MODERNIZATION OF GENERATING CAPACITIES

AND ELECTRICAL SYSTEMS

May 15, 2013

2000 - 2012

Replacement of an existing turbine by a new one, type К -165-130, in Maritsa East 2 TPP

May 15, 2013

Object: TPP Maritsa East 2 EAD, village of Kovachevo, Stara Zagora district

Period of implementation: year 2000 - 2003

Description: The steam turbine type К-165-130 is a new generation turbine of modern design and high technical and economical parameters.

By design, it is a double body turbine with intermediate steam reheating. It is the first time that a turbine of such power capacity is implemented as a double body one; this considerably simplifies its design and facilitates its operation.

The high technical and economical parameters ensure additional 20 MW power. For nine years operation the turbine has amply paid for itself.

At a later stage, within the scope of the overall modernization of Maritsa East 2 TPP, the Russian turbine was successfully coupled with a Japanese electric generator, and henceforth the aggregate steady operation continues.

One of the main elements of the turbine unit – the condenser, as well as part of the auxiliary equipment thereof, are manufactured in Bulgarian factories.

Replacement of an existing turbine by a new one, type К -165-130, in Maritsa East 2 TPP (2)

The project implementation includes the following activities: Design work – elaboration of construction-

structural, technological, electrical, and I&C parts of the design;

Construction work related with the changed foundation;

Dissembling and removal of the old turbine, pipelines and reheaters;

Installation of the new turbine K-165-130, complete with all the auxiliary equipment, 35 new pipeline systems, 3 new nigh pressure reheaters;

Start-up and adjustment work, training the personnel and commissioning into normal operation (Act 16).

Replacement of an existing turbine by a new one, type К -165-130, in Maritsa East 2 TPP (3)

Construction and installation work on reconstruction of SG No. 5 in Republika TPP

Object: Steam generator №5 in Republika TPP, town of Pernik

Period of implementation: year 2006 - 2009

Description: Risk Engineering Ltd. has performed the activities which include all stages, up to installation of the fully functioning steam generator. Main activities: Project management; Elaboration of the detailed design for the

steam generator reconstruction; Replacement of the turbine vibration

monitoring system;

General view of steam generator №5

Manufacturing and procurement of different elements of the stream generator as per the detailed design;

Dissembling the existing equipment; Construction and installation work according to

the detailed design; Commissioning into operation, including 72-

hour trial; Training the Employer’s personnel on

operation and maintenance. Object certification – Act 16.

The digital automation system (DAS) performs all monitoring and control functions with high response speed, in compliance with the requirements on the turbine, steam generator and electrostatic filter control.

Construction and installation work on reconstruction of SG No. 5 in Republika TPP (2)

The rehabilitated steam generator achieves nominal operation parameters when the plant works with high-ash coal fuel; its operation life will be not less than 25 years. The utilization coefficient has been upgraded. The facility has 8000 hours availability per annum. The operation and maintenance costs have been optimized, the steam generator reliability has been upgraded, as well as the environment protection parameters.

Within the scope of the general reconstruction, a new electric filter has been installed, thereby resolving one of the crucial ecologic problems of the town of Pernik.

Construction and installation work on reconstruction of SG No. 5 in Republika TPP (3)

Installation of a turbine and generator in “Svilocel” EAD under turnkey contract

Object: “Svilocel” EAD, town of Svishtov

Period of implementation : year 2007 - 2010

Description: Before the project implementation, the main unit in the process cycle – the soda recovery boiler, generates steam with power parameters 40 bar and 440 °C, which steam is thereafter reduced into two stages of process steam – 11 bar and 4 bar. In case of regular production process, permanent big losses are faced. Through the project implementation, a steam turbine with generator was introduced within the process cycle, thereby reducing the steam parameters down to the required values, and additionally producing electric power. Thus, the cogeneration principle was employed for electric and thermal power generation.

The project is implemented by installing a steam turbine type ПР-8,8-4,1/1,1/0,4, coupled with an electric generator of 12 MW. The turbine provides for two steam takeoff outlets, which cover the production process requirements of steam. In addition, the generated electric power fully satisfies the needs of the factory.

The project scope includes construction of a new reduction-cooling installation, which is operated in parallel with the turbine and in case of necessity plays a redundancy role.

Installation of a turbine and generator in “Svilocel” EAD under turnkey contract (2)

General view of the turbine and generator

Turbine oil system

Control room

Implemented activities: Design work – elaboration of construction-structural,

technological, electrical, and I&C parts of the design; Construction work – demolishing the unused old

structures, construction of a new turbine foundation, overall rehabilitation of the turbine hall; construction of foundations of the auxiliary equipment;

Installation and dissembling work – dissembling old equipment, installation of the new turbine, generator and auxiliary equipment, new bridge crane, new reduction-cooling installation and pipelines, entirely new electrical part and control systems;

Start-up and adjustment work, personnel training and commissioning into operation (Act 16).

Installation of a turbine and generator in “Svilocel” EAD under turnkey contract (3)

Cooling tower

Main pipeline

Local control panel

A complex of engineering projects for Units № 6 and № 8 of Maritsa East 2 TPP

Object: TPP Maritsa East 2 PLC. Period of implementation: year 2008 - 2011 Description : Implementation of a complex of engineering projects, as follows: 1. Replacement of generators, Unit №6 & 8. 2. Replacement of generators №6 & 8

excitation systems. 3. Replacement of generators №6 & 8 relay

protections. Increase of Unit №6 power by 20 MW has been achieved, and that of Unit №8 power – by 15 MW. Technical characteristics: 1. Replacement of the generators by new

ones – of power 230 МW. 2. Replacement of the Excitation systems by

new, static excitation systems. 3. Replacement of the analog relay

protections by new, digital ones, of most advanced generation.

Transport of the generator stator -

outside

Transport of the generator stator – within

the turbine hall

Installation of the generator rotor Finally installed generator

Through the project implementation, a number of engineering tasks have been resolved of parts Electrical, I&C, Machine-technological and Construction-structural.

The work on Maritsa East 2 TPP site required activities to be coordinated with a number of other companies and subcontractors.

Stages of implementation: Each project included: design work, dissembling, installation/assembling, tests and commissioning into operation.

A complex of engineering projects for Units № 6 and № 8 of Maritsa East 2 TPP (2)

Transformer and cabinet with

disconnector for the excitation system

Unit control room with panels

and monitor

A view of a Unit relay protection cabinet

Unit relay protection cabinets

Excitation system cabinets

Electric power supply 20kV to movement stations 4x1000kW

Object: “Mini Maritsa Iztok” EAD

Period of implementation: year 2006 - 2007

Description: The 20 kV electric power supply to 7 movement stations 4х1000 kW includes: Implementation of 20 kV power supply to the movement stations, each thereof equipped with 4 1000 kW motors. For each movement station, a 20/6 kV transformer has been procured, installed and commissioned into operation. Accordingly, 20 kV and 6 kV switchgears have been procured and installed, complete with relay protections. All these components are encased in metal houses.

Movement station

Construction and installation work in Troyanovo 3 coal mine

Object: “Mini Maritsa Iztok” EAD

Period of implementation: year 2006 - 2007

Description: Rehabilitation of substation No 7, thereby including: Primary commutation of switchgears 20 kV

and 6 kV – grounding system – procurement, installation and commissioning into operation;

Secondary commutation of switchgears 20 kV and 6 kV – grounding of the transformer star center, side 20 kV and 6 kV – procurement, installation and commissioning into operation;

Lighting system installation and construction work.

Substation №7