The Nigerian Society of Engineers CALABAR BRANCH

INDUSTRIAL/TECHNICAL VISIT TO NIPP POWER PLANT AT ODUKPANI CROSS RIVER STATE ON 30TH JUNE 2010

TECHNICAL REPORT

Table of Contents S/No Subject Page

1. Overview of Visit 3

2. Additional Information & technical data 5

3. Layout of the Power Plant 6

4. NSE team members 7

5. Odukpani Power Station data 8

6. NIPP general data 10

7. Pictures 12

Industrial/Technical visit to NIPP power plant at Odukpani Date: 30th June 2010 Scheduled take off time from Calabar: 8.30 a.m Actual take off time from Calabar: 9.05 a.m. Actual arrival time at power plant: 9.50 a.m. Welcome The NSE team was welcomed by Engr. P. T. Akinola. In his opening remarks, he explained that the project is funded and managed by the federal government under the auspices of the Federal Ministry of Energy, National Integrated Power Project (NIPP) scheme. As a representative of NIPP, his official designation is Site Manager1. He further explained that the project had a main contractor, Marubeni Corporation, and a Project Consultant, Steag. He went ahead to introduce the Site Manager of the main contractor, Mr. Robert Mckay, while apologising that none of the representatives of the consultant was available. Mr. Mckay welcomed the NSE team, and then went ahead to explain that inasmuch they were the main contractors to the project, they had numerous sub-contractors who were handling various aspects of the works (mechanical, civil, electrical, etc).2 He invited the team to explore the entire facility and feel free to ask whatever questions they wanted. At this point the NSE team asked and received a large layout drawing of the project, and proceeded to ask a few preliminary questions. These questions and other comments were fielded by Engr. Akinola’s team.3 The NSE team, accompanied by Engr. Akinola’s team, were then taken on a guided tour of the project site The visit

i. Generators & Turbines The team was shown the storage location of two of the massive generating turbines & their generators. Installation is yet to be carried out as works on the combustion chambers pedestals are yet to be completed.

ii. Gas Receiving Plant Generally, this is the point where the LNG is received, regulated, cleaned and re-directed at controlled temperature and pressure to the combustion chambers. A staff, Mr. Augustine Uzoma, took the team around the various sections of the gas receiving plant, (metering station, separators, pressure regulators, heaters, scrubbers) answering questions and explained in details the processes of each section4.

iii. Combustion chambers The team was conducted to the combustion chambers, where the gas received from the receiving plant will be ignited, and combusted and energy conversion to generate electricity. The combustion chambers are actually where the five turbines will be finally installed to burn the treated gas and generate the electricity. Mr. Uzoma continued his detailed explanations of the processes involved5.

iv. Electrical Control Room The team was then taken to the main electrical control room. It is here that all the generated electricity is channelled, switched and routed for transmission. The control room is sectioned into 11KV, 33KV, 132 KV output transmission lines for various dedicated grid lines

v. Transmission Grid This is the grid of power lines, transmission stanchions, circuit breakers, insulators, lightning arrestors/conductors, transformers that actually separate and transmit the electricity to the end users and into the national grid.

(End of inspection – 12 p.m.) Before Departure The NSE team re-assembled in the conference room and was received by Engr. Akinola, who gave the team an opportunity to interact and ask some more questions.6 He thanked the NSE for their interest and promised to be available any time the branch needed his assistance in any form. A member of the NSE team, Engr. E. Ekpe Ita, who had been involved in the initial stage of the project as a consultant, also made some comments on the visit. He thanked the management of the project and informed that the NSE was always available to offer its services and advice any time called upon. Engr. Ekong gave the vote of thanks on behalf of the NSE Calabar, thanking the management for honouring our request, their reception and professional manner in which they conducted the team around the facility. The team departed at about 12.25p.m.

INDUSTRIAL/TECHNICAL VISIT TO NIPP POWER PLANT AT ODUKPANI

ON 30TH JUNE 2010

ADDITIONAL INFORMATION &TECHNICAL DATA

Sketch Layout of NIPP Odukpani Power Plant (Not to scale)

Calabar Itu

Transmission Grid

Central Control Room

Admin Offices Turbine/Generator

storage Gas receiving & treatment plant

Flow of Gas

Main Turbine 5 Nos

Security posts

Gate

NSE team:

