GE 9FA CCGT Plant – Exhaust Diffuser and Silencer Frame Retrofit in Singapore

DEKOMTE designed, manufactured and turnkey installed an integrated concept of frame, fabric, convectors and external insulation system. Both solutions were designed to integrate with the new cold casing silencer supplied and installed by Braden during the same outage.

Client: Sembcorp Pulau Sakra Power Plant

As Singapore’s largest and most efficient co-generation power plant, Sembcorp Sakra was a €650 million investment. It consists of two units, equipped with a GE Frame 9FA gas turbines, an Alstom steam turbine and low NOx combustion systems. In 2014, the plant was fitted with a third unit, a CCGT-2 GT26, with an output of 400 MWe.

Total Output:

815 MW

Date Operational: 2001
Location: Jurong Island, Singapore
Primary Fuel: Natural Gas

Original: Standard Expansion Joint

Significant maintenance problems were apparent with the P1 joint, silencer and P2 joint. Neither expansion joints were suitable for base loading, and required continual welding and repairing for successful and safe operation.

Regular problems caused by this design:
  • Significant frame distortion.
  • Cracking and corrosion of frames.
  • Fabric overheating and leaking.
  • Silencer and duct cracking.

Solution: DEKOMTE 3WA Fabric Expansion Joint

The DEKOMTE 3WA fabric expansion joint was selected to be capable of the high cycling requirements and the reliable operation during the remaining lifetime of the plant. DEKOMTE designed, manufactured and turnkey installed an integrated concept of frame, fabric, convectors and external insulation system. The complex frame geometry at the heart of the solution gives low fatigue stress from the thermal transients caused during cycling. The P1 joint is the transition from the hot casing exhaust diffuser to the new cold casing silencer. Both solutions were designed to integrate with the new cold casing silencer supplied and installed by Braden during the same outage.

Steel parts assembled on site and lowered into place.
Steel frame fully welded and fitted into position.
Installation of all insulation, final joint fittings and expansion joint.
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