Essar Power Hazira

Essar Energy Site Visit

8th Dec 2011

T.S. Bhatt

Head Essar Power Hazira

Operating Plants - Overview

Capacity: 515 MW

Fuel: Natural gas/Naphtha

Offtake: Gujarat Electricity Board, Essar

Steel

COD: Oct 1997

Location: Gujarat, India

Hazira I Bhander

Capacity: 500 MW

Fuel: Natural gas

Offtake: Essar Group companies

COD: Jan 2006 Oct 2008

Location: Gujarat, India

Algoma

Capacity: 85 MW

Fuel: Blast furnace gas / Coke oven gas

Offtake: Ontario Power Authority

COD: Jun 2009

Location: Ontario, Canada

Vadinar

Capacity: 120 MW

Fuel: Refinery residue

Offtake: Essar Oil

COD: May 2008

Location: Gujarat, India

Vadinar P1

Capacity: 380 MW

Fuel: Natural Gas

Offtake: Essar Oil

Sync: Unit I Oct 2010

Unit II Jan 2011

Location: Gujarat, India

Our Plants at Hazira, Commissioning Dates

Capacity: 515 MW Fuel: Natural gas/Naphtha Off take: Gujarat Electricity Board, Essar Steel COD: Oct 1997 Location: Gujarat, India

Capacity: 500 MW Fuel: Natural gas Off take: Essar Group companies COD: Jan 2006 Oct 2008 Location: Gujarat, India

Salient Features

Plant Configuration

EPOL- 515 MW

3 Gas Turbines Generators-3 X 110 MW

1 Steam Turbine Generator-1 X 185 MW

BPOL - 500 MW

3 Gas Turbines 1x100+2x110 MW = 320 MW

Steam Turbine - I 55 MW = 55 MW

Steam Turbine- II 125 MW = 125 MW

Fuel

NGL/ Naphtha / HSD / Natural Gas

COMBINED CYCLE PROCESS

Air

Gas

Turbine Compressor

Fuel

Combustion

System

Exhaust

Alternator

Boiler

Steam

Turbine Alternator

Condenser

Cooling Water

Boiler Feed

Pump

Condensate

Extraction Pump

Deareator To other

Boilers

From Other

Boilers

COMBINED CYCLE PROCESS (BPL)

270 MW Power Project ( Hazira 2 )

Essar Power Hazira Ltd

CONFIGURATION :

Steam Turbines : 2 X 135 MW

Boilers : 2 X 487 TPH (Multi-Fuel Fired )

Steam parameters :141bar(a) , 540degC

Reheater Parameters: 35.1bar(a), 540degC

FUEL :

Various combinations of following fuels can be fired :

Corex Coal, Corex Coal Fines, Corex Coal Dust, Corex Gas,

Coke Oven Gas & Thermal Coal

HIGHLIGHTS :

Generator (Unit 1) Inspection done on 12-Jul-2011

Steam Turbine testing HP turbine on 30- Nov-2011

LP turbine by End of Dec-2011

Boiler Drum (Unit 1) expected at site by Dec 2011

MULTI-FUEL FIRED POWER PLANT ( HAZIRA 2 )

