Rehabilitation and Full Repowering of Ambarlı Fuel-Oil Power Plant Units 4 and 5 Conversion to Dual Fuel Combined Cycle Power Plant

Rehabilitation and Full Repowering of Ambarlı Fuel-Oil Power Plant Units 4 and 5 Conversion to Dual Fuel Combined Cycle Power Plant

Project Description
Services Multi – Discipline Engineering Services (Architectural, Structural, Electrical, Mechanical, Process, I&C, Infrastructural Engineering Services)
Construction Management
Construction Supervision Services
Design Type Basic Design, Detail Design
Contract Date 10.11.2008
Completion Date 21.11.2013
Information About the Project The project was carried out by EPP Joint Venture (EKON Industry Construction and Trade Inc. 65 % – PROKON Engineering and Consultancy Co. 30 % – PROKON Manufacturing and Erection Co. 5 % Joint Venture)

Ambarlı Units 4 & 5 Rehabilitation Project involves the conversion of the existing 300MW Fuel-Oil fired boiler steam plant into 816MW Combined Cycle by addition of 2 new Gas Turbine Generators, 2 new Heat Recovery Steam Generators and rehabilitation & modification of existing Steam Turbines under new steam regime to achieve maximum performance. Thus, thermodynamic efficiency is increased from 36% to 54%, kwhour production costs are decreased, plant reliability is increased and excessive levels of atmospheric emissions are reduced significantly.

Ambarlı Project is a “Full Repowering by CCPP Conversion” Project that is a “first of its kind” Project in Türkiye and is equalled in magnitude and complexity by only a handful of worldwide examples.

Major Items in the Scope of Engineering, Procurement and Construction are;

  • Dismantling of 2 existing fuel-oil firing boilers,
  • Rehabilitation and modification of existing steam turbines, generators and auxiliaries,
  • 2 new 282 MW Siemens SGT5-4000F gas turbines and generator sets,
  • 2 new 357 ton/hour capacity, Vertical Type, three pressure level reheat Heat Recovery Steam Generators,
  • New HP, IP, LP electric motor driven Boiler Feed Water Pumps,
  • New 100% capacity HRSG Steam By-Pass (PRDS) Systems,
  • New Condenser Cooling Seawater Circulation Pumps,
  • New Seawater Treatment / Intake (TAPIS) Systems,
  • Complete Retubing of existing condensers and Rehabilitation of seawater supply system,
  • New 2km long NG supply pipe-line and RMS-A Station,
  • New 380kV switchyard system, GT Side Transformers, MV & LV Switchgear
  • I&C Systems and plant-wide DCS Integration
  • Miscallenous Building Utilities.
  • All other BOP Balance of Plant required conversion to a combined cycle power plant.

All the process/thermodynamic cycle optimization, conceptual, basic and detailed engineering, process equipment/system procurement, demolition, dismantling, construction, erection, installation, manufacturing, rehabilitation, modification, commissioning & start-up, performance testing and reliability run works, that pose special engineering and project management challenges beyond conventional needs of typical greenfield CCPPs, have been managed and implemented on a turn-key basis by Ekon-Prokon-Prokon JV, each of the party is a member of Prokon-Ekon Group of Companies, totally with local Turkish engineering and contracting teams, with no foreign entity consortium or joint venture partnership.