Integrated. for Steam Power Plants

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1 Integrated Service Solutions for Steam Power Plants

2 Services for thermal power plants Alstom is dedicated to keeping thermal power plants competitive. Thanks to our OEM expertise and involvement in around 25% of the world s power production capacity, Alstom operates from a position of proven expertise. With 15,000 power industry professionals spread across 200 world-wide locations, we support our customers with extensive service solutions for daily operations and maintenance while helping to enhance lifecycle management. In a changing competitive and regulatory environment, flexibility and expertise are key. Building on our global fleet and project execution experience, we partner with owners of Alstom and other OEM equipment to help maximise performance and lifetime profitability while keeping safety, reliability and environmental compatibility top priorities. Alstom is a global organisation that cultivates cutting-edge expertise at the product / technology level while maintaining a strong local presence to meet site-specific needs and efficiently deliver tailored solutions in both established and emerging markets. Whether you require support in the areas of skills or systems, we have the technology, solutions and presence to meet your needs.

3 Taking the holistic view delivers greater benefits than the traditional component improvement approach. Plant solutions The power of integration Optimise your plant strategy with integrated solutions In today s dynamic environment, fossil-fuel plant owners face significant lifecycle management challenges. On top of price pressures due to market liberalisation come climate change and other environmental concerns. Besides stricter emissions regulations there is a shift towards fluctuating renewables that is changing the energy mix. Operation and maintenance cost reductions are needed along with performance improvements across the board. As a result, fossil fuel steam plants need to be more flexible and efficient, while cutting emissions. In some market regions, there are also government fuel-saving programmes, which create further financial incentives for plant operators to reduce their fuel consumption. To address these challenges, Alstom offers a range of integrated service solutions; from whole plant or more targeted assessments, to product selection, customisation and execution, we are a reliable one-stop partner. By taking a holistic approach to understanding and addressing your plant and market requirements, we can help find the most cost-effective solutions and uncover hidden potential. We capture operational and implementation synergies that are normally missed when approaching the plant with a strict component perspective. To derive the maximum benefit from our solutions they need to be fully aligned with your business objectives and tailored to your specific plants. To this end, Alstom has developed advanced plant optimisation methods and technologies that build on our turnkey plant construction experience, universal product portfolio and rich technological heritage. 03

4 A coordinated for efficiency Plant and condition assessments Plant improvement products Integrated plant retrofits From status to roadmap An Alstom plant assessment is the best way to start planning and optimising the future of your existing assets. Our methodical analysis determines what options are available given your technical and budget constraints. In addition, our condition assessments provide a comprehensive review of the status of all plant equipment. New solutions Our unique set of steam plant products offer new and practical approaches to improving your production efficiency, flexibility and environmental performance. These products are pre-engineered solutions that can be easily adapted to your plant needs. This ensures transparent and reliable cost control and dependable performance outcomes. Optimised implementation We offer full planning and execution of refurbishment projects to optimise outage management and manage the risks. We can coordinate all the work even if it needs to be spread over different outages and encompasses different plant systems. 04

5 approach and flexibility Owners of existing coal-fired steam plants are under pressure to produce more efficiently with greater operational flexibility while reducing their environmental impact. Alstom s integrated solutions services are a fundamentally different type of response to the familiar component improvement approach. Adopting a holistic engineering approach, we help customers to identify opportunities for plant improvements that involve whole systems or process interactions. Coordinating various strategies, products and services, Alstom integration specialists help plant owners deliver the efficiency gains, flexibility improvements and green performance that their stakeholders demand. Integration experience As a provider of OEM turnkey power plants, Alstom has been integrating in-house technologies and equipment from other manufacturers for over 100 years. From boilers to bus bars and from pulverisers to particle filters, our portfolio and expertise cover all plant components and the entire plant process. Backed by a global installed base and leading market shares in many key components and technologies, we are positioned to stay one step ahead of the market. Our dedicated specialists solve the needs of our customers with well-founded proposals for optimisations at the whole plant or system level. Integration based on insights Alstom s integrated service solutions portfolio comprises assessments, improvement products and integrated retrofit projects. 3 types of assessments Needs-driven plant improvement products INTEGRATED PLANT RETROFITS Total plant Driver-focussed Specific condition Performance Environmental Flexibility One-stop service for planning and execution Understanding the interactions - managing the interfaces Integrated solutions services represent a shift from the component view to a whole plant perspective. Thinking in terms of systems and interactions uncovers opportunities for efficiencies and synergies and performance-optimised solutions that bring much greater value than traditional component upgrade projects. Alstom integration experts specialise in the interactions between main components and associated systems, whether this is Alstom or other OEM brand equipment. With an in-depth understanding of different plant processes and empowered with models and tools that Alstom has developed specifically for integration and customisation tasks, we are able to offer plant improvement proposals that are aligned with your capital constraints and business strategy. Besides maximising plant performance, integrated solutions also serve to minimise the project risk and simplify planning for the customer. 05

