Steam, gas turbine and combined cycle power

Dual-purpose seawater desalination and power plants

Coal-fired power plants

Combined heat and power plants

Industrial power plants

Waste-to-energy plants

Diesel and IC engine power plants

Steam, gas turbine and combined cycle power plants:

Construction of a new 500 MW thermal power plant, Sudan

To extend electrification in the Sudan, the National Electricity Corporation (NEC) is constructing a thermal 4 x 125-MW power plant some 300 km south of Khartoum. The natural circulation boilers are fired with crude oil and service water is extracted from the White Nile 12 km away. Flue gases pass through a recuperative heat exchanger to preheat the combustion air before they are cleaned in an electrostatic precipitator. As Owner’s Engineer, Fichtner is assisting NEC with review and completion of the technical and commercial contract documents, including drawing up the environmental impact study, support during contract negotiations, as well as reviewing preliminary planning and detail engineering, with a check of drawings, of the Indian general contractor. Subsequently, Fichtner will undertake site supervision, project management and quality control, training of operating staff, monitoring trial operation and commissioning, with support of local staff during the warranty phase.

Technical Advisor for two IPP power plant projects in Saudi Arabia

Fichtner is acting as Technical Advisor to Saudi Electric Company S.A. for two IPP projects. These are: construction of a heavy oil-fired 1200 MW power plant in Rabigh and a 2000 MW combined cycle power plant in Riyadh. Alongside project development, the services comprise investigations into fuel supply and drawing up the general techno-economic concepts of these plants. During project development, Fichtner is coordinating detailed siting investigations that, among others, cover cooling water supply and discharge, emission discharges as well as soil investigations, both onshore and offshore. Additionally, in close collaboration with legal and commercial consultants, Fichtner is drawing up the tender documents, providing support for bidder qualification, and leading contract negotiations with the preferred bidder up to financial close.

Feasibility study for extending a combined cycle power plant, Pakistan

In the city of Kot Addu, Muzzaffargarh District in Punjab Province, Kot Addu Power Company Limited is planning to extend the 1600 MW combined cycle power plant they operate by up to 500 MW, and supply the electricity to the national 220 kV grid. Fichtner was awarded a contract to prepare a bankable feasibility study. This included technical and economic comparison of options, with combined cycle configurations on the basis of residual oil-fired gas turbines, calculation of capital costs, financing model, detailed technical description of the preferred option, environmental impact study, geological investigations and a grid study, as well as review of contracts under technical, economic and financial aspects.

Project management for Ca Mau 720 MW Combined Cycle Power Plant, Vietnam

Vietnam Machinery Erection Corporation (Lilama) was nominated by the Vietnamese Government to the project owner, PetroVietnam (PV) as general contractor for Ca Mau Combined Cycle Plant. Fichtner was then awarded a contract by Lilama for tendering. Apart from project management for drawing up the tender, Fichtner’s services encompassed tendering for the entire plant in four lots: power island, HV switchgear, balance of plant and civil works. Fichtner then undertook technical and commercial bid evaluation and put together from this the client’s most favorable EPC offer for the project owner, PV. To conclude, Fichtner provided assistance during contract award negotiations with the project owner and subcontractors, and supported Lilama in drawing up the EPC contract and its subsidiary contracts.

Technical specifications for Campanario 400 MW Combined Cycle Power Plant, Chile

Fichtner was entrusted by Campanario Generación S. A. with drawing up technical specifications and tender documents for appointing an EPC contractor to erect this 400 MW gas-fired combined cycle power plant in Central Chile.

General planning for an 800 MW combined cycle project, Germany

Trianel Power Kraftwerk Hamm-Uentrop GmbH & Co. KG (TPH) is constructing in Hamm-Uentrop, Westphalia, a combined cycle power plant with an electrical rating of 800 MW. For this two-unit plant, technology for attaining the highest possible efficiency – at least 57.5% – finds application. Fichtner was retained as technical consultant at an early stage of the project to handle conceptual and basic engineering, tendering for contract award to a general contractor and permit engineering. Additionally, preparations were made for award of a contract to a service provider for plant operation. After the decision to go ahead with construction Fichtner was entrusted with follow-on planning, supervision of the general contractor and construction management.

