Cogeneration & Gas Turbine Power Station Australian Experience
t
Tamar Valley CCGT Project
»
Design Review (EPS and EPCM contractors)
GHD is providing Owner's Engineer services for Alinta Energy in the
»
Balance of Plant Design
Tamar Valley Power Station Project in Tasmania. GHD’ s scope of
»
Site Technical Overview of Construction and Commissioning
»
Engineering overview of reliability run and warranty period
works consists of: »
Site preparation works
»
Design Review (EPS and EPCM contractors)
»
Balance of Plant Design
»
Site Technical Overview of Construction and Commissioning
GHD is responsible for the design of all civil and structural works, fuel and water supply piping and other mechanical & electrical works.
Tamar Valley Open Cycle Gas Turbine Project GHD is providing Owner’ s Engineer services to Alinta Energy in this project. GHD prepared the technical section of a functional specification for the engineering, procurement and supply (EPS) of one aero derivative gas turbine. GHD’ s scope of works consists of: »
Site preparation works
GHD is responsible for the design of site services, including »
Geotechnical, soil resistivity testing and initial site leveling design
»
Civil & Structural design
»
Civil Interface design
»
Below ground earthing design
»
Lighting and small power including distribution board design
»
Transformer protection - basis of design
»
Protection interface to switchyard - basis of design
»
Water supply and discharge design outside Site boundary
Alinta Energy – Alcoa Pinjarra Cogeneration Plants
procurement services and construction management services
GHD was the Owners Engineer for Alinta Energy on the Pinjarra
associated with the power block for the 150 MW peaking station.
Cogeneration Plant Units 1 and 2. GHD provided the original conceptual design for these two units. Each of the units is a 140 MW
ETSA Energy - Peak Shaving Plant
GTG with a triple pressure HRSG capable producing 420 TPH of high-pressure steam. GHD performed a feasibility study and developed a specification for the plants. GHD performed bid evaluation, negotiation and conformance of the EPC contract, and developed the Long Term Service Agreement Specification. GHD
In 1997, this was the first of a new trend in second hand gas turbine projects. GHD jointly with Black & Veatch, carried out the full EPCM role for the development, delivery and commissioning of two 25 MW plants, at Port Lincoln and Snuggery, in only 6 months from release.
design,
Originally, the client appointed GHD to review the feasibility of
construction, commissioning and testing for Unit 1 and is performing
procuring, installing and commissioning 50 MW of gas turbines for
the same on Unit 2.
peak shaving duty at a number of different locations in South
provided
detail
review
of
the
cogeneration
plant
GHD undertook design, procurement and construction management of the interconnection with the existing Alcoa Powerhouse. This
Australia. It was quickly identified that only second hand machines would be available in the time required.
included all the civil design, the main steam interconnection,
GHD was able to source and procure two 1989 Frame 5P GTs in
condensate water transfer and cooling and other minor services.
Argentina which had not yet been brought onto the market. A site
GHD also provided and technical support for the EPC contract
inspection by our personnel confirmed the machine’ s suitability.
works and interconnecting services.
Export and shipping arrangements were put in hand while step up transformers were purchased, and design proceeded on whatever information was available. Civil and mechanical/electrical erection
Eraring Energy – Frame 6B Gas Turbine Generator GHD is providing engineering services for the installation of a 38 MW simple cycle gas turbine generator at the Eraring Energy power
subcontracts were placed and subsequently the machines were erected in record time.
station to provide black start capability. GHD managed the procurement of the used GT and balance of plant, designed civil, mechanical and electrical works, and are currently providing
116MW Kwinana Cogeneration Plant for Edison Mission Energy GHD provided detailed engineering, procurement and construction
construction phase technical assistance.
management services within the EPC Contract. Fuelled by natural gas and refinery gas, the facility is based on 2 x 39 MW gas
Queensland Alumina Limited (QAL) Cogeneration
turbines, supplementary-fired HRSGs and a 43 MW extraction GHD utilized its extensive experience and database to develop the conceptual design of this fast-track cogeneration project that will generate process steam by recovering exhaust heat from a heavy-
steam turbine. The plant successfully achieved commercial operation on time and budget, and with performance significantly better than guarantee.
duty industrial gas turbine with an output of 100-150 MW for the world’ s largest alumina refinery. GHD produced the conceptual design deliverables and obtained competitive bids for the gas turbine and HRSG packages. A cost estimate for the project was
GHD’ s services included optimisation studies and detailed costing for the cogeneration plant supplying steam and electricity to the BP Refinery with the sale of excess power to Western Power.
produced to +/- 10% accuracy, and this required the detailing of all associated systems, balance of plant, utilities and consumables.
