gas turbine parts life extension
TRANSCRIPT
Gas Turbine Parts Life ExtensionPaul Jeffreys – Department Head, Gas Turbine Solutions, Uniper Technologies Ltd, May 2019
Agenda
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Introduction to Uniper
Uniper Gas Turbine Strategy
Gas Turbine Parts Life Extension
Contractual Considerations
PLE Implementation
PLE Achievements
Questions7
Uniper at a glanceInternational energy company with more than 12,000 employees
Gas fired plants19.2 GW
Coal fired plants10.5 GW
Energy storageGas: 8.2 bn m3
Gas pipelines and infrastructure
Regasification
Nuclear plants1.9 GW
Hydroelectric plants 3.6 GW
Trading Energy sales (small to large clients, electricity and gas)
Services
Data: Uniper Annual report 2017
40+ countries around the world4th largest generator in Europe
Employees: 12,000
Power generation, Storage, Services - Europe
Power generation - International
Commodity Trading, Energy Sales
€1.7 bnEBITDA
100 yearsExperience
37 GW Total generation
Our operations
Power GenerationCommodity TradingEnergy StorageEnergy SalesIndustrial Services
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Expertise built on engineering excellence and owner operator asset experience
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We are independent of equipment and component suppliers, giving us freedom to choose the best solution for clients
We are a one-stop shop offering a broad range of services that work closely together, reducing complexity and risk for clients
Our background as an asset owner/operator gives us deep understanding of the energy industry and our clients’ needs
Our Conventional Plant Expertise
Ratcliffe (1967)4 x 500MW sub-criticalBabcock & Wilcox boilers 565°C, 165barFGD & SCR retrofits Efficiency ~37%
Maasvlakte 3 (2014)1100MW ultra-supercriticalHitachi boiler, Alstom turbine600/620°C, 285barCo-firing Bone meal &BiomassDistrict HeatingEfficiency ~46%
80+ years operating coal assets;
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Killingholme (1993)2 x 450MWSiemens SGT5-2000E525°C, 80barEfficiency >50%OCGT conversion
Irsching 4 (2011)570MWSiemens SGT5-8000H570°C, 170bar3 pressure + reheat, Benson boilerEfficiency >60%
25 years operating CCGTs
Agenda
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Introduction to Uniper
Uniper Gas Turbine Strategy
Gas Turbine Parts Life Extension
Contractual Considerations
PLE Implementation
PLE Achievements
Questions7
Uniper Gas Turbine Technology Strategy Harmonise technology
Understand & manage risks
Improve outage performance
Reduce costs in line with technology maturity & risk
Respond to market changes
Leverage fleet knowledge & size
Parts Life Extension (PLE) –a key strategic programme
for Uniper
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Agenda
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Introduction to Uniper
Uniper Gas Turbine Strategy
Gas Turbine Parts Life Extension
Contractual Considerations
PLE Implementation
PLE Achievements
Questions7
Gas Turbine - Parts Life Extension (PLE)Situation GT parts refurbishment & replacement (component
life) is specified by the OEM:
Running hours & starts formulae
Weighting factors apply (e.g. trips, starts, frequency response, peak firing, etc.)
At the end of the specified parts life, any residual operating life is wasted
Result is lower risk for the OEM - higher cost for the operator.
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SolutionUniper has developed a risk-based approach to extend GT parts life which can typically deliver 15-30% cost saving by
extending major outage intervals
Typical GT maintenance schedule
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Gas Turbine Illustration
Typical running costs over a GT lifetime
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1 Every 25k EOH
Every 50k EOH
Every 100k EOH
Hot Gas Path(blades, vanes, combustion)
1 + Compressor
+ + Rotor
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1 2
2
3 Every 2700 Starts
Every 1800 Starts
Every 900 Starts
NB: Numbers quoted above vary depending on GT type and are for illustration only
Optimised GT maintenance schedule Using the remaining life of the components…..Optimised maintenance
aims to remove one outage from the GT lifecycle of 100,000 hours
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Optimised lifecycles by components (ideal case)
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Every 25k EOH
Every 50k EOH
Every 100k EOH
Hot gas path(blades, vanes, combustion)
+ Compressor
+ + Rotor
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1 2
2
3
1
Every 33k EOH
Every 66k EOH
Every 120k EOH
Hot gas path(blades, vanes, combustion)
+ Compressor
+ + Rotor
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1 2
2
3
121
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321
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21
1
321 Typical
savings 23%
Running costs over
a GT lifetime
Optimised running
costs over a GT
lifetime
Maintenance lifecycles by components (OEM guidelines)
NB: Numbers quoted above vary depending on GT type and are for illustration only
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Robust Approach to Life Extension
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Identify and size the value opportunity
Preliminary risk review
Detailed technical evaluation
Implementation & monitor results
Assess technical risk against cost-benefit analysis, implement,
ongoing condition assessment, learn,
extend to other sites
Knowledge & data gathering, capability development, conferences, collaborative projects
Feedback, inform, learn
Develop work plan, obtain design & materials data,
testing, plant data, analysis, modelling
GT history, maintenance, parts condition, operating regime, fleet issues
