31 March 2005
Start of operation
Last quarter of 2007
Jurong Island, Singapore
Keppel Merlimau Cogen Pte Ltd. (KMC)
Design, construction and commission
Finance coordination and documentation bank
HSBC Project and Export Finance (PEF)
Calyon, ING Bank and Sumitomo-Mitsui Banking.
Singapore Petroleum Company Ltd. (SPC)
WENDT - Soundproofing and Insulation
Two GT13E2 gas turbines, two heat recovery boilers
Steam turbine and associated equipment
Imported natural gas, with auto-switchover to diesel standby firing
The 500MW combined-cycle plant on Jurong Island supplies power to the Singaporean network. The $525m plant is located in the Tembusu sector of Jurong Island, close to several potential customers.
Construction of the plant started in March 2005 and commissioning took place in 2007. The plant is operated by Keppel Merlimau Cogen (KMC) that was specially formed to develop, build, own and operate the plant.
The project provides utilities like steam, firefighting water, cooling water and pipe corridor services (Pipenet) to consumers on Jurong Island. It is fuelled by imported natural gas, with auto-switchover to diesel standby firing.
Development of GT13E2 gas turbines
The first GT13E turbine, commissioned in 1987, used a 21-stage compressor and a five-stage turbine, both with low-stage loading. Compressor and turbine sections were arranged on one common rotor with journal bearings.
The rotor itself was welded from a number of forged disks, resulting in a stiff and maintenance-free design with a long lifetime. A single ‘silo’ type combustor with a large single burner provided for a rugged and flexible engine, which is still in service today.
The need for higher thermal efficiency and dry-low NOx technology with emissions below 25ppm led to the development of the GT13E2 in 1991. This engine retains the fundamental aerodynamic and mechanical design features of the GT13E as well as many of its parts.
The new design uses Alstom’s EV (EnVironmental) dry-low NOx burner with annular combustor to replace the GT13E’s single, top-mounted ‘silo’ combustor. The resulting improvement in hot gas temperature distribution raised the turbine inlet temperature, increasing the compressor pressure ratio from 13.9:1 to 14.6:1.
These modifications yielded a GT output of some 165MW and combined cycle efficiency values of more than 53% (triple pressure configuration). Some 70 units in commercial operation have now accumulated more than two million operating hours.
New GT13E2 turbines incorporate further technical enhancements. M configuration (performance optimised) types feature an ISO performance rating of 172.1MW at 36.4% simple cycle efficiency on natural gas. They have 53.1% combined cycle efficiency if matched with a dual pressure water/steam cycle configuration (with two gas turbines and one steam turbine). In the Juron project, they operate in a 2x2x1 arrangement to generate 500MW.
KMC awarded the contract to build the turnkey dual-fuel (gas/oil) plant to Alstom. The €170m contract included design, construction and commissioning of the plant. Alstom also supplied two GT13E2 gas turbines, two heat-recovery boilers, one steam turbine and the associated equipment.
Alstom has also been awarded an 18-year operation and maintenance contract for the site, covering scheduled and unscheduled maintenance as well as operation and maintenance support.
Singapore power market
Singapore has no domestic oil reserves, but local companies have invested in overseas exploration and production of oil and gas reserves. One of these companies is Singapore Petroleum Company Ltd. (SPC), which will supply diesel to the plant.
Keppel Merlimau Cogen (KMC) was specially formed to develop, build, own and operate the greenfield Jurong Island plant. This will increase Singapore’s power generating capacity to nearly 10,000MW; almost double the present peak demand of 5,100MW.
Senoko Power and PowerSeraya supply about a third of this each, with the rest coming from Tuas Power and SembGas Cogen. Keppel expects the plant to produce to full capacity, despite Singapore’s current overcapacity.
The plant is expected to increase Singapore’s power generating capacity to nearly 10,000MW; almost double the present peak demand of 5,100MW. Senoko Power and PowerSeraya supply about a third of this each, with the rest coming from Tuas Power and SembGas Cogen.
The plant is one of the most cost efficient and flexible power generators in the market. The project secured limited recourse financing by the end of March 2005. A loan package financed 100% of total project costs, with a 16-year term loan and a two-year equity bridge loan.
HSBC Project and Export Finance (PEF) originated the deal and coordinated the execution with joint lead arrangers Calyon, ING Bank and Sumitomo-Mitsui Banking. HSBC PEF also undertook the role of documentation bank.