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Turbomachinery Magazine – Oil & Gas, Petrochemical and Power Insights

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Director of Global Technical Services, Ebara Elliott Energy

Explore how blade dynamics, velocity triangles, and flow path analysis help operators achieve higher efficiency and reliability in steam turbines.

Steam Turbine Optimization for Mechanical Drive Applications – Part 1

In spring 2025, we surveyed our readers about the state of the industry and the dynamic factors shaping the turbomachinery sector. Based on the survey results, we gathered insights, identified trends, and asked about solutions to ongoing challenges, such as supply chain constraints, rising material costs, labor shortages, and increasing power demand. With more than 100 respondents, we collected comprehensive perspectives on five main areas: industry challenges, external factors affecting the industry, solutions, current and planned investments, and recent advancements.

With the boom of AI and data centers, surging power demand, a rollback of U.S. support for clean energy in favor of fossil fuels, and backlogged gas turbine orders, the need for comprehensive and complex energy solutions is greater than ever.

“The power landscape is shifting faster than we’ve seen in decades,” said Doug Machon, VP of Business Development at IHI Power Services Corp. (IPSC). “Electricity demand is surging, driven in large part by the exponential growth of data centers and AI infrastructure, as well as increased electrification across sectors like transportation and manufacturing. Our customers are being asked to maintain grid reliability, manage aging assets, integrate battery storage, and stay aligned with long-term decarbonization goals—all while navigating market volatility and evolving compliance demands. It’s one of the most dynamic and operationally demanding periods in the history of U.S. power generation.”

OEMs like Baker Hughes are securing contracts for equipment deliveries specifically for data center projects. The company signed an agreement for 16 NovaLT gas turbines to power Frontier Infrastructure Holdings’ data center projects in Wyoming and Texas. It’s also providing TURBINE-X Energy with its NovaLT gas turbine technology and auxiliary equipment for various data center projects across North America.

Another example is the joint venture between Engine No. 1 and Chevron, which aims to build a multi-GW-scale, co-located power plant and AI data center using GE Vernova’s gas turbine technology powered by electricity generated from domestic natural gas.

Environmental factors, such as record temperatures and natural disasters, grid instability, and increased wear and tear on power plant equipment, are also significantly impacting the industry.

“Events such as the widespread blackout in Spain and Portugal this spring have underscored how rapidly a disturbance can cascade across interconnected systems, reinforcing the need for fast-reacting, reliable assets that support grid resilience,” said Giuseppe Tilocca, Technical Lead at ETN Global.

"Many power plants have been in service for decades, and the shift to more frequent start/stop cycles—driven by variable load demand and renewable integration—is accelerating wear on key systems,” Machon said. “Mechanical fatigue, thermal stress, and corrosion are all increasing as units operate less predictably than in baseload conditions. Weather-related stress in certain geographic areas only adds to the challenge.” 

Survey respondents ranked several key challenges facing the turbomachinery industry. The top three are:

The energy sector faces a critical challenge in workforce skills and availability, driven by experienced personnel retiring, an ongoing skills gap, and the rapid integration of new technologies like AI and digitalization.

“The turbomachinery industry is facing a deepening workforce crisis, marked by declining vocational interest, an aging labor pool, and increasing skill mismatches,” Tilocca said. “Unlike in other energy roles, skills in gas turbine operations and retrofits are highly specialized and not easily transferable. Despite rising demand, most energy companies report difficulty hiring qualified candidates, particularly for manufacturing, installation, and repair.”

OEMs like Atlas Copco work with universities and participate in job fairs to attract talent early in their careers and offer opportunities within the company. “We utilize various social media channels to reach potential talent, and we also employ AI to enhance efficiency and address potential labor shortages,” said Ulrich Schmitz, the Vice President of Marketing in the Gas and Processing Division of Atlas Copco.

to listen to Schmitz's interview with Turbomachinery International, discussing pressing issues facing the turbomachinery industry. 

IPSC sees people as its most valuable asset. “In today’s market, recruiting and retaining top talent requires intention,” Machon said. “IPSC keeps the focus on building a strong internal culture and a clear path for professional development. That includes formal skills training, leadership development programs, and a performance structure that prepares employees for the role they have right now and for what’s next. We also collaborate closely with local communities in harder-to-staff regions to create workforce readiness programs. Whether it’s internships, apprenticeships, or community partnerships, we’re working to grow the next generation of technical talent from the ground up.”

Organizations across the industry, like ASME’s Workforce Development Group, ETN Global’s Young Engineers Committee, the Turbomachinery Lab at Texas A&M, and the Southwest Research Institute (SwRI), promote learning, training, and education in the turbomachinery industry.

“[To address the need for qualified professionals], education and training initiatives are expanding globally,” Tilocca said. “Vocational and higher education programs are being modernized to reflect current industry needs, especially in digital technologies, system integration, and energy efficiency. The whole industry needs a collaborative effort to bridge this gap, making workforce development a strategic pillar for the sector’s long-term resilience.”