Project structure planning up to contract award of Lubmin 3 x 400 MWe Merchant Power Plant, Germany

At the site of the former Lubmin Nuclear Power Plant near the Baltic Coast, Concord Power GmbH & Co. Lubmin KG is erecting a 1200 MW combined cycle power plant. Since 1999, Fichtner has been awarded a number of contracts in support of this project, among others for project structure planning, conceptual engineering with outline planning of the power plant configuration; tendering for the power plant with evaluation of general contractor bids and technical clarification; and contract and award-of-contract negotiations with drafting of the order document appointing the general contractor. Additionally, Fichtner is assisting Concord Power Lubmin in the award of a maintenance contract and in drawing up permit application documents under German pollution control legislation. During power plant construction, Fichtner is also handling applications for planning permission and the plan approval procedure for an overland HP gas pipeline for supplying the power plant.

Concept study for rehabilitation of a combined cycle CHP plant, Germany

Pfaffenwald Combined Heat and Power Plant of the University of Stuttgart supplies the research and teaching facilities as well as student residences with electricity, heat and cold. Fichtner was awarded a contract for a concept study, resulting in a recommendation for measures for modernizing the plant, and in particular the 2 x 5 MWe gas turbines, 2 x 8.6 t/h HRSGs (37 bar / 440°C) and 3.9 MWe extraction-condensing steam turbine. Additionally, Fichtner is advising the University Building Services Department in assessing leasing concepts for the new facilities.

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Dual-purpose seawater desalination and power plants:

Seawater desalination with power plant, Fujairah, United Arab Emirates

For a seawater desalination facility linked to a power plant, alongside the power and water demand study, Fichtner prepared the plant concept and basic engineering for several options. On the basis of the resulting preferred option, Fichtner drew up the tender documents and supported the UAE Offsets Group (subsequently UWEC) during tendering and contract award. As the project proceeded, Fichtner supervised the entire project handling, including commissioning of the dual-purpose seawater desalination and power plant. The 500 MW combined cycle power plant is equipped with four gas turbines and two steam turbines. The seawater desalination plant – a hybrid system combining reverse osmosis with thermal multistage flash desalination – is designed for a capacity of 455,000 m³/d drinking water.

Combined power generation and seawater desalination plant Jebel Ali D, K and M, United Arab Emirates

The Dubai Electricity and Water Authority commissioned Fichtner in 1998 to extend the Jebel Ali Station D power plant through the addition of 450 MW and to rehabilitate the three MSF desalination plants with a total capacity of 17.16 MIGD. One year later, Fichtner was awarded the contract for engineering of the power plant and implementation of the 880-MW Station K combined-cycle power plant. The existing desalination plant was extended to a total capacity of 60 MIGD through the addition of three units each of 13.33 MIGD. The projects for Stations D and K were completed in 2004/2005. In September 2005, Fichtner was commissioned to prepare the optimization study and environmental impact assessment for Station M with an output of 2000 MW including its connection to the 400-kV switchyard. The production of drinking water will be 140 MIGD (636.000 m³/d). Fichtner's services for all three projects range from conceptual engineering, preparation of the tender documents, bid evaluation and contract award negotiations through checking and approval of drawings, project management and construction supervision to commissioning of the plants. In addition, Fichtner is working on the 400-kV switchyard project for Station M.

