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Execution period 2005 - 2011
Contractor TPP Maritsa East 2 EAD

REHABILITATION OF UNITS FROM 1 TO 6 AT MARITSA EAST 2 TPP

The rehabilitation program implemented at Maritsa East 2 TPP, related to the provided consultancy services under this contract, thus including activities on the modernization of Units from 1 to 6. The project envisaged reconstruction and modernization of Power Units from 1 to 6 at TPP Maritsa East 2 EAD by replacement of main components and components parts. The most significant changes were implemented at Units 1-4 where almost the whole main equipment was replaced by up-to-date equipment. As a result from the above mentioned activities the capacity of the Power Units was uprated. Furthermore, in implementation of the European ecological requirements, two desulfurization plants were constructed for the purification of boiler burning facility gases from sulphur dioxide. The first desulfurization plant serviced Units 1 and 2, while the other serviced Units 3 and 4.

The following basic construction and erection works were implemented:

  • Replacement of the turbines at Units 1, 3, and 4 with new ones and uprating the power output of these Units from 150 MW to 177,37 MW;
  • Replacement of generators at Units 1, 2, 3, and 4;
  • Replacement of condensers for Units 1, 3, and 4;
  • Replacement of regenerative heaters for Units 1, 3, and 4;
  • Replacement of the Turbine Control System with a Digital Electrohydraulic Control System for Units 1, 3, and 4;
  • Construction of instrumental turbine monitoring system for Units 1, 3, and 4;
  • Construction of two desulfurization installations (Fuel Gas Desulfurization (FGD) plants) for Units 1 and 2, and for Units 3 and 4, respectively, with 94% purification degree and with additional 50% reduction in the dust emissions passing through the electric filters.

Construction of all buildings servicing the two FGD plants (including all the necessary building installations: water-supply and sewerage, electrical, low current systems, HVAC, etc.), facilities, networks, and installations, as follows: technological process control building; oil supply stations for flue gas fans; four pump stations for service water and absorber suspension for the technological process maintenance; recirculation pumps building; pump station 1 and absorber 02 building; pump station 2 building for servicing the two absorbers; pump station building for emergency discharge tank for the two absorbers; hydrocyclone building; structures of two steel absorbers with the respective process and electrical equipment; construction of new gas ducts for flue gas removal; foundations under machines; installation of process, electrical, I&C equipment, etc.

  • Construction of two new glass-fiber reinforced plastic (GRP) stacks 135 m high, with tube diameter of 8.9 m, for purified gases release to the atmosphere;
  • Construction of limestone inventory for servicing of the two FGD plants, including all the service buildings, facilities, and installations: construction of mill building; crushing workshop and silo building; two pump stations – for process water and for limestone suspension; process control building (including all the necessary building installations - water-supply and sewerage, electrical, low current systems, HVAC, etc.); limestone bins; tanks; construction of shafts and channels with acid resistant lining around the limestone suspension tanks and the pump room thereof, etc.;
  • Construction of site water supply networks for potable, service and fire fighting water;
  • Construction of site sewerage networks for rain-waters and domestic waste waters. New ground leveling for collection and removal of surface waters at the FGD site and at the limestone inventory site;
  •  Piping and electric trestles, necessary to provide for the technological process, including for removal of the waste released by the machines, namely hydrous plaster, tanks, receivers, other equipment and pipes;
  •  The rehabilitation works implemented at Units 5&6 included replacement of main turbine components and components parts, which led to uprating the power output of these Units. As a result from the rehabilitation, the power output of the generator was uprated by 7,1% - from 210 MW to 225 MW, measured from the generator outlet;
  •  The rehabilitation of the façade and the roof water insulation of Units 1-4 Turbine Hall included the following: lining of the existing façade of Units 1-4 Turbine Hall from the outside by additional façade lining made of Alucobond, fixed on the existing façade elements; installation of dual-pane windows with 28 mm width; overall rehabilitation of the roof water insulation of Units 1-4 Turbine Hall, including repair of the damaged sections of the existing water insulation, and gluing on it the new EPDM water insulation.

