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HOMEDiscover MHIMHI GraphSpecial Feature

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2015 August No.179
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SPECIAL FEATURE --Filling the World with Light. New thermal power gene ration facility conceived and achieved under EPC project management.

Photo: Kozienice Power Plant, Poland

Kozienice Power Plant, Poland

Helping expand and improve the world's power generation infrastructure

Life today, without electricity, can hardly be imagined. Although the generation of electricity comes from many energy sources - thermal, hydro, wind, nuclear and solar power - the most significant contributor to the world's supply of electrical power is thermal generation, representing about 68 percents. Mitsubishi Hitachi Power Systems (MHPS (Note)), an MHI Group company, operates a "thermal power generation EPC project management enterprise," responsible for the engineering, procurement, construction and post construction processes involved in bringing many of the world's power generation plants online.

(Note) Created in February 2014 by combining the thermal power generation businesses of Mitsubishi Heavy Industries, Ltd. and Hitachi, Ltd.

EPC handles everything from engineering, procurement and construction.

Engineering

To accommodate the specific yet varying needs and regulations for a power generation plant, EPC engineers develop a design, layout and specifications for the entire facility, including major equipment such as boilers, turbines, and generators, along with the control systems and piping.

Procurement

The next phase of the project is the procurement of materials, components, and equipment from partner companies from around the world. These partner companies provide safe onsite delivery of project elements within strictly controlled time and cost parameters.

Construction

Employing highly skilled managers and crew, MHPS provides construction services for the facility's foundations and buildings plus installation of the power generation equipment and systems. Additionally, commissioning work of the facility is conducted and operators are trained, so the plant can be ready for full operation by the client.

Bringing a mammoth project to successful completion. Finely tuned management essential for smooth operation

In EPC projects, an army of people marshals resources over a long period of time. MHPS' commanding role covers designing the thermal power plant, manufacturing the main equipment, building on the site, and testing the facility. Success can be measured in how expertly MHPS coordinates various business sections inside and outside the company and accommodates customer requests.

Photo: Factory for manufacturing a turbine

Manufacturing key technology, such as the turbine seen here, enables MHPS to implement the right equipment, helping MHPS keep a tight rein on the project.

MHPS flexes its prodigious management muscles strengthened by extensive experience and in-house manufacturing capabilities.

An EPC contract containing the delivery of the plant in its entirety rather than each piece of the facility is becoming more common in the power generation industry. When a power supplier lacks sufficient construction expertise, the customer will seek a turnkey system. That way, the operation-ready facility can immediately respond after delivery to the urgent power demand it was designed to meet.
Project management is critical to completing an EPC project on time and on budget. A project manager directs the activities of numerous partner companies to address the customer's wishes, control costs, and maintain the schedule, with the goal of avoiding potential risks. Those who manage EPC projects must be finely tuned to the project to adapt to ever-changing conditions. MHPS, with its project management expertise honed by copious EPC projects, is steadily building a solid operating base. The company realizes further project management efficiencies by employing information and communication technologies to control the project through a central information channel.
Since MHPS has its own manufacturing divisions for major power generating technology, it can easily adopt systems most suited to the intricacies of the particular power plant. Only a few companies in the world can handle these types of tasks, and, in Japan, MHPS has demonstrated incomparable acumen in this arena.

Photo: 3D verification

3D designing technology is used to design the space of the power plant. Main equipment, piping layout, supporting devices, and control systems are verified in 3D to prevent any interference among them.

Photo: State to transport equipment

The main equipment manufactured by MHPS is transported to its final destination.

Photo: State to transport equipment
Photo: State to transport equipment

The procurement department transfers equipment safely to the construction site. Products arrive at the designated time thanks to the optimal transportation method that also takes costs into account.

Photo: State of manufacturing in overseas Group companies

Considering costs and scheduling, equipment is also procured locally and overseas. MHPS achieves predictable supply and enhanced quality by providing guidance to local manufacturers and acquiring and integrating the manufacturers into its group companies. (Photo: Welder from group company of MHPS Europe (Germany))

The means to meet localized needs. Providing facilities that satisfy power demands and 
differing supply conditions

Whether helping power a country or region, MHPS has the resources to build efficient power generation plants for the diverse needs of large regions or countries. A broad portfolio of equipment, environmental protection devices and project management contribute to installations across the globe.

Kozienice Power Plant in Poland
Photo: Kozienice Power Plant

Ongoing construction of the new coal-fired power plant Unit 11 at the Kozienice Power Plant, which is one of the largest in Poland. Currently, Poland has to fulfill a portion of its power needs by purchasing electricity from other countries like Germany. However, when their own power generation capacities are strengthened, they plan to sell electricity to other countries.

