coJen

GE Energy • Jenbacher gas engines • Issue 3/2009

More Power
Significant increase in type 6 engine efficiency

Southeast Asia and India

The need for more power

Lifetime Services Plus

The right service at the right time
Content
02 editorial

CEO story
03 Investing in the future

technology & product news

05 Latest development from Jenbach: J6F
07 J624 – The future has already begun
09 Type 6 engines now available in container

industry news
11 Pushing the envelope: Cogeneration in Europe
13 Smart Grid – Empowering smarter energy choices
15 Multiple-engine approach

applications and solutions

17 Promising electricity supplier for the future: Biowaste

distributors and service providers

21 News from the Champions League
23 Ultimate ambition: Maximized customer satisfaction

region special
25 Southeast Asia and India: The need for more power
33 Turning waste into energy

service
35 Investing in tailored solutions: Lifetime Services Plus
37 In top form
39 So far, so near: Connecting customers remotely in Asia
40 Faster and smarter: Digitizing field service
41 New from old: Major overhaul of Strass wastewater treatment plant

supply chain
43 The core component from Tyrol

personality story
45 An interview with Michael Wagner, Marketing Leader

47 feedback and masthead

home base
48 From the city to the mountain-top
 editorial coJen

Dear Customers
and Readers!

A great deal has changed since the last

issue of CoJen, our magazine for Jenbacher
concept for intelligent, demand-oriented elec-
tricity networks. In this issue of CoJen, we also
customers and all those interested in gas engine introduce one of our international distributors –
technology. The development of the world Clarke Energy, who has notched up impressive
economic situation has us all waiting with bated successes in fourteen years as Jenbacher
breath, and it is still not clear what the situation distributor. In the Regional Special, this time we
will be in the short term. Nevertheless, from analyze the interesting region of Southeast Asia,
the point of view of the gas engine industry, we where the expansion of the electricity grid has
are cautiously optimistic, since the business become a real driver of economic growth.
foundaments are strong and we can see that In the Service focus of the magazine we take a
worldwide demand for flexible, decentralized look at our new “Lifetime Services Plus” concept
energy solutions will continue to be high in the with active life-cycle management for our
medium to long term. customers.
We should therefore like to use this latest issue As always, we attach great importance to your
of CoJen to tell you more about interesting feedback on our magazine, which is why we are
technical developments and worldwide trends asking you please to take part in our survey. This
in the gas engine industry. A new version of the time there is also a very special prize to be won:
series 6 engines – developed in Jenbach and a weekend for two in Innsbruck, Tyrol. At this
now available in series production – offers in- juncture we should like to thank all those who
creased efficiency and power output, and hence took part in the survey in the last issue of CoJen.
greater profitability for the plant. Besides, there The winners of our Retro Radios were Jacques-
is naturally news about the J624 – the world’s Yves Bourgon of ArcelorMittal, France, and Elvinas
first 24-cylinder gas engine. Zabas of our distributors Filter in Lithuania. Finally,
Also in this issue, we examine the latest trends in on behalf of the entire editorial team, I wish you
the energy industry, and have also been fortunate an interesting read and look forward to your
enough to obtain some interesting guest con- feedback on CoJen!
tributors on the subjects of combined heat and Martina Streiter
power and “smart grid”, a particularly relevant Jenbacher Communications

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coJen CEO storyen

Investing in
the future
the current economic situation is resetting the entire world economy. many industries
face challenging times as financing issues delay numerous projects in nearly every
region. rising to this challenge is gE Energy’s Jenbacher team, which has found that
the recipe for success is really not that complex: Continuous investment in the future
is the key to emerging from this situation stronger than before.

A n unprecedented economic environment is putting pressure

on almost every industry today. Although predictions for the near
future are hard to make, GE’s Jenbacher team is convinced it is in
the right business with its gas engines. “We do not see projects
being cancelled. Postponements due to mainly financing issues is
what we currently face as a challenge,” says Prady Iyyanki, CEO
of GE’s Jenbacher gas engine business. “In the mid- to long-term,
we feel very confident that the gas engine business will continue
to grow.”

“In the mid- to long-term, we feel very

confi dent that the gas engine business will
continue to grow.”

Even if project owners and customers are facing economic pres-

sure, the need for power and decentralized highly efficient power
solutions based on gas engine technology has not disappeared.
In addition, growth assumptions for global power needs doubling
until 2030 still appear valid. “In order to come out of this current
situation stronger than before, we have taken some actions in
our business to remain competitive, build our strengths and foster
innovation,” Iyyanki says. GE’s gas engine team follows three key
initiatives in which it strongly invests: service, technology and
globalization.

“GE’s Jenbacher gas engine team

invests in three focus areas:
service, technology and globalization.”

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 JCEO story coJen

glObal SEtup fOr wOrldwidE SuCCESS.

From 2008 to 2009, the global Jenbacher
network of distributors and service providers
grew significantly from 45 to now 60 cooperat-
ing companies worldwide. Recent additions to
the network include additional distributors in
such key countries as China and Russia. “We
strengthen our global distribution network in
order to provide our customers with more local-
ized solutions, much-needed local engineering
expertise and consultancy on the technical as
well as commercial side,” Iyyanki explains.

“We strengthen our global

distribution network in order to
provide our customers with
more localized solutions.”

But the third-party network is not the only area

of growth for the Jenbacher organization. In ad-
dition, it is expanding on a global basis. “We are
just about to open a new Service hub in South
Africa that will serve the southern part of the
African continent with original Jenbacher spare
parts as well as highly experienced technicians
who can also be a valuable resource for our
distributors and service providers in the region,” campaign will provide customers with on-hand Strong cooperation with the GE Capital division
Iyyanki says. information on new service offerings, contract and financing partners with global reach has
A new service shop in Singapore is operational models and upgrade concepts. been kicked off to help customers receive much-
since last year, and recently the decision was needed funding for fundamental projects.
made to move some Jenbacher technicians into tEChnOlOgiCal innOvatiOn fOr futurE The significant investment being made in the
GE’s Kaluga Service Shop that will be built up in grOwth. In line with its strong history of innova- future will certainly pay off in the long run, allow-
Russia. “All moves aim to be closer to the custom- tion, GE’s Jenbacher team is now designing the ing GE’s gas engine business to come out of the
ers, addressing questions and issues in the local innovations for the future success of its custom- current economic situation even stronger than
language with local expertise,” Iyyanki says. ers. Just recently the new J624 engines reached before.
full commercialization. The newly released J6F
“All moves aim to be closer to version of the Jenbacher series 6 engines, com- “Our efforts in innovation
the customers, addressing mercially available since early 2009, is significantly are focusing on what
questions and issues in the local increasing output and efficiency. “Our efforts in our customers need to work
language with local expertise.” innovation are focusing on what our customers more effi ciently and achieve
need to work more efficiently and achieve better better plant economics.”
lifEtimE SErviCES frOm gE. Guiding custom- plant economics,” Iyyanki says. “Innovation is a
ers through the entire life cycle of their engines is growth tool not only for us at GE, but foremost for Until the world economy picks up again, con-
one of the key principles that the new Jenbacher our customers.” scious cost management and a strong focus
Service organization is following. “Enhanced Re- on execution on customer commitments paired
mote Service capabilities, strong global coverage “Our efforts in innovation are focusing on what with the investment in technology are how the
in terms of field technicians, and new commercial our customers need to work more efficiently Jenbacher team secures its business and best
as well as technological service offerings are and achieve better plant economics. Besides serves its customers._
designed to help our customers make the most of enhancements of our existing product lines, we
their GE equipment, benefiting plant economics are working on additional projects to expand
as well as taking a lot of workload from our end- our product portfolio, but also to enhance our
users,” Iyyanki says. The enhanced approach is service offerings,” Iyyanki says. Among these
reflected in a new marketing concept – “Lifetime enhanced offerings are financing opportunities
Services Plus” for Jenbacher gas engines. The that the team wants to create.

04
coJen technology & product news

Latest development from Jenbach:

J6F
GE’s Jenbacher team has another milestone from product
development to report in this issue of CoJen. In the wake of
the J624 24-cylinder gas engine, the latest innovation from
GE Energy’s gas engines division is referred to as the “J6F”, a
designation standing for the new, improved engine type based
on decades of experience with the tested and successful series
6 engines.

Significant power increase. For GE, the new Another technological enhancement is the new the way – as does the Jenbacher product team
Jenbacher J6F series represents an extremely generation of turbochargers, which have a higher in innovation and research in the field of energy
competitive gas engine that sets new standards pressure ratio. This makes it possible to optimize efficiency and power output. The fact that the
for engines with speeds of up to 1,500 rpm, the Miller valve timing, thus shifting the knock worldwide Jenbacher Center of Excellence
underscoring the competitiveness and techno- limit, which translates into improved combustion. for greenhouse applications is also located in
logy leadership of GE Energy’s gas engines the Netherlands shows that GE has long since
division. The remarkable feature of the J6F is a Lifelong savings. The improvements to the recognized these synergies and used them to
10% increase in power output – to 3.3 MW for the J6F series engines translate into cash for the good effect.
20-cylinder engine. The increase in electrical customer. Increased efficiency means a longtime
efficiency depends on the application, but can reduction of operating costs, and hence a reduc- Green engine, colorful fruit. Each of the
be improved by up to a whole percentage point tion in the overall cost of the electricity gener- two pilot projects for the improved J6F series –
to approximately 45%. Overall, this represents a ated, which depends mainly on the price the rose grower Baarenburg and the tomato
significant increase in engine efficiency. At the of gas. Since gas prices are expected to continue growing company of Prominent Kabel – has
same time, thanks to its optimized combustion, to rise over the next few years, this savings may installed a natural gas-fueled engine of the
the J6F also produces fewer uncombusted be particularly significant. type J612F. Together, these plants exceeded the
hydrocarbons (HC). 10,000 operating hour mark at the beginning of
High efficiency and increased 2008. Both plants are combined heat and power
A heart of steel. The new engines of the J6F power output ensure lower power stations that provide the greenhouses not only
series take advantage of the innovative techno- generation costs for customers. with electricity and heating, but also with CO2 for
logies that have already been successfully intro- fertilizing. The Prominent growers’ association,
duced with the J624. For example, the possibility Netherlands puts its trust in Jenbacher to which the tomato grower Kwekerij Kabel also
of operating the engine at a higher break means technology. The pilot customer for the J624 belongs, has already gained experience with
effective pressure of 22 bar was a decisive factor was in the Netherlands, and the two pilot plants three Jenbacher engines of the Type J616.
in increasing its efficiency. And it is here, too, that for the J6F series engines are also Dutch compa- “The J6F’s commercial launch has come at a
the value of a heart of steel becomes apparent: nies. This is not merely by chance, for when it perfect time to help horticultural companies and
Steel pistons have higher peak pressure capabil- comes to using the latest technologies for other industries support the energy efficiency
ity compared to aluminum pistons. At the same combined heat and power generation, or for standards set by the EU. The advanced technol-
time, the J6F geometry has also been optimized. CO2-fertilization for greenhouses, the Dutch lead ogy enables less power generation costs and

05
 technology & product news coJen

thus overall lower production costs,” agree Lars

van Bar, General Manager of Kwekerij Baaren-
burg, and Richard Hartensveld, General Manager
of Kwekerij de Kabel.

“The advanced technology

enables less power generation
costs and thus overall lower
production costs.”
– Lars van Bar,
General Manager Kwekerij Baarenburg, and
Richard Hartensveld, Kwekerij de Kabel

Better together – together better.

