Although European gas-powered generation continues to fall year on year, it will play a vital role in the energy transition for at least the next decade. With gas prices falling some 15% since the beginning of the year, many European countries have resumed their push to phase out coal in favour of less polluting gas-fuelled power. The requirement for electric system flexibility is also at an all-time high in Europe. While renewables now account for 40% of EU electricity generation, delays to battery energy storage projects mean that gas power generation remains critical, but with fewer operators in the market to provide this flexibility, reliability is key.
This has created extra pressure on many operators who face heightened maintenance challenges from ageing infrastructure while needing to comply with increasingly strict targets for sustainability, efficiency, cost, and safety. Depending on equipment age and rarity, some operators are more challenged than others. Indeed, as of 2020, nearly 70GW of Europe’s gas power capacity was over 20 years old, according to the IEA.
Filling the OEM gap
Like any product, as more innovation comes to the market, older designs become obsolete, and manufacturers reduce support when only a handful of the older models remain in use. However, for those still operating legacy or rare gas turbines, this can leave O&M teams struggling to arrange appropriate aftermarket services and keep up with changing emissions requirements. At best this creates frustration, and at worst it leaves national infrastructure exposed, with the potential to jeopardise essential services.
As a case in point, large power stations require back-up generation so that, in the event of an unplanned outage, power can be restored to critical path equipment within a matter of minutes. However, with plants over 30 years old, there are several sites across Europe that are finding it increasingly difficult to maintain their back-up generation equipment. In some cases, the turbine has been deemed obsolete, and though it runs well, the offered solutions are often a costly full-scale replacement to a new model.
In other cases, the aftermarket does not have the capacity to meet the growing demand for day-to-day maintenance, resulting in longer lead times as more pressing repair jobs for larger customers are prioritised. Imagine dropping your car off at the garage for service at 8am and taking the bus to work, only to find out later that the garage won’t be able to return your car for at least two years. It sounds implausible, but this is the reality faced by many operators with less common turbines.
This leaves operators with a choice to ensure continued operations; invest heavily in a somewhat unnecessary replacement, or spend time looking for an alternative approach? Over the years, Sulzer has focused on the latter, creating a complete rotating equipment solution that supports operators in maintaining critical infrastructure of all ages and brands through a collaborative, customer-tailored approach. In this instance, Sulzer’s solution was to create its own inventory by buying engines from decommissioned sites (such as those in the North Sea) and refurbishing the parts to hold in stock. Now, whether a customer needs a small pump or a complete engine overhaul, Sulzer can support them.
Tailor-made solutions for critical infrastructure
Advanced technologies, designs and retrofits are increasingly being used to solve complex or unusual critical infrastructure challenges or supply chain issues. In some instances, customers have approached Sulzer in search of an alternative; in others, they identify a gap in the market by talking to customers at industry events. Regardless, the challenge comes their way, and only needs to be shared by a handful of customers for there to be a sufficient business case for Sulzer to develop a solution that addresses the market’s key demands.
Once underway, the process is always completed with a view to improvement, with the potential to offer significant upgrades for combustion and emissions, energy efficiency, longevity and reliability. At the heart of this process is a full understanding of the customer’s industry, plant and processes, so that any upgrades made to maintain the reliability of ageing infrastructure are holistically designed, manufactured and futureproofed. Quality workmanship is combined with cost competitiveness and rigorous scheduling to ensure the work is completed within tight turnaround times.
As an example, several operators rely on the Avon gas turbine – a popular choice with oil and gas operators for over 50 years. Yet, it was expected to become non-compliant in some locations with increasingly stringent government emissions restrictions worldwide. Replacing the turbines in the region would have cost £15-20 million per site with the potential to cause significant disruption to services across Europe. Instead of replacing the generator unnecessarily, Sulzer took on the challenge of developing a retrofit solution.
The dry, low emissions solution reduces nitrogen oxides emissions by over 70% while also significantly reducing carbon monoxide. The solution fits neatly into the existing installation footprint and, being similar in weight, can be installed using existing overhead cranes, causing minimal disruption to the plant. Overall, it provides a cost-effective way to extend the life of existing gas turbines while reducing greenhouse gas emissions. For a major operator with Avon gas turbines, the solution could save tens of millions of pounds in compliance costs.
None of this would be possible without the unique blend of people, global capabilities, innovation and customer-centric thinking that makes the impossible seem possible. Whether it’s tracking down a spare part that hasn’t been manufactured in decades or completing a repair in 12 weeks instead of 2 years, Sulzer people are empowered to say, ‘can do’. When it comes to maintaining critical infrastructure that’s relied upon to provide essential services to millions of people, from flange to flange, Sulzer goes the extra mile to find a solution.
