HRSG Impact Assessment of

Gas Turbine Upgrades

Dan Blood, Uniper Technologies
European HRSG Forum, Bilbao, 15th -17th May 2018
Agenda

About Uniper

Rationale for gas turbine upgrades

Understanding the impact on the water / steam cycle

Case study: Impact of VLP upgrade for GE 9FA / 9FB

Summary

Questions
We are Uniper
Our operations: Where we operate: Employees: 12,000

Power Generation

Commodity Trading Power generation, Storage, Services - Europe

Power generation - International

Energy Storage
Commodity Trading, Energy Sales
Energy Sales

Energy Services
€ 1.7 bn 100 years 36 GW
40+ countries around the world EBITDA Experience Total generation
4th largest generator in Europe

Main activities:

Gas fired plants Coal fired plants Energy storage Gas pipelines and Regasification
19.2 GW 10.5 GW Gas: 8.2 bn m3 infrastructure

Nuclear plants Hydroelectric plants Trading Energy sales (small to large clients, electricity Services
1.9 GW 3.6 GW and gas)

Data: Uniper Annual report 2017

Expertise built on engineering excellence
and asset owner / operator experience

We are a one-stop shop Our background as an We are independent of

offering a broad range of asset owner/operator equipment and component
services that work closely gives us deep suppliers, giving us
together, reducing understanding of the freedom to choose the best
complexity and risk for energy industry and our solution for clients
clients clients’ needs

Expertise based on experience

UK Central Electricity Pipeline Engineering

Innwerke Generating Board GmbH

1917 1926 1957 1970 1978 1990 2000 2016

VEBA Kraftwerke Powergen

Ruhr AG Power Technology
Agenda

About Uniper

Rationale for gas turbine upgrades

Understanding the impact on the water / steam cycle

Case study: Impact of VLP upgrade for GE 9FA / 9FB

Summary

Questions
Rationale for gas turbine upgrades

Site / market specific but themes are:

Ÿ Increased need for flexibility due to
renewables growth, commodity
prices, demand volatility and
demand for balancing services
Ÿ Plants are displaced in the dispatch
order by new market entrants
Ÿ Change from hours-based to
starts-based operating regime
increases focus on start cost GWh/start Starts

Ÿ Low power prices and uncertain 250

environment for new-build 200

investment 150

100
→ Market survival
50
→ Market optimisation
0
2008 2009 2010 2011 2012 2013 2014 2015
Potential offered by gas turbine upgrades

GT upgrades offer a range of measures to Improved start-up time:

improve market value, including: Combined Cycle
with VLP
Ÿ Improved speed of response (fast starts,
fast ramps, fast shutdown) Open Cycle

Ÿ Increased maximum load

Ÿ Increased cycle efficiency
Ÿ Reduced minimum load Standard
Combined Cycle
Ÿ Enhanced ability to offer grid services

Such upgrades offer a CAPEX efficient Reduced minimum load:

means of keeping plants competitive →
push back up the dispatch order

→ Increase revenue
→ Generate value
Agenda

About Uniper

Rationale for gas turbine upgrades

Understanding the impact on the water / steam cycle

Case study: Impact of VLP upgrade for GE 9FA / 9FB

Summary

Questions
Key questions when considering GT upgrades

Ÿ What will be the impact on the water / steam cycle?

Ÿ Will it cope with the new process conditions?
Ÿ Will it be safe to operate?
Ÿ Will the water / steam cycle restrict the full capabilities of the upgrade?
Ÿ Will I get the full value of my investment?
Ÿ Will pressure part inspection regimes need to be adjusted or enhanced?
Ÿ How do I understand, quantify and manage the potential risks?
Ÿ Will reliability be compromised?
Ÿ Will the GT supplier ensure that the water / steam cycle is ‘fit for purpose’?

→ A formal process is needed to understand and mitigate the risks

→ GT suppliers may not do a comprehensive assessment or may make
assumptions which are not truly valid
Uniper’s recent experience of water / steam
cycle impact assessment
2011 2012 2013 2014 2015 2016 2017 2018

Variable Load Path Fast Ramp Rate

Variable Load Path Enhanced Variable Load Path

Variable Load Path Fast Ramp Rate

Variable Load Path

Variable Load Path

Black start capability

Low Part Load Advanced Performance Package
Low Load
‘Open Cycle’ start-up
Operating Concept
Minimum Load
CO Reduction / Extended Turndown
Reduction