The Prominent slogan could well stand for the
successful further development of Jenbacher
products from GE: “Together we can achieve
success.” For apart from the dedication of the
Jenbacher development team, the significant in-
crease in the power output of the J6F series was
mainly thanks to close collaboration between GE
and its customers. This proximity to the customer
has made possible the continuous development
and improvement of all our products. It will
be interesting to see what the project pipeline
produces next in the service of enhanced engine
efficiency!_
–> The improved series J6F already running at the dutch rose grower Baarenburg

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coJen technology & product news

J624 – The future

has already begun!
The J624 – the world’s first commercially operated 24-cylinder gas engine – was the most
important product innovation from Jenbach in recent years. In 2007, it was presented to
the general public, and it went into operation in a Dutch pilot program in 2008. The engine
embodied the concerted effort of over half a century of experience at the forefront of gas
engine technology.

I n the first issue of CoJen, we presented the innovative J624

24-cylinder gas engine as a quantum leap in gas engine techno-
Of vine tomatoes and bouquets of roses. The first series-
produced engine was also delivered to the Netherlands. In Febru-
logy. In the next issue, we were already able to report on its ary 2009, it was dispatched to the country’s largest producer of
commissioning in a Dutch pilot project with our customer Royal cut roses, Zuurbier. The biggest order to date for Jenbacher’s
Pride Holland. most powerful gas engine was received in November 2008, when
Ever since September 2008, the first two J624s have been supply- vine tomato grower Red Harvest ordered three J624 engines.
ing the Dutch tomato greenhouse with electricity, heat and CO2 However, the J624 also represents a highly efficient, innovative
for faster plant growth. engine concept for other energy-hungry industries the world over.
What does the future hold for the flagship amongst Jenbacher
A single J624 with engines? CoJen will keep you posted._
an output of 4 MW can cover
the power needs of about
9,000 European homes, reaching Facts & figures
46% electrical efficiency. J624 – key technical data

Meanwhile, the Netherlands has already installed five J624 pilot · First 24-cylinder gas engine for commercial operation
engines, which have logged a total of 6,000 operating hours. The · Lean burn, turbocharged, mixture cooled gas engine
optimization work, which naturally has to be allowed for in any · Compact high-speed engine with 1,500 rpm
pilot scheme, has since been carried out, making the J624 ready · First fast-running gas engine in the 4 MW power range
for operation for a wide group of customers. · About 11.6 m long, 2 m wide and 2.5 m high
· Total weight: 41 metric tons
Successful start of series production. Series production · Bore x stroke: 190 mm x 220 mm
of the J624 started in November 2008 with the objective of world- · Total displacement: 150 l
wide engine commercialization. It was not by chance that the first · Fuel flexibility: natural gas and a variety of renewable or
pilot plant was located in the Netherlands. With a large number alternative gases
of greenhouses and its enthusiasm for employing the very latest · Electrical output: 4 MW
technologies, the Netherlands is one of our most important target · Electrical efficiency: approximately 45%
regions for the J624. · Overall efficiency: up to 95%

07
 technology & product news coJen

The world’s first Jenbacher J624 pilot engine

provides electricity, heat and CO2 as fertilizer for
faster plant growth.

–> In September 2008, the first J624 24-cylinder gas engine went into operation for the dutch pilot customer Royal Pride Holland

08
coJen technology & product news

Another tailored customer

solution from Jenbach:

Type 6 engines now

available in container
The Komi Republic, an autonomous republic in Russia, lies in a sparsely inhabited region of taiga
and tundra. Although it is rich in natural resources such as petroleum and natural gas, the region’s
remote villages and industries often experience problems with local power and heat supply. For
distant parts of the world like this, GE has developed a modular container system that allows
Jenbacher gas engines to be delivered and assembled in a very short time period, even under
challenging conditions. Since the beginning of 2009, this successful container concept has been
available for the powerful type 6 gas engines, too.

T he idea of delivering a gas engine as a

modular container solution ready for installation
is nothing new in itself. GE’s Jenbacher type 2, 3
and 4 gas engines have been installed like this
for years. What is new, however, is that since
the beginning of 2009, the Jenbacher team has
been able to deliver its type 6 gas engines (out-
put 2 to 4 MW) all over the world as container
systems.

“The decisive factor in the decision to realize such

a technically demanding modular concept was
the request from a customer from Komi, Russia”,
says Martin Widner, Application Engineer at GE.
This was the impetus for the development of the
new “jumbo container”. Since the marsh forests
of the tundra are readily accessible only for a
few months in the winter and temperatures of
around minus 40 degrees Celsius are normal at
this time of year, a solution had to be found that
would allow plants to be built quickly and safely.

Customer success through innovation

and teamwork. In close cooperation with
Power Solutions, sales provider for Jenbacher
gas engines in Russia, a suitable associate for
the development of a modular container system
–> Since beginning of 2009, Jenbacher type 6 engines are available as READY-FOR-INSTALLATION container solutions for the powerful type 6 engines was sought.

09
 technology & product news coJen

Reliable energy supply for remote areas.

–> Even under challenging conditions, Jenbacher gas engines can be delivered and assembled in a very short time period, thanks to the modular container system

“Together, we succeeded More security for financing. When customers decide to

in building a standardized container buy a Jenbacher modular container system, they receive a com-
that combines excellent plete solution from one source – from production and assembly
transport stability and ready access to service and maintenance. The ability to rapidly disassemble
for maintenance work.” a container plant and reuse it for other projects represents ad-
ditional security for financing. Financing institutions are more will-
The issue was that up to 40 metric tons of lifting weight had to be ing to invest in mobile plants, especially in economically difficult
safely transported – a considerable strain on the container. times, and this makes it easier for customers to purchase urgently
GE therefore decided to enter into a collaborative agreement with needed energy systems.
a leading Austrian construction company that specializes in the
development of largescale containers in light-weight design. A complete power plant unit
“Together, we succeeded in building a standardized container can be delivered in six trucks and
that combines excellent transport stability and ready access for completely assembled in
maintenance work. That has never been achieved before”, just a few days.
continues Martin Widner. The customer from Komi can now
completely cover its own energy needs and also dependably In addition to conventional credit financing, a wide variety of leas-
supply the surrounding villages in the region with power and ing possibilities are tailored to the customer’s needs. Finally modu-
heat. lar container systems are far easier to insure than, for example,
plants assembled in halls, as they have a clearly definable value at
Short delivery times and minimal preparatory any moment. Customers can feel an enhanced element of security
construction. With the modular container solution for type when purchasing a container system._
6 engines, a complete power plant unit can be delivered in six
trucks and completely assembled in just a few days. A base plate
suitable for the weight and size of the plant and the gas supply
are the only requirements the future plant operator must meet. A
complete water, oil and ventilation system are already integrated
in the container system. There are absolutely no tedious approval
processes for the construction of an engine room.

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coJen industry news

Pushing the envelope:

Cogeneration in Europe
Today, 11% of Europe’s electricity is supplied through cogeneration plants. There are several
industrial sectors where cogeneration is an integral part of the modern process: chemicals,
paper making and oil refining are three of the most visible. These industrial processes demand
a high heat load, and electricity can be generated as a by-product either for use on-site or for
export to the grid. In northern Europe, the significant domestic heat loads of modern cities have
encouraged district heating schemes, which typically now are also cogeneration applications.
However, the vast majority of cogeneration plants are small, with generating capacity under
10 MW. Schools, hospitals, universities, farms, commercial buildings and sports complexes are
all potential applications for cogeneration.
A story by Fiona Riddoch, Managing Director COGEN Europe

Y et, the use of cogeneration as an efficiency

measure for the joint production of heat and
benefits to the European Union. However, mem-
ber state governments must show leadership, if
efficiently. But a new cogeneration operator has
to take on additional risks over and above his
power is still not a widely discussed option in the this advantage is to be achieved. Cogeneration core business requirement for energy use. In this
energy policy of European Union member states. today needs a supportive policy environment, if environment the role of policy is crucial. It signals
Decision makers may have little information the sector is to expand. While the logic of using to investors that there is structure to the risk they
about cogeneration, and the public at large (out- energy as efficiently as possible is clear, the eco- are undertaking and that they will be compen-
side a few specific member states) are not really nomics of today’s energy sector do not provide sated for taking that risk on behalf of society.
aware of the technology. Cogeneration gets very adequate returns to ensure cogeneration inves-
few column inches in the reports on energy news tors a financial return for their efficiency. While THE ADVANTAGES OF COGENERATION.
and climate change and is hardly mentioned in in a fully functioning, perfect, free marketplace Europe has a lot to gain from the wider use of
member state energy debates. efficient cogeneration would be competitive, cogeneration. Through its high energy efficiency,
today’s energy sector is far from perfect. the technology cuts down total fuel demand
EUROPEAN ENERGY POLICY. The European compared to the separate production of electric-
Union has three pillars to its energy policy: With cogeneration there is ity and heat. Through the reduction in primary
Security of supply, climate change abatement clear and immediate benefit to energy use, and the higher efficiency, cogenera-
and economic sustainability. In 2004, it adopted society as a whole from tion reduces CO2-emissions, and as a mature
a Cogeneration Directive, which recognized that using fuel more efficiently. available technology today it is one of the most
the potential positive impact of cogeneration immediate solutions, which we have available
on security of supply and energy efficiency was The lack of internalization of the externalities of right now. Additionally, by its distributed nature,
such that the EU would seek to promote the wid- energy costs distorts the sector for cogeneration it reduces electrical grid losses and creates local
est possible adoption of cogeneration. Despite as do incomplete liberalization and the several employment. A cogeneration plant is compa-
good beginnings the legislation has made only subsidies (direct or indirect) on energy, which still rable in size to the boiler technology it replaces.
slow progress into active member state policy, exist in member states. All these things mean It can cohabit well with domestic or commercial
and it is only now in 2009 that the EU can really that the return on what is a wise investment organizations, and its effect is fuel independent.
claim to have completed the legislative process for society is lower than many investors will
and to be starting fully on implementation of accept and carries a sobering level of risk. With INCREASING CAPACITY. The member states of
the Directive. Full and robust implementation of cogeneration there is clear and immediate ben- the European Union are currently assessing just
the Directive will bring large energy efficiency efit to society as a whole from using fuel more how big the potential for cogeneration is. As part

11
 industry news coJen

of their responsibilities under the Cogeneration Directive member

states will submit their own estimates of the cogeneration poten-
tial in their country. Early results are interesting. Every member
state, which has reported, shows potential growth. Several, Through the reduction in primary
including Germany, targeted or have shown that a doubling of
the current capacity is possible, bringing cogeneration in Europe energy use and higher
to 22% of electricity supply. However, there is reason to believe
that more still could be achieved. The potentials study in Germany efficiency, cogeneration reduces
showed that there is economic potential for cogeneration to
supply over 50% of Germany’s electricity. If there was the political CO2-emissions.
will to do this, there is no technical impediment. The Netherlands,
Finland and Denmark already generate over 40% of their electric-
ity from cogeneration.

Cogeneration technology helps to realize

the European Union’s energy targets:
security of supply, climate change abatement
and economic sustainability.

INVESTMENTS PAY OFF. The benefits to European citizens of full

expansion of cogeneration are a low risk path to short and medium
term benefits in security of supply, climate change reduction,
employment and their economies. Investment in cogeneration
makes good social and economic sense._

COGEN Europe:

COGEN Europe works with the European Union Institutions and

promotes the interests of the cogeneration sector within the
European legislative process. The Association has a broad mem-
bership base and represents both the manufacturers of cogen-
eration equipment and the users of that equipment and most of
the supply and contract chain in between. Based in Brussels, the
association was founded in 1999 and was one of the main actors
in shaping and in forming the Cogeneration Directive (2004/08/
EC), which provides the main policy framework for cogeneration
in European Union law. COGEN Europe members are active par-
ticipants in the work of the association and collectively aim to
ensure that the interests of the sector are understood and taken
into account in all aspects of the legislative process that effect it.