6 Plant assessments Discovering Every assessment discovers opportunities to earn a return on investment A systematic approach Alstom has developed a number of assessment methodologies that can be employed to plan the future of your existing assets with a systematic focus on the drivers of your business. Comprehensive and confidential Our plant assessment team is qualified and capable of analysing equipment from any OEM. Safeguarded by a confidentiality agreement and in close cooperation with your team, we pursue the most promising options for your plant. Tailored for your targets Our plant assessments are tailored to focus on the targets you set. They can include: Improvement of plant performance Efficiency Reliability and availability Flexibility Lifetime extension Reduction of environmental impact A close cooperative approach ensures that you guide the direction of the assessment from start to finish. Over 10 years, all our plant assessments have revealed meaningful improvement potential. A solid basis for investment decisions An Alstom plant assessment is an objective technical and economic review of a plant. We take into account your plant operation concept current, and future market requirements, and specific strategies for assets and investments. The strength of Alstom s methodology is to incorporate existing and new ideas into a single investment plan. Potential for improvement is identified using a proprietary benchmarking database and solution catalogue for comparison and ranking, enabling decisions to be made based on a clear understanding of the relative value of each measure. 06

7 optimisation potential together Technical - Economic Assessments ECO RAM Total plant analysis of: Design Operation Maintenance Resulting in proposals for: Power increase Efficiency improvement Availability increase Reliability improvement Operational flexibility increase STEP X STEP S Investigation of plant status STEP C Capacity increase STEP P Plant performance STEP F Flexibility analysis / improvement STEP L Lifetime extension analysis STEP A Improvement of availability STEP W Optimisation of water quality / use STEP E Emission control optimisation Condition Assessment Risk Assessment Pre-outage / Pre-retrofit Damage Assessment Following fire, explosion, natural disaster, operational or other incident Component Assessment Specific review of plant components ECO RAM total plant assessments* A systems-level approach for total plant optimization, Alstom s ECO RAM assessment comprehensively analyses plant design, operation modes and maintenance strategies. It considers all market drivers in the light of your technical and financial targets to identify optimisation potentials. Pooling your plant experience and our installed base insights, ECO RAM is a quick and reliable way to establish a broad list of technically-feasible and economically beneficial ideas for further investigation. Then, following an in-depth analysis, we present a ranked short list of the most viable proposals. Each item is quantified in both technical and monetary terms for complete clarity with regard to initial investment, on-going operating costs, and projected payback time. The process identifies both low hanging fruits and larger investment opportunities. STEP X Assessments** These evaluations are focused technical and economic analyses focussed on particular market drivers such as performance, lifetime, flexibility or availability. Customers can choose any specific technical or economic target or ask for a more general investigation. Condition Assessments These evaluations focus on establishing the current condition of assets for more precise planning of refurbishment or optimisation. Risk assessments review factors influencing the operational reliability of plant components and assist in planning refurbishment activities. Damage assessments are used after an incident to identify affected equipment and guide repair efforts. Component assessments provide an up-to-date condition status of all components and systems. * ECO RAM = Economic, Reliability, Availability and Maintainability. ** STEP = Specific Technical Evaluation of Plants 07

