As the general contractor Ferrostaal succeeded in modernising the Wuppertal-Barmen CHP plant. This assignment extended to the planning, construction, delivery, construction, and commissioning of a combined cycle power plant (GSTP) that had to be integrated in existing structures. Designed on the CHP principle the new 90 MW unit combines efficient power generation with considerably reduced pollution to the environment: CO2 emissions were cut by 200,000 tonnes a year, nitrogen emissions by 50%. The CCPP started operations as scheduled in December 2005, providing the Wuppertaler Stadtwerke AG service area with about 320 GWh of electricity and about 300 GWh of district heating a year.

Logistics power
Nested between the River Wupper and the ICE Cologne-Hanover line the Wuppertal-Barmen CHP plant is located in a densely populated residential area. Extremely cramped conditions are also encountered on the power plant premises, where the new plant had to be installed in the available buildings, some gutted, and on sections of the existing plant - and all this during plant operations. The associated high demands for noise insulation and material logistics were fulfilled without restriction.

Maximum time efficiency
From the day the agreement was signed we had only twenty two months to realise this complex project. The official acceptance for phase 1, when the existing steam turbine was integrated in the new electrical and I&C installations, took place after just twelve months, and the entire construction work was completed in only seventeen months. As a consequence we had adequate time to spare for the last, and particularly complex phase of commissioning gas turbines and components, function tests, and optimisation. Thanks to the smooth course of the work we could complete the project before the deadline at the end of 2005.

Delivery and services

• Two 28 MW gas turbines from Hitachi, Japan, incl. generators'
• Two waste heat boilers from Innovative Steam Technology (IST), Canada
• Development of the architectural concept
• Elaboration of the whole thermal design
• Detail engineering
• Selection of all plant components
• Execution of all civil works above- and underground
• Civil work for the new boiler house annex, foundation slabs for waste heat boilers and gas turbines
• Coordination and site management
• Complete electrical, I&C, and safety installations incl. configuration
• Piping for the water/steam cycle incl. pumps and heat exchangers
• Installation of all auxillary systems: cooling water supply, air intake, fire protection facilities, heating/air conditioning/ventilation, etc.
• Installation of all components
• Commissioning incl. trial run
• Documentation and training