Technical consultancy and owner’s engineering for IWPP projects in Saudi Arabia

The Water and Electricity Company in Riyadh is developing three new combined desalination and power plants on a BOO basis in Saudi Arabia. For these, Fichtner has been retained for rendering full consultancy services, from kick-off meetings to financial closure, for the independent power plant and water projects (IWPP) Shuaibah Phase 3, Shuqaiq Phase 2 and Ras Azzour. Furthermore, the Shuaibah Water and Electricity Company has entrusted Fichtner with owner’s engineering for the Shuaibah Phase 3 IWPP, comprising a 900 MW power plant and an 880,000 m³/d seawater desalination plant. For this scheme, Fichtner is handling project management, design review and construction supervision.

Al Khobar II and III Dual-Purpose Desalination and Power Plant, Saudi Arabia

Under contract to Saudi Saline Water Conversion Corporation (SWCC), Fichtner has provided support over thirty years for construction and expansion of Al Khobar II and III desalination and power plants. As early as in the seventies, Fichtner was entrusted with all planning steps, from basic engineering with all necessary studies, tendering procedures, contract award to a general contractor, check of drawings, supervision of construction and commissioning, up to preliminary takeover by SWCC. Al Khobar II as it then was comprised, in addition to five power generation units, each with a 145 MWe steam turbine generator, a boiler of steaming rate 675 t/h (85 bar / 525°C) and a multistage flash seawater desalination plant, also a residential compound for 2500 inhabitants with complete infrastructure including a refuse incinerator. Even while Al Khobar II was under construction, Fichtner was commissioned with engineering an expansion: Al Khobar III. For this, too, Fichtner rendered all services, from the first conceptual designs up to takeover by SWCC of the new power generation units: four 120 MWe steam turbine generators, four boilers each of steaming rate 650 t/h at 85 bar / 525°C, and a seawater desalination plant with a total capacity of 273,000 m³/day drinking water. Additionally, Fichtner provided support for planning and construction of grounding and lightning protection systems for Al Khobar, and handled the installation of a telecommunications system for the power plant, seawater desalination plant and residential compound.

Privatization of seawater desalination plants of Abu Dhabi Water & Electricity Authority (ADWEA), United Arab Emirates

In preparation for privatization of several seawater desalination plants operated by ADWEA, Fichtner prepared technical concepts for rehabilitation and extending the various complexes. This concerned principally the plants of Taweelah A1 and A2, Taweelah B, Umm Al Nar and Mifra. Additionally, Fichtner developed models for determining electricity and water prices, drew up tender documents, formulated bidding conditions as well as various contracts, such as electricity and water purchasing contracts, leasing agreements and personnel takeover agreements. Fichtner was also responsible for drawing up tender documents, bid evaluations, and support during contractual negotiations, with formulation of contract documents.

Preparation for privatization of dual-purpose desalination and power plants, Saudi Arabia

For the Rabigh oil refinery power plant – 380 MW power rating, 1655 t/h steaming capacity, 1625 t/h feedwater and 5700 t/h demineralized water – as well as several IWPP projects between 700 MW/150 MIGD and 700 MW/37.5 MIGD in Saudi Arabia, Fichtner prepared conceptual studies, drew up tender documents, and handled contract negotiations.

For further examples of seawater desalination projects, refer to the sections on Water Supply and Industrial Power Plants.

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Coal-fired power plants:

Extension of a 132 MW power plant by 600 MW, Botswana

Morupule Power Plant, comprising 4 x 33 MW coal-fired generating units located 300 km to the north of the capital, Gaborone, that presently meets 30% of the electricity demand in Botswana, is being extended by a further four units, each of 150 MW. The intention is to permit reduction of present imports of 70% of the country’s power needs from South Africa by around 410 MW. Because the plant design is based on an existing feasibility study, Fichtner is first reviewing and revising this, then drawing up the tender documents for award of an EPC contract, assisting in contract negotiations with the successful bidders, and conducting the Design Review, followed by construction site supervision.

