PROJECT HIGHLIGHTS
1.
Project
2.
Plant capacity
1320 MW
3.
Plant configuration
4.
Location details
- Latitude
160 33 16.03 N
- Longitude
750 43 44.52 E
588 m
- Seismic zone
- Distance from
Basavanabagewadi town
18.5 km
0.5 km
15.0 km
5.0 km
165 km
460 km
Climatological data
5.
Sheet- 2
5.
32.9 0C
20.6 0C
44.9 0C
06.7 0C
- Relative Humidity
- Max.
- Min.
85%
28%
671.6 mm
181.1 mm
40.5
18.4 km/h
03.8 km/h
61.0 km/h
50 0C
Land
Area in acres
- Power plant
270.00
130.00
44.00
- Green belt
226.00
234.00
- Colony
65.00
120.00
1,089.00
marshalling yard
Sheet- 3
6.
7.
Water
- Source of water
Krishna River
- Water requirement
4,430 m3/hr
Fuel
- 16 km
Coal
Indigenous- 70%
Imported - 30%
- Source
Indigenous-CIL/coal blocks
Imported- S.A/Indonesia/ Austarlia
3500 k.cal/kg
5100 k.cal/kg
HFO/LDO
- Source
8.
9.
Steam Generator
10.
Cooling system
11.
Chimney
a Primary fuel
-
Blending ratio
b Secondary fuel
Sheet- 4
12.
Base Load
13.
Power Evacuation
14.
No R&R issues
15.
Ash
- Generation
2.01 M.MT
- Utilization
Cement industries/SSI
16.
Rs 7,020.56 crores
17.
Cost per MW
Rs 5.32 crores
18.
Cost of coal
Rs 2,900 / MT
19.
Rs 30,000/MT
20.
21.
Rs 3.32 / kwh
:
Unit # 1 - 46 months
Unit # 2 - 52 months
Sheet- 5
1.0
INTRODUCTION
M/s Luxor Energy Private Limited (LEPL) is being promoted by SANALI
GROUP and developing Coal Based supercritical Thermal Power
Generation Plant with a Capacity of 1320 MW in 2X660 MW configuration
keeping in view the efficiency of plant operations and the economies and
environmental aspects.
M/s Luxor Energy Private Limited was incorporated in Registrar of
Companies on 29.03.2010 date vide certification of incorporation ID no:
U40300AP2010PTC067703 under Indian companies act 1956.
The total installed capacity on all India wise is around 1,64,508.8 MW as on
31.08.2010. Out of this total installation the State , central and private sector
installation capacities are 80,849.12 MW (52.5%) , 51,727.63 MW (34%) and
31932.05 MW (13.5%) respectively. The supply and demand gap for energy
requirement and peak load is around 10.1% and 12.07% respectively in the
year 2009-2010 on all India basis. The annual growth rate in power generation
was recorded as 6.6% for the year 2009-2010.
The total installed capacity in Karnataka state is 10,386.34 MW as on
31.03.2010 and the state has met peak demand of 7084 MW. The peak and
Energy deficit in the state of Karnataka are recorded as 10.6% and 7.7%
respectively for the year 2009-2010.
As per the Electricity Act 2003, any generating company may establish,
operate & maintain power generating station. However, state/central
government approvals for various infrastructural requirements like land,
water, Rail transportation, Environmental clearance etc. and allotment of
domestic coal linkage by coal India Ltd. are required.
LEPL has explored three sites for the proposed project and the merits and
demerits of each site are discussed in the subsequent sections of this
report. Project report has been prepared based on central electricity
Sheet- 6
b.
c.
d.
e.
f.
g.
Environmental considerations.
h.
i.
The justification of the project and the requirement of various statutory and
non statutory clearances are discussed in the subsequent section of this
report.
It is proposed to have two units each of 660 MW capacity with supercritical
technology and pulverized coal fired boiler. Salient Technical features of the
main and balance of plant equipment are discussed in the subsequent
sections of this report.
Sheet- 7
Sheet- 8
control. The system will also integrate the various proprietary control
packages supplied by the main equipment vendors for plant operation.
There will be signal exchange from BOP packages/switchyard control
systems to central control room for monitoring.
Electrostatic Precipitators with 99.9% efficiency and of adequate size will be
provided at the exit end of each boiler to bring down SPM emission level
under 50mg/NM3. One No. twin flue 275 meters high stack common for
both units will be provided.
Civil and structural engineering aspects are discussed in the subsequent
sections. It is proposed to provide staff quarters for O&M staff.The required
infrastructure facilities will be provided for project execution. Project
construction activities will be monitored by LEPL staff and technical
consultants. The period of construction will be 46 months for first unit and
52 months for the second unit from the date of commencement. The
operation and Maintenance of the plant will be done by the LEPL O&M
staff. The required manpower will be recruited from local area.
The total Project cost based including interest during construction is
estimated as Rs. 7020.56 Crores. The total capital cost will be met from
promoters equity and debt from various Indian/external financial institutions.
The proposed debt and equity ratio is 70:30. The equity capital will be built
up by M/s. LEPL & its joint venture partners.
Sheet- 9
2.0
2.1
Sheet- 10
The Government of India has initiated several reform measures to create a
favorable environment for addition of new generating capacity in the country.
The Electricity Act 2003 has put in place a highly liberal framework for
generation. There is no requirement of licensing for generation. The
requirement of techno-economic clearance of CEA for thermal generation
project is no longer there. For hydroelectric generation also, the limit of capital
expenditure, above which concurrence of CEA is required, would be raised
suitably from the present level. Captive generation has been freed from all
controls.
In order to fully meet both energy and peak demand by 2012, there is a need
to create adequate reserve capacity margin. In addition to enhancing the
overall availability of installed capacity to 85%, a spinning reserve of at least
5%, at national level, would need to be created to ensure grid security and
quality and reliability of power supply.
Even with full development of the feasible hydro potential in the country, coal
would necessarily continue to remain the primary fuel for meeting future
electricity demand.
2.2
Hydro
Coal
State
3,599.8
1,970.0
Private
00.0
860.0
Central
0.0
1,072.7
Sector
Share
Total
3,599.8
3,902.7
Source : MOP/CEA Website
Thermal
Gas
Diesel
Nuclear
Wind /
NES
Total
Total
0.0
220.0
0.0
127.92
106.5
0.0
2097.92
1186.50
1,072.7
0.0
0.0
195.4
527.15
1,707
0.0
6,224.87
2,893.44
1,268.00
220.0
234.4
4,357.1
195.4
2,234.1
10,386.30
Sheet- 11
Status
Project Name
Type
Table 2.2
Likely Installed capacity addition during 11th plan including best efforts
projects for Karnataka state :Installed
capacity
(MW)
Capacity
addition
th
during 10
plan (MW)
Benefits
shares
of state
(MW)
Commissione
d/Slipped
during 20072012 (MW)
Last unit
commissioning
date/(Likely date
of commissioning
CENTRAL-SECTOR
NEYVELI II MC X
500.00
500.00
110.00
(2010-2012)
*SIMHADRI ST-II
1000.00
1000.00
176.00
(2010-2012)
*ENNORE JV COST
1000.00
1000.00
80.00
(2010-2012)
440.00
440.00
119.00
KUDANKULAM 1&2
2000.00
2000.00
442.00
(2009-2010)
*KALPAKKAM PFBR
500.00
500.00
88.00
(2010-2011)
T
H
U
C
1000.00
230.00
RAICHUR U-8
250.00
COMM 220.00
11.04.2007
1015.00
STATE-SECTOR
1000.00
1000.00
230.00
230.00
250.00
250.00
COMM 500.00
COMM 230.00
03.12.2007
09.02.2009
(2010-2011)
1480.00
PRIVATE-SECTOR
UDUPI LANCO
1015.00
1015.00
1015.00
TORANGALLU
600.00
600.00
600.00
PRIVATE-SECTOR TOTAL:-
1615.00
GRAND-TOTAL:-
4110.00
COMM 600.00
24.08.2009
Sheet- 12
Table-2.3
ACTUAL POWER SUPPLY POSITION
Period
th
9 plan end
2002-03
2003-04
2004-05
2005-06
2006-07
2007-08
2008-09
APR,09MAR10
MAR ,2010
Peak
Deman
d
(MW)
Peak
Met
(MW)
Peak
Deficit/
Surplus
(MW)
Peak
Deficit/
Surplus
(%)
Energy
Requirement
(MU)
Energy
AvailAble
(MU)
Energy
Deficit/
Surplus
(MU)
Energy
Deficit/
Surplus
(%)
5338
6198
6213
5927
5949
6253
6583
6877
7,927
4428
4805
5445
5612
5558
5811
5567
6548
7,084
- 910
- 1393
- 768
- 315
- 391
- 442
- 1016
-329
-843
17.0
22.5
12.4
5.3
6.6
7.1
15.4
-4.8
-10.6
19716
32249
36153
35156
34601
40797
40320
43291
45,607
16684
29084
31145
33687
34349
39948
39230
40700
42,098
- 3032
- 3165
- 5008
- 1469
- 252
- 849
- 1090
-2591
-3,509
- 15.4
- 9.8
- 13.9
- 4.2
- 0.7
- 2.1
- 2.7
-6.0
7,927
7,084
-843
-10.6
4,943
4,478
-465
-9.4
-7.7
As per 17th Electric power survey of India , the peak load demad and energy
requirement for karnataka state is given as follows :Table-2.4
Year
Peak Load MW
Energy Requirement
MKWH
2011-12
8,826
53,540
2016-17
13,092
79,996
2021-22
17,464
1,07,471
The total installed capacity in the state of Karnataka including central sector
shares from various power generating stations is shown in table-2.1 as
10,386.3 MW as on 31.03.2010.
The likely installed capacity addition during 11th plan including best efforts
projects as shown in table -2.2 in Karnataka state is projected as 4,110
Sheet- 13
In the state Karnataka, Electricity Act 2003 has come in force. As per
Electricity Act 2003, clause 7 any generating Company may establish,
Operate and maintain a generating station without obtaining license under
this act if it complies with technical standards relating to connectivity with
the grid.
Section 73 (b) of the Act 2003 stipulates functions & duties of Central
Electricity Authority.
Sheet- 14
Requirement of input/clearances
Electricity Act 2003 do not indicate special requirement like
clearances from the concerned statutory or non-statutory authorities
for setting up thermal power plant. However clause 10 (3)
stipulates that generating company will:a.
b.
Registration of the
company
2.
Government of Karnataka
Approval for Infrastructural
requirements.
3.
Land Availability
Sheet- 15
4.
Water Availability
5.
Coal Availability
6.
Ministry of
Environment &
Forest Clearance
7.
Rehabilitation &
Resettlement plan
8.
9.
Sheet- 16
Sheet- 17
3.0
IMPLEMENTING
Sheet- 18
Sheet- 19
REMAX CONSTRUCTIONS.
LUXOR ENERGY
CYBER TOWERS.
LAKEFRONT TOWERS.
MILLENNIUM ESTATES.
AMIR ADS.
Sheet- 20
Sheet- 21
AMIR ADS
Amir Ads is the advertising arm of Sanali Group, a foray into the world of
outdoor advertising. This company deals with the advertising requirements
of their clients with the media of Hoardings, Display Panels and Pole
Kiosks. Its business strategy is to be the premier provider of outdoor
advertising in each of the markets it serves. The talented design staff uses
state-of-the-art technology to help the advertisers prepare creative, eyecatching displays. They also help with the strategic placement of
advertisements throughout an advertiser's market by using software that
allows us to analyze the target audience and its demographics.
SANALI SOFT PVT LTD
Sanali Soft, Inc. is the software arm of Sanali Group, a software
development and consulting firm. Since its inception, Sanali Soft, Inc.
demonstrated the unique ability to identify and align itself with emerging
technologies. Their vigorous insistence on high performance standards and
excellence is the driving force behind every project. Excellence is their top
priority because they know that their success is inseparable from their
clients' success providing quality solutions and services in project
management, software development and consultancy services in US and
abroad. Sanali Soft, Inc. has offices located both in India, United States and
abroad.
PROJECT IMPLEMENTING COMPANY:
This 2 X 660 MW Thermal Power Project will be Implemented by Luxor
Energy Pvt. Ltd., by raising equity share capital subscribed and by Term
loan to meet the project cost. The authorized and paid-up share capital of
the company will be raised in stages as and when required as per statutory
and financial requirement to execute the project, complying with standard
lending norms of lending institutions in India & Abroad (ECB Loans).
Sheet- 22
4.0
4.1
BASIC REQUIREMENTS
The following infrastructure facilities/basic requirements are required to set
up a coal based power plant.
Land requirement and availability
Water requirement & availability
Fuel availability and transportation facilities.
Power Evacuation Facilities and proximity to the site.
Rail/Road accessibility.
Fulfillment of Pollution & Environmental stipulations.
Human resettlement and rehabilitation.
As per CEA regulations-2007, the following criteria shall be considered in
selection of site for thermal generating stations:
4.2
i)
ii)
iii)
iv)
v)
vi)
Sheet- 23
Description
Site- A
Site-B
Site-C
1.
Location
2.
Latitude
16 33 16.03
proposed site
Longitude :
75 43 44.52
(approximate)
3.
Type
of
Land
dry
Forest /
Latitude
16 29 16
Longitude :
75 54 27
environmental
feasibility
including
rehabilitation
and
resettlement
Proximity
to
villages.
from
the
16 27 32
Longitude :
75 56 38
Latitude
requirement , if any
nearest
Preliminary
4.
one block.
Lift
Lift
irrigation
scheme.
project.
Hangargi : 1.6 Km
Uppal Dinni : 3.0 Km
Nagavada : 1.75
Under
UKP
irrigation
scheme.
project.
Hangaragi : 0.60 Km
Mukartihal : 2.56 Km
Unnibhavi:0.9 Km
Under
UKP
Sheet- 24
Ronihal village
: 4.23 Km
Golsangi : 1.8Km
Hebbal: 0.5 Km
Villages are in close proximity to the Halihal: 3.2 Km
proposed project boundary site
Villages are in close proximity to the
proposed project boundary site
5.
Accessibility by Rail,
Telgi Rail way station (on South Western Vandal Rail way station is nearest
proposed site, in Km
site
6.
Coal Transportation
logistics , Rail way line
distance from source to
nearest RS in Km.
Coal requirement: 6.92 Million Tonnes Coal requirement: 6.92 Million Tons per Coal requirement: 6.92 Million Tons per
per year (100% PLF)
30% of coal will be imported from 30% of coal will be imported from 30% of coal will be imported from
Indonesia/ Australia
70% Indian coal
1200 km distance
km distance
km distance
Sheet- 25
In land transport of Imported Coal from Inland transport of Imported Coal from Inland transport of Imported Coal from
7.
8.
