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Podcasts

Klaus Brun and Rainer Kurz discuss root-cause analysis—what it is, its methodologies, and why it’s so important to managing turbomachines.

TurboTime Podcast: Root Cause Analysis with the Myth Busters 

Myth Busters Klaus Brun and Rainer Kurz join the TurboTime podcast to chat about additive manufacturing. They dive into its history in the industry, its advantages as a viable technology, its limitations, and new advancements that could drive the technology further.

Brun explained: “About 40 years ago, additive manufacturing technology started coming out based on using materials such as polymers and resins that were heated up and layered on top of each other using some kind of robotic arm or plotter that in the 3D space. It wasn’t all that relative from a turbomachinery perspective at the time because yes, you could use that to make a mold for a cast, but other than that, it wasn’t realistic. About 20 years ago, we started seeing additive manufacturing using metals. There are a number of techniques, but the most popular ones are direct metal sintering or selective metal-laser sintering—these techniques are when you have a layer of metal and a heat source, and you put the heat source on the powder-metal layer to create a 3D geometry in 3D space. That technique has developed over the last 20 years—it came out with lots and lots of promises, some of which held up while other promises didn't hold up."

“From a turbomachinery perspective, there are many parts in a compressor, for example, or a gas or steam turbine, that are relatively standard pieces; you would probably not use additive manufacturing for those pieces because they're always the same, so you would cast them or quickly machine them. But then there are certain pieces that are either very intricate in geometry, so they require many smaller pieces to be put together or that are customized like impellers for centrifugal compressors. So here, theoretically, additive manufacturing should have an advantage because additive manufacturing provides you with the potential to build customer parts.” 

What’s the history of additive manufacturing, how is it used to manufacture turbomachines, and does it really have a future in the turbo industry? Find out more from the Myth Busters in this episode of the TurboTime Podcast. 

TurboTime Podcast: Additive Manufacturing with the Myth Busters 

In this episode of the TurboTime podcast, we talk about geothermal power generation with Joseph Bonafin, sales and business development manager at Turboden, a part of Mitsubishi Heavy Industries Group. We dive into the history of geothermal power, how it’s grown over the past 20 - 25 years, and how it fits into the decarbonization journey. We also look at what’s next for geothermal power generation.

Bonafin said there are several innovations in the pipeline for Turboden and geothermal power: “The integration of organic Rankine cycle (ORC) technology with other innovative geothermal technologies, such as enhanced geothermal systems (EGS), closed-loop geothermal systems, and lithium extraction from geothermal brine, can improve efficiency, sustainability, and economic viability.

“EGS generates electricity from hot dry rock locations, enhancing the heat exchange by circulating clean water through artificially engineered fractures. This efficiently converts moderate temperature into electricity, expanding the geographic applicability of ORC projects to previously inaccessible heat sources, especially for large-scale projects.

“Closed-loop geothermal systems provide environmentally friendly alternatives by creating a thermosyphon effect by drilling multiple lateral wells underground. Integrating ORC with closed-loop systems minimizes the environmental impact and reduces water consumption,” he continued.

“Lithium extraction from geothermal brine, crucial for electric batteries, is a sustainable source. ORC technology works as a cooler for the lithium extraction process in the shared infrastructure, contributing to a more economically viable and environmentally friendly process. Sale of electricity is added on top to the additional revenue stream coming from lithium extraction, promoting a cleaner and more profitable energy supply chain.

“In summary, the amalgamation of ORC technology with EGS, closed-loop systems, and lithium extraction from geothermal brine creates a holistic approach to geothermal energy production. This synergy enhances diverse resource utilization, promotes environmental sustainability, and contributes to the production of rare materials required for emerging technologies. This integrated approach underscores geothermal energy's potential in a sustainable and diversified global energy portfolio.”

Joseph Bonafin, sales and business development manager at Turboden, a part of Mitsubishi Heavy Industries Group, joins the TurboTime podcast to discuss geothermal power generation.  

TurboTime Podcast: Geothermal Power Generation with Turboden

Myth Busters Klaus Brun and Rainer Kurz join the TurboTime podcast to talk about turbomachinery factory and field testing—why are turbomachines tested, what’s standard, what’s extra, are the costs really worth it, uncertainty versus accuracy testing, different types of compressor-performance tests, how to test a gas and a steam turbine, and when is a full-string test necessary?

