Background

The North American power market is undergoing a transformative phase driven by a growing need for dependable, efficient, and sustainable energy sources. Much of this is driven by “hyper-scaling” (bit-coin mines, data centers, etc.) as well as the need to support the fluctuating outputs of renewable power sources.
The relocation of existing, fast-start gas turbines emerges as an ideal solution to several of these requirements.
This article explores the many advantages of relocating gas turbines within this fast-growing North American power market and introduces the proven capabilities of TTS to support these projects.

Introduction to TTS Relocation Experience

Turbine Technology Services (TTS) is a leading gas turbine engineering firm, with a solid reputation spanning over four decades. The company specializes in gas turbine upgrades, conversions, and power plant relocations, boasting an impressive portfolio of over 90 successful turbine relocations. 

As a full project service provider, TTS offers a wide range of expertise, including everything from EPC responsibility to equipment upgrades, engineering, and technical direction and commissioning services. 

Currently, TTS is active in the relocation of 11 gas turbines, including General Electric (GE) Frame 9 and Frame 6 models.

This experience underscores TTS’ leadership in this niche field, confirming both the knowledge and resources needed to execute complex relocation projects efficiently. 

Why Relocate a Gas Turbine Power Plant?

Relocating a gas turbine power plant is a strategic decision driven by several factors:

• Cost-Effectiveness: The reapplication of existing gas turbines offer significantly lower asset purchase costs compared to new equipment, making relocation a more economical option for many operators.
• Time to Market: Relocation projects are generally much faster than waiting on arrival of a new unit. Existing turbines are immediately available, as opposed to the current wait time of 2-3 years for delivery of new equipment. This results in a much faster project timeline and substantially quicker project cash flows.
• Flexibility: Relocated units can be quickly adapted to match specific project needs, whether traditional land-mounted, trailer-mounted, or configured as power barges. This versatility extends to fuel options, enabling operation on natural gas, diesel, or hydrogen, if available.

While older turbines may not be as efficient as newer equipment, they are well-suited for peaking and renewable support operation, where their reduced initial costs and faster deployment outweigh efficiency concerns.

Key Project Considerations

Each relocation project has its own unique requirements. These may include the need for asset  refurbishment, fuel conversions, frequency conversions (if moving between 50Hz and 60Hz countries), other upgrades and modifications, and installation of equipment necessary to allow the units to operate in compliance with local environmental regulations. 

When planning a turbine relocation, the following questions help define the project’s scope and requirements:

• Capacity Needs: What is the required amount of megawatts?

• Timeline: What is the optimal project schedule?

• Transportation & Logistics. Is there any major hurdles to moving all the turbine equipment from the existing to the new site?

• Site Specifications: What are the new site’s requirements, such as local interconnection permits, air permits, interconnection voltage, noise restrictions, emission standards, etc.?

• Equipment Needs: What existing components can be reused from the existing plant, and what new equipment is required?

• Fuel Availability: What types of fuel are readily accessible at the new location?

• Warranty: Is a warranty necessary for the relocated unit? This question deserves more consideration than many may think. 

For example, why spend $3-$8 million on a full mechanical overhaul if the unit is currently operating well, and major maintenance can be deferred to a later date? This decision will require input from both engineering and financial stakeholders. 

Typical Project Processes

Relocating a gas turbine involves a series of systematic steps:

• Evaluation and Planning: Define the project’s scope, including the turbine’s condition and required upgrades. Options may include refurbishing the unit at the current site, the new site, or a dedicated facility.

• Dismantling and Transport: Each component should be carefully dismantled, tagged, and transported to the new site. This process should use TTS’ proven dismantling and equipment preparation methodology and would incorporate TTS’ advanced equipment tagging software and procedures. 

• Upgrades and Modifications: Depending on the turbine’s condition and project goals, performance, and emissions systems may be upgraded to meet modern standards.

• Reinstallation and Commissioning: The turbine is reassembled at the new site, with TTS overseeing commissioning to ensure optimal performance.

These steps, supported by TTS’ extensive documentation and industry expertise, will minimize risk and ensure a safe, successful, project completion.

New Plant Engineering and Balance of Plant (BOP) Equipment

Design of a relocated power plant is very different from construction of a new unit, which will use all new drawings and equipment manuals. TTS has experience of using original design drawings (often up to 30 years old), together with modern engineering, to overcome these challenges. 

A well-planned layout, often based on reusing existing site project drawings, is key to relocation success. Specific considerations include:

• Layout. Maintaining the same general layout of the power plant island, and auxiliaries will significantly speed up, and reduce costs, of the plant design process.
• Switchyard Proximity: Ensuring the plant is close to a suitable switchyard will  minimize costs. Should the existing step-up transformer not have the correct high-side voltage for interconnection to the new grid, then a new transformer will be required. This can have a major effect, both financially and schedule-wise, on completion of the power plant. 
• Fuel Systems: These days, virtually all power plants require gas-fuel only operation. It is important that the plant is sited close to a suitable high-pressure source of gas. Many peaking plants use two separate sources of gas fuel, which provides the operator a hedge against both price fluctuations and fuel interruption. 
• Electrical Protection and Studies: Comprehensive design and analysis ensure safety and reliability when connecting to the new power grid. .

TTS’ expertise ensures seamless integration of these elements, leveraging a combination of existing documentation and new designs, as necessary.  

TTS Contributions to Gas Turbine Relocation Projects

TTS brings a wealth of specialized knowledge to every relocation project, including:

• • Unique Relocation Expertise: Relocating a gas turbine is different from constructing a new unit. TTS combines knowledge of using outdated drawings with modern engineering to overcome these challenges.

• Best Practices and Project Management: From dismantling, to scheduling and reporting, to installation services, to technical direction and commissioning, TTS will use its own proven methodologies and procedures through the project. These procedures will meet, or exceed, those of the OEM. 

• • Upgrades, Maintenance and Commissioning. Relocation often involves substantial work to maximize performance and adapt the turbine to its new environment:
    • Engine and Performance Upgrades: Refurbishment improves efficiency and extends the unit’s lifespan.
    • Controls and Instrumentation: Modernizing control systems ensures reliability and compliance with updated standards, including Cybersecurity protocols. .
    • Fuel and Emissions Modifications: Conversions to alternative fuels or improvements in emissions systems enhance operational flexibility.

• Technical Services: TTS processes ensure smooth and comprehensive plant commissioning, including advanced technical services such as Dry Low NOx (DLN) tuning.

Summary

Relocating gas turbines is a mature, well-proven process that delivers significant cost and time advantages to all owners and developers wishing to quickly generate project cash flows.  

While older units may have reduced efficiency, they remain valuable assets for peaking and renewable support markets. By leveraging TTS’ expertise, clients benefit from a seamless relocation process, using comprehensive upgrade offerings, and faster time to generation.

Why Choose TTS?

TTS Energy Services is at the forefront of the gas turbine relocation market. We have contributed to the relocation of over 90 gas turbines, having a total of almost 4,000 megawatts. 

We have been involved at all levels including Engineer / Procure / Construct (EPC) contracts, project management and design engineering, upgrade and modification services, cost control, project feasibility studies and finally, site supervision. 

With over 30 years of experience in the turbine relocation market, we are the ideal partner for any reapplication project.

How Can We Help You?

Contact TTS and speak with a specialist to discuss and evaluate your possible opportunities for gas turbines relocations, as well as to enquire about assistance with your current relocation project. 

Leave us a message or call +1 (407) 677-0813 to speak with an expert today.