Railways
Railways
Railways
Distance :460 Km
Distance :442 Km
Distance :431 Km
commitment of requisite
capacity &
Proximity to project site
in Km,
a. Metropolitan/ National
Golagumbus
an
Archaeological
/ Golagumbus
historical
sanctuaries/ ecological
importance place is
sensitive areas/
archaeological /historical/
religious /tourist
importance / defense
religious
an
Archaeological
/ Golagumbus
an
Archaeological
tourist
28.5 km (radial
Basavana Bagevadi, religious place Basavana Bagevadi, religious place 11 Basavana Bagevadi, religious place 14
24.5 Km (radial) from proposed site
Sheet- 26
9.
10.
land
required.
required.
required.
NH 218 : 0.5 Km
NH 13: 2.5 Km
NH 13: 3.25 Km
Accessibility by Road
Distance from
National High way, in
Km
Sheet-27
3.3
Location:
The site is located near Mulwad village and about 31 Km (by road) south
of Basavana Bagewadi town in Bijapur district, Karnataka state. The
nearest railway station is Mulvad at a distance of 5 km and National
Highway 218 passes 500 meters away from this site. The longitude
and latitude are 750 4344.52 and 160 33 16.03 respectively. Project
location topo map is enclosed as Annexure-3.
Land :
The area of land measuring about 904 acres consisting the mix of Fallow
land, waste land with shrubs and dry agriculture land with low yielding
single crop is available as one block for the power plant. This land is
adequate for 1320 MW capacity. In addition to this, about 65 acres of
land for colony is also available.
Water :
Source of water for this project is Krishna River and proposed water offtake point is 16 kms away. Consumptive water requirement is estimated
as 4,430 m3/hr. for the power Plant.
Right of way/acquisition of land for the corridor for laying pipeline for
transportation water from the intake point to the plant site will be
organized by M/s LEPL.
In line with the MOEF guidelines for the new thermal power Stations, it is
proposed to adopt closed circuit cooling system deploying cooling towers
and draw only makeup water requirement from the source. The plant
water system is described in section subsequent sections.
Sheet-28
Sheet-29
Environmental Aspects:
There is no eco-sensitive spot like Natural Park, Wild Life sanctuary, BioSphere Reservation, Historical or Cultural Site in the vicinity of the
proposed site. LEPL will get the EIA studies conducted and obtain
Environmental Clearance based on the Terms of Reference of MOE&F.
Resettlement & Rehabilitation issues, if any, will be implemented with the
approval of state Government. There is no reserve forest or protected in
the proposed power plant identified area and no important historic place
is situated in the near-by vicinity. R & R issues (if any) will be resolved by
LEPL with the approval of State Govt. River water will be used in closed
circuit for circulating water system and for sweet water needs. Super
critical technology for steam generator will be adopted. Electrostatic
precipitator of high efficiency, stack height as per CPCB norms will limit
the emission levels. As such, no undue problem of installation of the
power plant at said location from environmental aspect is envisaged.
Sheet-30
5.0
5.1
Sheet-31
Advanced USC plants have steam outlet pressure above 22.1 MPa and
steam outlet temperatures above 625-650 oC. Typical net plant efficiency:
42.5-46.0 percent.
Pulverized coal technologies & efficiency
Pulverized coal option
Subcritical
Supercritical (SC)
Ultra-supercritical (USC)
Advanced USC
Steam Conditions
<22.1 MPa/538oC/538oC
24.7 MPa/538-565 oC /565 oC
27 MPa/565-625 oC
27 MPa/above 625 oC
Typical Efficiency
(% HHV)
35.0-38.0
38.0-40.0
40.0-42.5
42.5-46.0
Sheet-32
However, this also requires more sensitive and quick responding control
systems.
Supercritical power plants use special high grade materials for the boiler
tubes. The turbine blades are also of improved design and materials. In fact,
the very increase in higher pressure and temperature designs are dependent
on the development of newer and newer alloys and tube materials.
In subcritical units the drum acts as a fixed evaporation end point. The
furnace water walls act as the evaporator. Not so in the case of a
supercritical unit. The evaporation end point can occur in various levels of
the furnace depending on the boiler load. The percentage of Superheat in
supercritical units is higher than subcritical units. Because of this the furnace
tubes act more as super heaters than water walls. This necessitates the use
of higher grade of materials like alloy steels in the furnace.
Higher steam temperatures in supercritical units results in a lesser
differential temperature for heat transfer. Because of this, heat transfer areas
required are higher than subcritical units.Higher Superheat steam
temperatures entering the HP turbine also mean higher reheater inlet
temperatures which again results in a higher heat transfer areas.
In supercritical units the water entering the boiler has to be of extremely high
levels of purity. Supercritical boilers do not have a steam drum that
separates the steam and the water. If the entering water quality is not good,
carry over of impurities can result in turbine blade deposits.
(b)
(c)
(d)
(e)
(f)
(g)
(h)
Sheet-33
(i)
In India, the units ranging upto 500 MW have been operating with
subcritical parameters of 170 kg/cm2 (abs) pressure and 540 0C steam
temperature from many decades. Now the ultra Mega capacity plants with
single unit rating of 660/800 MW with Supercritical parameters are under
implementation with parameters of 255 kg/cm2 pressure and main steam
& RH temperatures as 5680C and 5960C respectively. The first Indian
supercritical coal based thermal power plants are under construction by
NTPC at Sipat & Barh.
5.2
Sheet-34
5.3
SC STEAM GENERATOR:
S.NO
MANUFACTURER
COUNTRY /
COLLABORATION
INTERNATIONAL
JAPAN
2
3
4
MITSUBISHI HEAVY
INDUSTRIES
BABCOCK HITACHI
ANSALDO
ALSTOM
ISHIKAWAJIMA-HARIMA HEAVY
INDISTRIES (IHI)
MITSUI BABCOCK
REPUBLIC OF
KOREA
JAPAN
8
9
10.
PODOLSK
BABCOCK & WILCOX
SHANGHAI
11.
12.
HARBIN
DONGFANG
II
1.
INDIAN
BHEL
JAPAN
ITALY
FRANCE
UK-JAPAN
REMARKS
INCLUDING COMBUTION
ENGINEERING -USA ,
EVT -GRMANY & STEINFRANCE
INCLUDING DEUSTCHE
BABCOCK &
STEINMULLER
(GERMANY)
POLAND
USA
CHINAALSTOM&SIEMENS
CHINA/MITSUBISHI
CHINA/HITACHI
In collaboration with
ALSTOM
Orders Executing :
A) Barh-II 2 X 660 MW
B) Krishnapatnam 2 x 800
MW
2.
L&T
MHI
500 MW TO 1000 MW
Sheet-35
SC STG :
S.NO
MANUFACTURER
COUNTRY /
COLLABORATION
INTERNATIONAL
1
2
3
4
5
JAPAN
JAPAN
JAPAN
JAPAN
GERMANY
6
7
8
9
10
11
ANSALDO
ALSTOM
FOSTER WHEELER
GENERAL ELECTRIC
LMZ
MITSUI BABCOCK
ITALY
FRANCE
USA
USA
RUSSIA
UK-JAPAN
II
INDIAN
1.
BHEL
2.
3.
4.
L&T
BHARATH FORGE
JSW
In collaboration with
SIEMENS
MHI
ALSTOM
TOSHIBHA
REMARKS
INCLUDING
WESTINGHOUSE USA
INCLUDING DEUSTCHE
BABCOCK &
STEINMULLER
(GERMANY)
Orders Executing :
Barh-II 2 X 660 MW
Krishnapatnam 2 x 800 MW
Sheet-36
6.0.0
6.1.0
6.1.1
Furnace Type
(i) Two path / tower type
Furnace configuration is derived from each equipment
manufacturers specialty. Two path types is mainly adopted in
Japan and tower type is typical in Europe.
No significant difference is observed in the applicability to kind
of coal. It is because boiler design can be adjusted in
accordance with coal characteristics such as abrasion of ash.
(ii) Spiral (plain/bare tube) wall and vertical (rifled/ribbed tube )
Wall type
The principal concern with a variable super critical pressure
design is the requirement for once-through operation. The
mass flow in the furnace wall tubes must be sufficiently high to
Sheet-37
Sheet-38
Sheet-39
tube (or rifled tube used for vertical water wall), and circulation
system with boiler circulation pump (BCP) can be applied to this
type of boiler. This system can shorten the start up time and heat
loss during start up period.
3. Minimum Load with dry Range / Control Range
Changing point (Benson Point) or dry/wet condition is about 30%
TMCR load. Minimum control range is set at 40% TMCR load with
consideration of undershoot during load reducing, turn-down of
pulverizers, ignition stability etc. There is no difference is spiral
water wall and vertical tube water wall in minimum load
requirement.
4.
Material Selection
The materials for the range of steam temperature to the level of
566 0C are already proven. There is no difficulty in technical
aspects in material selection.
On the other hand, the applicable materials shall be selected
considering the combination of applied temperature and pressure
levels.
Table below shows the typical material selection in boiler pressure
parts. This material application just shows the general concept
and each manufacturer has his criteria considering his design
concept.
Judging from Indian sub-critical plants, 9% Cr steel and austenitic
materials have already used for high temperature zones.
Therefore for supercritical power plants, 538 0C temperatures for
main steam and 566 0C for reheat steam, no new materials are
required as the material basket used in sub-critical plant is
adequate. Only a shift in quantum of superior material is there due
to higher parameters.
Sheet-40
Temperature
range
component
Super heater tubes
Repeater tubes
246 kg/cm2g
538 0C / 560 0C
1-2% CrMo steels
9% Cr steels
5. Emissions
Coal consumption is reduced with efficiency improvement led by
upgrading of steam conditions. Consequently, emissions of CO 2,
NOx & SOx is reduced.
i. CO2 emissions
Super critical plants reduce CO2 emission at least 2-3%
Compared to sub-critical plant.
ii. SO2 emissions
Securing of FGD (Flue Gas Desulfurizer) space and the
installation of 275 m tall chimney as per M.O.E.F guidelines.
iii. NOx emissions
The amount of NOx emissions is limited to 40 micro gm/m3
(Annual Arithmetic mean of 104 measurements in a year) as
per National Ambient Air quality standards specified by MOEF
Sheet-41
iv.
Particulate Emissions
MOEF guidelines for particulate emission of less than 60 micro
gram/m3 for size less than 10 micro m (Annual Arithmetic mean
of 104 measurements in a year) will be satisfied by adoption of
high efficiency electrostatic precipitators (ESP).
6.1.2
Draft system
The furnace draft system comprises of two (2) nos of Forced
Draft (FD) fans each one will rated capacity of 60% of BMCR.
The FD fans will be axial impulse type, constant speed with
variable blade pitch controller with drive motor. Each fan shall
contain bearing lubrication and hydraulic blade pitch control unit
consisting of
a) 2x100 % oil pumps, each with motor drive, coupling and
coupling guard.
b) 2x100% oil coolers.
c) 2x100% filters, differential pressure switches.
d) One (1) oil storage tank.
e) Instrumentation, interconnecting piping, valves and fittings
including pressure relief valves and non return valves
(NRVs) etc.
f) Electrical/ pneumatic actuators with all accessories.
Silencers will be provided at the suction of the fans to limit the
noise levels to specified values.
Sheet-42
Also, Two (2) induced draft (ID) fans, each one will have rated
capacity of 60% of BMCR, radial type with variable speed
hydraulic coupling with drive motor. Each ID fan shall be
provided with bearing lubrication unit consisting of
a) 2x100% oil pumps each with motor, coupling and coupling
guard.
b) 2x100% oil coolers.
c) 2x100% filters, differential pressure switches, etc.
d) One (1) oil storage tank.
The equipment will be complete all other accessories necessary
for continuous operation and suitable for outdoor installation.
(2)
(3)
Sheet-43
(5)
(6)
Boiler unit will be equipped with two (2) 60% primary air fans,
gravimetric raw coal feeders for each mill and two 100% seal air
fans to provide seal air for bearings, journals etc. The primary
and seal air fans will have a design margin on flow and pressure
of not less than 25% and 30% respectively.
Sheet-44
(7)
(8)
(i)
(ii)
Heavy Fuel Oil (HFO) for low load operation and flame
stabilization for minimum capacity of 25% of BMCR.
Electrostatic Precipitators
The high efficiency electrostatic precipitators having an
efficiency of 99.9% will limit the outlet emission to 50 mg/Nm 3
while the boiler is operating at its BMCR and firing worst coal
having maximum ash contents.
The electrostatic precipitators will have four (4) parallel gas
streams, isolated from each other on the electrical as well as gas
side and will be provided with gas tight dampers at inlets and
outlets of each stream, so as to allow maintenance to be carried
out safely on the faulty stream, while the unit is working.
Electrostatic precipitators will be provided with microprocessor
based programmable type rapper control system and ESP
management system to ensure the safe and optimum operation
of ESP. ESP transformer rectifier sets will use high fire point oil
as the cooling medium. The dust collection hopes at all strategic
locations will have a minimum storage capacity of eight (8)
hours. The hoppers will have heating arrangements to prevent
ash sticking to the sloping sides and down pipers. Level
indicators to indicate and trip the ESP in case of high ash levels
in the ash hoppers which will jeopardize the safety of ESP
otherwise.
(9)
Sheet-45
parameters
Particulars
Super heater outlet steam
flow
Steam pressure at SH outlet
(minimum)
Steam temperature at SH
outlet
Reheat steam flow
of
steam
generator
(660
Units
T/hr
Unit Parameters
1919.7
Kg/m2 (abs)
248.7
539.10
T/hr
1720
300
567.4
Kg/m2 (g)
48.2
MW
Sheet-46
Kg/m2 (g)
45.9
259.3
139
20
FD fans
Nos./Type
Soot blowers
ID Fans
Nos./type
6.2.0
6.2.1
Power Cycle
By spray attempt.
between stages of S.H
By burner tilt/flue gas
recirculation and
emergency spray
attemperators
2 nos. Axial impulse
type
Retractable blowers,
and rake blowers as
per requirement
2 nos. double suction
radial type
2 nos. regenerative
air pre heaters and 1
no steam heated air
pre heater.
50
Low NOx pulverized
coal burners
More than 86.4%
a) Superheated steam from the final super heater (SH) of the boiler
will be led to the HP turbine inlet through two main steam leads,
the two leads from SH outlets will be connected to two (2) main
Sheet-47
steam stop cum control valves at turbine inlet chest. Branch tapoffs will be provided on the common main steam lead for
connections to 60 percent HP bypass valve as well as to the
pressure reducing desuperheating station for auxiliary steam
service.
b) Steam
leaving
the HP
for reheating
through (2)
back to the
cold reheat
Sheet-48
1.
HP turbine
to HP heater # 8
2.
IP turbine extraction I
to HP heater # 7
3.
IP turbine extraction II
to HP heater # 6
4.
to Deaerator
5.
IP turbine exhaust
to LP heater 4
6.
