Two Combined-Cycle Facilities Maximize Same Design

Sargent & Lundy provides "single design approach" to two energy centers--one on the East Coast, the other in the Midwest

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EPC Combined-Cycle Design 
Cleveland County, North Carolina / Butler County, Ohio
Client: Gemma Power Systems
Project Names: Kings Mountain Energy Center Middletown Energy Center

Project Highlights:

  • Fuel: Natural gas / Natural gas
  • Size: 475 MW / 475 MW
  • Configuration: 1x1x1 / 1x1x1
  • Major Equipment: M501GAC CTG - MHPSA, HRSG - Vogt Power, STG - Toshiba
  • Schedule: Begin engineering mid-2015, commercial operation October 2018 / Begin engineering mid-2015, commercial operation April 2018

Project Description:

In 2015, NTE Energy (NTE), as owner, initiated development of the Kings Mountain Energy Center (KMEC) and the Middletown Energy Center (MEC), two 475-MW 1x1x1 combined-cycle energy facilities located in North Carolina and Ohio, respectively. Gemma Power Systems (GPS) is the EPC Contractor responsible for the engineering, procurement, construction, startup, and commissioning of both projects.

NTE’s project expectation is that the designs of the two plants be replicated to the maximum extent possible. To meet this objective and to consistently focus on a single design approach requires a collective mindset and close collaboration between owner, contractor, engineer, and vendors.

Sargent & Lundy, as a subcontractor to GPS, is providing full engineering design in support of their EPC contract obligations. This includes balance-of-plant (BOP) and engineered equipment specifications. Sargent & Lundy is using a single intelligent 3-D plant model platform to maximize common design document development for the two sites.

The 501GAC CTG (260 MW), negotiated by NTE, is being supplied by Mitsubishi Hitachi Power Systems Americas, Inc. (MHPSA). The steam tail is a single contract with GPS for a Vogt Power-supplied HRSG, a Toshiba-supplied TCSF STG (225 MW fired, 140 MW unfired), and condenser by TEI.

Other major features in both designs are:

  • Auxiliary boiler
  • Selective catalytic reduction and (CO2) control systems
  • Mechanical-draft cooling tower
  • Electrical and I&C systems
  • Distributed control system (DCS)
  • Water supply and treatment system
  • Wastewater system
  • Fire protection system
  • HRSG equipped with duct burner system and exhaust stack (200-foot-high at MEC and 180-foothigh at KMEC

Both projects will supply power to new adjacent switchyards designed and built by Duke Energy, 230-kV from KMEC and 345-kV from MEC.

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