GE Energy gas engines

2 0 1 1

I s s u ecogen 05

Two-stage turbochargingThe next gas engine generation

Eastern Europe and Russia special Major raw material reserves with enormous potential

24/7 serviceA 168-hour week in the service of our customers

editorial

president story 03Combining three powerful offerings

technology and product news 05The next gas engine generation

The J624 with two–stage turbocharging

Plant Maintenance 2.0 – the myPlantTM virtual service

GE’s Waukesha 275GL+ gas engines for power generation

industry news 13An imminent growth leap for decentralized energy supply

applications and solutions 15Heat Recovery Solutions Technology a perfect fit

South African industry booming; reliable power supply needed

Waukesha rich-burn engine delivers energy independence

distributors and service providers 21Holistic energy solutions for power generation in Eastern Europe

Complete solutions are the key to Filter´s success

region special 27Speeding up in Eastern Europe and Russia

Coal bed methane – a subterranean energy treasure

success story 33More power for the automotive industry

GE‘s Jenbacher gas engines cited for energy efficiency

GE’s Waukesha gas engine still going strong in Chile

service 3924/7 service

supply chain 41Area 53

personality story 43An interview with Scott Nolen,

product line leader of GE‘s gas engines business

feedback and masthead 45

cogen2.0 46

Dear Reader,

02

editorial cogen

This edition of our magazine bears

a new name, as “coJen” has become

“cogen.” This change reflects the fact that in

recent months, GE Energy’s gas engines

division has been enlarged considerably

with two acquisitions, and now stands for

cogeneration to an even more comprehensive

extent. In addition to electricity generation

with Jenbacher and Waukesha gas engines,

Heat Recovery Solutions provides efficient en-

ergy recovery from waste heat. It’s not just our

customer magazine that has a new face. We are

also pleased to introduce Rafael Santana, the new

leader of GE Energy’s gas engines division.

Highlights of this edition include a presentation of

two-stage turbocharging, representing yet another

genuine quantum leap in the history of Jenbacher

gas engines. In addition, we feature the new 275GL+

from Waukesha. By ensuring reliable operation in

the challenging oil and gas business with the addition

of Clean CycleTM, the 275GL+ showcases efficient

solutions for electricity generation from waste heat

for the low output area. Look for the Region Special,

dedicated to Eastern Europe and Russia. GE Energy

is already well-equipped to deal with the demands

of these important, high-potential

regions with a full coverage network

of 5,700 employees.

We would like to take this opportunity

to thank you for the extensive mail

that we receive following each issue of

the magazine. We welcome all letters

and, as a gesture of appreciation, will

enter your name into our super prize raf-

fle. On behalf of the entire editorial team, I

wish you exciting and instructive reading.

Yours sincerely,

Martina Streiter

Communications

PS: In this edition, for the first time, we are

thrilled to offer you an opportunity to experi-

ence “augmented reality” first-hand. Simply

hold the icons at the end of the individual

articles in front of your integrated web

camera. You can learn more about cogen2.0

on the inside back cover. _

cogen2.0

03 04

Changes are happening with GE’s gas engines business. First, GE is forming a new integrated

gas engines division after acquiring heat recovery technology from Calnetix Power Solutions

(CPS) and adding Dresser’s Waukesha gas engines business. And not only has GE placed these

units under one umbrella, along with the Jenbacher gas engines product line, it also has

appointed Rafael Santana, former CEO for GE Energy in Latin America, as the new president

for the gas engines business. He succeeds Prady Iyyanki, who leaves after five years leading

GE’s Jenbacher gas engines business to become vice president for turbomachinery within

GE Oil & Gas.

Combining three powerful offerings

COMMITED TO INVESTING IN TECHNOLOGY. After the economic

downturn, the gas engines industry is growing again, and

customers are looking for short delivery times and high-efficiency,

fuel-flexible offerings. GE Energy’s gas engines business emerged

from the downturn in a very good position, as GE made key busi-

ness investments during the last two years: It continued to invest

in the business even in the downturn, made the Heat Recovery

Solutions and Dresser acquisitions, and announced two major

technological milestones to the public.

“Our new expanded gas engines business is an ideal platform for taking these three

product lines to the next level.”

The first innovation was the updated J624, the first gas engine in

the world featuring the power boost of two-stage turbocharging

technology. Since it offers great performance in hot and humid

conditions or at high altitudes, the new J624 significantly improves

operating efficiency. The second innovation that GE invested

heavily in and, which soon will be fully launched commercially, is

GE Energy’s largest gas engine to date: the 9.5MW output J920 –

again featuring two-stage-turbocharging technology – gives GE a

more comprehensive offering targeting the growing Independent

Power Producer (IPP) segment. With the successful testing of the

first J920 units in Austria, the start of serial production of this new

flagship engine model is planned to start 2012.

The new ideas don’t end there, because a number of key

technological innovations for power generation – including a

strong expansion in service offerings – are under

way across all three gas engines business units.

INTEGRATING FOR GROWTH. Given their obvi-

ous synergies, it was a logical decision to bring

all three businesses together. Inherent in this new

structure is a strategy to accelerate and improve

technology developments and market penetra-

tion for the overall gas engines business. The

good news for customers is that this will make

more and better solutions available to them for

a wider variety of industrial applications.

By combining power generation offerings for the

gas engines business into one product line, GE

can expand its customer outreach and create a

unified and an even stronger services network

in that sphere. The integration will help make GE

a true one-stop-shop provider for all currently

relevant gas engines applications for power

generation and mechanical drive, and the Heat

Recovery Solutions technology enables GE to of-

fer comprehensive Organic Rankine Cycle (ORC)-

based solutions for the smaller output range.

From the former Dresser Waukesha business,

GE not only receives 600 additional employees

– including a highly experienced engineering

team – but also an installed base of more than

20,000 engines in the field. Rafael Santana sums

up the changes this way: “Our new expanded gas

engines business is an ideal platform for taking

these three product lines to the next level so that

we can serve our customers even better with

technology and services that meet their demand

for availability, reliability, fuel efficiency and low

emissions performance.” GE’s strong installed

combined fleet has coincided with the growing

global interest in gas engine technology to make

the new gas engines division a reality.

COMPLEMENTARY STRENGTHS. Because the

product, technology and expertise bases of the

Jenbacher and Waukesha segments mesh to-

gether so well, GE can be an even better player in

the gas engines sector globally. Santana asserts

that Waukesha’s compression expertise and the

complementary relationship between its power

generation capabilities and “the Jenbacher

domain knowledge and footprint” put both busi-

nesses in great shape for the future. More specifi-

cally, the Waukesha segment’s compression and

mechanical drive technologies and applications

add to GE’s gas engine offerings and allow GE

to achieve deeper penetration of its gas engine

technology into the oil and gas arena. Building on

president storyen cogenpresident storyencogen

Gas engines business is evolving

about Rafael Santana:

Current Position:

President – gas engines, GE Energy

Previous Positions:

· CEO for GE Energy Latin America

· President – Latin America, GE Transportation

· Product Manager - Off Highway Vehicle

Division, GE Transportation

· Marine and Stationary Power Regional

Manager – South America, GE Transportation

· Commercial Leader – GEVISA,

GE Transportation Systems

South America – GE Transportation

· Rafael spent another seven years at British

American Tobacco and Exxon Mobil in

various roles.

the Waukesha technologies will directly benefit

GE’s Oil & Gas customers, who need small-scale

compression as well as power generation solu-

tions. Now, GE can marry the Jenbacher product

line’s fuel flexibility and high efficiency with the

Waukesha line’s low emissions and reliability to

bring more gas engine solutions to petrochemi-

cal, mining and manufacturing customers. Also,

both the power generation and compression

segments have a strong service base and

continuously work to expand service offerings

so that customers are assured of getting the

quality and expertise that only the original equip-

ment manufacturer can offer. “This is what the

customer remembers,” Santana stresses. “We

need to provide a competitive quality product

with full services support. That will be key for our

business units to continue to be successful in

the long run.” The heavy involvement of GE’s gas

engines customers with renewable energy is a

major driver for the integration of Heat Recovery

Solutions into the gas engines business.

“We are now well-positioned to become the industry’s

waste-heat-to-power expert.”

Heat Recovery Solutions’ product development is

in an early stage, but the business brings a great

deal of innovative technology in a new space to

GE. By combining waste-heat-to-power tech-

nologies from Heat Recovery Solutions with the

technical and distribution capabilities of GE’s gas

engines business, GE can provide best-in-class,

comprehensive solutions to its power generation

customers engaged in waste heat recovery ap-

plications. With GE already boasting an array of

gas turbines and engines that use waste gases,

Santana believes the linkage with Heat Recovery

Solutions will bolster GE’s gas engines reach even

more. “We are now well-positioned to become

the industry’s waste-heat-to-power expert,” he

proclaims.

A LEGACY OF GROWTH. Santana is taking on

a gas engines business that has experienced

impressive growth. He observes, “We have grown

significantly through increased globalization,

services and product portfolio expansion, includ-

ing the recent acquisitions of Heat Recovery

Solutions and Waukesha gas engines.

We have a tremendous opportunity in front of

us to continue growing this business with unique

and flexible offerings.” _

Rafael Santana,

president of gas engines, GE Energy

Conceptualdesign Simulation

Single cylinderengines

Final designed multi cylinder test engineand pilot engines at customer sites

Component tests

J624 Two-stage turbochargedReleased product

J624 Single-stage turbocharged

0605

developed turbocharger unit consists of a low-

pressure compressor with subsequent intercool-

ing, a high-pressure compressor with charge-air

cooling and the corresponding high- and low-

pressure turbines on the exhaust gas side.

THE ADVANTAGES. Due to the new two-stage

turbocharging, gas engines will get a much bigger

role in the decentralized energy supply.

The applications are ranging from temperate

latitudes and Arctic regions to hot and humid

tropical climates. Two-stage turbocharging in

combination with the Miller cycle allows a charg-

ing air temperature of more than 158°F(70°C) at a

mean effective pressure of 24 bar. This prevents

mixture condensation even under tropical ambi-

ent conditions, and the engine can also provide

maximum performance even under extreme

climatic conditions.

In the case of the J624, the new technology also

facilitates a 10 percent increase in electrical

output, a 1 percent point rise in efficiency and a

simultaneous reduction in emissions. In combina-

tion with cogeneration, two-stage turbocharging

THE DEVELOPMENT. Jenbacher gas engines are characterized by

their extremely compact design and consist mainly of a basic en-

gine, a generator and an auxiliary unit including the turbocharger.

The engines of the type 6 series operate with an air/fuel mixture

provided by an external upstream mixer, turbocharging, a Miller

cycle, a lean combustion system and a scavenged pre-chamber.

“The new two-stage turbocharging advance constitutes a genuine quantum leap and will

enable us to continue to play a pioneering role in the creation of new technologies.”

– Volker Schulte, general manager engineering of GE´s gas engines division

Especially the Miller cycle and the lean combustion system are

reducing the knocking tendency and ensuring a stable engine

operation, but require a higher charging pressure.

With a Miller cycle, the inlet valve closes earlier, reducing the

filling time and causing incomplete filling of the combustion

chamber, which results in power loss. A higher charging pressure

allows filling the combustion chamber in a shorter time and even

with higher mass, resulting in further increased engine output

potential. Two-stage turbocharging was developed specifically to

achieve this higher charging pressure, and this technology is also

a strong contributor to increase engine efficiency.

Volker Schulte, general manager engineering of GE´s gas engines

division and responsible for the development, is highly enthusi-

astic: “We had progressed so far with the previous engines that

we had reached the development limits. The new two-stage

turbocharging advance constitutes a genuine

quantum leap and will enable us to continue

to play a pioneering role in the creation of

new technologies.”