LP turbine extraction I
to LP heater 3
7.
LP turbine extraction II
to LP heater 2
8.
LP turbine extraction I
to LP heater 1
6.2.4
Turbine
The turbine will have one single flow HP, one double flow IP and one
double-flow low-pressure cylinder. All components will be selected
based on long-proven records and standardized modules. The
turbines will be of the tandem compound design. The individual shafts
Sheet-49
of the cylinders and the generator rotor shaft will be coupled rigidly
together.
HP Turbine
The HP turbine will be designed with single flow. This will have a
double shell casing consisting of inner casing carrier and barrel type
outer casing. Main steam to the HP turbine will be supplied through
two combined stop and control valves. The exhaust branch will be
located below the turbine.
IP Turbine
The IP-turbine will be designed with double flow. This will have a
double-shelled casing with horizontally split inner and outer casing.
Reheat steam will be admitted through two combined stop and control
valves of the turbine. The valves will be arranged on either side of IP
casing. The exhaust branches will be on the top of the casing. The
steam flows to the LP turbine through a crossover pipe.
LP Turbine
The LP-turbine will comprise of horizontally split multi-shell casing.
The outer casing will consists of two end walls, a bracing system, the
top half and the sidewalls. The inner casing will be double shell axially
split supported by support arms that are bolted to it and that rests on
the bracket supports of the bearing pedestals. The bearing pedestals
will be mounted on the foundation. They will carry the shaft seal
casings, which shall be joined to the outer casing by means of
expansion joints.
6.2.5
Blades
The short moving blades and guide blades for the first LP stages will
be one-piece machining with integral T-roots and shrouds. The long
moving blades will be twisted and will have no lacing wires or
shrouding. They will be drop forge and will have fir-tree roots/T-roots
Sheet-50
that will fit into similar grooves in the rotor. The guide blades of the
last stage will be hollow and fabricated.
6.2.6
Valves
The HP-Turbine will be fitted with two combined stop and control
valves and one overload control valve for main steam admission. Two
combined intercept stop and control valves will be installed at the IPTurbine for hot reheat steam admission.
Each combined valve consists of a stop valve and a control valve that
will be mounted on a common body. Every stop valve and control
valve will be equipped with an electro-hydraulic actuator. The main
steam valves will be directly mounted on the HP-turbine.
6.2.7
Sheet-51
6.2.8
Shaft Glands
All shaft glands will be of the axial-flow labyrinth type. The glands on
the LP turbine will be mounted in glad casings that will be bolted to
the bearing pedestals.
6.2.9
Sheet-52
(e) Each unit will be provided with an oil tank of sufficient capacity for
oil changes. 2x100% duty vapor extraction fans and 2x100%
capacity oil coolers will be provided for oil cooling.
(f) A lube oil purification unit will be permanently installed for each
unit for the total oil charge on a continuous basis.
6.2.10
6.2.11
Governing/Regulation Systems
The turbine will have throttle or nozzle controlled type governing. The
steam turbine generator unit will be equipped with an electro hydraulic
governing system backed up by 100% mechanical hydraulic or
electro-hydraulic control system. The governing system will be highly
reliable and operationally safe and it will be capable of controlling with
stability, the speed of the turbine at all power outputs between zero
and the specified maximum power output when the unit is operating
isolated, or the energy input to the steam turbine when the unit is
Sheet-53
6.2.13
6.2.14
Turning Gear
Rotor turning gear will be provided to ensure uniform and rapid
heating/cooling of casing during start up/trip conditions. The turning
gear motor will be mounted on the housing and will be connected
through gears and pinions for turning the rotor at a speed of 3 rpm
Sheet-54
6.2.16
6.2.17
HP LP Bypass station
60% H.P. and L.P turbine bypass station will be provided to act not
only as a protection to the turbine during pressure rise resulting from
sudden load throw-off but also to enable operation of the unit at loads
lower than the control load. Further HP/LP bypass will permit quick,
repeated hot starts of the unit on its tripping.
The LP bypass station will be connected to the hot reheat line and
discharges the steam into the condenser. The hot reheat steam will
Sheet-55
6.2.18
(a)
Quick start up of the steam generator from cold, warms & hot
conditions.
(b)
(c)
(d)
Condensing Plant
The function of the condenser is to condense the steam exhausted
from the LP cylinders and to produce and maintain as high a vacuum
as possible in order to increase the enthalpy drop, which can be
utilized in the turbine.
The condensing unit will comprise two length wise condensers with
identical cooling surfaces. The cooling water will pass connectively
through the condenser in two parallel flows, thus making it possible to
shutoff one of them with out stopping the turbine.
6.2.19
Design features
The condenser unit will consist of two connected condensers and
three water jet ejectors. The condensing unit will comprise two
lengthwise condensers with identical cooling surface. The cooling
water will pass connectively through the condensers in two parallel
flows, thus making it possible to shut off of one of them without
Sheet-56
Sheet-57
6.2.20
Air Extraction
The unit will comprise of (2x100%) vacuum pumps along with all
accessories and instrumentation for condenser air evacuation. The
vacuum pumps and accessories will be used to create vacuum by
removing air and non-condensate gases from steam condenser
during plant operation. Vacuum pumps will be of single/two stage
liquid ring type with both stages (If two stage pump is selected)
mounted on a common shaft. Vacuum pumps will be sized as per
latest HEI requirements.
6.2.21
Condensate System
Condensate from the divided hot well of the condenser of each unit
will be pumped by 3x50 percent capacity condensate extraction
pumps (CEP) through steam jet air ejectors (alternately vacuum
pumps) gland steam condenser, drain cooler and LP heater to the
deaerator. Condensate extraction pump recirculation are envisaged
to arranged through an adequately sized control station located
upstream of the gland steam condenser. Condensate discharge flow
will be measured through a flow meter installed on the discharge
line between the CEPs and steam jet air ejectors (if provided) :- The
condensate will be utilized for the following apart from use for
steam generator :1.
Sample coolers
2.
3.
4.
5.
6.
Alkali flushing
7.
8.
Sheet-58
Condensate pumps
Each unit has 3x50% capacity motor driven condensate extraction
pumps (two operating and one standby). The condensate pumps will
be vertical canister type, multistage centrifugal diffuser design with a
double suction first stage designed for condensate extraction service
having low suction head requirement. The pumps will be capable of
handing the condensate from the condenser together with feed heater
drains when the machine is operating at maximum unit output with HP
Heaters out with 3% make-up and discharging this quantity through
the condensate polishing unit and the LP heaters to the deaerator.
The pump will have adequate margins on capacity and head to cater
for most adverse conditions of operation such as:
6.2.23
a)
e)
Sheet-59
through
control
valve
will be also
stations to the
Turbine Drains
Drain from steam turbine, extractions lines etc., will be connected
to unit flash tank subsequent flow to unit drain tank system.
6.2.25
6.2.26
HP & LP Heaters
Regenerative feed heating cycle will consist of LP heaters, one drain
cooler, deaerator and HP heaters. The number of LP and HP heaters
will be based on the optimization of feed heating cycle.
Feed water will be heated by uncontrolled turbine extraction steam
from turbine inter/stage tap offs and cold reheat line in feed water
heaters. The deaerator will normally be operated under variable
pressure on extraction steam from the cross over pipe, between IPT
and LPT modules. Each feed water heater will be capable of handling
Sheet-60
the drains from the preceding heater under operating conditions of the
unit.
The equipment will be designed in accordance with latest applicable
standard or codes of heat exchanger institute. ASME, IBR etc. The
feed water heaters will be of U-tube with all welded stainless steel
tubes, surface type and horizontal with integral condensing and drain
cooling zones. The HP heaters will also have de-superheating zone.
6.2.27
Deaerator
Horizontal spray cum tray type deaerator with a storage tank will be
provided. The deaerator will be capable of deaerating the dissolved
oxygen and carbon dioxide in condensate & HP Heater drains. The
minimum capacity of the deaerator will be 6 minutes between normal
operating level and low level with a filling factor of 0.66. The deaertor
will be normally operating by taking extraction steam from IP turbine
except during low load operation and start up when the steam is
drawn from the auxiliary steam header.
6.2.28
Sheet-61
discharge
check
valve
will be
provided. Motorized
HP bypass valve.
2.
Auxiliary PRDS.
3.
SH temperatures.
4.
RH attemperators.
The feed control station will comprise three (3) parallel sets of control
valves each provided with motor operated inlet and outlet gate valves.
Out of the 3 control valves, two valves will be of full capacity control
one working and one standby) and the third will be of smaller capacity
control valve for starting purpose.
6.2.29
Sheet-62
The boiler feed pumps will be of horizontal, centrifugal type with stiff
shaft design. The boiler feed pumps outer casing will be of barrel type
with end removal. The inner pump assembly comprising of shaft,
impellers, stage casings will be capable of being removed and
replaced as a unit without disturbing the feed piping. Each feed pump
will be provided with ON-OFF / modulating type recirculation control
valve to protect the pump under low flow condition. The boiler feed
water system will be designed to operate primarily in an automatic
mode over the range of system design loads. The arrangement will
provide automatic start-up one of the standby motor driven feed pump
under conditions like tripping of the running TDBFPs and / or
discharge header pressure low etc.
The feed flow will be controlled by throttling the turbine steam inlet
control valve in case of turbine driven pumps whereas hydraulic
coupling will be utilized to achieve speed control of motor driven
pumps. Provisions will be made for warm up to standby pump, if
required.
6.2.30
6.2.31
Unit
-
660 MW
Tandem Compound
Four (4)
Electro hydraulic
Sheet-63
Speed
Rated output (Continuous)
Steam pressure before
emergency stop valve HP
Steam temperature before
emergency stop value
Reheat steam inlet pressure
Reheat Steam outlet temp.
SH Steam flow required with
0% make-up and 0.1033 ata
back pressure
Rated pressure at exhaust of
LP turbine
Reheat steam flow
Rated quantity of circulating
Water to condenser
Max. temp. rise of circulating
water
6.2.32
RPM
KW
Kg/cm2(a)
0
3000
660,000
245
537
Kg/cm2(g)
48.2
567.4
T/hr
1919.7
Kg/cm2(a)
T/hr
M3/hr
0
0.09
1720
2 x 68,824
10
Sheet-64
b) Boiler PRDS
Steam coil air presenters through control station
Fuel oil atomizing through control station.
Fuel oil unloading / storage heating through control station.
c) Soot blowing
The 16 kg/cm2 (g) auxiliary steam headers of both the units are
envisaged to be interconnected for operational flexibility. The 3.5
kg/cm2 (g) auxiliary steam system for each unit will supply steam
to desecrator which will normally fed from two sources namely
auxiliary steam system through pressure-reducing station or
through cold reheat line through pressure reducing station.
6.2.33
Sampling System
Centralized automatic and manual sampling and analysis will be
provided for monitoring of quality of steam and water. Online
instrument like ph meter, conductivity meter, dissolved oxygen
analyzer; silica analyzer etc. will be installed as per the scheme. The
sampling system will cover for measurement of H2 purity, conductivity
of stator water.
6.3.0
Generators
The generators will be directly connected, horizontal shaft, cylindrical
rotor, continuously rated for the turbine VWO output and at a rated
power factor of 0.85 lagging 3 phase, 50 HZ, star connected, in IP
55 enclosure. The generators will be provided with static or brushless
excitation as per manufactures standard. The generators will be
capable of operating in isolation or in parallel with each other and the
state power grid, with voltage variation of (+) 10% and frequency
variation of 47.5 to 51.5 hertz. The generator will have class F
insulation with temperature rise upto class B limits.
Sheet-65
The generators will have overload capacity as per IEC 34-3. The
unbalance load capacity will 0.08 pu continuous with I2. 2t equal to 10
sec. The generator rotor will be capable to withstand an over speed of
20% for 2 min.
The excitation system will be capable of supplying required excitation
current of the generator under all conditions of operation of load,
voltage and power factor and under fault conditions. Rated current
and voltage of the exciter will be at least 120% of normal excitation
current and at least 110% of no load excitation voltage with minimum
ceiling voltage of 200% of rated.
Each generator will be provided with the following:a) Automatic high speed digital dual channel (auto-manual) AVR,
capable of maintaining steady-state terminal voltage within +
0.5% of the present value under all operating conditions and
capable of smooth and continuous running over the operating
band width.
b) Excitation control cubicle.
c) Surge protection equipment.
d) Neutral grounding equipment.
e) Current and potential transformers.
f)
Sheet-66
6.3.1
660,000 kw
77647 kVA
808400 kVA
24 kV
0.85 lagging
18680 Amps
3000 RPM
50 Hz
98.75%
5823 Amps
200/178
26.5/23.3
23.5/18.8
28.8/23.0
10.0/8.0
390 volts
0.56 +10 %
4.0 kg/cm2
1000 M3/hr
220 MVAR
350 MVAR
90 dBA
540 Tones
353 Tones
Sheet-67
7.0.0
7.1.0
7.1.01
Sheet-68
i.
ii.
iii.
=
=
=
2 x 660 MW
(1320 MW)
789.95
18,958.8
5.92 Million MT
Sheet-69
Sheet-70
Sheet-71
a) When coal bunkers for both the units are full, crushed coal from
crusher house will be transported to crushed coal storage yard and
stacker/reclaimer together with reversible yard conveyors.
d) In the event of non-availability of coal at track hoppers crushed coal
from stockpile will be reclaimed by bucket wheel/boom belt of
stacker/reclaimer and transported by yard conveyor to junction tower
for-filling boiler bunkers.
e) When stacker / Reclaimer, track hoppers and conveyors are under
maintenance or inoperative, then the crushed coal from stockpile will
be dozed into reclaim hoppers, equipped with four (4) vibrating
feeders at the bottom to discharge crushed coal onto bunker filling
conveyor, via reclaiming conveyor for filling onward coal bunkers.
7.1.05
Sheet-72
Sheet-73
Sheet-74
7.3.0
Sheet-75
b).
c)
2.
3.
4.
5.
6.
Sheet-76
7.4.0
7.4.01
Design parameters
The ash handling system will be designed to meet the following
requirements:One unit
of 660 MW
( TPH)
Two units
1320 MW
( TPH)
394.98
789.95
26.86
53.72
13.43
26.86
94.00
188.00
134.29
268.58
S.No
i
DESCRIPTION
Sheet-77
7.4.04
Sheet-78
in wet form and convey either to ash silos in dry from or in wet form to
ash slurry sump.
Fly Ash System (Wet Disposal)
Fly ash collected in electrostatic precipitators and stack hoppers
along the flue gas path will be automatically and sequentially
extracted and pneumatically conveyed dry to the elevated collector
tanks through vacuum created by mechanical exhausters. Dry fly ash
prior to its entry to the collector tank will pass through wetting head
which wets the dry fly ash and discharge ash water slurry formed in
collector tank to the slurry sump. Collector tanks will be connected to
mechanical exhausters through Air washers. Flow of air to the
mechanical exhausters will contain negligible dust. Air washer drain
will be connected to collector tank discharge pipe. Jetting nozzles will
be provided below each collector tank to further convey the slurry to
the slurry sump. For dry fly ash conveying, cast iron pipes to IS:
1536/BS: 1211 Class-D will be used. For ash water slurry, carbon
steel pipes to IS: 1239(H) is: 3589 will be used.
