Essar Power Hazira

Essar Energy Site Visit

8th Dec 2011

T.S. Bhatt Head Essar Power Hazira

Operating Plants - Overview

Hazira I

Bhander

Vadinar

Vadinar P1

Algoma

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

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

Capacity: 120 MW
Fuel: Refinery residue Offtake: Essar Oil COD: May 2008 Location: Gujarat, India

Capacity: 380 MW
Fuel: Natural Gas Offtake: Essar Oil Sync: Unit I Oct 2010 Unit II Jan 2011 Location: Gujarat, India

Capacity: 85 MW Fuel: Blast furnace gas / Coke oven gas Offtake: Ontario Power Authority

COD: Jun 2009

Location: Ontario, Canada

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 Steam Turbine - I 55 MW Steam Turbine- II 125 MW
Fuel NGL/ Naphtha / HSD / Natural Gas

= 320 MW = 55 MW = 125 MW

COMBINED CYCLE PROCESS

Exhaust
Boiler

To other Boilers

Deareator

Fuel From Other Boilers Air

Combustion System

Boiler Feed Pump

Steam Turbine

Alternator

Compressor

Gas Turbine

Condenser Alternator Cooling Water Condensate Extraction Pump

COMBINED CYCLE PROCESS (BPL)

Essar Power Hazira Ltd

270 MW Power Project ( Hazira 2 )

MULTI-FUEL FIRED POWER PLANT ( HAZIRA 2 )

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

270 MW PLOT PLAN ( HAZIRA 2 )

MAIN EQUIPMENT SUPPLIERS 270 MW

PACKAGE
STG & Auxiliaries

VENDOR
SIEMENS
BWE SPIG Jyoti Tyco Sanmar ABB ABB ABB GMMCO Honeywell

Boiler & Auxiliaries

IDCT CW Pump Safety Relief Valves EBOP Generator Transfomers Gas Insulated Switchyard Emergency DG Set Plant DCS