THE TECHNOLOGY. At present, turbocharger

suppliers offer single-stage charging up to a

pressure ratio of around 6. If higher pressure ra-

tios (charging pressures) are needed, the single

stage turbocharging system requires the use of

expensive compressor material and at the same

time the charging efficiency would significantly

drop below 60 percent.

For these reasons, GE decided to develop two-

stage turbocharging, which offers a charging

efficiency of more than 75 percent. The newly

· 10 percent increase in efficiency

· Enhanced electrical efficiency

· Far lower emission levels

· Improved engine use under

extreme climatic conditions

· CHP efficiency of 90 percent

· Excellent basis for further developments

technology and product news cogentechnology and product newscogen

The next gas engine generation GE’s gas engines division has once again demonstrated its leadership in the field of gas engine innovation. Because of

their efficiency, low emissions, fuel flexibility and natural gas availability, stationary gas engines are playing an increas-

ingly important role in the decentralized energy supply. These benefits have now been further enhanced by two-stage

turbocharging. Introduced by GE in 2010, two-stage turbocharging allows the new Jenbacher J624 and J920 gas engines

to reach electrical efficiencies of 46.5 percent and 48.7 percent, clearly demonstrating GE’s leadership in innovative gas

engine technology.

ILLuSTRATION OF SYSTEM ENGINEERING DEVELOPMENT

facts and figures:

can result in an improvement in overall efficiency

to as much as 90 percent.

THE FuTuRE. Despite continuous development

over many years, the potential of large, stationary

gas engines is far from being fully exploited.

The intelligent combination of innovative, tech-

nological elements and the new cornerstone of

two-stage turbocharging permits crossing of old

boundaries towards higher mean effective pres-

sures, improved efficiencies and extended areas

of application. However, this promise can first be

realized through the simultaneous optimization

of charge exchanges, valve timing, combustion

processes and control concepts.

The J624 is impressively demonstrating this

with an electrical efficiency of 46.5 percent at

4.4MW output and adherence to the Technical

Instructions on Air Quality Control (TA Luft), and

it forms the basis for a new GE engine genera-

tion. In fact, GE continuous to employ two-stage

turbocharging in the recently-developed new

J920. In the near future, efficiency levels close

to the 50 percent mark and NOx raw emissions

of less than 200 mg/Nm³ (5 percent O2) will be

possible. Moreover, these features will naturally

be combined with the same degree of robustness

and reliability that has for decades characterized

GE’s Jenbacher gas engines. _

FuNCTIONAL DIAGRAM OF THE TuRBOCHARGER

uNIT WITH SuBSEquENT INTERCOOLING

up to 40° C 50°-70° C 50°-70° C

cogen2.0

–> THE J920 IS ONE OF TWO GE GAS ENGINE MODELS FEATuRING TWO-STAGE TuRBOCHARGING

07

A LEADING INNOVATOR. For more than 50

years, GE has been a leading innovator in gas

engine technology. This tradition sparks a

desire in the Jenbacher team to always be on

the cutting edge in terms of in-house technol-

ogy, achieving quantum leaps and establishing

milestones in the history of gas engines.

For GE’s Jenbacher team, leadership in the innovation

field means pushing ahead with the ongoing optimization and

further development of energy solutions.

For the company leadership, innovation means

pushing ahead with the ongoing optimization

and further development of energy solutions.

J624 – uSED TO BEING THE FIRST. At the time

of its presentation in June 2007 as the world’s

first 24-cylinder gas engine, the J624 was the

most important new product of GE’s gas engines

division. Then and now, it amazes with its power

density. With an output of 4.4MW, a single gas

engine can now supply the electricity for almost

10,000 typical European households.

Moreover, upgrading with revolutionary two-

stage turbocharging has now helped the best-

selling J624 to once again play a pioneering role.

NOTHING BuT ADVANTAGES. For customers,

this further development of the J624 means

a tangible reduction in operating costs due

to a notable 10 percent increase in output to

4.4MW, and a 1 percent point pt improvement

in maximum electrical efficiency to 46.5 percent

(which, under hot, ambient conditions, improves

2 percentage points as compared to the original

version). Furthermore, not only the electrical,

but also the total efficiency could be improved

by about 3 to 4 percentage points, up to 90 per-

cent. The advantages as compared to standard,

single-stage turbocharging are clearly evident

and include higher total efficiency, an improved

specific output and environmental benefits as

well as enhanced flexibility with regard to ambi-

ent temperatures and gas fuel composition.

FROM THE MOuNTAINS TO THE TROPICS. GE’s

gas engines must be able to operate anywhere,

from the temperate zones and polar regions to

the tropics, running at 8,000 annual operating

hours throughout a long service life, mostly at

full load, and reaching availability levels of more

than 95 percent. These application conditions

08

In 2007, GE unveiled the Jenbacher J624, the world’s first 24-cylinder gas engine. The success of GE’s new flagship

quickly captured the hearts of our customer’s power plant stations. Moreover, in summer of 2010 the J624 became the

first gas engine to be equipped with revolutionary, two-stage turbocharging and has since occupied the international

spotlight, providing further evidence of GE’s innovative strengths.

The J624 with two–stage turbocharging

technology and product news cogentechnology and product newscogen

Successful customers, the best evidence of successmake massive demands on engine durability,

but represent a challenge that GE’s gas engines

division is gladly willing to face, just as it accepts

an obligation to meet strict emission limits, in

spite of fluctuating gas quality and composi-

tion. The new J624 offers exactly this flexibility

needed for applications in the different climate

zones, and is especially suited for operating

under hot and humid environments where

Gas engines must be ableto operate anywhere, from

the temperate zones and polar regions to the tropics.

gas engines already play an important role

in the decentralized energy supply. With an

electrical efficiency improvement of 2 percent-

age points under hot environments, the new

J624 is especially attractive in those countries. _

Another global first:

cogen2.0

“For us the new J624 offers still greater flexibility

for the combined generation of electricity and heat.”

JAAP NOORDAM,

one of the owners of the Dutch

greenhouse operator Red Harvest

GIL MARGuERAT,

the director of the power production

department at French plant

builder Forclum

WILLI GOLDSCHMIDT,

the CEO at Navigat Energy,

and authorized sales and services provider

for Jenbacher gas engines in Indonesia

“The J624 offers us an increased cogeneration efficiency in tandem with a reduction in NOx emissions

from 500 to 300 mg/Nm3 (at 5 percent O2)!“

“For us, the fact that even in our hot and humid climate

the new J624 with two-stage turbocharging provides top

performance is a huge plus.”

09 10

technology and product news cogentechnology and product newscogen

when an engine is running out of spec or is

stopped due to a failure.” The myPlant system,

which currently is being set up, “will promptly

notify the local service helpdesk for a pro-active

response,” adds Johan Brink, “so we can work

on the problem before the customer notices the

effect. This will increase plant availability and

save time and money.”

myPlant uses globallyinstalled references

to benchmarkindividual engines.

Customers can obtain detailed, advance

information about the myPlant system from the

Jenbacher gas engines service sales organiza-

tion and local sales providers. _

Apart from a completely redesigned inter-

face, myPlant provides numerous additional

advantages – chief among them the integration

of existing services, interface and operator stan-

dards into a centralized application character-

ized by uniform, user-friendly handling.

WEB-BASED SERVICES CREATE FLExIBLE

HANDLING. myPlant will enable customers

to monitor and control their global fleet of

Jenbacher gas engines from a single platform.

Moreover, GE’s centralized Web hosting will

reduce installation and servicing costs to a mini-

mum and make special hardware or software

unnecessary. Customers will be able to access

myPlant at any time and from anywhere through

a secured Internet link.

As a result of myPlant, in future, customers will only require

a single platform for the surveillance and control

of their Jenbacher gas engines installed around the world.

The system automatically collates the data from

all the connected Jenbacher gas engines around

the world either in real time or within defined

intervals, depending upon priority. Since custom-

ers will receive a picture of the entire fleet from

myPlant, they no longer will work directly with

the individual control systems of their engines.

EVERYTHING uNDER ONE uMBRELLA? NO

PROBLEM WITH MYPLANT! With myPlant,

customers will be able to do basically everything

they did before – and a great deal more besides.

For example, they still can conduct remote

monitoring of the installed fleet and access the

electronic control systems for targeted adjust-

ments in the running behavior of individual

engines. But myPlant not only will present the

relevant information clearly, it also will add role

management functionality that individually

adjusts the depth of displayed information to

match the respective user group.

SERVICE ExPERT SYSTEM SOLVES PROBLEMS.

The most outstanding of many myPlant innova-

tions is the Service Expert System (SES) – GE’s

knowledge database – which can provide

descriptions and solution scenarios for about

80 percent of all possible plant defects. Axel

Dancker, global service leader for Jenbacher

gas engines, puts the advantages of myPlant

in a nutshell: “myPlant offers our customers

myPlant is GE’s new, online service platform for customer-oriented fleet management. Customers with Jenbacher gas engines will have a marked

expansion in their remote plant monitoring capabilities in mid-2011, when the newly developed myPlant online services platform will be unveiled.

myPlant combines familiar, individual elements from services and remote applications into a single solution that will be augmented by attractive,

supplementary packages.

myPlantPlant Maintenance 2.0 - the myPlantTM virtual service

maximum flexibility, integrates existing systems

for plant surveillance and can be extended to

include other features such as the Service Expert

System. We see myPlant as intelligent service

that is available to our clients around the clock.”

The Service Expert System (SES) constitutes GE’s knowledge

database, which has been built up over the years.

myPlant also can use globally installed refer-

ences to benchmark individual engines, since all

the data gathered is evaluated through the cen-

tral server in Jenbach. This will help customers

optimize the operation of their in-house systems.

SuCCESSFuL TEST OPERATION HEIGHTENS

INTEREST. Pretests of the myPlant system, con-

ducted at various customer sites, demonstrated

its huge potential. One of the system’s strengths,

the free configuration of all parameters, allowed

the determination of appropriate actions to take

at the right times to prevent serious damage to

an engine during one of the pretests. As Johan

Brink, service leader for Belgium and the Nether-

lands, reports: “With myPlant, we will be able to

react immediately to fix performance problems

The advantages of myPlant™ at a glance

· Concentration of all existing elements

in a centrally hosted Web application

· Newly developed interface for

maximum operating comfort

· Customer access via a secured Internet link

· Enlargement options involving other systems

such as the SES knowledge database

· Benchmarking with comparable

reference plants

· Integrated role management

TM

Distributor HelpdeskService HelpdeskHermes portal to

DIA.NE RMCDIA.NE Win

HiDat

Common tools and pogramsCommon user interface

Common designEasy intallation

Benefits

myPlantTM

myPlantTM

–> MYPLANTTM uSES GLOBALLY INSTALLED REFERENCES TO BENCHMARk COMPARABLE PLANTS

11 12

technology and product newscogen technology and product news cogen

GE Energy’s $3 billion acquisition of Dresser, Inc. in February included Dresser’s compression business, Waukesha. Located in

Wisconsin, in the united States, Waukesha joins the Jenbacher power generation platform and Heat Recovery Solutions segment

to form the third segment of GE’s gas engines business. Now, Waukesha 275GL+ high-performance engines are available from GE

for power generation applications at oil and gas production sites.

GE’s Waukesha 275GL+ gas engines are pow-

erful units that operate reliably in the most chal-

lenging oilfield power generation applications. “At

highly demanding oil and gas production sites,

both the 12- and 16-cylinder models deliver high

performance on a wide range of fuels,” said Scott

Nolen, product line leader power generation of

GE’s gas engines business. “These engines are

designed specifically to deliver maximum perfor-

mance and to withstand the rugged conditions at

oil and gas production sites.”

GE’s Waukesha 275GL+ gas engines are

powerful units that operate reliably in the most challenging

oilfield power generation applications.

