Combined Cycle Power

 Combined Cycle Power

Title:
Supervising the Construction of Riyadh’s PP10 Combined Cycle Power Plant:
A Real-World Engineering Model

Article Body:

The PP10 Combined Cycle Power Plant in Riyadh stands as a testament to the scale, complexity, and coordination required in modern power generation projects. As an engineer who directly supervised the execution of this massive infrastructure, I’d like to share an insider’s perspective on how this project evolved from blueprint to reality.

Project Overview

The PP10 power station, located in the heart of Saudi Arabia’s capital, was developed to meet the rising electricity demands of the country. The station operates under the combined cycle model, which significantly increases efficiency by utilizing both gas and steam turbines in a single integrated system.

The project comprises:

10 Gas Turbine Generators (GTGs)

10 Heat Recovery Steam Generators (HRSGs)

5 Steam Turbine Generators (STGs)

Auxiliary systems including water treatment units, control buildings, transformers, and extensive cabling networks

Scope of Supervision

My role involved full-time site supervision, coordination with contractors and suppliers, and ensuring strict adherence to design, safety, and environmental standards. This included:

Reviewing design packages and shop drawings

Approving construction methodologies

Verifying quality control procedures

Leading technical meetings and progress evaluations

Coordinating inspection and testing with third-party agencies

Supervising installation of turbines, HRSGs, BOP systems, and control panels

Supporting the commissioning and synchronization with the national grid

Execution Highlights

1. Site Preparation and Civil Works:
Site mobilization, grading, and foundation works were executed with precision, ensuring stability for heavy rotating equipment and HRSG units.

2. Turbine Installation:
Gas and steam turbines were installed using high-capacity cranes and laser alignment tools, with tolerance levels under 0.1 mm for critical joints.

3. Piping and Electrical Works:
Over 500 km of cables were laid and connected, while pressure-tested steam piping systems were welded and inspected using X-ray and ultrasonic methods.

4. Control Systems and Commissioning:
DCS (Distributed Control System) programming and loop checks were carried out in collaboration with OEMs. Grid synchronization was done after successful performance and reliability tests.

Challenges and Solutions

Large-scale coordination with multiple subcontractors, extreme summer temperatures, and strict operational timelines were among the key challenges. Weekly coordination meetings and real-time issue tracking were instrumental in keeping the project on track.

Legacy and Impact

The PP10 power plant has become a model for efficient power generation across the region. Its success story lies not only in the engineering marvel it represents but also in the collaborative effort of hundreds of dedicated professionals.

As someone who witnessed the transformation of a barren site into a high-tech energy facility, I consider this project a highlight of my engineering career—and an example worth sharing with future engineers and energy professionals.

Presented by Eng. Mohammed Ibrahim
Member of the Arab Engineers Union & Professional Engineering Organizations
Experience Shared – Knowledge Spread.

Experience Shared – Knowledge Spread
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