Unique energy storage upgrade for APS Arizona, USA

Modernisation and Streamlining of Gas Power Plants

Why We Committed to the Project

Modernising conventional power plants and integrating advanced energy storage solutions are key steps on the path towards a more stable and sustainable energy mix. Arizona Public Service Company (APS) is the largest and longest-operating electricity provider in the state, supplying power to over 1.3 million customers.

To enhance grid stability and support the integration of renewable energy sources, APS is upgrading its power plants with a unique energy storage solution that combines the flexibility of conventional generation with the advantages of battery storage.

How We Contributed to the Project

As part of this project, 2JCP delivered a comprehensive solution that included the complete engineering of an upgraded air intake system with cooling units, a tailor-made process vessel for the cooling circuit, and all associated pressure piping. The entire system was manufactured at our main plant in Račice, shipped across the Atlantic Ocean, and installed as a full retrofit of the existing filtration and cooling systems at both the Redhawk and Sundance power plants in Arizona.

“This project confirms that our specialised technology and expertise have a place in demanding projects overseas. Supplying key equipment for one of the largest energy companies in the southwestern United States is a great achievement for our team — and a strong motivation for future growth,” said Vojtěch Křenovský, our Group CEO.

Although the project involved only two power plants, the scope covered air intake modifications for a total of 14 turbines — ten modular coolers for the Sundance power station, which is powered by ten LM6000 gas turbines rated at 45 MW each, and four substantially larger modular cooler assemblies for the Redhawk plant, which operates four 7F.04 gas turbines, each producing 309 MW in a combined cycle configuration.

“The APS project was one of the largest undertakings in 2JCP’s history. However, the scope of engineering and manufacturing itself was nothing new to us. The real challenge lay in meeting the extremely tight installation deadlines for all modules on site. The equipment had to be delivered precisely on the agreed dates — despite being shipped halfway around the world — and several installation teams had to be deployed simultaneously. At one point, we had nearly 60 people on site in Arizona,” said Daniel Newton, Group Chief Sales Officer, who supervised the project throughout its entire lifecycle.

Given the capacity constraints of the entire Arizona power grid, we were under significant pressure from the end customer, APS, to minimise downtime and complete our installation work as quickly as possible — particularly at the larger Redhawk power plant.

Instead of the originally planned four-month outage for the four 7F.04 turbine units at Redhawk, the client required all assembly work to be completed within a shortened schedule of just 70 working days. To meet this demand, we had to plan for an unusually large on-site workforce, coordinating up to 60 installers, welders, and mechanical and electrical engineers working in continuous shifts (24/7) during peak periods.

Our pros at work: unloading and installing cooling systems in Arizona

MORE ABOUT THE PROJECT

Arizona Public Service (APS) is a major energy provider based in the state of Arizona, USA, committed to exploring innovative ways to improve power generation efficiency. One such initiative involved the implementation of Stellar Energy – 2JCP TIAC technology at the Redhawk and Sundance power plants.

The Redhawk facility is a 1,060 MW gas-fired power plant located in Arizona. Developed in multiple phases, it began operations in July 2002. Powered by four GE 7F gas turbines, Redhawk serves as a baseload power source for the region.

Sundance is a 450 MW gas-fired power plant, also located in Arizona. Commissioned in May 2002, the plant operates with ten GE LM6000 gas turbines and is primarily used for peaking capacity during times of high demand.

This project demonstrates how advanced technologies can be utilized to enhance the efficiency of electricity generation. APS continues to seek opportunities to reduce greenhouse gas emissions and transition to more sustainable energy sources. The successful implementation of this system serves as an example for other energy providers aiming to optimize performance and sustainability.

MORE CASE STUDIES

With a strong legacy in energy products, we are constantly moving towards cleaner energy solutions.

Turnkey delivery of a renewable gasification plant
Sofidel, Kisa plant, Sweden

Packaging of industrial electrolyzers for production of e-methanol
Power-to-X plant, Kassø, Denmark

Delivery of special-purpose storage and process tanks for an offshore HVDC station
Sunrise Wind offshore farm, New York, USA

OUR APPROACH

We have grown through a combination of engineering know-how, courage, common sense and the proven skills of our workers. We are the bridge between thinking and making, between an idea and a multi-ton product, between our generation and the next.

Engineering and innovations

Many of our works delivered around the world were the first of their kind, whether they were components of drilling systems or green methanol production solutions. We have always tended to be co-creators of engineering solutions, never giving up on any technological challenge.

Whatever can be invented can be manufactured.

Manufacturing and delivery

Our roots are in the welding shop where it all began thirty years ago. We know well enough about steel to make it work perfectly for the energy projects of the future.

We also know that even a well-made component is useless until it's delivered, up and running. That's why we handle the entire product lifecycle - from design to go-live.