1300 MW Repowering Project: Claus C

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1 1300 MW Repowering Project: Claus C Fondazione MEGALIA 5 Giornata sull Efficienza Energetica nelle Industrie Simone Turina Milano, 14 June 2011

2 Agenda Introduction Repowering Claus B: finding a solution Claus C Repowering: describing the solution Benefits Claus C project execution: the challenge 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 2

3 Introduction, ESSENT - ALSTOM Clauscentrale (A, B) Maasbracht, Netherlands Plant commissioning: 1978 CLAUS plant characteristics (Claus A, Claus B): 2x gas fired boiler, 2x 640 MW ST (supercritical) 7x pre-heaters Power: 1280 MW, Efficiency: ~39% Clauscentrale (A, B): 30 years old gas fired steam power plant owned by Essent 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 3

4 Introduction Claus plant was facing problems connected to:! Ageing! decreasing of reliability! Low profitability (high fuel costs due to low efficiency)! Non compliancy with the new emission limitations (IPPC)! Unsuitability to the required power dispatch profile (daily start, part load operation, ) Clauscentrale (A, B) at the fork way: dismissal or retrofit 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 4

5 Introduction Essent decided the following way:! Convert the plant to state of art combined cycle plant (CCPP)! Claus B to be repowered into Claus C! Minimize the investment! maximal re-use of the existing equipment/infrastructure! Minimize the use of new land Essent decided to REPOWER Claus B into Claus C (CCPP) 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 5

6 Agenda Introduction Repowering Claus B: finding a solution Claus C Repowering: describing the solution Benefits Claus C project execution: the challenge 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 6

7 A Technical Challenge Transforming a conventional 640 MW supercritical steam cycle with 7 preheaters into a subcritical combined cycle is a technical challenge! Essent started to query the market for technical solutions and feasibility studies back in 2005 Repowering Claus B: a technical challenge 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 7

8 A Technical Challenge GT26: sequential combustor GT Alstom succeeded to work out the most effective solution with the goal to provide the best possible efficiency together with highest flexibility and at the same time maximizing the reuse of existing equipment. The selected technology has been based on the sequential combustion gas turbine GT26 Repowering Claus B: a technical challenge 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 8

9 A Technical Challenge The steam cycle to be optimized was representing a challenge: Challenge : converting the maximum possible GT exhaust energy within the constraints of LP ST & condenser PROJECT TARGET: ALSTOM solution!!!!! Minimum specific cost (!/kw) Maximum efficiency max re-use of site structure and equipment Max flexibility (cycling, daily start) State of art emission levels solution!!!! 3x GT26 multi-shaft! KA26-3 3x HRSG w/o duct firing ST retrofit Control system replacement Alstom engineering: a solution for Claus B repowering 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 9

10 A Technical Challenge Alstom engineering & plant integration for repowering Claus B 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 10

11 Agenda Introduction Repowering Claus B: finding a solution Claus C Repowering: describing the solution Benefits Claus C project execution: the challenge 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 11

12 The Solution Alstom target: Most effective and compact layout to get the best use out of the site area CLAUS B CLAUS C Claus C proves the capability of Alstom as Plant Integrator 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 12

13 GT26 Gas Turbine Claus C Repowering: GT26 advanced class sequential combustion GT 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 13

14 GT26 Gas Turbine Leading combustion technology for flexible operation and minimized emissions 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 14

15 Claus C GT26 Gas Turbine! EV temperature maintained high from: ~ 10% - 100% load -! low emissions over a wide GT-load range T EV Combustor Temperature! Exhaust temperature maintained high between ~ 25% - 100% load -! superior CC part load efficiencies -! quick CC start-up time 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 15 SEV Ignition ~10% Load SEV Combustor Temperature GT Exhaust Temperature VIGV Position 0% 25% 100% Relative GT Load

16 GT26 Gas Turbine! EV temperature optimized from ~10-100% load -! low emissions over a wide load range! SEV follows the GT load demand and keeps exhaust temperature maximal between ~ 25% - 100% load -! high CC part-load efficiency -! quick CC start-up time GT Exhaust Temperature EV Combustor Temperature SEV Combustor Temperature High performance and low NOx emissions over wide load range 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 16