SwRI’s mission is to benefit the government, industry, and the public through its research, “so we are very active in trying to enhance and enable technology learning across the industry,” said Tim Allison, Director of R&D in the Machinery Department of SwRI. The Institute runs a monthly webinar series where “we freely talk about turbomachinery or energy system technologies” and offers several on-site trainings.

The Turbomachinery Laboratory at Texas A&M trains graduate students in industry practices, ensuring they are well-prepared for their careers. And throughout the year, the team also organizes several short courses and designs the technical agenda at the Turbomachinery & Pump Symposium to support education and enhance the professional development of engineers.

Listen to industry leaders discuss strategies

—collaborating with academia, partners, and networking—to cultivate a skilled workforce and address labor challenges.

Rising material costs are posing significant challenges for manufacturers, as they struggle to maintain competitive pricing while ensuring the quality and performance of their products. Many manufacturers are working to expand their supplier base, localize their efforts, and diversify their options to buffer disruptions such as geopolitical events and natural disasters.

“Hanwha is actively working to secure stable international supply chains by expanding its network of raw materials and components and reducing dependency on any single region or supplier,” said Kihun Do, VP and General Manager of the Equipment Business Division at Hanwha Power Systems. “We are also planning to build packaging and service centers in the Middle East and the United States, and an after-service storage facility in Europe. Operating various overseas service centers helps provide more direct control over the supply chain and transportation costs and reduce the lead time to handle customers’ needs.”

Atlas Copco is also addressing rising material costs by leveraging its global footprint. “We have factories in various regions, including the United States, Europe, and Asia, that provide us with a broad pool of qualified vendors,” Schmitz said. “This approach also helps when tariffs are involved; we can produce more locally if we have suitable suppliers. That’s one of our key initiatives.”

Duke Energy has developed strategies to ensure materials are ready and available to respond to emergencies, including storms. “We are looking ahead to identify risks and partnering closely with other business units within the company to be proactive,” said Shawna Berger, APR/Enterprise Communications at Duke Energy. “We took the lessons learned from being reactive during COVID-19 and applied them to our proactive strategy today. We’re building a stronger supply chain that is data-driven, customer-centric, and resilient against dynamic supply markets.”

Matthias Grapow, VP of Business Development and Digitalization at Everllence, said in such a volatile and fast-changing political environment, providing fixed solutions is extremely challenging: “Local procurement is one approach we’ve used for years, and we continue to explore it where possible. However, expanding local sourcing depends heavily on the capacity and stability of suppliers, who are themselves navigating uncertainty. Given the long-term and global nature of our business, we focus on flexible strategies rather than rigid solutions. Devising solutions where the situation changes daily and for a business with long lead times is a loss of time and effort.”

More than 51% of respondents identified supply-chain constraints as their primary challenge. The industry is responding by utilizing local supply chains, collaborating closely with customers and suppliers, and modernizing or leveraging existing equipment.

“To address the various supply-chain challenges—many of which are industry-wide or arise from conditions beyond our control—we maintain strong supplier relationships and prioritize opportunities to localize our supply chain to serve our distinct geographies,” said Dave Ross, GE Vernova’s Gas Power business CEO and President for the Americas region. “At the same time, we maintain a globally diverse supply chain for operational resiliency.”

In March, GE Vernova acquired Woodward’s heavy-duty gas turbine combustion parts business based in Greenville, SC, to strengthen its domestic supply chain. “Combustion parts, like those manufactured by [Woodward], play an integral role in GE Vernova’s gas turbines, supporting customers’ ability to meet growing energy demands from load growth, data centers, and other areas,” he said.

51% of respondents identified supply-chain constraints 
as their primary challenge.

GE Vernova is also investing more than $160 million and hiring over 650 new employees at its Greenville facility to increase capacity to help meet market needs. Most notably, the facility is increasing its production capacity by more than 25% to 70 - 80 heavy-duty gas turbines per year (beginning in the second half of 2026) and will ship approximately 20 GW annually starting in 2027.

Mark Babyak, Vice President of New Apparatus at Ebara Elliott Energy (EEE), said EEE is challenging its suppliers to adapt their sourcing to minimize the impact of tariff costs and remains flexible in adjusting its sourcing strategies to manage market fluctuation successfully.

Many organizations are modernizing existing power plant equipment or retrofitting legacy or existing gas turbines to meet increasing power demands and supply-chain constraints. Investing in upgrades and modernizations also helps organizations stay competitive.

“By jointly defining schedules, anticipating potential bottlenecks, and streamlining procurement strategies, we reduce the risk of disruption and ensure the timely delivery of critical components and services,” said Luigi Coltelletti, SVP of Strategic Marketing at Ansaldo Energia. “A key part of our approach lies in offering upgrade packages that are specifically tailored to be minimally invasive. These solutions require only limited modifications to existing plant configurations, enabling fast implementation and shorter outage durations. This helps our customers maintain high availability while minimizing exposure to volatile material costs and logistical delays.”