S/No Name Organization Telephone

1 Ekpere Joseph R. Subro Nig td 08038726737 2 Ifeoma Onyekwere Zenith Construction 08063448252

3 Ohagwu Chiedozie 08034928053 4 Engr. Henry A. Okonkwo Lindem Haicon 08062824755

5 Odunlami Nasiru N. I. C. 07032603284 6 Engr. Ephraim Jackson UniCal 08033807337

7 Engr. Ekpe E. Ita Ekpe Ara & Partners 08035501815

8 Wariso Joseph S. PHCN Transmission 08056322860 9 Abegunde Akindele MJD Oilfield Services 08038077470

10 Sylvester Ita Onyoh State Electricity Agency 08035502152 11 Engr. Thomas Solomon SUTRAPA 08037162893

12 Engr. Offor Jonah UCTH 08033623543

13 Engr. Odo J. Ukpata CRS Min of Works 08037182583 14 Engr. Solomon Agboje NDDC 08030477928

15 Idongesit Esa Geokinetic Int Inc 08033425735 16 Engr. Myke Ogbodo NPA 08033097226

17 Udom Anietie Udo CRUTECH 08034048764 18 Ita E. Bassey CRUTECH 08063607983

19 Engr. G. P. I. Agunwa Federal Ministry of Housing 08035227558

20 Engr. Emmanuel Oyo Ita CRS Min of Works 08037081401 21 Engr. Umo B. Ekong Federal Ministry of Works 08033359106

22 Mrs. Cyndi C. Ene-Ita NSE Office Manager 08035526070 Some questions asked during Q & A sessions in conference room Q: How many companies are working here? Engr. Ukpata Q: Can you give us an overview of the project’s proposed capacity? Engr. Ogbodo Q: Can you give us a general pictorial presentation of the project? Engr. E. Ita Q: What is the main fuel and source for the plant? Q: Are there any special considerations for Calabar, Tinapa, Free Trade Zone? Q: How will the power plant be managed if energy sector is fully privatized? Q: How do the immediate community benefit from the project?

ODUKPANI POWER STATION DATA [1][3]Personnel NIPP: Engr. P. T. Akinola - Site Manager Engr. K. O. Abawu - Engineer Marubeni Corporation: Robert Mckay - Site Manager Engr. Bola - Civil Engineer Augustine Uzoma - Technician [2]Structure Client/owner: Ministry of Energy (Power) Niger Delta Power Holding Company Project Consultancy: STEAG encotec West Africa (SeWA) Engineering Procurement & Construction (EPC) Contractors: Marubeni Corporation & Gitto Construzioni Mechanical Sub-contractors: Engineering Construction services Civil Sub-contractors: Construction Kaiser Ltd Electrical Sub-contractors: Siemens Corp. Project commenced in 2006 and was originally scheduled to be completed by 2009, but has now been extended to 2011 Type: Open cycle Power plant, comprising five (5) gas turbines. Capacity: 5 x 112.2 MW = 561 MW Fuel: The plant is designed to receive and run on Liquefied natural gas (LNG) which is to be supplied by a 107-kilometre pipeline from Adanga oil field (Akwa Ibom) run by Addax Petroleum Company. There is a planned alternative pipeline from UniCem pipeline, which can run 1 turbine, and which is to be completed by 2012. The power plant does run internal power sources which run on diesel and High/low pour fuel oils. [4][5]Power Plant Sections & processes Gas receiving plant: this is made up of several sections

i. Metering station This is the point where incoming gases are monitored. Usually the gases arrive at a pressure of 32 bar and should have a density of 0.56 g/m3.

ii. Receiving tank This is the tank that collects & stores all the incoming condensate from the separators, at regulated temperature & pressure. Condensate is later disposed of commercially.

iii. Separators These are located severally along the line and they separate the incoming LNG into gas and condensate. The gas piped along towards the combustion chambers, while the condensate is collected and stored.

iv. Pressure reducing skid These skids are designed to reduce the gas pressure to an acceptable 26.5 bars

v. Water bath heaters These are used to elevate the temperature of the gases from an original 20oC to between 50oC – 60oC. This is the ideal temperature range for running the gas turbines

vi. Scrubbers As the name implies, these are specially fitted to remove impurities (condensate, trace chemicals) that may have escaped up to this point.

The entire system is installed with shut down valves, that can identify and prevent build up of pressure, or excessive temperatures which may be potentially threatening to life and property. Regular and monthly checks are carried out along the gas receiving plant line to ensure that incoming product, gas being fed to the turbine constantly satisfy physical and chemical requirements for the turbines, as well as spot defects and maintenance requirements. Combustion Chambers: These are where the five (5) turbines/generators are to be mounted and run on pedestals. Each of these five (5) Gas Turbine/ Generator Pedestals comprises of 450 cubic meters of grade 40 concrete, and 52 metric tons of high yield steel reinforcement, on this project. The combined weight of the Gas Turbine / Generator to be carried by these Pedestals is about 424 metric tons, (Gas Turbine- 250tons and Generator – 174tons) When fully installed, each turbine will be initiated to start with a cranking motor (output 6.6KV). Starting process –

Rachetting is done at 3 r.p.m. → Purge speed 600 r.p.m →Ignition speed 810 r.p.m. (At this speed, the spark plugs of the turbine ignite the gases, commencing combustion). The speed is increased → to 1950 r.p.m (self-sustaining speed i.e at this point, the generator is disengaged) →Full speed 3000 r.p.m (At this speed, the turbines are loaded in part loads of 5MW till full capacity) Temperatures in the turbines can reach 1700OC

For maintenance, enhanced minor inspections are carried out after every 4000 hours of operations. On the issue of emissions and environmental pollution, the power plant is a relatively clean system, with a Dry Low Nox Emmission of mainly Carbon Dioxide and vapour. Electrical Capacity/Output The plant is designed to produce 561 MW of electricity into the national grid. However, there is a dedicated 132 KV line for Calabar. There is also an 11KV dedicated line for the immediate community/environs within a 5-kilometreradius of the power plant.