LOWER FuEL CONSuMPTION, LOWER EMIS-

SIONS. GE’s Waukesha 275GL+ gas engines for

power generation have an improved turbo-

charger match, allowing for a leaner air-to-fuel

ratio. This, in turn, reduces fuel consumption

and emissions levels – and delivers more power.

Both the 12- and 16-cylinder 275GL+ units

are equipped with a NOx sensor that directly

measures NOx in the exhaust stream enabling

real-time, closed-loop control of the air-to-fuel

ratio to assure optimum performance. A display

panel mounted on the engine provides a read-out

of NOx emissions and other key engine operating

parameters. The statistics speak for themselves.

Both the 12V275GL+ and 16V275GL+ engines are

capable of 0.5 g/bhp-hr NOx and 1.8 g/bhp-hr CO

emissions levels without after treatment. These

emissions levels correspond to ½ TA Luft Europe-

an requirements for NOx emissions and also meet

2010 EPA Spark-Ignited New Source Performance

Standards (SI NSPS) without additional exhaust

treatment costs.

ADDED BENEFITS: MORE POWER, FuEL FLExI-

BILITY. When packaged as an Enginator® genera-

tor set, the 16-cylinder 16V275GL+ model is rated

3,480 kWe at 50 Hz (1,000 rpm) and 3,110 kWe

at 60 Hz (900 rpm). The 12-cylinder 12V275GL+ is

rated 2,600 kWe at 50 Hz and 2,330 kWe at 60Hz.

They have 1,000 rpm ratings of 4,835 bhp and

3,625 bhp, respectively. “GE’s Waukesha gas en-

gines are known for their fuel flexibility and 275GL

engines are no exception,” said Brian White, presi-

dent of Waukesha gas engines. “Because these

engines can operate reliably at higher power lev-

els on variable, low-quality gas pulled directly out

of the ground, they are particularly well-suited for

Designed to operate reliably in the most challenging oil and gas surroundings

facts and figures:

· Maintenance intervals

(oil/filter change,

spark plug maintenance,

valve adjustments) – 4,000 hours

· Turbocharger service – 25,000 hours

· Top end overhaul – 36,000 hours

· Major overhaul – 72,000 hours

President

of Waukesha gas engines

BRIAN WHITE

oil and gas production sites.” Both the 12V275GL+

and 16V275GL+ models have been designed to

operate at full power on fuels with heating values

down to 600 BTU/ft3 (23.6 MJ/m3) and at almost

70 percent load with fuels up to 2,350 BTU/ft3

(92.4 MJ/m3). In addition, 275GL Series engines

will operate at higher altitudes without derate –

the 12V275GL+ up to 4,000 feet (1,219 m) and the

16V275GL+ up to 3,000 feet (914 m).

uPTIME MAxIMIzED. All 275GL engines are

equipped with an enhanced version of Wauke-

sha’s ESM® engine control system to optimize

engine performance and maximize uptime.

The 275GL engines have long maintenance

intervals, allowing for high uptime and low

maintenance costs. “Waukesha has designed and

manufactured 275GL engines with an array of

benefits that make these engines an ideal choice

for oil and gas exploration and production sites in

remote and not-so-remote locations anywhere in

the world,” Brian White said. _

GE’s Waukesha 275GL+ gas engines for power generation

expansion during the period studied will be provided by renew-

able energy technologies, and in this regard wind energy will

demonstrate by far the largest growth. However, toward the end

of this decade, markedly stronger expansion is anticipated for

photovoltaics, and although bio-energy will also gain ground, it

will not be able to keep pace with the extremely dynamic advance

of wind and solar power. As a result of their ability to provide

demand-related power generation, fast reacting bio and natural

gas plants will assume an important function. That is because Eu-

ropean energy generation in 2030 will have a renewable energy

share of about 48 percent and will have to be far more flexible

than it is at present.

INVESTMENTS IN NEW CAPACITY WILL ALSO INVOLVE CONVEN-

TIONAL POWER PLANT TECHNOLOGIES. For this reason, in the

period up to 2030, roughly a third of investment in new capacity

will involve conventional power plant technologies. Apart from

the necessity of providing fluctuating renewable energies with

backup capacity that can be used flexibly, the obsolescence of

the power station park will constitute an important driving

Beginning in 2020, an increasing number of new, small-scale gasfired

power plants will be built.

force in this regard. Through the use of the large energy deficits

between existing power plants and new capacity, modernization

will create the preconditions required for a sizeable reduction in

INCREASING ENERGY CONVERSION EFFICIENCY. The energy sup-

ply system in Germany and the EU is currently facing fundamen-

tal change. The reduction of greenhouse gases and the accelerat-

ed depletion of fossil fuel reserves due to the rise in global energy

demand necessitate increasing energy conversion efficiency. A

number of studies describe this future development, in which a

diversity of electricity-generating technologies plays an important

role, although the producers are generally relegated to the status

of a supporting cast.

In the years up to 2030, Europe will require every energy source

and a drastic change in the energy mix will occur.

This is in spite of the fact that it is the latter who, through innova-

tions and investments in new technologies and the latest produc-

tion capacity, will exert a decisive influence on the restructuring

process. To make an active contribution to this debate within the

framework of the VDMA, the producers of differing electricity-

generating technologies have prepared a forecast regarding

development of the electricity mix in the EU 27 during the period

up to 2030.

A FOCuS ON RENEWABLE ENERGY TECHNOLOGIES. The most

significant conclusions of the expert report are that in the years

up to 2030, Europe will require every energy source and a drastic

change in the energy mix will occur. Almost two-thirds of capacity

The efficient use of renewable and fossil fuels in decentralized electricity and heat generation plants will be a major factor in the

restructuring of the European energy supply network in the coming decades. In fact, the VDMA (Verband Deutscher Maschinen-

und Anlagenbau – German Engineering Federation), one of the key association service providers in Europe and provider of the

largest engineering industry network in Europe, predicts in its expert outlook “Electricity Mix in the Eu 27” that – in the period up

to 2030 – some 86.5 GW will emanate from newly built and modernized decentralized engine power plants in Europe.

An article by Thorsten Herdan, VDMA Power Systems

the CO2 emissions from fossil fuel-fired power

plants. On the basis of a rapid update of the

fossil fuel-fired power plants, it will be possible

to attain the EU’s climate protection targets.

Beginning in 2020, an increasing number of

new, small-scale gas-fired power plants will be

built . In addition to flexible operation using heat

storage, these also offer the advantages of co-

generation, with fuel utilization levels in excess

of 90 percent.

THE IMPORTANCE OF DECENTRALIzED ENGINE

POWER PLANTS IS GROWING. The VDMA expert

forecast anticipates that by 2030, over 10 per-

cent of the 800 GW in additional capacity will be

provided by decentralized engine power plants.

In addition to new plants, it is also expected that

replacement capacity will play a central role,

meaning that by 2030, around 9.5 percent of

European electricity demand will be met on the

basis of decentralized engine power plants.

THIS TRANSITION IS ACHIEVABLE. With total

investments of well over EUR 1,000 billion in

new power plant capacity only, this transition

represents a colossal financial challenge.

Whether or not it takes place will depend to

a major extent on the political environment.

Jen industry newsco Jenindustry news co

13 14

Success will only be attainable when the politi-

cal sphere provides clear signals resulting in a

sustainable framework that permits planning.

A decisive factor in this connection will be the

creation of a trans-European electricity network

and the provision of power stores across the

continent.

With total investments of well over EUR 1,000 billion in new

power plant capacity only, this transition represents

a colossal financial challenge.

Industry can make an important contribution in

this regard through further technical innovations

such as improvements in the network compat-

ibility of power plants, new storage concept

research and testing, and the provision of manu-

facturing capacity. _

An imminent growth leap for decentralized energy supply

VDMA facts and figures:

· The largest association of capital goods

manufacturers in Europe

· Over 3,000 member companies, organized in

more than 40 branch associations

· 350 employees, with offices in Frankfurt and

Brussels as well as the capitals of other

important countries such as Beijing,

New Delhi and Moscow

· Assistance and secretarial management in

a large number of specialist bodies and

European branch associations

Further information is available under

www.vdma.org/powersystems (right-hand

column „Databases”, „Publications”).

VDMA Power Systems

Author

THORSTEN HERDAN

–> HEADquARTERS OF THE VDMA IS LOCATED IN FRANkFuRT AM MAIN, GERMANY

cogen2.0

CORE TECHNOLOGY. GE’s Heat Recovery Solutions product line

offers proven technology that recovers low temperature waste

heat from small-scale applications such as gas turbines, recip-

rocating engines, and biomass boilers and turns it into electric

power for onsite re-use or sale back to the grid.

GE’s Heat Recovery Solutions product line offers proven technology that recovers

low temperature waste heat from small-scale applications.

The core Heat Recovery Solutions technology is based on the

Organic Rankine Cycle (ORC), which is similar to the cycle that

a steam power plant uses except the working fluid has a much

lower boiling point. This allows the ORC to generate electricity

from much lower temperature heat. The heat is absorbed in the

evaporator, causing the working fluid to boil high pressure vapor

(like steam in a power plant). This high pressure vapor drives a

turbine, which generates electricity. While ORC has been applied

to large-scale industrial applications for a long time, small-scale

operations waste much more heat. It’s estimated that billions of

dollars worth of low-grade heat is wasted in this way every year.

Recycling even a tiny portion of that heat instead of dispers-

ing it into the atmosphere could cut down on fossil fuel usage

and significantly reduce CO2 emissions. A report published by

the American Council for an Energy-Efficient Economy in 2007

estimated that “waste heat recovery could substitute for 9

percent of total energy used by U.S. industry – or 1.4 quadrillion

Coming into the Fold

15 16

applications and solutionscogen applications and solutions cogen

GE’s Heat Recovery Solutions segment – part of GE Energy’s portfolio for more than eight months now – perfectly

complements the energy efficiency goals of GE‘s gas engines customers by providing them with advanced,

cleaner-technology solutions for generating power through waste heat recovery. Given the global potential that GE

projects for this industry sector, the integration of this business into GE’s gas engines division creates tremendous

opportunities for optimized energy delivery from an increasingly important alternative energy source. The initial

GE offering in this space already is yielding significant cost- and energy-savings paybacks.

Heat Recovery Solutions technology a perfect fit for GE Energy’s gas engines business

British thermal units (BTU).” To help salvage that

lost heat resource and meet the growing waste

heat-to-power demand, the Heat Recovery

Solutions team has developed Clean Cycle™, a

small-footprint, packaged ORC model that easily

integrates with machinery in the vast majority

of smaller-scale heat-wasting processes. Clean

Cycle takes waste heat from sources as low as

250°F (121°C) and transforms it into 125 kW

of electricity for the renewable and distributed

energy segments. Because it has satisfied a

rigorous third-party product review that proves

its ability to improve customer operating and

environmental benefits, Clean Cycle has just

received GE’s ecomagination approval.

MEETING CuSTOMER DEMANDS AND NEEDS.

Much of the activity in the small-scale, waste

heat recovery sector is concentrated in Europe,

where the European Union has set a goal of

generating 20 percent of the continent’s energy

from renewable sources by 2020. GE’s team

has responded to customer demand there by

starting pilot projects in Italy, Romania and

the United Kingdom. A pilot project using the

heat from two of GE’s Jenbacher type 3 biogas

engines in Dublovice, Czech Republic, is the

latest to come on line, starting up on April 20,

2011, at a power output of 125 kW. Recovering

waste heat from reciprocating engines, biomass

boilers, and microturbines and converting it into

electricity has become increasingly popular with

the global power industry, too, because it is a

highly efficient, clean-energy operation. GE is

very cognizant of that trend: by the end of 2011,

five independent third-party distributors will

help advance Heat Recovery Solutions products

globally. The introduction of Clean Cycle has

huge implications for renewable biogas projects,

which are especially attractive to countries that

have high electricity feed-in tariffs. Together

with Clean Cycle, GE’s Jenbacher gas engines

give onsite power plants the ability to generate

extra electricity without burning additional fuel

or producing more emissions. “Our technologies

mesh very well with Clean Cycle,” says Rafael

Santana, president of GE’s gas engines division.

