Salaya Power Project

Essar Power Gujarat Limited

Salaya Power
• • Total capacity planned 3120 MW (3 Phases) Site selected near to – Existing refinery – Sea coast – On Highway Project site area - 330 H Sea water used as condenser 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

• • • • •

Salaya Thermal Power Station

Phase 1(EPGL) : 2 X 600 MW – Sub critical – PF boilers

Phase 2 (EPGL) : 2 X 660 MW – Super Critical – PF boilers

EPSL (600 MW) : 4 X 150 MW – Sub Critical – CFBC boilers

Phase-1

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Phase-1 overview
Particulars Project Description Fuel linkages 1200 MW (2 X 600MW) Imported coal based power plant  Imported coal .  Agreement signed with Essar Shipping & Logistics. Fuel Off-take Coal  1000MW to GUVNL  Balance: Merchant (through PTC) Environment EPC Water Aviation Land Obtained Awarded: jobs are in progress Obtained Obtained Full Possession of Land Received

Commercial Opn. Date
Financial Closure

Unit 1 – Q1, CY2011, Unit 2 – Q2, CY2011
Achieved

Technology
• • • • • • BTG technology supplier – Harbin Power, China 2 X 600 MW power plants Pulverized boiler Sub critical technology Sea water cooling Evacuation at 400 KV

Features
• • – – – – – – • • • BTG technology supplier – Harbin Power, China BOP from reputed vendors E-BOP – Areva I-BOP – ABB CW system – Kirlosker Brothers Desalination plant – IDE AHS - McNalley Bharat DM plant – Thermax Ltd EPC – Essar Projects Engineering – Essar Engineering / TCE Expansions in active stage

Engineering Progress

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Highlights - Engineering
• • • • • • • • Concreting – 97% released Structural – 99% released Piping –99% released Overall engineering completed – 92.5 % Concept notes & Technical specifications for all packages have been released. All civil foundations are released. All major structural engineering released All major fabrication details released
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Procurement Progress

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Highlights – Procurement
• • All Major long delivery packages ordered to globally reputed companies &

manufacturing in advance stage.
Short delivery packages are being ordered under umbrella contract to cut short procurement cycle.


Material received from HPE, China : 76%
100% material receipt at site is expected by Oct – 10

Highlights – Procurement (Contd…)
• All major unit-1 equipments received from HPE


• • • • • • •

Unit-2 boiler drum dispatched from China
E-BOP – 90 % Material recd Desalination plant received. DM plant 80% received Air Compressor received Fuel oil system material :85% received. Ash Handling System material received Sea water pipes received

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Construction Progress

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Major Milestones of the Project during 2010
• Boiler -1 Drum erected and other Pressure parts erection is in verge of completion. • • • Switch yard erection completed. TG foundations completed for both the units. Unit1 Generator stator erection completed and turbine erection is in

progress

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Milestones achieved during 2010

Tower crane erected and commissioned in a world record time

Cooling water piping erection completed without any hurdle to other erection
activities

• •

Switchyard control room ready Boiler 2 ceiling girder erection in verge of completion

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Highlights – Construction
• • • • • Concreting – 81% completed Structural fabrication – 86% completed Structural erection – 60% completed Equipment erection- 25% completed Sea water Piping- 32% completed

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Upcoming Milestones

Switchyard ready for back charge Sept’10


• •

Boiler – 2 Drum lifting – Sept 10
Boiler # 1 Hydro Nov’10 Boiler #1 Light up Jan’11

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HSE
• Occupational Health Centre is operational at site. • Ambulance is available at site round the clock. • Team of 7 safety officers and 12 safety supervisors are closely monitoring the safe execution of construction work. • Each contractor has area wise safety officer / supervisor . • Regular safety audit of construction equipments • Strict usage of PPEs at site • Induction training for safety to all new entrants is mandatory. • Senior level officer is in the team for dealing environment issues.

