOTT ENERGY, JEANNETTE, PENNSYLVANIA, U.S.A. AND SODEGAURA, CHIBA, JAPAN
FS-ELLIOTT www.fs-elliott.com
INGERSOLL RAND
Inlet Volume Discharge Power Number Maximum Type of Type of Type of Gas Compressor Type of
Model (m3/hr) Pressure P2 (bar) Requirement (hp) of Stages rpm Casing Split Seals Can Handle Design
INTEGRALLY GEARED CENTRIFUGAL COMPRESSORS
MSG PRODUCT LINE: Applications engineered with many configurations to efficiently provide oil-free air and gas
Inlet Volume Discharge Power Number of Maximum Type of Type of Gas Compressor Type of
Model (m3/hr) Pressure P2 (bar) Requirement (hp) Stages rpm Casing Split Type of Seals Can Handle Design
Centrifugal Compressors: Horizontally Split
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Turbocompressor Specifications
VGS/VGSP/VGS7 800–500,000 3,620 67,000 1 to 8 40,000 V D, C, L, other than air & N2 617 Part 3
VG/ VGP/VG7 800–500,000 1,500 67,000 1 to 8 60,000 V D, C, L air, N2 617 Part 3, 672
DH series 800–150,000 1,300 33,500 Single 18,000 V D, C, L all 617 Part 2
api Reciprocating Compressors
API 617 = Centrifugal API 618 = Reciprocating API 619 = Rotary Screw
Seals: D = Dry gas, L = Labyrinth, O = Oil/Mech, C = Carbon Ring
Inlet Volume Discharge Pressure Power Requirement Number of Type of Casing Type of
Model (m3/hr) P2 (bar) (hp) Stages Max rpm Split Type of Seals Design
Integrally Geared Compressor Specifications
SIEMENS ENERGY
Inlet Volume Discharge Pressure Power Required Stages Speed Casing Gas Capability Design
Model m3/hr cfm bar G psig (hp) # (max) (rpm) Split Type Seals Type Discharge Pressure Type
Radial
STC-SH 100-500,000 59-294,000 50 725 as required 10 20,000 H D,L,C All C
STC-SV 100-500,000 59-280,000 450 6,350 as required 10 20,000 V D,L,C,O All C
STC-SVm 200-315,000 118-185,000 350 5,000 as required 10 20,000 V D,L,C All C
DATUM 150-440,000 90-260,000 1,000 14,500 as required 12 26,500 V D,L,C,O All C
Pipeline
RFA24/36 43,000-103,000 25,000-61,000 125 1,800 20,000-50,000 1 14,500 V D Nat Gas C
RFBB20/24/30/36/42 22,000-107,000 13,000-63,000 155 2,250 25,000-75,000 5 14,500 V D Nat Gas C
Intergrally Geared
STC-GV 1,500-1,200,000 880-708,000 250 3,625 as required 8 45,000 V D,L,C, O All I-C
STC-GC 10,000-400,000 6,000-240,000 20 290 as required 4 45,000 V L AIR & N2 I-C
D= Dry Gas, C=Centrifugal, L= Laby, A= Axial, O=Oil, I=Intergrally Geared, R=Radial flow, C=Carbon Ring, S=Screw, G=Gas
94 • www.turbomachinerymag.com
Turbocompressor Specifications
Discharge Pressure P2
Inlet Volume Number of Maximum Type of Casing Type of Type of Gas Compressor Can Type of
Model (m3/hr) (bar) (Kpag) Stages rpm Split Seals Handle Design
C16 3,600 310 31,025 10 23,800 V D natural gas C
C31 8,520 344 34,475 9 16,000 V D natural gas C
C33 16,200 186 18,620 10 19,000 V D natural gas C
C40M 15,300 172 17,235 6 14,300 V D natural gas C
C40P 18,000 186 11,030 2 15,500 V D natural gas C
C41 (1) 30,600 259 25,855 10 14,300 V D natural gas C
C45 31,500 124 15,513 3 12,000 V D natural gas C
C50 33,900 103 10,350 5 14,000 V D natural gas C
C51 (1) 42,600 207 20,685 10 12,000 V D natural gas C
C61 59,400 207 20,685 10 10,200 H D natural gas C
C65 40,800 110 11,030 2 10,500 H D natural gas C
C75 51,000 155 15,510 3 8,860 V D natural gas C
C85 76,500 110 11,030 2 7,000 V D natural gas C
1 Pressure Ratios are higher for the C41/C51/C61. Dual Compartment compressors depending on cooling capability
Discharge Power Number Maximum Type of Type of Type of Gas Compressor Type of
Model Inlet Volume (m3/hr) Pressure (barg) Requirement (kW) of Stages rpm Casing Split Seals Can Handle Design
Centrifugal Compressors
Inlet Pressure Inlet Number of Type of Type of Type of Gas Compressor Type of
Model (bar A) Temperature (°C) Stages rpm Power (kW) Casing Split Seals Can Handle Design
EC/ECM/ETB up to 200 –253 to +200 1 up to 100,000 up to 22,500 V L/C/D (1) R, (2)
EG/EGI/ETG up to 200 –253 to +550 1 to 4 up to 50,000 up to 30,000 V L/C/O/D (1) R, (3), (4)
EHB, ETF up to 200 –253 to +120 1 up to 105,000 below 250 V L/F (1) R, (5)
1 All industrial gases and hydrocarbon gas mixtures, including condensing streams. Hydrogen and hydrogen rich gas, super critical CO2, ammonia, etc.