“The combination will create more compre-

hensive waste heat-to-power solutions and

enhances our global leadership in the renewable

energy segment.” Clean Cycle’s flexibility caters

to varying customer requirements because it is

compatible with Jenbacher Type 3, 4, and 6 gas

engines, it can operate in small spaces, and it

can be moved from site to site.

“Our technologies mesh very well with Clean Cycle, the combination will create more comprehensive waste heat-to-power solutions

and enhances our global leadership in the renewable

energy segment.”- Rafael Santana, president of GE’s gas engines division

It also will accommodate applications in a broad

range of facilities, including factories, foundries

and cement plants. Heat Recovery Solutions

president Brad Garner describes the essential

value of Clean Cycle in this way: “We have cre-

ated the first commercially viable, ORC-based

waste heat recovery system that harvests

heat at the lower temperatures generated by

reciprocating engines, biomass boilers and

microturbines and then turns it into electricity

without creating additional environmental emis-

sions. Waste heat-to-electrical power generation

really is about the most environmentally friendly

technology there is, and that’s very attractive

to our customers. But their major incentive for

using Clean Cycle is economic, because if you’re

wasting heat, you’re wasting money. Our system

saves that heat from being wasted.” _

IS THE CLEAN CYCLE 125kW FEASIBLE FOR MY INSTALLATION?

Thermal Input required to reach 125 kW grid output 1,02MW @ 302°F (150°C) 0,27 kW can be replaced by lower temperature heat @ 201.2°F (94°C) from engine cooling water

Thermal Input required to reach 75 kW grid output0,65MW @ 302°F (150°C) 0,19MW can be replaced by lower temperature heat @ 201.2°F (94°C) from engine cooling water

Engine and Clean Cycle combinations 1 engine – 1 or 2 Clean Cycle, 2 engines – 1 Clean Cycle

Maximum Distance (from gas engines)Minimum possible distance between Clean Cycle and engines, to reduce heat losses. Distance from exhaust duct to heat exchanger should be less than 65.6 feet (20 meters). Water pipes can be longer.

Available Space 90.4 square foot (84 square meters), including clearances for container

Rate of Feed in Tariff Variable by country. High feed in tariffs yield better ROI.

Brad Garner,

president of Heat Recovery Solutions

cogen2.0

the company is a respected partner in the South African mining

industry, specializing in chrome-manganese steel and copper

castings which, above all, are intended for export. The foundry’s

highly complex special furnaces must be provided with an

uninterrupted supply of energy. A standstill that leads to cooling

means plant damage and serious financial losses.

SECuRITY THROuGH IN-HOuSE POWER SuPPLY. Because the

South African public grid is subject to the constant risk of power

outages, the Thos Begbie management decided in 2007 that the

company should generate its own electricity.

In an initial step in 2008, four of GE’s Jenbacher J620 gas engines

with a total output of 11.6MW were installed. Additional expan-

sion with another 20MW is planned for 2011 and 2012.Explains

Gert van Zyl, the managing director of ADC (PTY) Ltd, a private

project management company specializing in electricity solutions

and a long-term GE partner in South Africa, “Following Thos

Begbie’s decision to install an autonomous energy supply, it

evaluated a number of alternatives for on-the-spot generation.

Jenbacher gas engines from GE represented the final choice, as

these could already refer to a notable track record with regard

to similar applications and, above all, were able to offer the flex-

ibility, reliability and high levels of efficiency that constitute vital

competitive factors for the company.”

THE ECOLOGICAL FOOTPRINT – SMALL IS BEAuTIFuL! Apart from

security of supply, environmental protection is also an important

reason for the adoption of Jenbacher gas engines. With low emis-

Especially rich in resources, South Africa numbers among the

world’s leading exporters of raw materials. With manufactured

goods also gaining in importance, South African industry is be-

coming increasingly competitive on an international level, result-

ing in the rise of production locations throughout the country.

FROM uNCERTAINTY TO AuTONOMY. In recent years, South

Africa has embarked on an extensive program aimed at providing

the entire population with electricity. However, this undertak-

ing, along with rapid industrial growth, has pushed the country’s

outdated power supply network to its limits. Frequent power

outages can

South African industry is becoming increasingly competitive on an

international level.

result in production losses – a serious problem for the nation’s

budding industry, which is not only confronted with the prob-

lem of security of supply, but also with rising prices due to the

increased demand for electricity. Production costs are naturally

a major factor in business competitiveness and, as a result,

autonomy in the energy field – especially for heavy industry –

is a decisive advantage.

THOS BEGBIE – LONG TRADITIONS AND A PROMISING FuTuRE.

The Thos Begbie company is a foundry in Middleburg, a center

of South Africa’s metal processing industry. Founded in 1887,

17 18

sions and the cogeneration of electricity and heat, which provides

overall efficiency of almost 90 percent, they make a considerable

contribution to a reduced ecological footprint.

MuLTIFACETED PROJECTS FOR THE FuTuRE. GE’s success in

South Africa is ongoing. In 2008, the first power plant fueled

by landfill gas went into operation near Durban. This not only

allows the use of renewable energy and raises markedly the

reliability levels of the local energy supply, but also cuts carbon

Apart from security of supply, environmental protection is also

an important reason for the adoption of Jenbacher gas engines.

dioxide emissions. In addition, a contract was signed in 2010 with

Transnet Limited, a state-owned South African infrastructure

company, which foresees the constant supply of power to a new

fuel pipeline running between Durban and Johannesburg by GE

diesel generators. Once installed, these generators, with a total

output of 34MW, will provide emergency power for the pipeline’s

pumping stations and terminals. The new pipeline is intended

to furnish South Africa’s domestic market with a secure flow of

diesel, gasoline and aviation gasoline.

As a result of the successful projects completed to date, GE has

established an outstanding position in the South African energy

segment and is a strong partner to industry, commerce and

government in this up and coming industrial nation. _

applications and solutionscogen applications and solutions cogen

South African industry is in top gear, but local enterprises are faced with numerous uncertainties, including the

reliability of the electricity supply system. Because outages and shortages are a repeated occurrence, many

companies are looking for reliable and innovative possibilities with low environmental impact. South Africa

has more than sufficient resources for alternative energy production, and the innovative plants from Jenbach

constitute an optimal solution in achieving autonomy from the fault-prone public grid.

South African industry booming; reliable power supply needed

–> INSTALLATION OF THE FIRST FOuR GE’S JENBACHER J620 GAS ENGINES IN 2008

cogen2.0

–> CAPE TOWN, SOuTHAFRICA

2019

ENERGY SuPPLY DILEMMA. BBARWA’s waste-

water treatment plant could not count on a

secure, dependable, uninterrupted supply of

electricity. The local community is susceptible

to rolling blackouts during peak demand hours,

and energy prices are some of the highest in

the United States. Moreover, the plant is located

in a resort area that experiences sharp fluctua-

tions in demand because of the seasonal ebb

and flow of the population. Further complicating

things, BBARWA operates the plant at ultra-low

emissions levels – specifically, 11 parts per mil-

lion (PPM) of nitrogen oxide (NOx) and 72 PPM of

carbon monoxide (CO).

RICH BuRN VERSuS LEAN BuRN. Plant officials

decided to confront these challenges by generat-

ing all of the plant’s power onsite and cutting its

dependence upon the local utility. With an ex-

tremely high altitude capability available in a gas

engine, the rich-burn F3524GSI generator-set,

paired with a three-way catalyst, made the most

sense because it provided full-rated power – even

at the facility’s 6,700-foot altitude (2,046-meter

altitude) – and a low-cost option for satisfy-

ing those exacting emissions limits. Lean-burn

engines made less sense because they sustain

a significant power derate at high altitudes and

have selective catalyst reduction (SCR) systems

that require urea injections, which add an extra

operating cost and present environmental

concerns.“We needed a high-performance en-

gine that made us completely energy-independ-

ent, kept our costs down and let us pass cost

savings on to our ratepayers,” said Joe Hanford,

the plant superintendent at BBARWA.

With the Waukesha engine, BBARWA can retrieve peak usage

electrical power to treat 5.4 million gallons.

“The Waukesha engine made it possible for us

to achieve each of those goals.” Engineered for

dependability and durability, the robust feature

set of the F3524GSI includes the fuel flexibility to

operate at rated output on a wide range of fuel

qualities, and an ESM® engine system manager

that monitors and controls vital engine functions

for optimal performance and maximum uptime.

MAJOR CHANGE IN OPERATIONS AND COSTS.

Seven years after the engine became opera-

tional, BBARWA has gone from being one of

the community’s largest energy consumers

to being a surplus energy generator. Being its

own power plant has left BBARWA immune to

local service problems – a particularly critical

advantage in winter, when its electricity usage

is highest. With the Waukesha engine, BBARWA

can retrieve peak usage electrical power to treat

5.4 million gallons per day (mgd) (20.44 million

liters) of wastewater – at a 40 percent lower

cost than what the utility would charge. That’s

not the only way the plant cuts its costs. It also

saves money by purchasing large amounts of

natural gas at reduced rates, avoiding the util-

ity’s $6,500 charges for on-peak demand – and

diverting the excess power it generates to the

agency’s administration building, a measure that

saves more than $1,200 per month. As if all that

weren’t enough, BBARWA even got some help

paying for the engine, as it took advantage of a

state government rebate that covered half the

cost. To illustrate how economical the F3524GSI

engine is, Joe Hanford makes a comparison with

diesel fuel. “At today’s prices, if we were using

diesel-powered engines, it would be at six times

the cost per kilowatt hour, which we’d have to

pass on to our ratepayers.” _

applications and solutionscogen applications and solutions cogen

Off Grid Power Solution

Waukesha rich-burn engine delivers energy independence By investing in a Waukesha F3524GSI gas engine, the Big Bear Area Wastewater Agency (BBARWA)

in Southern California has become independent from the local utility’s high energy prices and uncertain

power supply. BBARWA installed a self-sufficient solution delivering power at considerably less cost

while meeting local emissions regulations that are among the strictest in the united States.

facts and figures:

· Cylinders: Inline 6, turbocharged and

intercooled

· Compression Ratio: 8:1

· Control System: Waukesha Engine System

Manager (ESM®), which integrates spark

timing control, speed governing, air/fuel

ratio control, detonation protection, start-

stop control, diagnostic tools, fault logging

and engine safeties.

· Starting System: 125-150 psi air/gas

24V electric

· Fuel System: One natural gas, 4” (102 mm)

updraft carburetor and one mounted Fisher

99, 2” (51 mm) gas regulator, 30-60 psi (207-

414 kPa) fuel inlet pressure required. 10 ft.

(3 m) harness provided for ESM® control of

customer supplied fuel shutoff valve.

· Bore and stroke: 9.375” x 8.5” (238 x 216 mm)

· Piston Displacement: 3520 cu. in. (58 L)

–> THE WASTEWATER TREATMENT PLANT COuNTS ON A SECuRE, DEPENDABLE, uNINTERRuPTED SuPPLY OF ELECTRICITY.

–> BIG BEAR LAkE, SOuTHERN CALIFORNIA

Considered one of Eastern Europe’s “Baltic

Tigers,” Estonia’s strongly expanding economy

has led to higher energy requirements and grow-

ing environmental awareness. FILTER, headquar-

tered in Harjumaa, Estonia with a workforce of

320 employees, operates in the water treatment

and energy generation plant segments, as well as

in the field of boiler facilities designed to generate

steam for industrial purposes. In addition to plant

construction, FILTER also offers comprehensive

consulting, maintenance and training services.

Customer-oriented services and a dense network

of branch offices are further important success factors.