Author

Fiona Riddoch
Managing Director COGEN Europe

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coJen industry news

Empowering smarter energy choices now:

Smart Grid
Imagine a world powered by clean energy, a world where consumers are empowered to save
energy and money, and a world where plug-in electric vehicles are commonplace. All of these
scenarios contribute to reducing our dependence on foreign fuels, slashing carbon emissions,
and improving energy security. This is a more sustainable world — a world made possible by a
“smarter grid”.
A story by Bob Gilligan, Vice President GE Energy Transmission & Distribution

B ut why now? Currently, world energy consumption is predicted

to triple by 2050 worldwide. Power outages and interruptions cost
DOING MORE WITH LESS. With world energy consumption fore-
casted to triple by 2050, we need to find a way to do more with
the U.S. economy $100 billion annually. The U.S. spend $200,000 less – and quickly. Smart grid technologies can help us get there
per minute, or $13 million an hour, on foreign fuels, and are produc- through increased energy efficiencies and better utilization of our
ing less than 10% of energy domestically from renewable sources. existing electrical infrastructure. What most people don’t know
Moreover, increasingly overburdened electrical infrastructure is is that there’s inherent waste in the way our power is currently
quickly aging, undergoing little investment in 25 years. delivered. Without intelligent devices sensing how much voltage
consumers need, utilities will often deliver too much.
Today, we operate in a 21st century society, built on a 19th century Smart grid, on the other hand, delivers just what’s needed. If
electrical infrastructure, which functions with very little intelligence. installed on 10% of the distribution feeders in the U.S., GE’s grid
It might be surprising to learn that utilities typically hear about efficiency technology (i.e. GE’s Coordinated Volt-VAr Control) is
power outages only through consumer calls. The “smart” grid, designed to reduce electricity consumption by approximately
however, will reflect the way we live today. 9.3 billion kWh per year, avoiding annual CO2-emissions equivalent
to the emissions of 1.1 million cars on U.S. roads.
THE ENERGY INTERNET. Simply put, the smart grid marries IT with
our current electrical infrastructure, helping us support our 21st The smart grid is essentially
century energy needs. The smart grid is essentially an “energy in- an energy internet, delivering real-time
ternet,” delivering real-time information and knowledge – empow- information and knowledge.
ering smarter energy choices and delivering significant benefits:
RETHINK AND REDUCE - EMPOWERING CONSUMERS TO
• Optimizing renewable energy sources and enabling broader MANAGE ENERGY USAGE AND SAVE MONEY. Today, most con-
penetration. sumers are in the dark when it comes to energy consumption and
• Empowering consumers to manage their energy usage and costs. Yet, with electricity rates rising, consumers might be com-
save money without compromising their lifestyle. forted to know that smart energy tools – such as smart meters
• Delivering increased energy efficiencies and decreased carbon and home energy panels – provide real-time information to help
emissions. manage energy usage and save money.
• Increasing power reliability and operational efficiencies, deliver- It’s a fact! The utility’s cost of producing electricity varies through-
ing greater productivity. out the day. Yet the majority of residential electricity customers

13
 industry news coJen

It might be surprising to learn that utilities typically hear

about power outages only through consumer calls.

pay one set price – all day long. Smart meter tive energy sources are integrated into the senses faults and operates controls to isolate
technologies and demand response programs power system, further deployments will not problems in seconds. Smart meters will also
can change that through a feature called “time be as simple as just “plugging them in”. One of help pinpoint exactly which customers are being
of use” pricing, a method by which consumers the greatest challenges with renewables – like impacted.
pay lower prices for electrical power during off- wind and solar – is that their power output is
peak periods. inherently variable. Smart grid technologies can “Smart grid” will help turn our greatest energy
help manage the variability of wind and solar to challenges into lasting solutions. Empower-
Smart energy tools help alleviate reliability issues caused by power ing consumers with choice and control will
provide real-time information fluctuations. make them part of the solution. Technological
to help manage Automated demand response technologies will investments can make the grid more capable
energy usage and save money. act as a lever that utilities can pull to help lower of integrating renewable energy or “at-home”
demand in the event there is a gap in renew- generation, and improved efficiency will help us
Empowering consumers with this knowledge can able power generation – for instance, if the wind do more with less._
help save them money by encouraging off-peak stops blowing. To address such contingencies,
usage of higher consumption devices, like wash- a utility may incentivize consumers to opt into
ers, dryers or air conditioners. In addition to put- programs that allow certain devices to be
ting consumers in control of their energy destiny, temporarily switched off during peak times. In
these technologies will help utilities manage peak the future, storage technologies could also help
demand from the source side. In a yearlong study utilities manage the short term imbalances in
by the U.S. Department of Energy, smart grid cus- the supply and demand of energy.
tomers reduced peak consumption by up to 15%,
and overall consumption by up to 10%. KEEPING YOUR LIGHTS ON JUST GOT EASIER. Author
Smart grid technologies provide real-time
FUELING THE NATION WITH CLEANER, knowledge of grid status, enabling utilities to
RENEWABLE POWER JUST GOT EASIER. prevent trouble before it occurs, or, in the event
Developing “homegrown” renewable energy of an outage, react quickly to reduce the impact. Bob Gilligan
is critical to reducing dependence on foreign Ultimately, utilities will move from “guessing” to Vice President, GE Energy,
oil. However, once significant levels of alterna- “knowing” with a technology that automatically Transmission & Distribution

14
coJen industry news

The preferred method of electricity generation for

independent power producers:

Multiple-engine
approach
In a highly competitive environment where the ability to offer flexible, low-cost, reliable and high-efficiency power can mean the difference
between winning or losing a bid for an electricity supply contract, independent power producers must explore the most mutually beneficial
options for constructing a generation facility and meeting capacity needs. The stakes increase in developing areas where demand is high and
an IPP may be the only power supplier supporting the grid.

T he world is experiencing enormous energy

challenges. Thanks in large part to strong
the equipment and method of generation IPP
companies employ is just as important to their
of the units. Utilizing the region’s natural gas
supplies as a primary fuel source to generate
economic growth and increasing populations in businesses and the utilities they support as their electricity, the generator sets support the
the world’s developing countries, global energy ability to maintain and offer it reliably. national grid and help Bangladesh to meet its
consumption is expected to double by 2030. The increasing power demand. The move was part
electric power utilities industry has been gearing High fuel efficiency, of a government initiative to reform the
up for this issue of supply and demand for quite availability and reliability country’s power sector, including through the
some time, exploring many new options to de- supplemented with flexibility development of IPPs. It also gave GE an oppor-
liver efficient, reliable electricity to its customers. are the most important tunity to showcase GE’s Jenbacher gas engines
advantages of multiple as a viable option for growing power demand
independent power producers (IPPs). gas engine plants. in rural areas, along with proven success in the
Still relatively new kids on the block, IPPs aid industrial sector.
utilities in meeting power demand by generating PROVEN TECHNOLOGY SUPPORTING LOCAL “GE’s Jenbacher gas engine technology is
the power they need to support area growth POWER NEEDS. In one of the largest orders of already well-known as a cost-effective power
and peak demand periods. Not only has the GE’s Jenbacher gas engines to date, indepen- generation system approach for the Bangladesh
existence of a third-party player introduced dent power producers Doreen Power Generation industrial sector. We have chosen Jenbacher
incentives like cost savings and performance & Systems, Ltd., and Doreen Power House & gas engines for our rural electrification projects
enhancements, but the highly competitive Technologies, Ltd., (subsidiaries of Asian Entech based on the units’ reliability and performance
nature of independent power production means Power Corp., Ltd and Saiham Power Plant Ltd, record,” said Tahzeeb Alam Siddiqui, managing
that IPPs are charged to employ, operate and respectively) purchased 28 of GE’s Jenbacher director of Asian Entech Power Corp.
maintain the very best and most efficient gene- J620 natural gas-fueled engines to support a
ration systems. major rural electrification initiative in Bangla- A QUESTION OF PROFITABILITY. Generating
Independent power producers may be privately desh. Combined, the engines generate approxi- electricity with multiple natural gas-fueled
held facilities and most often do not possess mately 81 MW of electricity at four new power engines offers the added benefit of combined
their own transmission facilities. IPPs usually plants in developing areas of the South Asian reliability and accessibility not available with a
operate within the franchised territories of host country. Three power plants were built, each single prime-mover, as well as other significant
utilities and make electric energy available with eight of GE’s JGS 620 GS-N.L. Jenbacher advantages, making this approach a highly
for sale to utilities or the general public. But, generator sets; and a fourth plant features four economical solution for IPPs.

15
 industry news coJen

–> Generating electricity with multiple gas engines offers the added benefit of combined reliability and availability

• High fuel efficiency: Using multiple en- ABBILDUNG 1: Efficiency of multiple gas IPPs high flexibility when capacity needs must
gines offers near maximum value efficiency with engine plant compared to a single PRIME- be increased. With gas engines, extending or
the combined conversion of energy. A multiple- MOVER. downsizing the plant can be done in a much
engine approach ensures that the engines are shorter time and at a lower cost as compared to
constantly running at or near their projected traditional prime-movers.
5dT[
4UUXRXT]Rh


load, which yields the highest efficiency and the

lowest possible maintenance costs. Because of • Low emissions: Natural gas is characterized
their high fuel efficiency as single engines, multi- by the lowest CO2-emission level among fossil
ple gas engines provide a rapid response to load fuel. The utilization of natural gas in gas engines
changes. In other words, if demand changes, 

!
"
# allows for particularly low emissions of SO2, NOx,
the output, or delivered electricity, can be easily ;^PS
<F and particulate matter.
adopted by switching a number of engines on or Multiple gas engines
off, keeping the combined efficiency high. Single prime-mover “Distributed power generation with multiple gas
engines provides high efficiency and maximum
• Availability and reliability: In the event the customer the advantage of a stable electric- reliability at relatively low specific costs. Our
of an outage emergency, the necessary quantity ity grid. Service maintenance also becomes a engines are characterized by a compact design
of reserve power is also relatively low when mul- more seamless process in the multiple engine and high power density, and therefore require a
tiple units are employed because one unit failure approach. Unlike plants run by one prime-mover, comparatively small footprint”, explains Martin
affects only a small sum of the total output. where a great deal of supply capacity is needed Schneider, product line manager at GE’s Jen-
for scheduled maintenance, smaller engines bacher gas engine business. “It is the combina-
“It is the combination of benefits, operating in parallel can receive scheduled tion of benefits, that makes the multiple engine
that makes the multiple engine maintenance in sequence so that less spare approach an economical and highly attractive
approach an economical and capacity and no outage time is necessary. solution for Independent Power Producers.”_
highly attractive solution for
Independent Power Producers.” • Flexibility: An added bonus is the ability
to install or remove engines quickly and alter
In fact, multiple engine plants have achieved configurations in the multiple engine approach
near 100 percent reliability ratings, which gives to satisfy changes in demand. This allows the

16
coJen applications and solutions

Promising electricity supplier for the future:

Biowaste
All over the world, consumption of energy is increasing steadily due to industrialization and population growth. More and more
countries are now looking for alternatives to fossil fuels as a means of generating power. The goals of these initiatives are usually
to protect the environment and to gain independence from foreign suppliers. Above all in agriculture and waste management, the
use of organic waste products in biogas plants is opening up undreamed-of potential for the generation of electricity and heat.
Germany, for instance, is taking a leading role in these international efforts with its renewable energy law. Numerous countries
are following this example, and biogas plants are achieving a boom never seen before.

