Ghana Prestea 55MW Gas Engine Combined Cycle Power Plant: Construction in Progress

ZHM is proud to announce that the Ghana Prestea Gas Engine Combined Cycle Power Plant project, a key EPC (Engineering, Procurement, and Construction) undertaking, has successfully completed equipment production and shipment, and is now in the active construction phase. This 55MW power generation facility represents a significant milestone in Ghana's energy infrastructure development, leveraging advanced gas engine technology to deliver reliable, efficient, and clean power to the Prestea region.

Project Overview and Technical Specifications

The Prestea power plant adopts a combined cycle configuration that maximizes energy efficiency by integrating gas engine generation with heat recovery systems. The project features a total installed capacity of 55MW, consisting of 5 gas engine generator sets (2 units for 60Hz operation and 3 units for 50Hz operation) to meet diverse power grid requirements.

Core Equipment Configuration

* Gas Engines: 5 units of Bergen B36:45V20AG gas engines, renowned for high reliability and fuel efficiency in industrial power generation applications.
* Generators: 5 units of 11MW generators (2×60Hz + 3×50Hz), designed to convert mechanical energy from gas engines into stable electrical output with low harmonic distortion.
* Cooling Systems: Comprehensive temperature control infrastructure including:

    **High-temperature circulation pumps (Q=240t/h, H=25m)

    **Low-temperature circulation pumps (Q=90t/h, H=32m)

    **Oil coolers and preheating modules for engine thermal management

Fuel Supply: Dedicated natural gas intake modules with safety isolation valves and pressure regulation systems, ensuring stable fuel delivery to each gas engine unit.

Advanced Control and Instrumentation Systems

To ensure optimal plant operation and safety, the Prestea power plant is equipped with state-of-the-art control and monitoring technologies:

Distributed Control System (DCS)

The plant's DCS system serves as the central control hub, enabling:

*Real-time monitoring of all key process parameters
*Automatic load adjustment based on grid demand
*Remote operation and troubleshooting capabilities

*Integration with safety interlock systems to prevent equipment damage

Instrumentation Network

A comprehensive instrumentation system provides precise measurement and control of critical operational parameters:

*Pressure Transmitters (Model 2088G2S22A1M5B4): Measuring gas pressure, water pressure, and exhaust pressure with 4~20mA DC + HART protocol output, IP65 protection, and 316L measuring elements.
*Temperature Sensors:
Armored thermal resistance (Pt100, Class A) for exhaust gas (0~600℃) and cooling water (0~100℃) temperature monitoring
Bimetallic thermometers (Φ100mm, 304SS) for local temperature indication

Flow Meters: Accurate measurement of fuel gas, cooling water, and air flow rates to optimize energy efficiency

Safety Systems

Safety is prioritized throughout the plant design, with multiple layers of protection:

Fire Alarm and CCTV System: 24/7 monitoring of plant premises with automatic fire detection and video surveillance.
Fire Fighting System: Dedicated fire suppression equipment strategically located to protect critical equipment.

Emergency Shutdown System (ESD): Automatic shutdown of equipment in case of abnormal operating conditions to prevent accidents.

Construction Progress and EPC Services

As an experienced EPC contractor, our company provides end-to-end services for the Prestea power plant project, including:

Project Phases Completed

1.Engineering Design: Detailed design of mechanical, electrical, instrumentation, and civil systems.
2.Equipment Procurement: Sourcing of high-quality equipment from reputable suppliers (e.g., Bergen engines, DCS systems).
3.Manufacturing and Quality Control: In-house production of custom components with strict quality inspection.
4.Shipment: Safe delivery of all equipment to the project site in Ghana.

Ongoing Construction Activities

1.Civil Works: Construction of generator buildings, control rooms, and auxiliary facilities.
2.Mechanical Installation: Mounting and alignment of gas engines, generators, and cooling systems.
3.Electrical Installation: Wiring of power cables, transformers, and distribution systems.

4.Instrumentation and Control Installation: Calibration and commissioning of sensors, transmitters, and DCS systems.

Installation Support

Our team of experienced engineers and technicians is on-site to provide:
*Technical guidance for local construction teams
*Equipment installation supervision
*System testing and commissioning

*Operator training for long-term plant operation

Project Benefits and Environmental Impact

The Ghana Prestea Gas Engine Combined Cycle Power Plant offers multiple benefits:

Energy Security

55MW of reliable power supply to meet the growing energy demand in Prestea and surrounding regions.

Flexible operation with both 50Hz and 60Hz capacity to integrate with Ghana's national grid.

Economic Development

Creation of local jobs during construction and operation phases.

Support for industrial and commercial growth through stable power supply.

Environmental Sustainability

Lower greenhouse gas emissions compared to coal-fired power plants.
High energy efficiency (combined cycle efficiency >45%) reduces fuel consumption and carbon footprint.

Compliance with international environmental standards for emissions control.

Conclusion

The Ghana Prestea 55MW Gas Engine Combined Cycle Power Plant represents our commitment to delivering high-quality, reliable, and sustainable power solutions. With production and shipment completed and construction in progress, we are on track to commission the plant and start power generation soon. This project not only strengthens Ghana's energy infrastructure but also showcases our expertise in EPC projects for gas engine combined cycle power plants.

We look forward to continuing our partnership with Ghana to support its energy transition and economic development goals through innovative power generation technologies.

1 55MW power generation facility

2 3D BIM Model CCGT Power Plant

3 power plant building steel structure erection

4 plant building workshop mezzinane floor deck sheet

5 power plant control room building

6 power plant prefabricated control room DCS substations

7 power plant UPS power room

8 Power plant main workshop under construction

9 Bergene Engine Generator Installation

10 Power plant overhead cranes under Roof

11 Power distribution control System Room Elevated Floor Installation

12 Exhausted Flue Gas Boiler Duct Installation

13 Power plant warehouse skid mounted equipment

14 Power plant cable tray bridge structure Erection

15 Power plant cable tray cable installation

16 Power plant LV MV cable tray Installation

17 Exhaust Flow Gas Chimney Stack Installation

18 60Hz 50HZ Frequency Convertor Cabinet Room

19 Bergene Engine Skidding Inside Workshop

20 Prefabricated Containerized Substations LV MV HV

21 Bergine Engine Piping Instrument Installation

22 Bergine Engine Mechanical Electrical Installation

23 Bergine Control System Erection

24 Engine Exhaust Gas Outlet Nozzles

25 Control room cable tray outlet

26 Plant 2nd floor wall cladding system installation

27 Pipe Rack Cable Tray Installation

28 Exhaust Flow Gas outlet Duct Connection

29 Heat recovery plant outside

30 Pipe supporting rack fuel Gas Supply Route

31 Mechanical Installation and Inspection

32 Tube Duct fitting installation

33 Natural Gas Fuel Supply Pipeline Construction

34 Duct Butterfly Valve Installation

35 Hot oil heat recovery pipeline system

Why ZHM Huawu Metal for Gas Engine Combined Cycle Power Plant?

Reliable and Customized Designs	Cutting Edge Designing Process	Free Online Price System	Easy Bolt-by-number Assembly
Over Two Decades of Experience	Value For Money	Unmatched in Quality and Craftmanship	Excellent Customer Service

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ZHM’s world-class team — together with our raw material suppliers and subcontractors — works to solve your most challenging design, engineering, farbrication or construction issues.

Contact ZHM by telephone at +86 135-8815-1981 (wechat and whatsapp) or send us your questions via email to info@zhmsteelworks.com