270 MW PLOT PLAN ( HAZIRA 2 )

MAIN EQUIPMENT SUPPLIERS 270 MW

PACKAGE VENDOR

STG & Auxiliaries SIEMENS

Boiler & Auxiliaries BWE

IDCT SPIG

CW Pump Jyoti

Safety Relief Valves Tyco Sanmar

EBOP ABB

Generator Transfomers ABB

Gas Insulated Switchyard ABB

Emergency DG Set GMMCO

Plant DCS Honeywell

Fuel Oil Handling System Thermosystems

Ash Handling System Mcawber Beekay

ENGINEERING PROGRESS - 85%

DESCRIPTION PROGRESS

BASIC ENGINEERING 100%

TECHNICAL SPECIFICATION 95%

ENGINEERING EESL 70%

ENGINEERING VENDORS 90%

S.N. DESCRIPTION UNIT TOTAL SCOPE COMPLETED % COMPLETION

1 Piling Nos 4400 3270 77

2 Concreting Cum 45140 9438 21

3 Structural Fabrication MT 8262 3813 46

4 Structural Erection MT 12035 804 6.5

5 Equipment Erection MT 16244

6 Piping IM 190952

7 Cable Laying RM 315000

OVERALL CONSTRUCTION PROGRESS

2 x487 TPH Multifuel Fired Boilers from M/s BWE

Elevation Plan for Boiler

2 nos STEAM TURBINES 2X135MW FROM SIEMENS

PROJECT SITE RIGS MOBILIZATION FOR PILING

CHIMNEY

AREA

BOILER-1 BOILER-2

TG

BUILDING

ESP- 2 AREA

ESP- 1 AREA

BOILER -1 & TG BUILDING ERECTION UNDER PROGRESS

BOILER-1 STRUCTURE

TG BUILDING STRUCTURE

TG-1

DECK TG-2

DECK

CHIMNEY

STG DECK 1& 2 UNDER CONSTRUCTION

STG DECK 1 STG DECK 2

CURRENT

STATUS

CURRENT

STATUS

TG DECK & BUILDING VARIOUS STAGES OF CONSTRUCTION

TG BLDG FOUNDATIONS PILING EXCAVATION TG DECK REINFORCEMENT

TG DECK CONCRETING TG DECK RAFT COMPLETED TG DECK COLUMNS

BOILER FOUNDATIONS AND ERECTION UNDER PROGRESS

BOILER -1FOUNDATIONS

BOILER -2FOUNDATIONS

COAL MILL AND PA

FOUNDATIONS COMPLETED

ESP-1 FOUNDATIONS UNDER PROGRESS

CURRENT

STATUS

ESP-1 FOUNDATIONS AND

RAFT UNDER PROGRESS

PILING EXCAVATION

ESP-2 FOUNDATIONS UNDER PROGRESS

CURRENT

STATUS

ESP-2 FOUNDATIONS AND

RAFT UNDER PROGRESS

PILING EXCAVATION

CHIMNEY RAFT CASTING AND REINFORCEMENT

CURRENT

STATUS

ONE QUADRANT OF

CHIMNEY RAFT CASTING

COMPLETED

REINFORCEMENT FOR

REST OF RAFT UNDER

PROGRESS

PILING EXCAVATION & PCC

REINFORCEMENT

COOLING TOWER - PCC & BASIN CONCRETING UNDER

PROGRESS

PILING PCC WORK

BASIN FOUNDATION

UNDER PROGRESS

BASIN FOUNDATION

UNDER PROGRESS

CURRENT

STATUS CURRENT

STATUS

TG BUILDING STRUCTURE UNDER FABRICATION

AT VARIOUS YARDS

FABRICATION OF COAL BUNKER UNDER PROGRESS

PRESSURE PARTS AND FABRICATED STRUCTURES

Plant Performance

Operating Units

Essar Power and Bhander Power

Year Generation

(MU)

Average

MW

Export to

ESTL

(MU)

Export to

GUVNL

(MU)

PLF (%)

2006-07 4714 538 2852.2 1779.0 74.1%

2007-08 5394 616 3357.1 1946.3 76.8%

2008-09 4858 555 2979.7 1782.3 59.2%

2009-10 5086 581 3192.1 1796.8 57.2%

2010 - 11 5364 612 3778.0 1493.1 60.3%

Generation at Hazira

3188

2821

2084 1968

2975

2516

3643

4228

4714

5394

4858 5086

5364

0

1000

2000

3000

4000

5000

6000

1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11

Gen

era

tio

n (

MU

)

Generation MU

95.6%

97.0%

93.5%

96.9% 97.1%

94.6%

98.1%

96.9%

97.1%

94.2%

96.7%

97.2%

98.3% 97.9% 98.5%

93.5%

98.9%

99.8%

98.5%

99.6%

97.3%

99.7% 99.9% 99.9%

99.0%

99.9%

86.0%

88.0%

90.0%

92.0%

94.0%

96.0%

98.0%

100.0%

1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11

Availability % Reliability (%)

Availability and Reliability

Plant Performance

0.0%

0.3%

0.6%

0.9%

1.2%

1.5%

1.8%

2.1%

2.4%

2.7%

0%

10%

20%

30%

40%

50%

60%

70%

80%

90%

1998-99 1999-00 2000-01 2001-02 2002-03 2003-04 2004-05 2005-06 2006-07 2007-08 2008-09 2009-10 2010-11

Au

x C

on

su

mp

tio

n (

%)

PL

F (

%)

PLF % Aux Cons %

Highlights

Essar Power 515 MW:

Received Integrated Management Systems, PAS:99

OHSAS 18001:2007 and ISO14001 in January 2009.

