salaya dec 2011

Salaya Power Project Essar Energy Site Visit

7th December 2011

KVB Reddy Executive Director

Madan Gopal Gupta Head Power Business –Salaya

Salaya Power

• Total capacity 3120 MW ( 3 Phases )

• Phase I – 1200 MW

• Phase II – 1320 MW

• Phase III – 600 MW

• Site selected near:

• Existing refinery

• Sea coast

• On Highway

• Project site area - 330 Ha

• Sea water used as cooling water

• Essar’s own jetty for importing coal

• 17 km of coal conveyer for

transporting coal from jetty

• Power evacuation at 400 KV to state

utility

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7th December 2011

Phase I- 1200 MW

Plot Plan

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Technology

• BTG technology supplier – Harbin Power, China

• 2 X 600 MW power plant

• Pulverized boiler

• Sub critical technology

• Sea water cooling

• Evacuation at 400 KV

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Features

• BTG technology from proven vendor – Harbin Power, China

• BOP from reputed vendors

• E-BOP – Areva

• I-BOP – ABB

• CW system – Kirloskar Brothers

• Desalination plant – IDE

• AHS - McNalley Bharat

• DM plant – Thermax Ltd

• EPC – Essar Projects

• Engineering – Essar Engineering /TCE

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Engineering – Highlights

• Engineering (100 %) completed.

• Reputed consultant (TCE) is engaged for BTG

• BOP is engineered by Essar Engineering (EESL)

• 17 KM long conveyor designed in house by EESL

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Procurement – Highlights

• Overall procurement progress is 98.4 %

• All long delivery packages ordered to globally reputed companies & material

is received for all packages.

• Short delivery packages ordered under umbrella contract to cut short

procurement cycle

• All equipments for BTG received from HPE

• All BOP packages received at site

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Construction – Highlights

• Overall construction progress is – 93.7 %

• Concreting – 98% completed

• Structural fabrication – 100% completed

• Structural erection – 97% completed

• Equipment erection- 95% completed

• Overall EPC Progress – 96.1%

Unit-1 – Start of erection to Synchronization in record time of 29 months

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Status of Commissioning Activities

• Unit – 1 Synchronization completed

• 400 KV switchyard charged

• Plant UPS commissioned

• DM Plant commissioned

• CW system commissioned

• Plant air system commissioned

• Coal handling system commissioned

• Boiler -2 Hydro test completed

• Unit-2 ESP air leak test completed

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Status of Erection Activities

• Unit-2 Turbine box up in advance stage

• Unit-2 Condenser box up completed

• Unit-2 Boiler Insulation work in advance stage

• Unit-2 ID/FD/PA fan erection in advance stage

• Unit-2 Coal mill erection completed

• Unit-2 Motor driven Boiler Feed Pump erection completed

• Unit-2 Cooling tower erection in advance stage

• Chimney flue cans erection completed

• Tower crane erected and commissioned in a world record time

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Recognition by Fine Hope

Progress Photographs – Phase I

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Salaya Administration Building (SAB)

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Project Overview

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CHIMNEY

COAL CONVEYOR

BOILER # 2

TG #2

BOILER #1

TG #1

SWITCH YARD

Unit #1 Synchronisation

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UNIT #1 SYNCHRONISATION COMPLETED SUCCESSFULLY

Main Control Room

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400KV Switchyard 400 KV SWITCHYARD CHARGED

DM Plant Overview

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DM TANK #1

DM TANK #2

DM PLANT

DM PLANT COMMISSIONED & IN SERVICE

DM Plant

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COMMISSIONED & IN SERVICE

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UNIT-1 CW PUMPS COMMISSIONED & IN SERVICE

CW System

Cooling Tower # 1A

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Plant Air System AIR COMPRESSOR COMMISSIONED & IN SERVICE

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Fuel Oil System COMMISSIONED & IN SERVICE

Tripper Coal Conveyor

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TRIPPER COAL CONVEYOR COMMISSIONED

Coal Stock Yard

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Unit #1 Vacuum Pumps

TG #1 Overview

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Boiler #1- Overview

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ESP #1 - Overview

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Ash Handling System

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INTERMEDIATE FLY ASH SILO

PAINTING IN PROGRESS

COMPRESSOR HOUSE

BAG FILTER

CABLE TRAY & PIPE

ERECTION IN PROGRESS

Unit #2 – Front View

BOILER #2

TG #2

JNT #1

TRANFORMER YARD #2

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Boiler #2 Hydro Test

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HYDRO TEST COMPLETED SUCCESSFULLY

CHEMICAL CLEANING PREPAREDNESS IN PROGRESS

ESP # 2 Air Leak Test

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AIR LEAK TEST COMPLETED

TG #2 erection

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LP #1 & LP #2 TRAIL BOX-UP COMPLETED

HIP ROTOR

GENERATOR STATOR

LP #2 ROTOR

REHEAT STEAM PIPE

ERECTION IN PROGRESS

LP #1 ROTOR

Unit #2 Coal Mills

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ESP #2

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Unit #2 ID Fan

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Unit #2 PA/FD Fans

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Unit #2 Flue gas duct

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Unit #2 Cooling Tower

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Unit #2 Transformer yard

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7th December 2011

Expansion – Phase II and III

Salaya Phase II: 1320 MW

• 2 X 660 MW Super critical – PF Boilers

• Fuel - Imported Coal

• PPA signed for 800 MW with SEB

• Boiler- ordered to M/S Harbin Power, China

• T G - ordered to M/S Toshiba

• Land, water available. EPC contracts awarded

• Aviation clearance is available

44

Engineering, Procurement & Construction Progress*

● Engineering (E) Progress – 23.8%

● Procurement (P) Progress – 19.98%

● Construction (C) Progress – 4.3%

● Overall EPC Progress – 12.92%

* As on 31st Oct 2011 45

Salaya Phase III : 600 MW

• 4 X 150 MW Sub critical – CFBC Boilers

• Fuel - Pet coke/Imported Coal

• Entire capacity on Merchant Power

• Boiler- ordered to M/S Foster Wheeler, China

• TG - ordered to M/S Siemens

• Land, water available. EPC contracts awarded

• Aviation clearance is available

• TOR clearance received

46

Engineering, Procurement & Construction Progress*

● Engineering (E) Progress – 19.7 %

● Procurement (P) Progress – 17.3 %

● Construction (C) Progress – 0 %

● Overall EPC Progress – 9.36%

* As on 31st Oct 2011 47

salaya dec 2011

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