Download - Engineers Ireland Site Visit 23rd March 2010
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Whitegate Independent Power PlantWhitegate Independent Power Plant
CER Site Visit 24th October 2008
CER Site Visit 24th October 2008nt
Engineers Ireland Site Visit23rd March 2010
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Agendag
• Presentation of project and progress to date.
• Site Tour• Site Tour
• Close Out
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Main Shipping Channel Fort Mitchell
Fort Carlisle Channel Fort Mitchell
(Spike Island)
Fort Davis Naval Base & Irish Steel& Irish Steel
Site
WIPP SiteRefinery
Jetty Whitegate Village
RefineryVillage
ESB Aghada Site
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WIPP Project Summary
• Bord Gáis are constructing a 450 MW Combined Cycle Power Plant (CCGT), located in
WIPP Project Summary
Bord Gáis are constructing a 450 MW Combined Cycle Power Plant (CCGT), located in Whitegate, Co. Cork.
– At 450 MW, this is the equivalent of powering approximately 135,000 homes.
• Bord Gáis leased 25 acres of land from the adjacent ConocoPhillips oil refinery.
• The power plant and refinery agreed a suite of interfaces covering the supply of distillate, steam, natural gas and refinery off gas.
Th j t i d ithi th I t t G f B d Gái• The project is managed within the Investments Group of Bord Gáis.
• The power plant is being constructed under an Engineer, Procure & Construct (EPC) contract.
G l El t i d G (GE G ) i t d th EPC t t• General Electric and Gama (GE-Gama) were appointed as the EPC contractor.
• Bord Gáis appointed PB Power as the Owners Engineer.
Th EPC t t d i A t 2007 d th C i l O ti D t (COD) i J l• The EPC contract commenced in August 2007 and the Commercial Operation Date (COD) is July 2010. The Project is currently on schedule for COD July 2010.
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Project DevelopmentProject Development
• 2005Bord Gáis and ConocoPhillips agreed to explore the potential for development of– Bord Gáis and ConocoPhillips agreed to explore the potential for development of a power generation plant on 25 acres of land owned by the ConocoPhillips oil refinery in Whitegate, Co. Cork.
2006• 2006:– Heads of Terms agreed for the long-term lease of 25 acres of land from
ConocoPhillips– Bord Gáis appointed consultants pp
• Arup’s for planning and environmental• Mott McDonald for engineering and design
– Submitted application to EirGrid for connection to the grid.– Motts developed original layout and design of plantMotts developed original layout and design of plant.– Arup’s developed planning application and EIS. – Planning permission for the project received in October 2006. – Developed Minimal Functional Specification (MFS) for EPC Tender
OJEC N ti– OJEC Notices:• Owners Engineer• Engineering, Procurement and Construction (EPC) for 450 MW CCGT Plant
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Project DevelopmentProject Development
• 2007– Appoint Owners Engineer: PB Power– GE-Gama and Siemens tender for the EPC ContractGE Gama and Siemens tender for the EPC Contract
• Tender evaluation process• Preferred bidder selection
GE-Gama selected as preferred bidder March 2007– GE-Gama selected as preferred bidder March 2007• Main contract based on Fidic Silver• Plant technical deliverables agreed within the MFS
EPC Contract signed with GE Gama in August 2007– EPC Contract signed with GE-Gama in August 2007– September 2007, GE-Gama mobilise to site– October 2007, site clearance works commence
November 2007 commence construction of site offices– November 2007, commence construction of site offices– December 2007, commence diversion of Glanagow Stream
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Landscape Plan & Site Layout
Entrance RoadWater
Treatment
Networks AGI
Gas Compressor
Treatment Building
Water Tanks HRSGCompressor
Security Gate House Air Cooled
CondensersDistillate Tank
Workshop Canteen &
Stores
EirGrid GIS & AIS