Planning and commissioning of Jimah 2 x 700 MW Coal-Fired Power Plant, Malaysia

Jimah Energy Ventures Sdn. Bhd commissioned Fichtner to act as Owner’s Engineer for planning and commissioning of the bituminous coal-fired power plant. This is provided with a ship unloading station, conventional coal handling and facilities for water treatment, seawater cooling, flue gas desulfurization and demineralization of boiler feedwater. In particular, Fichtner drew up the functional specifications and assisted the client during negotiations on coal supply and shipment agreements. Fichtner also evaluated the EPC proposal and supported negotiations and award of the EPC contract. The services covered review of general contractor’s engineering, project management and site supervision, including acceptance trials, commissioning and support throughout the warranty period.

Owner’s Engineer for Tanjung Bin 3 x 700 MW Coal-Fired Power Plant, Malaysia

As Owner’s Engineer under contract to Rentak Jitu, Fichtner prepared planning for coal-fired power plants, including coal and ash handling, as well as a ship unloading station. In this connection, Fichtner drew up the functional specifications and supported the client during negotiations of all contracts up to financial closure. During the further course of the project, Fichtner was entrusted with project management, site supervision and monitoring of acceptance tests and commissioning. Upon completion of construction, Fichtner is to support the client during the warranty period. The power plant, located on the Strait of Malacca near Singapore, employs seawater cooling and is provided with flue gas desulfurization equipment. The three power generation units are to come on stream at intervals of around six months.

General planning for a coal-fired unit in Rhine port thermal power plant, Germany

Rhine Port Thermal Power Plant in Karlsruhe is being extended by a state-of-the-art bituminous coal-fired generating unit with an electrical rating of 800 MW. Alongside stand-alone contract sections concerning solely the new unit, there are extensive interfaces with existing cooling and fuel supply facilities. Fichtner was awarded a contract by the energy utility EnBW Kraftwerke AG as general planner for the entire project. During the first phase, our services cover in particular review of concept, time scheduling, permit engineering, tendering, contract award and coordination of over thirty contract lots together with general coordination of all lot contractors.

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Combined heat and power plants:

General planning for Niederrad Combined Cycle CHP Plant, Germany

Under contract to Mainova AG, Frankfurt, Fichtner undertook general planning for construction and integration of a confined cycle plant rated at 75 MWe with 90 MWt district heating extraction. This new plant was constructed to replace a conventional oil- and gas-fired power plant unit while retaining the original building façade. Alongside preparatory engineering and support during permit engineering, Fichtner was responsible for tendering and appointing a general contractor. Fichtner also undertook general construction management and site supervision, and assisted Mainova up to award of a long-term maintenance contract for the gas turbine installation.

Construction of new combined cycle combined heat and power plant, Germany

Under contract to the municipal utility Stadtwerke Gera AG, Fichtner undertook optimization of plant concept; conceptual, procurement and permit engineering; and implementation planning for construction of a new 80 MWe / 100 MWt natural gas-fired combined-cycle combined heat and power plant additionally equipped with a 200 MWt peak load boiler. As the project proceeded, Fichtner was entrusted with project steering and supervision during plant erection. During construction, Fichtner planned and coordinated laying of 20 kV conduits along the hot water pipeline route, planned the joint electricity, gas and district heating control room, and investigated the staffing organization for the new plant.

General planning for Munich South Combined Heat and Power Plant, Germany

Under contract to the Munich municipal utility Stadtwerke München (SWM), Fichtner undertook general planning for construction and integration of a combined cycle plant rated 420 MWe with 460 MWt district heating extraction. This new plant was constructed next to an existing SWM-owned combined cycle plant that was to continue in operation, on a plot formerly occupied by a refuse incineration plant. This was demolished prior to the start of construction, for which Fichtner also provided consultancy services. To be particularly emphasized in this respect is integration of parts of the former waste storage pit into the new combined cycle plant. Apart from pre-project planning, permit engineering, tendering and contract award in 15 lots, Fichtner was responsible for general construction management and site supervision. Moreover, Fichtner was entrusted with planning the pressurizer system in the district heating network up to its acceptance, and for planning rehabilitation of the I&C installations for the entire operating site. Other Fichtner services were tendering, specification and contract award for a long-term maintenance contract for the gas turbine installation. Fichtner was also in charge of project monitoring and control in relation to the design and engineering of the construction project, competitive bidding process and awarding of contracts as well as construction and commissioning of the plant.

