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Engineers Ireland Site Visit 23rd March 2010

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Whitegate Independent Power Plant Whitegate Independent Power Plant CER Site Visit 24 th October 2008 CER Site Visit 24 th October 2008nt Engineers Ireland Site Visit 23 rd March 2010
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Page 1: Engineers Ireland Site Visit 23rd March 2010

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

Page 2: Engineers Ireland Site Visit 23rd March 2010

Agendag

• Presentation of project and progress to date.

• Site Tour• Site Tour

• Close Out

Page 3: Engineers Ireland Site Visit 23rd March 2010

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

Page 4: Engineers Ireland Site Visit 23rd March 2010

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.

Page 5: Engineers Ireland Site Visit 23rd March 2010

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

Page 6: Engineers Ireland Site Visit 23rd March 2010

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

Page 7: Engineers Ireland Site Visit 23rd March 2010

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

Page 8: Engineers Ireland Site Visit 23rd March 2010

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

Page 9: Engineers Ireland Site Visit 23rd March 2010

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

Page 10: Engineers Ireland Site Visit 23rd March 2010

EirGrid Circuit Routes

3rd circuit

Back-feed circuit

4th circuit

Page 11: Engineers Ireland Site Visit 23rd March 2010

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

Page 12: Engineers Ireland Site Visit 23rd March 2010

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

Page 13: Engineers Ireland Site Visit 23rd March 2010

3rd Circuit Route

3rd Circuit To CowcrossAghada 220kV

StationBack-Feed

Cable

(sub-sea) To Cowcross 220kV Station

Longpoint GIS(ESB)

Page 14: Engineers Ireland Site Visit 23rd March 2010

November 2007

Clearance of Lay down area

Storage of Site Site Clearance gMaterial and Levelling

Page 15: Engineers Ireland Site Visit 23rd March 2010

January 2008

Lay-Down Area established

Area for Main Construction

Offices

Page 16: Engineers Ireland Site Visit 23rd March 2010

April 2008

Site Zoned based on layout

Page 17: Engineers Ireland Site Visit 23rd March 2010

August 2008

Main Construction

Offices Finished

Page 18: Engineers Ireland Site Visit 23rd March 2010

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

Page 19: Engineers Ireland Site Visit 23rd March 2010

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

Page 20: Engineers Ireland Site Visit 23rd March 2010

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

Page 21: Engineers Ireland Site Visit 23rd March 2010

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

Page 22: Engineers Ireland Site Visit 23rd March 2010

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

Page 23: Engineers Ireland Site Visit 23rd March 2010

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

Page 24: Engineers Ireland Site Visit 23rd March 2010

HRSG Structural Steel Frame

Page 25: Engineers Ireland Site Visit 23rd March 2010

HRSG Module & Lifting Frame Attachment

Page 26: Engineers Ireland Site Visit 23rd March 2010

HRSG Module being lifting into position

Page 27: Engineers Ireland Site Visit 23rd March 2010

HRSG – 3 Modules in Position

Page 28: Engineers Ireland Site Visit 23rd March 2010

HRSG – Row 5 Modules being positioned

Page 29: Engineers Ireland Site Visit 23rd March 2010

HRSG Module Installation

Page 30: Engineers Ireland Site Visit 23rd March 2010

Major Equipment Off Loading at ESB Aghada

Page 31: Engineers Ireland Site Visit 23rd March 2010

Gas Turbine on Main Road through Village

Page 32: Engineers Ireland Site Visit 23rd March 2010

Passing Under ESB Aghada Bridge on main road

Page 33: Engineers Ireland Site Visit 23rd March 2010

Main Transformer transportation to site

Page 34: Engineers Ireland Site Visit 23rd March 2010

Gas Turbine Passing Corkbeg

Page 35: Engineers Ireland Site Visit 23rd March 2010

Gas Turbine Passing Corkbeg

Page 36: Engineers Ireland Site Visit 23rd March 2010

Gas Turbine on Gantry Crane

Page 37: Engineers Ireland Site Visit 23rd March 2010

Generator on Gantry Crane at Turbine Hall

Page 38: Engineers Ireland Site Visit 23rd March 2010

Main Transformer on Positioning Tracks

Page 39: Engineers Ireland Site Visit 23rd March 2010

May 2005 - Centreline

IP/LP Turbine Location for HP

Generator

BaseLocation for HP

Turbine

Page 40: Engineers Ireland Site Visit 23rd March 2010

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

Page 41: Engineers Ireland Site Visit 23rd March 2010

Gas Turbine on Centreline

Page 42: Engineers Ireland Site Visit 23rd March 2010

Centreline with IP/LP Rotor In Place

Page 43: Engineers Ireland Site Visit 23rd March 2010

HP Steam Turbine on Centreline

Page 44: Engineers Ireland Site Visit 23rd March 2010

IP/LP Steam Turbine Top Cover in Place

Page 45: Engineers Ireland Site Visit 23rd March 2010

Lagging of HP/IP/LP Steam Turbines

Page 46: Engineers Ireland Site Visit 23rd March 2010

Model of Air Cooled Condenser (ACC)

Fans

Page 47: Engineers Ireland Site Visit 23rd March 2010

Example of an ACC Under Construction

Page 48: Engineers Ireland Site Visit 23rd March 2010

Construction Area for Air Cooled Condenser (ACC)

Page 49: Engineers Ireland Site Visit 23rd March 2010

ACC Frame Construction

Page 50: Engineers Ireland Site Visit 23rd March 2010

ACC Fan Installation

Page 51: Engineers Ireland Site Visit 23rd March 2010

ACC Condenser Units Streets 3 & 4

Page 52: Engineers Ireland Site Visit 23rd March 2010

ACC A Frames for Streets 1 & 2

Page 53: Engineers Ireland Site Visit 23rd March 2010

ACC Streets 1 to 4 Condensing Units Complete

Page 54: Engineers Ireland Site Visit 23rd March 2010

ACC Construction Continued

Page 55: Engineers Ireland Site Visit 23rd March 2010

ACC Side Cladding Installation

Page 56: Engineers Ireland Site Visit 23rd March 2010

ACC Construction Complete

Page 57: Engineers Ireland Site Visit 23rd March 2010

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

Page 58: Engineers Ireland Site Visit 23rd March 2010

Whitegate Independent Power PlantWhitegate Independent Power Plant

Thank You For Your Attention


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