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HSE Statistics
Description Total Man hours worked without LTI No of LTI LTI Frequency Rate Near Miss cases and corrective action taken No of fatality cases No of Persons attended HSE orientation / Induction Current month Aug 2010 1.05 (MMH) 0 0 4 0 1418 Calendar year 4.17 (MMH) 8 1.34 28 0 11550

On line safety training – L1 (Once per year)
Certified HSE training – L2 HSE job rotation – L3

0
0 5

Completed for all employee
12 10

Expansion Projects Phase-2 & Phase -3

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EPGL Phase – 2 : 1320 MW
• 2 X 660 MW Super critical – PF Boilers • Main Plant Equipments are in advanced stage of ordering • Land, water available. EPC contracts awarded • PPA signed for 800 MW with SEB

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EPSL : 600 MW
• 4 X 150 MW Sub critical – CFBC Boilers • Pet coke • Main Plant Equipments are in advanced stage of ordering • Land, water available. EPC contracts awarded • Entire capacity on Merchant Power

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Plot plan – Phase – 1/2/3

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Progress Photographs Phase-1

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Salaya Administration Building (SAB)

BTG BLOCK
CHIMNEY

BOILER #1 TG #2

BOILER #2

SWITCH YARD

TG #1

BOILER #1- SIDEVIEW

SECOND PASS PRESSURE PARTS ERECTION IN PROGRESS

BOILER #1- BOILER CIRCULATION DISCHARGE CHECK VALVE ERECTION
BOILER CIRCULATION DISCHARGE CHECK VALE TEMPORARY KEPT AT 17M EL

BOILER #1- COLD PRIMARY AIR DUCT ERECTION

COLD PRIMARY AIR DUCT ERECTION IN PROGRESS

BOILER #1- PRESSURE PARTS ERECTION (SECOND PASS)