8 Plant products New thinking, Tapping into hidden reserves Most conventional fossil fuel plants have unexploited capacity and capabilities due to the conservative nature of their original design. To capitalise on this latent potential, Alstom has developed a unique set of modular steam plant products that improve performance, environmental impact and operational flexibility. Pre-engineered solutions The products are easily adapted to your specific plant. They can be implemented alone or combined into package solutions to meet specific technical and economic requirements. Thanks to standardisation and pre-engineering, all it takes is a quick feasibility check for Alstom to establish an accurate picture of what the customer can expect in terms of price, scope and performance. Efficient integrated implementation Our integrated products are designed so that the majority of implementation work can be done without affecting normal plant operations. The final interfacing between new and existing components is performed during a regular planned outage. 08

9 dependable solutions Unique solutions to meet the new requirements of existing power plants PERFORMANCE FLEXIBILITY ENVIRONMENTAL Plant Performance The products to start with when plant performance is your priority Cold End Performance This performance product is a holistic optimisation of the main cold end components. These can include an LP turbine retrofit, modular condenser retrofit and improvements to cooling water system auxiliaries. Benefits: Increase in power output / efficiency green MW s Improvement in part load operation Overall enhancement in component interaction Lifetime extension Steam Temperature This performance improvement product modernises temperature control system components to maintain steam temperature much nearer to design limits, without exceeding safety limits. Unique precision self-calibrating thermocouples are among the advanced new components fitted. Benefits: Increased efficiency & power output Reduced fuel consumption Reduced CO 2 emissions Response improvements for dynamic operations Improved lifetime management and reduced maintenance costs Heat Recovery This performance product improves the water steam cycle efficiency by reducing flue gas back-end temperature and in addition improves electrostatic precipitator performance for high resistivity fly ash. Benefits: Heat rate improvement in a range of 1-2% Reduction of CO 2 costs Reduction of particulate emissions by up to 60% Meet more stringent environmental regulations without costly installation of additional ESP fields 09

10 Plant products New thinking, Plant Environmental The products to start with when mitigating environmental impact is your priority Solar Boost This environmental product allows the integration of solar energy into existing power plants to generate green MWs. Benefits Reduced fuel consumption and CO 2 emissions at constant power output or the same fuel consumption while generating additional green power Optimised utilisation of existing infrastructure to produce solar energy with lower capital costs. No cost risk for solar energy Water Economy This environmental product involves the integration of water-saving solutions for wet-cooled power plants enabling reduced water consumption when seasonal shortages occur. Benefits: Reduced water consumption and waste heat discharge Improved availability Power output improvement Hybrid Cooling This environmental product adds compact dry cooling capacity and high operational flexibility. This is especially beneficial where mandatory thermal discharge limits reduce plant availability during periods of peak demand. Benefits: Increased availability Reduced water consumption Reduced thermal discharge Latest turbine design with improved efficiency 10

11 dependable solutions Plant Flexibility The products to start with when plant flexibility is your priority Start-up Boost This flexibility improvement product integrates solution packages to help increase the flexibility of steam units and reduce start-up costs. Benefits: Increased flexibility Improved start-up procedure Better turbine trip handling Reduced start-up time & costs Peak Power This flexibility product provides thermal energy storage for steam plants. It enables the temporary supply of additional power and a reduced minimum load. Peak Power can also increase the operational range of a power plant. Benefits: Reduced minimum load Temporary supply of additional power output Reduction of power limitations due to supply of primary and secondary control Low Load This flexibility product reduces the minimum load of steam plants through boiler modifications and the decoupling of boiler and turbine operation, while maintaining high ramp rates. Benefits: Increased plant flexibility minimum load reduction Reduced annual number of start-ups and associated material stresses Arbitrage dealings with storage concepts Supply of primary and secondary control 11

