011112 vpcl

7/27/2019 011112 VPCL

1/30

Executive Director

Vadinar Power Company Ltd

Analyst Site Visit

October 31- November 1

KB Makadia

Executive Director - Power Business, VPCL

1

7/27/2019 011112 VPCL

2/30

INDEX

Introduction

Plot Plan

Plant Overview

Plant Operations

Project Journey

Initiatives

2Salaya TPP

7/27/2019 011112 VPCL

3/30

Introduction

Project Objective

To provide uninterrupted Steam, Power & Feed water to Refinery operation as well futurerequirement by way of Cogeneration power plant.

Installed capacity under operation

VPCL Base Plant- 120 MWe

3x175 = 525 TPH oil fired Boilers

2x38.5 = 77 MW Steam Turbines

Feed Water supply facility

VPCL Phase 1- 380 MWe

Combine Cycle Cogeneration Plant

2x110 = 220 MW Gas Turbines + HRSG with supplementary firing

VPCL Phase 2A- 510 MWe coal + FO fired cogeneration plant

Unit #1, Boiler 1- 1x750= 750 TPH

Unit #2, Boiler 1- 1x750= 750 TPH ( Being commissioned)

2x105= 210 MW Steam Turbine

3

7/27/2019 011112 VPCL

4/30

Base

Plant

(120MW)

Phase 1

GT &

HRSG 1

Phase 1

GT &

HRSG 2

Phase 2A

Boiler 1Phase 2A

Boiler 2

Coal

conveyor

Cooling

Towers

Admin

Building

Pipe Rackto

Refinery

Fuel oil

Tanks

Phase 2A

Station

Building

Plot Plan

4

7/27/2019 011112 VPCL

5/30

VPCL Plant Overview

Boiler-2

PFBoiler-1

77 MW

Boiler-2

120 MW

Boiler-3

120 MW

HRSG1HRSG2

VHP

HHP

HP

MP

LP

38.5MW-

238.5M

W-1

Boiler-1

PF

105

MW-2

105

MW-1

92.8MW

GT-1GT-2

LP

Coal

HFO/CSO

HFO

Fuel Gas

NG, HSDNaphtha

Base Plant

Phase 1

Phase 2

5

7/27/2019 011112 VPCL

6/30

VPCL Operations

6

7/27/2019 011112 VPCL

7/30

Power Generation

18

76

76

80

85

92

10

5

124

125

123 1

28

140

11

2 2 2 2 2 2 2 2

10

2 224 4 4 4 4

0

6 79

12 1

3

0

20

40

60

80

100

120

140

160

Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12

MW

POWER GENERATION

Power Generation Power Import From Grid Auxiliary Power Consumption@ Power Generation

Load requirement reduced due

to Refinery Annual Shut down

Load increased gradually as Different units of Refinery

Train-1 commissioned and under operation now.

Including Base plant, Phase-1 and Phase-2A.7

7/27/2019 011112 VPCL

8/30

Plant Availability

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

100.00


66.0

88.6

99.4 9

8.5

99.6

98.6

100.0

100.0

99.3

99.9

99.9

100.0

95.5 1

00.0

98.0

99.8

100.0

99.5

100.0

100.0

99.7

99.4 9

9.9 1

00.0

100.00

100.00

%

TURBINE AVAILABILITY

MHI STG GTG Siemens STG

Due to 33 KV AIS to GIS reshuffling job

Including Base plant, Phase-1 and Phase-2A.8

7/27/2019 011112 VPCL

9/30

Plant Availability

0.00

10.00

20.00

30.00

40.00

50.00

60.00

70.00

80.00

90.00

100.00


57.3

100.0 1

00.0

100.0

99.5

99.5

100.0

98.8

100.0

93.0

100.0

97.9

94.1 1

00.0

100.0

93.9

100.0

100.0

100.0

100.0

100.0

100.0

100.0 1

00.0

88.

82

64.

45

%

BOILER AVAILABILITY

OFB HRSG CFB

Due to Coal Fired Boiler S/D for SH

CFB S/D for inspection of Super heater, 102 Metallic

foreign pieces recovered which was left inside due to

manufacturing defect.

Graph showing availability for Base plant Boilers, Phase-1 HRSGs and Phase-2A CFB 9

7/27/2019 011112 VPCL

10/30

Plant Efficiency

0

10

20

30

40

50

60

70

80


64.7

63.2

60.3

62.9

60.9

62.8

66.1

68.6 6

9.5

74.8 6

6.9

63.8

%

PLANT COGENERATION EFFICIENCY

Cogeneration Efficiency

Including Base plant, Phase-1 and Phase-2A.

