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Isgec Corporate Overview

1933: Founded by setting up a Sugar Plant; Today Saraswati Sugar Mills is oneof the largest Sugar Mills in India (13 000 TCD)of the largest Sugar Mills in India (13,000 TCD) .

1947: Facility for manufacturing of spares for Sugar Mills which eventuallytransformed into manufacturing facility of pressure parts with approvalsfrom ASME, OHSAS and Nuclear ‘N’ stamp etc.

1964: Joint Venture with John Thompson, UK to form ISGEC John Thompson(IJT) for Design, Engineering and Manufacturing of Boilers and & SugarPlants on Turnkey Basis.

1998: License Agreement with M/s. Amec Foster Wheeler Inc., USA (FW) for Circulated Fluidized Bed Combustion Boilers and Oil & gas fired ‘D’ typeBoilers.

2007: New Manufacturing Plant commissioned at Dahej for manufacturing of2007: New Manufacturing Plant commissioned at Dahej for manufacturing ofLarge Size Boilers and Heavy Engineering Equipments.

2010: Technology Transfer Agreement signed with Amec Foster Wheeler Genevafor Subcritical & Supercritical range of Pulverized Coal Boilers up to1000MW1000MW.

2011: Joint venture with M/s Enviro Therm for manufacture of ESP for plantcapacities up to 1000 MW.

2012: Joint venture with Hitachi Zosen, Japan for manufacturing special vesselsat Dahej.

2013: Technical tie up with NEM Netherland for Heat recovery Steam generatorupto 350 MW

Yamunanagar Our Locations

Noida (suburb of New Delhi)

Pressure Parts & Pressure Vessels Manufacturing Facility, 200 km from New Delhi

New Delhi

Corporate, Marketing, Project Mgmt. & Purchase Office INDI

APuneIsgec West Region & M t i l H dli Offi

Kolkata

ChennaiEPC Engineering, Design & South Region Office

Bay of Bengal

Arabian Sea

Material Handling Office

Not to Scale

Isgec East Region Office

Our EPC Global Presence

Isgec Group StructureIsgec Group Structure

PROCESS EQUIPMENT

EPC POWER PLANTS

PRESSES

INDUSTRIAL & UTILITY BOILERSCONTRACT

MANUFACTURING

SUGAR PLANTS & MACHINERY

TRADING

CASTING FOR TURBINES

Global FootprintGlobal Footprint

Isgec Turnover & Exports - in Millions

2749029420

33320

30000

35000 $ 555 Millions€ 456 Millions

24340

2749025900

25000

17650 18100

12400 1178010080

1516015000

20000

52903270

799010080

5000

10000

TurnoverExports

02009 2010 2011 2012 2013 2014 2015

Oct.–March( li d)

October - September Apr.–March(annualised)

F 2014 was for 6 months as financial year changed to March ending

Conversion @ 60/- to $1Conversion @ 73/- to € 1

Overview

Commissioned - 900 MW with Max. unit size of

61 MW (50 Plants)

Under execution 231 MW with Max. unit size of

50MW (15 plants)

EPC Offerings

Captive Power Plant Solutions for Cement, Metal,Petrochemical & Other Industries.

Co Generation Power Plant Solutions for Sugar Co-Generation Power Plant Solutions for Sugar,Paper, Textile & Chemical Industries.

Waste Heat based Power Plant Solutions for CokeOven Sponge Iron Cement & Metal Industries &Oven, Sponge Iron, Cement & Metal Industries &Combined Cycle Power Plant

Combined cycle power plant with HRSG forrefinery petrochemical and Oil & Gas sectorrefinery, petrochemical and Oil & Gas sector

Independent Power Plant Solutions for Biomass &Utility Sector.

Energy from Waste Solutions in association withHitachi Zosen.

Operation & Maintenance Services Operation & Maintenance Services.

5 decades of experience in EPC business.

Isgec for EPC Power Projects

Experienced, qualified, trained manpower.

Zero debt organization.

On time delivery record.y

Specialized in both brown & green field project.

More than 50 Power Plants in Operation &

Experience in executing Power Plants with various Boilers Technologies such as

More than 50 Power Plants in Operation &more than 15 Power plants underexecution at various stages Worldwide.