ISCP is increasingly supporting its customers well beyond day-to-day plant operations by assisting with acquisition due diligence, plant optimization efforts, and lifecycle strategy development. “Clients are asking for deeper technical insight, especially during M&A activity and when evaluating capital upgrades or retrofit options,” Machon said. “We’ve expanded our capabilities accordingly, tapping into the robust power generation design and deployment expertise of our parent company, which spans a wide range of thermal and renewable technologies.”

Utilities like Duke Energy are partnering with OEMs to preemptively procure equipment, staying ahead of supply-chain bottlenecks and meeting the rising demands of advanced manufacturing, data centers, and population growth. It partnered with GE Vernova for the option to purchase up to 11 HE gas turbines, steam turbines, and other related equipment, including generators. “The agreement allows for turbine delivery to support our current integrated resource plans and to accommodate even the most robust growth scenarios,” Berger said. “Using these turbines at Duke Energy plants also allows us to leverage existing infrastructure, including transmission capabilities, significantly reducing costs and accelerating deployment.”

Respondents ranked external factors influencing strategic decisions on a scale from 1 (most impactful) to 7 (least impactful). Global economic conditions were considered the most impactful, with 40% of respondents ranking it first and an average score of 2.24. Next was energy market volatility (2.64), with 24% of respondents ranking it first, and decarbonization and sustainability goals (3.87). Factors considered less influential included advances in digitalization and Industry 4.0 (4.93) and the availability of investment or funding (5.05).

“GE Vernova’s Gas Power business engages in discussions daily with our customers about how to satisfy the growing demand of critical energy markets while maintaining a stable electric grid to support growth, prosperity, and energy security for their communities,” Ross said.

The conversations focus on three key areas: risk management, technological investments, and global supply-chain strategies. “Given the market realities of today—and likely for the foreseeable future—project timing becomes one of the toughest challenges for our customers’ ability to support the electricity demand of their customers.”

Ross highlighted four key considerations for project timing:

Equipment availability: There is an urgency to lock down manufacturing slots for the long lead items necessary to build a new power plant: gas turbines, generators, transformers, and other electrical gear.

Engineering, procurement, and construction (EPC) companies’ capacity: Many of the top-tier EPC firms are filling up, and access to skilled labor, technicians, and experienced project managers is a key pacing item.

Acquiring the required permits and satisfying all regulatory requirements.

The wait for the grid interconnection queues is, in some cases, pushing projects out.

In terms of technical logistics investments and supply-chain management, GE Vernova is investing nearly $600 million in its U.S. factories and facilities over the next two years to help meet the current growing demand, including a $300 million investment in its Gas Power business globally.

“Given the global nature of energy markets, GE Vernova is focusing on strengthening supply chains to ensure reliability and minimize disruptions caused by geopolitical tensions or other external factors,” Ross said.

Grapow said Everllence recognizes that much of the volatility in today’s energy markets and global economic environment stems from politically driven developments and policies from major global players. “While these external factors do influence the broader landscape, our focus remains on the project, the contract, and the long-term relationship,” he said. “We believe in the resilience of our industry and the critical role we play in the global energy transition. This is not a short-term market; we operate with a long-term perspective, confident that energy infrastructure and turbomachinery will remain vital for decades to come.”

Coltelletti made a similar point: “Despite current volatility and uncertainty, the heavy-duty rotating machinery market remains strong. These technologies will continue to play a critical role in ensuring energy security and enabling the energy transition. Efficiency, operational flexibility, and green-fuel capability are exactly what energy producers need to navigate today’s complex landscape, ensuring dispatchable power, grid stability, and long-
term sustainability.”

A total of 61.05% of respondents are opting for modular solutions to meet rising power demands and limited equipment supply. Fewer than one-third (29.47%) are using smaller gas turbines. Among "other" respondents (29.47%; respondents could select multiple options, so totals exceed 100%), notable trends include the accelerated adoption of renewable energy, particularly solar power, a strong emphasis on optimizing and upgrading existing energy infrastructure for better efficiency, and the evolving role of gas-fired power generation. Additionally, there is a recurring focus on improving supply chain dynamics and offering tailored solutions.

“There is a clear and growing global trend toward smaller, modular, and even mobile gas turbine technologies, especially in emerging markets and for decentralized applications,” Tilocca said. He named several factors that are driving this shift:

Fast start-up and ramp rates make small turbines ideally suited to support intermittent renewable generation and provide ancillary services.

Lower capital expenditure and shorter deployment timelines make micro-units attractive in rapidly changing or resource-constrained environments.

Operational flexibility is increasingly valued in power systems dealing with volatility, partial load operations, and localized reliability issues.

Mobile power solutions are increasingly being adopted to address temporary or remote energy needs.

“There’s a real sense of optimism in this space. Mobile power is no longer just a short-term solution; it is a strategic enabler for countries and companies looking to build energy systems that are faster, cleaner, and more resilient for the future,” Midhat Mirabi, GE Vernova’s Managing Director of Aero New Units, said in an interview with 

 on how mobile solutions give islands like the Bahamas (where it shipped its trailer-mounted TM2500 mobile aeroderivative solution) a means to modernize island power generation systems and provide stable, affordable electricity, especially during summer peak times.