2 EC and ETB have compressor load with oil bearings. ECM has Compressor load with active magnetic bearings
3 EG has electric generator load with external gearbox. EGI has electric generator load with integral gearbox
4 ETG has electric generator load with gearbox
5 EHB and ETF have oil brake load.
6 Seal types: L=Labyrinth, C=Carbon Ring, D=Dry gas, O=Oil
7 Type of casing Split: H=Horizontal, V=Vertical
8 R = Radial inflow
Inlet Pressure Inlet Temp. Inlet Flow Number of Type of Type of Type of Gas Expander Type of Type of
Model Frame (bar A) (°C) (m3/h) Stages rpm Casing Split Seals Can Handle Design Bearing
EC/EG 10 2 to 230 –270 to 315 300 1–4 110,000 V D,L,O HC,S,I R,C,I M,P,0
EC/EG 15 2 to 230 –270 to 315 500 1–4 70,000 V D,L,O HC,S,I R,C,I M,P,0
EC/EG 20 2 to 230 –270 to 315 2,000 1–4 60,000 V D,L,O HC,S,I R,C,I M,P,0
EC/EG 25 2 to 230 –270 to 315 3,000 1–4 35,000 V D,L,O HC,S,I R,C,I M,P,0
EC/EG 30 2 to 230 –270 to 315 5,000 1–4 25,000 V D,L,O HC,S,I R,C,I M,P,0
EC/EG 40 2 to 230 –270 to 315 7,000 1–4 22,000 V D,L,O HC,S,I R,C,I M,P,0
EC/EG 50 2 to 140 –270 to 315 11,000 1–4 20,000 V D,L,O HC,S,I R,C,I M,P,0
EC/EG 60 2 to 140 –270 to 315 15,000 1–4 16,000 V D,L,O HC,S,I R,C,I M,P,0
EC/EG 80 2 to 90 –270 to 315 20,000 1–4 12,000 V D,L,O HC,S,I R,C,I M,P,0
EC/EG 100 2 to 90 –110 to 315 35,000 1–4 10,000 V D,L,O HC,S,I R,C,I P,0
EC/EG 130 2 to 50 –110 to 315 50,000 1–4 8,500 V D,L,O HC,S,I R,C,I P,0
EC/EG 160 2 to 50 –110 to 315 80,000 1–4 7,000 V D,L,O HC,S,I R,C,I P,0
EC/EG 180 2 to 20 –110 to 315 110,000 1–4 6,000 V D,L,O HC,S,I R,C,I P,0
Notes:
1 Model: EC = Expander Compressor, EG = Expander Generator, ED = Expander Dyno
2 Type of Casting Split: H = Horizontal, V = Vertical
3 Type of Seals: C = Carbon ring, D = Dry gas, L = Labyrinth, O = Oil, W = Water
4 Type of Gas: HC = Hydrocarbons, S = Steam, I = Industrial gasses, incl. Air, Nitrogen, CO, CO2, Waste, NH3, etc., F = Flue Gas
5 Type of Design: A = Axial, R = Radial, C = Centrifugal / Centripetal, I = Integral gear, S = Screw
6 Type of Bearings: M = Magnetic, P = Pressurized oil bearings, O = Oil bearings
Inlet Volume Inlet Inlet Flow Number of Type of Type of Type of Gas Expander Type of
Model (bar A) Temperature (°C) (kg/hr) Stages rpm Casing Split Seals Can Handle Design
NAE 11 500 up to 300,000 7 4,500 H L I A
Notes:
1 Model: EC = Expander Compressor, EG = Expander Generator, ED = Expander Dyno
2 Type of Casting Split: H = Horizontal, V = Vertical
3 Type of Seals: C = Carbon ring, D = Dry gas, L = Labyrinth, O = Oil, W = Water
4 Type of Gas: HC = Hydrocarbons, S = Steam, I = Industrial gasses, incl. Air, Nitrogen, CO, CO2, Waste, NH³, etc., F = Flue Gas
5 Type of Design: A = Axial, R = Radial, C = Centrifugal/Centripetal, I = Integral gear, S = Screw
6 Type of Bearings: M = Magnetic, P = Pressurized oil bearings, O = Oil bearings
96 • www.turbomachinerymag.com
Turboexpander Specifications
EBARA ELLIOTT ENERGY, JEANNETTE, PENNSYLVANIA, U.S.A. AND SODEGAURA, CHIBA, JAPAN
Inlet Pressure Inlet Inlet Flow Number of Type of Casing Type of Gas Expander Type of
Model (bar A) Temperature (°C) (kg/hr) Stages rpm Split Type of Seals Can Handle Design
TH-85 4.5 760 220,000 1–2 7,500 V L (1) A
TH-100 4.5 760 330,000 1–2 5,800 V L (1) A
TH-120 4.5 760 505,000 1 4,700 V L (1) A
TH-140 4.5 760 772,000 1 3,960 V L (1) A
Notes: Ebara Elliott Energy designs, manufactures, tests, installs, services and repairs FCC flue gas power recovery expanders. Our proven designs and technology result in rugged, reliable
machines with millions of hours of operation in the field and up to 10 years of blade life from a single row of blades. Product features include: • Aerodynamic design to eliminate secondary
erosion • Integral expansion joint • Superior materials technology • Overspeed protection • After burn protection
1 FCC, blast furnace, coal gas
2 V = Vertical, L = Labyrinth Seal, A = Axial Inlet