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Industrial power plants:

Project management and consultancy services for BOOT gas-fired combined heat and power plants, Saudi Arabia

For four gas turbine combined heat and power plants to be constructed on a BOOT basis – build, own, operate, transfer – on the Arabian Gulf, Fichtner undertook project management, conceptual engineering and tendering. These power plants, rated at 150-330 MWe and 300-560 t/h steaming capacity, are to supply electricity and steam to gas treatment plants and an oil refinery. The consultancy team entrusted with full technical, financial and legal planning was coordinated by Fichtner. To provide the basis for taking a decision to proceed, Fichtner prepared a techno-economic analysis and shortlisted candidate bidders in a prequalification round. Fichtner was also responsible for overall coordination of contract formulation and the economic evaluation program as well as for processing the technical content of the contracts.

Power plant with desalination for supplying an oil refinery, United Arab Emirates

For expanding the supply of electricity and desalinated water to an oil refinery operated by Abu Dhabi National Oil Company (ADNOC), during an initial project phase Fichtner was retained by ADNOC to investigate expansions of the existing power and desalination plants that will become necessary in the future. Because these revealed the need to expand the capacities for both electricity and desalinated water, the power and desalination plants were extended by three 165 MW gas turbines and 30,000 m³/day water production. During subsequent project phases, Fichtner undertook, among other tasks, bid evaluation and contract award negotiations with the suppliers. Fichtner was also responsible for checking drawings, construction management and site supervision as well as assistance during commissioning and warranty monitoring. Excess electricity generated by the plant is exported to the countrywide electricity grid via a 220 kV HV link that was also laid under Fichtner’s responsibility. The desalination plant comprises two trains with multi-stage flash technology, each supplying 15,000 m³/day water.

Refinery power plant with seawater desalination, Iran

For supplying an oil refinery complex in Bandar Asaluyeh, Iran, Fichtner was awarded a contract by the Belgian company Unit International S.A. to act as technical consultant for construction of an industrial power plant with seawater desalination on a BOOT basis (build, own, operate, transfer). Fichtner’s services covered conceptual engineering, preparation of a cost estimate and drawing up the tender documents for award of contract to a general contractor for detailed engineering and constructing the facility. Apart from generating electricity at a regular capacity of 500 MW and producing over 200,000 m³/h of desalinated water, this unusual plant will additionally supply the petrochemicals park with ten different media. These include, alongside 900 t auxiliary steam per hour and 36,000 m³/h compressed air, also 25,000 m³/h of nitrogen.

Restructuring of SZFG power plant and renewal of power supply to an iron and steel works, Germany

Salzgitter Flachstahl GmbH (SZFG) operates its own power plant for supplying its iron smelting works with electricity and process steam. In a power plant concept designed to provide security of operation into the future, Fichtner recommended construction of two new identical power plant units, and has been entrusted with fleshing out the concept, preliminary and basic engineering, the follow-up planning phases including permit engineering, as well as tendering with support during award of contract negotiations for the main components. Then Fichtner will be responsible for general project management up to commissioning.

Extension of Heide/Holstein oil refinery power plant from steam to combined cycle operation, Germany

Under contract to DEA Mineraloel AG, Fichtner prepared pre-project, conceptual and permit engineering as well as detailed engineering for extension of the steam turbine power plant at the Heide/Holstein refinery to combined cycle operation. For this purpose, a 10 MWe gas turbine was erected ahead of an existing boiler, whose load-carrying burners were retained. The gas turbine is fired with LPG and gas oil, can be operated on its own and is also suitable for operation with an HRSG. Under this project, the excitation systems for the three steam turbine generators were renewed and recabled.

