UK Steel Mills use waste steam to generate profit

STEAM TURBINE EDITION | 2016

1st extraction-condensing STG on a FPSOSee page 2

Highest powered back pressure STG’s in the global sugar industrySee page 2

Specialist application engineering for low temperature, low pressure steam turns waste into profitable power generation. Heat and steam created during the smelting process in steel production is often wasted and vented into the atmosphere. UK Steel Mills have worked with the engineering team of Peter Brotherhood, the Steam Turbine specialists, to discover how waste steam can be used to generate power.

“Most people believe you need high pressure and temperature (superheated) steamforanefficientandcosteffectiveSteamTurbineGenerator(STG).Thisisn’ttrue,ourturbinescanharness‘lowgrade’steam and convert this into usable energy.” says Chris Greenham, Business Development, Peter Brotherhood.

Designed and manufactured in PeterBrotherhood’sstateoftheartfacility in Peterborough, the STG package included a fully integrated control panel and instrumentation. The machine is supported with condition monitoring to enable real time viewing of machine performance as well as a range of innovative safety systems designed specificallyforthewetsteam operational environment. Ifanyparameterexceedspre-determinedlimitsthenanalarmnotifiesthe operator so corrective work can be carried out, along with failsafe shutdown to ensure no damage to the equipment and personnel. Installed and commissioned within 43 weeks from order placement by Peter Brotherhood’sspecialistfieldserviceengineers, the UK Steel Mill industry is now harnessing what was wasted energy and converting this back into free power.

On 30th October 2015, UK Engineering group Hayward Tyler Group PLC completed the acquisition of the trade and assets of the Peter Brotherhood business for £10 million cash, from Dresser-Rand, an arm of German industrial giant Siemens. Peter Brotherhood is a UK manufacturer of steam turbines and gas compressors, neatlycomplementingHaywardTyler’sexistingbusinessofspecialistelectricmotors and pumps, whilst bringing in a number of new customers, such as the Keppel Shipyard. HaywardTylerchiefexecutive,EwanLloyd-Baker, said: “Over the last few years Dresser took the name away and it simply became the Peterborough operations of Dresser-Rand. The plan now, is to bring the brand and all it stands for, back to the forefront, and build on its near 150-year heritage.” With nearly 350 years of combined experiencebetweenthem,HaywardTyler’s(AIM:HAYT.L)acquisitionofPeterBrotherhood ties together two of the UK’soldestengineeringfirms.

Peter Brotherhood designs, manufactures, installs and services specialist turbines and compressors used in the power generation, marine, sugar, petrochemical and processing, Waste to Energy power plants, Combined Heat and Power (CHP) and oil and gas markets globally. PeterBrotherhoodistheUK’sonlyproducer of steam turbines with an output up to 40 MW, which has applications in waste heat recovery, the FPSO and FLNG markets and the British Navy Astute class submarine new build programme. Returningthebusiness’snameabovethedoorsignalsHaywardTyler’sintentionto re-energise and develop the business, having supplied steam turbines to the likes of Woodside, SBM, Saipem, Aker, Fred Olsen, Samsung and Maersk.

PeterBrotherhoodcurrentlyhasrevenuesofcirca£25millionperyear,employs 146staffandhasover1,500unitsoperatinginover100countries.

Peter Brotherhood Proud to be back!

Ewan Lloyd-Baker, CEO, unveiling the return of the Peter Brotherhood brand last year

“Great British engineering brands, such as Peter Brotherhood have a well-deserved kudos for reliability and quality around the world. We value our engineering heritage and what it means to our customers both in the UK and overseas.”EwanLloyd-Baker,ChiefExecutiveOfficer,PeterBrotherhood

Steam turbine innovation for generations

PROFITABLE TIMESSTEAM TURBINES. GENERATING PROFITS FOR YOUR BUSINESS.

High reliability, low maintenance, efficient performanceand a rapid return on capital investmentPeter Brotherhood steam turbines are designed for a variety of applications from 1 MW to 40 MW andinletpressuresto70bar;condensing,mixedpressureandback-pressure.Oursteamturbinesprovideover1000MWofinstalledpowerinWastetoEnergypowerplantsandwehaveinexcessof 500 machines installed in the Cane Sugar industry alone.

