Gas Turbine Parts Life Extension

Paul Jeffreys – Department Head, Gas Turbine Solutions, Uniper Technologies Ltd,
May 2019
Agenda

1 Introduction to Uniper

2 Uniper Gas Turbine Strategy

3 Gas Turbine Parts Life Extension

4 Contractual Considerations

5 PLE Implementation

6 PLE Achievements

7 Questions

2
Uniper at a glance
International energy company with more than 12,000 employees

Employees: 12,000
Our operations

Power Generation Power generation, Storage, Services - Europe

Commodity Trading Power generation - International

Energy Storage Commodity Trading, Energy Sales

Energy Sales
€1.7 bn 100 years 37 GW
Industrial Services 40+ countries around the world EBITDA Experience Total generation
4th largest generator in Europe

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, Services
1.9 GW 3.6 GW electricity and gas)
3
Data: Uniper Annual report 2017
Expertise built on engineering excellence and owner
operator asset experience
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

We are independent of equipment

and component suppliers, giving
us freedom to choose the best
solution for clients

4
Our Conventional Plant Expertise

80+ years operating coal assets; 25 years operating CCGTs

Ratcliffe (1967) Killingholme (1993)

4 x 500MW sub-critical 2 x 450MW
Babcock & Wilcox boilers Siemens SGT5-2000E
565°C, 165bar 525°C, 80bar
FGD & SCR retrofits Efficiency >50%
Efficiency ~37% OCGT conversion

Maasvlakte 3 (2014) Irsching 4 (2011)

1100MW ultra-supercritical 570MW
Hitachi boiler, Alstom turbine Siemens SGT5-8000H
600/620°C, 285bar 570°C, 170bar
Co-firing Bone meal & 3 pressure + reheat,
Biomass Benson boiler
District Heating Efficiency >60%
Efficiency ~46%

5
Agenda

1 Introduction to Uniper

2 Uniper Gas Turbine Strategy

3 Gas Turbine Parts Life Extension

4 Contractual Considerations

5 PLE Implementation

6 PLE Achievements

7 Questions

6
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

7
Agenda

1 Introduction to Uniper

2 Uniper Gas Turbine Strategy

3 Gas Turbine Parts Life Extension

4 Contractual Considerations

5 PLE Implementation

6 PLE Achievements

7 Questions

8
 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.
Solution
Uniper has developed a risk-based approach to extend GT
parts life which can typically deliver 15-30% cost saving by
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extending major outage intervals
Typical GT maintenance schedule

Gas Turbine Illustration

Hot Gas Path
(blades, vanes, combustion) 1
2
1 Every 25k EOH Every 900 Starts
3

11 + Compressor

2 Every 50k EOH Every 1800 Starts

Typical running costs over a GT lifetime

1
2
1 + 2 + Rotor 3
1
3 Every 100k EOH Every 2700 Starts
2
1
1 1

NB: Numbers quoted above vary depending

on GT type and are for illustration only

10
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

Maintenance lifecycles by components (OEM guidelines)

1 Hot gas path 1
(blades, vanes, combustion)
2
Every 25k EOH 3

Running 1
2 1 + Compressor costs over 2
a GT 1
Every 50k EOH 1 1
lifetime

3
1 + 2 + Rotor
Every 100k EOH

Optimised lifecycles by components (ideal case)

1 Hot gas path
(blades, vanes, combustion) 1 Typical
Every 33k EOH 2 savings
1 3
23%
Optimised
2
2 1 + Compressor running
costs over
Every 66k EOH 1 1
a GT
lifetime
3
1 + 2 + Rotor
11
Every 120k EOH
11
NB: Numbers quoted above vary depending on GT type and are for illustration only
Robust Approach to Life Extension
Feedback, inform, learn

Identify and size the Preliminary risk Detailed technical Implementation &
value opportunity review evaluation monitor results

Assess technical risk

Develop work plan,
GT history, against cost-benefit
Confirm contract obtain design &
maintenance, parts analysis, implement,
status, outage materials data,
condition, operating ongoing condition
schedule, fleet data testing, plant data,
regime, fleet issues assessment, learn,
analysis, modelling
extend to other sites

Knowledge & data gathering, capability

development, conferences, collaborative projects

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Agenda

1 Introduction to Uniper

2 Uniper Gas Turbine Strategy

3 Gas Turbine Parts Life Extension

4 Contractual Considerations

5 PLE Implementation

6 PLE Achievements

7 Questions

13
Contracting strategy to support PLE CONFIDENTIAL

 Uniper has a mix of contract styles appropriate

for its gas turbine fleet, based on: Transactional Frame LTSA
Contracts
Price Certainty   
 Technology
Security of Supply of Parts & Services   
 Risks Performance Guarantees   
 Market Conditions 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

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Agenda

1 Introduction to Uniper

2 Uniper Gas Turbine Strategy

3 Gas Turbine Parts Life Extension

4 Contractual Considerations

5 PLE Implementation

6 PLE Achievements

7 Questions

15
 PLE Implementation
 A structured methodology for PLE, underpinned by technical
expertise:- K
n
o
w
Feedback, inform, learn

l
e
d
Identify and size the Preliminary risk review g Detailed technical Implementation &
value opportunity e evaluation monitor results
&
d
a

 Identify opportunities for interval extensions; complete initial

t
a
g
a
t
h
e

assessment of the value

r
i
n
g
,
c Assess technical
a Develop work plan, risk against cost-
GT history,
Confirm contract p obtain design & benefit analysis,
maintenance, parts
status, outage a materials data, implement, ongoing
condition, operating
schedule, fleet data b testing, plant data, condition
regime, fleet issues
i analysis, modelling assessment, learn,
l extend to other sites
i
t
y

 Carryout preliminary risk review

d
e
v
e
l
o
p
m
e
n
t
,
c
o
n

 Complete detailed technical evaluation to address identified risks

f
e
r
e
n
c
e
s
,
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o
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a
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o

 Preparation business case

r
a
t
i
v
e
p
r
o
j
e
c
t
s

 Implement proposed outage interval extension

 Regular reviews to monitor and manage risk during operation

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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

Thermal
fatigue
Intergranular crack crack

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Advanced Inspection of Critical Components

Borescope pathway

Laboratory simulation to develop

improved NDT of blade cracks 20
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

1 Introduction to Uniper

2 Uniper Gas Turbine Strategy

3 Gas Turbine Parts Life Extension

4 Contractual Considerations

5 PLE Implementation

6 PLE Achievements

7 Questions

22
PLE Achievements
Successful delivery of extended intervals on 4000F,GT26 and 9FA:
OEM Limits Outturn Supported PLE Limits

4000F EOH Limit 20% increase EOH Limit

GT26 EOH Limit 15% increase

EOH Limit

WCE Limit 15% increase WCE Limit

9FA Starts Limit 25% increase Starts Limit

Significant Value Delivered to Uniper from PLE:

Average benefit – Euro 1M/unit/year 23
Summary
• 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.

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Agenda

1 Introduction to Uniper

2 Uniper Gas Turbine Strategy

3 Gas Turbine Parts Life Extension

4 Contractual Considerations

5 PLE Implementation

6 PLE Achievements

7 Questions

25
Thank You
Questions?

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Thank you!

If you need any further information, please contact us:

Uniper SE
Holzstraße 6
40221 Düsseldorf
www.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.