AFBC Travelling Grate CFBC (Licensee agreement with Acme

Foster Wheeler) Oil & Gas (Licensee agreement with Oil & Gas (Licensee agreement with

Acme Foster Wheeler) Waste Heat Recovery Boilers HRSG (Licensee agreement with NEM

Energy B.V., Netherlands) Pulverized Coal Fired Boilers

(Licensee agreement with Acme Foster Wheeler)

END TO END SOLUTION PROVIDER

Mechanical Electrical + C&I Services

• Gas Turbine Generator with • Switchyard up to 220 KV • Plant Engineering• Gas Turbine Generator with Auxiliaries•Turbine Generator with Auxiliaries• Biomass, Bagasse, Lime stone, Coal

Handling & Unloading system, Fuel

• Switchyard up to 220 KV• Plant Electricals• HV Transmission lines• Plant Instrumentation• Plant DCS

• Plant Engineering• Project management &

monitoring• Procurement management• Inspection

Oil and Gas• Ash Handling system• Cooling Towers/ACC• Complete Plant piping• Water intake & Treatment System

• Plant load Management & shredding system

• Emergency & Black start DG Set

• Complete Plant civil works• Supervision of erection &

commissioning• Erection & Commissioning• Operation & Maintenance

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Water intake & Treatment System• Zero discharge system• Fire Hydrant / fighting system• Air conditioning & ventilation system

Operation & Maintenance

EPC EXPERIENCE IN WASTE TO ENERGY POWER PLANT(BOP)

EXPERIENCE LIST IN W/E PLANTS

PROJECT LOCATION CAPACITY STATUSPROJECT LOCATION CAPACITY STATUS

Essel infra limited Jabalpur 11.50 MW Commissioned in May 2016

PLANT DESCRIPTION

• The plant is designed to intake waste up to 600 tons per day

PLANT DESCRIPTION

p g p p yhaving a calorific value range from 1100 to 2200 kcal/kg.

• The fuel to the power plant is the MSW and its mode of transport to the plant is through the trucks & tractor trolleystransport to the plant is through the trucks & tractor trolleys

• The waste pit is designed to handle waste for its size and composition

h f l h l d• The crane is given in waste pit for clearing the unloading area, mixing, stocking and continuous feed of waste to boiler

• The electrical power output at alternator terminal for this p pcapacity plant is 11 .50 MW.

MAJOR PACKAGES

• Steam Turbo Generator and its auxiliaries• Air Cooled Condenser

EOT C• EOT Crane• Water Treatment plant with DM tank• Auxiliary cooling tower• Compressed Air system• Compressed Air system• Ventilation and Air conditioning System• Fire Fighting and Protection system• Feed water systemFeed water system• Miscellaneous Pumps• Complete Plant piping system including steam, water & Air system• Effluent Treatment systemy• Fuel Oil Unloading & Forwarding system• Weigh Bridge• Plant Electrical

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• Control and instrumentation

SPECIAL REQUIREMENT

WASTE PIT TRIPPING BAYS G C GRAB CRANE EFFLUENT TREATMENT PLANT DUMPING POWER HOUSE BUILDING POWER HOUSE BUILDING BLACK START DG SET

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WASTE PIT

• Designed to handle waste for its size and composition. p

• Considerable amount of water gets drained from the waste and collected at the bottom of the pit while handling and stocking of waste.

• To properly drain out the water from the pit, the pit will be designed with a

l dproper slope towards one end & one corner of the pit from where water will be collected collected

WASTE PIT

• Depth of pit selected based on Available natural terrain, soil condition and ground water condition and ground water level.

• Pit wall designed to withstand crane impact load crane impact load.

• Pit is completely closed on all sides with suitable number of Doors for truck unloading on Doors for truck unloading on tipping bay side.

• Forced draft fan suction duct provided on top of waste pit to provided on top of waste pit to create negative pressure in the pit are so that no Odur comes out of the pit p

TRIPPING BAYS

• Tripping bays are designed pp g y gto feed the waste into the pit

• The tipping bays will be designed according to the designed according to the waste transport system (e.g. size of trucks & hrs of transportation)transportation).

