Precision Engineering Corporation

EPC Contractors for Thermal Power Plants

Precision Engineering CorporationAn ISO 9001 : 2008 company

email: pec.marketi g@pecve tures.comn nWe site: www.pecve tures.comb n

QUALITY DOMI A CEN N SCHEDULED DELIVERY CUSTOMER DELIGHT

Marketing Office :

B-46, Sector-57,

Noida - 201301, U.P.

Phone: 0120 249 0699

Fax: 0120 428 3095

99- , I dustrial Estate, B n

Bhilai - 490026, Chhattisgarh

Pho e: 0788 2286 709n

Fax: 0788 2286 411

Works :

Co-generation and capacity augmentation for captive power plants

New plant setup with energy conservation through waste heat recovery

IBR and Non-IBR pipeline and boiler spares upto 500MW



M/s Rashtriya Ispat Nigam Limited (RINL), Vishakhapatnam Steel Plant (VSP), Vishakhapatnam is setting up a 20.6 MW sinter cooler Waste Heat Recoverybased power plant through waste heat being recovered from both the straight line coolers of sinter machines 1 & 2, each of 312 sq. m. area.The waste heat recovery system essentially consists of the cooler hood and hot waste gas duct to recover the hot air discharged from the cooler, the dust catcher to remove the dust from hot air, the boiler to recover sensibleheat from the hot air, the circulation fan to circulate comparatively cool air/gas for cooling sinters and recovering the waste heat through boiler and finally the turbine generator to convert the steam into electricity.

M/s JP Steel Plantech Co. (SPCO), of Japan is providing the basic engineering for 20.6 MW sinter cooler waste heat recovery system and is supplying boiler and turbine generator. Precision Engineering Corporation is the primary contractor entrusted to set up this plant and owns the responsibility of the entire mechanical balance of plant in an extremely tight timeline of 15 months.Specifically, the package includes the following :

Complete detailed engineering, bought out equipment order placement and drawing preparation for the entire project worth ~Rs. 42 Cr was completed in 9 months from the date of award of contract. Overall 2,500T fabrication is to be completed; about ~350-400T of fabrication is being carried out on a monthly basis to meet the tight timelines. ~850T of ducting is being fabricated in parts and subsequently assembled and erected on site.

The project involves significant modification in the existing plant to make provision for extracting waste gases from sinter cooler bed. Apart from fabrication of bulky cooler hoods of ~100T, gas header ducts of 6.6m x 4.7m size for each sinter cooler, precision casting of 25% Cr Steel and extensive machining based assembled equipment are also being fabricated and installed.

• Detailed design and engineering: Preparation of ~1,200 detailed fabricationdrawings based on basic drawings provided by SPCO and preparation of detailedspecifications for bought out items

• Fabrication: of technological structure for boiler and other equipment; ofducting up to 6.6m x 4.7min size; mechanical equipment such as dust catcher and multiclones; a total of ~2500T

• Supply: of a number of ancillary equipment such as ACVS, air compressors, EOTcranes, hoists, dust handling, dampers and expansion joints all bought out items

• Erection, Testing and commissioning: of all the items under BOP package as well as boiler, turbine and circulation fans.

MECHANICAL BOP FOR 20.6MW WHR SYSTEM AT VSP

Further, scope also includes facilities for dust extraction systems, such as dust catchers and multiclones, EOT cranes, dust pneumatic handling, ACVS system for TG building.

6

1 2

3 4

5



Plant Modification Jobs New Plant Setups

Boiler Erection Various EPC Contracts

Coal Handling Plant IBR Piping

12

7 8

Boiler structure erection9 10

11



Ducting upto 6.6m Conveyors and structures

Sand Blasting

Technological Structures Heavy equipment and ducts

18

13 14

15 16

17



Calcium Silicate insulation with SS lining Equipment Structures

Equipment support parts Round ducts

MS Piping Coal Bunker

19 20

21 22

23 24



Reheater Coils for 210MW ABL boiler T-91 Welding with heat treatment

Superheater coils with 0.6D squeezed bends Economiser Coils for 210MW BHEL boiler