W hat do Austrian wine growers, a Thai

palm oil producer, a U.S. dairy farm and a Paki-
on the source material. For example, a ton of
chicken manure can produce 50 m3 of biogas.
From “manure lakes” to “energy lakes”.
With 1,100 milk cows, the Norwiss dairy farm
stani biofuel producer have in common? Quite The same amount of pig manure will yield only appears quite similar to countless others in the
simply, they all produce tons of organic waste 21 m3 of biogas. “dairy state” of Wisconsin. Every day, the animal
that can be used to generate biogas. “I really residents of the farm produce an incredible
don’t like using the term ‘waste’ when we are Biogas is an especially 70,000 liters of liquid manure, which are stored
talking about residue from agricultural produc- high-value fuel that is in so-called “manure lakes”. Apart from the
tion. Rather, we see it as a valuable source of en- ideally suited for running unpleasant odor, these vast amounts of liquid
ergy, where the objective is to make good use of gas engines. manure caused by the density of cattle in the
it,” says Thomas Elsenbruch, Marketing Program U.S. make up approximately 15% of anthropo-
Manager for GE’s Jenbacher gas engines. Biogas is an especially high-value fuel that genic methane emissions.
is ideally suited for running gas engines. The The Norwiss farm differs from the area’s other
Biogas is a natural, purely energy produced can be used either for the farms in one respect: By using the biogas gained
ecological product that is company’s own electricity needs or can be fed from the fermentation of cow manure for power
extracted from biomass at into the public power grid. The heat generated is generation, the “manure lakes” have been
biogas plants. typically used as heat supply for the plant. And turned into “energy lakes”. The farm now not
finally, the material left over from the fermenta- only completely covers its own energy needs,
Following Nature’s Example. Biogas is tion process is used as a high-quality fertilizer in it also supplies 600 households with reliable
a natural, purely ecological product that is agriculture. electricity. The original rethinking in this case
extracted from biomass at biogas plants. When GE’s Jenbacher business has been supplying took place on a small scale. Now, Wisconsin is
organic waste material undergoes anaerobic biogas-fueled gas engines all over the world for expected to introduce changes at the state level
fermentation – a controlled decomposition pro- more than 30 years. The number of delivered en- that could lead the U.S. to a greener future.
cess – a mix of gases is given off that consists of gines has now grown to more than 1,500 units
50 to 70% methane (CH4) and 30 to 50% carbon – and growth has accelerated rapidly in recent The most plentiful oil in the world and
dioxide (CO2), depending on the makeup of the years. From the vast expanses of the northern what it is used for in Thailand. In terms of
source material. Almost all organic substances U.S. to the tropical hills of Thailand, Jenbacher volume, at more than 42 million metric tons, more
can be transformed into biogas in this way, biogas engines operate reliably in extremely palm oil is produced than any other plant oil in the
although the yield may vary significantly based varied climatic conditions. world. It is used primarily in the food, cosmetic >

17
 applications and solutions coJen

Residues from agricultural production are a

valuable source of energy, where the objective is
to turn waste into energy.

18
coJen applications and solutions

> > and aluminum industries, but it can also be

mixed with diesel or converted directly to biodie-
sel. Planting oil palms is very promising because
the industry boasts a particularly high yield per
acre – one of the main reasons for the popular-
ity of palm oil farms around the world. There is
a dark side, however: The oil production process
generates huge quantities of organic waste
material that, if not processed, has a negative
impact on the ecological balance of the region.

More countries now recognize

the benefits of ecological
and autonomous power supply
as a huge advantage and are
following the example of Germany.

Natural Palm Oil Ltd. in southern Thailand has

made a long-term goal of recycling the waste
material from its palm oil mills. Two Jenbacher
gas engines are already supplying 33,000 Thai
households reliably with electricity. Recently,
an order was placed for a third engine. “We are
very pleased with both power plants’ results. The
high reliability of Jenbacher gas engine on-site
power technology convinced us to install another
Jenbacher unit for our power plant production
capacity expansion at the Chumporn mill,” said
Preecha Kuansongtham, Director of Natural Palm
Oil Ltd.

High-proof power supply. In Pakistan, a

Jenbacher gas engine found its way to a local
ethanol factory run by Shakarganj Mills Ltd. It is
used there to convert the biogas incurred in the
production of ethanol from sugar cane into elec-
tricity. As a renewable energy project, the plant
is eligible for carbon credits because it enhances
energy efficiency at the mill and displaces the na-
tional grid’s energy generated from fossil fuels. By
using the biogas instead of fossil fuels for power
generation, the plant is expected to produce
approximately 20,000 tons of certified emissions
reductions annually. However, the potential is far
greater. “With 225 million liters of ethyl alcohol
produced annually in Pakistan, we expect many
other distillery companies to install similar plants
to support the energy needs of the national grid,”
said Kashif Kazmi, Project Manager for the plant.

A clean affair: countries promote biogas.

As these examples demonstrate, the advantages
of biogas plants are apparent. And these are just
–> Biogas project in Italy: the government supports power generation using renewable energy sources a few of the types of organic waste that can be

19
 applications and solutions coJen

–> China’s First Chicken Manure-Biogas Plant

–> Traditional biogas application: utilizing sewage gas in wastewater treatment plants –> Biogas from cow manure: Norswiss dairy farm

turned into hard cash. In addition to the more tra- of plants using renewable energy sources a fixed certificate corresponds to one metric ton of saved
ditional applications, such as utilizing sewage gas price for the power they generate for a certain CO2-emissions and can be sold.
in wastewater treatment plants, new opportuni- period of time. The EEG and its revisions of 2004 The numbers for Jenbacher gas engines with
ties are constantly developing. and 2009 have been decisive in promoting power carbon credit projects are remarkable. A sewage
generation using renewable energy in Germany. plant in South Africa can earn 33,000 emission
From an international perspective, Today, the German law is already considered a reduction certificates a year, which corresponds
the Kyoto Protocol also plays an huge success story and, as a result, served as to the same amount in CO2-equivalents saved.
important role in the construction a model for 47 other countries, including the A farm with three million chicken in China can
of biogas plants. Italian government, which has issued so-called save as much as 95,000 metric tons of CO2-
“certificati verdi” (green certificates) for power equivalents. Obviously, Jenbacher gas engines
So why has demand only grown so rapidly in generation using renewable energy sources. are making a verifiable contribution to reducing
recent years? The answer is simple: Thus far, bio- These certificates are transferable commercial CO2-emissions around the world and are at the
gas plants have only been able to compete with instruments verifying that the power generated same time helping companies lower their energy
the price of power generated using conventional comes from renewable energy sources. In Eastern costs and recycle waste in a responsible and
sources of energy, such as nuclear energy, hydro- Europe and the emerging countries of Asia, ef- effective way._
power or calorific power, under certain circum- forts are increasing to promote the expansion of
stances. In order to be economically competitive, biogas plants by guaranteeing certain prices for
the state has to provide assistance with fixed electricity.
power prices to biogas plant operators, at least
for a certain period. Achieving the Kyoto goals with biogas.
“More and more countries now recognize that the From an international perspective, the Kyoto Pro-
benefits of ecological and autonomous power tocol also plays an important role in the construc-
supply are a huge advantage and are following tion of biogas plants. Since 2005, companies that
the example of Germany,” Thomas Elsenbruch produce more greenhouse gases than the speci-
explains. The German Renewable Energy Sources fied threshold values have been required to pay
Act (EEG) took effect in 2000 and promotes the fines – unless they buy emission certificates from
expansion of power and heat generation using other companies that produce less greenhouse
renewable energies. The idea is to offer operators gases than the permitted levels. One emission

20
coJen distributors and service providers

News from the Champions League

Thanks to a dense network of local sales and service providers, Jenbacher power plants can
now be found virtually everywhere in the world. Authorized Jenbacher sales and service
providers offer professional support and outstanding service to customers of GE’s gas engine
division – including communication in the local language and knowledge of significant regional
information. The largest independent sales and service provider out of these is Clarke Energy.
The Jenbacher team has been working closely with Clarke Energy since 1995 – to the mutual
benefit of both companies, which are now playing in the “Champions League” of the industry.

F rom its headquarters in Liverpool, UK,

Clarke Energy Ltd. sells and provides support for
engines in Great Britain. The outstanding quality
of the engines made in Jenbach and Clarke
Jenbacher products in many countries around Energy’s strong service and customer orientation
the world, for everything from individual gen- resulted in resounding success.
sets, fueled by natural gas or alternative gases
such as biogas, landfill gas or coal mine gas, to With customer proximity and
entire combined heat and power plants. Clarke more than 370 highly qualified
Energy‘s core competence is in the conception employees Clarke Energy ensures
and realization of complete solutions for power top-quality service, technology
plants with an output of up to 45 MW. With its and customized solutions to meet
policy of maintaining good customer proximity customer’s energy needs.
and with the expertise of more than 370 highly
qualified employees, Clarke Energy ensures top- The company continued to develop, expanding its
quality service, state-of-the-art technology and range of products and services with a number of
customized solutions to meet customers’ energy technologies for various gas engine applications,
needs. From a project’s start to its completion, including professional project management and
Clarke Energy offers professional project man- product expertise that is constantly growing. It is
agement and ISO-certified quality management. particularly important to Clarke Energy to offer
All services – engineering and design, consultan- its customers economical and ecologically sound
cy and conception, installation and commission- complete solutions. In addition, the company has
ing, and service and maintenance – come from set up a dedicated customer service division for
a single tried and tested source. Jenbacher products. The extensive range of ser-
vices includes a comprehensive stock of original
From spare parts supplier to energy pro- Jenbacher spare parts, service, repair and remote
fessional. The decisive milestone regarding monitoring.
the company’s current expertise in the power
generation segment came in 1995, when Clarke Sharing success around the world.
Energy began working with Jenbacher gas Reinforced by its successful collaboration with

21
 distributors and service providers coJen

–> Largest independent sales and service provider for Jenbacher gas engines: Clarke Energy

GE, Clarke Energy soon committed to interna-

tional expansion.

The decisive milestone regarding

the company’s current expertise
in the power generation segment
came in 1995, when Clarke Energy
began working with Jenbacher
gas engines in Great Britain.

In 1998, the company became the exclusive

sales and service supplier for Jenbacher prod- –> Clarke Energy’s headquarters in Liverpool, UK
ucts in Australia and New Zealand, with Nigeria
following in 1999. Just a few years later, Clarke Clarke Energy Ltd.
secured its position in India and France with its
own branches. The Clarke Energy international · Largest independent distributor of Jenbacher
network now includes branches in Ireland, China gas engines from GE Energy
and Tunisia, and the company is still gathering · More than 370 employees in nine countries
momentum._ · To date, plants installed with 1,700 MW
· More than 900 MW under O&M (operation &
maintenance) operator contract

22
coJen distributors and service providers

Clarke Energy’s core competence is in the conception

and realization of complete solutions for power plants.

–> Coal mine gas project in Moranbah, Queensland, Australia: complete solution from a single tried and tested source

23
 distributors and service providers coJen

Ultimate ambition:

Maximized customer
satisfaction
CoJen talks to Jim Clarke, CEO of Clarke Energy

CoJen: How would you describe the activities of Clarke Energy using 15 Jenbacher J620 engines. Our services ranged from gas
in a single sentence? purification and treatment to feeding electricity into the public
Jim Clarke: We constantly strive to find and realize innovative so- grid two kilometers away. As with all coal mine gas projects, the
lutions to meet our customers’ needs. We meet these challenges biggest challenges were removing dust and moisture from the
by collaborating with the Jenbacher gas engine division of GE. gas and regulating the fluctuating methane content of the gas.
Another outstanding project recently was the combined heat and
How important is the cooperation with GE to you, and what power plant for Hydro Polymers Ltd. in Durham, Great Britain. Here,
characterizes it? too, our assignment was the design and construction of a turnkey
We have been collaborating with the Jenbacher team since 1995, plant. The plant, with a natural gas-powered Jenbacher J612
and we are currently working together in nine countries around engine and an electrical output of 1.8 MW, was commissioned in
the world. Both companies have grown significantly in the last July 2008. The waste heat from the engine is used to preheat the
few years. This is due in part to our excellent cooperation, which air used in the customer’s drying production process. With this, the
is based on considerable mutual trust, technical expertise and a plant achieves an outstanding efficiency factor of 90%.
shared customer focus. Thank you very much for this interview.

What joint goals have you set?