PROTECTION SHEILD OVER COILS ERECTION IN PROGRESS

HORIZONTAL LTSH COIL ERECTION IN PROGRESS

ECONOMIZER HANGER TUBE ERECTION IN PROGRESS

BOILER #1- PRESSURE PARTS ERECTION

RISER TUBE ERECTION & WELDING WITH DRUM & INLET ROOF HEADER IN PROGRESS

ECONOMIZER FEED PIPELINE ERECTION STARTED

BOILER # 2 STRUCTURE ERECTION
CEILING GIRDER #C,#A & #B

5th B –LAYER

5th A –LAYER

4th B -LAYER

4th A -LAYER

3rd B-LAYER

3rd A-LAYER 2ND LAYER 1ST LAYER

BOILER #2- APH
APH MODULE ERECTION COMPLETED

APH #2

APH #1

MAIN CONTROL BUILDING ERECTION

FLOOR BEAM ALIGNMENT IN PROGRESS

TG # 1 BUILDING ERECTION

SIDE SHEETING PLATE ERECTION IN PROGRESS

TG #1 DECK OVERVIEW
BEARING HOUSING #1 BLUE MATCHING IN PROGRESS BEARING HOUSING #2 BLUE MATCHING IN PROGRESS

BEARING HOUSING #3 PLACED IN POSITION

LP #2 BOTTOM CASING PLACED IN POSITION

TG # 1 – CONDENSER ERECTION
HP SIDE CONDENSER TUBE SHEET ALIGNMENT & ERECTION IN PROGRESS

LP SIDE CONDENSER TUBE SHEET CLEANING IN PROGRESS

TG #1 – LP HEATER # 5 & # 6 ALIGNMENT COMPLETED
TG #1 LP HEATER - 5 TG #1 LP HEATER - 6

TG # 1 – MAIN OILTANK (MOT) ERECTED

MAIL OIL TANK ON POSITION

TG #1 MAIN STEAM PIPE FIT UP
MAIN STEAM PIPE FIT UP IN PROGRESS AT EL 6.9 M

TG #1- COAL MILL FOUNDATION CIVIL WORK IN PROGRESS
SHUTTERING FOR COAL MILL FOUNDATION IN PROGRESS

TG # 2 STRUCTURE ERECTION

AXIS-A12
AXIS-A13 AXIS-A11

AXIS-A15 AXIS-B17 AXIS-B21 AXIS-B18 AXIS-A14

CST #1

CST #2

UNIT # 1 BUNKER ERECTION

UNIT # 1 BUNKER TOP

ESP # 1 ERECTION (SECTION-A, 1376/3526 COLLECTING PLATES ERECTED)
INSULATOR ERECTION ON INNER FRAME IN PROGRESS

COLLECTING PLATE ERECTION IN PROGRESS

ESP # 1 ERECTION (SECTION-B, OVERVIEW)

GD SCREEN ERECTION IN PROGRESS

ESP #2 FRAME ERECTION
SIDE CASING PLATE ERECTION IN PROGRESS
HOPPER ERECTION IN PROGRESS AT ESP #2 (SECTION B)

INTERMEDIATE FRAME ERECTION IN PROGRESS

ESP CONTROL BUILDING

FLOOR BEAM ERECTION IN PROGRESS

CHIMNEY FLUE CAN ERECTION

2ND SEGMENT OF CHIMNEY FLUE CAN ASSEMBLY IN PROGRESS

COAL MILL FOUNDATION

ASH HANDLING SYSTEM –INTERMIDIATE FLY ASH SILO
COMPRESSURE HOUSE CIVIL FOUNDATION

FOUNDATION FOR INTERMIDIATE FLY ASH SILO

CW PUMP HOUSE SUPER STRUCTURE ERECTION (PHOTOGRAPH TAKEN DURING RAIN)
MAINTENANCE BAY SUPER STRUCTURE ERECTION IN PROGRESS

FO MCC ROOM STRUCTURE ERECTION IN PROGRESS

FOUNDATION FOR PIPE RACK IN PROGRESS

COOLING TOWER # 1A- MECHANICAL ERECTION
SIDE SITTING PLATE ERECTION IN PROGRESS

COOLING TOWER # 1B- MECHANICAL ERECTION

FRP STRUCTURE ERECTION IN PROGRESS

COMMON INTAKE CHANNEL FOR COOLING TOWER

COOLING TOWER # 2A

COOLING TOWER # 2B

TRANSFORMER YARD FOR UNIT #1
GT- 1 GT- 3 GT- 2

FIRE WALL CIVIL WORK IN PROGRESS

UT- 1A

UT- 1B

SWITCH YARD – OVERVIEW

SWITCH YARD CONTROL ROOM

MAIN FLY ASH SILO
FOUNDATION CONCRETING IN PROGRESS

AHS INTERMEDIATE FLY ASH SILO & COMPRESSOR HOUSE FOUNDATION

MISC. PUMP HOUSE STRUCTURE ERECTION
MISC. PUMP HOUSE STRUCTURE ERECTION IN PROGRESS

DM PLANT ERECTION
DM PLANT STRUCTURE ERECTION IN PROGRESS SAC -2 (STRONG ACID CATION ) ERECTION COMPLETED ACF- 2 (ACTIVATED CARBON FILTER) ERECTION COMPLETED

WAC -1 & 2 (WEAK ACID CATION ) ERECTION COMPLETED

WBA-1 & 2 (WEAK BASE ANION EXCHANGER) ERECTION COMPLETED

SBA-1 & 2 (STRONG BASE ANION EXCHANGER) ERECTION COMPLETED

MB- 1 & 2 (MIX BED) ERECTION COMPLETED

COAL CONVEYOR STRUCTURE ERECTION AT CC – 8A/8A1

COAL CONVEYOR GALLERY ERECTION IN PROGRESS

O & M BUILDING

OHC BUILDING

BACHELOR’S COLONY

Thank You

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