Boiler Bank tubes with swaged ends Studded bed coils

CASE STUDIES


BOILER CONVERSION FROM BAGASSE TO COAL BASED AT BIJAYANANDA SUGAR

Bhilai Steel Plant’s power and blowing station is core to the plant’s operation. Out of the six boilers, five are Russian make and one was supplied at a later stageby Isgec. The feedwater line of all the six boilers is due for replacement and wehave been entrusted with the responsibility to carry out the entire replacement.The project spanning two years started with detailed design and engineering, i.e. preparation of flow diagram, general arrangement drawings, isometrics and stress analysis. Procurement of pipes, fittings, valves, flow instruments, orifice plates, were procured and fabricated. Post site mobilization, the entire replacement job will be carried out over one year. Boiler related pipeline will be replaced sequentially during annual shutdowns of the respective boilers.Other pipeline will be isolated in the sections and replaced continually with plant under operation

REPLACEMENT OF HP FEEDWATER LINE FOR POWER & BLOWING STATION AT BSP


Sugar plants are generally equipped with bagasse-fired boilers so utilise the rejects of cane crushing. Hence, sugar plants run their power plants during the crushing season only. To ensure better plant utilisation, sugar plants are switching over to multi-fuel boilers to enable coal based power generation during the off-season. We are currently supporting such boiler conversion for a 40 TPH, bagasse-fired boiler for M/S Bijayananda Cooperative Sugar Mills Ltd. (BCSML) to coal fired. As a part of the project we are constructing a new Coal Handling Plant of 25TPH capacity, leading to a new coal bunker with 16 hours storage capacity. Underground Coal Hopper will receive raw coal and feed it to the crushing and screening plant for processing. Drag Chain feeders and Coal spreaders are being introduced. Necessary conveyors are being supplied. Relevant modifications are being carried out on the boiler to make it suitable for coal firing. New ash handling system will handle the excessive amount of ash generated by coal-firing. A new ESP is proposed to be installed to make the entire plant compliant with environmental norms.

IBR AND NON-IBR SPARES FOR BOILERS UP TO 500MW

We are IBR approved manufacturers of all kind of tubular pressure parts for boilersup to 500MW. We are regularly supplying such parts to utility scale customers, PSUs as well as privates. We have successfully manufactured coils out of diverse grades of material ranging from ordinary carbon steel to high alloy SA213 T-91.In a recent case, we supplied reheater coils for 210MW ABL make boilers to Chhattisgarh State Power Generation Company Ltd. To accommodate the urgency of the situation at the client’s site, the complete project was delivered, including procurement of tubes from ISMT to supply of finished product, in an extremely short time frame of three months. All tubes were inspected by M/s. Lloyds Register Asia at ISMT. Manufacturing process included specialised mandrel less bending.Demanding quality standards were met with 100% radiography, demetering, hydraulic test and ball test.



MANUFACTURING CAPABILITIES

Mechanical equipment and structure, pressure partcoil headers

Mechanical equipment and structure, boiler pressurepart coils upto 500MW

Mechanical equipment and structure, ducting of largesizes, ACVS and other general fabricationUnit-III 100,000 sq.ft. 30,000 sq.ft.

Facilities Primary Output

MAJOR CLIENTS

Backed by our extensive experience in fabrication of critical boiler components of plants up to 500MW and our experience of executingEPC projects, we are moving into complete boiler manufacturing. We have, on board, designers with 20+ years of experience in boiler manufacturing and operation. We plan to start with smallerboilers of up to 100TPH and take up projects to set up the entire power plant on an EPC basis. To support these plans, we arein the process of procuring land for developing another manufacturingunit of about 450,000 sq. ft. area.

FUTURE PLANS

BOILER MANUFACTURING

Setup initially as an ancillary unit to Bhilai Steel Plant, we have diverified into a number of industries, geographies and product capabilities. 60% of our revenue comes from what we call as our Flagship customers - these are the big names that keep returning to us year after year. Thanks to our customer centric approach, we can boast of a long list of satisfied customers.

Precision Engineering Corporation

Documents

Transcript of Precision Engineering Corporation