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Executive Director
Vadinar Power Company Ltd
Analyst Site Visit
October 31- November 1
KB Makadia
Executive Director - Power Business, VPCL
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INDEX
Introduction
Plot Plan
Plant Overview
Plant Operations
Project Journey
Initiatives
2Salaya TPP
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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
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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
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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
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VPCL Operations
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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
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Plant Availability
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12
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
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Plant Availability
0.00
10.00
20.00
30.00
40.00
50.00
60.00
70.00
80.00
90.00
100.00
Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12
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
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Plant Efficiency
0
10
20
30
40
50
60
70
80
Oct-11 Nov-11 Dec-11 Jan-12 Feb-12 Mar-12 Apr-12 May-12 Jun-12 Jul-12 Aug-12 Sep-12
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.
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VPCL Phase 2A
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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.
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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
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Commercial Snapshot
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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
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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
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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%.
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Vadinar Power Company LimitedEssar Energy Site Visit
Project Photographs
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Phase-I & IIA: Overall View
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120MW Plant
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380 MW Plant
Pipe Rack to
Refinery
HRSG-2HRSG-1
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Phase IIA: Overall View
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Phase I & IIA Overall View
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Phase-IIA : Boiler-1 & Boiler-2
Station
Building
Boiler 1
Boiler 2
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Phase-I & IIA : overview
Station building Bunker Bays
GTG - 1 GTG - 2
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STG Floor STG 1
STG 2STG 3 Commissioning
activity under progress
Phase-IIA : STG Floor overview
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Phase-IIA : control room & Electrical room overview
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Phase-IIA : Boilers & Mills overview
Boiler 1
Boiler 2
Boiler 1 & 2
Mills
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Phase-IIA : Coal Conveyor & Cooling tower overview
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Phase-IIA : Cooling Tower