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As one might expect, maintenance costs are higher for any type of plant in countries that have not had as much exposure to the OEMs technology. As a significant extension of their revenue, OEMs offer overall “power by the hour” maintenance contracts. These costs vary, even for the same basic modular configuration and mechanical design, depending on the location’s demographics. So then will the actual and contractually set “cost per fired hour” figures. There would be a significant difference between what actual operational costs are for the same OEM’s CC block in a well developed area of the USA and a remote area in Azerbaijan, for instance. Demographics also alter construction costs. (As an illustration, in 1990s figures, costs varied from $592/kW for a new 1,080 MW combined-cycle plant in Egypt to $875/kW for a steam addition to convert four gas turbines in Pakistan to a combined-cycle plant, according to World Bank data). OEMs are aware that end users compare cost data at various meetings and forums, and that price variations are a sore and much negotiated point. Therefore OEMs continually strive to optimize designs and assembly methods to minimize the steepness of new operators’ learning curve. Fig. 79. Schematic Diagram of a Parallel Combined Cycle Block with Full Flue Gas Cleaning 11 “Modularization” (for instance the Siemens Westinghouse GUD block which is 2, V94.3 gas turbines, their HRSG boiler capacity and a steam turbine) reduces construction costs. Compared with the customized design and construction, modularization can reduce project costs of detailed engineering, material price contingencies and financial loan interest during construction. Downsizing power delivery (to the grid) requirements will change overall operational cost figures. “Repowering” will change operational statistics significantly. Repowering is a term used to define the reconfiguration of a power station. It may mean replacing a steam turbine with a gas turbine or combined cycle. One example of a repowering option offered by an OEM is Alstom’s combining their 181 MW GT24 gas turbine with a dual pressure reheat cycle consisting of a 70 MW LP/IP steam turbine and a 20MW HP steam turbine, to generate a total of 270 MW. The most common configuration is called (Figure 79) parallel powering, where the gas turbine exhausts are used in the existing steam cycle. This is achieved by feeding the exhausts into a heat-recovery steam generator (HRSG) which provides additional steam to the existing steam turbine. Typically, parallel powering requires the addition of a gas turbine, associated electrical and instrumentation and control equipment, civil engineering, HRSG, additional piping and pumps as well upgrading the steam turbine. Generally, parallel powering can be undertaken fairly separately from the existing part of the plant, with a final integration phase and a plant down time of 1.5 to 2 months. The typical cost range is $US$ 300-500/kW. In some cases, national or international markets alter a power plant’s budget by changing available fuels. An example would be the United Kingdom’s temporary moratorium on their indigenous natural gas (which promoted coal for that period). When the decision was made to allow North Sea petrochemical liquid deposits to vaporize and be delivered as gas instead, that move created operational ripples in all industries that used petrochemical fuel, including power generation. Since the late eighties10, market growth in plant additions/ optimization technology retrofits has shifted in part, from Europe, North America and Japan to newly industrializing countries in Asia and Latin America. Financial means keep many of the end users in these 67PDF Image | GAS TURBINES IN SIMPLE CYCLE COMBINED CYCLE APPLICATIONS
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