The products of GE’s gas engines division com-

prise an important component of innovative, total

energy technology solutions. As a result of its

large-scale success in Estonia, FILTER has already

set up subsidiaries in Latvia, Lithuania, Russia,

Belarus, Bulgaria and Finland.

RELIABLE PARTNER. Many FILTER customers in

industry, commerce and public administration

rely on the competence of this Jenbacher gas

engine distribution and service provider. FILTER

takes advantage of the mature Jenbacher gas

engine technology to complement its intelligent

and environmentally-friendly power and heat

generation product offerings. As a result, holistic

energy solutions are offered, enabling the pro-

duction of heat, cold and electricity.

In its cooperation with GE, FILTER has gained

extensive expertise concerning the Jenbacher

gas engine products and their manifold applica-

tions and combination possibilities. This depth of

knowledge is a key to FILTER’s success.

PERFECT SERVICE. Customer-oriented services

and a dense network of branch offices are further

important success factors. In line with the phi-

losophy of Jenbacher’s gas engines team, FILTER

also strives to extend the useful life of its facilities

through optimal service and the replacement

of individual parts. The modular construction

of the Jenbacher engines allows customers to

perform upgrades rather than having to acquire

completely new aggregates. Even older motors

are always up-to-date in terms of efficiency and

eco-friendliness, serving as the basis for a longer

and trouble-free operating life. FILTER’s service

portfolio also includes the turn-key, ready-to-op-

erate handover of all facilities, including training

and education for optimal operation.

THREE-FOLD STRENGTH. At present FILTER is

installing a major project in Belarus at a com-

bined heat and power plant facility. Joint Stock

Company Grodnochimvolokno in Grodno, one

of the largest chemical companies in Belarus,

manufactures polyamide and polyester yarns,

polyamide 6 granulate and composite materials.

Three engines were delivered in 2004, and now

the facility has twelve J620 gas engines with a

capacity of 36MW, enabling the simultaneous

generation of electricity, heat and cold. All are

required for production and processing work.

The trigeneration plant at Grodnochimvolokno

thus serves as an important reference project in

this region. Grodnochimvolokno is both FILTER’s

first customer in Belarus, but also its largest

single contract order. _

21 22

distributors and service providerscogen distributors and service providers cogen

Holistic energy solutions for power generation in Eastern EuropeSince 1992, Estonia’s FILTER AS has positioned itself as a successful and reliable business associate for

power generation and water treatment technologies. GE’s Jenbacher gas engines have long been bestsellers

in FILTER’s product portfolio. They offer optimal complete energy generation solutions in combination with

other technologies.

facts and figures:

Founded: 1992

Cooperation with GE: Since 1998

Employees: 320 at 22 locations

Installed units: 197

Total electrical output: 298MW

Total thermal output: 250MW –> TALLINN, ESTONIA

distributors and service providerscogen distributors and service providers cogen

eight heat recovery generators, manufactured

at the FILTER production facilities in Finland, this

plant represents an optimum and complete en-

ergy technology solution for Joint Stock Company

Grodnochimvolokno.

How important to you is the cooperation with

GE’s Jenbacher gas engines team? It is difficult

for me to imagine our business without GE. Over

the years, we have become strong partners with

excellent synergies derived from our respective

corporate strategies.

“For our customers, perfectly functioning, efficient and

complete solutions in combination with a professional, local service provided by our team are of the

greatest importance.”

What business objectives do you have for

the future? We are looking for stable growth in

Eastern Europe, and we see the greatest poten-

tial in Russia. The main target is further market

development per se and the further expansion

of the customer base in those regions where we

are active.

What makes FILTER so special? We seek to

be a specialist in our various business areas

such as energy (electricity, heating, steam,

hot oil, bio-energy), water treatment, pump

technology, automation, etc. For our customers,

perfectly functioning, efficient and complete

solutions in combination with a professional,

local service provided by our team are of the

greatest importance.

How has your business changed since you

became a distributor and service provider

for GE? The initial contacts with the Jenbacher

gas engines team date back 13 years, and we

sold the first engine in 1999. For us, GE’s

significance grows year by year and the busi-

ness with engines from Jenbach has become

FILTER’s most important business segment. _

Many thanks for the interview.

cogen: Over the years, you have expanded successfully beyond

Estonia’s borders, and you now occupy an excellent position in

six countries. What is the secret of FILTER’s success?

Antti Toppi: FILTER was founded in 1992, and from the outset

we endeavored to achieve geographical growth. The second

important success factor was cooperation with leading technol-

ogy suppliers such as GE.

“For us, it is especially important that we serve our customers as a long-term partner.”

One of your focal points is customer service. Why do you

invest so heavily in this area? For us, it is especially important

that we serve our customers as a long-term partner. Any machine

downtime we can prevent means hard cash and faster ROI for our

customers. Outstanding performance also enables us to generate

additional service contracts, which today already constitute over

50 percent of our total business.

In your opinion, what has been your most important project up

to now involving a plant equipped with Jenbacher engines?

The modern trigeneration plant for Joint Stock Company Grodno-

chimvolokno in Grodno is certainly our most important project in

Belarus to date for several reasons. First, this is the first customer

in the region for whom we have delivered a gas engine, and the

contract thus constitutes a very important reference for potential

clients. Second, this is the biggest CHP plant order yet placed in

Belarus. Twelve Jenbacher J620 gas engines provide a combined

output of 36MW and, together with the absorption coolers and

23 24

Complete solutions are the key to FILTER´S success

–> HEADquARTERS OF FILTER AS IN HARJuMAA, ESTONIA.

–> INSIDE A MODERN TRIGENERATION PLANT IN GRODNO

An interview with ANTTI TOPPI, CEO at FILTER AS,

and authorized sales and services provider for

Jenbacher gas engines in Estonia.

2625

region specialregion specialcogen cogen

JENBACHER SALES AND SERVICE PROVIDERS

IN EASTERN EuROPE AND RuSSIA

01. BuLGARIA

Filter EOOD

02. MOLDOVA

Vipropat S.R.L

03. POLAND

kWE - Technika Energetyczna Sp.z o.o.

04. ROMANIA

SC Total Energy Business SA

05. RuSSIA

GE Russia

Max Motors LLC (South Region)

Intma CJSC (South ural Region)

Vapor CJSC (North West Region)

06. SLOVAkIA

EMES s.r.o

07. SLOVENIA

IMP Inzeniring d.d.

TES d.o.o.

08.CzECH REPuBLIC

klor GmbH

JMP (Service)

09. ukRAINE

PS&IC Sinapse

10. HuNGARY

GE Energy Jenbacher Hungary (Service)

11. BELARuS

Filter SzAO

For additional information, please contact jenbacher.bulgaria@ge.com, jenbacher.poland@ge.com,

jenbacher.russia@ge.com, jenbacher.ukraine@ge.com, jenbacher.hungary@ge.com–> MOSCOW, RuSSIA

2827

region specialregion specialcogen cogen

The countries of Eastern Europe and Russia are referred to repeatedly as Europe’s most important trade and

growth territory, and without doubt, the region continues to offer great promise for commerce and industry.

However, since Russia is recognized as Western Europe’s most significant supplier of raw materials, this creates

dependencies, as underlined by massive supply projects such as the new “Nabucco” gas pipeline. Moreover, a

general tendency towards a cross-border closing of ranks in the energy sector is already apparent. under these

circumstances, GE has identified the major potential for modern power generation with low environmental

impact and has moved into an ideal position as a supplier.

Speeding up in

Eastern Europe and Russia

>

E

astern European countries remain important growth drivers

for the European economy as a whole. Despite a slowdown dur-

ing the past few difficult years, growth continued in some coun-

tries, and the need to catch up has coincided with an improve-

ment in living standards to significantly increase energy demand.

However, some of the modern, technical possibilities for power

generation have not been fully exploited – particularly, innovative

solutions from GE Energy’s gas engines division. Consequently,

sizeable opportunities are still available.

COAL AND OIL ARE PREDOMINANT BuT PROBLEMATIC. Eastern

Europe and Russia currently depend heavily on the fossil fuels

of coal, oil and gas. But coal and oil in particular have major

negative environmental impact and oil has extremely limited

availability in the long-term. At present, coal accounts for 40 to

50 percent of the total energy requirement in Europe, and that

creates an enormous ecological burden. But the push to counter

the growing greenhouse effect by sharply reducing global CO2

emissions within the framework of the Kyoto protocols will inspire

and accelerate a trend away from coal and gas and towards

largely-untapped environment-friendly and renewable forms of

energy.

uNCONVENTIONAL AND ExTREMELY ATTRACTIVE “NEW”

GASES. In its “World Energy Outlook” for 2010, the International

Energy Agency (IEA) predicted an even greater role in energy sup-

ply for gas – especially natural gas, which already is the world’s

third most important energy source. Indeed, gas-generated

electricity could double by 2035. That bodes very well for the use

of Jenbacher gas engines, along with the fact that coal – the

world’s second biggest energy source after oil – will become more

important in the near future despite its serious environmental

consequences. Above all, unconventional gases such as coal bed

Eastern Europe and Russia currently depend heavily on the fossil

fuels of coal, oil and gas.

methane (CBM), landfill and biogas will become more impor-

tant in power generation on a regional level during the coming

decades. Today, these gases are relatively underused because

extracting and transporting them is somewhat complex and

inefficient. However, it is anticipated that optimal and therefore

extremely cost-effective ways to obtain and exploit these gases

will be developed in the years ahead. International Energy Agency

estimates that up to 35 percent of total power generation could

come from unconventional gases. The future will see a growing

number of low-emission, high-efficiency solutions that generate

more than one form of energy. In fact, GE’s gas engines division

already is meeting the existing, considerable industrial sector

demand for this by offering customers cogeneration and even

trigeneration systems.

MAJOR RAW MATERIAL RESERVES... The bulk of the world’s raw

materials deposits are found in countries belonging to the so-

called “strategic ellipse”. Indeed, one half of global natural –> MOSCOW, RuSSIA

region specialregion specialcogen cogen

their extensive performance range and applica-

tions flexibility in serving this business. JMP,

Poland’s largest flower growing company, is a

case in point. With one of the biggest green-

house facilities in Europe (around 27 acres, or

11 hectares) and a workforce of over 100

employees, company management decided to

generate its own electricity and heat production.

After a precise analysis of what their competi-

tors in the Netherlands were doing, JMP chose

GE’s Jenbacher gas engines primarily because

they also produce CO2 for fertilizer – which is a

very expensive process otherwise. The system

JMP installed at its facility in Stezyca has three

J420 engines for combined heat and power

(CHP) and downstream CO2-fertilizer production.

The resulting electricity output of 5.6MW com-

bines with thermal energy production of

Prevailing climatic conditions have boosted the Polish

horticultural industry and made Poland the third most important

flower supplier in Europe.

4.5MW for an overall efficiency level in excess of

80 percent. Since the GE system is so efficient,

and there is no need for offsite production and

gas reserves are located in three nations

within this region: Russia, Iran and Qatar – and

this does not include unconventional gases and

flare gas.1 Russia is the European Union’s most

important natural gas trading partner, while

countries belonging to the Commonwealth of

Independent States (CIS) account for more than

40 percent of gas requirements. In 2009, Russia

was the world’s second largest gas producer be-

hind the USA and in the preceding years, it com-

pletely dominated global exports.2 Two-thirds of

the Russian gas produced has to meet domestic

needs, while the remainder is exported. The gas

volumes extracted are increasing steadily from

year to year and the nation’s reserves of brown

and hard coal also are among the largest in the

world.

...MEAN ENORMOuS POTENTIAL! The vast

quantities of gas available, in the form of natural

and alternative gases, present GE with an excel-

lent opportunity to provide its high-performance

gas engines for electricity generation. Russia

currently generates approximately 67 percent of

its energy from coal, oil and gas. Part of the ex-

isting installed plant capacity for this dates from

the Soviet period and must be replaced. The

government also is planning the liberalization

and regionalization of the electricity segment.