10

7/27/2019 011112 VPCL

11/30

VPCL Phase 2A

11

7/27/2019 011112 VPCL

12/30

Highlights Phase-IIA

Configuration

Project Capacity : 510MW Number of Steam Turbines : 3 (Three)

Capacity : 2 x105MW + 1x92.8MW

Capacity of Boilers : 750TPH

Number of Boilers : 2 (Two)

Type of Boilers : Pulverized Fuel and Oil Fired

Boiler technology : Sub-critical

Condenser Cooling : Sea Water

Boiler-1 Made operational with coal.

Boiler-2 light up completed on October 10,2012, steam blowing completed and restoration is in

progress and getting ready for Coal firing.

STG 1 & STG 2 synchronized and made operational.

STG-3 lube / control oil flushing activity completed and restoration is in progress.

12

7/27/2019 011112 VPCL

13/30

Particulars (As on September 2012) VPCL P2 (510MW)

Physical Progress (%) Overall 97.5%

Engineering (%) 95%

Procurement (%) 99.8%

Construction (%) 95.7%

Dates Synchronisation Unit 1 Synchronized

Commercial Operations Oct. 2012

Evacuation ProgressConnected to State Grid

via EOL switchyard

Statutory Approval Progress (Key approval pending) All approvals in place

*INR/US$ - 50

Highlights Phase-IIA

7/27/2019 011112 VPCL

14/30

Commercial Snapshot

14

Unit Customer Supply Tariff FuelPower Steam

Base Essar Oil 77 MW 230 tons/hr.Annual FC- INR

794 Mn Fuel and

water

supplied by

EOL

Phase 1 &

2A

Essar Oil 300 MW 1500 tons/hr.

Annual FC for

Phase 1- 1750 MnAnnual FC for

Phase 2- 3350 Mn

ESTL 90 MW -

Annual FC for

Phase 1 & 2- INR

800 Mn

Fuel and

water

supplied by

ESTL

7/27/2019 011112 VPCL

15/30

Unit -1 pre-commissioning and commissioning activities successfully

completed without any incident.

Boiler -1 under operation with 100% coal firing.

STG -1 & 2 synchronized and under operation.

Steam and Power supply to Refinery from Phase 2A started from

12thJuly 12 for Power and 16thJuly12 for Steam.

Power Export to ESTL started from Sept12.

Boiler 1 full load trial completed successfully at 750 TPH on coal.

Refinery Train 1 which include additional unit of down stream likeVacuum Gas Oil, Deep Hydro Deep Treating, Delayed Coker Unit

operating facility have been commissioned successfully. VPCL has

started to supply process feed water to the expansion Refinery.

Achievements- Phase 2A

15

7/27/2019 011112 VPCL

16/30

7/27/2019 011112 VPCL

17/30

Accomplishments

The plant uninterrupted operation from last 46 months and nodisturbance to Refinery operation.

LTI free man days 2183 days (till 25th Oct 2012).

All Maintenance activities completed with Refinery shut-down

schedule and with all safety consideration.

Zero Leakage since last five years.

Process Safety Management third party audit compliance 97%.

17

7/27/2019 011112 VPCL

18/30

Vadinar Power Company LimitedEssar Energy Site Visit

Project Photographs

7/27/2019 011112 VPCL

19/30

Phase-I & IIA: Overall View

7/27/2019 011112 VPCL

20/30

120MW Plant

7/27/2019 011112 VPCL

21/30

380 MW Plant

Pipe Rack to

Refinery

HRSG-2HRSG-1

7/27/2019 011112 VPCL

22/30

Phase IIA: Overall View

7/27/2019 011112 VPCL

23/30

Phase I & IIA Overall View

7/27/2019 011112 VPCL

24/30

Phase-IIA : Boiler-1 & Boiler-2

Station

Building

Boiler 1

Boiler 2

7/27/2019 011112 VPCL

25/30

Phase-I & IIA : overview

Station building Bunker Bays

GTG - 1 GTG - 2

7/27/2019 011112 VPCL

26/30

STG Floor STG 1

STG 2STG 3 Commissioning

activity under progress

Phase-IIA : STG Floor overview

7/27/2019 011112 VPCL

27/30

Phase-IIA : control room & Electrical room overview

7/27/2019 011112 VPCL

28/30

Phase-IIA : Boilers & Mills overview

Boiler 1

Boiler 2

Boiler 1 & 2

Mills

7/27/2019 011112 VPCL

29/30

Phase-IIA : Coal Conveyor & Cooling tower overview

7/27/2019 011112 VPCL

30/30

Phase-IIA : Cooling Tower

011112 vpcl

Documents