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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
Plot Plan
Phase 2A Boiler 2
Phase 2A Boiler 1
Coal conveyor
Admin Building
Coal HFO/CSO
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
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 Generation 7
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
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
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
93.9
100.0
93.0
88.82
97.9 100.0
100.0 100.0
60.00
57.3
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
Cogeneration Efficiency
63.8
10
VPCL Phase 2A
11
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.
12
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
Fuel
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
14
Achievements- Phase 2A
Unit -1 pre-commissioning and commissioning activities successfully completed without any incident. Boiler -1 under operation with 100% coal firing.
15
16
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%.
17
Project Photographs
120MW Plant
380 MW Plant
HRSG-1 HRSG-2
Boiler 1
GTG - 1
GTG - 2
STG 2
Mills
Boiler 2