Todiscusshowoursteamturbinescanhelppoweryourprofits contactRayBowellon+44(0)1733292219.

www.peterbrotherhood.com/steam-turbines

Peter Brotherhood engineers have pulled off another first in the marine power industry, through the design, manufacture and installation of the first extraction-condensing Steam Turbine Generator (STG) to operate on a FPSO. It is also rated as the highest output STG in the North Sea.  PeterBrotherhoodwasselected duetothecompany’scredentialsforspecialistapplicationdesignaswellastheirextensiveexperienceinmarineapplicationsincludingFloatingProductionStorageandOffloading(FPSO)vessels.High-pressuresteamisraisedthroughamulti-fuelboiler,andprocesssteamisextractedasaheatingmediumfor the crude oil. Peter Brotherhood designed and manufactured the complete system – turbo generator set,controlsystem,thecondenserandtheirauxiliaries.Theteamwasworkingtocomplyacrossthreesetsofdesignspecificationsandsafetyrequirements–Lloydsclassificationstandards,thecontractor’sextensivespecifications,aswellasthestringentUKHSEregulations for the North Sea.

“Offshore is a notoriously challenging environment for machinery to work. Onceoperationalyou’remilesawayfromshorewithlimitedworkshopfacilities,spares and maintenance personnel. Therefore, reliability and availability of the machineareparamountbecauseiffailuresstoptheSTGrunningthenauxiliaryandprocesspowerarelostmeaningthevesselcan’tprocessanyoil,productionstops and money stops being made in a highly cash driven market.“ says JamesRichmond, BusinessDevelopmentDirector,PeterBrotherhood.

Designing for offshore, topside and hazardous area locations As well as impressive reliability, the application design that went into the engineering makesthissystemimpressive.Themachineryislocatedontheexposeddeckofthevessel; the harshest environment for any equipment – a merciless wind, rain and salt-laden environment, producing much higher stresses and forces on the equipment, movementandaccelerations, duetoitslocationonthetopdeckofthevessel.

Another world-first• Highest output steam turbine generator (STG) in the North Sea• 1st extraction-condensing STG on a FPSO

Having supplied the world’s first FPSO extraction steam turbine, Peter Brotherhood has since supplied two of the largest ever extraction condensing steam turbine generator sets for a FLNG, rated at 33 MW each.  The project is based on the allocation of 500 bcf of natural gas reserves from offshore Kribifields,tobeexportedtoglobalmarketsvia the GoFLNG facility Golar Hilli, which is currently under construction at the Keppel Shipyard in Singapore. Keppel Shipyard wasawardedtheproject,afirst-of-its-typeconversion of a Moss LNG carrier, the Hilli, into a FLNG. Both the steam turbines are located within the sponson tank mounted to the side of the original LNG vessel. The sponson tank was the only solution to enable all the necessary processingequipmenttobefittedwithoutbuilding a completely new vessel. Peter Brotherhood has provided technical support to the engineering team at Keppel Shipyard for the design of the supporting structure to the turbine and generator. Peter Brotherhood also supplied the complete steam bypass system and dump condensers for the three steam process lines – Start-up steam and both High Pressure (HP) and Low Pressure (LP) steam.

This by-pass system is not only located withintheconfinesofthesponsontank but certain control valves are also located topside within a hazardous area environment. The pressure reducing system, whichde-superheats bypass steam, as well as the associated control system, were similarly designed by Peter Brotherhood. A major engineering challenge was with the turbines being located in the sponson tank, whichseestheextremesoftheship’smotion.Therefore during the design phase of the project, special consideration had to be given tonotjusttheship’smotion,butalsothewaveinduceddeflections.

“It is crucial that the turbine alignment is maintained within strict parameters under all running and load conditions to ensure there is no risk of mechanical damage. Therefore the supporting deck was designed to tolerate thewaveinduceddeflectionsandreferredloads from the steam turbine generator.” says Nathan Abbott, Technical Director, Peter Brotherhood. Additionally space within the sponson tank is at a premium. The complete steam turbine generator package and main surface condenser has all been engineered to suit such tight requirements whilst still giving due consideration to maintenance spaces required.

Theoilextractionandprocessingonthevesselcreatesthepotentialforan explosivegascloud –therefore“hazardousarea”precautionsarebuiltintothemachineryto ensuretherearenosourcesofignition,including theessential electricalequipment and instrumentation that must be suitable for hazardous areas. To overcome the physical and environmental constraints, the design engineers at Peter Brotherhood not only designed the entire system, but they designed and manufactured an additional safe area segregation enclosure for the machinery.