Ross said GE Vernova sees gas power playing a big role in providing dispatchable and affordable power and firming the grid to allow more wind and solar to be integrated. “We continue to see an increase in demand for flexible dispatchable generation where GE Vernova aeroderivative solutions have a strong fit,” he said.

Its trailer-mounted TM2500* mobile aeroderivative solution is what “we call a ‘power plant on wheels,’” Ross said. “We are proud to increase power generation capacity and work toward providing more reliable power for the growing communities and the critical tourism sector. Plus, our aeroderivative solutions help power-plant operators transition from heavy fuel oil to a solution that can burn less carbon-emitting fuels, like natural gas.”

Another example is Siemens Energy and Eaton: They developed a fast-track approach to modular data-center construction with integrated onsite power that provides reliable, grid-independent energy supplies and standardized modular systems. It allows the simultaneous construction of data centers and onsite power generation with grid connection and renewable integration when needed. The configuration offers customers the flexibility to choose the right mix of energy sources with quick construction and start-up times.

The standard configuration of Siemens Energy’s modular power plant concept generates 500 MW of electricity. The size of the plant can be scaled up and down depending on its modular approach. It also includes an optional emission-free clean air grid connection that can be installed either during construction or as a retrofit.

Although its turbomachinery business is not directly focused on mobile power, Grapow said Everllence is seeing its engines increasingly being used in modular and mobile power solutions: “These solutions are deployed in crisis regions around the world to provide urgently needed electricity. Moreover, we are seeing a marked increase in the demand for our emergency diesel generators. They are becoming a key part of future energy security strategies. The large-scale blackout in Spain underlined the importance of reliable backup systems, showing many operators that emergency power is now a necessity, not just a fallback.”

“From small- to micro-sized turbines, micro gas turbines remain an area of active innovation and deployment,” Tilocca said. “These compact systems are particularly promising for distributed energy and combined-heat-and-power (CHP) applications in decentralized and integrated settings.”

Baker Hughes, Hanwha Power Systems, and Hanwha Ocean signed an agreement to combine Baker Hughes’ small gas turbine technology with Hanwha’s ammonia combustion system. The goal is to develop dual-fuel small turbines—capable of 100% ammonia combustion with natural gas—for use in marine, onshore, offshore, electric generation, and mechanical drive applications.

Ansaldo Energia has also tapped into the micro-turbine market, as its group portfolio includes 100-kW fuel-flexible microturbines ideal for distributed electricity production and designed to offer high-efficiency solutions for cogeneration and trigeneration. “Modular installation allows us to cover a wide range of different power needs, with each module delivering 100 kW of electrical power and approximately 200 kW of thermal power,” Coltelletti said.

Its AE-T100 microturbines work with different fuels, including biogas, and are tested for burning up to 100% hydrogen in the fuel mix. They can also be powered by external sources, which complement biomass combustion and concentrated solar generation plants.

SwRI is also seeing increased interest in R&D for modular/small-scale distributed generation enabled by low-cost PV and anywhere-suitable energy storage technologies such as pumped thermal energy storage or liquid air energy storage. “With the interest in geothermal power along with the fact that every geothermal application has slightly different well and/or ambient conditions, we are seeing interest in developing modular systems that are easily adaptable to a wide range of sites,” Allison said.

To stay competitive, 59.80% of respondents said they are investing or planning to invest in energy-efficiency improvements; 42.16% are focusing on predictive maintenance and/or workforce training; and 36.27% are investing in emissions-reduction technologies.

“Every one of our clients is looking for ways to improve plant performance while reducing operational strain and resource consumption,” Machon said.

Tilocca named several trends in efficiency improvements:

Waste heat recovery systems, heat upgrade technologies, and heat pumps

Traditional gas turbine CHP with electric heating like boilers

Predictive maintenance is a recurring trend in this space. “One of the most important trends we’re watching is the rising demand for near-perfect uptime,” Machon said. “These users are energy-intensive, availability-sensitive, and increasingly central to grid demand. To meet these expectations, facilities will need more than just upgrades—they’ll need a more sophisticated design, highly optimized operations, and a greater reliance on predictive maintenance, automation, and workforce readiness.”

IPSC is already working with clients to prepare for this shift, supporting both new project development and long-term optimization of legacy sites. “As the industry navigates more frequent cycling, tighter margins, and aging infrastructure, asset owners are seeking smarter, more proactive ways to manage reliability and cost,” he said. “IPSC’s expanded fleet-wide training, enhanced CMMS deployment, and analytics-based maintenance planning are all designed to meet these needs.”

In terms of technological advancements, companies are primarily considering or investing in decarbonization technologies (51.55%), followed by AI and machine learning (ML) (44.33%), and fuel-focused advancements (29.90%). Advancements are also being made or considered in nuclear or other renewables that pair with turbomachines (25.77%) and auxiliaries and components (22.68%).