Four (4) adequately sized fly ash piping steams per unit will be
provided and connected to individual collector tanks, mechanical
exhausters and other connected accessories. Normally all the four (4)
streams will be in operation simultaneously for fly ash removal.
Fly ash removal will be sequential according to a preset arrangement
and valves, which will be electrically interlocked accordingly. At the
operators option, it will be possible to bypass ash removal from any
hopper/s. fluidizing pads ensure free flow of ash from collection
hoppers of ESP will be provided Two (2) adequately sized ceramic
fluidizing pads located on opposite sides of each ESP hopper are
envisaged near hopper outlet flange.
Fly ash removal of each unit at full load with four fly ash streams
working simultaneously will not take more than four (4) hours in a shift
of eight hours while fining worst coal as shown in
Annexure 9.g
Sheet-79
Sheet-80
Two (2) number silos each of 1600 tonnes capacity and one no of
1000 tonnes capacity at plant boundary will be provided for both the
units.
The fly ash handling system capacity will be for 90% of total ash. This
ash will disposed in 6 hours for the ash collected in 8 hours. However,
the system will operate continuously.
Four (4) Ash disposal pump sets having a capacity of about 650 M 3/hr
consisting of two pumps in series to dispose slurry unto disposal area
will be provided. One set will be working and one set will be standby
with independent line without any cross over will be provided.
Ash disposal pipelines will be routed on concrete pedestals. Facilities
for easy rotation and replacement of the disposal will be ensured.
Disposal pipe lines will be joined by sleeve type couplings. Each pipe
length will not be more than 15 meters length and rest on three (3)
independent supports/pedestals.
Disposal line will be of 300 mm carbon steel pipes having minimum
9.5 mm thickness conforming to IS: 3589/API SL Gr. B.
Dry fly ash management plan is discussed in chapter 8 of this report.
The ash & water ratio for the ash slurry is generally 1:5. The total
slurry generation for both units will be around 1387 M3/hr or 1664.4
TPH.
7.4.06
Sheet-81
HP Water pumps
3 x 100% duty HP pumps (one working per unit & one common
standby for two units) will be installed in the ash water sump to cater
the needs of jet pumps below BA hoppers, feeder ejectors below
coarse ash hoppers and slurry sump agitation nozzles.
LP Water pumps
3 x 100% duty LP pumps (one working per unit & one common
standby for both units) will be installed in the ash water sump to cater
the needs of BA hopper fill, wetting head and air water on collector
tank tower etc
Refractory cooling water pumps
3 x 100% duty refractory cooling water pumps (one working per unit &
one common standby for both units) will be installed in the ash water
sump to cater the needs of refractory cooling of each bottom ash
hopper.
Seal water pumps
3 x 100% duty seal water pumps (one working per unit & one
common standby for both units) will be installed in the ash water
sump to cater the sealing water requirement of ash disposal pumps
and coarse ash disposal pumps sealing. For this requirement, water
will be tapped from filtered water system.
The ash handling system for unit -1 & 2 are given in Annexure 9.f &
9.g
7.4.07
Power supply for the ash handing plant will be received form
11 KV station Buses through two feeders and stepped down
to 3.3 KV and 415 Volts voltage level to supply power to
Sheet-82
7.4.08
b).
c).
d).
a)
b).
Blower Room
Blower room for both the units will accommodate mechanical
exhausters and fluidizing air blowers located between ESPs
Sheet-83
7.4.09
Table
S.No.
Target date
The unutilized fly ash in relation to the target during a year, if any,
shall be utilized within next two years in addition to the targets
stipulated for these years. The unutilized fly ash accumulated during
first four years (the difference between the generation and utilization
target) shall be utilized progressively over next five years in addition
to 100% utilization of current generation of fly ash.;
The Central Electricity Authority and other approving agencies may
permit the land area for emergency ash pond or fly ash storage area
Sheet-84
b)
c)
Boiler makeup
d)
e)
Plant service
f)
Fire fighting
g)
Sheet-85
7.5.01
S.No
Description
DM Water Requirement
Make-up water in power cycle @ 1.5% of 2x1920 M3/hr.
Aux. cooling water make-up @0.2% of 2x4200 M3/hr
H2 plant make-up
Condensate Polishing Unit
Chemical Feed
Sub-total
Say
Considering regeneration time of 4 Hours, the capacity
of DM plant is Worked out to 100x24 : 120 M3/hr.
20
Hence, Three DM streams (2w+1s) each of Capacity 60
M3/hr. will be provided
Clarified/filter water requirement:
Clarifier slurry to Sludge sump
Feed to DM Plant including regeneration requirement
(with regeneration @ 10 M3/hr)
Plant & colony potable water
Plant service water, sealing, & A/c & Ventilation
R.G Filters back wash
CHP Dust suppression & green belt from waste water
recycling.
Cooling tower make up @ 2.055% of 2 x 79,545 M3/hr.
(Based on COC 5)
Cooling tower blow down
Sub-total
Say (A)
Recycling water
a
b
c
d
e
ii
a
b
c
d
e
f
g
h
iii
Water
quantity
(M3/hr)
57.60
16.80
05.00
15.00
05.00
99.40
100.00
200.00
110.00
40.00
400.00
100.00
00.00
3269.29
820.00
4939.29
4940.00
Sheet-86
100.00
170.00
600.00
870.00
30.00
45.00
75.00
4070.00
160.00
200.00
4430.00
Consumptive water for the power station will be made available from
Krishna River as per allocation by WRD, Govt. of Karnataka and
pumped to site through pipelines.
7.5.02
7.5.03
Pre-treatment System
Two (2) working + one (1) standby 2300 M3/hr. capacity raw water
pumps will be installed in intake pump house located at intake system
provided at river Krishna will supply water to site through
2 x 100%
capacity pipelines. Boosting stations as per requirement will be
provided at suitable locations.
Requirement of raw water will be stored at site in-plant reservoir for
15 days consumptive requirement. Raw will be drawn from the
reservoir through 3 x 2300 M3/hr pumps (2w+1s), will be clarified
through PLC operated 3 x 2, 000 M3/hr capacity clariflocculators (two
working plus one as a common standby). Alum/Sodium
Sheet-87
carbonate/lime/ polyelectrolyte and chlorine will be dosed in the pretreatment plant to accelerate coagulation process. The clarified water
(not exceeding 10 ppm turbidity) will flow by gravity to Nine (9) PLC
operated gravity filters each of capacity 500 M3/hr ( 8 working + 1
standby). The filtered water will be stored in a 8,000 M 3/hr sized
filtered water tank including separate storage for
firewater
requirement. Sludge from the clarifiers and rapid gravity filters will be
taken into sludge sump. The sludge will be pumped to the sludge
thickeners from sludge sump. Under flow from the thickeners will be
pumped to centrifuge-by-centrifuge feed pumps. Concentrate from the
centrifuges and supernatant from the thickeners will be taken back to
the inlet of the clarifiers. Solid cakes from centrifuge will be collected
in sludge dumpers for ultimate disposal.
Filtered water will be distributed to various areas of the plant through
dedicated pump sets as follows:a)
b)
c)
d)
Sheet-88
e)
7.5.04
7.5.05
Sheet-89
7.5.06
a)
b)
c)
Demineralization plant
a)
b)
- Ph
7.0 + 0.2
- Conductivity
Sheet-90
The DM water will be used for heat cycle make up, auxiliary
cooling circuit make up, hydrogen generation plant. DM water
from storage tanks will be transported to the unit condensate
storage tanks of capacity 500 M3 through three (3) nos. (
2w+1s) 75 M3/hr. capacity pumps. Two (2) 100% capacity
boiler fill pump sets common for both boilers will eb installed
at DM water storage tanks for initital fill of boilers. 60 M3/hr
capacity separate unit wise pump sets will be provided for
supplying DM water to hot well make-up as shown on the DM
water system.
f)
d)
7.5.07
Sheet-91
7.5.08
i)
ii)
Sheet-92
g) The effluent water from ash pond & other waste will be
pumped to the guard pond; and will be treated in ash water
recycling system to maintain acceptable standards to pollution
norms; and recycled back to ash handling plant sump for
further ash disposal.
7.5.09
Sheet-93
condenser tube leakage to maintain the feed water and steam purity
requirements of the boiler and turbine. The condensate polisher will
be located in condensate feed water cycle between the condensate
pump discharge and the gland steam condenser.
Condensate polishing system will consist of 4 vessels of 33.3%
capacity for each unit complete with all equipment and separate
external regeneration arrangement will also be provided.
Composite water & waste water Schemes are given in Annexure
9h & 9i
7.5.10
Chemical Laboratory
A chemical laboratory will be provided for the day-to-day testing of
water quality, steam quality, blow down etc.
7.6.0
Sheet-94
7.7.01
b)
c)
Sheet-95
e)
f)
g)
h)
Ventilation System
a) Adequate ventilation system is considered as detailed below for
the power plant machine room building, ESP control building;
and other areas such as DG set room, air compressor room, A/C
plant room, DM plant building, Battery rooms and various pump
houses such as fuel oil pump house, DM water pump house etc
to achieve:
i) Dust free comfortable working environment.
Sheet-96
ii) Scavenging out structural heat gain and heat load from
various equipment, hot pipes, lighting etc.
b) Power plant machine room building
Supply air system will be provided with evaporative cooling
plant by a set of air washers of 2x50% capacity with cooling
water coils ( water supplied with an independent source ) .The
system The system will include 2 x 50% capacity supply air fans,
inlet louvers, bird screens, viscous filters, cooling coils,
recirculation water system with 2 x 100% circulating water pump
sets, bank of spray nozzles & flooding nozzles, eliminators plates
and masonry sump tank etc. for supply and distribution of cooled
air at various locations. The exhaust system will consist of roof
extractors (for machine room); axial flow wall mounted exhaust
fans with GI ducts, dampers, grilles and other accessories as
necessary. The system will be designed and other maintain close
to ambient dry bulb temperature inside the building.
Various rooms of the power plant building such as cable
spreader room, switchgear room etc. will be ventilated by means
of pressurized supply and exhaust fans suitably located.
c) ESP control building
For ventilation of this building, ambient air will be draw through
unitary air filtration unit comprising fresh air intake louver, dry
type filter and cooling coils conveying water [supplied from an
independent source] and supplied to the space by means of
centrifugal fans through ducting, grilles, etc. The supplied air will
be exhausted through wall mounted gravity operated dampers to
maintain higher over pressure (measurable) in mm water column
to reduce dust and fine sand.
d) Other buildings
Sheet-97
Sheet-98
Sheet-99
ii.
iii.
Sheet-100
f) Fuel oil tanks in the fuel oil farm area will be provided
with MVWS system as well as mixed foam mechanical
system to extinguish accidental fires in tanks as well as
outside the dyke. Water for foam system will be drawn
from the plant hydrant system. Adequate numbers of
hydrant points will be distributed near the oil tanks foam
area. Fire hoses fitted with couplings and nozzles will be
located suitably at the oil unloading station and kept in
house boxes.
g) Automatic inert gas based flooding type-extinguishing
system will be provided for unit control room, areas
independently apart from the provision of detection and
fire alarm system in that area. Suitable fire detection
system will also be provided at cable vault rooms, unit
control rooms and other MCC rooms etc to detect
outbreak of fire at an early stage.
h) Adequate number of fire hydrant points will be distributed
through out the plant building, service building. Coal
handling plant, ash handling plant and other areas along
with fire hoses fitted with couplings and nozzles and kept
in the hose boxes.
In addition to the above facilities adequate number of manual call
points (MCP) as well as portable and mobile (wheel mounted) fire
extinguishers of soda acid type; foam type; chemical type; and
carbon-dioxide type will be provided at suitable locations throughout
the plant area to meet NFPA and Loss preventive Association codes,
Tariff Advisory committee stipulations ETC.. These extinguishers may
be used during the early stages of fire to prevent from spreading.
Two (2) nos. of fire tenders will be located and kept in readiness
complete with all accessories at fire station located close to fire
control room.
7.9.0
Sheet-101
Sheet-102
7.10.0
Elevators
Sheet-103
7.13.0
ELECTRICAL SYSTEM
7.13.01
b)
c)
Sheet-104
7.13.02
d)
i)
400 kv
ii)
iii)
11 kv
iv)
3.3 kv
v)
415 volt
e)
d)
e)
Sheet-105
Power Evacuation
The net power available at the power station bus bars for evacuation
to PGCIL/KPTCL grid will be of the order of 1241 MW.
Depending upon the conductor configuration used, the surge
impendence loading of 400 kv line varies from about 500 to 650 MW.
Thus, minimum three (3) single circuits 400 kv lines would
theoretically suffice to evacuate the entire net output of the plant.
However, the system should provide for outage of a 400 kv line from
a major generating station. Therefore, it is proposed to provide four
(4) 400 kv line bays power evacuation from power plant.
7.13.04
400 KV Switchyard
The 400 KV Switcyard is proposed to have conventional 3-bus (Main1, Main-2 and Transfer bus) arrangement with the consideration of
simplicity of switching and protection schemes. The switchyard will
comprise following bays: 2-Generator transformer bays
4-O/G line bays
2-station transformer bays
1- Bus coupler bay
1-Transfer coupler bay
Total 10 bays
For the above mentioned configuration the switchyard will require a
space of about 350 M (L) X 200 M (D)
The switchyard will be complete with galvanized steel structures,
lightning surge arrestors, wave traps, PLCC equipment, CTs, PTs of
suitable VA burden and accuracy class as required for measurement
Sheet-106
a)
Circuit Breakers
Circuit breakers will be 420 KV class conforming to IEC
62271-100 SF6 type with 40 KA (rms) symmetrical
interrupting capacity comprising three (3) identical single pole
units.
b)
Sheet-107
d)
e)
Surge Arresters
Sheet-108
: 360
: IV
: 20
7.13.07
Station Transformer
Sheet-109
Unit Transformers
The 660 MW units will each have two (2) 28/35 MVA, ONAN/ONAF
cooled , 3 phase Dyn1 Unit Auxiliary Transformers (UATs) with onload tap changer ( OLTC) having a variation range of +10% in steps
of 1.25% on HV side and a voltage ratio of 24/11.5 kv. The
impedance of UATs will be around 9% at the principal tap so as to
limit 11 kv fault level to less than 40 Ka.
Each UAT of 660 MW unit will be sized for sixty ( 60) percent of unit
MCR auxiliary load.