Green Tech Safety Award, 2010 in Gold Category

Green Tech Environment Award 2010 in Silver Category

Accident free Days : 3462 Days ( Data up to Nov 2011)

Bhander Power Limited :

Received OHSAS:18001 certification in February 2009.

Green Tech Safety Award, 2010 in Silver Category

Green Tech Environment Award 2010 in Silver Category

CII award for Water Efficient Power company 2011

Accident Free Days : 2492 Days ( Data up to Nov 2011)

Highlights

Shreshtha Suraksha Puraskar for EPOL in 2001 from National Safety Council of India

Major Overhaul and Other Scheduled Inspections of Gas Turbines and Steam

Turbines carried out In house at Essar Power Limited and Bhander Power Limited

Multi fuel Capability with Gas and Naphtha fuels that can be used

independently, as well as in Mixed mode. Leads to flexibility in case of fuel

pricing variations, and ensures cost benefit to customer

Energy Conservation at EPOL.

Increase of 3- 4 MW STG Output after replacing Plugs and

seat lapping of HP Bypass control valves and providing

isolations.

STG bearing cooling requirement complied through additional

cooler . Increased Cooling resulted into stoppage of One ACW

Pump(55 KW ) and one ACW Booster Pump ( 31 KWH)

Instrument air system modified to reduce aux power (saving of

75 kW) and to improve compressor life.

Clarified water pump impeller trimmed to reduce power

consumption. Net power saving would be 20 KWH

Raw water Pump replaced by VFD Motor. Saving potential of

35 KWH.

Installation of Wind Spin Fans, in place of Roof Ventilator in

all Roofs. Wind Spin

Bypass Control

Valves

Improvements in O&M Design.

New Installations :

GTG Inlet Air Cooling System.

STG IDCT fills height Increase from 3 to 5 . Expected

STG output gain would be 2.5 MW.

Provision to receive fuel gas supply from three different

gas supplier .

GTG lube oil filtration and dehydration machine

installed.

Flux detectors installed on STG generator.

Plant Efficiency Improvements

STG Output increased by 2 MW by minimising the

hot flue gas leakages in HRSGs.

Honey Comb seals and Cutter teeth buckets

installed in Gas turbine for Efficiency improvements.

Periodical replacement of Gas turbine inlet air filters

to minimise loss due to high filter Dp.

Monthly Monitoring of Bypass stack Flue gas

losses.

Plant Aux. Consumption considerably reduced due

to running of Single HPBFP during 2 GT operation.

Hydro jetting of condensor tubes to remove scale &

improve the condensor vacuum.

Reduced Spill over to GUVNL by better Load

coordination with ESTL.

Single HPBFP

during 2 GT

operation

Plant Efficiency Tracking

On- Line Monitoring of Station Performance. Daily Monitoring of Plant

Performance related Parameters.

Daily Monitoring of Equipment Performance.

Daily Monitoring of Consumables and Water Consumption.

Periodical GT , Station , Bypass Stack Measurement and Condenser PG

Tests.

Regular Water wash of GT based on Performance.

Unique Features of Essar Power and Bhander Power

First IPP Post Liberalization

Best Safety Practices- Sword of Honor/OHSAS 18001

Most Environment Friendly with CDM

Unique Islanding Systems for Grid Support

Multi fuel with online change over systems

In-house O&M

Lowest Man MW Ratio

High availability and PLF among Similar plants Globally

Energy Efficient with low Aux consumption and low Heat Rate

High level of Plant and Business process automation

Maintenance Standards

Maintaining high availability of major equipments Viz. Gas Turbines, Steam turbine and HRSGs

Over 300 modifications carried out to improve various systems performance

In house capability to carry out major inspections of gas turbines and steam turbines

Various modifications done on turbine parts to extend the parts life

High reliability of Liquid Fuel System by improvements on the Flow divider , Warren Pump seal design, Liquid fuel lines, etc

Commissioning of inlet air cooling system carried out with in house expertise

In House Expertise for inspections

Major inspection of GTG# 3 carried out in 21 days

Major Inspection of steam turbine carried out in 22 days simultaneous with

Gas Turbine Major Inspection

Developed card repair facility for Mark V and DCS electronic cards.

In house repair of expensive equipments like Warren pump, Flow divider,

Dual fuel nozzles, Hydraulic pump, CW Pump

Relay testing facility developed for testing and calibration of relays

Health, Safety and Environment

Essar Power Hazira

SAFETY MEASURES

Hydrogen sensors in Battery Room.