Confidential Clients (alumina refineries and others) Cogeneration Projects »
AGL Power Generation – Somerton Power Station
–
GHD recently developed a conceptual design of a heavy-duty industrial gas turbine based cogeneration project with a total
GHD was engaged to provide Owner’ s Engineer and EPCM
output of 100-200 MW for a major alumina refinery. Besides
services for the client.
generating steam for process using a dual pressure HRSG, the
GHD initially undertook pre-purchase inspections assessment of
electrical output was augmented by a 35 MW steam turbine.
four used Frame 6B gas turbines in Europe. It then provided full
Process features to optimise process steam generation were
design
evaluated. GHD produced conceptual design deliverables
services
for
civil,
mechanical
and
electrical
works,
addressing siting, various refinery operating conditions, process
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design parameters, grid connection, etc.
»
In addition, a
Pacificorp Australia - Kemerton Park Cogeneration Plant
competitive bid review process for the gas turbine, HRSG and
GHD worked with Pacificorp for the development of a cogeneration
steam turbine was completed. A detailed material take-off was
plant to serve industries at Kemerton, Western Australia. Various
developed to estimate the project costs.
plant configurations were studied for outputs ranging from 50 MW to
GHD provided Owner’ s Engineering (OE) services to the client
over 100 MW. Heat recovery from existing processes, grid
in relation to the development of combined heat and power
connection and water balances were included in the study. Water
generation facilities at an alumina plant in Australia. The plant
sources
consisted of two 220 MW, continuously rated coal fired power
considered. A draft environmental approval document was prepared.
generation units, with steam production and conditioning to suit
EPC pricing was developed for selected plant alternatives.
the generation units and also to provide 577 TPH of 13 Bar (g), 250°C and 334 TPH of 4.5 Bar (g), 175°C process steam. In
were
evaluated
and
wastewater
disposal
options
Millennium Inorganic (SCM) Chemicals - Cogeneration Plant
the pre-feasibility study phase, GHD developed the design basis and steam cycle as well as the capital and O&M costs and plant performance of generating units. GHD undertook project
coordination
activities
and
developed
project
communication procedures. Among other engineering and project management services delivered were the following: •
Provide interfacing arrangements, and site layout, plant and lay down footprint and drawings
•
‘ Owner’ s Engineer’for the development of a Build Own Operate (BOO) cogeneration plant at Kemerton. The gas turbine based plant of a nominal 40 MW capacity would supply power and steam to Millennium.
Newmont – Telfer Power Station GHD was engaged to review electrical power transmission versus
Define design conditions such as steam parameters, operating regimes, terminal points and location of water intake and switchyard
•
GHD was commissioned by Millennium Inorganic Chemicals as
gas pipeline and on site gas turbine based power station. Following the decision to proceed with the gas pipeline and on site power station, GHD developed the contract documentation for the gas
Perform studies on coal handling and water supplies, plant
pipeline and power station.
reliability, and suitability of a gas hybrid option •
Develop
or
update detailed
Capital Cost
estimate,
Various – Peaking GT Stations in S.E. Australia
including EPC pricing, costing of interconnection works,
GHD provided advice to several clients on peaking GT stations
and Owner’ s Costs, as well as O&M Cost
including air modelling studies, concept design, capital cost and
•
Undertake financial evaluation of competing options
contract strategy development. GTs included aero-derivatives,
•
Provide detailed project schedule
Frame 5s, 6Bs, and 9Es.
•
Define contracting strategy
Western Power – 240MW Kwinana CCGT Project
•
Assist in initial environmental submission
•
Carry out wage/labour rate survey
GHD was appointed Owner’ s Engineer to Western Power for the preparation of a project definition report, a procurement specification and assistance with tender evaluation. The project definition report
Western Power - Tiwest Cogeneration Plant
provided a description of the key features of the proposed mid merit The Tiwest cogeneration plant consists of a relocated and refurbished Frame 6 gas turbine, modified for combined cycle operation and mated to a single pressure HRSG on the Tiwest pigment plant site in Kwinana Western Australia.
GHD’ s role as
240 MW CC plant, performance data based on the range of GTs suitable for the project and a cost estimate for project approval. A comprehensive single EPC contract specification was prepared. GHD assisted WP with design review and site inspections.
‘ Owner’ s Engineer’ included project definition, cost estimation, specification preparation, tender evaluation, contract management and construction supervision. Unique features of the plant are the use of a relocated gas turbine and the staging of the plant configuration for current and future Tiwest steam demands.
Synergen - Gas Turbine Relocation GHD prepared an initial report for Synergen to relocate one of their 25 MW peaking gas turbines in South Australia to provide additional grid support. Subsequently, GHD were engaged on an EPCM basis to dismantle, transport and reassemble the gas turbine on a new set of foundations.