Service Pack 7 package

Siemens SGT5-
GE 9FA GE 9FB Alstom GT26
4000F

Includes VLP experience at 12x 9FA units and 1x 9FB unit

and global ‘first of kind’ installations for both GT types
A structured approach to impact assessment

Define new Instigate Reassess

mode of risk
operation Initial reduction Assess
review of plan plant trials
risks (e.g.
HAZOP or
HAZID)

PLANNING TESTING IMPLEMENTATION

Quantify Implement
risks
(engineering
Review Adapt and
impact
impact of assessment) enhance
mode of maintenance
operation / inspection
(e.g. by regimes (e.g.
plant Undertake pressure
modelling) plant trials parts)
Thermal plant modelling

Ÿ PROATES® is a whole plant modelling software package – enables impact of

plant upgrades, modifications or changes in operation to be quantified

1 2 3 4
Build site-specific Model the impact Identify differences Calculate critical
model and validate of the new GT between pre- and parameters such
with real plant data exhaust conditions post- upgrade as saturation and
process conditions superheat margin

Ÿ Outputs are used to inform:

- HAZOP studies and resulting risk mitigation measures prior to testing
- engineering impact assessment
- future pressure part component inspection strategy
Typical PROATES model for a CCGT plant

Modelling is essential to understand the complex

interactions between components and process flows!
HAZOP (HAZard & OPerability) Study

Ÿ Reduces risk of potentially disastrous incidents and operational problems by

identifying hazards and suitable risk controls
Ÿ Detailed review fulfilling international, local and company requirements
Ÿ Used on new plant, ageing plant and for plant modifications
Ÿ Uniper provides HAZOP study leadership and plant specialists to
complement the knowledge and experience of site personnel (and OEM)
Ÿ Considers the causes of process deviations, consequences and safeguards
Ÿ Provides recommendations with actions & responsibilities categorised as:
- ‘pre-commissioning’
- ‘commissioning’
- ‘post-commissioning’
Agenda

About Uniper

Rationale for gas turbine upgrades

Understanding the impact on the water / steam cycle

Case study: Impact of VLP upgrade for GE 9FA / 9FB

Summary

Questions
GE9FA / 9FB Variable Load Path ‘VLP’ upgrade

Ÿ GE / Uniper joint development Conventional operating ‘path’:

project (2011-)
Ÿ VLP is a GT control feature which
uses IGV control to keep exhaust
temperature low during start-up
Ÿ Allows independent control of GT
load and exhaust temperature within
an ‘operating space’
Ÿ Significantly decouples GT output
from HRSG / ST thermal constraints VLP operating space:

VLP enables: HOT PATH

→ more MW in less time
→ reduced fuel burn
→ reduced load imbalance PA
T H
LD
→ reduced start emissions CO

→ reduced start cost

GE9FA / 9FB Variable Load Path ‘VLP’ upgrade

Plant A Hot Start Comparison Plant B Hot Start Comparison

Pre-VLP VLP Pre-VLP VLP

Start-up Fuel Cost 40% Compare Op 143 Starts 233 Starts

Savings Jun’14 – May’15 1,900 Hours 3,100 Hours
Start Time c.130 mins c.65 mins Time to 150MW 55 mins 10 mins

BUT…this causes a redistribution of heat in the balance of

plant – requires detailed HRSG & ST assessment
VLP Impact/Risk: HRSG Heat Balance Comparison
At same output:
H
AT

T H
TP

PA
LD
HO

C O

Cold path reduces heat in

the HP and Reheat sections
and “pushes” more heat
energy to the IP and LP
sections of the HRSG
VLP Impact/Risk: HRSG Heat Balance Comparison
At same exhaust temp:
H
AT

T H
TP

PA
LD
HO

C O

Cold path enables the GT to

deliver more output and
increases / redistributes the
overall heat energy into the
HRSG - particularly in the IP
& LP sections

For the cold path, modelling predicted that the IP Evaporator

would be overwhelmed (more than 100% of full load heat input)
→ the VLP operating space needed to be reduced
VLP: Requirement for ‘Exhaust Flow Boundary’

Ÿ In some assessments, modelling predicted that the IP Safety Valve

capacity would be insufficient at the extremes of the VLP operating space
Ÿ Required ‘Exhaust Flow Boundary’ to be imposed for plant integrity / safety
Ÿ Boundary determined via plant modelling, impact assessment, HAZOP and
carefully monitored and controlled plant trials
650

