Power plant life extension |
GT replacement transforms ageing assets into high performance power plants
Life extension of ageing gas-turbine-based power plants can be achieved cost-effectively by replacing the gas turbine — the core driver of performance and determinant of plant life — with a modern, efficient, and future- ready machine that elevates plant efficiency above original design, ensures compliance with today’s emission and operational standards, and, depending on fit, may improve plant capacity. With targeted upgrades to the HRSG, steam turbine, and balance-of-plant systems, operators can transform existing assets into flexible, reliable, and hydrogen-ready plants capable of meeting the demands of future energy systems
Anders Stuxberg Siemens Energy
3D visualisation showing typical scope for replacement/modification as part of a combined cycle life extension project. Image: Siemens Energy
Ageing power plants don’t have to be headed for retirement – many are standing on the threshold of a second, far more efficient life. Across the globe, gas-turbine-based power plants built around the year 2000 are reaching the limits of their initial design life. Rising O&M costs, poor efficiency due to outdated design combined with degradation, sourcing challenges for spare parts, and tightening emissions regulations paint a familiar picture. At first glance, shutting down or replacing an ageing plant may seem inevitable. But in reality the story doesn’t need to end here.
With modern technology, thoughtful refurbishment, and strategic upgrades, an existing plant can be transformed into a high- performing, flexible, and future-ready asset – at only a fraction of the cost and time needed for a new build project. Much of the plant’s
infrastructure remains robust for decades, and by focusing on the true heart of performance – the gas turbine – operators can unlock dramatic improvements in efficiency, flexibility, emissions, and operating costs. As global power demand rises and grids are increasingly shaped by renewable generation, extending the life of existing gas-turbine-based plants is becoming not only attractive but essential. This article explains how plant operators can breathe new life into ageing assets and position them for the next generation of energy systems.
Gas turbine: main life limitation and the core of plant performance The gas turbine can be replaced with a new, modern one, often installed on the existing foundation. A gas turbine, in addition to general ageing, suffers from degradation of performance compared with its original new
20 | April 2026 |
www.modernpowersystems.com
status. To make it worse, it has also become outdated, as GT technology has developed significantly over the years. A new gas turbine with higher efficiency and similar capacity to the replaced machine leaves somewhat less waste heat in the exhaust. Therefore, often the bottoming cycle fits well in terms of capacity even if gas turbine capacity increases. Since the gas turbine is at the core of plant performance, replacing it with a new and modern machine brings plant performance close to what is achievable with a new plant at the same location. The concept of bottoming cycles has not changed much over the years, even though some modern combined cycle plants utilise higher steam conditions than were common 25 years ago. That said, start/stop operation favours lower steam conditions, so an old plant with some adaptations may still be suitable for future operating scenarios.
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