Brun explained: “When you make a machine of any kind, before delivering it to a customer, you want to make sure it actually functions, so standard tests are performed and then there are additional tests that some customers may require. Complex turbomachines—compressors, gas turbines, steam turbines, and even pumps—require some kind of factory testing to make sure the machine meets the basic functionality, it doesn't fly apart, and it performs at a certain level. From there, it gets a little more complicated, as each machine is different. For example, a gas turbine performance test can be performed in the factory or the field. In the factory, a prescribed test by API 616 could be used.

“A field test is a fundamentally different test where the machine is already installed, commissioned, started up, and sent to some engineers or technicians in the field to test under the conditions that may not necessarily be identical to the conditions that the machine was originally designed for or contractually agreed to or under factory testing conditions, so it's a more challenging test.”

In this episode of the TurboTime podcast, Klaus Brun and Rainer Kurz discuss turbomachinery factory and field testing—what they are good for, cost, and more. 

TurboTime Podcast: Factory and Field Testing with the Myth Busters

During this episode of the TurboTime podcast, we discuss digital ecosystems with Jim Nyenhuis, the Performance Consultant at Emerson’s Power and Water Solutions Business. We focus on software, including AI-based software, detection and monitoring technologies, software’s influence on a turbomachine’s life, as well as cybersecurity and potential risks that power plants are exposed to.

Q: How does a digital ecosystem improve operational efficiency, plant safety, etc.?

 Digital technologies allow us to address all those issues. We work with customers to understand what operational efficiency means to them based on their objectives. Plant safety is without question built into everything we do. We want to understand and leverage what the underlying technology can tell us and let that information feed up through the digital ecosystem—how do we understand what's working well at the plant level, how do we identify if there are control problems or if individual pieces of equipment are having issues? A lot of that information is lying within the automation infrastructure, and I don't think we've leveraged that to the degree we want to. We find many customers do not understand the performance characteristics of their closed-loop controls or areas to drive additional improvement, efficiencies, etc.

Performance and control management is another big area that we look at. Our information, such as the automation system, will oftentimes track what operators are doing within the system. In the past, that information was stored in text-based logs, but there's a lot of valuable information stored in those log files that if we expose that information, we can understand how operators are interfacing with the system during different periods of operation, be it startup, shut down, various operating modes, etc., and based on that we can determine where operators are spending a lot of their time.

In this episode of the TurboTime podcast, we talk about digital ecosystems, including AI-based software, cybersecurity, and more with Jim Nyenhuis from Emerson. 

TurboTime Podcast: Software & Cybersecurity with Emerson 

In this episode of the TurboTime podcast, the Myth Busters, Klaus Brun, the Director of R&D at Elliott Group, and Rainer Kurz, a recent retiree from Manager of Gas Compressor Engineering at Solar Turbines, discuss turbomachinery codes and standards. The two differentiate codes versus standards, which are important for turbomachinery, and what to do if an operator or manufacturer disagrees with a standard.

Brun broke down the four components: standards, codes, specifications, and guidelines. “A standard is somewhat of a generic requirement; you can almost call it the minimum requirement that industry associations agree on for a piece of equipment,” he said. “There's a lot of gray area between here. Next are specifications—they are often related to a specific customer—one of the major oil companies may have its own specifications, and they often tie in standards. For example, let's say Shell or Chevron has their own machinery specification, and they may refer to standards, such as American Petroleum Institute (API) 616 or the American Society of Mechanical Engineers (ASME) standards, material standards, etc. And then you get into things like codes, where the gray area becomes even bigger. But codes traditionally refer to something a little stricter. These can be test codes, where there is a process that you have to follow, and you don't deviate from this process. There are codes related to OSHA requirements or legal requirements. Codes tend to be a little more rigid, more relevant, and more richly followed. Finally, there are industry guidelines from the API and other professional societies. They give advice and guidance on how to handle testing processes, design, etc.”

Kurz stressed that standards are not legally enforceable unless included in a purchasing agreement: “What makes a standard enforceable is if a customer in the purchase specifications says ‘Thou shalt follow such and such API requirement or these ASME standards.’ And then it becomes part of the contract and enforceable” he said.

Kurz also pointed out that one purpose of codes and standards is for system integration. “If you build a refinery, there's one manufacturer who builds the compressor, then there are people who build the pressure vessels, others who build the piping, and maybe the steam turbines. So, there are a lot of different parties involved that have to come together. And one thing that these codes and standards do is create a reasonable definition of the interfaces. At the end of the day, somebody needs to integrate all that equipment.”

