The experienced team at Doosan Škoda Power is currently completing the civil works phase of a project to modernize two turbine sets for the heat and power plant in Plock. This order, unique in its scope and the technologies employed, involves several phases, with its comprehensive completion planned for 2029.
Doosan Škoda Power continues its long-standing presence in the Polish market. After successful completion of Orlen Plock TG7 project, with an output of 70 MW in 2017. The current order, concerning the modernization of units TG4 and TG5 at the ORLEN Group's heat and power plant in Plock, Poland, represents a key project valued at approximately 125 million EUR.
Doosan Škoda Power is responsible not only for the supply of two 55MW back-pressure turbines and a two-pole generator but also for the complete project execution. "This investment is being realized as an EPC contract, which means a turnkey delivery of technology – from the design of the turboset through manufacturing, installation and commissioning. The newly supplied turbosets and associated technology will have 9% higher efficiency compared to the original technology, which will significantly contribute to more efficient electricity and heat generation and reduced operating costs as well as environmental step foot," says Tomáš Winkler, Head of Project Management Department at Doosan Škoda Power.
Innovation and Challenges: The Uniqueness of the Plock Project
The Orlen Plock TG4 and TG5 project is considered absolutely unique for many reasons. Unlike standard deliveries, it includes an extended scope of services and technologies. A key challenge is the reconstruction's execution while the other six existing machines, boilers, and technological equipment remain in full operation, requiring extraordinary coordination. Moreover, this is not only a replacement of existing technology. "The newly supplied units are significantly more complex in terms of layout and redundancy and must be integrated into available existing layout. To ensure maximum precision and minimize risks, we utilized state-of-the-art 3D scanning technology, which formed the basis for detailed design preparation," explained Tomáš Winkler.
The scope of delivery in this case also includes the complete execution of the civil works, including specific foundation construction using micropiles. The Doosan Škoda Power team has been on the construction site in Plock for eight months and can boast significant progress. Almost the entire civil works phase of the project is complete, which is a crucial milestone for subsequent phases.
At the heart of the delivery is a single-casing extraction back-pressure steam turbine of the DST-S10 series with power output of 55 MW, and a two-pole generator. The first deliveries of turboset components took place this spring, and the turboset assembly has been ongoing for several months. In addition to the standard scope of delivery, Doosan Škoda Power will also supply several types of transformers and complete set of bus ducts. A significantly challenging part will be the installation of two underground 30kV high-voltage cable interconnections between the existing and newly built switchgear.
Long-term Cooperation for a Sustainable Solution
The Doosan Škoda Power team still faces several challenging months as work gradually intensifies. The assembly of unit TG4 is expected to be fully completed by the end of this year, with its handover for operation in October 2026. To maintain continuous and safe operation, the realization will be divided into two stages. After a six-month break, during which the owner will shut down and dismantle the unit TG5, work will continue. The team will then start the works on second unit TG5, with its handover for operation expected in mid-2029. Furthermore, the contract also includes a long-term service agreement set for 10 years for each of the modernized turboset.