Simply put, our goal is to install as many Jenbacher gas engines
as possible and achieve the highest possible degree of customer
satisfaction. We are working together to accomplish this with
our comprehensive range of services and our knowledgeable
employees.
CoJen talking to:
Can you describe a couple of outstanding projects that Clarke
Energy has completed recently?
The first example that occurs to me is our coal mine gas project
for Energy Developments Ltd. in the Australian town of Moranbah, jim clarke
Queensland. The plant was commissioned in November 2008. We CEO
designed and built a turnkey 45 MW plant fueled by coal mine gas Clark Energy

24
coJen region special

The Need for

More Power

–> Jakarta, Indonesia

25
 region special coJen

India

Thailand

Malaysia
Singapore
Jenbacher Sales & Service Providers
in Southeast Asia and India

India – Clarke Energy India Private Limited

“Shivkiran”, Lane no. 4, Dahanukar Colony, Kothrud, Pune 411 038 Indonesia
Phone: +91 20 30241704

Thailand – Italthai Industrial Co., Ltd.

2013 New Petchburi Road, Bangkapi, Huay Kwang, Bangkok 10310
Phone: +662 3191031-40

Indonesia – Navigat Energy Pte. Ltd.

139 Cecil Street, 04-02 Cecil House, Singapore 069539, Rep. of Singapore
Phone: +62-21-5724944

Malaysia and Singapore – JD Group Sdn. Bhd.

1, Jalan Lada Hitam Satu, 16/12A 40200 Shah Alam
Phone: +603 55191 000

For additional information, please contact our GE offices in India (jenbacher.india@ge.com) and Singapore (jenbacher.singapore@ge.com).

26
coJen region special

The countries of southeast Asia and India couldn’t be more

different, but most share one characteristic:

The Need for

More Power
As their energy requirements grow along with their populations, the diverse countries of Southeast Asia and
nearby India are seeking ways to fulfill their power needs. Stymied by lack of infrastructure and funding, many of
these countries still have rural areas that are largely unserved by their power grids. And even those nations that
have plenty of natural resources are faced with populations that have grown so quickly – or are so spread out –
that their power supplies have not kept up with demand.

G reater energy stability, security and sustainability were some

of the energy goals outlined at the annual ASEAN (Association
IndonesiA. Unlike Thailand, Indonesia has plenty of natural gas,
with resources estimated to last more than 50 years. Still, with
of Southeast Asian Nations) Ministers on Energy Meeting last less than 60% of the population served by the grid, Indonesia is
August in Thailand. But although they agree on their countries’ especially hungry for power. The country’s 230 million population is
energy needs, the nations participating in ASEAN couldn’t be more spread over a country that is made up of more than 17,000 islands,
diverse. 6,000 of which are inhabited. The country’s people, most of whom
are Muslims, work primarily in agriculture, such as rice, coffee and
THAILAND. There’s Thailand, for instance, found in the heart of palm oil, as well as in industry, including petroleum and natural gas.
Southeast Asia and one of the most devoutly Buddhist countries
in the world. Thailand’s economy is dependent on its exports, Indonesia will need at least 20 GW
primarily rice and palm oil. Energy-wise, the country, which is of power expansion within
about the size of Spain, supplies electricity to about 80% of its 65.5 the next ten years.
million population. A big problem is lack of natural resources, with
Thailand importing most of its natural gas from Myanmar and The supply challenges in Indonesia are many. The country is
Malaysia. Political uncertainty has plagued Thailand, too, ham- dependent on oil for electricity generation, but oil production is de-
pering some infrastructure megaprojects. pleting, and the country sees coal as the primary energy source of
the future. Although coal and natural gas reserves are abundant,
Thailand is the leading consumer of electricity the supporting infrastructure is limited, with a lack of gas pipe net-
compared with its neighbors. works, coal transportation and electricity transmission networks.
Indonesia will need at least 20 GW of power expansion within
Still, Thailand is the major economic power in the Mekong region the next ten years. In Indonesia from 1970 to 2006, the average
and also is the leading consumer of electricity compared with growth of primary energy averaged around 8%, and the growth
its neighbors. In 2003, for instance, the country consumed 1,448 rate of demand through 2026 is estimated at 7%. Making up the
kilowatt-hours of electricity per capita, as opposed to China’s energy largest energy consumer is the industrial sector at 40%, followed
consumption at 827 kilowatt-hours per capita. The current installed by transportation at 38% and household and commercial at 22%.
power generation capacity is about 30 GW, not including imports With a total installed capacity of about 29 GW, Indonesia relies on
of 340 MW from Laos and 300 MW from Malaysia. Peak demand is coal at 46% as its primary power supplier, followed by oil at 24%.
expected to rise to nearly 50 GW by 2021. Natural gas is third at 14%.

27
 region special coJen

INDIA. Nearby India – not considered part of

Southeast Asia nor a member of ASEAN – has
the fourth-largest coal reserves in the world. The
country currently has about 140 GW of genera-
tion capacity, mainly based on coal, thermal and
hydro, with about 8% from renewables. Domi-
nating the South Asia continent, India – made
up primarily of Hindus – has a diverse economy,
with about half its population in agriculture.
Services are the country’s major source of
economic growth, however, accounting for
more than half of India’s output with less than
one-third of its labor force. Commercial energy
demand is expected to grow by 4% annually.

Commercial energy demand in

India is expected to grow by 4%
annually.

Although the government’s goal is power for all

by 2012, most rural Indian households do not
use electricity – about 80 million households still
use kerosene for lighting – and even in electrified
villages, supply is inadequate and unreliable.
Per capita energy use is just one quarter of the
global average at 630 kW/annum.

While most countries in the region lack electrical

power, there are exceptions, such as the highly
industrialized nations of Malaysia and Singapore.
A peninsula bordering Thailand, Malaysia has
plenty of petroleum and natural gas – and not
nearly enough people to use it all. The island of
Singapore does import most of its fuel, mainly
natural gas from Malaysia and Indonesia, to
support the densely populated country, which
has 4.7 million people on 700 square kilometers
of land.

BUT INCREASING POWER IN THESE COUNTRIES

ISN’T SIMPLE. Industrialized countries such as
Malaysia and Singapore generally rely on large,
centralized power sources to meet their electric-
ity needs. While these plants are usually quite
economical, they transmit electricity for long
distances over huge power lines. That approach
won’t work in most rural areas of Southeast Asia
and India, where many remote villages are not
yet electrified or have low load densities. Exten-
sion of the grid is uneconomical and would lead
to heavy transmission and distribution losses.
Around the globe, too, prices for fossil fuels have
risen sharply. In fact, some Southeast Asian
–> Southeast Asia’s major problem: power supply has not kept up with demand countries – Vietnam, for instance – have faced >

28
coJen region special

> energy crises because, as import prices rise, they just don’t
have the resources to meet their countries’ power needs.
Those countries that have natural resources must deal with the
consequences of using them. India, for instance, has relied heavily
on coal, but realizes it must reduce its greenhouse gas emissions.
Finally, lack of funding can make energy expansion difficult. Many
countries are looking into carbon credit programs, emissions
trading schemes designed to help mitigate global warming. The
Clean Development Mechanism, an arrangement under the Kyoto
Protocol, allows industrialized countries that have a greenhouse
gas reduction commitment to invest in projects that reduce emis-
sions in developing countries.

Reliable power supply is key

for economic growth.

Financing can also take place through sales of excess power. In

India, for instance, there is a ready market for excess power since
power shortages are frequent. Through such programs, existing
and new customers could add additional capacity and trade up to
50% of the total installed capacity.

GE: A MAJOR PRESENCE IN SOUTHEAST ASIA AND INDIA.

Traditional energy sources such as coal and oil will continue to be
used and needed in Southeast Asia and India, and GE’s product
and service offerings can be found in many countries in the
region. GE’s presence in Indonesia, for instance, dates back to supply and preserving the environment.
the 1970s with the introduction of the turbine business and has In India, more state governments are moving toward renewable
continued to grow since then. purchase obligations, and the Electricity Act 2003 mandates the
In India, GE installed the first hydropower plant in 1902. Today, Science and Engineering Research Council (SERC) to promote
all of GE’s global businesses have a presence in India, and the renewable energy development.
company participates in a wide range of manufacturing, services
and technology businesses there. Thailand – perhaps because of its lack of
While GE Energy is well known throughout the region for its large natural resources – leads the region in terms
steam and gas turbines and even for its nuclear business, huge of governmental support
centralized power sources simply can’t meet all of the needs of for renewable energy projects.
the rural communities in Southeast Asia and India. A more suit-
able approach for those areas is distributed generation, where BIOGAS IN THE FOCUS. While the more traditional renewable
energy is produced very near where it is used, sometimes even in sources of wind and solar have been employed in a number of
the same building. Southeast Asia projects, one option gaining widespread support
is biomass – plant matter, such as agricultural waste, grass, crops
DISTRIBUTED GENERATION, RENEWABLES AND ALTERNATIVE or waste materials from such industries as sugar cane and palm
ENERGY SOURCES. The Association of Southeast Asian Nations oil that can be used as a solid fuel or converted into liquid or
(ASEAN) has recognized the need and benefits of renewable, sustain- gaseous forms to produce heat and electricity.
able energy sources, which often are a natural fit with distributed Thailand, for instance, produced 1,500 MW from biomass in 2007,
generation. Thailand – perhaps because of its lack of natural resour- and the Ministry of Energy is targeting 2,800 MW by 2011. Also
ces – leads the region in terms of governmental support for renew- gaining popular support is the utilization of biogas from animal
able energy projects. The country has implemented a law that en- manure, which lowers greenhouse gas emissions as well as ani-
ables small power producers to invest in renewable energy projects. mal waste. That’s significant in Southeast Asia and India, where
In Indonesia, the country has put priority on alternative energy such waste increasingly poses groundwater contamination issues
development including renewable energy. The government’s in some areas.
pricing policy gives major influence to better energy efficiency Currently, Thailand’s power generation output from biogas is
and energy diversification, which could play an important role in about 28 MW, but that figure could expand to 60 MW by 2011
reducing the cost of electricity production, securing the energy – and the Department of Alternative Energy Development and

29
 region special coJen

As their energy requirements grow along with their populations,

the countries of Southeast Asia and India are seeking ways to
fulfill their power needs.