7.13.09
Start-up power
Startup power for the unit will be draw from the 400 KV system
through station Auxiliary transformers. Once the unit is synchronized
with the system through generator transformer, the unit auxiliary
power requirements will be drawn the unit auxiliary transformers.
7.13.10
Sheet-110
7.13.12
Bus ducts
Each generator will be connected to the generator transformer
through isolated phase naturally cooled, pressurized type bus duct
with continuous type aluminum /aluminum alloy separate enclosure
for each phase. Arrangement will be made for blowing hot dry air
through the bus duct on starting a unit after prolonged shut down.
Current & voltage transformers for AVR, relay protection,
instrumentation etc. will be provided in the generator bus duct. Surge
protection equipment housed in metal clad cabinets will be provided
on the generator bus duct tap off. A generator neutral grounding
cubicle housing a single phase distribution transformer and secondary
loading resistor will also be provided along with the neutral side bus
duct. The connection of the unit and station transformer to their
respective 3.3 KV & 11 KV switchboards will be by means of phase
segregated bus duct.
7.13.13
Coal/Ash
Handling/water
Transformers
system
pump
House
Auxiliary
Sheet-111
To cater to the MV loads of off site BOP systems suitably rated 11/3.3
KV Dyn11 oil-filled ONAN cooled auxiliary transformers will be
provided. These transformers will have off load tap changer with
+10% range in steps of 1.25% on 11 KV side. Each auxiliary
transformer will be sized to cater for 100% of the system load. Two
(2) such transformers will be provided for achieving redundancy &
reliability.
The power supply for water intake system at river end will be
arranged from the local power supply net work of the state utility
7.13.14
7.13.15
415 V Switchgear
Power from unit/ station service transformers will be supplied to 415V
switchgears. These switchgears will distribute power to LT auxiliary
motors and also to other auxiliary loads viz. MCC / ACDB, etc. LT
switchgears will be of metal enclosed indoor draw out type having
degree of protection class IP44 for bus bar chamber and IP-54 for
balance portions. Incomers as well as all the outgoing feeders will be
equipped with air circuit breakers of fault interrupting capacity of 50
KA rms.
7.13.16
Sheet-112
The MCCs will be of modular, metal enclosed, indoor, draw out type.
Each outdoing motor feeder will have a direct on-line (DOL) starter
unit. The motor starter will consist of MCCBs/switch-fuse unit,
contactor, Control fused and Bi-metallic over load relay and phasing
preventers.
The DBs will be of metal enclosed, indoor, fixed type and suitable for
3 phase 4-wire 3 phase 3-wire, and 1phase 2 wire distribution system,
as applicable.
The incomers, ties and motor feeders of size above 110 KW & upto
200 KW will be controlled by circuit breakers while other feeders will
be controlled by MCCB/switch fuse, contractor for the lower sized
motors and MCCBs/switch-fuses for other feeders. Circuit breakers
will be of air-break type with symmetrical fault interrupting capacity of
50 KA (rms). DOL starters of essential Boiler & TG LT auxiliary
motors such as seal oil pumps, lube oil pumps, jacking oil pump etc
will be provided with a delayed drop off feature to permit auto-restart
following change over of supply from one bus to another bus.
7.13.17
Electric Drives
HT & LT motors will be energy efficient type (class eff-2), F class
insulated with maximum temperature rise within class B limits, IP-55
enclosure (with canopy for vertical outdoor motors ) designed for
direct-on-line starting with as low starting current as possible. Starting
current of boiler feed pump motors will be restricted to 4.5 p.u. (with
no positive tolerance). For other motors, the starting current will be
restricted to 6.0 p.u subject to a tolerance of + 20%.
Motor rating will be at least 1.1 times the power requirement of the
driven equipment at the duty point or the maximum power
consumption of the driven equipment.
Motors will be capable of starting and accelerating to full speed at
80% of the nominal voltage and will be capable of either two starts in
quick succession with third start after 5 min., in cold condition or two
Sheet-113
Metering
Microprocessor
based
multi-function
energy
meters
with
communication facilities and non-volatile memory and MMI will be
provided for all 400 KV feeders, generators, on HV side of station and
unit auxiliary transformers and on incomers to 11 KV and 3.3 KV
buses for energy audit.
AVAILABLE Based Tariff ( ABT) grade energy meters will be provided
for main and check metering for both import and export of power from
the 400 KV buses. For this purpose, separate dedicated CTs and PTs
of accuracy class 0.2 will be used.
All 11 KV and 3.3 KV feeders connected to station and unit
switchgear buses will be equipped with multifunctional
microprocessor based feeder management devices having protection
and meeting facilities along with fault recording, event logging,
continuous self- monitoring and communication ports/ gateways with
IEC 61850 protocol for interface with plant DDCMIS system.
Sheet-114
Protection
Electrical protection proposed for the various equipments will be
generally as per guidelines of CBIP/CEA and IEEE and as indicated
below:1. Generator/GT/AT: Three (3) sets of numerical protection relays
Protection
Providing
100%
triple
redundancy,
continuous, self monitoring and metering and
event/fault recording & communication
facilities & comprising the following
protections:a) Generators:
i. Differential (87G)
ii. Stator Inter-turn fault (95)
iii. Stator earth fault (64G)
iv. Loss of excitation (40)
v. Negative phase sequence current
(46)
vi. Reverse power (32)
vii. Low forward power (37)
viii. Rotor earth fault (64R), if feasible
ix. Over-voltage (59)
x. Under-voltage (27)
xi. Generator pole slipping (90)
xii. under/over frequency (81)
xiii. Voltage balance (60)
xiv. VT fuse fail Monitoring
xv. Thermal Overload (49)
xvi. Stator winding temp high
Sheet-115
i. Differential (87 T)
ii. Overall differential (87GT) covering
2x100%
numerical
comprising of
protection
protection (21)
i. Distance
i
phase over current & E/F
ii. Directional
i
i & 67N) Feeders.
(67
Sheet-116
motor
7. Contactor
controlled 415
volts motors
below 110 KW
220 V DC
system
7.13.20
Control Rooms
There will be one Central Control Room (CCR) at the operating floor
of steam turbine-generators building in which control panels for the
steam generators, station / unit auxiliary transformers and distributed
digital control system (DDCMIS) equipment will be housed. In
addition, auxiliary system electrical relay panels and fire alarm control
p[panels will also be provided.
The control & synchronizing of generators excitation systems,
generator transformers, unit & station auxiliary service transformers,
11/3.3 Kv/415 V incomers, ties and main outgoing circuit breakers to
Sheet-117
Grounding
The grounding requirement of the power station complex will be
divided into the following two main categories viz. system grounding
and equipment grounding:a)
grounding at
b)
Sheet-118
Sheet-119
7.13.24
a)
b)
Sheet-120
Plant DC System
a)
The batteries will be either planet positive plate lead acid type or
Nickel-cadmium alkaline type.
The following sets of batteries, battery chargers & Distribution
boards (DBS) will be provided:i)
Two (2) sets 220 V DC battery, float & boost chargers and
DBs for the two units.
Sheet-121
ii)
Two (2) sets 220V DC battery, float & boost charges and
DBs for 400 kv switchyard.
iii)
One (1) set 220 V DC battery, set of float & boost chargers
& DBs as common standby for the unit batteries and also
catering for common station loads.
iv)
Two (2) sets 220V DC battery, float & boost chargers and
DBs each for coal & ash handling plants and water intake
Pump house.
Battery
Normal requirement of the battery is to supply power for the
following: Control and monitoring of the entire power plant.
Alarm and annunciation of plant condition under
emergency. The duty of the battery is strenuous
particularly during the first one minute after occurrence
of emergency. During this first minute, the battery is
required to supply.
Tripping power
simultaneously.
for
all
major
circuit
breakers
Sheet-122
Battery charger
Battery chargers of suitable capacity will be provided with
trickle charging and boost charging for each of the aforesaid
battery sets. Completely automatic and self-regulating type of
battery charger comprises of independent float cum boost
charges. The float charger will be capable of floating the
battery and at the same time supply the continuous DC load.
The boost charger will be capable of quick charging the
battery to a state of fully charged condition in 10 hours and at
the same time supply the continuous DC load. 20% spare
margin over the maximum charging rate is considered.
c)
DC Distribution board
One main DC distribution board for each of the battery sets
will be provided with DC sub-distribution boards as required.
The DC distribution board will have two incomer DC switchfuses and required number of outgoing switch fuse units
Sheet-123
Telephone system
A 200 extension, 15 incoming line digital automatic EPABX
exchange based on time division-multiplexing technique will
be installed at one convenient location. This will serve the
thermal power plant. A separate 200 extension EPABX will be
provided for the colony. There will be interconnection between
plant and colony exchanges.
b)
Inter-communication system
The inter-communication system will be provided in power
plant to facilitate plant operations by establishing quick
communication among the operating personnel at various
locations of the plant. A public address system with page and
party channels and a number of walky-talky or radio pagers
will be provided for this purpose.
7.13.27
Illumination system
Suitable illumination is necessary to facilitate normal operation and
maintenance activities and to ensure safety of working personnel.
This is achieved by artificial lighting. Power for the illumination system
will be obtained from the 415V bus through a number of 415/433 V
transformers of adequate capacity for plant areas and buildings.
The rating of the transformers will be decided in order to restrict the
fault level of the lighting circuits to safe level for humans and to avail
of MCBs. For yard illumination, 30 to 40 meters high lighting masts
with cradle mounted flood lights will be installed at suitable locations
to provide requisite level of illumination. Pole mounted high-pressure
sodium vapor fixtures will be used for approach and work roads.
Sheet-124
Areas
a)
b)
c)
d)
e)
f)
g)
T
h)
h
e i)
J)
Recommended
average
Illumination
level(Lux)
300 400
(continuously
available)
300
250
200
100
50
30
20
20
10
Sheet-125
Electrical Laboratory
An electrical lab will be provided for the day-to-day maintenance /
testing and calibration of the electrical equipment of the power plant.
7.14.0
7.14.01
Design Philosophy
The Instrumentation and Control System will be provided with modern
power plant practices and shall be in compliance with all applicable
codes, standards, guides, statutory regulations and safety
requirements in force.
The Instrumentation and Control System will comprise of DDCMIS,
measuring instruments, power supply system, SWAS etc., cables,
fittings, conduits, calibration and lab equipment, control desks/panels
etc. The availability of the complete C&I system shall be 99.7%.
Adequate redundancy in system design shall be provided at
hardware, software and sensor level to satisfy the availability criteria.
Sheet-126
Sheet-127
Sheet-128
below and all other applicable ANSI, ASME, IEEE, ISO, IEC, IGCI,
AWS, NFPA, AISC, IGS, SAMA, UBC, UL, NESC, NEMA, ISA, DIN,
VDE and Indian Standards and their equivalents.
7.14.02
DISTRIBUTED
DIGITAL
CONTROL,
INFORMATION SYSTEM (DDCMIS)
MONITORING
AND
Sheet-129
Sheet-130
Signal Exchange
All the signal exchange between various functional groups of each
control group (i.e. within SG - C&I, TG - C&I and BOP - C&I) shall be
implemented through redundant main system bus (the main bus
connecting various subsystems) and local system bus within a subsystem as per the standard practice of the system. It shall be ensured
that any single failure in electronics involved for such communication,
e.g., communication controllers, bus interface modules, physical
communication media, etc. does not result in loss of such signal
exchange and there in no deterioration in specified system response
and system parametric requirements.
In case a controller utilises some inputs generated/ processed by any
other controllers/functional group and the requirement of controller
response time as specified elsewhere is not met due to inadequate
communication rate/ procedure, then the hardwired signal exchange
for such inputs will eb provided. Control & protection signal exchange
between SG- C&I, TG-C&I and BOP - C&I shall be hardwired only.
Protection signals like MFT shall necessarily be hardwired even for
exchange within the same sub-system.
No single failure either of equipment or power source shall be capable
of rendering any part/system/sub-system of DDCMIS in-operative to
any degree.
System Spare Capacity
Over and above the equipment and accessories required to meet the
fully implemented system as per requirements, DDCMIS shall have
spare capacity and necessary hardware/ equipment/ accessories to
meet following requirement for future expansion at site:
a) 10% spare channels in each of the functional groups, fully wired
upto marshalling cabinets.
Sheet-131
Sheet-132
Sheet-133
Sheet-134
Sheet-135
Sheet-136
Sheet-137
Sheet-138
Sheet-139
Sheet-140
i) The SG- C&I part of DDCMIS system shall perform the following
function as minimum but not limited to
a) Burner management system (BMS) including control &
protection of coal mills, fuel oil system etc.
b) Analog control functions pertaining to secondary air damper
control etc.
c) Soot blower control.
ii) The TG- C&I part of DDCMIS system shall perform the following
functions:
a) Turbine protection system function (TPS)
b) Turbine governing system for main turbine
c) Turbine stress control system (TSCS)
d) Automatic turbine testing (ATT)
e) Automatic turbine run up system. (ATRS)
f) HP&LP bypass control system
g) Turbine generator control system
h) EHG, interlock & protection for turbine driven BFP
iii) The BOP- C&I system shall perform the following functions:
a) Analog control functions, other than those covered in SG-C&I
and TG-C&I, like co-ordinated master control, furnace draft
control, SH/RH steam temperature control, FW flow control,
heaters/deaerator/condenser level control, Auxiliary PRDS
pressure & temperature control etc.
b) Binary control functions pertaining to main plant auxiliaries like
FD/ID/PA fans, APH, BFP etc., Generator auxiliary systems
and electrical breakers etc.
iv) Functional grouping of various controllers shall be decided during
detailed engineering which shall be subject to purchaser's
approval. Functional grouping shall meet following general
requirements:
Sheet-141
Sheet-142
Sheet-143
Sheet-144
f)
h)
i)
j)
Sheet-145
Sheet-146
Sheet-147
Sheet-148
Sheet-149
Sheet-150
xi) The output modules control module shall have the feature that
ensures that in case of failure, all the outputs are driven to zero.
The 24V DC command outputs to drives for on/open, off/close
shall be separate and independent and inverted outputs shall not
be employed. For inching type of drives, position transmitter
power supply and monitoring of position transmitter signal shall be
provided.
xii) The termination for open/ close command for the drive actuator
shall be performed in the actuators with integral starter specified.
However, open/ close and disturbance status as a minimum shall
be monitored in OLCS.
The sequence interlock & protection requirements shall be
finalised during detailed engineering and the same shall be
subject to Purchaser's approval.
xiii) The OLCS shall also include the control of electrical systems in
addition to the auxiliaries of boiler & turbine such as open/close or
on/off etc. of various electrical systems such as generator,
generator auxiliary systems, breakers of 11kV, 3.3 kV. 415 V
switchgears , synchronisation of unit etc. as described in previous
sections.
Analog Controls/Closed Loop Control System (CLCS) Functions
Analog controls of SG - C&I , BOPC&I and TG - C&I .
