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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Salaya Power Project Essar Energy Site Visit
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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COMMISSIONED & IN SERVICE
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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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COMMISSIONED & IN SERVICE
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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Salaya Power Project Essar Energy Site Visit
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
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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
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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
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