• Suitable ramp for truck movement is provided

• Sufficient bay area provided to handle around 10 trucks at a timeat a time

GRAB CRANE

• Two no. of waste grab cranes will be installed

• The cranes are remotely controlled from the control room

• The waste grab cranes are equipped with a weight

dmeasuring system to record the waste flow transported to the feed hopper

h d d f• The crane is designed for clearing the unloading area, mixing, stocking and continuous feed of waste continuous feed of waste

EFFLUENT TREATMENT SYSTEMEFFLUENT TREATMENT SYSTEM

The waste water collected in the sump of the waste pit will be pumped to the waste water treatment plant. p p pAfter treatment of waste pit drain water, the water will be pumped to the Process water Basin to reuse the water in the area of bottom ash extractor Effluent Parameters:

in the area of bottom ash extractor.

Sl. No. Description Unit Data1 Total Suspended solids mg/l, max 20002 COD /l 410002 COD mg/l 410003 BOD mg/l 160004 TDS inorganic mg/l 230004 TDS inorganic mg/l 230005 Total Solids mg/l 25000

Contd:…

ETP PRODUCT WATER PARAMETERS1 Total suspended solids mg/l <50p g/2 BOD mg/l <504 COD mg/l <2505 TDS mg/l 23000

• Effluent Treatment system scheme is as follows:• Raw EffleuntAeration TankSecondary claarifierTube

settler tankFilter feed tankMGFFilter water tanksettler tankFilter feed tankMGFFilter water tank

DUMPING

Typical arrangement • Plant is designed for 100% goff line dumping to fire the waste even turbine is trippedpp

• By pass PRDS and condenser is selected accordinglyaccordingly

BLACK START DG SET

• Black start DG set is provided to start the plant and p psafe shutdown of the plant

• DG set shall be used during 100% off line dumping d l b l f dcase due to non availability of grid power

BOTTOM ASH EXTRACTOR The bottom ash falls at the

end of the grate through a hopper into the bottom ash extractor The grate and the extractor. The grate and the ram feeder riddlings are transported into the bottom ash extractor. Bottom ash and grate riddlings are and grate riddlings are discharged to a local storage area.

h l l h The water level in the extractor ensures cooling of the bottom ash and seals the furnace from the environment. Water evaporated inside the bottom ash chute remains in the combustion chamber.

FLY ASH HANDING SYSTEM

• Mechanical conveyors shall collect the ash from the 2nd / 3rd (superheater area) and from the 4th boiler pass (economiser)boiler pass (economiser).

• Residues from the flue gas treatment are collected at the filter hoppers and transported to the top of the silo usingto the top of the silo using Elevators

PLOT PLAN

PLANT LAYOUT

• Road layout for easy truck movement and truck y yparking provided

• Location of Tipping bay and Waste pit selected to h C d f llminimise the Cutting and filling requirement

• Compact and Aesthetically designed

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TG BUILDING

COMPARSION PERFORMANCE –GUARANTEE

DESCRIPTION W/E PLANTCOAL BASED

DESCRIPTION W/E PLANTPLANT

Power Plant Capacity 11.50 MW 11.50 MWAuxiliary Power Auxiliary Power Consumption

16% 10.5%

STG Heat rate 2875 Kcal/kwhr 2758 Kcal/kwhrSteam cycle Low pressure (46

bar(a) & 410°C)High pressure (67

bar(a) & 490°C)Process parameters 5 bar(a)/4.247

NILTPH /160°C

NIL

Condensate return parameters

NIL NApFeed water temperature 130°C 130°C

ELECTRICALELECTRICAL

ELECTRICAL

• Generator • Variable Frequency Drive

SCOPE OF SUPPLY :-

• MV Panel• Grid / Generator

q y(VFD)

• Power Control CentreTransformer

• SwitchyardAuxiliary Distribution

• Motor Control Centre• Power and Control cable

Battery and Battery• Auxiliary Distribution Transformer (ADT)

• LT Busduct

• Battery and Battery Charger

• Lighting• Black start cum

Emergency DG set

g g• Earthing and Lightning• Cable Tray

ELECTRICALELECTRICAL

DESCRPTION PARAMETERS

GENERATION VOLTAGE 11KV ±10%, 50Hz ±5%, 3 PHASE

GRID VOLTAGE 132 KV ±10%, 50Hz ±5%, 3 PHASE

MV SYSTEM VOLTAGE 11 KV ±10%, 50Hz ±5%, 3 PHASEMV SYSTEM VOLTAGE 11 KV ±10%, 50Hz ±5%, 3 PHASE

LV SYSTEM VOLTAGE 415 V ±10%, 50Hz ±5%, 3 PHASE

MAX. COMBINED VARIATIONFOR VOLTAGE AND 10% (ABSOLUTE)FOR VOLTAGE ANDFREQUENCY

10% (ABSOLUTE)