The Myth Busters, Klaus Brun and Rainer Kurz, discuss turbomachinery codes and standards on the TurboTime podcast. 

TurboTime Podcast: Turbomachinery Codes and Standards with Myth Busters

In this episode of the TurboTime podcast, Myth Busters Klaus Brun and Rainer Kurz close out our two-part discussion on compressor drivers. Brun and Kurz talk about gearboxes—their advantages and disadvantages, and why are engineers afraid of them. They also discuss dual-drive compressors and compressors with both drivers and generators in a string—when are they used, and where they fit best.

In Part II of our TurboTime podcast on compressor drivers, the Myth Busters discuss gearboxes and dual-drive compressors.

TurboTime Podcast: Part II: Gearboxes + Dual Drives

In our two-part podcast episode on compressor drivers, the Myth Busters give a detailed account of various drivers, including gas turbines, steam turbines, and electric motors. Klaus Brun and Rainer Kurz talk about the general features of each driver, the advantages and disadvantages of each, and how to match a compressor with a driver when factoring in fuel sources, power, speed, the type of compressor, and other determining factors. They also dive a little into gearboxes and why they are, at times, needed.

“First, we need to look at what is the compressor?” Brun said. “A compressor is used to compress the gas; it is a machine that requires some kind of driver that puts energy into the compressor. So, you need a device that the compressor wants to run at a certain speed and certain power. There has to be some kind of input device that can be divided by application, fuel source, power source, and so on. So, let's say you have a centrifugal compressor—you probably want something that spins, right? An electric motor drive, a gas turbine, a steam turbine …if you're driving a reciprocating compressor, you would like something like an engine that also reciprocates because that tends to match a little better. But you can also use an electric motor.

“Then the question becomes—before you get into the technical stuff—what fuel is available? Let's say you are running a centrifugal compressor on a natural gas pipeline. Then the obvious choice is a device that can burn natural gas as a fuel, and that's typically a gas turbine. Similarly, if you're in a refinery or some kind of petrochemical application where you have a lot of steam available because you have boilers and other processes that require steam, then you would select a steam turbine as your driver. In many cases, because electricity is available or other restrictions keep you from running a gas or steam turbine, you would choose an electric motor drive, which presents advantages and disadvantages. But you have to remember that an electric motor drive does require quite a bit of electric power.”

In this episode of the TurboTime podcast, the Myth Busters break down the types of compressor drivers—their advantages and disadvantages, optimal applications, and more.

TurboTime Podcast: Part I: Myth Busters Talk Compressor Drivers

In this episode of the TurboTime podcast, Joshua Kohn, the R&D Manager of Power Systems at Camfil, talks about the effects of poorly designed air filters on modern-day turbines and compressors. He also discusses their impact on various processes and capabilities—such as sealing, water handling, and pressure drops—how they work preventatively to reduce or avoid equipment downtime, and the various advantages and disadvantages of static versus pulse filters.

Kohn said that when most people think about air filters, they think of them as a way to stop particles in the outside air from entering the turbine or compressor. “But it's also important that air filters are well-sealed and water-tight,” he said. “After all, a lot of gas turbines don't just run in dry laboratory conditions inside buildings, but turbines are being run all over the world—coastal sites, dusty environments, etc. And a lot of these outdoor turbines are exposed to water on a regular basis, so it's really important that gas turbine air intake filters are well-sealed and that they're able to stop particles in both a dry and also a wet form.”

Kohn also discussed the new ISO standard that was released last year, ISO 29461-2:2022—it focused on answering this question, “looking into how to measure the sealing and the water handling performance of different filters, since it's so important … that you don't just stop a lot of particles when the air filter is running dry and then as soon as you have a heavy rainstorm, the filter gets soaking wet and all the particles caught in the filter leach through onto the downstream side of the filter and go into the turbine, which lead to all sorts of problems,” Kohn said. 

In this episode of the TurboTime podcast, Joshua Kohn, the R&D Manager of Power Systems at Camfil, talks about air filtration. 



TurboTime Podcast: Air Filtration with Camfil 

In this episode of the TurboTime podcast, Paul DiMascio, VP of Engineering at ProEnergy, talks about aeroderivative gas turbines—what sets them apart from other types of turbines, their repair and maintenance needs, and other points.

DiMascio kicks off the discussion by explaining what makes the aeroderivative LM6000 and LM2500 turbines unique. 

