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Sulaymaniyah 1,500 MW CC Power Plant Conversion

The existing simple cycle Sulaymaniyah Gas Power Station had been developed by MGH – Mass Group Holding Ltd. with a capacity of 1,000 MW with eight GE – 9E gas turbines.

Through the use of steam turbines manufactured by GE, the combined cycle gas turbines conversion added 500 MW installed capacity to the plant, making an overall capacity of 1,500 MW.

The Sulaymaniyah Combined Cycle Power Plant Project was designed to work on two types of fuel – natural gas as the primary and diesel as the secondary source and to utilize the exhaust heat produced by the existing Sulaymaniyah Gas Power Station.

MGH – Mass Group Holding Ltd. signed an EPC contract with ENKA in July 2013 to convert its Sulaymaniyah Power Project from simple cycle to combined cycle technology.

Project Description

Sulaymaniyah 1,500 MW CC Power Plant Conversion

  • Engineering
  • Procurement
  • Construction
  • Testing & Pre-Commissioning
  • Commissioning
  • Start-up

Project Features

Contract Type
Lump Sum Turn Key
Scope of Work
Engineering, Procurement, Construction, Testing & Pre-Commissioning, Commissioning, Start-up, Training of the personnel
Client
MGH – Mass Group Holding Ltd.
Contractor
ENKA İnşaat ve Sanayi A.Ş.
Key Quantities
Earthworks 260,000 m³
Concrete 45,000 m³
Structural Steel 5,800 tons
A/G Piping 2,000 tons
Cabling 1,100,000 lm
Mech. Equipment 36,000 tons
Insulation & Paint 52,000 m²
Buildings 6,500 m²
Project Duration
Start Date 01.07.2013
Finish Date 27.07.2016
Duration 37 Months

Location

Sulaymaniyah, Iraq
UNIQUE CHALLENGES

The project consists of conversion of live simple cycle to a combined cycle power plant project under brown field conditions. ENKA worked under unstable grid conditions nevertheless successfully managed to minimize the negative impacts of the grid on the power plant by implementing tailor-designed control.

One of the major challenges of the project was to work under major civil unrest in the region. ENKA prepared and implemented a solid safety and security plan based on risk avoidance through careful planning and defensive protection measures to cope with the challenges. Our security approach consisted of good community relations, countermeasures to reduce the risk by deterring, detecting or delaying the threat, and an ever ready evacuation plan should any incident occur.

Through this approach, ENKA minimized the potential risk factors and managed to work without interruption and with no effect to contract schedule.

Due to the circumstances, at times, shipments to the jobsite were interrupted and high labor turnovers were experienced causing ENKA to apply and obtain visas for the new workforce multiple times.

Similarly, US based engineering subcontractor, European and Japanese vendors restricted their engineers to visit the jobsite due to security concerns. ENKA handled all of these challenges by true commitment of the project team to the project’s success, extensive planning, and careful recruiting program and by carrying adequate redundancy at each phase of the execution.

Flexible logistics management approach has been used during project execution by creating alternative shipping solutions and making timely and accurate decisions and adapting to the frequently changing Iraqi Customs regulations. 2,750 trucks (more than 46 thousand tons of project materials and equipments) have been brought to site.

ENKA SCOPE OF SERVICES

The major works under the contract were the design, engineering, procurement, shipment/ delivery, installation construction, interconnection, pre-commissioning, commissioning and start-up of eight Heat Recovery Steam Generators, two nominally rated 250 MW GE Steam Turbine Generators, two GSU Transformers, two 40-cell Air Cooled Condenser systems and all other Balance of Plant equipment to convert the simple cycle plant into two blocks of 4x4x1 combined cycle configuration, as well as demonstrating parallel operation with the grid at the required net output, performance testing, classroom training of the operating and maintenance personnel, and preparation of the integrated operation and maintenance manuals. The scope also includes a 400kV switchyard for which the interconnection point will be a dead-end structure to be erected by the Ministry of Electricity.

ENKA workforce reached to 1,285 employees during the peak periods of the Project. ENKA further provided training for the O&M personnel who will be operating and maintaining the plant.

SIGNIFICANT FEATURES AND ACCOMPLISHMENT
  • Sulaymaniyah Combined Cycle Power Project is designed to run on two types of fuel, mainly natural gas, and diesel fuel as standby. The Natural Gas is reaching the station via pipelines from Khor Mor gas field station, while the diesel is transported to the plant via mobile trucks. Then the diesel is purified and treated before it can be used for the turbines
  • 3 million work hours without a lost time incident.
MAJOR SPECIFICATION
Type of Plant Combined Cycle Power Plant
Capacity 1,500 MW
Type of Fuel Natural gas as the primary and Diesel as the secondary source
Configuration 2x(4x4x1)
Steam Turbine Generator General Electric, Unit: 2 Sets, Model: C7, Rating Per Unit: 252 MW
HRSG CMI, Unit: 8 Sets, Type: Vertical – Natural Circulation Cold Casing
Cooling Type Air Cooled Condenser, GEA, Unit: 2 Sets, Type: Each with 40 cells

Gallery

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