The Zeran power project involves the construction of a new  490MW gas-fired combined-cycle unit to replace the aging coal-fired boilers of the existing Zeran combined heat and power (CHP) plant located in Warsaw, Poland.

The project is being developed by PGNiG Termika, the leading producer of cogenerated heat and electricity in Poland. The total investment on the project is estimated to be approximately £336.46m ($444.37m).

The construction works were officially started in October 2017 with the plant commissioning expected by September 2021.

The new unit is expected to increase the capacity of the Zeran CHP plant to produce up to four tera-watt hours (TWh) of electricity and 1.9TWh of heat energy.

Location and site details

The Żerań gas-fired combined cycle power project (CCPP) is located in the Zeran suburb, in the Warsaw district of Poland.

Żerań combined cycle power plant make-up

The Żerań combined-cycle power plant (CCPP) will comprise an F-class gas turbine, a steam turbine, and a heat recovery steam generator (HRSG) from Mitsubishi Hitachi Power Systems (MHPS) for a total power output of 496MWe and a heat output of 326MWt. The new unit will be fitted with a selective catalytic reduction (SCR) system for controlling the emissions of nitrogen oxides.

The project also involves the construction of pipelines and the installation of storage batteries, process water coolers, and a multi-tap transformer.

Infrastructure facilities

The Żerań combined-cycle power project involves the upgrade to the existing cooling water system, including the discharge pipeline and the water preparation system, and the connection of the existing Żerań CHP plant to new switchgear of Polskie Sieci Elektroenergetyczne (PSE), as well as new pipeline connections to the GAZ-System.

Natural gas consumption

The Żerań combined cycle power project is expected to consume approximately 650 million cubic metres (mcm3) of natural gas a year.

Contractors involved

A consortium of Polimex-Mostostal and Mitsubishi Hitachi Power Systems (MHPS) signed an engineering, procurement, and construction (EPC) contract agreement for the project with PGNiG Termika in June 2017.

Mitsubishi Hitachi Power Systems (MHPS) is responsible for the manufacturing and supply of gas turbine and generators along with the associated equipment. The contract also includes a long-term service agreement (LTSA) for the turbine section.

Polimex-Mostostal has been engaged for the basic and detailed engineering, as well as the balance of plant (BOP) construction works.

Famet was contracted for the delivery of heat exchangers, while  Wouter Witzel and AVK Valves supplied the butterfly valves equipped with SIPOS Electric actuators.

Inženjering Zagreb was engaged for the basic and detailed engineering of the piping system, while ILF Consulting Engineers was engaged for the design, engineering, and consulting services, and Enetecs Technologies provided the electrical, instrumentation, and control engineering services for the project.

Ramboll was contracted for the preparation of tender documents, while Yas Consulting Engineers was engaged for the complete project documentation work.

Żerań combined cycle power project background

The preparatory works for the construction of Żerań gas-fired combined-cycle power project were launched in 2012. It is being developed to replace the existing worn-out coal-fired boilers of the existing Zaran CHP plant.

The environmental permits for the high-pressure gas pipeline to the power project were approved in the third quarter of 2012, while an agreement for connecting the combined-cycle unit to the OSP Gaz-System SA transmission network was signed in the fourth quarter of 2012.