Takoradi Power Plant Project in Ghana
Takoradi Monthly – 4Q 2011
Introduction
One rapidly growing segment at HPI is the development of turnkey, fast-track electric power generation plants. Recently, HPI was selected to provide the engineering, procurement and construction (EPC) for a 135MW power plant for the developing nation of Ghana, West Africa.
Building on a distributed power concept, the project will use Combined Cycle turbine technology from the Canadian packager, Orenda Aerospace, based in Mississauga, Ontario. Utilizing high efficiency Zorya-Mashproekt combustion turbines, the combined cycle process is expected to achieve an efficiency rating near 50%. The plant will use a dual fuel configuration of light crude oil (LCO) and natural gas. HPI’s modular design approach involves the pre-fabrication of major plant systems in the US and Canada allowing for easy assembly and commissioning in-country. This strategy reduces installation cost and construction lead-time and mitigates risk while making the configuration easier to repeat in future power plants.
The plant is expected to help meet staggering projected load growth needs in the region and provide grid backup for seasonal shortfalls in the availability of hydroelectric power. The station is designed around two nominally-rated 65MW combined cycle modules, each powered by two 25.6MW Orenda OGT 25000 gas turbine generator, two unfired HRSGs and one 17.2MW steam turbine generator.
Summary Report
December
With the Christmas holiday approaching, a reduced workforce has been onsite with full crew expected to return the first week of January. Despite the smaller crew size, work has been able to continue with few disruptions thanks, in part, to the improved weather conditions.
Materials shipments have continued to arrive, and all works onsite are ongoing and in line with the current schedule. Laterite and rock supplies continue to be more than has been required to meet project demands.
As the project has progressed, technical meetings have been held with the major equipment suppliers, and we have received the applicable detailed drawings from them. The receipt of this information has allowed the electrical design progress to continue. In addition, the modular control rooms are nearing completion and will soon be ready for commissioning.
November
The Ghanaian rainy season has begun its decline this month leading to an increase in work productivity due to improved visibility.
Rock deliveries have exceeded need requirements and have been halted until the current supply has been diminished. Laterite has been purchased and is being delivered to site and mixed with 0-40 rock to be used for backfilling in non-structural areas.
A group of 123 students from Takoradi Polytechnic School visited the jobsite to witness a turnkey power plant EPC project and develop firsthand experience. The students are in the civil engineering field and are working toward careers in Quantity Surveying (QS).
Worker morale remains good and has been improving in anticipation of the holiday break.
October
The Takoradi jobsite continues to receive some rain, but the rainfall levels have decreased somewhat compared to last month as the rainy season is now over. Shipments of site material continue to arrive on schedule. Critical building packages for the Steam Turbine Generator and Water Treatment Building have now been received onsite.
Representatives from Magellan arrived on site and have completed inspection of works to date and preparations of plans to proceed with erection of turbine, generator and auxiliary units. Assembly and installation of the inlet air filter house and rough alignment of the turbine module and generator have also been discussed. The elevations of all components have been checked and adjustments are being implemented as required. Additionally, the Ghanaian Ministry of Energy / Volta River Authority visited a chiller manufacturer and operational site in the United States for inspection and approval.
Site security continues to be effective. New site badges have been issued to assure good control of access to site. All equipment and personnel entering the site are checked before entering and leaving of the site. All works on site are ongoing and in line with current schedule.
September
While the heavier rains have stopped, the end of the month has brought on a new rainy season with showers and light rains occurring several days a week. This has not caused a major impact on site work so far. Rock deliveries are now sufficient to keep up with all of the current requirements. Shipments continue to arrive onsite, and the steel and materials for the two major buildings arrived this month.
Detail drawings continue to be issued to support construction activities. The engineering team is working with the site team to coordinate the interface with T1 services. Work is ongoing with QA/QC to assure documentation is available for manuals as well as with equipment vendors to finalize the electrical connections.
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