Pre-project planning of an industrial power plant for a chemicals plant, Germany

Under contract to Wacker Chemie GmbH, Fichtner prepared a techno-economic analysis for meeting the entire demand for electricity and heat at the Nünchritz plant. Following this study, Fichtner prepared the pre-project engineering for the preferred option of replacing the existing power plant by various in-plant and purchasing concepts.

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Waste-to-energy plants:

Expansion of Amsterdam Refuse Incineration Plant (AVI) Amsterdam, Netherlands

This three-train incineration plant with a throughput capacity of 780,000 t/a was expanded by two further trains, each 260,000 t/a, to 1,300,000 t/a, including its associated power plant components. A particular feature of this expansion is the requirement to develop and realize a highly efficient plant concept with greater than 30 % fuel efficiency, but without accepting any compromises in plant availability and reliability. The contract encompassed concept development in compliance with the terms of reference, pre-project planning and system design for the developed concept, as well as preparation for and participation in contract award with a contract award recommendation for expansion of the incineration plant in more than 20 individual lots. Power plant parameters are: 130 bar, 440°C, two trains each of 33 t/h, with high fuel efficiency. As well as engineering, the contract covered project management, coordination of technical development, site supervision, commissioning and acceptances for the plant as a whole. Thanks to implementation of this project, about 200,000 t/a CO₂ emissions are avoided.

Construction of new Mainz Waste-to-Energy Plant, Germany

The municipal utility Kraftwerke Mainz/Wiesbaden (KMW) retained Fichtner for complete planning services and consultancy for this project, with an incineration capacity of 230,000 t/a. A particular technical feature of this facility is that the steam from the waste-fired boilers is piped to the water-steam circuit of the neighboring 400 MW combined cycle plant. Fichtner rendered for KMW all services, from conceptual and layout planning, through functional tendering and flanking support of the general contractor, up to compilation of the operating manual.

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Diesel and IC engine power plants:

Construction of new Balingué IV Diesel Power Plant and extension of MV switchgear in Dar Salam, Mali

Energie du Mali retained Fichtner for construction of a new 19 MW diesel power plant in Balingué. Under this contract, Fichtner provided consultancy support for supply, installation and commissioning of the power plant that is equipped with three new 16 cylinder diesel engines. Additionally, Fichtner was responsible for grid tie-in and extension of 15 kV and 30 kV electricity distribution switchgear.

Consultancy support for diesel power plants from tendering to commissioning, Yemen

On behalf of the Yemeni Public Electricity Corporation, Fichtner prepared the tender documents for Tehema 25 MW Diesel Power Plant, and provided support to the client during the tendering phase, bid evaluation, and contract negotiations. Finally, Fichtner was retained for site supervision, check of drawings and commissioning of this diesel power plant as well as others in Yemen.

Construction of a new 50-MW diesel-fired power station, El Salvador

In order to guarantee the future supply of energy in El Salvador, the state-owned utility Comision Hidroelectrica del Rio Lempa (CEL) made the decision, in addition to hydropower, also to expand its inventory of thermoelectric power stations. In this connection, Fichtner won the contract to support CEL in relation to the evaluation of bids and awarding of the contract for a 50-MW diesel-fired power station and to supervise the entire construction phase including commissioning.

Appraisal of operability of an existing combined heat and power plant, Germany

In preparation for financing, Raiffeisenleasing, Vienna, retained Fichtner for assessing the operability and convertibility of the engines of the Tangermünde IC engine cogeneration plant to fuels classified under the German law on renewable energies. In this connection, Fichtner also determined the plant’s asset value and capitalized value of anticipated yields.

Brief appraisal of an IC engine cogeneration plant for conversion to biogenic fuels, Germany

On behalf of Immo-Office GmbH, Mainhausen, Fichtner evaluated and assessed the physical possibility and technical feasibility of converting Calbe IC Engine Cogeneration Plant to run on vegetable oils and animal fats. This appraisal was conducted in particular against the background of the requirements of the (original) German law on renewable energies.

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