Engineering & installing a Bypass Exhaust System for Gas Turbines at Pelican Point Power Station

Bypass Exhaust System for Gas Turbines: Baltec’s Turnkey Solutions

April 2025

Project Overview – Bypass Exhaust System for Gas Turbines

The Environmental Group is proud to have delivered an innovative engineering, procurement, and construction (EPC) solution for Pelican Point Power Station in Adelaide, Australia. Baltec designed, manufactured, and installed a Bypass Exhaust System for the GT13E2 Gas Turbine (GT11). As a result, This upgrade enhances the plant’s flexibility, allowing it to operate more efficiently and respond quickly to fluctuating energy market demands. Baltec, an expert team within The Environmental Group, executed the work, ensuring the successful delivery of this complex project.

Currently, the project commenced in April 2024 and is therefore, scheduled for completion in May 2025. The team installed a Diverter Damper Bypass Stack, strengthened existing foundations, and removed outdated equipment, all designed to optimise plant performance and flexibility.

Key Project Details – GT11 Gas Turbine and EPC Scope

Client: Pelican Point Power Station, Adelaide

Project Duration: April 2024 – May 2025

Project Location: Adelaide, Australia

Product Shipment: January 2025

Size of Product: 40m H x 10m D

Total Weight of System: 350 tonnes

Project Scope and Objectives:

The primary objective of the project was to install a Diverter Damper Bypass Stack between the GT11 Gas Turbine and its associated Heat Recovery Steam Generator (HRSG). This installation is designed to allow the gas turbine to operate in either ‘Open Cycle’ or ‘Closed Cycle’ modes, with the ability to switch seamlessly between the two modes without interrupting power generation.

Consequently, this flexibility will significantly improve the plant’s operability, therefore, enabling faster and more efficient responses to energy market demands. As a result, Pelican Point will be able to capture additional revenue opportunities and improve operational efficiency.

The system's features include:

Increased Plant Flexibility: The ability to transition between operational modes without interrupting power generation.

Enhanced Efficiency: Faster response to market conditions, improving overall energy production efficiency.

Improved Revenue Capture: Furthermore, the flexibility to adjust operations in line with energy market demand. As a result leading to increased revenue generation.

Core Challenges and Solutions
Heavy Engineering & Diverter Damper Design

Strengthening Existing Foundations

Supporting 350-Tonne System:

A key challenge was ensuring that the existing foundations were strong enough to support the new 350-tonne Bypass Exhaust System. The team addressed this by installing six piles (800mm diameter, 18m long), therefore, ensuring the foundation could support the weight and maintain structural integrity.

Removal of Existing Equipment

Efficient Turbine Upgrade Execution:

Additionally, removing the existing Fin Fan Coolers and their structure presented a logistical challenge. The team carefully planned and executed the removal of these components to ensure safety and efficiency, as a result, minimising any disruption to ongoing operations.

Complex Engineering Design

Open & Closed Cycle Operation:

Baltec designed the Diverter Damper Bypass Stack with a sophisticated control philosophy, enabling the GT11 Gas Turbine to operate efficiently in both ‘Open Cycle’ and ‘Closed Cycle’ modes. The team developed a robust system to handle quick transitions between these modes without compromising the turbine’s performance or the overall power generation process.

The Baltec Team
Experts in Bypass Exhaust System for Gas Turbines

The Environmental Group entrusted Baltec with this critical project. The team’s collective expertise in engineering design, manufacturing, project management, and risk mitigation ensured the successful execution of the project. The collaboration between our expert team allowed the project to progress smoothly, with effective management and a high-quality delivery.

Project Management Approach:

The success of this project was underpinned by a comprehensive and strategic project management approach. Key components of the management process included:

Project Planning and Management:

Detailed planning and clear milestone definitions allowed for proactive risk management and therefore, early identification of potential delays.

Project Scheduling:

The project schedule was created with tight deadlines and an understanding of the plant’s operational requirements. The team provides regular updates to keep the project on track.

Stakeholder Management:

Moreover, stakeholder management involved clear and consistent communication with Pelican Point, subcontractors, and other stakeholders ensuring alignment and timely delivery.

Cost Control:

The team created a detailed budget to monitor and control costs. The team ensured that all aspects of the project were executed within financial parameters, with close monitoring of resource use.

Risk Management:

Potential risks were proactively identified, and the team implemented effective mitigation strategies. All aspects of safety, environmental impact, and project delivery were closely managed.

Quality Management:

The team established a strict quality control process to maintain high standards across design, procurement, and manufacturing. Each stage was subjected to rigorous checks to ensure compliance with industry standards.

Subcontractor Management:

Subcontractors were carefully selected and managed, ensuring their work aligned with the project’s high standards and timeline.

Procurement:

A thorough procurement process was followed to source high-quality materials and equipment. The procurement team closely monitored suppliers to ensure timely delivery and adherence to technical specifications.

Conclusion – Baltec’s Success in Gas Turbine Exhaust Projects

Baltec, as an expert team within The Environmental Group, has demonstrated its engineering prowess through the successful design, manufacturing, and installation of the Bypass Exhaust System for Pelican Point Power Station. By ensuring a flexible, high-performance system that enhances operational efficiency, the project aligns with the growing demand for adaptable, responsive energy solutions in today’s dynamic market.

In summary, the collaborative approach, technical expertise, and commitment to quality shown by Baltec will not only improve Pelican Point’s operational capabilities but also set new industry standards for energy generation systems. This project exemplifies The Environmental Group’s commitment to delivering innovative, sustainable solutions that meet the evolving needs of the energy sector. If you have a project you would like to discuss, get in touch with us today!