In years to come, decentralized power genera-

tion in Russia will become even more important,

as the sheer size of the country and the supply

The vast quantities of gas available, in the form of natural

and alternative gases, present GE with an

excellent opportunity.

of its widely-dispersed population would other-

wise involve excessively long transport routes.

This can drive an enormous amount of business

growth for GE’s efficient generating systems,

which have the additional advantage of gen-

erating energy from a diverse range of gases –

including coal gases that have remained unused

because of their (problematic) waste emissions.

For example, the Russian government has

stipulated that over 90 percent of flare gas must

be utilized from 2012 onwards.

Even thin gas mixtures with a low calorific value

can be burned for electricity generation by GE’s

products. Although Russia contains climatic

zones ranging from Siberia to the subtropical

Black Sea coast, Jenbacher gas engines can be

optimally used in any of them because they fea-

ture innovative technologies such as two-stage

turbocharging. GE’s advanced power generation

plants are ideal for handling the extreme tem-

perature variations found in this country.

POLAND SHOWS RAPID DEVELOPMENT. Since

1990, the Polish economy has demonstrated im-

pressive performance while the energy industry

has restructured. In 2008, Poland responded to

the Kyoto targets and the problem of resource

availability by releasing the “Energy Policy Strat-

egy up to 2030”. Besides emphasizing increased

energy efficiency and fewer CO2 emissions,

this document also focused on the combined

generation of differing forms of energy such as

electricity, heat and cold. Poland also intends

to move away from coal, its primary source of

energy to date, and towards renewable energy

sources with a smaller environmental footprint.

THE POLISH FLOWER INDuSTRY IS IN FuLL

BLOOM. Prevailing climatic conditions have

boosted the Polish horticultural industry and

made Poland the third most important flower

supplier in Europe, after Germany and the Neth-

erlands. GE’s gas engines have demonstrated

transport of power or CO2 fertilizer, JMP has been able to save

40 percent of its primary energy requirements. Now, JMP is

planning to install additional Jenbacher engines for even greater

production. The JMP CEO, Jaroslaw Ptaszek, is highly enthusiastic

about this investment: “As a result of the cogeneration system,

we have been able to slash our liquid CO2 fertilizer costs, since

today we quite simply produce it ourselves. The installation of the

GE system has made a tangible contribution to our positive busi-

ness development and our greenhouses currently are among the

most modern in the world.” The whole Lublelskie region of Poland

where Stezyca is located possesses major resources which could

be converted into energy on the spot.

Though gas now supplies a mere 0.4 percent of the local energy

requirement, biogas, landfill and coal mine gas are available in

sizeable quantities. Therefore, the JMP system will serve as an

important reference project for GE in the area.

EMPLOYEES POISED FOR THE FuTuRE OF EASTERN EuROPE.

Eastern Europe not only is an important region for plant produc-

ers, but also independent power producers (IPPs). GE Energy is

well positioned to serve this significant customer group through

a full coverage network of almost 5,700 employees located in 11

production and service operations. Gas engines already produce

more than 450 GW of energy in Eastern Europe.

GE Energy has more than 300 employees in Russia, and one of

its key facilities in the country is the Kaluga Power Technology

Center, which is located 112 miles (180 km) from Moscow and

opened in 2010. This location specializes in the repair, servicing

and maintenance of existing capacity, as well as the installation

of new and innovative systems. Further expansion is planned.

GE Energy is well positioned to serve this significant customer group

through a full coverage network of almost 5,700 employees located in

11 production and service operations.

GE’s largest heavy-duty gas turbine parts manufacturing plant in

Central and Eastern Europe is in Veresegyház, Hungary, while the

Engineering Design Center (EDC) in Poland is a state-of-the-art

technology incubator with more than 1,000 engineers collabo-

rating in the development of world-class aviation, energy and

oil & gas technologies. Decentralized power generation should

continue to grow throughout the entire region, and GE’s gas

engines division is perfectly suited to support it .

Thomas Achrainer, regional sales leader Eastern Europe for GE

Energy’s gas engines division, is optimistic: “Given the geographi-

cal conditions and the resources available in Eastern Europe, we

expect that the regionalization of power generation will continue.

Our modern systems represent ideal, complete solutions, and

they are enhanced with strong customer service. In the future,

we must remain focused and aggressive on innovations and

product development. By doing that, I am convinced that we will

remain the pacesetter in this field in the years to come.” _

1 http://www.bgr.bund.de/cln_160/nn_331084/DE/Themen/Energie/Erdgas/

erdgas__inhalt.html2 http://de.wikipedia.org/wiki/Erdgas/Tabellen_und_Grafiken#Nach_

L.C3.A4ndern

sources:

facts and figures:

Nations: 28

Inhabitants: 360 million

Average, annual per capita electricity consumption: 2,500 kWh

GE Energy’s employees in the region: 5,700

Total gas engine capacity installed: 450 GW

>

3029

–> MAJOR BROWN AND HARD COAL RESERVES ARE FOuND IN RuSSIA

–> WARSAW, POLAND

3231

In the search for new energy sources and low-cost alternatives to natural gas, a previously little-used gas has

moved into the spotlight. With major reserves found all over the world, coal bed methane (CBM) is already being

used as an energy source in the united States, Canada and Australia. In addition, Russia is beginning to take an

interest in this subterranean treasure. In fact, the first CBM-powered Jenbacher gas engine supplied to Russia

by GE recently went online in kusbass/Siberia, and it is already clear that this will by no means be the last ...

(ALMOST) PuRE METHANE. As opposed to the mine gas that is ex-

tracted from active and closed pits, CBM can be obtained directly

by drilling into unused coal deposits (beds). CBM is a free gas that

exists in cracks, fissures and pores and as an adsorbed gas on the

inner, upper surface of the coal and the surrounding rock. Above

all, it can be obtained from coal beds that, due to their location or

characteristics, are unsuitable for mining.

Apart from the possibilities for its efficient exploitation in many

parts of the world, the prime reason CBM is a suitable alternative

to natural gas is its high methane content of over 95 percent,

which makes it an excellent fuel.

A SINGLE GAS FROM MANY PARTS OF THE WORLD. Large re-

serves of CBM can be found all over the world. These are already

being exploited successfully and employed as an energy source,

especially in the U.S., Canada and Australia.

An outstanding example of the use of CBM for decentralized

energy supply is in the Australian state of Queensland, which in

recent years has installed a gas-fired, electricity generating plant

with a capacity of over 150MW and has thus covered a consider-

able part of its local power needs from this new energy source.

NEW, SAFER CHANCES FOR COALFIELDS. The extraction of CBM

in the vicinity of active collieries not only offers the potential of a

local energy source, but also the advantage of pre-degassing of

the methane in the coal. As a result, safety is increased during

subsequent mining operations.

DOuBLE CLIMATIC BENEFITS. In such cases, the use of CBM

also demonstrates its value through a two-pronged reduction

in greenhouse gases. First, with CBM, the highly active green-

house gas methane is transformed into less harmful CO2 even

prior to its release during coal mining (methane released into the

atmosphere has a 21-fold greater climate relevance than does

CO2). Second, CO2 emissions per kWh can be reduced markedly

by substituting fossil fuels. In addition to the ecological benefits,

this also results in an economic advantage, since related projects

qualify for carbon credits.

NEW ENERGY FOR kuSBASS. The province of Kemerovo in the

Kusbass is a Siberian coalfield with an area of around 59,651

miles² (96,000 km2) with a history of over 300 years and major re-

serves of CBM. To date, these resources were generally neglected

in Russia, but that is now likely to change. Following recent test

drilling by Gazprom, the first plant in the country for the energetic

use of CBM recently went online near Kemerovo, which is located

some 124 miles (200 kilometers) east of Novosibirsk and is the ad-

ministrative center of the Kusbass region. For this operation, the

local mine operator, Kuzbasskaya Energosetevaya, is using a J320

gas engine from the Jenbacher product line that converts the

extracted gas into electricity, which is then fed into the public grid.

In such cases, the use of CBM also demonstrates its value through a two-pronged

reduction in greenhouse gases.

Peter Kuruch, the Kuzbasskaya Energosetevaya CEO: “The in-

novative technology of the Jenbacher gas engines from GE has

enabled us to put a gas that constitutes an environmental prob-

lem into cost-efficient use as a valuable fuel for reliable energy

generation. Apart from enormous specialist competence, the fact

that installation and startup were possible in just two and a half

months was decisive in our decision to choose GE.”

THESE FIGuRES SPEAk FOR THEMSELVES. At present, Jenbacher

gas engines with a capacity in excess of 400MW are being oper-

ated with mine gas and CBM. These provide an annual production

capacity of over 3 million MWh of electricity, thus saving 30,000

billion foot³ (830 million m3) of natural gas equivalents and pre-

venting methane emissions equating to over 8 million metric tons

of CO2. Once again, these figures provide confirmation of the en-

vironmental advantages of the Jenbacher gas engines from GE,

which demonstrate great flexibility with regard to fuel and – apart

from natural gas – can also be operated with a large number of

biological and special gases. _

region specialregion specialcogen cogen

Coal bed methane – a subterranean energy treasure

VALuABLE POTENTIAL – GLOBAL CBM RESERVES

Country CBM reserves in TCF1 CBM ultilization in BCF1

u.S. 9702 2009: 1,7002

Canada 1,7502 2009: 2702

Australia 3502 2009: 1402

China 5002 2009: 292

India 922 2010: 92

Russia 2,3002 2010: 12

Indonesia 1122 2010: 23

ukraine 1,4002 2009: 0

Further CBM reserves and/or initial test drillings in Germany, uk, Poland, kazakhstan, Bulgaria, Turkey, South Africa, Vietnam, Thailand and Colombia.

1 TCF = Trillion Cubic Feet, BCF = Billion Cubic Feet, 1 m³ = 35.3 Cubic Feet2 ifm RWTH Aachen, Alternative Geogene Lagerstätten, Lecture 2009 3 IHS, Recent CBM Developments in Asia, March 2010

CSM

(CO

AL S

EAM

MET

HAN

E)

CBM CBM

(Coal Bed Methane)

Gas from unexploided

coal deposits

> 90%

mehtane content

Min

e ga

s

CMM

(Coal Mine Methane)

Gas from

active collieries

25-60%

mehtane content

AMM

(Abandoned Mine Methane)

Gas from

closed collieries

60-80%

mehtane content

–> THE kuSBASS IN SIBERIA HAS MAJOR RESERVES OF COAL BED METHANE

cogen2.0

–> THE J320 AT THE MINE OPERATOR kuzBASSkAYA ENERGOSETEVAYA

33 34

success storycogen success story cogen

The automotive industry is subject to stringent regulations. Both production and emission targets must be attained. Furthermore, vehicle

production standstills are to be avoided at all costs. Therefore, with Jenbacher gas engines, GE offers optimum solutions for energy supply

in this industry, not only furnishing the electricity required, but also heat that can be used for the manufacturing process and plant heating.

Accordingly, the cooperation between GE in Jenbach and the automotive sector is a genuine success story.

In the automotive industry, reliability, simple operation, high ef-

ficiency levels and low emissions are all critical aspects of energy

technology. Moreover an island operation that is completely

independent of the public grid must be possible at any time and at

the individual location. Jenbacher gas engines, which are designed

for combined heat and power generation, constitute an ideal and

complete solution in this regard. CHP power plants can thus pro-

vide both the necessary electricity output and heat at overall

Island operation that is completely independent of the public grid

must be possible at any time and at any individual location.

efficiency levels of up to 90 percent. The advantages of Jenbacher

gas engines are clear: Due to the product’s flexibility, the solu-

tions can be adapted to specific construction conditions and to

specific customer needs. In addition, Jenbacher gas engines can

be integrated directly into the existing plant capacity. GE is also ex-

perienced at project management, which can be a challenge since

the exchange of the existing gas engine often needs to take place

without any interruptions to the backup power supply.