The CLCS shall continuously act on valves, dampers or other
mechanical devices such as hydraulic couplings etc., which alter the
plant operation conditions. The system shall be designed to give
stable control action in steady state condition and for load changes in
step/ramp over the load range of 60% to 100% MCR with variation or
parameters within permissible limits to be finalised during detailed
engineering state. The system shall have the following minimum
features:
Sheet-151
i)
ii)
iii) Any switch over from auto to manual, manual to auto and
switchover from TFT operation to auto manual station operation
and vice versa shall be bumpless and without resulting in any
change in the plant regulations and the same shall be reported to
the operator.
iv) Buffered analog output (positioning signal) of 4-20mA DC shall be
provided from CLCS to the respective E/P converters. For
electrical actuators, pulse type output (bound less control) shall be
preferred. CLCS shall also provide all the necessary outputs for
indicators & recorders with output loop resistance of 500 ohms for
each channel of the output module.
v) The functional requirement of the CLCS loops as well as the
detailed schemes shall be finalised during detailed engineering
stage and shall be subject to Purchaser's approval.
vi) The system being supplied shall be such that when permissible
limits are exceeded, an automatic switchover from an operation
Sheet-152
Sheet-153
Sheet-154
Sheet-155
(d) Carry out a fatigue analysis for all affected components of the
turbine and also to compute the percentage service life
consumption of the turbine.
(e) Display the stress margins etc. on a separate dedicated colour
VDU/Printer as well as on OWS for operator guidance and
storage of necessary data such as percentage service life
consumption etc.
(f) Store long term data & carry out residual life analysis.
BFP Turbine Electro hydraulic Governing System
a) The drive turbine speed shall be controlled by electro - hydraulic
governor, stable and satisfactory speed control over full speed
range from 0% to 100%. The electro-hydraulic governing system
hardware shall be microprocessor based, with hot back up.
b) When the governing system is in auto mode, it will receive speed
demand signal from FW control loop and in manual mode shall be
fed either from TFT of OWS or through auto/manual stations. The
actual speed of the turbine should be measured by three
independent speed sensors and three independent speed
measurement channels. These three signals shall be fed to the
selection circuit which will choose the median value. The speed
controller output shall be fed to the valve lift controller. The output
of the valve lift controller shall be fed to the electro-hydraulic
converter which will vary the position of the control valve. The
electro-hydraulic controller shall be designed such that the
transfer between different steam sources should be bumpless.
The electro-hydraulic control system to be provided shall be of
proven design, whose configuration and hardware implementation
should have been employed in at least six(6) turbine driven
pumps of equivalent capacity which are in operation for not less
than two(2) years.
Sheet-156
c)
Sheet-157
Sheet-158
Sheet-159
Sheet-160
Sheet-161
iii) Displays
Various displays on the TFTs shall as a minimum include P&ID
displays or mimic, bar chart displays, X-Y & X-T plot (trend) displays,
operator guidance message displays, group displays, plant startup/shutdown message displays, generator capability curves, heat rate
deviation displays, system status displays etc. Number of displays
and the exact functionality shall be on as required basis and as
finalised during detailed engineering. Other types of displays as
applicable for convenience of operation shall be provided. However,
the minimum quantity of major types of displays shall be as follows:
a) Control displays (group/ sub-group/ sequence/loop) 500
b) P&ID/ mimic display 100
c) Bar chart 100
d) X-Y/ X-T Plot 100
e) Operator guidance message 100
f) Plant starting/ shutdown guidance message 100
g) Other misc. displays 25
h) System status & other diagnostic displays on as required basis.
The system shall have adequate storage capacity for storing the last
72 hours of data at scan rate for a minimum 500 points (operator
selectable) for use in trend displays.
iv) Logs/Summaries
The system shall generate three basic types of reports/logs i.e., event
activated, time activated and operator demand log & summaries. The
log format and point assignment for each logs/ report and other
design features shall be as finalised during detailed engineering. The
system shall have the facility for viewing of time activated and
operator demand logs/summaries on the TFT(s).
(a) Event activated logs shall as a minimum include alarm log, trip
analysis log, start-up - shutdown logs (Boiler start-up log, turbine run-
Sheet-162
up log, turbine shutdown analysis log/ turbine recall log) & control
related logs.
The trip analysis log shall record a minimum of 30 pre-trip and 30
post-trip readings for the pre-defined parameters but not less than
250 points, sub-divided in to 25 groups. The data collection rate shall
be variable, i.e. faster near the trip point and gradually slower with
time. The exact details shall as finalised during detailed engineering.
The system shall be capable of generating and printing SG & TG
start-up and shutdown logs.
(b) Time activated logs shall as a minimum include shift log and daily
logs. Each of these shall provide hourly record of a minimum 225
points sub divided into 15 groups.
(c) Operator demand logs shall include, as a minimum, trend log,
maintenance data log, summary log, performance logs and some
special logs as decided during detailed engineering stage.
The system shall be capable of generating and printing trend log for a
minimum of 80 groups of 15 points each. Maintenance data log shall
provide schedule of preventive maintenance and routine equipments
inspection.
(d) Various summaries shall include off scan summary, constants
summary, point quality summary, substituted values summary,
peripheral status summary etc.
(e) The assignment of logs to any of the printers shall be possible
from MMIPIS TFTs/ keyboards and programmer station.
v) Log Generation Utility
The system shall cover all features of log generation utility to
generate a log/report with format design , point selection, data
collection in different interval etc.
(vi) Historical Storage and Retrieval system (HSRS)
Sheet-163
The HSRS shall collect, store and process system data form MMIPIS
data base. The data shall be saved online on hard disk and
automatically transferred to erasable dual Magneto-optical disk
(removable type) once in every 24 hours periodically for long term
storage. Provision shall be made to notify the operator when optical
disk is certain percentage full. The disk capacity shall be sufficient to
store at least seven days data.
The data to be stored in the above system shall include alarm and
event list, periodic plant data, selected logs/reports such as event
activated logs, sequence event log, trip analysis log, start-up log etc.
The data/information to be stored and frequency of storage and
retrieval shall be as finalised during detailed engineering.
The system shall provide operator function to retrieve the data from
historical storage. The operator shall be able to retrieve the selected
data on either colour TFT or printer and suitable index files/directories
shall be provided to facilitate the same.
In addition to the HSRS, the system shall also have facility to store
and retrieve important plant data for a very long duration (plant life) on
Magneto optical disk.
A PC along with a laser printer shall be provided for this purpose. This
PC shall be connected with the system bus, on which all the data can
be accessed.
MMIPIS Hardware
i) The MMIPIS as specified shall be based on latest state of the art
workstations and servers and technology suitable for industrial
application and power plant environment. Two possible alternatives
for MMIPIS can be envisaged. For alternative-I, the no. of redundant
servers shall be as required to achieve the processing capability to
meet all the functional requirements. For alternative-II, the
workstations other than OWS shall be configured in such a way that
loss of one workstation does not result in loss of any function.
Sheet-164
The actual size of the main and bulk memory shall be sufficient to
meet the functional and parametric requirements as specified with
25% additional working memory and 50% additional bulk memory
over and above the memory capacity required for system
implementation. The exact system configuration and sizing shall be
as approved by Purchaser.
ii) The workstation/servers employed for MMIPIS implementation shall
be based on industry standard hardware and software which will
ensure easy connectivity with other systems and portability of
purchaser developed and third party software. These will be 32 bit/ 64
bit machines. Each workstation/ server shall be provided with an UPS
each for 60 min. back-up with output messaging facility for loss of
input power.
iii) Redundant sets of communication controllers shall be provided to
handle all the communication between the MMIPIS and redundant
system bus and to ensure specified system response time and
parametric requirements. Each communication controller shall have
message checking facility.
iv) Power fail auto restart (PFAR) facility with automatic time update
shall be provided.
v) The LAN shall be provided under MMIPIS and shall support TCP/IP
protocol (Ethernet connectivity) and shall have data communication
speed of minimum 100 MBPS.
Operating Stations
a)
The main control console provides the primary manmachine interface through the operator station. The
system will consist of six (6) Operating Stations.
Overview of the plant systems, complete controls and
monitoring of the plant equipment and parameters,
Sheet-165
Sheet-166
b)
Three nos B/W laser Jet printers and one colour laser
jet printer are provided along with main control
consoles.
Computer Room
The computer room is located adjacent to the unit
control room to provide easy access for control room
Personnel. This room contains all distributed digital
control, monitoring and information system (DDCMIS)
related equipment necessary for configuring and
maintaining the power block management information
and balance of plant systems such as one (1)
engineering/diagnostic workstation and laser jet printer
and all programming devices for configuration of the
system and graphics also having diagnostic features,
one (1) workstation and dedicated dot Matrix printer for
Sequence of event recording, two (2) workstation and
dedicated dot matrix printers for alarm, historian and
MIS, one (1) workstation and laser jet printer for
performance calculation and optimization package, one
(1) workstation and laser jet printer for vibration
monitoring and analysis (OCAMMS) system, one (1)
work station and laser jet printer for boiler leak
detection system, one (1) color laser jet printer ((A3
size).
ii).
Sheet-167
One (1) Workstation and laser jet colour printer for shift
supervisor, which will be common for all units.
iii).
machinery
Sheet-168
7.14.06
Sheet-169
The redundancy will be provided, for all input/output cards, used for
control signals. No redundancy at I/O card level is envisaged for non
control signals and Data Acquisition/Monitoring functions. The inputs
or inputs of any of I/O card shall not have more than 16 channels per
I/O card except Analog output card. In case of Analog output card the
out puts shall have max. 8 channels.
7.14.08
Description
100% capacity float-cum-boost
100% capacity static switches
30 min backup VRLA
DC power distribution boards
Qty. / Unit
2
2
1
1
The use of 24V DC charger and Valve regulated lead acid / sealed
maintenance free batteries (having 20 years life ) for providing
uninterruptible power supply of 24V DC for the control portion of the
system requirement (Voltage requirements). The DC supply from
battery/charger is given to DC distribution board on redundant feeders
Sheet-170
240 V UPS
The other system loads not fed with DC are taken on the 240 V AC
supply through UPS.
Redundant ACDB with redundant feeders will be provided for UPS
supply in order to ensure no-break power supply of 240V AC
The total requirement of C&I power supply is fed from 240V AC
industrial graded parallel redundant UPS and valve regulated lead
acid, sealed maintenance free batteries having 20 yrs life. 240V AC
UPS supply is fed to MMI.
For the AC portion of the loads, the use of completely 100%
redundant charger cum inverter system is envisaged with 50% load
sharing. However, the battery bank for the system would be 100%
capacity batteries only. The envisaged 50% load sharing also ensure
that there is increased margins in the inverters to blow branch fuses.
The equipment included for the UPS for such a scheme is given
below. UPS is located in AC room.
Sl.no
1.
2.
3.
4.
5.
6.
7.
8.
Description
100% capacity float-cum-boost chargers
100% capacity static inverters
100% capacity static switches
Manual by-pass switch
30 min backup VRLA/SMF batteries with 20
yrs life.
Step-down transformer (415V, three phase
to 240V, single phase)
Voltage stabilizer
AC power distribution boards
Qty. / Unit
2
2
2
1
1
1
2
Sheet-171
7.14.10
Sheet-172
7.14.11
This section covers the philosophy and design criteria for continuous
on line analytical measurements of important process media such as
water, steam and flue gas . All analytical instruments are of
microprocessor based only.
Analytical measurements are of two types:a) Gas Analysis: Flue gas analysis is carried out for
percentage oxygen (O2 zirconium oxide probe type),
Combustibles (Co) (in-situ type), Sox / Nox (in-situ type )
and smoke emission density.
b) Steam and Water Analysis: Continuous analysis is
done on steam and water media to establish their purity
and suitability for long life of pressure parts. The
measurements are carried out at different cycle points of
the plant to establish Conductivity, PH, silica, sodium,
phosphate & Dissolved oxygen content.
The steam and water analysis system (SWAS ) includes all requisite
analyzers, sampling system, complete with sampling table, chiller unit
and analyzer panels. All data are available in DDCMIS for
information.
The measurements of samples will be as follows:
Sample Sample
No
stream
1)
2)
Make-up DM
water
Type of
Measurement
a) GRAB
Range of
Monitor/
Indicator
-
b)
Conductivity
c) pH
0-10 Micro
(Mho/cm)
6-14pH
a) GRAB
Alarm
Spare
Output
DCS
Yes
Yes
Yes
Yes
Yes
Yes
Yes
yes
Sheet-173
3)
Outlet
Condensate
b)
Conductivity
0-10 Micro
mhos/cm
Condensate
Pump
Discharge
a) GRAB
b) pH
c) Dissolved
oxygen
d)
Conductivity
e) Cation
cond.
f) silica
g) Sodium ion
Yes
Yes
yes
Yes
6-14pH
yes
Yes
Yes
0-20 ppb
0-200ppb
0-1000 ppb
0-10 Micro
mhos/cm
0-10 Micro
mhos/cm
0-100 ppb
Yes
Yes
yes
Yes
Yes
yes
0.1 to 1000
0.2 ppb
Yes
Yes
Yes
yes
Yes
Yes
yes
Yes
Yes
Yes
yes
h) Chloride
4)
5)
6)
Feed water
BF booster
pumps
suction
(common
header
deaerator
Feed water
Economizer
Inlet
Boiler Water
a) GRAB
b) Dissolved
oxygen
0-20 ppb
0-100 ppb
a) GRAB
b) pH
6-14 pH
Yes
Yes
Yes
yes
Yes
Yes
yes
Yes
Yes
yes
Yes
Yes
Yes
Yes
Yes
yes
Sheet-174
b) pH
6-14 pH
8)
9)
10)
Boiler
saturated
steam
FP discharge
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
yes
Yes
a) GRAB
b)
Conductivity
c) Ph
a) GRAB
0-100 Micro
mhos/cm
6-14 Ph
-
Yes
Yes
Yes
Yes
-
Yes
-
Yes
Yes
b)
Conductivity
c) Silica
0-10 Micro
mhos/cm
0-100 ppb
Yes
Yes
Yes
Yes
d) pH
6-14 pH
Yes
Yes
Yes
e) Hydrazine
0-50 ppb
0-100
0-10 Micro
mhos/cm
Yes
yes
Yes
Yes
Yes
yes
Yes
Yes
yes
Stator water
flow
Conductivity
Measurement
Main steam
a) GRAB
b)
Conductivity
c) After cation
0-10/0-1
Micro
Mhos/cm
0-1/0-2
Micro
mhos/cm
Sheet-175
d) Silica
0 to 100
ppb
6-14
Yes
Yes
yes
yes
0-500 ppb,
0-5ppm
-
Yes
Yes
Yes
Yes
6-14 Ph
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
yes
e) Sodium ion
Yes
Yes
yes
e) pH
11)
12)
Condenser
a) Chlorine
Cooling water
Out let of
a) GRAB
Condenser
Polishing unit b) pH
0.3 to 1000
0.4 ppb
f) Chloride
FLUE GAS ANALYSERS
13)
14)
15)
Flue gas at
eco. Outlet
before air
0-10 %
volume O2
Yes
Yes
Yes
Yes
Yes
Yes
Yes
Yes
yes
c) CO
0-300
PPM
0-500,
1000,2000
3000 PPM
0-100,
500,
1000PPM
Yes
Yes
Yes
d) O2%
Oxygen %
0-10
0-10%
Yes
Yes
Yes
Yes
Yes
yes
Sheet-176
16)
7.14.12
heater ( 2
Nos L & 1 No
R)
Flue gas at
chimney
height of 8
times of
chimney
base
diameter
Particulate
0-200,
1000
mg / NM3
Yes
Yes
yes
Field Instrumentation
Transmitters
Smart Transmitters will be provided for pressure, temperature, flow
and level measurements. Transmitters will be electronic type, twowire configuration. The output signal will be 4 to 20 mA DC HART
compatible & capable of drawing loads upto 600 ohms at 24 V DC.
