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 1200 MW (2 X 600MW) Imported coal based power

Description plant

Fuel linkages  Imported coal .

 Agreement signed with Essar Shipping & Logistics.

Fuel Coal

Off-take  1000MW to GUVNL

 Balance: Merchant (through PTC)

Environment Obtained

EPC Awarded: jobs are in progress

Water Obtained

Aviation Obtained

Land Full Possession of Land Received

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

Opn. Date

Financial Achieved
Closure
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 Current month Calendar year

Aug 2010
Total Man hours worked without LTI 1.05 (MMH) 4.17 (MMH)
No of LTI 0 8
LTI Frequency Rate 0 1.34
Near Miss cases and corrective action 4 28
taken
No of fatality cases 0 0
No of Persons attended HSE 1418 11550
orientation / Induction
On line safety training – L1 (Once per 0 Completed for all
year) employee
Certified HSE training – L2 0 12
HSE job rotation – L3 5 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 BOILER #2

TG #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-A15
AXIS-B17
AXIS-A13
AXIS-B21
AXIS-A11
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 SBA-1 & 2 (STRONG BASE ANION MB- 1 & 2 (MIX BED)
COMPLETED EXCHANGER) ERECTION COMPLETED 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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