“AI stands to impact every part of the energy value chain, and our industry is seeing significant growth,” Berger said. “It has helped us automate processes, optimize decisions, and predict the likelihood of certain events occurring, among other use cases. Our journey has brought us to a place today where we are ready to scale our AI use cases in support of our energy modernization strategy—the investment in talent and planning for this technology is creating intentionality to deliver the best possible solutions to benefit our employees, customers, and communities.” 

IPSC is also actively exploring and integrating AI-driven capabilities into its operations. “While IPSC hasn’t fully deployed standalone AI platforms yet, we’re using advanced analytics to monitor equipment trends and predict potential failures before they occur,” Machon said. “There’s also growing curiosity about AI and ML applications in the O&M space. Most customers aren’t ready to deploy large-scale investments yet, but interest is high. We expect to see more adoption as the technology matures and ROI becomes easier to quantify. We see AI not as a replacement for expertise, but as a multiplier for the knowledge already embedded in our teams and systems.”

Allison said AI and ML’s most significant impacts are already being felt, and this was underscored at Turbo Expo 2025, as the conference explored how AI is changing the industry—from surging power demands to gas turbine technology, computational tools, and turbomachinery design.

“[AI and ML’s] high power demand is driving purchases of gas turbines across the United States, such that lead times are now stated as 7 to 8 years out!” he said. “Whether for power or cooling, data centers require large-scale technologies that align well with the scalability and power density of turbomachinery-based technologies.” 

In the United States, significant investment in decarbonization continues across the industry despite recent policy shifts that have reduced support for the Inflation Reduction Act and indicated a renewed backing for fossil fuels.

OEMs are actively integrating decarbonization into their advanced technologies—from gas turbines and mobile power solutions to key components.

The turbomachinery industry is navigating a transformative period marked by rising energy demand, supply chain disruptions, and a shift towards decarbonization. Key challenges include labor shortages, rising material costs, and supply-chain constraints. Companies are responding with modular solutions, investments in energy efficiency, and technological advancements like AI and decarbonization technologies. The industry is also focusing on workforce development to address skills gaps. External factors such as global economic conditions and energy market volatility significantly influence strategic decisions, emphasizing the need for resilience and adaptability.

Turbomachinery faces challenges like labor shortages and supply chain issues, but innovative solutions help the industry meet growing energy demand.



Energy Industry Outlook: Strategies to Tackle Supply Chain Issues, Power Demand, and Decarbonization 

With new technology continuously integrated in the turbomachinery industry, market dynamics, regulations, and standards must evolve alongside this innovation. 

 serves this function for pump users, manufacturers, and engineers in North America and around the world, developing industry standards and providing education on pumps and pumping systems.

Michael Michaud, Executive Director of the Hydraulic Institute, spoke with 

 about the group’s history, the advantages/disadvantages of rapid technology integration, education and certification, and much more. Per Michaud, AI-enabled performance data analysis and efficiency improvements will require the establishment of new standards and training methodologies.

Hydraulic Institute (HI) was founded in 1917, when several leading pump manufacturers decided to develop a common methodology to test pumps and streamline procurement. The pump test standard was the first, and HI now has 36 ANSI/ HI Standards. Membership has grown as well, from the dozen or so manufacturers in 1917 to over 120 corporate members that manufacture pumps and pumping systems and associate members who supply components like motors, drives, seals, bearings, etc.

In addition, HI has a growing group of partners who are not manufacturers but align with our core interests. Standards partners include engineering firms that design and specify pumping systems and end-users like municipal water/wastewater or chemical processing facilities. Training partners include end-users and other organizations, which both contribute to and consume training through Pump Systems Matter, HI’s training organization. Today, HI is where pump manufacturers, designers, end-users, and more come together to advance the mission to drive all pump system stakeholders toward a sustainable future.

What are the biggest challenges for the pump industry?

Helping customers solve their fluid-handling needs will still be front and center, but keeping pace with technological changes brings some exciting new challenges. Some of these challenges will stem from new customer needs as they push pump manufacturers to advance designs and achieve new performance levels for brand new requirements/materials. Other challenges include embedding new technologies in our products to make them smarter, more adaptive, and more communicative.

How is the Hydraulic Institute seeing advanced pump technology being integrated to enhance the performance, predictive maintenance, and energy efficiency of modern pumping systems?

From hydraulic design improvements to more efficient motors to better connectivity or integrated drives that can adjust automatically to different flow requirements—pumps and pump systems keep getting better. These changes improve the operational reliability, as uninterrupted service, fewer incidents, and fewer maintenance calls are what most want in a pumping system. As a byproduct, however, a well-designed, efficient pumping system can also give back in terms of savings: saving dollars, downtime, and lowering electric bills.

How does the Hydraulic Institute support decarbonization in the pump sector?

When pump systems are operated at (or close to) their best efficiency point (BEP), they are the most efficient, and while a carefully selected pump can be very efficient, most pumping systems are oversized and do not run close to their BEP. Putting in place a system to conduct regular pump system assessments is a good place to start, so HI develops tools that can be used across virtually any application or pumping system.

