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

Supply of New Equipment • If necessary: new furnace walls and new

superheater tubes. All instrumentation & control system

• Electrical cabling

• Motor control system (MCC) if necessary • Boiler furnace cleaning equipment such as soot

blowers. New air pre-heater packs • New lagging and cladding

Typical Exclusions • All necessary foundations and civil works

including stack • Coal storage building and storage bunkers

within boiler house. Permits and approvals of any kind

• First filling of lubricants • Any fuel for testing of plant

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

26th June 2012

Boiler With Steam Turbine Generator Set HFO /

NG Fired - Rated Output In MW

(Boiler Modification For Coal Firing Possible,

However Cost Thereof Currently Excluded)

No. Of Units

Location

Price Turn-

Key In Mio

Eur per

Unit

392 2 Holland 175

275 1 Austria 145

165 1 Austria 125

150 2 Austria 78,5

110 1 Austria 67,5

Gas Turbine Generator Sets (Single Cycle)

In Combined Cycle - Marked *

NG / Light Oil Fired - Rated Output In MW

93*(+40 MW) 1 Italy 48,5

80*(+30 MW) 1 Austria 41

48 3 Greece 18,5

Coal Fired Power Plants - Rated Output In MW

330 1 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

client’s 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.