Coal & Gas Fired Power Plants

Refurbishing Relocation Turn-Key Capability

The Company
We represent a consulting engineering company, based in Durban, South Africa that focuses on large international engineering projects, including the refurbishment and relocation of complete power (coal & gas) plants, mostly ex European. The company has been in operation since 1980.

Power Plants ex Europe

We are able to provide, via a German owned, South African company with strong ties to Germany, a number of coal and gas fired steam power plants, fully refurbished and certified, Units currently available are from 14 MW to 676 MW, with a constantly changing inventory. Coal fired steam power plants are complex systems and the planning, dismantling and relocation of such power plants requires specialized companies with specific know how. This company has already executed relocations of complete power plants in the USA and in Turkey. On completion of the refurbishment process, all equipment supplied, including ultrasonic testing and and x-raying of boiler pressure parts according to BS (British Standard) code, will have residual life expectancy certification through Chartered Engineers (TUV or LLOYDS) in Europe. All moving (revolving) components such as turbine rotors, generator rotors, pumps, motors, fans, gearboxes, valves etc are checked by professional teams and the level of refurbishment is set by them. Upon completion of refurbishment, all components are tested and certified for release to site and installation. Note that all refurbishment works and / or replacement of any parts are included in our final quoted price offer. From our pre-inspection of the offered power plants we have a close indication of the standard of the plant in consideration. We are able to market and sell such power plants on an FOB Hamburg basis or on a turn-key basis as a fully operational plant in a new location. In such cases, the foundation design and structural steel design for buildings etc will be carried out by Certified Engineers.

An example of a 330 MW, coal fired power plant, complete with turbine, boilers etc., ready to be dis-assembled, refurbished and relocated to other parts of the world.

Power Plant Relocation Project

Typical Schedule
Power plant assessment Pressure parts design review and inspection by Authority for Boiler Certification Identification of components / parts to be refurbished or even replaced Revise all existing P&I and wiring diagrams and technical drawings and compare with the as built status Revise and complete power plant O & M Manuals Revise and complete AUTOCAD and original Drawing package Review boiler performance design Establish project time schedule Establish transportation routes and means of transportation for the individual components Complete or establish unclear or missing drawings / P&I and wiring diagrams Marking of all components for erection works Disassembling of the existing power plant and packing of all components Place orders for all items to be repaired, modified or even replaced. E.g. parts of the boiler heat exchanging tubes (especially the evaporator & super heater tubes), ductwork, instrumentation, flue gas cleaning system and DeNox, etc Place orders for parts to be refurbished, e.g. steam turbine, feed water pumps, coal mills, combustion air and exhaust gas fans, etc Structural steel design and foundation design for new site Preparation of the new site. Install all necessary foundations and civil works including boiler house and turbine building, coal storage building, coal storage bunkers within boiler house, stack, cooling tower or fresh- or sea water cooling system Transportation of the individual parts of the power plant Re-assembling of the power plant Cold and hot commissioning Test run and acceptance test Handover of power plant

Typical Scope
General Services
Complete back up engineering and project execution

Steam Turbine and Generator Set

HP and LP top and bottom casings complete HP and LP rotors Condenser complete with auxiliary equipment and cooling water pumps Cooling water system Lube oil system Generator Exciter system Step up transformer Feedwater heating station complete with piping and valves Turbine building including steelwork, roof and overhead crane beams