The transmitters will be provided with integral indicator of 5 display
with an accuracy of + 0.075%
Pressure Measurements
The pressure sensing element/movement material will be SS316
with die cast aluminum cable. The accuracy will be +1. Local
pressure gauges will be 150 mm dial type. The bourdon tube will be
SS316 and case material will be die-cast aluminum. The pointer will
be of micrometer type with adjustable zero adjustment in the front.
Gauges will be provided with snubbers/ pulsation dampers, siphons,
seals as required.
Pressure switches are provided for pressure measurements.
Pressure and differential pressure will be selected based on
pressure and temperature operating conditions.
Sheet-177
Temperature Measurements
a)
b)
a)
b)
Level Measurements
Accuracy of measurement will be + 1% of full scale or better for
granular or powdered material level measurement, ultrasonic, RF
type detectors will be used. For liquid level measurement, float,
Sheet-178
Control Valves
For pneumatically operated control valves, the valve will operate on
0.2 to 1 Kg/cm2 air signal. Control valves will be sized so that the CV
required for normal flow will not be more than 62.5% of the
manufactures published CV for 100% valve opening: and the
minimum flow will occur at 30% of value opening and more to have a
Sheet-179
good operating range. Valve lift will be limited to 80% of the travel at
max. Flow load.
Control valves will be complete with I/P converters, position
transmitters, Air lock relay, Positioners, limit switches, solenoid valves
and filter regulators as needed. The valves will be provided with hand
wheels for local operation.
Critical service valves like PRDS, HP/LP bypass, Auto recirculation
values, Boiler feed control, SH/RH steam temperature control, Soot
blower pressure control valves will be drag design.
The control valve will have valve position indication in the control
room. Position transmitters will be 2-wire type with 4-20 mA DC
output. Teflon/asbestos packing will be used up to 200 0C
temperature; and graphite lubricated asbestos will be used for
operating temperature higher than 2000C. The noise level of the
control valves will be less than 85 dB. The control valves will be
installed after the flow sensing devices in the direction of flow.
7.14.14
Instrumentation Cables
Instrument (Pair / core) cables (tinned copper conductor, 650V Ext
grade, 0.5 / 1.5 sqmm, FRLS type, PVC insulated, armored) and
compensating cables (KX, 1.5sqmm, FRLS type, PVC insulated,
armored ) complete with all accessories.
Compensating cables are used to interconnect thermocouples to
control and monitoring systems. The type of compensating cable
depends on the type of thermocouple being connected to the control
and monitoring systems in any one of the following ways:a)
b)
Sheet-180
7.14.15
Erection Hardware
All required installation hardware including impulse pipes, tubes,
valves, manifolds fittings, etc. required for proper installation and
interconnection of instrumentation and control systems will be
provided. All materials and installation thereof will confirm to latest
editions of American national standard Code for pressure piping,
ANSI B 31.1, ANSI B 16.1, ASME Boiler and pressure vessel codes,
IBR and other application ASME, ANSI and local standards.
7.14.16
Sheet-181
8.00.0
8.01.01
8.01.02
Wind speed
The applicable design wind pressure will be computed during design
of buildings and structures as per IS:875 (part 3) for the zone in which
the proposed power station is located. This basic wind speed will be
used to determine wind load for all structures.
8.01.03
Temperature
Systems and system component design criteria which require
ambient temperature extremes shall use the range from minimum to
maximum temperature existing at site for dry-bulb temperatures.
8.01.04
Relative humidity
i) Absolute maximum : 100%
ii) Highest monthly mean : As per site condition
8.01.05
Seismicity
Sheet-182
The power station is located under Zone-II as per IS: 1893 (part-I):
2005. The design and analysis of structures to withstand the seismic
forces will be done/carried out as per the provisions of IS: 1893.
8.01.06
Soil Characteristics
The area is generally covered with medium Red sandy loam Soils.
Type of foundations will be decided based on the geotechnical
investigation. LEPL will carryout the detail geo-technical investigation
of the proposed project site for the plant structures as per the plot to
decide about the type of foundations for the plant equipment
8.01.07
8.02.0
Sheet-183
a)
All the walls and floors will be provided with approved painting and
floor finishing. RCC roofs will be provided with approved water
proofing treatment.
Special foundations - Rotating equipment
The foundation systems for rotating equipment will be sized and
proportioned not to exceed the bearing and settlement criteria and
to assure satisfactory performance of the equipment. In addition to a
static analysis , a dynamic analysis will be performed to determine
the fundamental frequencies of the foundation system. To preclude
resonance , the fundamental frequency of the foundation will be 25
percent removed from the operational frequency of the equipment.
The dynamic behavior of the foundation will meet the requirements
of IS:2974 (Part I to IV) code of practice for design and
Construction of machine foundations.
All rotating equipment will be provided with vibration isolation spring
system mounted foundations. The vibration isolation system
supplied will be of proven make, consisting of steel helical spring
units and viscous dampers (Providing damping resistance in all
three planes). The vibration isolation foundation system will be
provided for Turbo-generator, Boiler feed pumps, ID/FD/PA fans,
Coal mills and Coal crushers.
The vibration isolation system will be capable of vibration isolation
more than 95%
Sheet-184
Sheet-185
All building will be provided with 1500 mm wide and 150mm thick
plain cement concrete paving around on the outside. The plinth
protection will be laid over prepared sub-base and base.
Steel doors, windows, rolling shutters will be provided with glazing
as required.
b) Structural works
Structural works will be designed for dead-load plus adequate live
load plus worse of wind load and earthquake load with importance
factor of 1.5 and seismic load as per IS: 1893 as applicable for
zone-II.
Mill & bunker bay will comprise of structural steel framework
supporting the coal bunkers, feeder floor and tripper floor. The
structural frame will be designed as a fixed joint frame in the
transverse direction and braced frame in the longitudinal direction.
Coal bunkers will be of structural steel plates and will be lines with
stainless steel liner plates in the entire conical portion. The floors will
be of reinforced concrete with hardened top and supported on steel
beams. The column foundation and mill foundations will be
supported on raft/spread foundations. Tripper bay and conveyor
galleries will be provided with color coated sheet cladding.
Stairs, platforms and galleries will be of minimum 900 mm width
complete with hand-rails, toe-plate and curbing as required. Stair
treads will be of 250 mm with 150/190 mm height between
successive treads.
c) RCC foundations for Turbo-generators, Boiler feed pumps, (as
required) ID/FD/PA fans, coal mills and coal crushers will be
provided with vibration isolation systems supporting the top RCC
deck to support the machine/equipment.
Sheet-186
8.04.0
8.05.0
8.06.0
Sheet-187
8.07.0
Water system
The consumptive water requirement will be drawn from river Krishna
and pumped to plant through MS pipelines. Intake water pump house
will be provided at suitable location at river end with pumping
facilities. The make up water pumping station will be of RCC
construction. In plant water storage for 15 days requirement will be
provided. The in plant water reservoir will be compartmentalized to
ensure de-sludging/maintenance of any section without affecting plant
operation.
Pre-treatment plant & overhead tanks for potable water/service
water
Pre-treatment plant consists of clarifloculator along with Aerator, flush
mixture, clarified water tank and pump house, sludge disposal
system. The design and construction of these structures will be based
on IS-3370 Part-01 to IV along with the provision of leak proof
arrangement of structures.
With a view to conserve water, the fire water reservoir will be provided
with concrete slabs on top as protective cover, PVC lining will be
provided on bed and sides to prevent seepage loss.
8.08.0
Sheet-188
8.10.0
Sheet-189
8.11.0
8.12.0
8.13.0
Chimney
One(1) twin flue having flues of steel or acid resistant/fire clay bricks
with insulation (insulated outside the flue) RCC chimney will be
provided. The height of the chimney as per CPCB will be 275M. The
chimney will be fitted with 500 Kg capacity elevator, staircase inside
the windshield of RCC slip form construction. Chimney will be fitted
with pollution ,measuring apparatus & warming lights at top. chimney
will be provided with lighting arrestor, aviation warning lights as per
Sheet-190
Railway Siding
Railway linkage to the project site will be from Mulvad Railway station
of Hubli-Bijapur section of South western Railway at a distance of
about 5 Km.
8.15.0
Auxiliary Buildings
In addition to the power plant technological structures/buildings,
following non-technological buildings/structures will also be provided.
a).
b).
c).
d).
e).
f).
g).
h).
i).
Green belt around the power plant area covering about 30%
of the plant area as per Environment Pollution Control norms.
Sheet-191
8.16.0
j).
k).
Residential Colony
i.
II.
The operation and maintenance staff for a wellmanaged proposed power station has been assessed
as 350 personnel besides security staff. Availability of
some of skilled manpower for the project in the
neighboring areas is envisaged. Project site being
close to Basavana Bagewadi town at about 25 KM, the
manpower likely to be available. A residential colony for
the plant will be built for O&M Personnel in about 65
acres of land. There is no big developed town nearby
area of the proposed site and as such the rental
accommodation may not be available in abundance.
b)
Housing Categories
About 260 personnel are proposed to be accommodated in
the town ship. About 10% employees will be provided with
bachelor hostel accommodation and the remaining will be
accommodated in A, B, C, D type residential quarters.
Security barracks (bachelor accommodation) is proposed for
Sheet-192
III
Housing type
A-type
B-type
C-type
D-type
Total
Covered
area
Number of
Flats
50 M2
75 M2
100 M2
125 M2
120
80
50
10
260
IV.
Community Facilities
In order to attract and retain a competent work staff, the
township will be developed with an aim to satisfy the
diversified needs of the employees and their families.
Accordingly, adequate and various type of community
facilities will be provided in township area. These will include
childrens play areas and play fields, primary cum nursery
schools, cruche, health center and hospital, shopping
facilities, community center, club house, open air theater,
bank, post office, police outpost etc.
Sheet-193
9.00.0
9.01.0
CEA Guidelines
As per CEA regulations 2007, the following Layout considerations
shall be adopted.
General layout of the Station shall be developed considering space
optimization, functional requirements, future extensions (if envisaged)
and provision of space requirements during construction stage.
Following minimum layout requirements shall be complied with as
may be applicable for coal/lignite and/or gas turbine based Stations:
i)
ii)
iii) Due consideration shall be given for the wind direction while
deciding on the relative location of the following:
a) cooling tower and switchyard to minimize the moisture drift
towards the switchyard.
b) chimney and ash disposal area with respect to township and
adjoining habitation areas (applicable for coal/lignite based
generating stations)
iv) Adequate space shall be provided for unloading and maintenance
purposes in Turbine - Generator (TG) area.
In case of coal/lignite based generating stations, two transverse
bays shall be provided in TG area, at ground level at one end of
the building for unloading and maintenance purposes. For
Stations with multiple units, adequate space shall be provided to
meet the requirement for simultaneous maintenance of two units.
Sheet-194
vii)
Plot Plan
The general plant layout for the proposed power station is shown in
plot plan drawing is given at Annexure-9.a
The Plot plan shows the location of main plant equipment with its
auxiliaries, raw water storage reservoir, railway marshalling yard, coal
Sheet-195
storage area, switchyard, fly ash silos, and ash dyke. The plant layout
has been developed keeping in view the following:i.
Location within the designated area best suited from the point of
view of available land offering least site grading costs.
Sheet-196
9.03.0
9.04.0
Switchyard
400 KV switchyard will be located North-west of station building
beyond transformer yard as shown in the plot plan drawing. Power
will be evacuated from the plant switchyard at 400 KV voltage level.
Natural draft cooling towers, water reservoir are located in Nort-East
side of the main plant, where as the coal handling plant and railway
marshalling are in the East.
Separate provision for gate complex comprising security office, first
aid centre and time office will be made in gatehouse complex.
The auxiliary and building includes:
i.
Fire station
ii.
Work shop
iii.
iv.
Canteen
v.
Compressor House
vi.
Sheet-197
The flue gas ducts from the air heater pass below feeder floor for
connection to ESP; and then will be connected to a 275 M high RCC
stack, with steel flues, each flue connected through two (2) ID fans for
each unit.
ESP control room will be provided separately for each unit.
Ash pump house with slurry sump will be located near ESP.
One (1) passenger-cum freight-elevator of 2000 kg. capacity will be
located between two (2) boilers. Elevator will be connected to various
platforms of the boilers.
The elevators machine rooms will be provided with pressurized
ventilation/air-conditioning to avoid ingress of dust from boiler & mills
area. The elevator-shafts will be covered on all with CGI sheeting or
perforated corrugated metal cladding.
9.06.0
Sheet-198
extent possible to minimize the cable lengths. 240 Volt ACDB etc.
dedicated for each unit will be located at higher levels scattered close
to the equipment to the extent possible to minimize the cable lengths.
240 Volt Station Battery units and its chargers, room along with UPS
Battery will be also located in B/C bays. The air-conditioning plant
with its associated auxiliaries such as Air handling unit (AHU) room
etc. Serving the control rooms will located in B/C bay at higher
elevation floor. Deaerator with its storage tank (one per each unit) will
also be located at 36.0 M floor level separately for each unit.
The ground floor, apart from the unloading space for handling the
equipment through EOT cranes, in between A/B bay, the following
equipment with auxiliaries will be installed: 3x50% capacity condensate extraction pump sets
Turbine dirty oil & clean oil tanks with associated pump sets;
& purification plant - common for both units
Gland steam condenser / drain coolers
Chemical dosing equipment
Hydrogen cooling system for generators
Regenerative feed water heaters will be located in the machine hall
between A/B bays (LP heaters below operating floor while HP heaters
will be located at operating floor, in case horizontal heaters are
selected) close to B-row so that theses are approachable to EOT
crane when shell is withdrawn.