Confirm contract status, outage
schedule, fleet data
Agenda
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Introduction to Uniper
Uniper Gas Turbine Strategy
Gas Turbine Parts Life Extension
Contractual Considerations
PLE Implementation
PLE Achievements
Questions7
Contracting strategy to support PLE CONFIDENTIAL
Uniper has a mix of contract styles appropriate for its gas turbine fleet, based on:
Technology Risks Market Conditions
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Transactional Frame Contracts
LTSA
Price Certainty Security of Supply of Parts & Services Performance Guarantees Long Term Maintenance Flexibility Operations Flexibility Parts Ownership Low Lifetime Price
Frame contracts are seen as the optimum for many Uniper assets and are an enabler for PLE
Agenda
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Introduction to Uniper
Uniper Gas Turbine Strategy
Gas Turbine Parts Life Extension
Contractual Considerations
PLE Implementation
PLE Achievements
Questions7
PLE Implementation A structured methodology for PLE, underpinned by technical
expertise:-
Identify opportunities for interval extensions; complete initial assessment of the value
Carryout preliminary risk review
Complete detailed technical evaluation to address identified risks
Preparation business case
Implement proposed outage interval extension
Regular reviews to monitor and manage risk during operation
Identify and size the value opportunity
Preliminary risk review Detailed technical evaluation
Implementation & monitor results
Assess technical risk against cost-benefit analysis,
implement, ongoing condition
assessment, learn, extend to other sites
Knowledge & data gathering, capability development, conferences, collaborative projects
Feedback, inform, learn
Develop work plan, obtain design & materials data,
testing, plant data, analysis, modelling
GT history, maintenance, parts condition, operating regime, fleet issues
Confirm contract status, outage
schedule, fleet data
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Technical Innovations to Support PLE Programme
Uniper Technologies has developed in-house expertise in a number of technical areas to support the PLE programme. These include: Component Modelling, including:
Blue light Scanning CFD and FE Analysis
Metallurgical evaluation of service run components Advanced Inspection Techniques, including:
Boroscope/NDT inspection of high risk components Image recognition algorithms
These support the Risk Based Approach to extended parts life.
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PLE Modelling Methodologies Blue light Scanning
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Detailed Metallurgical Evaluation of Components
Destructive examination To characterise the condition of the coating and substrate alloy To characterise the extent of any observed defects or
degradation
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Intergranular crack
Thermal fatigue crack
Advanced Inspection of Critical Components
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Borescope pathway
Laboratory simulation to develop improved NDT of blade cracks
Advanced Inspection Techniques
Use of image recognition techniques to: Identify and correlate specific blades between
sequential inspections Evaluate component degradation e.g. coating
loss between inspections
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Agenda
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Introduction to Uniper
Uniper Gas Turbine Strategy
Gas Turbine Parts Life Extension
Contractual Considerations
PLE Implementation
PLE Achievements
Questions7
EOH Limit
PLE AchievementsSuccessful delivery of extended intervals on 4000F,GT26 and 9FA:
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EOH Limit EOH Limit
Starts LimitStarts Limit
OEM Limits Supported PLE LimitsOutturn
20% increase 4000F
WCE LimitWCE Limit
GT26
9FA
Significant Value Delivered to Uniper from PLE:Average benefit – Euro 1M/unit/year
EOH Limit15% increase
15% increase
25% increase
Summary
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• Uniper has significant experience (> 25 years) in operating CCGT assets and adapting them to market conditions.
• Research & development over several years to understand GT Hot Gas Path components, materials, design, coating and life expectancy
• Systematic processes in place to evaluate the risks and benefits for GT Hot Gas Path Parts Life Extension (PLE).
• PLE successfully implemented on 9FA, 4000F & GT26 machines.
• Average savings of Euro 1M / year on every asset where PLE has been implemented.
• Uniper is working with external clients to improve their CCGT assets performance and profitability at acceptable risk levels.
Agenda
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Introduction to Uniper
Uniper Gas Turbine Strategy
Gas Turbine Parts Life Extension
Contractual Considerations
PLE Implementation
PLE Achievements
Questions7
Thank YouQuestions?
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Thank you!
If you need any further information, please contact us:
Uniper SEHolzstraße 640221 Düsseldorfwww.uniper.energy
Uniper disclaimer:This presentation may contain forward-looking statements based on current assumptions and forecasts made by Uniper SE management and other information currently available to Uniper. Various known and unknown risks, uncertainties and other factors could lead to material differences between the actual future results, financial situation, development or performance of the company and the estimates given here. Uniper SE does not intend, and does not assume any liability whatsoever, to update these forward-looking statements or to conform them, to future events or developments.