Power Plant Relocation Project

Boiler Part
Main boiler and boiler house steelwork and roof Platforms & stairways, flooring & grating Steam-drum and support slings / hardware Down comer tubes evaporator walls Boiler feedwater pumps with frames and base plates including motors - 2 sets Economizer elements and headers including bypass system Economizer flue gas bypass Primary and secondary superheaters and headers Live steam (HP) outlet headers and pipes complete with spring supports Boiler feedwater pipes complete with supports Boiler feedwater tank with de-aerator HP valves Feedwater tubes Riser tubes ID fans with drives ID fan ductwork and dampers. FD fans with drives FD fan ductwork and dampers. Secondary air fans with drives. Secondary air fan ductwork and dampers Coal chutes to coal feeders and mills / Pulverizers Coal feeders Coal mills / pulverizers with gearbox and drives Combined coal / oil burners including fuel feeding systems and wind boxes Hanger & supports for combustion chamber Access doors New thermal insulation and cladding for boiler, ductwork and piping Rotary air pre-heater with ductwork Soot blower supports and access platforms and stairs Electrostatic precipitator Flue gas cleaning plant Ash hoppers with ash removal system Motor control system (MCC) if necessary Boiler furnace cleaning equipment such as soot blowers. New air pre-heater packs New lagging and cladding First filling of lubricants Any fuel for testing of plant

Supply of New Equipment

If necessary: new furnace walls and new superheater tubes. All instrumentation & control system Electrical cabling All necessary foundations and civil works including stack Coal storage building and storage bunkers within boiler house. Permits and approvals of any kind

Typical Exclusions

The relocation of a complete coal fired power plant is a big and challenging project and the time frame from the first groundbreaking until commercial operation at the new site may be more than one year depending on the size of the power plant.

Current Availabilities 26th June 2012

Available Power Plants As Of 26-06-12 Boiler With Steam Turbine Generator Set HFO / NG Fired - Rated Output In MW (Boiler Modification For Coal Firing Possible, However Cost Thereof Currently Excluded) 392 275 165 150 110 Gas Turbine Generator Sets (Single Cycle) In Combined Cycle - Marked * NG / Light Oil Fired - Rated Output In MW 93*(+40 MW) 80*(+30 MW) 48 Coal Fired Power Plants - Rated Output In MW 330 1 1 1 3

26th June 2012 Price TurnKey In Mio Eur per Unit 175 145 125 78,5 67,5

No. Of Units 2 1 1 2 1

Location

Holland Austria Austria Austria Austria

Italy Austria Greece

48,5 41 18,5

Austria

225

ALL UNITS CERTIFIED AND TESTED PRIOR TO FOB DELIVERY CLIENT TO SUPPLY: COOLING WATER, FUEL, SERVICE WATER, ROADS, (ALLOW FOR HEAVY AND ABNORMAL MACHINERY TRANSPORT), FOUNDATIONS, COMMUNICATION SYSTEMS AND ACCOMODATION FOR SITE PERSONNEL, PERMITS OF ANY KIND;

How to Proceed?
If you are an interested party, please contact your representative and advise if you are interested in one of our existing units on our current Schedule of Availabilities on Page 6 - or otherwise provide us with all of your own requirements, from size (MW) to fuel source to end location. If one of our existing units works for you, we need to know: location of where you want plant to go: infrastructure/facilities available at location; and most importantly, if coal, a full coal analysis, ultimate and proximate. This analysis will tell us the type of furnace we need to supply in order to achieve the required output. From there we will provide a firm proposal, on an FOB basis. Providing budgets, timelines and so forth. Additional costs will be for shipping to ultimate location and cost of rebuilding (as an estimate, site costs usually come to around 15% of FOB).

Costs
As an indication for turn-key price re 330 MW coal fired power plant ex Austria would be EUR 225 Million (including purchase of existing plant, dismantling, refurbishing, packing and shipping to clients port and site works) excluding internal transportation costs from destination port to new site. By comparison, a new, similar plant with European equipment (not Chinese or Indian) will cost EUR 450 Million at least and will take 2-3 years longer to build due to long delivery items for turbine and special boiler parts. In addition, there is no escalation on our price since we are not dependent on price fluctuation of special steels or materials, copper etc.

Competition
India and China have some local 2nd hand refurbished power plants, however there have been some cases in Indonesia where Chinese turbines have been known to fail so quality does not match up to European standards.