Naphtha Detectors in Gas Turbine Compt.

Monsoon preparedness improved.

Behaviour Based Safety on Stream.

Auto HVWS system at Station Transformers.

OHSAS 18001 Certified

HIGH RISK JOBS

DONE SAFELY

Environmental Management

ESSAR POWER LIMITED received Integrated

Management Systems, PAS:99 Certification for

OHSAS 18001:2007 and ISO14001

Uses clean fuel, natural gas with very low emissions level .

Green belt developed all around the plant with planting of over one lakh trees.

Water systems modified to optimize the water requirements.

Chlorine Dioxide System introduced in Nov 2005 COC improved from 5 to 5.5.

Cooling Water blow down used for Cooling purpose in HBI plant and gardening in township. Treated

effluent water used for horticulture.

Control room - back up alarm system, made paperless.

Environment - Consents & Ambient Air Quality

Consents for Essar Power.

1. Air

2. Water

3. Waste Hazard .

Consents are valid till 24.06.2014

Month SPM (PPM) (500) SO2 (PPM) (120) NOX (PPM) (120)

Sep-07 211 7.9 34.4

Oct-07 143 7.6 32.8

Nov-07 253 7.2 31.1

Dec-07 272 8 32.1

Jan-08 216 8.1 32.7

Water Conservation at EPOL

Water Saving

Condenser cooling 5200 m3/day

Filter Back wash 168 m3/day

Salt Recovery water 90 m3/day

Treated effluent used

for gardening 500 m3/day

Total Saving 5758 m3/day

Savings @ Rs. 25900 / day @Rs. 12/m3

Annual Rs.335 Lakh

Reliability Improvements.

DD 1 & 3 hydraulic system accumulators.

Naphtha settling & Inter tank Filtration Scheme introduced to ensure clean

Naphtha without filterable particles for the gas turbines.

Significant improvements on the reliability of Liquid Fuel System by

improvements on the Flow divider , Warren Pump seal design etc.

Accumulator for GTGs Naphtha forwarding system.

Auto islanding scheme for station with stable load.

New common header for GT ACW IDCT.

GTG Misc MCC- DC supply 110 V DC instead of 110V AC

6.6 KV Station switchgear auto-changeover scheme.

HR Development Practices

12 Engineers sent to G.E, USA for Systems training

Simulator operation training a regular feature

Regular O&M training from leading suppliers

HR Development through in-house and external Management Programs

Job Rotation within functions and lateral transfers for wider exposure

Employees exposed to seminars & workshops related to Power industry

Manpower to MW Ratio

National Standard -Thermal 2.75

Best - Coal based 1.50

Gas Based average 0.43

Essar Power Ltd. 0.11

Awards and Achievements

Essar Power Hazira

Certifications and Accolades

51

Green tech award

Gold and silver award

BSI Management System

ISO14001 & PAS 99

BSI Management System

OHSAS 18001

Gujarat Safety Council

Certificate of Appreciation

Gujarat Safety Council

Certificate of Appreciation

National Safety Council

Shreshtha Surksha Puraskar

BSC - National Safety Award

GSC - Certificate of Appreciation

BSC - Five star rating & Sword of honour

GSC - Certificate of Appreciation

National Safety Council

Yogyata Praman patra

Essar Power 100% operational

DNV - ISRS Level III

1997 1998 1999 2000 2001 2005 2006 2007 2008 2009 2010

BPL receives CII "Most Water Efficient Unit" award November 2011

Greentech Foundation Silver award for Environment Excellence 2011 EPOL & BPL

BSI Management System BPL - ISO14001 & PAS 99

Greentech

Gold and silver award

BSI Management System

EPOL - ISO14001 & PAS 99

BSI Management System

OHSAS 18001

Gujarat Safety Council

Certificate of Appreciation

Gujarat Safety Council

Certificate of Appreciation

National Safety Council

Shreshtha Surksha Puraskar

BSC - National Safety Award

GSC - Certificate of Appreciation

BSC - Five star rating & Sword of honour

GSC - Certificate of Appreciation

National Safety Council

Yogyata Praman patra

Essar Power 100% operational

DNV - ISRS Level III

1997 1998 1999 2000 2001 2005 2006 2007 2008 2009 2010 2011

Safety at EPOL and BPOL

Green Tech Safety Award 2010