1300 MW Repowering Project: Claus C

Fondazione MEGALIA 5° Giornata sull’ Efficienza Energetica nelle Industrie

Milano, 14 June 2011

Simone Turina

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 2

Agenda

Introduction

Repowering Claus B: finding a solution

Claus C Repowering: describing the solution

Benefits

Claus C project execution: the challenge

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 3

CLAUS plant characteristics (Claus A, Claus B): 2x gas fired boiler, 2x 640 MW ST (supercritical) 7x pre-heaters

Power: 1280 MW, Efficiency: ~39%

Claus C Repowering Introduction

Clauscentrale (A, B): 30 years old gas fired steam power plant owned by Essent

Clauscentrale (A, B) Maasbracht, Netherlands Plant commissioning: 1978

, ESSENT - ALSTOM

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 4

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,…)

Claus C Repowering Introduction

Clauscentrale (A, B) at the fork way: dismissal or retrofit

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 5

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

Claus C Repowering Introduction

Essent decided to REPOWER Claus B into Claus C (CCPP)

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

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Agenda

Introduction

Repowering Claus B: finding a solution

Claus C Repowering: describing the solution

Benefits

Claus C project execution: the challenge

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 7

Claus C Repowering A Technical Challenge

Transforming a conventional 640 MW supercritical steam cycle with 7 pre-heaters into a sub-critical 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

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 8

Claus C Repowering A Technical Challenge

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 re-use of existing equipment. The selected technology has been based on the sequential combustion gas turbine GT26

Repowering Claus B: a technical challenge

GT26: sequential combustor GT

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 9

Claus C Repowering A Technical Challenge

Alstom engineering: a solution for Claus B repowering

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:

•! Minimum specific cost (!/kW) •! Maximum efficiency •! max re-use of site structure and

equipment •! Max flexibility (cycling, daily start) •! State of art emission levels

•! 3x GT26 multi-shaft ! KA26-3 •! 3x HRSG w/o duct firing •! ST retrofit •! Control system replacement solution

ALSTOM solution

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 10

Claus C Repowering A Technical Challenge

Alstom engineering & plant integration for repowering Claus B

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 11

Agenda

Introduction

Repowering Claus B: finding a solution

Claus C Repowering: describing the solution

Benefits

Claus C project execution: the challenge

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 12

Claus C proves the capability of Alstom as Plant Integrator

Claus C Repowering The Solution

Alstom target: Most effective and compact layout to get the best use out of the site area

CLAUS C CLAUS B

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 13

Claus C Repowering GT26 Gas Turbine

Claus C Repowering: GT26 advanced class sequential combustion GT

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 14

Leading combustion technology for flexible operation and minimized emissions

Claus C Repowering GT26 Gas Turbine

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

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Claus C GT26 Gas Turbine

•! EV temperature maintained high from: ~ 10% - 100% load -! low emissions over a

wide GT-load range SEV Combustor Temperature

SEV Ignition ~10% Load

•! Exhaust temperature maintained high between ~ 25% - 100% load -! superior CC part load

efficiencies -! quick CC start-up time

25%

GT Exhaust Temperature

VIGV Position

Relative GT Load 0% 100%

EV Combustor Temperature T

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

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•! 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

High performance and low NOx emissions over wide load range

GT Exhaust Temperature

EV Combustor Temperature

SEV Combustor Temperature

Claus C Repowering GT26 Gas Turbine

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 17

Lowest NOx emissions over CCPP load range 30%-100% and below

GT26 Typical NOx Emission

10% 20% 30% 40% 50% 60% 70% 80% 90% 100%

Relative CCPP Load

NO

x E

mis

sion

(vpp

m)

Typical GT26 NOx Emission (measured) Typical Single Combustor Engine Characteristic

0

25

Claus C Repowering GT26 Gas Turbine

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 18

•! 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

Claus C Repowering GT26 Gas Turbine

GT26: a technology to maximize efficiency and flexibility

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 19 Completely customized ST for maximum performance

Claus C Repowering The Steam Turbine

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

"! Non-Alstom ST "! Different steam cond. "! retrofit required in order

to maximize the plant performance

"! Dedicated retrofit team

Solution implemented is:

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 20

Agenda

Introduction

Repowering Claus B: finding a solution

Claus C Repowering: describing the solution

Benefits

Claus C project execution: the challenge

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 21 KA26–3 (3-on-1) for maximum performance and flexibility

Claus C Repowering 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 GT @ 90% load)

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 22

Claus C Repowering Repowering Performance Overview

CO2 savings > 2.1 Mt/y

Power: +104% add. Eff.: + 20% add. CO2: - 40% NOx: - 73%

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

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Claus C Repowering 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

ALSTOM high value solution: Claus C repowering is optimizing points 1 and 2

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 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 24

Claus C Repowering Economics

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 shows a clear advantage of specific overall cost of electricity (CoE ! !/MWh):

"! ~ 4% lower than a new CCPP "! ~ 17% lower than a modernized STPP

Claus C repowering: better CAPEX for higher NPV

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

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Claus C Repowering Economics

Repowering: the optimum match scope ##!! performance is a project specific case and it is defined according to the customer requirements

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

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 26

Agenda

Introduction

Repowering Claus B: finding a solution

Claus C Repowering: describing the solution

Benefits

Claus C project execution: the challenge

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 27

Claus C Repowering Work in progress

interfaces and construction challenges: > 900 specialists are required on site

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!

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 28

Claus C Repowering Work in progress

Claus C: from paper to… steel!

© ALSTOM 2010. All rights reserved. Information contained in this document is provided without liability for information purposes only and is subject to change without notice. No representation or warranty is given or to be implied as to the completeness of information or fitness for any particular purpose. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited.

1300 MW Repowering Project Claus C - S. Turina - 24 Nov 2010 - P 29

Claus C Repowering Work in progress

And thanks to THEM (and many many more)… …it is becoming REAL!!!

GRAZIE

per l’attenzione