Greenspan Power successfully completed the turnkey installation and commissioning of a combustion turbine-based power generation facility for a leading global energy client.
The project involved full EPC (Engineering, Procurement, and Construction) responsibility — covering mechanical, electrical, and civil works, as well as testing, commissioning, and operational handover.

The 60+ MW facility was designed to operate as part of a combined-cycle configuration, integrating both gas and steam turbine systems to achieve maximum energy efficiency.
Our engineering scope extended across core turbine installation, generator coupling, auxiliary system integration, and balance of plant (BoP) systems — all delivered under demanding performance and timeline requirements.

⚙️ Project Background

The client sought to replace an aging turbine system with a modern, high-efficiency combustion turbine capable of stable, low-emission operation in variable load conditions.
Greenspan Power was selected as the EPC partner due to our proven experience in turnkey turbine installation and global project management under high safety standards.

The project site, located in a remote desert region, presented logistical challenges related to extreme weather, long-distance material transport, and limited grid access.
Our team implemented a phased construction plan and on-site modular assembly strategy to ensure work continuity and efficiency under such constraints.

🏗️ Engineering & Construction Scope

The scope of work spanned all major phases of power plant setup — from detailed engineering to commissioning.

Engineering Phase

• Detailed design and simulation of gas turbine foundation and structural supports.
• Piping and instrumentation diagram (P&ID) development for fuel and lube oil systems.
• Electrical system design, including 132kV grid interface and protection coordination.
• Development of control logic for plant automation and interlocking systems.

Procurement & Fabrication

• Global sourcing of turbine components, auxiliary skids, heat recovery steam generator (HRSG), and generator units.
• Factory acceptance testing (FAT) of control and switchgear panels before shipment.
• Third-party inspection of structural and mechanical components.

Construction & Installation

• Civil works including foundation, turbine pedestal, and electrical substation.
• Erection and alignment of the combustion turbine, inlet air filters, exhaust stack, and cooling systems.
• Integration of BoP equipment: fuel treatment, water injection, and lubrication systems.
• Generator alignment and coupling with vibration and resonance analysis.

Testing & Commissioning

• Cold and hot commissioning cycles with safety interlocks testing.
• Full-system load trials and thermal performance validation.
• Synchronization with the national grid and operational tuning.
• Operator training, documentation, and project handover.

🧠 Challenges & Technical Solutions

1. Site Logistics:
   Remote location limited equipment mobility. Greenspan Power used modular pre-fabricated turbine skid assemblies transported via heavy-lift vehicles to reduce on-site construction time.
2. Extreme Climate:
   High ambient temperatures required custom thermal insulation and specialized inlet air cooling systems to maintain turbine performance above 98% rated output.
3. Vibration Control:
   Vibration studies were conducted using ANSYS models and laser sensors to ensure compliance with ISO 7919-3 limits for rotating machinery.
4. Grid Synchronization:
   Integration with regional grid required advanced control tuning. Our automation engineers configured load sharing and ramp-up logic in the DCS for stable transition during peak operation.

🌍 Safety & Compliance

Greenspan Power’s Safety Management Team implemented a zero-incident policy under ISO 45001 and OHSAS 18001 standards.
More than 110,000 man-hours were completed without any lost-time injuries (LTI).
Regular third-party audits ensured full compliance with ASME, IEC, and API standards throughout construction and commissioning.

⚡ Results & Achievements

• Installed 60+ MW combustion turbine operating at 99.3% availability.
• Achieved 15% improvement in fuel efficiency versus previous generation systems.
• Reduced emission output by 18%, aligning with environmental compliance targets.
• Delivered full EPC project 15 days ahead of schedule.
• Maintained continuous operation for 8,000+ hours post-handover without downtime.

🧾 Project Summary

🚀 Outcome

This project stands as a key demonstration of Greenspan Power’s global EPC expertise in combustion turbine installation and power plant commissioning.
The plant continues to operate at exceptional efficiency, serving as a benchmark for future high-performance energy projects worldwide.
Our proven process — from concept to commissioning — reinforces Greenspan Power’s position as a trusted partner in advanced turbine engineering.