RAMBOLL ENERGY

LIFETIME EXTENSION OF POWER PLANTSLifetime extension – LTE – often offers a better return of investment than new build power plants when the future of ageing power plants is to be decided

Energy utilities with aging power plants face challenges when political decisions are put on hold, because of e.g. uncertainty regarding the direction of future energy market structure and technology. Hence, investment in new production capacity is not favoured. Here, considering lifetime extension (LTE) of existing power plants presents an efficient way of both maintaining the ability to satisfy customer needs and keeping investments at a manageable level.

Lifetime extension can stand alone or be part of a lager refurbishment project with the aim to meet new authority and market demands at low cost. Ramboll has been involved in a number of such projects e.g. establishment of new plants for emission control, fuel conversion to biomass and many others.

Feasibility Study

Critical parts of power stations are normally designed for 25 years corresponding to 200,000 opera-

tional hours for high temperature/pressure equipment.

When approaching the designed lifetime, Ramboll offers a feasibili-ty study enabling the customer to determine the right solution which could be LTE, new build, continued operation or end of operation. In case of LTE, the study will form the basis for subsequent engineering and procurement work.

Lifetime extension

In LTE projects major attention is paid to the high temperature/ pressure parts, as failures in these parts potentially could lead to serious accidents. For the purpose of assessing the remaining life of these parts Ramboll has developed its own unique software method based on international standards.

Ramboll has comprehensive experience in evaluating all kinds of plant equipment including exchanging DCS systems, another major part of most LTE projects.

Ramboll’s highly experienced experts perform feasibility studies not only to identify how to extend the lifetime of power plants, often the study also uncovers possible improvements leading to increased plant efficiency and availability and/or reduction of operational costs further adding to the competitive-ness of the unit.

In such projects Ramboll supports the customer from the initial feasi-bility study, through engineering and procurement and until commis-sioning and acceptance testing.

For further information please visit www.ramboll.com/power or contact our Service Line Manager directly.

CONTACTJan HagenauService Line ManagerTel +45 51262 7220jah@ramboll.comwww.ramboll.com/Power

Power Plant Fuel Period

Køge CHP Station Wood 2012-21015

Studstrup Power Station Unit 3 Coal 2009-2014

Kyndby Power Station GT 2010-2011

Masnedø CHP Station GT 2009-2011

DTU CHP Station GT 2005-2009

Ensted Power Station Unit 3 Coal 2001-2007

Asnæs Power Station Unit 5 Coal 2007

Hillerød CHP Station GT 2005

Studstrup power plant Unit 3 is a coal fired unit commissioned in 1984.

In 2005 Ramboll assisted in modifying the unit to substitute up to 10% of the coal with straw.

In 2007 Ramboll assisted in retrofitting the unit with a SCR DeNOx unit.

In 2009 the unit reached 185,000 hours of operation, and therefore the owner, DONG Energy, decided to perform an analysis of the complete unit to get an overview of the investments needed to continue operation to the year 2030.

Based on the recommendations and CAPEX budget from this analysis DONG Energy decided to continue with the project and extend the lifetime of the unit. The planned exchanges/refurbishments are conducted in the plant outages of 2013 and 2014. Ramboll’s responsibilities in the project, acting as owner’s engineer, were:

• Technical assessment of the complete plant• CAPEX budget • Planning of execution• Tendering/contracting • Supervision and commissioning• Hand-over and documentation.

Client: DONG EnergyLocation, Aarhus, Denmark Commissioned: 1984Data:359 MWe (condense mode)268 MWe + 455 MJ/sec. (Back pressure mode)

CASE - LIFETIME EXTENSION OF STUDSTRUP POWER PLANT UNIT 3

SELECTED REFERENCES FOR LTE

TYPICAL PLANT EQUIPMENT TO BE ASSESSED AT LTE PROJECTS

• Distributed Control Systems (DCS)• 6kV/150 kV systems, low voltage systems• Transformers, generators, motors, UPS• Components subject to creep and fatigue• Fuel handling (cranes, stacker reclaimers, conveyors,

screens, tanks, pumps etc.)• Boiler systems (silos, feeders, mills, dust systems,

burners, APH etc.)

• Flue gas treatment plant (flue gas ducts, ESP, FGD system etc.)

• Water/steam cycle equipment• Turbines (casing, blades, rotors etc.)• BoP equipment such as pumps, heat exchangers and

water treatment• Fire and safety equipment.