Inlet Volume Inlet Temp. Inlet Flow Number of Type of Type of Gas Expander Type of
Model (bar A) (°C) (kg/hr) Stages rpm Casing Split Type of Seals Can Handle Design
EN/E up to 16 540 up to 360,000 multi up to 20,000 H/V L+O,G (1) A
EH up to 12 760 up to 650,000 single or multi up to 24,000 H/V L,O (1) A
ER up to 15 500 up to 450,000 1/2 or multi up to 48,000 V L+O,G (1) R
1 all industrial gases
98 • www.turbomachinerymag.com
Turboexpander Specifications
SIEMENS ENERGY
Inlet Temp
Inlet Pressure Inlet Flow Number Type of Type of Type of Gas Expander Type of
Model (bar A) psia °C °F (m3/hr) of Stages rpm Casing Split Seals Can Handle Design
STC-GT 20 290 550 1022 9,000–600,000 4 25,000 V L all I-C
E-516/520/ 1.85 typical 27 typical
760 1400 45,000–165,000 5 7,000-11,000 H L&H (1) A
522/526 17.7 max 257 max
E-132/232 3.75 max 54 760 1022 165,000–200,000 2 7,500–8,500 V L (1) A
E-138/238 3.75 max 54 760 1400 345,000–350,000 2 6,000 V L (1) A
E-148/248 3.75 max 54 760 1022 450,000–555,000 2 4,000 V L (1) A
E-156 3.75 max 54 760 1400 730,000 1 3,600 V L (1) A
1 Nitric acid, ethylene oxide, FCC, coal gas, blast furnace gas. D = Dry Gas, L = Laby, H = Honeycomb seal
P
process repeats, and various surge cycles
occur until the compressor operating
art one of our myth manufacturers and industry specifications point changes.
covered the fundamentals put the map’s flow limit and, arbitrarily, the On the other hand, rotating stall is an
of centrifugal compressor surge line at peak head, or to the right of aerodynamic instability that sometimes
head-flow maps. Although we’ve previously this point if rotating stall is detected. occurs in a compressor component before
covered surge and choke in other Myth Manufacturers also place a surge control the machine enters surge. Periodic com-
Busters columns, part two discusses it again line on the map parallel to the surge line, pressor diffuser or impeller inducer flow
since it’s such an integral part of compres- usually at a 10-15% flow margin to the right separation leads to a localized and complete
sor maps. of it, which is used for controlling the surge loss of through-flow in a single diffuser
control recycle valve with sufficient safety passage (or areas and moves from passage to
margins during fast system transients. passage). For vaneless diffusers, it is simply a
SURGE In reality, the surge (and surge control) rotating stall cell. This instability spins in
All centrifugal compressors have a limit line line does not need to be linear—and in the direction of the impeller’s rotation at a
that is nearly linear (at least for machines most modern control systems it is not— frequency below synchronous speed.
operating at modest Mach numbers) on the since it is defined by the onset of surge of The major difference is that surge is a
low-flow side of the map that corresponds different impellers in a compressor and is global phenomenon in which the entire
to surge onset. Very often, this line crosses also impacted by viscous flow effects, fluid compressor flow reverses, whereas rotating
the peak head point of the speed lines, but density (which is a function of pressure and stall only affects small areas of the diffuser
there isn’t a good physical reason for this temperature), and other fluid properties at any time. Rotating stall can potentially
because surge is a system, not a compres- such as heat capacity and specific heat cause axial and radial vibrations that can
sor-related issue. Regardless, in most cases, ratio. Furthermore, in some cases, the damage the compressor, but operational
surge occurs reasonably close but at lower surge line can be far to the left of peak restriction in this operating regime needs to
flow than peak head on a speed line. For head, but this is, as previously noted, a be evaluated on a case-by-case basis, while
safety and engineering conservatism, most system issue. full surge should always be avoided.