The custom enclosure provides multiple safety features and benefits:• STGpackageincludinggenerator andoilsystemarelocatedwithinasafearea segregation enclosure, designed to maintain a positive pressure from the atmospheric conditions outside• If a gas cloud is detected, louvres in the enclosure close off, sealing the turbine so that it will not provide a source of ignition• As the turbine can be isolated during the presence of a gas cloud it can continue to operate–providingauxiliaryandprocesspowersothevesselcancontinueprocessing oilandthereforegeneratingrevenueandprofit• Intheeventofanexplosiononthetopsideofthevessel,thecustomenclosure will take the force, leaving the turbine intact

Collaboration delivers the finest marine application engineering, in the first-of-its type conversion of a LNG into a FLNG

One of the highest powered back pressure STG’s in the global sugar industry producing 38 MWExporting energy to the grid provides an additional revenue stream to the sugar mill.Secure electricity supply in remote locations brings vital energy to hospitals, schools and the local community.  Peter Brotherhood has designed and manufacturedhighlyefficientandreliablesteam turbine generators to sugar mills all over the world for more than 50 years. BuildingonPeterBrotherhood’spowergenerationinthesugarindustry,2x38MWback pressure steam turbines were designed and manufactured for a sugar co-generation plantinMexico.Similarmachinesareinstalledin sugar mills in Fiji, Vietnam, Mauritius, Australia, Tanzania and Southern Africa. The sugar co-generation plant burns the by-product from the sugar cane crushing process, bagasse, to raise steam.

The CO2 produced during this process is released into the atmosphere but is consumed by the growing sugar cane as part of the process of photosynthesis. This gives the overall growing, processing and plant power production the prestigious title of carbon neutral. The remote location of the sugar mills meanthatself-sufficiencyiskey;theability of the sugar mill to produce its own electrical powerensurestheefficientrunningofthesugarmill,butthelocalcommunitybenefitsfrom a secure source of power and drastically reduces the number of black-outs. To ensure this reliable source of energy for the mill and the local community, Peter Brotherhood designed, manufactured highlyefficient,highlyreliablesteamturbinegenerators that are capable of operating for inexcessof5yearswithoutanymaintenance.

Mechanical power

Using Bagasse to generate profits

Turbine Mill / Shredder DrivesBoiler £ £

TurbineAlternator

LP Steam for process

Power for process needs

Power for sale to utility

carbon neutral

CO2

Bagasse Steam

£

Mechanical power

Using Bagasse to generate energy

Turbine Mill / Shredder DrivesBoiler £ £

TurbineAlternator

LP Steam for process

Power for process needs

Power for sale to utility

Carbon neutral

Bagasse Steam

£

Using Bagasse to generate energy

Peter Brotherhood launches tailored customer care and support service Peter Brotherhood takes great pride in how they support their clients and is dedicated to ensurethemaximumpossiblereliabilityandavailability of all OEM and non OEM rotating equipment they have supplied and support.

AREAS OF EXPERTISE• Steam Turbines• Reciprocating Compressors• Screw Compressors• Gearboxes• Gas Reciprocating Engines• Gas to Power• Combined Heat and Power

Peter Brotherhood have a comprehensive range of services to support customers during the life cycle of owning, operating and maintainingcomplexrotatingmachinery.Thus helping to protect the operational need for which the investment was initially made.

A REPUTATION FOR EXCELLENCE PeterBrotherhood’sreputationisbasedon trust and is one of the most responsive in the industry.

Peter Brotherhood achieve this through:• Theirextensiveexperienceinmobilising

to different locations throughout the world

• Forward planning with their clients to understandthespecificneedsforcertain

areas of the world on anything that might slow down the ability to respond quickly, for exampleanyvisarequirementsorcustoms clearance in the case of replacement parts

• Remote technical support to start analysing and trouble-shooting an issue before our Field Service Engineer or a spare part has arrived

WORLDWIDE SUPPORT With equipment installed in 150 countries worldwide, a team of internationally experiencedFieldServiceEngineersandofficebasedstaff,PeterBrotherhoodhavetheknowledge and competence to understand whattheyneedtodoquicklyandefficientlyto mobilise their engineers to wherever they are needed.

For worldwide 24/7 support ensuring operational availability andefficiencypleasecontactMatt Down, Customer Services Director, Peter Brotherhood on:

+44(0)1733292399

PeterBrotherhoodCustomerCareAgreements(CCA)aredesignedtobringtogethercombinationsoftheirrangeofservicestocreateapackagebasedoncustomersindividualneeds.