12 Integrated plant Proven EPC tools, Alstom is a pioneer in integrated retrofits, which continue to benefit from on-going investment in advanced technologies and focussed R&D. Coordinated optimisation Retrofitting individual components is a necessary step towards extending plant life or improving performance. But a component improvement approach is not sufficient when your goal is total asset optimisation and the most efficient generation. By coordinating a retrofit program that incorporates various upgrades across and beyond the steam path, matching the capabilities of any combination of main components and associated equipment, we deliver more significant increases in plant performance and the most cost effective lifetime solutions. Any size of plant and scope There is no plant or project too small or too large to warrant our attention. With budgets tight and plant owners juggling multiple priorities, integrated retrofit solutions are a great way to exploit hidden potential without necessarily having to embark on a huge capital investment project. We can adapt our products and services to suit your budget constraints and required scope. Moreover, projects are not constrained to a specific outage or investment window they can be staggered across a number of years with work being done step by step during successive major outages to make the most of every shutdown opportunity. 12

13 retrofits processes and experienced teams Based on deep component knowledge, integration is the key to maximising plant performance and improving project risk management. Experience counts While we work with pre-engineered solutions, every retrofit project is unique, requiring adaptation and coordination expertise that depends on extensive experience. Alstom is ideally qualified as your partner for any integrated retrofit given our complete offering based on: Cutting-edge technology Performance improvement know-how Expertise in turbines, generators, boilers, heat recovery systems, air quality control systems, automation and control, and balance of plant equipment Expertise in EPC (engineering, procurement and construction) contracts Involving the customer, we develop customised plant solutions through the integration of multiple products and services. Whether from Alstom or other OEMs, we offer an optimised value package to meet your specific asset strategy, investment plans and plant operation concept. Engineering expertise Water steam cycle process design Mechanical components Arrangement planning Piping design (HP / IP / LP) Material handling Electrical components / cabling Foundations / steel structures Project expertise Tender management Project management Site management Balance of plant and water steam cycle engineering / supply / erection and commissioning Integration and coordination of other partners (for example digital control system suppliers and equipment from other OEMs) 13

14 Optimisation for operational Integrated solutions With a complete offering on the core components of a power plant we are able to investigate, offer and execute innovative solutions to improve the flexibility and performance of power plants including: Steam temperature optimisation & control Firing system improvement Flue gas optimisation New oil burner Coal mill optimisation Heat recovery 14 Unit control optimisation

15 flexibility & performance to maximise plant potential Cold end optimisation Hybrid cooling & water Economy solutions Swallowing capacity adaptation Start-up boost Integration of additional heat sources e.g.: Peak Power, Solar Boost Condensate stop optimisation LP & HP train optimisation 15

16 Project highlights References Plant Assessments Prior to 2013, fifty two studies have been executed in 13 different countries using the ECO RAM and STEP x methodologies. Units Fuel: lignite, hard coal, mine gas, oil / gas Capacity range: MW Commissioning date: Results MW output increase of up to 15% Efficiency increase of up to 5% Lifetime extension of up to 15 years Maintenance cost reduction Optimisation of operation mode By early 2013, 12 ECO RAM projects had been carried out at various plants in Germany, Denmark, South Africa, Serbia, Spain and the United Kingdom. Overall, more than 450 improvement ideas have been identified. From these over 150 technically and economically viable potentials were identified that matched the customers specific criteria. Outcome Per project: More than 12 potentials measures were identified per project. A total benefit of over 400 million identified for the customers Recent STEP assessment references include: STEP S Size: 6 x 40 MW - Fuel: Lignite Commissioned: End-of-life: 2017 Customer goals achieved Minimise capital expenditure as end of life approaches Establish performance and condition baseline prior to Alstom maintenance contract Recommendations to maximise summer availability & output STEP L Size: 6 x 500 MW - Fuel: Lignite Commissioned: End-of-life: Customer goals achieved Plant life time extension of > 10 years for all units Determine and optimise required technical measures in order to: - Maintain the current availability - Fit into the existing overhaul plan & agreed budget Compile a 7 year investment plan / strategy 16

