Repowering Fossil Steam Plants with Combustion Turbines

Evaluate cost and performance of replacing existing boilers with new combustion turbines and heat recovery steam generators Establish re-use plan for the steam turbine and balance-of-plant equipment Optimize gas turbine selection and duct firing based on plant-specific equipment capacities Compare projected life-cycle costs with a new combined-cycle reference plant

Background, Objectives, and New Learnings Many conventional fossil steam plants face uncertainty in future operation due to environmental regulations that would require significant upgrades to meet new emission standards. The capital expenditures required may be relatively high, particularly for moderately-sized to smallersized units firing coal or heavy oil. Older units may need significant boiler refurbishment to continue operation into the future. A reduction in carbon emissions also may be desired. One option commonly considered is conversion to a natural gas-fired combined-cycle configuration while maximizing reuse of existing equipment. This option is being more frequently implemented in the industry now that a period of secure availability of natural gas and relatively low fuel prices is projected. The objective of this project is to support the decisions involving the future of existing fossil steam plant assets in the generating fleet, particularly for those assets that require capital improvements and can no longer continue to operate at the status quo. In particular, owner/operators need to assess alternatives based on natural gas firing, such as repowering with combustion turbines in a combined-cycle configuration and either reusing the steam turbine(s) or installing a new combined-cycle unit at the existing plant site.

This project adds the experience and lessons learned in repowering over the last decade to the background of EPRI experience in repowering to provide general guidance on repowering configurations, cost and performance attributes, and considerations unique to repowering existing fossil steam plants. These lessons then are applied to specific site repowering, leading to additional new learnings. Benefits Results from this project provide plant owners with a thorough assessment of costs to repower their sites with combustion turbines in a combined-cycle configuration, including reuse of existing equipment such as the steam turbine. Comparisons of performance and life-cycle costs with an all-new combined-cycle plant lead to better-informed decisions regarding repowering options. In addition, updated repowering guidelines summarize lessons learned from previous repowering projects that can be applied to other plants in the owners fleet. Project Approach and Summary EPRI will conduct targeted evaluations of existing fossil plants to identify the technical and economic issues associated with converting conventional fossil steam units to combined-cycle operation. EPRI will use an extensive background from previous repowering studies and modeling tools such as the SOAPP Combustion Turbine/Combined-

Cycle and SOAPP Repowering Workstations to provide an initial screening evaluation. After initial screening and focus, a detailed engineering evaluation of repowering the designated site will be performed. Information on completed repowering projects will be gathered, and lessons learned from completed projects and studies will be compiled. Deliverables Site-Specific Evaluation of Repowering Costs and Performance: The design, performance, and cost for retrofitting combustion turbines and heat recovery steam generators at a host's existing site will be compared with a greenfield combined-cycle reference plant using the same combustion turbine at the same site. The re-use of the steam turbine and other balance-of-plant equipment will be determined, and refurbishment costs will be estimated. Host site personnel will have the opportunity to provide input at key decision points in the evaluation to incorporate funder needs. Each site-specific report will include: Site design basis (site conditions, duty cycle, capacity factor, plant availability requirements during construction, emissions requirements, transmission capacity, natural gas availability, and water availability) Steam turbine constraints (main and reheat pressure and temperature, low-pressure section exhaust flow, generator rating) Re-use plan (condenser, cooling towers, pumps, water treatment, demineralizer, air compressors) New equipment (combustion turbines, heat recovery steam generators with duct-firing capability, fuel gas compressors, and natural gas and electricity transmission capacity) Instrumentation and controls upgrades Performance evaluations (thermal optimization, full-load and part-load heat rates, heat and mass balances, water balance, and emissions) Plant configuration (general arrangement, constructability assessment, and schedule) Capital cost estimate (engineering, demolition, foundations, construction, electrical and mechanical

equipment, materials, natural gas pipeline from main, additional electrical transformers, switchgear, and transmission upgrades) Life-cycle cost assessment (capital, O&M, fuel, consumables, savings from early retirement of boiler and fuel handling) Recommendations for detailed condition assessments and potential modifications (steam turbine, heat rejection equipment, and pumps) General guidance on combustion turbine/combined-cycle repowering and a synopsis of non-confidential information from repowering studies of other sites representative of a range of repowering situations also will be included. Price of Project The cost to participate as a host site for a single-unit study is $180,000. cost is $65,000 for non-host participants. This project qualifies for Tailored Collaboration (TC) funding.

Project Status and Schedule The project will start as soon as initial host site funding is secured. Each host site evaluation will require four to six months. An initial repowering guideline and lessons-learned report will be commenced at the start of the project and updated after completion of multiple site evaluations. Who Should Join Power generating companies that own and operate existing fossil steam units which may be at risk of shutdown due to environmental regulations, or due to boiler conditions are nearing end of life, could benefit from participation in the project. Contact Information For more information, contact the EPRI Customer Assistance Center at 800.313.3774 (askepri@epri.com). Technical Contact Dale Grace at 650.855.2043 (dgrace@epri.com).

Product ID: 1023270

Project ID: 072059

June 2011

Electric Power Research Institute 3420 Hillview Avenue, Palo Alto, California 94304-1338 PO Box 10412, Palo Alto, California 94303-0813 USA 800.313.3774 650.855.2121 askepri@epri.com www.epri.com 2011 Electric Power Research Institute (EPRI), Inc. All rights reserved. Electric Power Research Institute, EPRI, and TOGETHERSHAPING THE FUTURE OF ELECTRICITY are registered service marks of the Electric Power Research Institute, Inc.