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Boral Energy - Roma Gas Turbines
including detailed design for coal receival marine facilities and site
GHD provided advice to Boral Energy on the purchase and
preparation, and receipt of coal supply tenders.
installation of two used 35 MW gas turbines for a site in Roma,
decision to change from coal to gas, GHD carried out the detail
Queensland. Specific tasks included check pricing for GTs and
design, procurement, construction management and commissioning
transformers,
Following a
grid
of a six unit 200 MW gas turbine/combined cycle power station
interconnection advice and review of initial contract documentation
comprising 5 x 36 MW gas turbines, 1 x 35 MW steam turbine and
and implementation plans. Commissioning staff were provided to
two HRSGs. Included 58 km of 132 kV transmission line and 132
complete the project.
kV GIS switchyard.
Energy Equity Corporation - Barcaldine Frame 6 Conversion to Combined Cycle
BHP Iron Ore
GHD was engaged by EEC as ‘Owner’ s Engineer’initially to review
100MW Power Station at Port Hedland (2 x 37 MW combustion
conceptual design, produce cost estimates, then prepare an EPC
turbines, two HRSGs, and 1 x 35 MW steam turbine).
standby
fuel
installation
cost
estimation,
Conceptual design studies, specification, and cost estimates for the
specification for converting the existing Frame 6 gas turbine to combined cycle utilising a second hand steam turbine. The brief
Pioneer Sugar Mill Cogeneration Project
was
negotiation,
GHD was appointed as the Design Consultant for all aspects of this
environmental approval documentation, civil design and ongoing
A$100m project. This included process, HAZOPs, all civil/structural
technical advice and assistance.
works, mechanical, piping and electrical works, and controls for the
GHD were able to considerably reduce the costs and increase the
cogeneration plant and other works necessary to increase the steam
efficiency of the plant during the conceptual design phase by
efficiency of the Sugar Mill.
confirming the suitability of a wet cooling system.
The Pioneer Sugar Mill Cogeneration Project consisted of the
extended
to
tender
assessment,
contract
Fletcher Challenge/ITOCHU - Power Station for An Feng / Kingstream Midwest Iron and Steel
following major elements: »
New bagasse fired boiler 130 TPH @ 65 Bar
GHD acted as Owner’ s Engineer during the bid phase for the
»
New condensing steam turbine 36 MW
development of a Build Own Operate (BOO) 350 MW combined
»
Upgraded bagasse fired boiler
cycle plant at Geraldton in the State’ s Midwest. The role included
»
New back pressure steam turbine
thermal
»
New balance of plant including cooling towers, ash plant, demin
analysis
and
optimisation studies,
electrical system
smoothing studies, reliability analysis and detailed costing estimates for a wide range of plant configurations.
Electricity Tariff Reduction for SIMCOA
240 TPH @ 31 Bar 31 MW
plant and substation »
New sugar evaporation stage (10,000 m2)
»
Electrification of the milling train (11 MW) and other major drives with a total of 8 MW of variable speed drives.
Preliminary engineering and costing studies for energy recovery and energy cost reductions for SIMCOA. Study included combined cycle
GHD’ s specific responsibilities include:
configurations up to 200 MW capacity.
»
Interfacing with major equipment packages including new boiler, revamped boiler, condensing turbine, backpressure
Palmerston Gas Turbine Station (4 x 20 MW) - For Northern Territory Electricity Commission GHD provided planning, design and procurement services for a four unit simple cycle gas turbine station. Tenders were called, but the project was put on hold.
turbine, pre-evaporators »
Plant layout
»
Civil works and drainage
»
Concrete foundations for
all equipment
including major
packages
200MW combined Cycle Channel Island Power Station for Northern Territory Electricity Commission
»
Structural steel including turbine house
»
Steam pipe work
GHD initially carried out the Preliminary Design and Specification
»
Services area including raw water, demineralised water, cooling
Consultancy for a 300 MW coal fired power station. Scope included engineering
and
detailed
cost
estimates
for
the
complete
towers, chemical dosing fire systems »
HV and LV electrics
development of the 6 x 5 MW station on a ‘green fields’ site,
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»
Control and Instrumentation
»
Conversion of sugar mill drives from steam turbine to electrics
»
Ash handling systems for new and revamped boilers
»
Engineering support during construction and commissioning
For more information, please contact: Gour Choudhuri +617 3316 3442
[email protected]
C:\Documents and Settings\Gchoudhouri\Local Settings\Temp\wz4568\Experience List - Cogeneration & GT Projects.doc
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