100 • www.turbomachinerymag.com
MYTH BUSTERS
CHOKE losses are responsible for the gradual head bypass the machine. However, starting a
On the other side of the compressor map is reduction. If actual choke occurs, it is one machine against a depressurized system
choke. A centrifugal compressor’s maxi- stage of the compressor that chokes first; it makes this unavoidable at times. If
mum flow is mechanically limited by its then does not increase the pressure but acts operators decide to run their machines in
allowable speed, the torque its shaft can as a flow restriction. choke, then they need to be aware of the
handle, and the power provided by its Thus, when compressor engineers talk risks involved.
driver (hopefully the latter before the about choke it usually corresponds to the
former). Beyond that, the aerodynamic right side of the compressor map where the
performance is limited by a maximum flow. speed-lines head rapidly declines with flow. THE VALUE OF A COMPRESSOR MAP
What defines “rapid decline” is A compressor map is more than just test
mostly conjecture and specula- results. The map contains relevant physical
A compressor map is more than tion. As previously noted, the and performance characteristic informa-
just test results. The map contains reason that the head either tion that most turbomachinery engineers
gently or rapidly declines in this should understand to improve machine
relevant physical and performance area on the map is solely operations. It’s not just graphics—the
characteristic information that because the velocity vectors compressor map provides actual insight
significantly deviate from the into what is happening inside a compressor
most turbomachinery engineers incidence angles of the com- at any operating point. It relates velocity
should understand to improve pressor inlet, and because of the incidence and discharge vectors to head and
high throughput, blade-flow flow. Unfortunately, the compressor map
machine operations. guidance is limited. This results sometimes shows what went wrong and,
in significant incidence and often in hindsight, why a machine failed in
This limit is often referred to as choke, secondary flow losses, including large flow the field. Gaining this insight before failure
stonewall, or overload. Many manufactur- separation and recirculation regions in the is imperative.
ers define a distinct overload limit; others impeller, which results in the impeller not There are some obvious takeaways:
provide performance maps where the speed converting all its energy into head and Understand the difference between rotating
lines end somewhere in mid-space. Of all pressure losses dominating. Because of stall and surge so you can use the full
the physical phenomena that affect a these significant secondary flows, periodic operating range without risking the health
centrifugal compressor, choke creates the aero instability and even stall flutter of the compressor. Know when you are in
most disagreement among turbomachinery (especially in open-faced impellers) are also choke and why choke can be damaging.
engineers, and it does not have a clear possible, leading to high-cycle blade loads Finally, centrifugal compressors have an
industry definition. and subsequent fatigue failures. incredibly wide operating range but try to
The classical definition of choke is when Most, but not all, compressor manu- operate as close as possible to the best
a fluid reaches its sonic point (Mach 1) in a facturers restrict operation in this region efficiency point for higher performance and
flow constriction and volume flow cannot due to the risk of high-cycle fatigue clean mechanical operation.
be further increased. Volume flow reaches a damage and impeller blade failures. In
maximum and mass flow can only be some cases, the maximum flow is limited
increased through pressure; thus, density by other considerations, such as thrust
Klaus Brun is the Director of R&D at
increases. This phenomenon rarely occurs load, the mechanical excitation of shaft Ebara Elliott Energy. He is also the past
in centrifugal compressors except when components, or because the manufac- Chair of the Board of Directors of the
ASME International Gas Turbine Institute
heavy gases with a low speed of sound are turer doesn’t have adequate data beyond and the IGTI Oil & Gas applications
compressed. Specifically, this type of choke the map endpoints. Unfortunately, there committee.
does not occur within many compressors, are no established industry criteria as to
especially when lighter gases are com- what constitutes as “operating in choke” Rainer Kurz is a recent retiree from
pressed or the pressure ratios are low. and when it’s damaging the machine. One Manager of Gas Compressor Engineering
at Solar Turbines Inc. in San Diego, CA.
Rather than going rapidly vertical, the head can make the argument that for basic He is an ASME Fellow and has published
gently slopes downward as flow increases. thermodynamic reasons you shouldn’t over 200 articles and papers in the
turbomachinery field.
In these cases, the flow never actually operate in choke when it barely produces
chokes, instead increased aerodynamic head—you may as well shut down and
102 • www.turbomachinerymag.com
vision
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