Risk Engineering Ltd. was the Bulgarian Contractor for the consulting services implemented under the above contract, which included a wide range of activities, both activities defined in the Spatial Planning Act (SPA), and activities according to the FIDIC contractual terms and conditions. The consulting services as per the Spatial Planning Act (SPA) were fully implemented by Risk Engineering Ltd. as licensee for the respective activity as of the date of signing the contract. The full scope of consulting services provided by Risk Engineering Ltd. under the contract included, as follows:

  • Consulting services as per the Spatial Development Act, including assessment for compliance of the investment projects with the essential requirements to construction sites, and exercising construction supervision during the implementation of construction and installation works. The Company was liable for the strict control over deliveries, including production quality control and control for correctness of the supporting documentation. In the project development phase operating control of the design process was also carried out.
  • Additional consulting services set forth in the contract were also provided, namely consultation to the Customer TPP Maritsa East 2 EAD on financial issues, contractual and legal issues, surveys, etc.

The construction was divided into 9 stages, where each stage was accepted independently by the State Acceptance Commission (SAC) as per Art.3, Para 2, Item 1 of Regulation No.2 from 31.07.2003 for the commissioning of construction sites in the Republic of Bulgaria and for the minimal warranty periods of performed construction and installation works, facilities, and construction sites. Up to now 8 (eight) State Acceptance Commissions have successfully been carried out and Utilization Permits have been issued to the following 8 (eight) stages:

  • Stage 2 – Rehabilitation of Unit 1 Steam Turbine and Generator; the stage was completed and accepted according to Utilization Permit issued by the National Construction Control Directorate, Outg. No.CT-05-1349/16.11.2009;
  • Stage 3 – Replacement of Unit 2 Generator; the stage was completed and accepted according to Utilization Permit issued by the National Construction Control Directorate, Outg. No.CT-05-418/02.2009;
  • Stage 4 – Rehabilitation of Unit 3 Steam Turbine and Generator; the stage was completed and accepted according to Utilization Permit issued by the National Construction Control Directorate, Outg. No.CT-05-277/08.03.2010;
  • Stage 5 – Rehabilitation of Unit 4 Steam Turbine and Generator; the stage was completed and accepted according to Utilization Permit issued by the National Construction Control Directorate, Outg. No.CT-05-540/05.05.2010 ;
  • Stage 6 – Construction of flue gas desulfurization system for Units 1 and 2, including common facilities; the stage was completed and accepted according to Utilization Permit issued by the National Construction Control Directorate, Outg. No.CT-05-276/08.03.2010;
  • Stage 7 – Construction of flue gas desulfurization system for Units 3 and 4; the stage was completed and accepted according to Utilization Permit issued by the National Construction Control Directorate, Outg. No.CT-05-539/05.05.2010 ;
  • Stage 8 – Rehabilitation of Unit 5 Steam Turbine; the implementation of this stage was postponed for 2014 due to changes in the Customer’s investment priorities;
  • Stage 9 – Rehabilitation of Unit 6 Steam Turbine; the stage was completed and accepted according to Utilization Permit issued by the National Construction Control Directorate, Outg. No.CT-05-1329/08.11.2010;
  • Stage 10 – Structure rehabilitation and strengthening works on Turbine Hall external façade; the stage was completed and accepted according to Utilization Permit issued by the National Construction Control Directorate, Outg. No.CT-05-1328/08.11.2010;

Currently, all the 8 stages, for which Utilization Permit has been obtained, are in operation. The modernization, uprating and significant service lifetime extension of Maritsa East 2 TPP Units 1-6 have been achieved as a result of the implementation of the above mentioned contract. The construction of the Fuel Gas Desulfurization Plant (FGD) at Units 1-4 guarantees that the European ecological requirements on purification of the sulphur dioxide gases emitted to the atmosphere are compliance with.

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