600
H
GT Exhaust Temperature (°C)

T
PA

550 T H
AD

PA
AD
LO

LO
T

500
LD
HO

A RY CO
ND
OU
WB
450
T FLO
A US
EXH Control system
400
prohibits operation in
this region
350

300
0 50 100 150 200 250
GT Load (MW)
VLP: ‘Exhaust Flow Boundary’ relaxation

Ÿ Flow boundary provides a safeguard, but restricts full exploitation of VLP

Ÿ Desirable to relax the boundary as far as possible, subject to rigorous
assessment / implementation of additional risk control measures
Ÿ At one site, relaxation possible via retrofit of additional IP Drum safety valve

New IP Drum safety valve

VLP: ‘Exhaust Flow Boundary’ relaxation

Ÿ At another site, safety valve capacity was reassessed against current design
code requirements (EN12952) which supersede the original design code
Ÿ Enabled a case for flow boundary relaxation to be made
Ÿ ‘Relaxation test’ confirmed the high IP steam volumetric flow anticipated,
confirming the validity of the predictive modelling

IP/LP steam volumetric flows

TH

H
PA

T
PA
AD

ST
TE
LO
T

ARY
HO

ND 126%
W BOU H
FLO
PAT
AD
LO
LD Beyond EFB
CO

Test moves beyond

flow boundary

Relaxation test profile

VLP: Example impacts / risks to Balance Of Plant
Impact Typical Risks (site-specific) Potential Mitigations
• Monitor for indications of boiler /
• Economiser steaming causing stagnation / reverse Balance of Plant control issues or
flow / water hammer / drum level fluctuations equipment damage
Reduced sub-cooling
• Steam flashing across level control valves causing • Increase steam pressure to reduce
margin at economiser
valve damage steam volumetric flow
outlet
• Drum level instability due to loss of natural circulation • Use economiser bypass to improve
• Forced circulation pump damage due to cavitation sub-cooling margin and reduce
steam flow
• Increased feed water demand requiring backup • Limit gas turbine exhaust flow by
pumps to operate using the Exhaust Flow Boundary
Increased steam flow • Insufficient capacity of safety pressure relief valve(s) control feature
from IP & LP • Water carryover from drums • Retrofit high pressure trips to HP /
Evaporators • Insufficient capacity of steam turbine bypass systems IP / LP drums prior to testing
and attemperation • Enhance maintenance / inspection
• Change in steam turbine thrust (bearing loading) regimes to target areas where
modelling / testing suggests
enhanced rates of damage
Increased steam • Droplet impingement in superheaters
velocity in IP & LP • Liberation of debris with consequent risk of erosion & • Minimise personnel exposure
steam circuits steam turbine damage • Consider probability of failure in
risk assessments, given the
Increased gas-side duration of operation expected at
• Stack temperature exceeds design limit challenging conditions
conditions
Agenda

About Uniper

Rationale for gas turbine upgrades

Understanding the impact on the water / steam cycle

Case study: Impact of VLP upgrade for GE 9FA / 9FB

Summary

Questions
Summary

Ÿ GT suppliers offer upgrades to increase plant flexibility and competitiveness

Ÿ Upgrades can have negative impacts on the HRSG / ST or the benefits can
be restricted or negated by balance of plant limitations

Ÿ Plant modelling, engineering impact assessment and HAZOP before upgrade

implementation is key to understanding the risks and appropriate mitigations

Ÿ A structured approach minimises risks to component integrity, process safety

and operability, ensuring maximum value can be gained from the investment
Agenda

About Uniper

Rationale for gas turbine upgrades

Understanding the impact on the water / steam cycle

Case study: Impact of VLP upgrade for GE 9FA / 9FB

Summary

Questions
Any questions?

2011 2012 2013 2014 2015 2016 2017 2018

Variable Load Path Fast Ramp Rate

Variable Load Path Enhanced Variable Load Path

Variable Load Path Fast Ramp Rate

Variable Load Path

Variable Load Path

Black start capability

Low Part Load Advanced Performance Package
Low Load
‘Open Cycle’ start-up
Operating Concept
Minimum Load
CO Reduction / Extended Turndown
Reduction

Service Pack 7 package

Siemens SGT5-
GE 9FA GE 9FB Alstom GT26
4000F
Thank you!

If you need any further information, please contact:

dan.blood@uniper.energy

Uniper Technologies
Technology Centre
Ratcliffe-on-Soar
Nottingham
NG11 0EE
UNITED KINGDOM

www.uniper.energy

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.