17 GT26 Gas Turbine GT26 Typical NOx Emission NOx Emission (vppm) 25 Typical GT26 NOx Emission (measured) Typical Single Combustor Engine Characteristic 0 10% 20% 30% 40% 50% 60% 70% 80% 90% 100% Lowest NOx emissions over CCPP load range 30%-100% and below 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 17 Relative CCPP Load

18 GT26 Gas Turbine! High exhaust temp of >600 C! high CCPP efficiency! High exhaust temp also at part load! superior CCPP efficiency at every load! Low emissions down to CCPP load <25%! Parking the CCPP overnight at ~20% CCPP load being emission compliant & load up to full load in <30 min! Fuel flexibility! Robust to fuel gas composition on-line changes, oil no. 2 GT26: a technology to maximize efficiency and flexibility 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 18

19 The Steam Turbine "! Non-Alstom ST "! Different steam cond. "! retrofit required in order to maximize the plant performance "! Dedicated retrofit team Solution implemented is: 1.! New HP and IP module 2.! Rebladed (new inner casing) LP module 3.! New controller 4.! Re-used: bearings, LP outer casing, part of the auxiliary systems Completely customized ST for maximum performance 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 19

20 Agenda Introduction Repowering Claus B: finding a solution Claus C Repowering: describing the solution Benefits Claus C project execution: the challenge 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 20

21 The CCPP Solution engineered!!! High GT26 part load performance in part load Optimized operating concept Turn-down capability from 100% down to 30% CCPP load Example:! 100% CCPP load! 59% eff.! 60% CCPP load! ~58.7% eff. (2x 90% load) KA26 3 (3-on-1) for maximum performance and flexibility 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 21

22 Repowering Performance Overview Power: +104% add. Eff.: + 20% add. CO 2 : - 40% NOx: - 73% 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 22 CO2 savings > 2.1 Mt/y

23 Economics The economical drivers of Repowering are:! Reduced investment! reduced capital costs! Better NPV and shorter payback! Reduced permitting time and efforts! Carbon tax reduction/credits on CO2 emissions Profitability of repowering projects depend for every electricity market characteristic on: 1.! balance between performance improvement and investment 2.! capacity to maximize performance increase for the chosen retrofit set-up ALSTOM high value solution: Claus C repowering is optimizing points 1 and MW Repowering Project Claus C - S. Turina - 24 Nov P 23

24 Economics Claus C repowering shows a clear advantage of specific overall cost of electricity (CoE!!/MWh): "! ~ 4% lower than a new CCPP "! ~ 17% lower than a modernized STPP The lower CAPEX can be straightforward translated into higher NPV, especially because the efficiency is practically the same as a new CCPP Claus C repowering: better CAPEX for higher NPV 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 24

25 Economics the positive effect of efficiency variations on NPV is 5 times higher (@ 6!/GJ fuel price) than the negative effect of EPC variation (3% vs. 0.6%). This means that any project scope increase lower than 5% capable to produce better efficiency of 1% is a benefit for NPV Repowering: the optimum match scope #! performance is a project specific case and it is defined according to the customer requirements 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 25

26 Agenda Introduction Repowering Claus B: finding a solution Claus C Repowering: describing the solution Benefits Claus C project execution: the challenge 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 26

27 Work in progress Claus C is an extremely complex project due to high number of interfaces between the new equipment and the one existing on site. The management of these >500 interconnection points requires 2 highly committed groups of engineers and field specialists working together: Alstom team and Essent team which all together account to circa 900 people! 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 27 interfaces and construction challenges: > 900 specialists are required on site

28 Work in progress 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 28 Claus C: from paper to steel!

29 Work in progress And thanks it to is THEM becoming (and many REAL!!! many more) 1300 MW Repowering Project Claus C - S. Turina - 24 Nov P 29

30 GRAZIE per l attenzione

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