PuTTING POWER INTO BMW. Quality is a convincing argument.

Today, leading German automotive manufacturers rely upon Jen-

bacher technology. As early as 1982, an initial plant was installed

at the BMW engine plant in Steyr, Upper Austria. Since then, the

company’s plants in Leipzig, Regensburg and Landshut have all

More power for the automotive industry

>

CuTTING CARBON EMISSIONS WITH CHP. Cogeneration, or com-

bined heat and power (CHP), dependably generates onsite electric

power while capturing excess thermal energy to produce heat. This

makes CHP a much more efficient process than dual-source heat

and power generation. In addition, using CHP is a critical anti-pol-

lution strategy in a world where two-thirds of all fuel is wasted and

global energy requirements will grow by 44 percent within the next

20 years – along with demands to cut greenhouse gases.

In Europe, where the European Union has set a goal of reducing

CO2 emissions by 20 percent by the year 2020, cogeneration is pro-

viding eleven percent of total electricity and saving an estimated 35

million tons of oil equivalent per year. The Coca-Cola Hellenic

Bottling Company for example has supported the goal by installing

15 CHP plants featuring GE’s Jenbacher units in twelve countries.

With this GE technology, each plant can eliminate more than 40

percent of its annual CO2 emissions.

FuEL FLExIBILITY. Jenbacher gas engines can run on almost any

gaseous fuel. Besides operating at top efficiency on natural gas,

they can generate power while safely disposing of environmentally

harmful gases from landfill, agricultural, coal mining, chemical

processing and other industrial applications.

THE LATEST GENERATION. The newest development in the

Jenbacher product line is the J920, which can provide enough

energy to power 18,500 average European households. With an

electrical efficiency of 48.7 percent, the J920 can reduce annual

CO2 emissions by about 1,500 tons per year. _

Low Carbon Technology Innovation

36

success story cogen

World Finance magazine has honored GE’s ground-breaking cogeneration technology by naming

Jenbacher gas engines the Best Carbon Markets Energy Efficiency Pioneer for Western Europe

in 2011. “This award recognizes companies whose development of and investment in innovative

carbon-efficiency methodologies create the deep reductions in carbon output needed to protect

the environment,” said Alexander Redcliffe, Editor of World Finance magazine.

success storycogen

35

GE‘s Jenbacher gas engines cited for energy efficiency

“This award recognizes companies whose development of and investment in innovative carbon-efficiency methodologies create the deep reductions in carbon output needed to

protect the environment” - Alexander Redcliffe, Editor of World Finance magazine

facts and figures:

Engines in operation: 16

Plants: 7

Total electricity output: 29.6MW

Total heat output: 27.6MW

been equipped with CHP plants from GE. In 2007, two Jenbacher

CHP plant modules with J420 engines and an electricity output

of 2.8MW and heating output of 3MW were installed at the BMW

plant in Landshut. The BMW engine plant in Steyr has had four

Jenbacher J420 engines with a total capacity of 5.6MW in opera-

tion since 2007. The BMW plant in Leipzig, which is regarded as

the most modern car plant with the highest level of sustainability

in the world, also uses a Jenbacher J620 gas engine with a capac-

ity of more than 3MW for the production of electricity and heat.

Finally, the largest project of this kind can be found at the BMW

plant in Regensburg, where four Jenbacher J616 engines with a

total output of almost 11MW are supporting the uninterrupted

production as of 2011.

MERCEDES-BENz LuDWIGSFELDE AND GE – A STARRY

CONSTELLATION. Mercedes-Benz is a major German automotive

manufacturer in the premium classification to rely on the perfor-

mance and operational possibilities offered by Jenbacher CHP

plants. GE and Mercedes-Benz have maintained a cooperative

relationship for more than 10 years. The first plant was installed in

Rastatt in 1997. Today, the Mercedes-Benz works has two

Jenbacher J412 and J416 gas engines, generating a combined to-

tal of 2MW of electricity. In 2011, a new plant consisting of a J412

and a J416 with a total output of 2MW began supplying the

Ludwigsfelde commercial vehicle plant with its power require-

ments. Matthias Westermann, the project manager of the CHP

plant at Mercedes-Benz in Ludwigsfelde: “Our plants number

among the most modern in the world and with the help of Jen-

bacher gas engines, this also applies to our electricity generation.

Above all, the performance and efficiency of the engines are highly

impressive and were decisive in our decision to purchase.”

STEPPING ON THE GAS WITH JENBACHER ENGINES. Apart from

BMW and Mercedes-Benz, a leading German sports car manu-

facturer is also already using Jenbacher engines. In 2010, the

company installed two J612s with a total output of around 4MW.

CO2 EMISSIONS HEADING FOR zERO. The automotive industry

is continuing its efforts to minimize its CO2 emissions. On the one

hand, these endeavors relate to the specific CO2 emissions from

vehicles and on the other, to the aim of turning production centers

into zero emission locations by means of low energy construc-

tion methods and modern energy solutions. Within this context,

due to their low emissions and high efficiency levels derived from

the combined production of electricity and heat, Jenbacher gas

engines are already making a sizeable contribution to a reduction

in the ecological footprint of the automotive industry. _

>

“Our plants number among the most modern in the world and with the help of

Jenbacher gas engines, this also applies to our electricity generation.

Above all, the performance and efficiency of the engines are highly impressive and

were decisive in our decision to purchase.”- Matthias Westermann,

the project manager of the CHP plant at Mercedes-Benz in Ludwigsfelde, Germany

37

success storycogen success story cogen

38

GE Energy recently acquired Dresser, Inc.,

the parent company for Waukesha, to augment

GE’s global technology offerings across the en-

ergy spectrum. The Waukesha product portfolio,

which stocks a fleet of top-in-class, durable,

low-emissions, rich-burn mechanical drive

engines, complements the clean-burning, fuel

flexibility and high efficiency expertise GE has

developed with its Jenbacher gas engines –

some of which also are part of EDELMAG’s

installed fleet. The merged capabilities of the

Jenbacher and Waukesha offerings are expect-

ed to generate additional gas-engine technology

The merged capabilities of the Jenbacher and Waukesha

offerings are expected to generate additional

gas-engine technology solutions.

solutions that will serve petrochemical, mining

and manufacturing applications, as well as the

power generation industry.

That EDELMAG has had an ongoing customer

relationship with both product lines underscores

the strategic common sense that brought them

together within GE.

RuGGED DuRABILITY. Since its installation in 1982, the Waukesha

gas engine has been shut down solely for regularly scheduled

maintenance, including top-end overhauls at 22,000-hour inter-

vals and bottom-end overhauls at 44,000-hour intervals.

An automotive analogy is a good way to assess

the durability and reliability.

Aside from a new control system upgrade in 2002, the unit always

has operated – smoothly and continuously – as original equip-

ment, “It’s a relatively simple, open system, and it’s easy for our

technicians to work on the engine, so we handle the maintenance

ourselves,” Wurth said. An automotive analogy is a good way to

assess the durability and reliability of the VHP7100GSI:

Operating this stationary engine for 200,000 hours is equivalent

to driving a car at 35 mph (56.3 km/h) for 7 million miles (11.3

million kilometers). The VHP7100GSI is part of the product line of

gaseous-fueled, VHP 12-cylinder generator sets built for longev-

ity and dependable performance in a wide range of operating

conditions. It is particularly suitable for isolated sites and mission-

critical power generation facilities. Porvenir, a town of more than

5,000 people on the southernmost tip of South America that still

lacks access to a central power grid, fits both of those criteria.

The engine has continuous power ratings of 840-920 kWe at

50 Hz (1000 rpm) and 1000-1100 kWe at 60 Hz (1200 rpm).

VHP GSI series engines also have good fuel tolerance and excel-

lent load response.

A REWARD FOR PERFORMANCE. When the Porvenir station

needed to boost its generating capacity within the last decade to

meet the growing local electricity demand, EDELMAG’s positive

experience with the Waukesha gas engine prompted its decision

to buy two Waukesha VHP9500GSI generator sets. The additions

increased total gas-fueled electrical output to 3.275MW. “The

performance of the VHP7100 at Porvenir has been spectacular! It

is a strong, robust engine. Its impressive reliability – along with the

responsiveness of the distributor and factory technicians – were

key factors in our decision to select two more Waukesha units

to accommodate the growing power needs of this community,”

Wurth said. “I expect that GE will continue to develop gas engines

that are robust, durable and highly efficient. For all of those rea-

sons, we always consider GE and its Waukesha gas engines any

time we need to add more power generation units.” _

200,000+ Hours and Counting…

GE’s Waukesha gas engine still going strong in ChileAfter more than 200,000 hours contiuos opperation, a Waukesha gas engine still supplies electrical powert ot the town of Proventir, Chile. For

two decades, the generator set was the sole – and indispensable – primary power source for Porvenir, whose location in a region with abundant

natural gas supplies made it a good fit for the Waukesha product. “If the engine turned off, the town turned off,” declared Juan Carlos Wurth,

the maintenance chief for EDELMAG, the Chilean utility that owns and operates the Porvenir power station.

facts and figures:Edelmag, Punta arenas, Chile

· Business Area – Punta Arenas, Puerto

Natales, Puerto Williams, Porvenir

· Region – xII Region of Magallanes

and Chilean Antarctica

· Porvenir Power Generating Station Installed

Capacity – 3.275MW (As of Dec. 31, 2009)

· Porvenir Population Served – 5,465

–> THE VHP7100GSI IS BuILT FOR LONGEVITY AND DuRABILITY

–> ONGOING CuSTOMER RELATIONSHIP WITH WAukESHA AND JENBACHER PRODuCT LINES

39 40

servicecogen service cogen

24/7 service means that GE’s Jenbacher gas engine team is on call around the clock. Saturday, March 5, 2011. At 3 a.m.,

Jochen Duell, an employee of Bioenergie Rottenbauer GmbH & Co. kG in Reichenberg, Germany, called the 24/7 hotline for

Jenbacher gas engines. A few minutes before, a J312 engine had shut down, and urgent action was vital. For Bioenergie

Rottenbauer, which operates a biogas-fired heating power plant in Germany, every minute lost costs hard cash.

F

ortunately, Bioenergie Rottenbauer has a long-term mainte-

nance contract – also known as a customer service agreement

– with GE’s Gas Engine service team. As a result, the company

automatically benefits from the new 24/7 service, complete with

a global hotline, which appropriately enough became operational

on 7/24/2010. Since then, a team of 37 highly qualified service

engineers have been stationed at locations across Europe to pro-

vide Jenbacher customers all over the world with telephone sup-

port 24 hours a day, seven days a week. In the first nine months

of operation, the hotline helped more than 400 customers, with

more than half the inquiries dealt with purely by phone.

The new 24/7 service hotline is thus far more than just

a simple call center.

SHORT REACTION TIMES THANkS TO THE NEW 24/7 SERVICE

HOTLINE. Axel Dancker, global service leader for Jenbacher gas

engines, says the new service provides customers with increased

benefits. “Very often it’s the case that a plant shutdown is caused

by difficulties which can be quickly corrected,” he expresses.

“However, this is only possible due to the precondition that a

qualified Jenbacher service hotline expert is connected to the

customer and the engine in case on demand, whenever needed.”

The 24/7 service team possesses the required competence; team

members average 13 years of experience in dealing with the

company’s gas engines. The new 24/7 service hotline is thus far

more than just a simple call center, where calls are received and

transferred, but a place where customer problems are solved by

qualified specialists.