Efficiency has targeted a potential capacity of 190 MW. Sources per day from other municipalities and 1,000 tons per day from
are livestock farms, agriculture and the palm industry. industry.
Biogas is also seen as a solution in India, where plants could use
cow manure, slaughterhouse and vegetable market wastes, as SOLUTIONS WITH JENBACHER GAS ENGINES. Gas engines often
well as urban and industrial wastes. Co-digestion of farm and are a practical solution for decentralized power generation. Offer-
agriculture residues can be mingled with urban and industrial ing small footprint requirements and quick installation, they can
wastes. The country’s Ministry of New and Renewable Energy even help solve environmental dilemmas. Financing can be done
estimates biogas potential from agro-industrial wastes at about utilizing carbon credits, and payback on investment can take just
1,300 MW, primarily from distilleries, but also from such industries a couple of years. Following are solutions that could be signifi-
as sugar, starch and slaughterhouses. cantly expanded in Southeast Asia and India, based on those
countries’ resources and needs:
The Association of Southeast Asian Nations
has recognized the need and benefits of • Palm oil plants. Malaysia is the top producer of crude palm
renewable, sustainable energy sources. oil, followed by Indonesia and Thailand. In Thailand alone, GE has
about 20 installations, some of which have several engines, at
The financial viability of biogas projects in India depends on palm oil plants – where 40 to 45 tons of palm oil fruit can create
revenue sources, such as sale of power, sale of manure and the equivalent of 1 megawatt of electrical power within an hour.
compost, and carbon trading through the Clean Development At the Tha-Chang mill, the Thai Biogas Energy Company (TBEC)
Mechanism (CDM). Government support has included provisions in processes 60 tons of palm oil fruit per hour. Palm oil mills involved
Electricity Act 2003 such as open access to the grid for renewable are collecting carbon credits and can even sell electricity on the
power, preferential tariffs by state regulators, targets for renew- grid. Read more about this project on page 33.
able power and captive generation decontrolled. Fiscal incentives
or concessions include customs duty for imports, excise duty for • Tapioca starch factories. A new biodigester system at the
manufacture of renewable power devices and income tax. largest tapioca starch factory in Southeast Asia provides nearly
Dumpsites, too, constitute a valuable energy source. Municipal 100% of the factory’s considerable energy demand, displacing
solid waste (MSW) now just produces 4 MW of power in Thailand, significant annual purchases of fuel oil and grid electricity. The
but the government has targeted 100 MW by 2011. The source: grid-connected 5 MW power plant supplies all its electrical energy
9,000 tons per day of waste in Bangkok alone, with 6,300 tons to the factory, with the added capability of selling surplus >

30
coJen region special

–> Tradition meets innovation: GE’s solutions are helping to meet the region’s energy demand

31
 region special coJen

> electricity to the local utility. The Korat Waste-to-Energy Co. Facts & Figures
Limited (KWTE) is a pioneer in this field and owns and operates
the facility as a renewable energy services company. The factory India
includes three Jenbacher J320 generator sets. Natural resources: Coal (fourth-largest reserves in the world), iron
ore, manganese, mica, bauxite, titanium ore,
• Landfill sites. Using Jenbacher engines, companies can pro- chromite, natural gas, diamonds, petroleum,
duce green power, while minimizing land and water pollution. The life limestone
span of the dumpsite can be increased three to five times as well. In Population: 1.15 billion (2008)
Singapore, for instance, Jenbacher gas engines are being used in the Government: Federal republic
country’s first organic waste biomethanization treatment plant. Economy: Average growth rate of more than 7% from
1997 – 2007. Poverty reduced by about
• Cow manure. In India, a methane-to-energy plant uses 235 tons 10 percentage points.
per day of cattle manure to produce 1 MW of power and 35 tons Electricity production: 665.3 billion kWh (2007)
per day of organic fertilizer. The project, which uses Jenbacher gas Electricity consumption: 517.2 billion kWh (2006)
engines, received the “Best ‘Green’ Power Plant in Asia” award at Natural gas production: 31.7 billion cu m (2007)
Power-Gen Asia 2007. Natural gas consumption: 41.7 billion cu m (2007)

• Sewage gas. Biogas can be produced by the digestion and Indonesia

incineration of sewage sludge. In India, for instance, sewage treat- Natural resources: Petroleum, tin, natural gas, nickel, timber,
ment plants have been established in major cities, with funding bauxite, copper, fertile soils, coal, gold, silver
available through Jawaharlal Nehru Renewable Urban Mission Population: 237.7 million (2008)
(JNURM), providing an opportunity for Jenbacher engines. Government: Republic
Economy: GDP real growth rate 6.1% (2007)
• Associated petroleum gas. In Indonesia, opportunities exist Electricity production: 125.7 billion kWh (2006)
to use associated petroleum gas, often called flare gas, unwanted Electricity consumption: 110.7 billion kWh (2006)
natural gas that is disposed of by burning as it is released from an Natural gas production: 56 billion cu m (2007)
oil field or at a gas processing plant. Natural gas consumption: 23.4 billion cu m (2007)

GE’s Jenbacher solutions are helping Thailand

to meet the region’s energy demand. Natural resources: Tin, rubber, natural gas, tungsten, tantalum,
timber, lead, gypsum, lignite, fluorite
Programs are being developed for associated petroleum gas Population: 65.5 million
utilization, mostly for small power generation. For a long time, this Government: Constitutional monarchy
unwanted oil by-product has been simply flared. But because of Economy: Annual real GDP growth averaged 6% from
the increase in both environmental consciousness and energy 2002 – 2004; but declined to 4.9% from 2005 – 2007
demand, flaring is now often avoided or even prohibited. Electrical production: 130.7 billion kWh (2006)
GE’s solutions are helping to meet the region’s energy demand. Electrical consumption: 123.9 billion kWh (2006)
A well-established sales and service network for Jenbacher gas Natural gas production: 25.4 billion cu m (2007)
engines in Southeast Asia and India ensures that GE is set up to Natural gas consumption: 35.3 billion cu m (2007)
support the region’s needs. In addition, the Hangzhou packag-
ing operation for Jenbacher gas engines, which ships engines for
Southeast Asia, ensures fast response and excellent customer
support. A strong network of distributors – Clarke Energy in India,
Italthai in Thailand and PT Navigat in Indonesia – provide local ex-
pertise with their thorough knowledge of the countries we serve._

32
coJen region special - sucess story

Turning waste into

energy
The area around the Tha-Chang palm oil processing mill in Thailand used to emit
a pungent odor. Even worse, wastewater from the plant discharged methane –
a leading cause of global warming – into the air. But that was before Thai Biogas
Energy Company (TBEC), using GE’s Jenbacher gas engines, began …

T oday, there’s no longer a strong odor. There

are no environmentally detrimental emissions.
And palm oil producers are able to make money
by generating power from the wastewater pro- The oil production process generates
duced from processing palm oil.
The palm oil business is a major industry in Thai- huge quantities of organic waste
land, second only in the world to Malaysia and
Indonesia. Palm oil, which is used for cooking material that, if not processed, has
in most Southeast Asian kitchens, comes from
the fruit from palm trees. Fruit bunches grow on a negative impact on the ecological
the palm trees for six to eight months until they
are ripe and weigh 30 to 40 kg, and then they balance of the region.
are cut off and collected. At a processing mill,
the fruit bunch is steamed and the crude oil is
pressed out of it. Wastewater that is created in
the process is pumped into a lagoon.

THE THA-CHANG MILL PROJECT. In Thailand,

temperatures reach 90 degrees Fahrenheit – or
higher – each day. The steamy wastewater cre-
ates bacteria, which quickly begins to smell, and
the bacteria creates methane, which climbs into
the atmosphere.
Or that’s what used to happen at the Tha-Chang
mill. TBEC has covered the wastewater lagoon
with what looks like a huge blanket. The meth-
ane that is emitted from the lagoon is collected
and sucked out from under the blanket into a –> The palm oil business is a major industry in Thailand, as well as in Malaysia and Indonesia

33
 region special - sucess story coJen

Jenbacher engine where it, along with oxygen, can be burned

directly. 40 to 45 tons of palm oil fruit can create the equivalent
of 1 MW of electrical power within an hour. The Tha-Chang mill
produces 60 tons per hour.
The palm oil mills involved can collect carbon credits for the pow-
er produced, which can be turned into money. In Thailand, too, an
innovative government program allows palm oil mills to connect
their power to the grid – and sell it. Since this energy comes from
a renewable energy source, they are also entitled to an add-on
tariff. “Obviously, the palm oil producers are very eager to do this,”
says Dietmar Rauter, GE Energy Sales Manager – Southeast Asia.
“They are taking what used to be a malodorous area that emitted
gases into the environment, and turning it into electricity. It is a
winning situation for them.” Payback on the initial investment is
usually within two to two-and-a-half years.

“The palm oil producers are taking

what used to be a malodorous area
that emitted gases into the environment,
and turning it into energy.”

TBEC, one of the leading biogas companies in Thailand, has four

operating projects that create biogas and electricity. In addi-
tion, annual carbon credits from TBEC’s projects exceed 130,000
per year. The company develops, designs, finances, implements,
operates and maintains the projects. “Thailand’s shape really
benefits this conversion of methane to electricity,” Rauter says.
“The palm oil mills are mainly in the south of Thailand – fairly near
tourist areas and major cities – and are very well connected to
the electric grid.”

THE JOURNEY HAS JUST BEGUN … GE sold its first Jenbacher

engines for Thailand’s palm oil industry in 2006 – coinciding with
the passage of Thailand’s carbon credit laws. Today, GE has about
20 installations, some of which use several Jenbacher engines.
The plants range in size from 500 kW up to 6 MW of power. Very
large plants process some 200 tons of fruit per hour.
“Carbon credit trading development has been a major factor
in this industry, since it is a big part of the payback to the palm
oil producers,” Rauter says. Educating those palm oil producers
about the benefits of becoming electricity producers has been a
challenge, but more and more palm oil mills are recognizing that
they can profit from the system. And this business gets more and
more interesting in other countries, such as Malaysia, as well.
The system used at palm oil mills is also easily replicated for other
industries, such as tapioca starch factories. Meanwhile, however,
palm oil farmers in Thailand are reaping the benefits from TBEC’s
projects as their smelly lagoons are replaced with the smell of
money._

34
coJen service

;XUTcX\T
BTaeXRTb QMVT
U^a
9T]QPRWTa
VPb
T]VX]Tb
Investing in tailored solutions for our customers:

With the Jenbacher service team,

customers
;XUTcX\T
BTaeXRTb get an alliance for life
U^a
9T]QPRWTa
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T]VX]Tb
The Jenbacher service team offers its customers customized, professional service throughout the life cycle of their Jenbacher gas engines, living
up to its responsibilities for the smooth operation of the customers’ equipment. It is not just the development and production of best available
gas engine technology that makes GE’s Jenbacher product line highly successful. After all, it is the right service at the right time that ensures
optimum operation of the engine, and thus the efficiency of the plant.

;XUTcX\T
BTaeXRTb
TJenbacher
he 450-plus employees of the global
U^a
9T]QPRWTa
VPb
T]VX]Tb
service organization and the 1,500
service technicians working for authorized sales
and service providers – more than 60 around the Upgrades, Repair and Overhaul Commissioning
world – ensure that GE customers have the very
best care and support.

“GE’s life-cycle management under-

scores the company’s high quality
;XUTcX\T
BTaeXRTb
?[db Spare Parts
standards and assures us of the
best service whenever we need it.” Contractual
Service
U^a
9T]QPRWTa
VPb
T]VX]Tb
– Kwekerij Baarenburg, Niederlande
Agreements

“When signing a contract for a Jenbacher gas

engine, you are really entering into a life-long
partnership. GE’s life-cycle management under- Field Service
Training
scores the company’s high quality standards
and assures us of the best service whenever we
need it,” says the Dutch rose grower Baaren-
burg, describing the longtime relationship with
;XUTcX\T
BTaeXRTb
?[db
the gas engine division of GE Energy.

U^a
9T]QPRWTa
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T]VX]Tb
Lifetime Services Plus for Jenbacher
gas engines. With Jenbacher gas engines, life
cycle management begins the moment they Remote Monitoring, Diagnostics and Servicing
are commissioned. Customers around the world
value the secure feeling of all-around support –
whether they are in a Dutch tomato greenhouse,

35
 service coJen

the elegant Plaza Indonesia hotel and shopping countries around the world ensures the very best
complex in Jakarta or at the Strass sewage treat- care and support for customers at their loca-
ment plant in Austria. tions. This in turn creates a high level of customer
satisfaction.
Investing in flexible, customized
solutions for customer success. Spare parts. The first-class quality of Jenbacher
original spare parts contributes significantly to
Commissioning. Our experienced certified field the engines’ long service life of 60,000 operating
technicians make sure the engines are installed hours – and more. Parts can be delivered on time
according to our customers requirements. around the world.

Service agreements. Flexible service agree- Upgrades, repairs and overhauls.

ments meet our customers maintenance require- With upgrades consistently installed in the course
ments while giving maximum cost control for the of regular maintenance work, the power plant
life of the gas engines. can run even more efficiently. In the case of major
overhauls, the Jenbacher Repair Center offers at-
Training. Specialized, practical training tractive, flexible solutions. Downtime is minimized
programs for customers, operators, and sales with time-saving exchange engine options._
and service providers are targeted to meet the
individual needs of participants.