17 Lifetime extension and emissions reduction Major plant overhaul and life-extension Plant: Belchatow 6, Poland 370 MW Client: PGE Elektrownia Bełchatów S.A. Alstom was charged with a full scope retrofit of unit 6 with the goals of lifetime extension, emissions reduction, performance optimisation and availability improvements. The contract covered the boiler, steam turbine and generator. Benefits Thanks to the Alstom retrofit, the unit lifetime was extended by 25 years, while efficiency was increased to 41% and output to 394 MW. CO 2 and NOx were cut to < 200 mg / Nm 3. There was also a general increase in reliability, availability and maintainability. Plant: arnot 1-6, South Africa 6 x 350 MW Client: Eskom In this retrofit of six thirty-year old units, Alstom was required to improve peak margins and base load capacity with minimal outage time and cost. Alstom supplied new HP and IP turbines and modified the LP turbine. Steam and condensate pumps were replaced. Various boiler components and materials were also upgraded. Benefits Alstom optimised the steam water cycle and boosted the total power output per unit to 400 MW. The plant lifetime was extended by 20 years with sustainable NOx emissions reductions. The careful Alstom project management ensured minimum outage time for a rapid return to full availability. 17

18 Presence Elblag (Poland) Execution Centre Mannheim (Germany) Product Centre Noida (India) Execution Centre Specialist teams embedded in the global Alstom network Our integrated solutions technology global experts and experienced project teams combined with Alstom s strong local presence and capabilities give us the ability to handle integrated projects anywhere. Our global reach brings major benefits to retrofit projects. For example, we have supply chain flexibility in terms of raw materials and manufacturing locations. Alstom currently has a strong specialist team of close to 150 Integrated Solutions experts based in Germany, Poland and India to support plant projects worldwide. Product Centre Mannheim, Germany Mannheim leads our Integrated Solutions tendering, project and site management activities and houses the R&D teams responsible for plant assessments, products and plant retrofits. Execution Centre Elblag, Poland To better serve customers in the heart of Eastern Europe an execution centre was set up in Alstom s Elblag facility in Poland. It handles tenders, engineering and project management Execution Centre Noida, India For integrated projects in India, Alstom has formed a joint venture company with the National Thermal Power Corporation (NTPC). This is known as NASL (NTPC Alstom Services Ltd.) The JV is able to do tenders, design, project and site management as well as carry out residual life assessments. 18

19 Alstom Power generation Alstom is a global leader in the world of power generation, power transmission and rail infrastructure and sets the benchmark for innovative and environmentally friendly technologies. Alstom builds the fastest train and the highest capacity automated metro in the world, provides turnkey integrated power plant solutions and associated services for a wide variety of energy sources, including hydro, nuclear, gas, coal, wind, solar thermal, geothermal and ocean energies. Alstom offers a wide range of solutions for power transmission, with a focus on smart grids. Power generation Alstom Power offers solutions which allow their customers to generate reliable, competitive and eco-friendly power. Electrical grid Alstom has the industry s most comprehensive portfolio of thermal technologies coal, gas, oil and nuclear and holds leading positions in turnkey power plants, power generation services and air quality control systems. It is also a pioneer in carbon capture technologies. Alstom offers the most comprehensive range of renewable power generation solutions today: hydro power, wind power, geothermal, biomass and solar. With ocean energies, we are developing solutions for tomorrow. Alstom is one of the world leaders in hydro power, the largest source of renewable energy on the planet. Rail transport

20 TPWR/PROSOL/ISSSPP/EN/4.2013/FRA/1378 ALSTOM All rights reserved. Information contained in this document is indicative only. No representation or warranty is given or should be relied on that it is complete or correct or will apply to any particular project. This will depend on the technical and commercial circumstances. It is provided without liability and is subject to change without notice. Reproduction, use or disclosure to third parties, without express written authority, is strictly prohibited. Photo credits: ALSTOM. Printed on environmentally friendly paper. A PDF version of this brochure is available at: Alstom Power GmbH Boveristrasse Mannheim Germany ALSTOM Power Sp. z o.o. ul. Stoczniowa Elblag, Poland NTPC Alstom Power Services Private Limited IGL Building, Plot No. 2 B Tower B, Sector 126 Noida