Bier Rooncnetacls Oca TC NC oI) ROL ercaaccacs STM Op Act Me Reems ae Pa So Peery uA Ur nuked y from persistent power shortages that would have crippled industrial growth Picket aiacunckON uC mecet iia Cen m Uy ce SAL ot VAT Rly billon for high-etficieney natural gas-fired power plants designed to boast Egypt's power generation capacity by more than 40% compared tothe country’s installed base in 2018; Together with Elsewedy Electric and Orascom Constustion, Siemens was invited to design, supply, and deliver three combined cycle power plants in Beni Suef ito service Upper Cave New Capital (to energize the new ac. ministrative center east of Cato and theSP 0 HY me iit inches one steam strategic area at New Suez Conel Devel: ‘opment Zonel, and Burulus (to supply the Nile Datta and the Mediterranean coast]. Siemens’ Financial Services structured the financing package for Siemens’ role in the contracts, includ ing # tailored guarantee concept. The envisaged loan faclities—supported to a large extent by coverage from two export credit agencies in Germany and htaly—were provided by Intemational and regional banks While Siemens was tasked wid engingering, supplying, and delivering of the Egyptian Megaprojact on a turnkoy basis, many other companies anc gov femment periners would also play key roles. Siemens formed consortiums with Elsewedy Electric forthe Beni Suet plant and with Orascom Constiuction for the Bunullis and New Capital plants. Both Egyatian-based partners would perform admirably in bringing the projects 10 completion in record-setting time of 275 ‘oaths trom financial closure, Leveraging Industry Expertise Grucal to their selection for the Mega project was thet both Elsewedy and Orascom had garnered the necessary expertise and experience to complete & task of this magnitude and urgency. When Egypt adopted its Fast Track Power Plan in December 2014 urging grid-connection of 2,632 MW before the end of 2075 to avoid debilitating power shortages, Cairo-based muting tional conglomerate Elsewedy sprang to action, erecting the first project of the program—the G40-MW Attage Power Plant in Suez City-in a record: breaking 159 days to help ease the ia A summer demand surge. (Attaga was a POWER Top Plant in 2018) Global engineering and const contractor Orascom had also already boen heavily involved in helsing Egypt achieve is ambitions 10 nearly double its capacity over a sparse the-year timeframe. Among Orascom's notable fast-track projects ate two simple cycle ower plants in Assiut and West Dam: fa (a ota of 1,500 MIM, wich it deiv- fered in under eight months in 2015 land which it has since converted to com. bined cycle to boost their total capacity 102,260 MVM). Since 2018, Orascom has. ‘added more than 12 GW to the national grid @s en engineering, procurement, {and construction contractor. Yet, Elsewedy Electric Group Legal Director Mahmoud Sharazwy daseribed his company’s €820 milion share of the project—purting up the 12 turbines at Beni Sust—as a massive undertaking that required deliberate and precise oraa- POWER POINTS Winning Attributes Aan pore reaking ate Te rh oe ot rd ae enor ot ey ere Be meen ing anew worldwide bonchmark Cer eer ray ery Sere eee te a ore oat) nization. One aspect that helped soeed ‘along the project wes clarity about ex pectations, said Sharaawy, Eleewedy's ‘scope of work included engineering, ro ccurement, site preparation, leveling, ci works, installation of ‘halance-otplant equipment, as well as instalation of the Siemens turbines. The company spent wo manths negotiating ageaments and technical parameters of each unt at the Beni Sust site with Siemens and Eoyat, talks which culminated in e final agree ment in June 2015 and set the stunning two-year timeframe,PLA OF TY A LL “We finalized overything in less than Challenging Terrain [At Boni Suet, Elsewedy also spent four three years” Sharsawy pointed out, adc Although the three plants are designed months backfiling: four more months, ing, “Supposeciy, these types of plants similar, certain espects were affected reinforcing concrete; five months com take four to five years” At Beni Suef, by local factors, Beni Suet is located pleting the steel structures; and three 6,000 workers toled day and night t© on the west bank of the Nile River in months installing opan-cyele piping rmaet the tight schedule, amassing 2 Upper Egypt, about 110 kilometers Bunulus also faced extreme challang stunning 22 millon hours. “Those were (km) from Cairo. New Capital is locat- 6, owing to cifcult site conditions, The safe working hours” he stressed fed about 45 km east of Greater Cairo project