A NEW SPARE PART SERVICE FOR ON-THE-SPOT CuSTOMER

ASSISTANCE. In addition to the 24/7 service hotline, GE has been

working intensively since last year on the implementation of

another special global customer service, the 24/7 express supply

of emergency spare parts. This development required a complete

overhaul of the existing logistics structure. Explains Axel Dancker:

“In 2010, we had to deal with problems regarding the availability

of our spare parts, and thanks are due to all our customers and

partners for their understanding and patience. With the new 24/7

service, in future we will be able to react to customer problems

with greater speed.” In January 2011, the first of three new logis-

tics centers was opened in Duisburg, Germany, and two more are

to follow this year. From the third quarter of 2011 on, following the

24/7 service A 168-hour week in the service of our customers

receipt of an order, emergency components will

be supplied to customers in Germany, the

Benelux nations and Denmark in an ensured

time of four hours. Deliveries will be completed in

close cooperation with an international hauling

company.

GE has been working intensively since last year on

the implementation of another special global customer service,

the 24/7 express supply of emergency spare parts.

Moreover, additional locations in Southern Eu-

rope are planned for next year with the medium-

term aim of extending the ensured supply time

to all of Western Europe and extending the

actual delivery period to a 24/7 level.

ExTENSIVE AVAILABILITY OF THE NEW 24/7

SERVICE. Although any customer can use the

new service, GE’s Jenbacher customers with

long-term maintenance contracts can call on

the 24/7 service at no extra charge, according to

Stefaan Verbanck, service operations manager

for the Jenbacher gas engines: “With the 24/7

service we have taken a further step forward

in the direction of best-in-class service and

wish to provide a large number of customers

with access to this offer. However, as a result of

remote-controlled plant access, customers with

long-term maintenance contracts have an ad-

ditional advantage.” With the 24/7 service,

GE’s Jenbacher gas engines team has signifi-

cantly increased its reliability, benefiting plant

owners and customers. _

facts and figures:

· A team of qualified service hotline experts

with an average of 13 years of experience

in dealing with Jenbacher gas engines

· Service support in English, German, Italian,

Spanish and Danish

· Over 400 customers helped successfully

since July 2010

· More than 50 percent of all inquiries dealt

with by phone (without an onsite service

engineer visit)

· Spare part deliveries within four to eight

hours in Germany (in future,

throughout Europe)

41 42

supply chaincogen supply chain cogen

Test stands have a long tradition in GE’s gas engines division, as they are vital to the new and further development of efficient

engines. 2009 saw the completion of the largest test stand yet installed at the Jenbach location. In recent months, this test

stand has been used to subject the new J920 engine to intense scrutiny in order to bring it up to serial production maturity.

Moreover, in the newly completed building 53, the stage is being set for the engine classes of the next generation.

Before a new GE engine is launched, it has already been sub-

jected to numerous test runs on in-company test stands.

The examinations carried out are comparable with the functional

tests used in the automotive industry. Engines intended for future

serial production are subjected to the most rigorous checks. Vari-

ous gas compositions and a number of possible defect sources

and numerous load situations, right up to overloads, can all be

quickly and simply simulated on the test stands.

Engines intended for future serial production are subjected to the most

rigorous checks.

Moreover, the stands can also simulate the conditions in hot and

tropical regions to perfection. This is vital, as countries in these

climatic zones constitute a major future business segment for

GE’s gas engines division.

TWO TEST STANDS WITH A SINGLE OBJECTIVE – THE PERFECT

ENGINE. A company team looks after the completion of the indi-

vidual tests while, internally, a differentiation is made between a

development and a serial production test stand. The former is em-

ployed primarily for pilot series production and the validation of

new engine design. Engine reliability is examined and conclusions

drawn concerning the functionality of the engine throughout its

service life. The development test stand is also employed for the

simulation of various operating conditions likely to be encoun-

tered in customer plants. In this manner, possible sources of

faults in the pre-series models can be corrected at an early

stage. Volker Schulte, general manager engineering of GE’s gas

engines division: “The development test stand plays a critical role

in the design of engines of the next generation and therefore is

equipped with a more comprehensive range of measurement

technology systems than its serial production counterpart. We

can use it to investigate completely new technologies. As a rule,

Jenbacher engines are tested on the development stand for three

years prior to serial maturity.” Finally, the development test stand

establishes all the parameters for the finished product, including

the key parameters for testing on the serial production test stand.

These checks include engine operation at levels far in excess of

standard running, as part of a process that eventually results in a

control strategy and limits for the shutdown of serial production

The development test stand is also employed for the simulation of various operating

conditions likely to be encountered in customer plants.

engines. Lastly, the final examination of the functionality of the

finished product takes place on the serial production test stand

using various key parameters. Only when these are fulfilled is the

engine delivered to the customer.

GE’S TEST STAND OF THE FuTuRE FOR SPECIAL CLASS ENGINES.

The fact that a test stand cannot be employed for every type of

engine does not serve to make things simpler. In 2009, the largest

test stand yet installed in Jenbach was complet-

ed. Building 53 contains two test cabins which,

due to their dimensions and the simulation pos-

sibilities they offer, constitute a milestone in

Jenbacher test stand development. Last

autumn, the first J920 engine to be built was

transferred to building 53 for assembly and serial

testing. In addition, the training of the installa-

tion crew for the first pilot project in Rosenheim,

Germany, was carried out on the Jenbacher test

stand.

TEST STANDS WILL ALSO BE NEEDED IN

FuTuRE. In the past, new engines were checked

almost entirely on tests stands. And, although

in recent years simulation software has found

increasing employment, test stands will continue

to be essential in the future – simulation can

never entirely emulate reality. A test stand is an

ideal tool to simulate the service life of an engine

at short intervals and to carry out numerous test

procedures that go far beyond everyday opera-

tion. Test stands not only assist the development

of new engines, they can also aid the ongoing

improvement of existing products. This is evi-

denced by the fact that the performance of the

type 6 Jenbacher engines has been more than

doubled during the past 20 years. _

Working at full speed on the gas engines of the future

Area 53–> LAST AuTuMN, THE FIRST J920 ENGINE WAS TRANSFERRED TO BuILDING 53

–> IN BuILDING 53 THE STAGE HAS BEEN SET FOR THE GAS ENGINES CLASSES FOR THE NExT GENERATION

cogen2.0

43

cogen: As Product Line Leader, what do you see

as your basic mission?

Scott Nolen: We want to coordinate develop-

ment and maximize the marketplace solutions

capabilities for power generation segment. It’s

really a cradle-to-grave responsibility for all these

products: making sure they’re competitive in

the field and that we do smart development of

new products, reduce costs on existing products,

increase our supply chain capability and develop

strong aftermarket solutions for our products in

the field.

How does your function reflect the integration

focus for the Jenbacher and Waukesha product

lines and Heat Recovery Solutions segment?

The intention is to create synergies so that the

products we develop can be used across all

the business units. Previously, when all three

businesses were separate, some research and

development activities – especially within

Waukesha gas engines and GE’s Jenbacher gas

engines businesses – focused on the same areas.

But now, we can optimize R&D (research and

development) work and obtain better efficiency,

higher power density, better fuel flexibility and a

greater capability to hold power and efficiencies

at higher ambient temperatures and altitudes.

We’ll optimize our R&D dollars and, more im-

portant, our R&D resources to the benefit of our

customers.

What are your short- and long-term business

goals?

In time, there will be a multi-generation product

plan that incorporates all the gas engines product

lines. An integrated offering combining gas

engines and the products supplied by the Heat

Recovery Solutions segment, currently in the early

development phase, will be created over the com-

ing months and years as those products mature.

The commercial launch of the J920 gas engine is

the major priority for 2011. That involves what I

call a “macro-sale” and a “micro-sale”. The

macro-sale is well under way, and included the

formal introduction of the J920 last fall at series of

launch events at the Jenbacher headquarters.

“The intention is to create synergies so that the products

we develop can be used across all the business units.”

The next step is the micro-sale, which really is the

key to launching a new product. It requires sitting

with customers, listening to their concerns and

priorities and developing solutions that emphasize

the products’ superior attributes and mitigate any

In March, Scott Nolen became product line leader for the entire power generation product line within GE’s gas engines business. He’ll be based

in Jenbach, so it helps that skiing is his favorite sport. “They’ve already taken me out on the slopes and made sure I’m good at that.” Actually,

Nolen has a wealth of other qualifications for his new position, including leading the power generation and compression product line managers

for the Waukesha product line, which GE recently acquired. He discussed his new role and its major challenges with cogen.

Scott Nolen, product line leaderpower generation of GE’s gas engines business:

profile:

Age: 43 years

Education: B.S. in mechanical engineering,

university of Vermont; M.B.A. in business

administration, university of Rochester

Married, one son

Scott’s leisure activities are skiing,

hiking and bicycling

His dream job as a child was airline pilot

“because I always wanted to travel when I

was young, so I guess it all worked out.”

Previous position: Vice President,

Power Generation, Waukesha gas engines

44

issues that may arise in support of the units.

What are the major challenges and opportuni-

ties that you will confront?

I think our significant investment in natural gas

products strongly positions GE’s gas engines

business for a future where there will be few other

power generation options using fuels that are

going to be acceptable in a carbon-constrained

world. In a world with a growing concern around

the production of CO2, natural gas is the best

“The challenge, though, is to generate the

most power possible with the fewest emissions, because

many power generation gas engines will be installed

near population centers.”

hydrocarbon-based fuel available, and the interest

in biogas continues to expand, too. Both of those

fuels promise a strong future for our gas engines

business. The challenge, though, is to generate the

most power possible with the fewest emissions,

because many power generation gas engines will

be installed near population centers. So there will

be two main drivers of technology development –

maximizing efficiencies and minimizing emissions.

personality storycogen personality story cogen

Integrating and optimizingPower Generation resources

As the fuel of the future, natural gas will power

formats ranging from big-baseload power plants

using gas turbines in combined-cycle service to

gas engines in cogeneration applications. GE has

been spending a significant amount of R&D effort

to maximize

efficiency for both electrical and heat genera-

tion. Now, with emissions, whether they’re from

exhaust, noise or vibration, it’s going to be very

critical to control them to very low numbers in

order to locate engines next to populated areas

where the waste heat can be used to maximize

the overall efficiency.

How has your career prepared you for your new

position?

What was so important was my previous sales ex-

perience, both in the field and in the home office. It

gave me a real strong focus on looking at project

applications from the customer viewpoint and ap-

preciating what customers value. That translates

well into how we develop products and how GE

competes – on solutions rather than price. Our ef-

forts go well beyond just ‘here’s a one-page quote

with a price at the bottom’. We’re about under-

standing and delivering efficiency, maintenance,

availability and numerous other attributes that go

well beyond the dollars at the bottom of the sheet.

Thank you for talking to us.

Publisher

GE Jenbacher GmbH & Co OHG

Achenseestr. 1-3, 6200 Jenbach, Austria

Editorial team:

Thomas Achrainer, Nancy Deptolla,

Andreas Eberharter, Sheila Gailloreto,

Ekaterina Goron, Christof Harrasser,

Petra Kalaskova, Claire Kelly, Stephan Laiminger,

Eugen Laner, Thomas Misch, Debra Murphy,

Scott Nolen, Klaus Payrhuber, Ray Pelosi,

Gerhard Pirker, Susanne Reichelt, Martina Streiter,

Chuck Taylor, Tatijana Uzelac, Stefaan Verbanck,

Michael Wagner, be.public Werbung Finanz-

kommunikation GmbH, KronthalerWaltl GmbH,

Texterei Theiner

Guest writers in this issue:

Gerd Krieger, VDMA Power Systems

Thorsten Herdan, VDMA Power Systems

Design and Layout:

Zimmermann Pupp Werbeagentur

Printer:

Alpina Druck GmbH, 6020 Innsbruck, Austria

Printed on paper free from chlorine.

Feedback:

We value your opinion and welcome your

comments or questions. Please send them to the

editorial team at gasengines.cogen@ge.com

Picture credits:

GE Energy

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