The main equipment erection hatch will be located at the end of AB
bay suitable for rail entry under the machine room EOT cranes and its
lifting beam. Subsidiary erection hatches will be provided for crane
access to equipment locaed on ground and mezzanine floors. As per
TAC requirement, access staircases will be provided for
interconnection to all main floors and for evacuation of operators
during an emergency.
Sheet-199
2 nos. natural draft cooling towers for cooling the circulating water will
be located to the East side of the power station building. The location
is selected, considering the wind directions such that it does not effect
the power plant equipment & 400 KV switchyard.
Transformer yard will have RCC rail track upto unloading bay of TG
hall for shifting of Generator transformer during erection &
maintenance.
The ash dyke area is located south-west of the main plant.
Sheet-200
10.00.0
ENVIRONMENTAL CONSIDERATIONS
Ministry of environment and forests (MOEF), through notification of
14th September, 2006 have laid down procedures for environment
clearance for industrial projects including thermal power stations. The
notification requires industry to carry out EIA study, in accordance
with MOEF guidelines to determine the impact of new industry on the
existing environment in respect of atmospheric and liquid pollutants
and resultant air and water quality in the area to ensure their quality
should be well within the prescribed limits and thus requires
Environmental clearance.
Sheet-201
10.02.0
Sheet-202
Effluent from the pretreatment plant (clarifier and filtration plants) will
comprise sludge and water. Sludge will be separated and compacted
in sludge presses and will be disposed off in solid form as landfill. The
balance water will again re-cycled in clarifier along with raw water
drawn from the reservoir.
Effluents from the dematerialized plant resin regeneration circuit,
generally acidic from the cation units and alkaline from the anion units
will be neutralized in a neutralizing pit. The neutralized effluents will
have less than 100 ppm suspended solids and a PH value of about
7.5 to 8.0. The neutralized effluents will be led will be led into Central
Monitoring Basin (CBM).
The cooling tower blow down will be led into CMB.
The boiler blow down will be controlled to maintain system solids
loading within normal limits for proper water chemistry. The effluents
will have less than 100 ppm suspended solids and will be led into the
CMB.
The run-off from the coal handling area will flow through channels
around the coal storage area and coal handling buildings into a
common basin (settling tank) from where it will be pumped into the
Central Monitoring Basin.
The oil-water mixture collected in the existing drains, provided around
the oil unloading area and the pump house, etc. is led to an oil-water
separator. The separated water containing less than prescribed limit
of oil and grease and will be led into the CMB. The waste oil as
separated out will be reutilized, if possible.
The sewage from the various buildings in the power plant as well as
the colony will be routed through a sewage treatment plant. The
treated effluents from the sewage treatment plant will be utilized
suitably for land application as per the existing standards.
Sheet-203
The ash pond will be suitably lined to prevent ingress of ash water in
sub soil. In the later years, when ash utilization is progressively
increased, lower quantity of raw water will be required and more
treated effluent water will be used for CHP dust suppression, BA
hopper refractory cooling and watering of green belt. Excess liquid
effluent will be discharged in a central monitoring Basin , where
treated liquid effluent will be monitored and recycled in DMF-UF-RO
system for reuse.
The effluent quality of various streams will be maintained as per the
existing standards of thermal power effluents (Attachment-13.i). The
final effluents, after treatment, will confirm to the standards for
discharging
into
identified
system
will
be
as
per
(Attachment- 13.I ).
10.03.0
Noise Pollution
The major noise generating sources are turbines, generators,
compressors, pumps, fans, coal-handling plant etc. Noise levels will
be limited as per CPCBs Ambient Noise Standards/MOEF notification
on noise pollution ( Regulation & control) Rules 2000. Suitable
acoustic enclosures shall be provided to control the noise level.
Personal protective equipment will be provided to the persons
working in high noise area.
Ambient noise inside and outside the plant area will conform to the
prescribed noise levels for various land use categories as per
National standards for Ambient noise (Attachment 13.J). This will
be ensured through proper designing of the equipment with adequate
acoustics permitting the ambient noise levels without of exceeding the
specified criteria from the source.
Green belt adequate width will be provided around plant boundary
and strategic locations and the total green belt comprises 1/3 of the
plant area.
Sheet-204
10.04.0
Sheet-205
program of ash utilization by user agencies, dry fly ash collection, and
storage and making available dry fly ash to the user agencies outside
the plant boundaries round the clock; so that it forms a continuous
process.
The important areas of ash utilization are indicated below:
i) Building Sector for use in bricks, blocks, tiles, cement, concrete,
plaster, etc.
ii) Land reclamation, filling low lying areas, raising ground levels.
iii) Roads, embankments, ash dykes, road blocks, kerb stones, etc.
iv) Agriculture and wasteland area development.
v) Hydro Sector, Irrigation, drains, water supply & drainage., lining of
rivers, tributaries, canals, minors, sub-minors etc.
vi) Mine filling.
vii) Industrial applications & high value areas.
viii) Roller compacted dams, pavements, roads etc.
ix) Special use for ash e.g., collecting cenospheres from floating ash.
x)
Sheet-206
As per the current practice, large quantities of water are used for the
transportation of fly ash in slurry form which otherwise could have
been saved for other more important requirements. Thus, ash water
recovery system is envisaged to re-use of ash water from ash pond.
With a view of proper utilization, fly ash has to be handled separately
by collecting in silos in dry form for subsequent utilization. The dry fly
ash could be transported in Railway wagons and closed trucks for
commercial utilization.
Bottom ash after being collected in ash bins for decantation will be
conveyed in trucks outside the plant site, and will be used extensively
as a replacement for cinders. The use of bottom ash in area filling has
been satisfactory over the years, by virtue of which it finds ready
marketability.
For the proposed power plant, fly ash will be collected in dry from in
ash silos and will be transported by Rail wagons/trucks to the ash
utilization facilities. Surplus fly ash not used in the manufacture will be
disposed off in slurry form to the ash disposal area in exigencies.
d) Ash utilization Plan:As per the Ministry of Environment & Forest (MOEF) notification dt 3 rd
November 2009, New coal and, or lignite based thermal power
stations and, or expansion units commissioned after this notification
have to achieve the target of fly ash utilization as per table given
below:
Table
S.No.
Target date
Sheet-207
The unutilized fly ash in relation to the target during a year, if any,
shall be utilized within next two years in addition to the targets
stipulated for these years. The unutilized fly ash accumulated during
first four years (the difference between the generation and utilization
target) shall be utilized progressively over next five years in addition
to 100% utilization of current generation of fly ash.
In line with above stipulations, LEPL will make necessary tieup with
cement manufacturing units to dispose major quantity of ash and
also encourage the entrepreneurs to set up ash based plants
including brick making plant, concrete blocks, panels or any other
material for construction of roads, embankments, dams, dykes or
construction activity near to power station.
The Central Electricity Authority and other approving agencies may
permit the land area for emergency ash pond or fly ash storage area up
to 50 hectares for a 500 MW unit, based on 45% ash content coal, or in
the same proportion for units in other capacities taking into account the
ash content in coal or lignite to be used.
As per above stipulation, the total land area works out for 1320 MW
capacity coal based power plant with ash generation @ 34% is up to
246.45 acres.
Total ash generation is estimated as about 2.013 million tons/annum
with ash content in coal @ 34% and unit operating at 85% PLF.
The dry fly ash will also be collected in 2 nos. silos of 1600 tonnes
capacity for Railway wagons loading and one silo of 1000 tonnes
capacity for loading into closed trucks and will be disposed off for ash
utilization facilities.
10.05.0
Sheet-208
10.06.0
10.07.0
Institutional Set-up
The Post operational monitoring programme will be under the
supervision of the Environmental Management Group (EMG) at the
project site. The station will be equipped with all necessary
instrumentation / equipment and manpower required for ensuring
effective monitoring. The EMG stationed at site will interact with State
Pollution Control Board for all environmental issues during operation
of the station.
Sheet-209
11.00.0
11.01.0
Sheet-210
Space will also be earmarked for labour hutments outside of the plant
area for temporary work force during execution stage.
Adequate construction office space and covered storage space will be
built during construction and the same will retained as site offices,
stores etc. after the power station is constructed.
In addition to the above, temporary facilities for the construction staff
are also needed apart from open storage space such as preassembly yard, canteen, garage, yard toilets etc. for which the
adequate open space will have to be made available.
A residential colony will be built for the project for the plant for which
the adequate land will be provided. The residential colony will have all
the required facilities of roads, electrical distribution system, water
and sewage disposal arrangement, community centers, shopping
complex, medical facilities and schools etc. One hostel building will
also be built as a first priority and will be utilized for housing staff in
the initial period. The hostel building will be for accommodating O&M
staff/security staff and/or as a hostel for visiting personnel during plant
operation.
Construction Water
The maximum requirement of construction water is estimated to be
about 200 M3/hr. Construction water is proposed to be drawn either
from Bhima/Krishna river.
Construction Power
The construction power will be drawn through the 33 KV or 11 KV
network from KPTCL sub-station in Mulvad at a distance of 8 km from
project site. The peak demand is estimated about 5 MVA assuming
structural steel fabrication work at site besides other power
requirements.
Sheet-211
Construction Material
Construction material such as stone, sand, bricks, cement are
available within 25 km distance from construction site.
11.02.0
11.03.0
Quality Assurance
An independent quality assurance group for ensuring the quality
during the project engineering, procurement and manufacturing, as
well as during material storages will be organized in the Corporate
Office. Before the award of any contract the QA Dept. Will discuss
Sheet-212
11.05.0
Sheet-213
issue
and
The stores arrangement will include covered and open storage yard
with facilities for material handling. Environment controlled rooms will
be provide for storage of sensitive spare parts and consumables like
electronic cards, chemicals etc.
11.07.0
Training
The training of O&M personnel at various levels will be arranged
through prevailing methods and practices which will include a
computerized plant operation simulator, various audio visual aids, a
well maintained library and most important the requisite set up for
training activity.
These will be reinforced by:
Sheet-214
i.
Completion Schedule
The Bar Chart for the project schedule indicating the major activities
of the project is as per (Annexure 12)
a) The zero date is taken as the EPC contractor is selected and
advance released. The zero date is projected to occur 6 months
after the decision to proceed with the project.
b) The project will be scheduled for the first unit to go into
commercial operation in 46 months after the zero date & second
unit at 6 months interval thereafter.
c) The first activity to be started at the site, namely the site
development work. i.e. soil investigation, leveling, grading etc. will
be scheduled to start three months prior to zero date and be
completed by the zero date.
Sheet-215
12.00.0
12.01.0
(i) The power projects with the following threshold capacity shall be
eligible for the benefit of mega power policy:
(a) A thermal power plant of capacity 1000 MW or more; or
(b) A thermal power plant of capacity of 700 MW or more located
in the States of J&K, Sikkim, Arunachal Pradesh, Assam,
Meghalaya, Manipur, Mizoram, Nagaland and Tripura or
(c) A hydel power plant of capacity of 500 MW or more
(d) A hydel power plant of a capacity of 350 MW or more, located
in the States of J&K, Sikkim, Arunachal Pradesh, Assam,
Meghalaya, Manipur, Mizoram, Nagaland and Tripura;
(e) Government has decided to extend mega policy benefits to
brownfield (expansion) projects also. In case of brownfield
(expansion) phase of the existing mega project, size of the
expansion unit(s) would not be not less than that provided in
the earlier phase of the project granted mega power project
certificate.
(ii) Mandatory condition of Inter-State sale of power for getting mega
power status has been removed.
Sheet-216
(iii) Goods required for setting up a mega power project, would qualify
for the fiscal benefits after it is certified by an officer not below the
rank of a Joint Secretary to the Govt. of India in the Ministry of
Power that (i) the power purchasing States have constituted the
Regulatory Commissions with full powers to fix tariffs and (ii)
power purchasing states shall undertake to carry out distribution
reforms as laid down by Ministry of Power.
(iv) Mega Power Projects would be required to tie up power supply to
the distribution companies/utilities through long term PPA(s) in
accordance with the National Electricity Policy 2005 and Tariff
Policy 2006, as amended from time to time, of Government of
India.
(v) There shall be no further requirement of ICB for procurement of
equipment for mega projects if the requisite quantum of power
has been tied up or the project has been awarded through tariff
based competitive bidding as the requirements of ICB for the
purpose of availing deemed export benefits under Chapter 8 of
the Foreign Trade Policy would be presumed to have been
satisfied. In all other cases, ICB for equipments shall be
mandatory.
(vi) The present dispensation of 15% price preference available to the
domestic bidders in case of cost plus projects of PSUs would
continue. However, the price preference will not apply to tariff
based competitively bid project/s of PSUs.
12.02.0
Cost Estimates
An estimate of the total cost of the project has been made. The
estimate has been made under three heads, namely Civil, Mechanical
and Electrical.
The following assumptions have been made in the preparation of the
cost estimates: The average cost of land for plant, ash disposal area including
green-belt area, colony and corridors for railway line approach
Sheet-217
road etc. has been considered at the rate of Rs.12.5 lakhs per
acre.
The estimate of civil and structural works have been prepared
assuming no piling except for TG foundations, natural draft
cooling towers and chimney.
Freight @ 4% and for the plant equipment insurance @ 1% has
been taken (total 5%).
Cost of spares has been taken as 2.5% of the project cost
excluding IDC & Finance charges.
Erection, testing and commissioning has been taken as 10% of
equipment cost.
25% of working capital requirement is capitalized and is included
as margin money. The margin money has not been considered
for the purpose of tariff calculations.
The cost of mechanical, electrical and C&I equipment are
exclusive of all taxes and duties on the assumption that Mega
status to the project will be available from Ministry of Power. The
Prevalent rate of excise duty applicable to boilers, TGs and
auxiliaries is 16.0% plus 2% surcharges. For the imported
equipment there is a levy of 21.8% towards custom duty. LEPL
will approach Govt of India, Ministry of Power for according mega
status to the Project.
Service Tax @ 10% and education cess @ 3% on service tax i.e
10.3% has been considered on erection, testing &
commissioning and freight and insurance costs.
Income tax & Minimum Alternate Tax has been considered in line
with 2010-11 financial bill.
The discount factor has been considered as 9.35 based on
CERC publication.
Sheet-218
12.03.0
Auxiliary Consumption
Station Heat Rate
6.0%
:
2380 k.cal/kwh
Depreciation
O&M
1 ml/unit
PLF
85%
Return on equity
Working capital
O&M expenses
1 month
Receivables
Fuel charges
2 month
2 month
Support fuel
2 months
Maintenance Spares
Life of plant
25 years
Secondary
consumption
12.04.0
Fuel
Sheet-219
Financing Structure
Equity Capital
Loan Capital
30%
70%
12.08.0
Cost of Generation
The cost of generation with the estimated project cost, CERC norms
and other input parameters has been computed as follows.
Levellised tariff @ 85% PLF with 25 years plant life Rs 3.32 /Kwh
The tariff computation sheets are enclosed.