Auxiliary Boiler
Main Turbine Building
Electrical Building
Main Transformer
Administration Building
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Key Project Milestones
• EPC Contract Award Aug 2007Sit M bili ti O t 2007
Key Project Milestones
• Site Mobilisation Oct 2007• Civil Works Mar 2008• Structural Steel Erection Sep 2008• Mechanical Works Start Nov 2008Mechanical Works Start Nov 2008• Electrical Works Start Jan 2009• Main Equipment Delivery Jan 2009• Main Equipment Installation Feb 2009
El t i l B k F d S 2009• Electrical Back Feed Sep 2009• First Fire Gas Turbine Feb 2010
• Base Load Operation Apr 2010Base Load Operation Apr 2010• Grid Code Testing May 2010• Performance & Reliability Run May 2010• AIS Commissioning (3rd Circuit) May 2010
C i l O ti D t J l 2010• Commercial Operation Date Jul 2010
• GIS Commissioning (4th Circuit) Aug 2011
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BGE External Deliverables
• Water Supply Feb 2009• Cork County Council
BGE External Deliverables
Cork County Council• Effluent Discharge Line Mar 2009
– DAFF (Foreshore Licence)• Gas Supply Apr 2009
– Bord Gáis NetworksBord Gáis Networks• IPPC Licence Apr 2009
– EPA• Electrical Back-feed Sep 2009
– EirGridEirGrid• Emissions Trading Licence Feb 2010
– EPA• Distillate Supply Mar 2010
– ConocoPhillipsConocoPhillips• Telecommunications Apr 2010
– Eircom (Fibre Optic connection)• Grid Connection (3rd Circuit) May 2010
– EirGridEirGrid• Grid Connection (4th Circuit) Aug 2011
– EirGrid
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EirGrid Circuit Routes
3rd circuit
Back-feed circuit
4th circuit
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EirGrid Deliverables
• Back-Feed CableS h d l d J l 2009– Scheduled July 2009
– Current network line capacity is ~860 MW– Installed base load capacity by January 2010= ~1140 MW (450 + 420 + 270)
• WIPP + ESB CCGT + ESB Steam Plant (ESB OCGT’s not included)WIPP ESB CCGT ESB Steam Plant (ESB OCGT s not included)
• 3rd Circuit– Scheduled May 2010– 3rd circuit increases network line capacity to ~1290 MW. – N-1 requirements has set grid firm access at ~860 MW: to be shared by BGE and ESB. – Circuit operational May 2010
• 4th Circuit– Scheduled August 2011– Submarine cable order July 2009Submarine cable order July 2009– Submarine cable installation December 2010 to February 2011– Circuit Operational August 2011
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Gas Line & EirGrid Back-Feed and 4th Circuit Routes
To Rafeen 220kV Station
Gas Line & EirGrid Back Feed and 4 Circuit Routes
4th Circuit (sub sea)
AGI RingaskiddyGlanagowGIS/AIS
220kV Station
ConocoPhillips Beach
From Aghada220kV Station
Back-Feed circuit
Gas Line
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3rd Circuit Route
3rd Circuit To CowcrossAghada 220kV
StationBack-Feed
Cable
(sub-sea) To Cowcross 220kV Station
Longpoint GIS(ESB)
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November 2007
Clearance of Lay down area
Storage of Site Site Clearance gMaterial and Levelling
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January 2008
Lay-Down Area established
Area for Main Construction
Offices
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April 2008
Site Zoned based on layout
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August 2008
Main Construction
Offices Finished
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Bund Wall for
September 2008
Main Turbine Building
Distillate Tank
De-MinWater Tank
East Retaining
Wall
Basement of Electrical Building
Workshop Stores
Building
Administration Building
CanteenBuilding
Foundation
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450 MW CCGT Power Plant
• GE Single Shaft Configuration (58% efficiency)– 9FB Gas Turbine – 280 MW– A15 Steam Turbine – 150 MW– Supplementary Firing – 30 MWpp y g– 450H Class Generator – 19 kV– SPX- Air Cooled Condensers – 20 fan units– CMI Vertical Tube HRSG – 3 pressure, re-heat.CMI Vertical Tube HRSG 3 pressure, re heat.
