THE ECHO - Ferrostaal

The new 60 MW Block 1 of the Wuppertal-Barmen plant reduces emissions of airborne
pollutants by more than 50 percent.
The crowded location of the new power plant in the Barmen
district of Wuppertal, between the Wupper river and the Cologne-
Hanover high-speed rail line, presented a particular challenge
during this project: the existing power plant is located in a highdensity
residential area. The new plant was constructed in very
cramped conditions in the partly gutted buildings of the existing
plant, which continued to be operational during the construction
phase, and was then connected to parts of the existing plant.
The construction phase remained on a very tight schedule within
17 months. This meant that a buffer could be built into the timeconsuming
phase that began with the first run-up of the gas turbine
and included commissioning of all components, functional
testing, and, finally, optimization. The agreed completion deadline
of the end of 2005, which was necessitated by the regulations
on cogeneration, was therefore never in question.
The agreed timescale for the plant from signing the contract up to
being ready for commercial use was just 22 months. The acceptance
test for Phase 1 of the project, i.e., the integration of the existing DT
23 steam turbines into the new electrotechnology and control
technology infrastructure, was conducted as early as December
2004. In December 2004 and January 2005, gas turbines, generators,
and boiler components were delivered for assembly. In June 2005,
the first gas turbine was started up, and, in December 2005,
Wuppertaler Stadtwerke signed off on the completed plant.
Helmut Wolff
SCOPE OF SUPPLY AND SERVICES
THE ECHO 1/2006 21
>> Two 30 MW gas turbines from Hitachi in Japan, complete
with generators, and two waste heat boilers manufactured
by Innovative Steam Technology (IST) in Canada
>> All electrical and process control technology
>> Piping for water/steam circulation, including pumps and
heat exchangers
>> Installation of all essential auxiliary systems including a
cooling water supply system, air inlets, fire protection
installations, heating/climate control/air conditioning
>> All required underground and structural engineering
services
>> Architectural design
>> Design of all unit operations
>> Detailed engineering
>> Selection of all plant components
>> Configuration of electrical and process control technology
and safety equipment
>> Construction of the new boiler house, foundation rafts for
boilers and gas turbines
>> Coordination and construction management
>> Assembly of all components
>> Commissioning and testing
>> Documentation and training