•Improvedreliabilityandavailability•Lowerandmorepredictablecost ofownership•Supportingtheextendedlife ofmachinery•Predictablemachineoperation andmaintenance•Correctsparepartsbeingavailable attherighttime• Theassurancethatsupportwillbe availablewhenneeded

Peter Brotherhood offers both standard and tailored Customer Care Agreements.

TAILORED CUSTOMER CARE AGREEMENTS (CCA):

Working together. Succeeding together.Proud to be Peter Brotherhood.PeterBrotherhoodareaworldleaderindesigning,manufacturingandservicingsteamturbinesandturbinegenerator(TG)setsupto40MW.Withthousandsofsteamturbineinstallationsinmorethan100countrieswehaveareputationforreliabilityandon-timedeliveryatacompetitiveprice.Priortoleavingourworld-classfacilityallproductsaretestedin-houseonlivesteam,toensuretheymeetthecustomer’srequirementsbeforetheyleavethefactory.

Visit www.peterbrotherhood.com/steam-turbines or contact Ray Bowell on +44 (0)1733 292219.Design.Manufacture.Install.Service. Steam turbine innovation for generations

availablewhenneeded

Peter Brotherhood offers both standard and tailored Customer Care Agreements.

Steam Turbines.Generating profits for your business.

Peter Brotherhood are a world leader in designing, manufacturing and servicing steam turbines and turbine generator (TG) sets up to 40 MW. With thousands of steam turbine installations in more than 100 countries they have a global reputation for reliability and on-time delivery at a competitive price.

Peter Brotherhood products include:• Steam turbines and turbo generators forFPSOs,FLNGsandmerchantfleets• Steam turbines for the cane sugar industry, industrial land based applications, gas to power, power generation in the process oil & gas industry• Gascompressorsforrefiningtechnology • Combined heat and power systems

Peter Brotherhood provide reliable and efficientsingle,andmulti-stagesteamturbinesfor mechanical drive applications offering flexibledesignoptionstomeetcustomer’spower and steam requirements.

COMMITMENT TO QUALITY Peter Brotherhood is proud to conform to the stringent quality assurance standard ISO 9001:2008 and the environmental management standard ISO 14001:2004 as well as the Occupational Health and Safety Management System OHSAS 18001:2007.

CUSTOMISED APPLICATION ENGINEERING Every steam turbine built by Peter Brotherhood is unique. They answer every customer’sspecificbusinesschallengeswiththeirknowledgeandexperienceofdifferentsteam turbine applications across various environments – fromcopingwithship’smotionand harsh environments in the North Sea to the extremetemperaturesofsub-SaharanAfrica.

CONTINUOUS DEVELOPMENT Ongoing R&D, combined with feedback from manyhundredsofsteamturbinesinthefieldenables Peter Brotherhood to continuously develop designs and manufacturing procedures, improving product capability, reliabilityandperformancetomaximiseefficiencyforlowerfuelconsumptionandhelpanswer industry challenges of climate change and reducing CO2 emissions.

PETER BROTHERHOOD PROVIDE A COMPLETE SERVICE FROM INITIAL CONCEPT DEVELOPMENT TO INSTALLATION AND COMMISSIONING,AS WELL AS AFTER SALES SUPPORTAND ON-SITE MAINTENANCE.

Increase efficiency, reduce cost of power generation, cut emissions, improve competitiveness.

Peter Brotherhood’s products are in operation across 100 countries

Steam turbines installed in the Cane Sugar industry

500+

Steam turbines supplied to merchantfleetsworld-wide

1,000+Installed power in Waste to Energy power plants

1,000 MWUK’sonlyproducerofsteamturbineswith outputs up to 40 MW

40 MW

ADVANTAGES OF CHOOSING A PETER BROTHERHOOD STEAM TURBINE:

• Highlyefficient,maximisingpower outputandprofitability

•Customisedsteamturbines answeringcustomersindividual requirements

• Bestinclassdeliverytimes

•Designandmanufacturerof steamturbinessince1907

•Globalreputationofdelivering energyefficientsolutionsforland- andmarinebasedapplications

•Rangefrom1MWto40MW

•Reliable,longservicelife (25+years)

•Lowmaintenance

PeterBrotherhoodLtd,85PapyrusRoad,Peterborough,PE45HG.Tel:+44(0)1733292200.www.peterbrotherhood.com Peter Brotherhood is part of the Hayward Tyler Group.