• Fuel N t l G ( i )– Natural Gas (primary)
• Gas turbine, Supplementary Firing, Auxiliary Boiler– Distillate (secondary)
G T bi A ili B il E G t• Gas Turbine, Auxiliary Boiler, Emergency Generator– Refinery Off Gas (ROG)
• Supplementary Firing
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Natural Gas Fuel Cycle for CCGTy
• Natural Gas
– Bord Gáis Networks AGI• Supply pressure 60 bar• Filters and meters only; no pressure reductiony; p
– Gas Reduction Station• Reduced to 38 bar• Gas Compressors available if supplied below 38 bar
– Fuel Performance SkidFuel Performance Skid• Filtered• Heated to 108 degrees C
– Gas Turbine• 35 bar inlet to gas turbine• 35 bar inlet to gas turbine• 57 tons/hr at base load (432 MW)
– Supplementary firing• Reduced to 3 bar
4 b it i id HRSG d t• 4 burner units inside HRSG duct• 5 tons/hr giving approx 30 MWe• 50 tons steam to the Refinery
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HP, IP, LP Steam Drums
Pressure
Main Air filterHRSG Tube
Stacks
Pressure170 bar
Air to Gas Turbine
19 kV transformed up to 220 kV
Gas Turbine Compressor
Gas Turbine Power Turbine
Bus DuctsPower Out to Transformer
up to 220 kV
MainElectrical Generator
Exhaust Temp640 °C
MainStack
640 °C
Gas Turbine Unit
Steam Turbine
HP, IP, LP sections
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Energy Cycle
• Gas Turbine (280 MW)– 55 tons/hr natural gas at full load
gy y
– 55 tons/hr natural gas at full load – Generates 2400 tons/hr exhaust gas @ 640 °C
• HRSGExhaust gas @ 640 °C inlet to HRSG– Exhaust gas @ 640 C inlet to HRSG
– Exhaust gas @ 85 °C exit from HRSG at main stack (60 meters)– Generates approximately 360 tons/hr of steam in HRSG– Increase steam output to 400 tons/hr using supplementary firing
• Steam to Turbines (150 to 180 MW)– HP Turbine: 340 tons/hr steam @ 140 bar (560 °C)
• Steam Exits @ 29 bar (333 °C) to Re-heaterRe heater to IP Turbine: 340 tons/hr steam @ 26 bar (560 °C)– Re-heater to IP Turbine: 340 tons/hr steam @ 26 bar (560 °C)
– LP Turbine: 40 tons/hr steam @ 4 bar (300 °C)• 380 tons/hr Steam Exits to ACC @ 0.6 bar (38 °C).
• Inlet Steam to Air Cooled Condensers (ACC)• Inlet Steam to Air Cooled Condensers (ACC)– 20 Cooling Fans (18 operational at full load, with 2 spares)– Condensate exits ACC @ 34 °C – Returns to condensate system
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Major Equipment Deliveriesj q p
• December 2008:December 2008:– HRSG Modules (18 off) @ approx 130 tons
each delivered by road at night timeeach, delivered by road at night time.• March 2009
– Gas Turbine (300 tons) Barged– Generator (281 tons) BargedGenerator (281 tons) Barged– Transformer (320 tons) Barged
HP T bi (97 t ) B d– HP Turbine (97 tons) Barged– IP/LP Turbine Delivered in sections
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HRSG Structural Steel Frame
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HRSG Module & Lifting Frame Attachment
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HRSG Module being lifting into position
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HRSG – 3 Modules in Position
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HRSG – Row 5 Modules being positioned
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HRSG Module Installation
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Major Equipment Off Loading at ESB Aghada
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Gas Turbine on Main Road through Village
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Passing Under ESB Aghada Bridge on main road
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Main Transformer transportation to site
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Gas Turbine Passing Corkbeg
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Gas Turbine Passing Corkbeg
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Gas Turbine on Gantry Crane
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Generator on Gantry Crane at Turbine Hall
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Main Transformer on Positioning Tracks
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May 2005 - Centreline
IP/LP Turbine Location for HP
Generator
BaseLocation for HP
Turbine
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GE Facility, Albany, New York
IP/LP Steam Turbine in
Lathe receiving final
blade tip finishfinish
IP Steam Section
Stages 1 to11
LP Steam Section
Stages 1 to 6
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Gas Turbine on Centreline
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Centreline with IP/LP Rotor In Place
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HP Steam Turbine on Centreline
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IP/LP Steam Turbine Top Cover in Place
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Lagging of HP/IP/LP Steam Turbines
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Model of Air Cooled Condenser (ACC)
Fans
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Example of an ACC Under Construction
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Construction Area for Air Cooled Condenser (ACC)
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ACC Frame Construction
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ACC Fan Installation
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ACC Condenser Units Streets 3 & 4
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ACC A Frames for Streets 1 & 2
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ACC Streets 1 to 4 Condensing Units Complete
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ACC Construction Continued
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ACC Side Cladding Installation
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ACC Construction Complete
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Current Status
• Operational to 70 MWOperational to 70 MW• Steam Blowing Process nearing completion• Next Stages:• Next Stages:
– Restore all steam pipe work– Steam to Steam Turbines– Steam to Steam Turbines– Tune to Base load (430MW)– Performance TestingPerformance Testing– Grid Compliance Testing– Reliability Runy– COD
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Whitegate Independent Power PlantWhitegate Independent Power Plant
Thank You For Your Attention