Remote monitoring. With timely and ac-

curate technical support, our remote monitoring,
diagnostics and servicing is provided globally
through the Jenbacher service network.

Field service. Local presence of Jenbacher

sales and service providers in more than 60

36
coJen service

Technology development is at the forefront for

GE Energy’s Jenbacher gas engine division

In top form!
Some 200 employees worldwide work on the technological development of Jenbacher gas engines. Between 2005 and 2009, the company doubled
its investment in this area, underscoring the importance that GE places on technological advancement. Since the beginning of 2009, a dedicated
team within the newly established Technology Service division has been working on improved service solutions for plants that have already been
installed.
CoJen speaking to Bernd Wilmsen, Technology Leader Service for the Jenbacher product line

CoJen: Mr. Wilmsen, GE is among the world’s of 90% for combined heat and power generation
leading companies in the design and produc- plants. There are, however, still applications with
tion of gas engines for the efficient genera- potential, such as when there has been no heat
tion of power and heat. How significant is the demand so far and therefore the waste heat
development of technology in your company? from the engines has not been used. We are
And what are the main objectives for the new presently developing a process for this applica-
Technology Service division for Jenbacher gas tion in cooperation with GE’s Global Research
engines? Center in Munich.
Bernd Wilmsen: Investment in technological ad-
vancement is at the forefront at GE. On the one “Our technological developments
hand, it helps to secure our technology leader- are always catered towards
ship for the future. On the other hand, advance- customer benefits.”
ment is critical because we are accountable to
our customers. After all, they are accustomed What further potential for development is the
to purchasing innovation when they buy a Service Technology division currently working
Jenbacher engine. In the Service Technology on?
division, we are working to continually improve On the whole, our technological developments
engines that have already been installed, to always have customer benefits in mind. For our
make it possible for our customers to operate customers, the reliability of their engines is par-
their plants in an even more economical manner. ticularly important. We achieve improvements
At the same time, we are also developing new above all through better adjustment of the plant
products, for instance for gas cleaning, which to the different areas of application, because
will deliver added value for existing plants. the better an engine is calibrated to its specific
use, the more reliably it runs. In addition, we are
Jenbacher plants already achieve an efficiency developing new service maintenance strategies
level of over 90%. Is an improvement in ef- in the Service division that are ideally suited to
ficiency even possible? the requirements of our customers. A key term in
Of course, it’s difficult to improve on peak values this context is “condition-based maintenance.”

37
 service coJen

At the same time, we are continually working on

improvements in the area of remote connection.
We are testing the use of satellite links, among
others, in order to offer this service in more
remote regions in which no Internet or telephone
connections are available. All in all, we see it as
our obligation to care for the engines over their
lifetime, in order to make it possible for our cus-
tomers to operate their plants in a cost-efficient
manner. An additional objective is also to further
improve the durability of core components.

Is there also potential for improvement of Jen-

bacher engines in the environmental area?
Gas engines are already among the cleanest
types of engines available, and we are achiev-
ing excellent results with such products as the
CL.AIR exhaust gas treatment. However, there
is still potential to further reduce emissions, for
instance in the area of combustion optimization,
catalysers or thermal after-treatment. It is a very
important area for us.

“We are investing in the future now,

so that we will continue to be a
technology leader in the gas engine
industry.”

How is Jenbacher coping with the current

tense economic situation? Are you more cau-
tious at the moment?
No – in fact the opposite is true. We keep on
increasing our investments in technological
development every year, and in 2009 we are
planning to spend about 10% more than the
previous year. We are investing in the future
now, so that we will continue to be a technology
leader in the gas engine industry.
Thank you very much for this interview.

CoJen talking to:

bernd wilmsen
Technology Leader Service –> GE‘s Jenbacher team is now designing the innovations for the future success of its customers

38
coJen service

So far, so near:

Connecting customers
remotely in Asia
Growing energy consumption in Indonesia presents a challenge to the state-owned
energy providers, and energy shortages are commonplace. With the showcase
project Plaza Indonesia Extension, GE has established itself in Asia as a competent
provider for the growing number of companies looking for a reliable, decentralized
energy supply. A decisive factor here is the possibility of remote monitoring for the
Jenbacher plant using the “Hermes” remote service package, which this customer
decided to purchase.

Plaza Indonesia Extension – remote service, without a service technician

a prestigious project in Asia. The Plaza having to drive to the plant. In addition, with
Indonesia Shopping Center and the Grand Hyatt regular maintenance and overhauls, the technical
Jakarta, one of the most symbolic buildings online support helps achieve better planning
in Asia, is located at the heart of the business and organization. Overall, remote service signifi-
district in Jakarta. The expansion project is also cantly improves both the availability of the plant
one of the most prestigious projects for the Jen- and its efficiency. And finally, the data analysis
bacher gas engine division of GE. Nine natural can be extremely helpful when optimizing the
gas-fueled J620 GS engines with total electrical individual plant with customized solutions, which
output of about 25 MW will in future supply the is another benefit to all customers.
entire complex with reliable, efficient energy.
Making use of learning. In addition to the
Remote – from Jakarta to Jenbach. One customers, the authorized service providers also
of the challenges of this first remote connection benefit from the use of remote technology. The
in Indonesia was the country’s IT infrastructure, availability of plant data has a direct impact
which had not kept pace with economic growth. on improved planning for services offered and
Together with the local sales and service pro- therefore on the expansion of the service com-
vider PT Navigat, the Jenbacher team set up an petence of Jenbacher service providers. In the –> Prestigious project: The Plaza Indonesia
Internet connection for the remote service. The case of complex issues, the Excellence Center in
connection has been as trouble-free as it is in all Jenbach can also dial into the plant quickly and Plaza Indonesia facts:
other areas of the world. easily to help with error analysis. Once again,
this means that the customer benefits from · Total space: more than 220,000 m2
Available for all eventualities – in an optimized plant availability thanks to the remote · 5 underground levels with parking for
instant. Remote service offers many benefits connection._ around 1,200 cars
to the customer. In case of a malfunction, re- · 6 floors of entertainment with a movie
mote service help is immediate, and downtime theater and shopping mall
can be minimized. Statistics show that 50% · 41 storeys office tower, 48 storeys residen-
of technical problems can be eliminated with tial tower

39
 service coJen

Faster and smarter:

Digitizing Field Service
GE keeps up with the latest technology, even when the issue at hand is
documentation of the services provided. Among other things, the Signature Pad
(digital signature) greatly simplifies paperless accounting between the service
technicians and customers, therefore speeding up the entire process.

Paperwork was yesterday.

In days gone by, Jenbacher service technicians had to fill out a
number of forms when they carried out maintenance work or
commissioning at the customer site. In addition to their technical
competence, they had to demonstrate their skills in a wide variety
of report writing: Assembly reports, time sheets, travel expense
and out-of-pocket accounting were all part of the program. The
customer onsite had to sign personally to confirm that the work
had been carried out in good order.

Signature pad is today.

With the introduction of the ERP system from Oracle, service
technicians can complete all reports onsite on their laptops. The
customer’s signature is digitized using the Signature Pad and
stored together with the reports. The advantage to the customer:
The entire process is simpler and better, and the time saved on
administrative work can be used for personal contact.

A small but important side benefit is that the new ERP system also
allows structured, simple recording of empirical values, concerns
and areas for improvement that can be addressed in the long
term to improve the Jenbacher products._

40
coJen service

New from old:

Major overhaul of the

Strass wastewater treatment plant
After 60,000 operating hours, it was time to overhaul the sewage gas cogeneration unit of the
Achental-Inntal-Zillertal Wastewater Management Association in Strass, Austria. The Jenbacher
unit at this sewage treatment plant is responsible for power supply of 167,000 residential
homes. After a record time of just 15 days, the engine was reinstalled – and performance has
been significantly improved ever since.

A fter the major overhaul, the combined heat

and power plant at the sewage treatment plant
CoJen talks to Josef Dengg, Managing Director
of the Achental-Inntal-Zillertal Wastewater
in Tyrolean Strass is ideally equipped for the next Management Association
60,000 operating hours or 2,500 days. Further-
more, it is more efficient and economical than
ever before. Its efficiency was increased by 1.5 A good fellowship
percentage points with the upgrades carried
out in the course of the general overhaul. In CoJen: Why did you decide to have your plant
addition, a number of technical innovations have completely overhauled instead of buying a
reduced the plant’s gas consumption by about new engine?
30,000 m3 per year. –> Record time for overhaul: 15 days Josef Dengg: Economic considerations were the
decisive factor. A major overhaul – which usually
With specific upgrades and since the Strass sewage treatment plant has two increases the service life of an engine by around
overhauls GE ensures that our older engines that operated during this time to 12 to 15 years – was much more profitable for
customers Jenbacher engines are “dispose of” the gas and secure power supply. us than buying a new engine. The upgrades car-
kept with the latest technology. ried out at the same time to improve efficiency
As good as new. This example clearly shows made it even more cost effective.
For the customer, the most important factor in how a major overhaul can bring huge savings
improving the profitability of the plant was not to the customer. The costs are about a third What are the most striking aspects of your
improving the output of the engine, but incre- of the cost of purchasing a new engine, which relationship with the Jenbacher service team?
asing its efficiency. In the past, because of the in many cases makes a major overhaul – due In our dealings with the Jenbacher team, they
natural fluctuations in sewage water volume, after 60,000 operating hours – a good alterna- have always been competent, reliable and have
biowaste had to be added at times to achieve tive to purchasing a new engine. With specific worked well with us. On this basis, we have de-
sufficient gas volume. Thanks to the now-redu- upgrades, Jenbacher engines are kept with the veloped an ecological and economical symbiosis
ced gas consumption, this is only necessary in latest technology by undergoing an overhaul. For based on fellowship over the last 19 years.
exceptional cases. the customer, these improvements ensure the
The Jenbacher service offer of an exchange efficient operation of their plant._
engine during the overhaul was not needed

41
 service coJen

The Jenbacher overhaul

resulted in 30,000 m3 less fuel
consumption per year.

–> Ideally equipped for the next 60,000 operating hours: sewage treatment plant in Tyrolean village Strass

42
coJen supply chain

The core component

from Tyrol
As one of the world’s leading manufacturers of gas engines, GE even has its
own crankshaft production facility in Jenbach. The facility is currently being
significantly expanded to achieve greater production depth and flexibility.
Customers will benefit from this move with shorter delivery times and superior
quality.

Crankshafts – a core engine component.

Every reciprocating engine contains a crankshaft,
which transmits power to other components,
such as the generator. Along with the conrods
and pistons, the crankshaft is therefore a core
engine component.

Continous investment in latest

manufacturing technology
increases flexibility and capacity.

It is hardly surprising that this component is

extremely strained through bending, torsion and
vibration. The requirements made on produc-
tion are correspondingly high. Besides material
quality, factors such as geometrical accuracy,
residual tension, surface quality and heat treat-
ment during production processes are all of
decisive importance to the equipment’s quality
and lifecycle.