“The really great story about those turbines is they were first very successful airplane engines developed for the U.S. military for the C5 Galaxy transport," DiMascio said. "They were originally called the TF39 and then GE decided that the commercial aviation industry, specifically McDonnell Douglas and Boeing, who were building wide-body aircraft, which surprisingly looks similar to the C5 Galaxy because it's the definition of wide-body, that they needed very powerful engines. Also, they were worried about fuel economy. So, what GE did was take the TF39 and redesign it into the CF6-6. That engine was what powered the Douglas DC10—the first wide-body—and the Boeing 747.

“Those initial aircraft were growing as passengers discovered how much more comfortable they were. The number of flights went up dramatically, and the need for bigger engines and bigger aircraft occurred, so they developed the CF6-50 and the CF6-ADC2 for the larger versions of those airplanes. Now, the reason that's important is, for example, the CF6-ADC2 that powers the bigger 747 and also powers the President's Air Force One aircraft, was one of the most reliable engines available at the time, with the best fuel economy. So, over 8,500 ADC2 engines were produced by GE, and they're still in production today.

“What makes them unique is that there were other airplane engines available from other manufacturers like Rolls Royce, etc., but the advantage of the GE engines was they could convert them to land and marine—that's what the LM stands for," he continued. "GE also had divisions of its business that understood marine power plants, which were primarily steam turbines at the time, and power plants for the grid, which were also primarily steam turbines. But they understood the differences between those demands versus what an airplane engine has, and they recognized that they would need to redesign the turbine to focus on those applications.”

DiMascio also talks about the advantages and differences between an aero-turbine used as a peaker, for example, versus a turbine used in marine propulsion. 

In this episode of the TurboTime podcast, Paul DiMascio, VP of Engineering at ProEnergy, talks about aeroderivative gas turbines.

TurboTime Podcast: Aeroderivative Gas Turbines with ProEnergy

Xu Xin, President of GE Vernova Gas Power - China Services, said natural gas will help China replace coal with a scalable power supply.

The Coal-to-Gas Transition: GE Vernova Decarbonizing China with H-Class Technology

Rotating Machinery Services conducts specialty repair, maintenance, overhaul, and custom manufacturing for critical OEM and non-OEM turbomachinery infrastructure.

Arcline Purchases Rotating Machinery Services

Harbin Electric and GE Vernova delivered steam turbines, generators, and three 9HA.01 gas turbines, producing 2 GW of power to satisfy China’s decarbonization goals.

GE Vernova’s H-Class Turbines Kickstart Operation at Guangming Power Plant

The new power plant replaces the current facility and reduces natural gas consumption by 15%.

Doosan Skoda Installs Combined-Cycle Equipment at Rayong Project

With over $80 million currently invested in the Global Repair Service Center, GE Vernova plans to meet regional population growth and power demand by keeping its fleets operational.

GE Vernova Invests $20M in HA Turbine Repair at Singapore Service Center

Turbomachinery International spoke to Klaus Brun, Ph.D., the Director of Research and Development at Ebara Elliott, at Turbomachinery & Pump Symposia (TPS) 2024 in Houston. He shared insight into Elliott Group’s rebranding under Ebara Corp. and how the new entity will tackle industry challenges with an upcoming portfolio of sustainability-focused products.

“Elliott, like any other company in our industry, must follow what our customers do and what our market does. We’ve seen a significant transition in the energy industry over the last 10-15 years. We’ve seen more sustainability and more green energy, and so our products need to change with that market. That doesn’t mean we’re neglecting our current customers or the industry we’ve been serving for over 100 years, but we do have to address the changes we see in the energy industry. Our new name is Ebara Elliott Energy Co., with a specific focus on the energy market and not just on products.”

TURBO: What are the biggest challenges facing the industry?

“Everybody’s talking about decarbonization of the industry, so we’re looking at hydrogen and CO

. These are very new products that need to be developed—they currently don’t exist or are not as optimal as they should be. To meet these drastic market changes, we must develop new products and it’s not just the products, but the entire organization. As our customers change toward decarbonization and sustainability, we must change with them.”

Dr. Klaus Brun of Ebara Elliott addresses the company’s rebranding, prominent industry challenges, and upcoming products for sustainability and green energy at TPS 2024. 

Ebara Elliott Discusses Rebrand, Upcoming Projects for Industry Challenges

At TPS 2024, Klaus Brun of Ebara Elliott addresses the company’s rebranding, prominent industry challenges, and upcoming products for sustainability and green energy. 

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