FAULT LEVEL132KV : 40 KA FOR 1SEC11KV : 26.2 KA FOR 3SEC415V 50 KA FOR 1SEC415V : 50 KA FOR 1SEC

POWER FACTOR 0.8 (lag)

ELECTRICAL DESIGNTEMPERATURE

50 DEG C FOR OUTDOOR & 40 DEG C FORINDOOR INSTALLATIONTEMPERATURE INDOOR INSTALLATION

ELECTRICAL ELECTRICAL

DESCRPTION PARAMETERS

GENERATOR

11KV, 0.8PF, 4POLE, CACW, 2X66% COOLER,BRUSHLESS EXCITATION SYSTEM THROUGHEXCITATION TRANSFORMER, CLASS FINSULATION TEMPERATURE LIMITED TO CLASS B,AVR WITH 1 AUTO + 1 MANUAL CHANNELS, ONENO GENERATOR PROTECTION RELAY.

MV PANEL INDOOR, 1250A, ALUMINIUM BUS BAR, DRAW-OUTTYPE VCB FEEDERSTYPE VCB FEEDERS

SWITCHYARD 132KV, 1250A, OUTDOOR SWITCHYARD WITH ONENO GENERATOR TRANSFORMER CUM LINE BAY.

GENERATOR TRANSFORMER 15MVA, 11/132KV, YNd1, ONAN, OLTC±10%GENERATOR TRANSFORMER , , , ,INSTEPS OF 1.25%

AUXILIARY DISTRIBUTIONTRANSFORMER

2.5MVA, 11/0.433KV, Dyn11, ONAN, OCTC±5%INSTEPS OF 2.5%

LT BUSDUCT NSPBD, 4000A, ALUMINIUM BUS BAR

ELECTRICAL ELECTRICAL

DESCRPTION PARAMETERS

LT PANEL (PCC/MCC/DB) NON DRAWOUT, FUSED, CONVENTIONAL TYPEPANELS

MOTOR UP TO 250KW : 415V & ABOVE 250KW : 11KVUP TO 30KW : DOL & ABOVE 30KW : STAR DELTAUP TO 30KW : DOL & ABOVE 30KW : STAR DELTA

VFD 415V, 6 PULSE VFD FOR PA FAN, ID FAN, BFP andACC FAN

DG SET 1250KVA, 415V BLACK START CUM EMERGENCY,

DC SYSTEM CHARGER : 1 FC + 1 FCBCBATTERY : 110V, SMF VRLA TYPEMV Cable : XLPE, ALUMINIUM CONDUCTOR

CABLE LV CBLE : XLPE/PVC, COPPER (UP TO 4SQ.MM) / ALUMINIUM (ABOVE 4 SQ.MM)CONTROL CABLE : PVC INSULATED, COPPER

PHOTOS OF ESSEL JABALPUR SITE J

CONTROL AND INSTRUMENTATION

DCS DESIGN CONCEPTDCS DESIGN CONCEPT

A Single System was Designed for Complete Boiler, TG & BOP PackageBOP Package.

Standard Library Packages for Waste to Energy Process Industry.

Modular, Flexible, Scalable & Powerful Design.

O S t A hit t hi h i C bl f A ti Open System Architecture which is Capable of Accepting 3rd Party Interface over Profibus, Modbus & IEC Protocol

Extensive Fault Diagnostics with Alarm Annunciation gFeature.

DCS DESIGN CONCEPTDCS DESIGN CONCEPTDCS DESIGN CONCEPTDCS DESIGN CONCEPT

• Redundancy Philosophy Adopted in DCS– Controller Level– Communication Level– Power Supply Level

• Major Functional Grouping– BMS– FGT– Stack to Chute

B tt A h E t t– Bottom Ash Extractor– Waste Pit Management– Residual / Activated Carbon / Evaporation / Fabric Filter

Systemy– Steam Turbo Generator Protection & Control– BOP Protection & Controls– Electrical Controls & Energy Monitoringgy g

DCS GRAPHICSDCS GRAPHICS

DCS GRAPHICSDCS GRAPHICS