A first for GE
Southern Power Generation’s 1440 MW Combined Cycle track 4A power project
Malaysia is targeting a 45% reduction in CO2 emissions by 2030. The country of 33 million consists of several large, hilly islands and a peninsula where open land suitable for building large wind or solar farms are scarce. The country’s recent economic growth has driven a steady increase in power capacity, answering the increasing need for more electricity, however, there is a need to achieve the right balance between cost and environmental impact.
Most of the electricity generated in Peninsular Malaysia is based on coal plants as this is the cheapest solution for $/kWh. Today, coal plant contributes to about 65% of electricity generated in Peninsular Malaysia. However, in line with government aspirations, there is a strong commitment from industry players for reduced/ near zero carbon emissions for their operations.
With the country’s latest development plan to add more renewable power while reducing dependence on coal, gas power remains critical for the country’s prosperity.
GE’s giant 9HA.02 gas turbine debuts
On February 2021, Southern Power Generation’s gas fired Track 4A Power Plant went online with 1440 MW. The plant is located in Pasir Gudang, an industrial city at the southern tip of Malaysia’s peninsula, just a few miles from Singapore. It will power approximately 3 million homes.
The plant consists of two generating blocks, each equipped with a 9HA.02 gas turbine and a STF-D650 steam turbine, driving a W88 generator, and, for the first time installed in an H-Class Plant, a GE Once Through (OT) Heat Recovery Steam Generator (HRSG). GE’s OT HRSG technology is a key enabler in advanced water-steam cycles delivering higher combined cycle efficiency.
Track 4A power plant is powered by GE’s first 9HA.02 gas turbines in commercial operation globally. The turbines come from a new generation of GE machines that had already set a world power plant efficiency record. The 9HA.02 integrates advances in additive manufacturing and combustion breakthroughs present also in the 7HA.01 and 7HA.02 models. The 9HA.02 features a DLN 2.6e combustor with axial fuel staging (AFS) which enables lower nitrogen oxide (NOx) emissions with improved turndown. In addition it embeds an evolutionary improvement to the premixing fuel nozzles, a technology GE developed in collaboration with the U.S. Department of Energy to deliver improvements in terms of performance, emissions, and fuel flexibility.
The combustion system DLN 2.6e allows the turbine to burn up to 50% by volume of hydrogen when blended with natural gas. In the future, the system could be adjusted to run on 100% H2. This capability is enabled by the DLN2.6e combustion system that is standard on current HA gas turbines offerings. Hydrogen is not the only path for decarbonizing gas turbines. GE’s H-class Combined Cycle Plants can also be configured with a post-combustion capture system to reduce CO2 emissions by up to 95%.
Advanced analytics across the plant
The plant is controlled by GE’s Mark VIe integrated Plant Control System. Equipped with a single Operator Interface and common troubleshooting tools, plant personnel can operate the plant more efficiently and, when issues do arise, rapidly recover to improve overall plant availability. Featuring superior responsiveness and flexibility, it enables plant operators to dispatch power to the grid quickly.
For 21 years, overall plant performance will be monitored and enhanced with GE Digital’s Predix Asset Performance Management software to help improve asset visibility, reliability, and availability while reducing operating and maintenance costs. In addition, data collected from sensors throughout the facility will be monitored and analyzed 24/7 at GE’s Monitoring & Diagnostics (M&D) Center in Kuala Lumpur.
Safety during a pandemic
This plant was safely constructed with the Taiwanese EPC partner, CTCI. Despite the COVID-19 pandemic, CTCI and GE have collaborated together without compromising on health and safety.
The turbines arrived in modular containers that enabled engineers to install them relatively quickly. GE’s H-class machines are engineered with more modular architecture that allows for quicker inspection and maintenance activities, resulting in better reliability. In addition, GE engineers and manufactures all major combined cycle equipment in-house for a full-system approach. GE’s full system approach enables high power output and efficiency as well as improved plant operability.
CTCI and GE have achieved more than 10 million safe man-hours on this project, a testament to the team’s reliability. The two companies’ joint success also paved way to another recent partnership in late 2020, helping GE win a multi-billion dollar EPC contract for five combined cycle gas power units in Taiwan. Together with GE’s expertise and support on site, this will ensure the long-term operations and sustained power dispatch to the grid.
“The world’s first commercial operation of our flagship turbine marks a tremendous milestone for our HA fleet,” said Ramesh Singaram, president and CEO of GE Gas Power in Asia “We look forward to helping Southern Power Generation reap the benefits of our latest technology as well as combined services and digital solutions, helping to deliver more reliable and flexible power generation for the country.”
Power in a time of crisis
MWM power plant keeps ventilator maker running smoothly
Dräger is a leading international maker of medical and safety technology products, including ventilators. In the current pandemic, it’s no surprise that the Lübeck, Germany-based company has great demand for its products, especially for the ventilators it produces. The company’s headquarters on Moislinger Allee in the Hanseatic city of Lübeck manage the production facilities and sales companies around the globe. To make sure that everything works smoothly at all times—not only in times of crisis—a dedicated MWM cogeneration power plant supplies about 30% of the heat and power. A substantial amount of energy is needed for the workforce of 3000 at the Moislinger Allee site.
When the cogeneration power plant was first set up in 2007, Dräger opted for reliable, efficient MWM engine technology in the form of a TCG 2020 V12. After 13 years of smooth operation, the core of the cogeneration power plant was replaced in 2020 with an MWM TCG 2020 V12 gas genset with improved efficiency.
“By replacing the engine of the Dräger cogeneration power plant, we want to achieve even more carbon savings and improve the profitability”, said Sören Sievertsen, project manager at Stadtwerke Lübeck. In the past, the cogeneration power plant was operated directly by Dräger; now, this will be handled by Stadtwerke Lübeck under a contracting arrangement.
The heat-controlled cogeneration power plant supplies heat energy and power for Dräger and heat energy for various service providers on the premises. All of the generated heat is used for heating the workplaces in the factory halls and offices, and almost all of the 1 MW of power that will henceforth be produced will be used locally and will not be fed into the local power grid. “In this way, we are able to cut Dräger’s power costs, as self-generated power is not subject to additional levies”, explains Björn Verwold, account manager at Stadtwerke Lübeck. Thermal output is 1272 kW, thermal efficiency is 53%, electrical efficiency is 41.7% which leads to an overall efficiency of 94.7%.
Modern engine, more…
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