Our Pump System Optimization (PSO) guidebook takes readers through the principles. Our PSO course guides students through the complete process of conducting an assessment and understanding how to optimize the system for both energy and performance. Remember, beyond the energy savings, a system that is operating at BEP has less wear, is more reliable, and requires less maintenance.

The Pump System Assessment Professional (PSAP) Certification is a stamp of approval for an individual who can identify savings and recommend adjustments to ensure long-term reliability and the most energy-efficient and reliable system. Facilities with many pumping systems or with complex fluid-handling requirements should consider having one PSAP-certified expert on staff to conduct regular audits.

How do pumps support the turbomachinery industry’s goals in terms of energy efficiency and reliability?

When you consider the energy consumed by rotating equipment in a facility, pumps are generally the most energy intensive, especially when compared to fans and compressors. This is why the Department of Energy (DOE) started to regulate pumps for energy efficiency in 2020. While the DOE regulations (and the HI Energy Rating) focus on clean-water commercial and industrial pumps up to 200 hp, other pumps still benefit from the industry-made design improvements to comply with the new requirements. Along with the advances in motor and drive technologies, more fully integrated pumps (often referred to as smart pumps) can adjust automatically to different flow requirements as the system needs change.

What trends and/or advancements are you anticipating over the next several years?

Look for more connectivity, which means more data and more opportunities to optimize. AI will play a role and is already making an impact in analyzing performance data, preventing failures, and optimizing maintenance opportunities. Sharing this data with OEMs will allow them to aggregate this data with data from other end-users to provide even better predictability.

What’s next for the Hydraulic Institute?

HI is on the same trend line as the overall industry, so as technology continues to evolve, new standards and guidelines will be needed, and HI will be there. As the workforce continues to change, more training, at different levels and for different audiences, will be needed. The recent Pump System Certified program was developed specifically for this purpose. It is one part training so that individuals have a clear learning path to prepare them for a career, and another part exam so that they (and their employers) have the confidence and skills needed for the job.

Of course, HI will continue to leverage technology to make its trusted resources more accessible. In addition to growing the online library of industry standards, training, and other resources, the 

 will become even more “intelligent” when we launch our new AI co-pilot.

The Hydraulic Institute (HI) plays a crucial role in the turbomachinery industry by developing standards and providing education on pumps and pumping systems. Founded in 1917, HI has grown to include over 120 corporate members and numerous partners. The institute addresses challenges such as technological advancements and decarbonization by offering tools and certifications like the Pump System Optimization guidebook and the Pump System Assessment Professional certification. Future trends include increased connectivity, AI integration, and the development of new standards and training programs to support industry evolution.

Michael Michaud of the Hydraulic Institute says design improvements, more efficient motors, and AI-enabled analysis technologies will improve pump reliability and maintenance.

Hydraulic Institute Talks Pump Technology, AI Analysis, and Certification

Many grid operators are struggling to maintain a reliable and stable power supply. Challenges arise when decommissioning a significant number of coal and gas power plants and replacing them with non-synchronous renewable energy sources, such as wind farms and solar photovoltaic panels. Key issues to address include grid stability, voltage control, short circuit power, and frequency control. A more flexible approach to the grid is needed, utilizing a combination of technologies such as flywheels, battery energy storage systems (BESS), synchronous condensers, static synchronous compensators (STATCOMs), and electrical controls.

“Grid operators in many parts of the world face challenges in maintaining a reliable and stable power supply,” said Andrew Crosby, Solutions Integration Manager, Siemens Energy. “When used in combination, synchronous condensers and BESS benefit the whole system by encompassing voltage support, reactive power, inertia, short circuit power, MW dispatch/operating resource, frequency support, and energy storage.”

Grid stability has never been more important. The loss of steam generators and gas turbines that once dominated the power generation network has led to a shortage of rotating inertia across the system. Consequently, frequency stabilization is essential to replace the inertia provided by rotating assets. Inertia helps balance generation and consumption levels. A drop in frequency occurs if a power plant or wind farm goes offline, for example. Failure to compensate can lead to load shedding and even blackouts.

Voltage stability is also critically important. System operators must maintain close control over voltage levels by balancing real power with reactive power. Real power is what turns on the lights, while reactive power is a necessary component of the electrical power network that flows back and forth between the source and the load without performing useful work. It is measured in volt-ampere reactive (VAR). Dynamic VAR controls are often deployed to help operators ride out voltage events.

And then there is short-circuit power. The grid needs it to maintain voltage reliability and stability during faults such as lightning strikes or equipment failures.

Grid stability services are now in high demand as a response to the onslaught of renewable capacity additions (585 GW of worldwide in 2024) and the AI boom that needs high-powered data centers in the hundreds.

“Regulatory pressure and the introduction of more attractive compensation models are further drivers for the adoption of grid stability services,” said Crosby. “Grid stability services often need incentives, or they can be difficult to finance and deploy.”