Stable environment-conscious power supply for people throughout the world

A major coal-producing country in Central Europe, Poland, uses the abundant mineral to fuel its thermal power generation plants, yielding more than 80 percents of its electricity for its 40 million people. Aging plants, increasing demands for power, and stricter environmental regulations to be in force in 2016 now that Poland is a member of the European Union (EU), means upgrades are essential.
The Kozienice Power Plant is one of the country's largest coal-fired operations. The stable performance of its previously supplied flue gas desulfurization (FGD) systems for reducing SO2 (sulfur dioxides) emissions, which have been in operation for some time, was a major factor in MHPS being awarded the Unit 11 power plant expansion project in 2012. MHPS has launched this EPC project (Notes 1) for upgrading the power generation complex with new systems that include a steam turbine, boiler and environmental devices.
In addition to the leading-edge FGD system, other clean coal technology to be equipped with this new ultra-supercritical pressure coal-fired plant (Notes 2) is a selective catalytic reduction (SCR) type de-NOx system that can reduce emissions of NOx (nitrogen oxides) by more than 80 percents.
MHPS is proud to develop and build thermal power generation plants around the globe that deliver more efficient energy and meet varying regional demands and supply conditions, while simultaneously reducing environmental loads. With a comprehensive range of products, technology and advanced management capabilities through EPC, we deliver highly valued engineering, procurement and construction services toward improving the quality of life and contributing to economic development.

(Notes 1) As of July 2015
(Notes 2) Generates electricity with higher efficiency by operating at higher steam temperatures (above 593°C) and boiler pressures (250 times or greater atmospheric pressure)

Photo: Kozienice Power Plant

Coal yard where coal is stored as fuel for the plant. Installation of a transport system between the yard and the boiler is part of this EPC project.

Photo: Kozienice Power Plant

Existing MHPS-supplied FGD system equipment. The dependable performance of this system was highly valued, contributing to the awarding of the power plant project to MHPS.

Photo: Kozienice Power Plant

View inside of FGD system equipment. Removing acid rain-causing sulfide from exhaust gases converts it to clean vapor for safe release into the atmosphere.

Photo: Kozienice Power Plant

The tower boiler can efficiently burn locally produced, low-quality coal. Only two companies in the world can manufacture this type of boiler.

Concern for the planet
and future of humanity

MHPS supports a secure and enriched life for people through the merging of its strengths forged by business integration.

EPC makes stable energy supplies and environmental solutions possible.

With the continued growth of developing countries, the global demand for efficient, environment-conscious energy multiplies. To meet those sustainability demands, coal and natural gas-fired thermal power plants need to implement technology and practices that help generate more effective, reliable power output while addressing issues like CO2 emissions that can impact the environment.
Those challenges were the catalyst in the formation of MHPS, which merged the thermal power generation systems businesses of Mitsubishi Heavy Industries, Ltd. and Hitachi, Ltd., in February 2014.
As an EPC enterprise, MHPS combines the strengths of the two companies' world-class technologies, equipment and highly experienced management and staff toward providing power generation facilities to countries in need of contemporary power supply infrastructures. MHI's vast experience in Asia and Central and South America and Hitachi's long term, expanding business in Europe, Africa and North America, plus their portfolios of high-performance gas/steam turbines, boilers and environmental systems, make MHPS a dynamic source for large-scale thermal power generation solutions.
MHPS will continue to apply its extensive capabilities to help deliver stable energy supplies and solutions to environmental challenges, accommodating the ever-changing needs for power generation and the sustainable development of societies around the globe.

Evolving EPC business

The following are some examples of how MHPS' outstanding quality and reliability help fulfill the expectations of customers on the world stage:

Design and procure high-quality products at lower costs

Performing the design process locally makes it easy to comply with local regulations. MHI has expanded procurement all over the world, increasing the range of options and reducing shipping costs.

Monitor project progress to avert risks

To sidestep any unforeseen risks, MHPS closely tracks every stage of the project. Information communication technology controls the progress through a single information channel. Implementing corrective measures early on keeps the project moving forward smoothly.

Deliver project procedures visually for better communication

MHPS delivers instructions to local plant employees in a 3D format that is more easily understood than traditional written information.

Photo: Night scene in the city of Warsaw

Global scope of MHPS technology

MHPS' EPC business answers robust power demand worldwide.

Photo: Linkou Power Plant in Taiwan

Linkou Power Plant in Taiwan

With its partner company, MHPS jointly received an order for the Linkou Power Plant (Units 1 - 3) renewal project from Taiwan Power Company, the sole power sales company in Taiwan. MHPS is in charge of manufacturing and supplying three units of boilers and steam turbines.

Photo: UThai Thermal Power Plant in Thailand

U Thai Thermal Power Plant in Thailand

MHPS, with its partner in Thailand, has received an order for the construction of the U Thai GTCC (Note) plant located 70 kilometers north of Bangkok. The plant, operated by Gulf JP UT Company Limited, will supply electricity in Thailand to meet the increasing demand resulting from the country's economic growth.

Photo: Sendai Thermal Power Plant in Japan

Sendai Thermal Power Plant in Japan

MHPS has been awarded the construction contract for a new GTCC (Note) power project planned by Sendai Thermal Power Plant of Tohoku Electric Power Co., Inc. Emissions of CO2 will be half of the existing coal-fired plant, enabling it to become the major electric power supplier for the Tohoku region.

(Note) Gas Turbine Combined Cycle: High-efficiency combined cycle power generation system using both a gas turbine and a steam turbine

Study Page

How thermal power generation EPC works

MHPS designs the machinery and buildings, procures all materials, and outfits the facilities. MHPS manages the process up to the point where the completed plant is ready to go into operation.

Figure: Thermal power generation EPC

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