POWER September 2017 - 23

TOP PLANTS
cluded the 300-ton main transformer, steam
condenser, heat recovery steam generator
(HRSG) parts, and steam turbine. The 320ton
generator arrived in January 2015, and the
combustion turbine (CT) reached site in July.
The process of moving the CT was no
small job. The journey would span about 330
miles from Belfort, near France's eastern border
with Switzerland, to the Bouchain site. A
steel " centipede " (Figure 1), that when loaded
measured 109-m long, 6.65-m wide, and
5.7-m high, and weighed about 800 tons, was
used for the first leg of the trip-Belfort to
Strasbourg. The roughly 150-km drive ended
up taking more than a week, with speeds
rarely breaking 15 km/hr.
Once in Strasbourg, the CT was lifted and
placed on a barge. The barge transported the
heavy load on the second leg of the journey,
beginning on the Rhine River and ending
seven days later within about a mile of the
construction site by way of the Scheldt River.
A smaller transport platform carried the CT
through the final on-land stretch. It arrived at
its new home on July 15, 2015.
Meeting Milestones
The fact that the gas turbine was not shipped
until after completion of full-speed, full-load
testing meant that it arrived on-site a bit later
than would have been optimal. The delivery
timetable forced the project team to follow a
rather unusual installation and commissioning
schedule, but that didn't prevent them
from meeting milestones on time.
One enhancement that made a big difference
was the use of modularized auxiliaries
from the factory. This new process first implemented
during the Bouchain project saved
on-site construction time. In the end, the gas
turbine went from factory to first fire in only
five months.
The unit was first synchronized to the
power grid on January 21, 2016. Little
more than a month later on March 1, 2016,
the plant operated for the time in combined
cycle mode. Trials were completed on July
26, 2016, and the unit entered commercial
operation.
The Bouchain plant is an important demonstration
of GE's latest digital power plant
capabilities. Real-time data from more than
10,000 sensor inputs is monitored and analyzed
to help personnel optimize plant operation.
In addition to delivering stable and
efficient control, the technology also provides
predictive insights, which helps avoid
unplanned downtime and leads to significant
maintenance improvements.
Utilizing the new 9HA turbine technology
did create some HRSG design challenges. A
new generation boiler was developed to accommodate
the significantly higher temperaSeptember
2017 | POWER
1. Crawling along. The GE 9HA combustion
turbine, affectionately nicknamed
HArriet, was loaded on a center stretcher
supported by two tow platforms each with
14 rows of triple-tire axles. The 800-ton load
required four trucks-two pulling and two
pushing-to move it. This image was taken as
the " centipede " left Belfort, France, on June
29, 2015, headed for the EDF Bouchain plant.
Courtesy: GE
POWER POINTS
Winning Attributes
World-record-setting combined
cycle efficiency-62.22%.
First-of-a-kind installation that
overcame logistics challenges
to deliver one of the largest gas
turbines ever built, going from
factory to first fire in five months.
Ability to go from startup to
combined cycle operation in less
than 25 minutes and turndown
to as low as 30% of maximum
generating capacity.
impact on protected species. The objective
of the measure is to maintain suitable habitat
for protected species, and ensure a tranquil
and prosperous environment.
tures, pressures, and outputs that result during
operation. The new boiler design increased
flexibility and ensured quicker startup than
had been achievable previously. In addition
to material improvements, a welding expertise
center was created to ensure all work was
able to meet strict quality standards.
High Safety and Environmental
Standards
Completing work safely was a top priority
for the construction team and continues to be
a focus for the power station. The Bouchain
facility has implemented a " zero-accident "
policy, which is consistent with other EDF
sites. Some actions taken to raise safety
awareness include:
■ All newcomers to the site are required to
complete a welcome security session with
the site's environmental, health, and safety
training staff.
■ Regular safety inspections are conducted
throughout the facility with a goal of
verifying compliance with requirements
as well as implementation of prevention
measures.
■ Emergency exercises including the involvement
of external assistance, such as
firefighters and rescue personnel, are organized
on-site to test crisis procedures.
An ecological compensation zone has
been created on-site to reduce the plant's
www.powermag.com
Market Evolution
The construction project peaked in 2015 with
up to 600 people working on-site at the time.
The €400 million investment had a positive
effect on the Bouchain region. As an operational
facility, the plant now employs about
40 full-time EDF personnel and another 20
contractors performing various functions.
The 9HA gas turbine isn't a one-hit-wonder
either. Today there are more than 10 HA
units connected to the grid, with plants now
in France, Russia, Pakistan, and the U.S.
More than 60 HA gas turbines are on order
around the world, with new units planned in
Argentina, Bahrain, Brazil, China, France,
Indonesia, Japan, South Korea, Mexico,
Pakistan, Taiwan, Thailand, and the U.S. Because
all the HA gas turbines use the same
technology, GE fully expects all units to meet
similarly high efficiency levels to those proven
at Bouchain.
But the company isn't resting on its laurels.
During the June 2016 media event, Joe
Mastrangelo, president and CEO of Gas
Power Systems, said the Bouchain plant's
62.22% efficiency mark is just a starting
point for what the company hopes to attain in
the future. He suggested that GE's technology
programs could propel efficiency toward
65% by the early 2020s.
Mastrangelo's team pointed out that the
company has invested more than $1 billion
developing the HA gas turbine. Based on the
success of EDF Bouchain, it appears to have
been money well spent. ■
-Aaron Larson is POWER's
executive editor.
23
http://www.powermag.com
POWER September 2017

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