Coal & Gas Fired Power Plants Refurbishing Relocation Turn-Key Capability
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.