Ownership/Management Structure The power plant is structured is such a manner that ownership is divided between the Federal, Cross River state, and local governments. This satisfies the current local content requirements in power and energy contract requirements, as well as encourages greater responsibility towards maintenance and vandalism of electrical property. In the privatization scenario, the power plant has a clearer role; the power plant should be able to charge directly for whatever quantity of electricity is generated and fed into the national grid, leaving the transmission/distribution companies the task of collecting retail revenue from the end-users.

THE NATIONAL INTEGRATED POWER PROJECT (NIPP) SCHEME Introduction The National Integrated Power Project (NIPP) was originally planned as a ‘Fast Track’ Project with 7 Power Stations conceived by the immediate past President Olusegun Obasanjo's Administration of the Federal Government of Nigeria to address the twin issues of low power generation and gas flaring from oil exploration in the Niger Delta region. Project parties: Employer: Ministry of Energy (Power) Niger Delta Power Holding Company Design Consultant: Lahmeyer/Otis Engineering (International/Local) Project Consultancy: APTEC/STEAG encotec West Africa (SeWA)- International/Local EPC Contractor (BOP): Consortium of Marubeni Corporation of Japan and Marubeni (West Africa) Limited OEM Contractor: General Electric Corporation of U.S.A Commencement Date: 20th December 2005 Estimated Completion Date: 19th December 2008 (24 months Project Execution Period & 12 months Defect Liability Period) EPC Contractor (BOP) Commencement Date: 16th February 2006 Estimated completion Date: 15th December 2007(22 months Project Execution Period) Power plants planned included: Ihovbor Power Station Benin, Edo State with the capacity of 4 x 125MW Calabar Power Station, Cross River State with the capacity of 5 x 125MW Egbema Power Station, Imo State with the capacity of 3 x 125MW Gbarain Power Station, Yenagoa, Bayelsa State with the capacity of 2 x 125MW Sapele Power Station, Delta State with the capacity of 4 x 125MW Overview This project was conceptualized as an intervention project to comprehensively address the state of electricity infrastructure in Nigeria. It is designed as a fast-track approach to improving the country‘s electricity power supply through the implementation of Generation, Transmission, Distribution and Gas Supply projects. The main thrust of the project is the design, manufacture and supply of seven new Gas Turbine Power Plants with the provision for conversion to combined-cycle operation. Aptec Engineers Nigeria Limited (AENL) and Steag Encotec West Africa (SeWA) was contracted as the Project Consultant of the Federal Government (Ministry of Power) for the power plants being built. The following are the services rendered:

Assist in EPC Contract Award

Engineering design vetting

Procurement Monitoring and Acceptance (FAT)

Site erection supervision

Project management Owner’s Engineer duties

Pre-commissioning and commissioning approval

Technical support during Defects Liability Period (12 months) Aptec Engineers Nigeria Limited (AENL)and Steag Encotec West Africa (SeWA) is the Consultant to the Power Holding Company of Nigeria (PHCN)The parent body of the NIPP. PHCN started several power projects in 2004 to comprehensively address the state of the electricity infrastructure in the country with open cycle power plants. The Phase II Power Projects in Nigeria consisted of an extension of four Open Cycle Power Plants under construction to Combined Cycle plants. After several technical studies done, and due to Aptec Engineers Nigeria Limited (AENL) and Steag Encotec West Africa's (SeWA) recommendations, the project changed course to increase power output and improve thermal efficiency. After several adjustments, the total additional Phase II power plant output will contribute to increase total generation in Nigeria by 2,430MW. Aptec and its subsidiary company Steag Encotec West Africa (SeWA) was also contracted as Consultant by Power Holding Company Nigerian (PHCN) for the extension to combined cycle of four plants built under Phase I. The following are the services rendered:

Review of Contractor’s Technical and Financial proposals

Advise on adequacy of Contractor’s Technical proposal

Negotiate total Phase II budgetary price

Recommendation of Phase II Project Cost

Represent Client as Owner’s Engineer

Preparation of Contract Documents The Ministry of Power working with Aptec Engineers Nigeria Limited (AENL) and Steag Encotec West Africa (SeWA) contracts a number of other engineering companies to support this national presidential vision and initiative. For clarification, AENL or APTEC and Steag Encotec (West Africa) Limited are individual companies. Though headed by the one and same management of two British John and Ian Appleby and one Nigerian, Stanley Obia.

SOME PICTURES OF THE VISIT

The Team on Arrival Engr. Akinola briefing the team

The Main Turbines Power Grid

At the Turbines Question & Answer Session