In response to this pressing need, a series of grid stabilization solutions has entered the market. Some are brand new, while others are mature technologies that are applicable to the modern grid. Here are a few of the options from Siemens Energy:

This advanced STATCOM features modular multilevel converter (MMC) technology for voltage regulation and reactive power compensation with rapid response.

Unified Power Flow Controller (UPFC) Plus: 

Offers dynamic load flow control for grid stabilization and resilience. Operators can use it to control load flow in alternating-current grids in milliseconds and facilitate the increasing integration of renewable energy

Provide short-circuit power, inertia, and reactive power for dynamic loads. They are available in various sizes, up to 1,300 MVA, at full speed. They consist of a horizontal synchronous generator connected to the high-voltage transmission network through a step-up transformer. The unit is started and stopped by a frequency-controlled electric motor (pony motor) or a starting frequency converter. Once the generator has reached operating synchronous speed, it synchronizes with the transmission network, and the machine operates as a motor providing reactive and short-circuit power to the transmission network. These units are available with and without flywheels, which can supply much-needed inertia and improve frequency nadir.

As an alternative to purchasing equipment to stabilize the grid, it is increasingly popular to convert existing turbogenerators into synchronous condensers. This represents a way to speed deployment and reduce costs. It can be done in several ways. A basic rotating grid stabilizer conversion (RGS) can be performed if the unit is decommissioned. The power turbine is disconnected and removed, allowing the generator to be converted into a synchronous condenser that supplies much-needed inertia to grids with an abundance of renewable power sources. To add frequency stabilization and added inertia, generators can be extended with additional rotating mass from a flywheel.

For those with unutilized or partially utilized gas or steam turbines, a synchro-self-shifting (SSS) clutch can be installed between the generator and the turbine. Known as a hybrid RGS, it is a good way to improve grid performance while adding flexibility and potentially generating another revenue source. Those wishing to increase inertia even more can include a flywheel coupled to the existing shaft line—a hybrid RGS results in dual-mode operation. The plant can alternate between power generation mode and grid stabilization mode.

“You can add a mechanical clutch between the turbine and generator in order to decouple the generator and use it as a synchronous condenser,” said Crosby.

In a remote area of Queensland, Australia, a Siemens Energy SGT5-2000E gas turbine-based combined-cycle plant is being upgraded to function as a peaking unit, providing backup power to the grid in case of disturbances elsewhere. As part of this RGS conversion, Siemens Energy is implementing minor adjustments to the power train, including a tapered design to accommodate a clutch from SSS Gears Ltd. between the gas turbine and the generator shaft. Replacing the intermediate shaft of the gas turbine with an SSS clutch allows for an instantaneous switch from power generation to synchronous condenser mode.

When in synchronous condenser mode, the RGS unit can provide rotating inertia and short-circuit power without needing to generate power. Its short-circuit contribution will range from 350 to 400 MVA, and its electrical inertia will be approximately 250 MW seconds (MW.s). In power generation mode, it can deliver about 1,000 MW.s. Dual-mode operation allows the facility to remain viable despite reduced revenue from power generation, as it will receive compensation from the state for ancillary services.

In the United Kingdom, power generator Drax is constructing a peaking plant using Siemens Energy SGT-4000F gas turbines with the RGS upgrade.

“These generators will provide both power and inertia services that can be decoupled,” said Crosby. “They will have optional hydrogen co-firing and will receive additional revenue from the grid operator for synchronous condensing services.”

At Highview Power in the United Kingdom, an air turbine will have a clutch and flywheel installed as part of a long-duration energy storage application. This 2.5 GWh liquefied air energy storage plant is due online by 2030.

“Air is stored when needed and then put through a turbine for power,” said Crosby. “When energy from the storage plant isn’t needed, the clutch is used to decouple the turbine and provide stability services.”

The final example is the Shannonbridge plant in Ireland, which will soon become the world’s first hybrid synchronous condenser, flywheel, and battery energy storage plant. It will provide +/-70 MVAR of reactive power, 500 MVA of short-circuit power, and 4,000 MW of inertia, along with 70 MW (140 MWh) of BESS. All of this is supported by several skids of MV switchgear, inverters, transformers, and communication devices, as well as hybrid controls to manage everything.

“When used in combination, synchronous condensers and BESS benefit the whole system by encompassing voltage support, reactive power, inertia, short circuit power, MW dispatch/operating resource, frequency support, and energy storage,” said Crosby. “There are commercial advantages in sharing the same grid connection point, site infrastructure, media supplies, redundant auxiliaries, and control and protection equipment.” 

Drew Robb is a freelance writer specializing in engineering and technology. Email Drew at drew@robbeditorial.com.

Grid operators face challenges in maintaining reliable power supply due to the transition from coal and gas plants to renewable energy sources. This shift necessitates addressing grid stability, voltage control, short circuit power, and frequency control. A hybrid grid approach, incorporating technologies like synchronous condensers, battery energy storage systems, and STATCOMs, is essential. Converting existing assets, such as turbogenerators, into synchronous condensers can reduce costs and enhance grid stability. Examples from Australia, the UK, and Ireland illustrate successful implementations of these technologies to improve grid resilience and flexibility.