Fuel Oil Handling System Ash Handling System

Thermosystems
Mcawber Beekay

ENGINEERING PROGRESS - 85%

DESCRIPTION

PROGRESS

BASIC ENGINEERING

100%

TECHNICAL SPECIFICATION

95%

ENGINEERING EESL

70%

ENGINEERING VENDORS

90%

OVERALL CONSTRUCTION PROGRESS

S.N. 1 2 3

DESCRIPTION Piling Concreting Structural Fabrication

UNIT Nos Cum MT

TOTAL SCOPE 4400 45140 8262

COMPLETED 3270 9438 3813

% COMPLETION 77 21 46

4
5 6 7

Structural Erection
Equipment Erection Piping Cable Laying

MT
MT IM RM

12035
16244 190952 315000

804

6.5

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

ESP- 1 AREA BOILER-2 BOILER-1 TG BUILDING

ESP- 2 AREA CHIMNEY 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

CURRENT STATUS

CURRENT STATUS

STG DECK 1

STG DECK 2

TG DECK & BUILDING VARIOUS STAGES OF CONSTRUCTION

PILING EXCAVATION

TG BLDG FOUNDATIONS

TG DECK REINFORCEMENT

TG DECK CONCRETING

TG DECK RAFT COMPLETED

TG DECK COLUMNS

BOILER FOUNDATIONS AND ERECTION UNDER PROGRESS

COAL MILL AND PA FOUNDATIONS COMPLETED

BOILER -1FOUNDATIONS

BOILER -2FOUNDATIONS

ESP-1 FOUNDATIONS UNDER PROGRESS

CURRENT STATUS

PILING EXCAVATION

ESP-1 FOUNDATIONS AND RAFT UNDER PROGRESS

ESP-2 FOUNDATIONS UNDER PROGRESS

CURRENT STATUS

PILING EXCAVATION

ESP-2 FOUNDATIONS AND RAFT UNDER PROGRESS

CHIMNEY RAFT CASTING AND REINFORCEMENT

CURRENT STATUS

REINFORCEMENT FOR REST OF RAFT UNDER PROGRESS

PILING EXCAVATION & PCC

ONE QUADRANT OF CHIMNEY RAFT CASTING COMPLETED REINFORCEMENT

COOLING TOWER - PCC & BASIN CONCRETING UNDER PROGRESS

PILING
CURRENT STATUS

PCC WORK
CURRENT STATUS

BASIN FOUNDATION UNDER PROGRESS

BASIN FOUNDATION UNDER PROGRESS

TG BUILDING STRUCTURE UNDER FABRICATION AT VARIOUS YARDS

FABRICATION OF COAL BUNKER UNDER PROGRESS

PRESSURE PARTS AND FABRICATED STRUCTURES

Operating Units
Plant Performance

Essar Power and Bhander Power

Year
Generation (MU) Average MW Export to ESTL (MU) Export to GUVNL (MU)

PLF (%)

2006-07
2007-08 2008-09 2009-10 2010 - 11

4714
5394 4858 5086 5364

538
616 555 581 612

2852.2
3357.1 2979.7 3192.1 3778.0

1779.0
1946.3 1782.3 1796.8 1493.1

74.1%
76.8% 59.2% 57.2% 60.3%

Generation at Hazira

6000 5394 5000 4858 4714 4228 Generation (MU) 4000 3643 3000 3188 2821 2516 2000 2084 1968 2975 5086 5364

1000

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 Generation MU

Availability and Reliability

100.0% 97.9% 98.9% 98.5% 98.5% 97.0% 96.0% 95.6% 94.6% 94.0% 93.5% 93.5% 92.0% 94.2% 96.9% 97.1% 97.3% 96.9% 97.1% 96.7% 97.2% 98.1% 99.8% 99.6% 99.7% 99.9% 99.9% 99.0% 99.9% 98.3%

98.0%

90.0%

88.0%

86.0% 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 (%)

Plant Performance
90% 2.7%

80%

2.4%

70%

2.1%

PLF (%)

50%

1.5%

40%

1.2%

30%

0.9%

20%

0.6%

10%

0.3%

0%

0.0% 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 PLF % Aux Cons %

Aux Consumption (%)

60%

1.8%

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.

Bypass Control Valves

Wind Spin

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

Essar Power Hazira

Health, Safety and Environment

SAFETY MEASURES
HIGH RISK JOBS DONE SAFELY

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

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 Sep-07 Oct-07 Nov-07 SPM (PPM) (500) 211 143 253 SO2 (PPM) (120) 7.9 7.6 7.2 NOX (PPM) (120) 34.4 32.8 31.1

Dec-07
Jan-08

272
216

8
8.1

32.1
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

Gas Based average Essar Power Ltd.

1.50
0.43 0.11

Essar Power Hazira

Awards and Achievements

Certifications and Accolades

Green tech award Gold and silver award BSI Management System ISO14001 & PAS 99 BSI Management System OHSAS 18001 Gujarat Safety Council

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 Certificate of Appreciation BSI Management System Gujarat Safety Council EPOL - ISO14001 & PAS 99 Certificate of Appreciation National Safety Council BSI Management System Shreshtha Surksha Puraskar OHSAS 18001 BSC - National Safety Award Gujarat Safety Council GSC - Certificate of Appreciation Certificate of Appreciation Gujarat Safety Council BSC - Five star rating & Sword of honour Certificate of Appreciation GSC - Certificate of Appreciation National Safety Council National Safety Council Shreshtha Surksha Yogyata Praman patra Puraskar BSC - National Safety Award Essar Power 100% operational
DNV - ISRS Level III

GSC - Certificate of Appreciation 1997 1998 1999 2000 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

2001

2005

2006

2007

2008

2009

2010

51

2005

2006

2007

2008

2009

2010

2011

Safety at EPOL and BPOL

Green Tech Safety Award 2010