110 MW Gas Reciprocating Cogeneration Plant in Tikhvin

CustomerObject locationStart/End of Work
Transmashenergo, LLCLeningrad region, Tikhvin2014/2016

Tikhvin Carriage Works, in the modernization of which the IST Group invested more than 1 billion USD in 2008-2011, in its scale and applied technologies, is unique to Russian machine-building industry and is now the leader in carriage building in Russia. High-tech machine-building production is very sensitive to power supply disruptions, therefore, to ensure the required level of reliability and quality of power supply, the IST Group decided to upgrade the existing boiler house at the production site with the construction of a 220 MW Thermal Power Plant based on several Gas Reciprocating Units (GRUs) of the 18V50SG brand (electric capacity is 18.32 MW and thermal capacity is 18 MW) produced by Wärtsila.

Construction of a Gas Reciprocating Power Plant of such capacity is a unique project for the Russian energy industry. The TPP has the most powerful gas reciprocating engines, Wärtsilä 50SG, which ensure electrical efficiency of the power units by 48% (and taking into account the operation of the waste-heat recovery system of power units with a total capacity of 90 MW, the power plant efficiency reaches 90%), as part of its main generating equipment. Such facilities are highly maneuverable and provide quick start (for 5-10 minutes at a full capacity) fast reset, work at partial load, and are well adapted for systems with variable loads. High environmental performance in terms of emissions and noise allow you to install the GRUs in close proximity to the consumer. It is also important that when fuel efficiency is comparable with combined-cycle plants, Wärtsilä modular power units provide shorter construction and commissioning periods at lower capital costs.

The project is being implemented by ISM Engineering Company, a joint venture of the IST Group and Baran Group Ltd. (Israel). The project operator is Transmashenergo LLC. Trest Sevzapenergomontazh  CJSC, in accordance with the obligations under two contracts concluded with Transmashenergo LLC in 2013-2014, fulfilled:

As part of the contract dated 23.12.2013 for the first step of construction, the following types of works were rendered:

  • Main building. General construction work of the zero cycle (arrangement of a pile field, reinforced concrete foundation frames, jumpers, socle panels, arrangement of underground facilities)
  • Chimney. General construction work of the zero cycle (piled foundation, reinforced concrete foundation frames)
  • Radiator cooling systems. General construction work of the zero cycle (piled foundation, reinforced concrete foundation frames)
  • Electrotechnical building. Full complex of construction and installation works (piled foundation, zero-cycle works, installation of metal structures, architectural and construction works, installation of engineering systems)
  • Combined auxiliary building. Full complex of construction and installation works (piled foundation, zero-cycle works, installation of metal structures, architectural and construction works, installation of bridge crane, installation of engineering systems, electrical installation works, automation of indoor gas pipeline, installation of thermal and mechanical equipment)
  • Combined auxiliary building. Full complex of construction and installation works (piled foundation, reinforced concrete foundation frames, installation of metal structures, architectural and construction works, installation of engineering systems, electrical installation works)
  • Waste-heat boiler unit (piled foundation, reinforced concrete foundation frames)
  • Arrangement of gas pipeline on the on-site trestles
  • Construction control over the construction of gas supply systems
  • Development of working documentation for connecting heat supply systems of building 140 to the existing water boiler of Tikhvin Carriage Works CJSC

As part of the contract dated 19.06.2014, a set of construction and installation works on construction and equipment of the main building with all engineering systems was performed:
Main building:

  • bearing and enclosing structures
  • arrangement of finished floor
  • installation of the main process equipment – six Wartsila 18V50SG gas reciprocating units with generators
  • installation of auxiliary process equipment (auxiliary module with platform, exhaust module, pipeline trestle)
  • installation of foam extinguishing automatic installation system
  • installation of heating and ventilation systems, including devices for thermo-technical control
  • electrical installation works
  • installation of water supply system
  • installation of water disposal system (sewage)
  • installation of gas system
  • installation of oil system
  • installation of compressed air system
  • installation of cooling system (six heat exchangers, two process tanks, pipelines)
  • installation of air intake system (12 dry-type air intake filters with air ducts)
  • installation of exhaust system
  • installation of waste-heat recovery system (six heat exchangers)
  • installation of lifting equipment (electric bridge crane with a lifting capacity of 5 tonnes, and crane runways)
  • installation of communication and alarm systems
  • installation of GRU automatic control systems
  • installation of GRU instrumentation

Chimney:

  • installation of metal structures
  • installation of six sets of chimneys, including insulation
  • installation of flue gas cleaning system (6 catalysts, 12 compensators)

Radiator cooling systems

  • installation of metal structures
  • installation of cooling system (radiators, above-ground structures of the cooling system, pipelines from the radiators to the Main Building), including insulation

Gas flues. Process trestles (arrangement of piled foundation, reinforced concrete foundation frames, installation of metal supports)


Oil control operating room and oil storage tanks (installation of reinforced concrete and metal structures, architectural and construction work, installation of oil systems and engineering systems of the oil control operating room)


Gas conditioning station (zero-cycle work, installation of a block-box of process equipment and a condensate tank of unit gas conditioning station)
Diesel generator set (arrangement of the base plate for the block container of a diesel generator)

The new gas reciprocating cogeneration plant has fully met the needs of Tikhvin Carriage Works and industrial enterprises of the Tikhvin site, taking into account the fact that no one has ever built a gas reciprocating power plant of such wattage in Russia.