Vadinar Power Company Ltd

Analyst Site Visit October 31- November 1

Executive Director

KB Makadia Executive Director - Power Business, VPCL

1

INDEX
Introduction Plot Plan Plant Overview Plant Operations Project Journey Initiatives

Salaya TPP

Introduction
Project Objective To provide uninterrupted Steam, Power & Feed water to Refinery operation as well future requirement 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

Fuel oil Tanks Cooling Towers

Plot Plan

Phase 2A Boiler 2

Phase 2A Boiler 1

Coal conveyor

Pipe Rack to Refinery

Base Plant (120MW) Phase 1 GT & HRSG 1

Admin Building

Phase 2A Station Building

Phase 1 GT & HRSG 2 4

VPCL Plant Overview

Boiler-1 PF Boiler-2 PF

Coal HFO/CSO

HFO Fuel Gas

Boiler-1 77 MW

Boiler-2 120 MW

Boiler-3 120 MW

VHP HHP
Base Plant

38.5MW2

38.5M W-1

Phase 1

HP
92.8 MW
105 MW-2 105 MW-1

HRSG2

HRSG1

Phase 2

MP
GT-2 GT-1

NG, HSD Naphtha

LP LP 5

VPCL Operations

Power Generation
POWER GENERATION
160 Load requirement reduced due to Refinery Annual Shut down

Load increased gradually as Different units of Refinery Train-1 commissioned and under operation now.
140 124 125

140

MW

60

40

11

18

10

12

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

Power Generation

Power Import From Grid

Auxiliary Power Consumption@

Power Generation 7

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

13

20

76

76

80

85

80

92

105

100

123

120

128

Plant Availability
Due to 33 KV AIS to GIS reshuffling job

TURBINE AVAILABILITY

100.0

100.00

100.0

100.0

99.8

98.5

99.6

99.5

98.6

100.0

99.7

99.4 98.0

100.0

80.00
70.00 60.00

95.5

50.00 40.00 30.00 20.00 10.00 0.00

Oct-11

66.0

Nov-11

88.6

Dec-11

Jan-12

Feb-12

Mar-12

Apr-12

May-12

Jun-12

99.3

Jul-12

99.9

99.4

90.00

100.0

100.0

Aug-12

99.9

Sep-12

MHI STG

GTG

Siemens STG 8

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

100.0

100.00

100.00
99.9

Plant Availability
BOILER AVAILABILITY
100.00
100.0 100.0 100.0 99.5 100.0 100.0 100.0 100.0 100.0 99.5 100.0 100.0 98.8 100.0 100.0

Due to Coal Fired Boiler S/D for SH

90.00 80.00 70.00

94.1

93.9

100.0

93.0

88.82

97.9 100.0

100.0 100.0

60.00
57.3

50.00 40.00 30.00 20.00 10.00 0.00

Oct-11

Nov-11

Dec-11

Jan-12

Feb-12

Mar-12

Apr-12

May-12

Jun-12

Jul-12

Aug-12

Sep-12

OFB

HRSG

CFB

CFB S/D for inspection of Super heater, 102 Metallic foreign pieces recovered which was left inside due to manufacturing defect. 9

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

64.45

Plant Efficiency
PLANT COGENERATION EFFICIENCY

80 70

60
50

40

66.1

69.5

64.7

60.3

62.9

74.8

66.9

30
63.2

20 10 0

Oct-11

Nov-11

Dec-11

Jan-12

Feb-12

60.9

Mar-12

62.8

Apr-12

May-12

68.6

Jun-12

Jul-12

Aug-12

Sep-12

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

Cogeneration Efficiency

63.8

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VPCL Phase 2A

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Highlights Phase-IIA
Configuration Project Capacity Number of Steam Turbines Capacity Capacity of Boilers Number of Boilers Type of Boilers Boiler technology Condenser Cooling : : : : : : : : 510MW 3 (Three) 2 x105MW + 1x92.8MW 750TPH 2 (Two) Pulverized Fuel and Oil Fired Sub-critical 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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Highlights Phase-IIA
Particulars (As on September 2012)
Physical Progress (%) Overall

VPCL P2 (510MW)
97.5%

Engineering (%)
Procurement (%) Construction (%) Dates Synchronisation Commercial Operations Evacuation Progress Statutory Approval Progress (Key approval pending)

95%
99.8% 95.7% Unit 1 Synchronized Oct. 2012 Connected to State Grid via EOL switchyard All approvals in place

*INR/US$ - 50

Commercial Snapshot
Supply Power 77 MW Steam 230 tons/hr.

Unit Base

Customer Essar Oil

Tariff Annual FC- INR 794 Mn

Fuel

Essar Oil Phase 1 & 2A ESTL

300 MW

90 MW

Fuel and water Annual FC for supplied by Phase 1- 1750 Mn EOL 1500 tons/hr. Annual FC for Phase 2- 3350 Mn Fuel and Annual FC for water Phase 1 & 2- INR supplied by 800 Mn ESTL

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Achievements- Phase 2A
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 12th July 12 for Power and 16th July12 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 like Vacuum 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.

15

STG 1 & STG 2 Synchronized

STG 1 Synchronized on 24th Jun12

STG 2 Synchronized on 15th Sept12

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Accomplishments

The plant uninterrupted operation from last 46 months and no disturbance 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 Limited

Essar Energy Site Visit

Project Photographs

Phase-I & IIA: Overall View

120MW Plant

380 MW Plant
HRSG-1 HRSG-2

Pipe Rack to Refinery

Phase IIA: Overall View

Phase I & IIA Overall View

Phase-IIA : Boiler-1 & Boiler-2

Boiler 2 Station Building

Boiler 1

Phase-I & IIA : overview

Station building Bunker Bays

GTG - 1

GTG - 2

Phase-IIA : STG Floor overview

STG Floor STG 1

STG 2

STG 3 Commissioning activity under progress

Phase-IIA : control room & Electrical room overview

Phase-IIA : Boilers & Mills overview

Boiler 1 Boiler 1 & 2

Mills

Boiler 2

Phase-IIA : Coal Conveyor & Cooling tower overview

Phase-IIA : Cooling Tower