Converting power stations to dual fuel: a rewarding challenge


The global power generation industry is under increasing strain to keep up with demand while also having to comply with more stringent environmental legislation. While fuel prices continue to be volatile, natural gas has recently become a more attractive option. This trend has led to a growing number of power stations looking at the possibility of modifying the power generating equipment to accept different fuel sources.

Many established power generation systems have used coal-fired stations to generate the base load of energy that is required, while oil and gas-fired units are held in reserve to meet peak demand for a few hours each day. However, these back-up facilities are increasingly being used to meet daily demand as it continues to increase; this being the best solution until additional generating capacity can be commissioned.

Power stations which are fuelled by oil or diesel face considerable running costs, and most of these facilities are run at a loss in favour of keeping the lights on and preventing outages at times of peak demand. However, extending this practice to cope with an increased base load is unsustainable, purely from a financial position, and now added pressure to reduce emissions is increasing the urgency to find an alternative fuel source.

Fig. 1: Planning for the project is essential.

One of the prime considerations is the time required to resolve this escalating situation; a new conventional power station will have a lead time of two to three years and a nuclear installation could be at least nine or ten years away.

A more immediate solution can be found in converting the liquid-fired turbine to a gas-fired version, a process which could be completed with the generator offline for less than two months.

Apart from the reduced fuel cost, the gas-fired turbine offers a number of additional advantages which help to reduce the overall operating cost of the installation.

As a fuel, gas burns more cleanly than oil, which means that the hot gas path (HGP) components should have increased intervals between inspections, when compared to the liquid-fired maintenance regime. Generally, the components within a gas turbine are exposed to less deposition and contamination, which can also extend the overall life of these components.

By increasing the periods between maintenance inspections, the availability of the generator is increased making it more productive and less costly, both in terms of direct maintenance costs and indirect loss of production. Furthermore, the cleaner burn provided by the gas option produces less particulate and gaseous emissions, which can significantly reduce the environmental burden of the power plant.

Fig. 2: Turbine blades last longer with cleaner burning fuel.

The change to dual-fuel

The actual process of physically changing from oil to gas is relatively straightforward; it is the technology and engineering expertise that holds the key to a successful project. In essence, the conversion requires a number of changes to the HGP components including the mixing chambers and fuel nozzles as well as new coatings for the turbine blades and vanes.

This change to dual-fuel combustion allows a turbine to continue running on oil until such a point that the change to gas is required. In this way a complete set of turbines can be individually converted, minimising disruptions to power generation until such a point that the plant is ready to convert to gas. With the mechanical modifications completed, only the electronics and control software remain to be changed before the transformation can be completed.

While the original equipment manufacturers (OEMs) of the equipment can provide a solution, either in the form of an entirely new turbine, or as a conversion, another option exists. A specialist independent service provider which has decades of experience in maintaining and repairing rotating equipment, such as Sulzer, can often provide an attractive alternative.

Fig. 3: Turbine vanes suffer less wear and tear when using cleaner burning fuels such as gas.

By the nature of their business model, OEMs tend to concentrate on their core business, viz. manufacturing new equipment, so that while replacement parts may be available, the process of getting a team on the ground may be rather drawn out. The increased flexibility offered by a more local field service team, supported by a global engineering base, can often present a more cost-effective solution.

One of the most important aspects of a project such as an oil-to-gas conversion is the planning. This forms the framework on which the rest of the project will be based and ensures that every aspect of a particular task is in place on time. As both the economic and political pressures build, countries which have a high percentage of oil-fired power stations will need to reduce emissions. The decision to alter the fuel source for these power stations will be driven more by politics than economics.

Contact Claudia Proeger, Sulzer,

The post Converting power stations to dual fuel: a rewarding challenge appeared first on EE Publishers.

Source: EE plublishers

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