is located near Lake Burulis, @ Orascom, 100, wielded is vast ex near a new city that Egypt is building brackish-water lake in the Nile Deke, pertse to get New Capital and Burulus from scratch to ease congestion and 2 remote site that required “additonal built on time, and it echoad Elsowedy’s overcrowding in Cairo. The city will complex geotechnical engineering with focus on safely. "We achieves over 20 ultimately house a new presidential significantly greater soll imorovement milion marchours on the Burulls and palace, @ new parliament building, @ and pling work than expected” Orascom New Capital Power Plants combined; central bank, business district, and air said. Orascom also chase to run the the company told POWER. Key to pro port. Burullus, meenwhile, is situated plant's cooling pipelines below ground fect completion was 2 “proactive and about 200 km'north of Caito ‘and under the saa, which raquirod build- strong team that was able ta look ahead Because Beni Suet is lacated on the ing an "immense" marine and water and forecast any issues that could arise, Nile Fiver and Burulus ison the Mediter intake structure in the open sea, Devel. resulting in an efficient risk-management raneen Sea, water for cooling purposes _opers opted for the design aspect over approach” it sad wes not@ mejor concern at those plants. easier alternatives because it was inte However the New Capita facityis ocat- gral to shoreline preservation, Mega Equipment fd in the desert where water is scarce Each of the thea sites consists of four Therefore, an aircooled condenser—the Mega Logistics blacks. Each block has two Siemens largest of fs kind in the world—was in-Shigping heavy leads from factory to site ‘SGTS-8000 H-class gas turbines (Figure corporated into that plant, ‘was as cumbersome. To ship the gas tur 1), one steam turbine (Figure 2), three The topogrephy of the Beni Suef site bines—each weighing 445. tons—from gonerators, two haat recovery steam posed some unique challenges. The Bern to Beni Suet, for example, volved Generators (HRSG), three transform- pant was built on a hilkop, which re a complicated thveemonth process, The fers (Figure 3}, anc associated auxllary quired the excavation of about 1.75 mik turbines were transported on a special equipment. Each site excorts power—up lon cubic meters of hard rock over five 192-wheel vehicle (Figure 4) fromthe as- 104.8 GW—to the gtd through @ 500-kV months. “You cen imagine it 2s eauive- sembly hall to a 250-meterlong leading cgas-nsulated switchgear lent tothe size ofa small Egyptian pyra- bay where they were placed on 2 heavy- Siemens’ H-class gas turbine oper mid” Dalia Abou El Seoud, Siemens’ cargo shutle. The transport route passed ates at more than 61% efficiency in deputy director for the Megaproject, through the residential araa of Beri combined cycle made. The high eficien- told POWER. “It’s hugel” To account Moabit, requiring poe to stop trafic for cy translates into significant fuel sav. for the 40-meter slope from the Nile # short while. ings and reduced emissions compared to the highest level, the site was ter The heavy-cergo shuttle was used to to many other units available on the raced, with the plant placed at the top move the gas turbines via waterways market. The Egyptian plants mainly rely and the water treatment piant nearor to through parts of Berlin to Westhafon— (on natural gas as ther fuel sources, but the river. “Irs actualy avery panoremic the city’s westem harbor. At Beir-Wes- fone module et each facility is dualfuel end picturesque power plant” she seid. thafen, the equipment was hoisted from capable, with fuel ol used as @ backup energy source. ‘The equipment was sourced from various manufacturing facilities around the world, The ges turbines came from Siemens’ Berlin, Germany, factory, while the steam turbines originated at the campany’s plant in Milheim, Germany Some of the gonorators wore sourced from Mulheim, while others shipped ‘rom Siemens’ Chariote Energy Hub in North Caroline NEM Energy BV—a Siemens com- pany—supplied the vertical, tiple-pros- sure reheat, once-though HRSGS for the Megaaroject from its South Korea manufacturing plent. The reletively ight- weight HRSG design allows fast and fiox ible startups, witha small footprint. Each 4. Moving H.less gos turbines, which weigh 445 tan, io amal tok. The speci! 192hee! poler contains 24 modules and approxi. vehicle shown here was used fr one portion ofthe journey frm te ectoryn Bern, Germany tmotely 14,000 single tubes, each sound !268ch ant stn Egypt. Cranes shes and other heevy-caro sutles were aso Use along 20 meters in length,