The Zest WEG Group, through subsidiary company Zest Energy, has successfully completed a benchmark steam turbo generator set contract at Mondi Richards Bay that showcases the Group’s value addition, innovation and customer focus. The original contract was awarded in May 2012 and partially handed over in December 2013, with final hand over in March 2014. This contract has been followed by a five-year long term service agreement (LTSA), where Zest Energy will be responsible for the overall maintenance of the steam turbo generator set. “The LTSA has also been linked to availability guarantees on this turbine,” explains Zest Energy managing director Coenraad Vrey.
The scope of work included the design, manufacture and delivery as well as installation and commissioning of the steam turbo generator set and associated equipment. Original equipment manufacturer supervision services were also provided during installation and commissioning, with 24/7 on call support for a period of four weeks following handover. The flagship project achieved a number of records: the largest ever steam turbine manufactured by technology provider TGM Turbinas. “Not only was this the first project to utilise a combination of a TGM turbine with a WEG EM alternator, it was also a first reference for both equipment manufacturers in South Africa,” says Vrey.
“Throughout the execution of this project, the Zest WEG Group has proved its ability to be involved in large scale projects, not only from a standalone product supply perspective, but also from an integrated solutions point of view. This is an important achievement that will drive sustainable growth within the Group,” adds Zest Energy general manager Alastair Gerrard.
Zest Energy supplied the turbo generator set equipment and took the overall lead on the package, which included steam technology from TGM Turbinas of Brazil and generator technology from WEG Electric Machinery of the United States. Local subcontractor TGS (Turbine Generator Services) undertook the mechanical installation portion of the scope. Bosch Projects was appointed by Mondi as the official Engineering, Procurement and Construction Management (EPCM) contractor on the project.
Mondi already had a 38 MW extraction back pressure steam turbine and a 34,3 MW extraction condensing steam turbine and required a new 48 MW multi-extraction condensing steam turbine to take up the additional high pressure steam from the plant at full load. The power generated is used on site with the excess exported to the national grid.
“To install a complex new system into an existing plant that is equally complex to begin with is not an easy task. With Zest Energy’s experience in electrical infrastructure, substations and power generation, especially on both standby and continuous power plants, meant we could draw on all this experience and apply it to the Mondi Richards Bay project, with all the electrical integration scope carried out in house,” concludes Gerard.
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