Flexible solutions such as synchronous condensers and battery storage stabilize power supply and address critical issues like inertia, voltage, and short-circuit power.

Hybrid Grid Technology Steps Up for 21st Century Grid Stability and Power Generation

David Ransom has over 25 years of experience in the turbomachinery industry. He joined Siemens Energy as Head of Technology and Systems in November 2019. His current responsibilities include leadership development; leading and managing technology development; support for operations and services; leading root cause analyses; developing innovative and disruptive technologies; and R&D strategy and planning. Ransom has experience in several technical disciplines, including rotordynamics, thermodynamics, structural dynamics, acoustics, machine design, prototype development and testing and leading people and projects through all phases of a project, from proposal to finished product.

Turbomachinery: What are the biggest challenges manufacturers face when implementing next-generation compressor systems?

 For industrial applications, the modern turbocompressor must be both custom engineered (no two applications are alike) and low-cost. This means that robustness and reliability must be built into the design and manufacturing process of each machine, and into each technology applied within the machine (aerodynamic components, rotating components, mechanical elements, etc.).

When we start to look at next-generation systems, which either require the application of existing technology to vastly different operating conditions/systems (i.e. multiple starts/stops per day for green energy applications), or the development of new technology for new applications (i.e. large volume of hydrogen compression), it is challenging to demonstrate robustness and reliability without multiple demonstration projects. And the challenge is compounded by the need to maintain the relatively low cost of the modern turbocompressor. This challenge then becomes an opportunity for innovation in design, continuously balancing the goals of technology advancement with robustness of the end product.

Cost is another important factor whenever you are introducing a new technology or product. On this front, we work closely with customers to understand their unique needs. Making sure that compression packages are optimized for specific boundary conditions is key to providing a solution that delivers the lowest total cost of ownership over the life of the facility.

At Siemens Energy, we have gained a reputation for staying ahead of industry trends and developing new compressor products before the market needs them. A good example is our hydrogen turbocompressors. Siemens Energy’s early investments in hydrogen compression technologies, like our advanced rotor platform, which is designed for low mole weight gases, is supporting decarbonization use cases today that otherwise might not be possible using traditional compressor designs.

TM:What role do compressors play in the hydrogen economy, and how are they being adapted for hydrogen applications?

 Compression of hydrogen gas isn’t new. It’s been a vital part of the refining industry for many decades. But as the market has shifted and new hydrogen applications have emerged, such as high-volume electrolysis plants and H2 pipelines, the demands placed on compression packages have also evolved, necessitating new designs.

Most technology development efforts we see today are in response to two main areas: one, lowering the cost and improving the capabilities of turbo-compressors; and two, increasing the service interval and capability of reciprocating machines for processing dry hydrogen.

At Siemens Energy, we’re using our single-piece advanced rotor technology (

) to overcome tip speed limitations often imposed by the conventional shrink fit or even tie-bolt-type rotor construction on turbocompressors. This has allowed us to increase the power density of the machine, leading to fewer compressor stages to achieve final delivery pressures. The technology is an excellent example of how we approach innovation — leveraging modern manufacturing methods with robust and time-proven machine design to enable new compressor capabilities with very little added risk to the end user.

TM: What non-traditional applications for industrial compressor technology have emerged in recent years?

 When it comes to non-traditional applications, the growing electrification of industrial process heat comes to mind. On the lower end of the temperature spectrum, the application of heat pumps to industrial processes is still new and in development. Even though they have long been used in residential and commercial buildings, the use of heat pumps in industrial processes is both interesting and challenging. Interesting because it’s one of the decarb opportunities that can demonstrate an attractive business case, even without considering any costs associated with carbon emissions. And challenging because, like all other large industrial applications, each system has custom requirements for operating conditions, available footprint, operating fluids permitted, etc.

Since the performance benefits of heat pumps aren’t attractive for higher-temperature process heat applications, direct heating with a simpler and more power-dense machine becomes the preferred solution. To address this need, Siemens Energy has developed a novel class of turbomachinery known as the Turbo Heater (

David Ransom, with over 25 years in the turbomachinery industry, discusses the challenges and innovations in next-generation compressor systems, particularly for hydrogen applications. He emphasizes the need for custom engineering, cost-effectiveness, and reliability in modern turbocompressors. Siemens Energy is leveraging advanced rotor technology to enhance power density and efficiency. Non-traditional applications like industrial heat pumps and Turbo Heaters are emerging, driven by decarbonization efforts. Modern engineering tools, including computer-aided engineering and machine learning, are crucial for developing new designs, while maintenance teams must adapt to advanced systems.

Next-generation compressor systems must balance custom engineering, cost-effectiveness, and reliability, particularly for hydrogen applications. Siemens Energy’s advanced rotor technology boosts power density, reduces stages, and improves efficiency. With rising demand in decarbonization-driven applications, modern engineering tools and adaptive maintenance are vital for hydrogen compression and high-speed turbomachinery

Adam Neil

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