Each year, GE needs several thousand crank-

shafts for Jenbacher gas engines as well as
for other business areas within the company,
such as GE Transportation and GE Oil & Gas.
Jenbacher is the only business within GE with
the expertise to manufacture them. This capabil-
–> GE is investing in the latest crankshaft production technology in Jenbach ity is the result of more than three decades of

43
 supply chain coJen

experience in the production of crankshafts for of a millimeter for diameter, conicity, concentric- engine function and lifecycle time. Overlap-
Jenbacher Series 2, 3 and 4 engines. ity, cylindricity and run out have to be achieved. ping regions of individual holes are particularly
This tolerance bench is equivalent to about half critical; a bulk particle less than 0.1 millimeter in
Capacity expansion brings benefits to the diameter of a human hair. size may result in expensive motor damage. For
customers and GE. GE’s decision in mid this reason, the intersections must be precisely
2007 to expand its crankshaft production was Highly qualified and experienced polished, cleaned and inspected. All this work is
prompted by steadily growing demand. The employees are the basis for carried out by hand by our specially trained staff
consequence has been not only a significant implementing such technology. – with the assistance of endoscopes similar to
expansion of capacity, but also increased pro- those used in medicine.
ductivity. For example, setup times have been Here, too, the Jenbacher team employs the very
reduced to such an extent that the Jenbacher latest technologies, making it possible to achieve It is understood that every crankshaft is subject
team has been able to shift from conventional new capacities and faster processing times. to a 100% inspection for accuracy and surface
batch production to single piece flow production. Over and above this, the new machine tools quality, cracks and cleanliness before it is
For the customer, this means shorter delivery offer higher processing quality and help to keep dispatched just-in-time for assembling in an
times – not just for new engines, but also for WIP (work in progress) to a minimum. engine. This is the only way to ensure that crank-
maintenance and repair work. In addition, the staff must be highly qualified shafts do not become soiled between production
However, the biggest advantage of this expan- and motivated for such an expansion – and and installation. The crankshafts of plants being
sion is the significantly increased flexibility. In Jenbacher certainly has such a staff. The gas overhauled are also inspected for damage in the
the future, it will also be possible to manufacture engines division of GE attaches great impor- crankshaft production department, and are sub-
crankshafts for type 6 engines. Production can tance to the training and further education of jected to the same quality inspection processes
then be adapted to changing customer demand. its apprentices and staff in all areas of the com- as new crankshafts. From initial delivery to
pany – from job preparation to development. overhaul, the maxim is: Do everything possible
Quality not left to chance. Both sophisti- to ensure unrivaled quality._
cated machine tools and skilled employees are Minute attention to detail. The fact that
needed to manufacture crankshafts that meet GE pays great attention to quality is illustrated
the high quality requirements for operation in by the oil holes in each crankshaft. These holes
Jenbacher gas engines. For example, criteria provide a reliable supply of oil to the bearings,
such as tolerances of less than two hundredths and are therefore of decisive importance to both

44
coJen personality story

An interview with Michael Wagner, Marketing Leader:

Innovative products and creative

solutions for a successful future
Michael Wagner has a passion for gas engines. Born in Salzburg, he has been working with
Jenbacher gas engines for more than 16 years now and has long since grown to consider Tyrol
his home. He is an innovative engineer with business foresight, and he attaches equal impor-
tance to striving for technically perfect products actively seeking for direct contact with the
customers. In an interview with CoJen, Michael Wagner talked about the exciting times in the
international gas engine business and the daily challenge of building customer enthusiasm for
gas engine technology from GE.

CoJen: Mr. Wagner, you have been working for marketing for our gas engines. We also put over the world. Europe will still play an important
the Jenbacher product line for more than 16 a lot of energy into the development of new role in our international business. In the medium
years. Would it be fair to describe you as an applications and services for our customers. term, however, I see the biggest potential for
“old-timer” in the company? Utilizing industrial waste gases, such as in the growth in Russia, India and Bangladesh, as well
Michael Wagner: You’re right. Sixteen years steel industry, is a good example. as in the Asian regions of Indonesia and China
working for the same company tends to be and in Brazil in Latin America. These emerging
a rare thing in the current day and age. But I My job is to create new countries offer ideal conditions for the use of
haven’t worked in the same position for that segments and develop regions gas engines: strong economic growth, combined
whole time, and furthermore, the growth and for future business. with rapidly increasing demand for electricity,
changes in the company have always made my with public power supply lagging behind.
work exciting and challenging. What area of your work is the most appealing
to you personally? How do you see this development in light of
Does that mean that we can count on you for Without doubt, the development of new applica- the current economic situation?
another 16 years? tions for our gas engines. Many of the segments Good projects that make economic sense are re-
By then I would definitely be an old-timer. But se- in which we want to be present today and in the alized even when the economy is down. In some
riously, we live in an amazingly exciting time. De- future do not fully exist yet; they must first be regions, however, there are delays because the
mand for efficient, decentralized power stations actively created. From the business standpoint, question of financing cannot be easily solved
has grown rapidly in the last few years. Given that is an extremely stimulating challenge. It re- there. In addition, most of our applications offer
the fact that worldwide energy consumption will quires innovative ideas and the ability to realize significant environmental benefits. The reduction
double again in the next 20 to 30 years, I see no them. That’s a quality that Jenbach as a location of greenhouse gases is a central point within
reason why I shouldn’t work for the company for has always been closely linked to. the European Union, with the renewable energy
another 16 years. directive and the energy efficiency directive.
GE does business in more than 70 countries all North America, too, has experienced important
You and your team are responsible for the over the world with its Jenbacher gas engines. changes in energy policy under the Obama
global marketing activities of Jenbacher gas Where else do you think this journey will take administration. And last but not least, the
engines. What tasks does that include? the company? subject of environmental protection will become
Together with my team of 12 people, I am Gas engines were traditionally a European appli- increasingly important in the emerging regions.
responsible for market research and strategic cation, but in recent years they have spread all As you see, there are not just economic factors,

45
 personality story coJen

but also environmental policy considerations lute core competence for years. In addition,
that validate the use of gas engines. For us, as service and customer support have the highest
a company, it is now extremely important to priority for the Jenbacher team. We manage to
position our Jenbacher products and services so maintain excellent customer proximity with our
that we emerge from the crisis stronger than we own subsidiaries and with our local sales and
were when we entered it. The current situation is service providers. Thanks to our global network,
therefore not just a risk, but also an opportunity. customers can be sure they are in good hands
with us.
Nevertheless, the international gas engine Thank you very much for this interview.
business is becoming progressively more
competitive. What are the arguments in favor
of a power plant from GE, from the customer’s
perspective?
For customers, what is decisive is that the gas
engine solves their energy problem. Sometimes
they have no access to the public grid and have
to generate their own power. Or, if they want to Profile
generate electricity and heat more efficiently,
they may find that a cogeneration plant is Age: 44
less expensive than are conventional means. Education: Degree in Mechanical Engineering
In Jenbach, we have been focusing for more and Economy from the Technical University in
than 50 years exclusively on the development, Graz, Austria
refinement and sale of stationary gas engines. Married, with two daughters
This specialization has given us a leg up, both Recreation: Enjoys spending weekends and
in terms of technology and in respect of our holidays with his family. Keeps fit by mountain
customer focus. For most of our competitors, climbing and ski touring
gas engines are simply a by-product of diesel Since 2003: Marketing Leader, Jenbacher gas
engines, whereas they have been our abso- engines

46
Answer an easy
question and win a
weekend in Innsbruck!
All good things come in threes. And more!

One time is no time at all, twice is better, and all good things come in threes.
Though such expressions may be of proverbial relevance, they do not apply to CoJen! With the
publication of our third issue we have now really got going, and are already looking forward to the
forthcoming issues. The fact that our magazine has continued to grow is mainly thanks to all those
who have once again fed our editorial team with ideas and constructive suggestions in the past
weeks.

We would like to invite you once more to give us your opinions. What is still missing from CoJen?
What would you like to see more of? Which themes should we devote more space to?
We call upon you once again to please give us five minutes of your time.
Simply answer the questions below and fax your answer to us on +43 5244 600-527.
Masthead
Or e-mail us your suggestions to jenbacher.cojen@ge.com.
Publisher
Once more, we’d like to express our heartfelt gratitude for your opinion and support. In return, we GE Jenbacher GmbH & Co OHG
shall organize a drawing of all your contributions: The lucky winner will receive a voucher for a Achenseestr. 1-3, 6200 Jenbach, Austria
weekend in Innsbruck for two persons.
Editorial team:
I would like to read more in CoJen about: Axel Dancker, Andreas Eberharter, Arnfried
Kiermeier, Katherina Koller, Julia Kronthaler,
Stephan Laiminger, Eugen Laner, Georg Male,
Herbert Nagl, Thomas Misch, Thomas Pupp,
Martin Schneider, Martina Streiter, Michael
Wagner, Manfred Waldenmair, Christof Waltl,
Salina Wieser, Karin Zogmayer

Guest writers in this issue:

Which topic would you like to know more about in the next issue of CoJen? Fiona Riddoch, Managing Director COGEN Europe
Bob Gilligan, Vice President GE Energy,
Transmission & Distribution

Design and Layout:

Zimmermann & Pupp Werbeagentur

Printer:
Alpina Druck GmbH, 6020 Innsbruck, Austria
Printed on paper free from chlorine.

personal data: Feedback:

We value your opinion and welcome your
name: address: comments or questions. Please send them to the
editorial team at jenbacher.cojen@ge.com
title: phone:
Picture credits:
company: e-mail: GE Energy, Clarke Energy, TV Innsbruck
There is no right of appeal.
 home base coJen

From the city to mountain-

top in just 20 minutes
1809. A year that is inseparably linked to the history of Tyrol and its provincial capital.
Napoleon’s army was sweeping across Europe. And the Tyrolean struggle for
independence was raging on Bergisel. Andreas Hofer and his peasant troops confronted
the French and the Bavarians, and were victorious. A folk hero was born, and a myth
created. These happenings have helped shape the identity of many Tyroleans up to
the present day. This year marks the 200th anniversary of this historic year, and it will
be commemorated by a host of events, including critical reflections on maintaining a
balance between the traditional and the modern. And plenty of good reasons for visiting
Innsbruck precisely this summer.

2009. Innsbruck today. Hardly any other city The trip on up into the northern Alps on
combines its Alpine temperament with urban flair the new Hungerburg funicular and an
quite like Innsbruck. It is this special charm that aerial tramway is positively breathtaking.
makes Innsbruck one of the most livable cities These facilities enable you to get from the city
in Europe, and a popular destination for many centre to an altitude of over 2,000 meters in
city travelers and students. Thanks to the open just 20 minutes. The architecture of the new
borders of the European Union, the university – funicular is also pretty spectacular. This is Zaha
whose medical faculty enjoys an international Hadid’s second bold statement for the Alpine
reputation – has become a colorful melting pot of metropolis. The rugged cliffs of Karwendel seem
young people. Like the locals, they too enjoy the close enough to grasp as your gaze falls on the
unique combination of recreation, outdoor sports Inn valley far below you. The panorama spans
and a lively restaurant and bar scene. 360 degrees, and the snow-capped giants of
the central Alps can be seen glittering in the
Several years ago, star Iraqi architect Zaha distance on the horizon to the South. Those in
Hadid created a new landmark for the city search of relaxation can tuck into a typical Tyro-
of Innsbruck here, where once the bayonets lean plate of cold meat and sausage on the ter-
clashed and Andreas Hofer made his mark race and simply enjoy the good life. For the more
on history, here on Bergisel: the completely athletic visitor, the entire region – as the trendy
refurbished and imposing Bergisel ski jump. At name Nordpark suggests – is ideal for hiking,
the beginning of January each year, ski fliers climbing and biking. Here you are always at one
convene here to compete against one another in with Nature, with the city before your eyes.
the “four ramps” tournament. For the remain-
der of the year, visitors to the airy café right at And how would Andreas Hofer have ended this
the top of the jump can enjoy a magnificent article? You guessed it:
panoramic view. And, on the opposite site of “Men, the time has come to travel to
the valley across the city, they can also see the Innsbruck!”
next destination worth a visit: Seegrube in the
–> Magnificent panoramic view from the Bergisel northern Alps.

48
GE Energy

Some energy lasts

for generations.
Power generation from biogas with Jenbacher gas engines. Generating power isn‘t just about meeting
today‘s demands, it‘s about being sustainable – and supporting future generations. So instead of leaving
organic waste to rot, turn it into energy by fermentation and use the gas in our engines that turn it into
power and heat. It’s a greener, cleaner way of creating power for today ... and tomorrow.

To learn more about our green, versatile engines,

please visit www.gejenbacher.com