1050 MW Maithon Power Project (Phase I)

The 1050 MW Maithon Thermal Power Project is the first Greenfield project undertaken by

Tata Power since the inception of Trombay Thermal plant almost six decades ago. This project

is a true example of public-private partnership. TATA POWER-the largest private owner utility

in the country joined hands with Damodar Valley Corporation-a multipurpose power and

irrigation control undertaking of Govt.Of India, Govt.Of West Bengal and Govt.Of Jharkhand

to bring up a project which brings out the best in each of them.

A decision was made to build the power plant on a site measuring 1100 acres which sits on

the right bank of river Barakar in the Dhanbad District of Jharkhand. The site is well

connected by National Highway 2 and is located on the rail network of Howrah-Mugal Sarai

grand cord line of Eastern Railways. More importantly , coal is widely available in Jharkhand

and its neighboring states which give good economics to the pithead plant. Hence, it was

proposed for a 1050MW Thermal power plant to be fired by coal on the selected site. The

name of the selected area is Maithon, which means ‘Mother’s Abode’ in the local Adivasi

language.

1050 Maithon Phase-I Power Project

Project Location

General Information

Name Maithon Power Limited

Constitution Public Limited Company

Promoters The Tata Power Company Limited (74.00%) and Damodar

valley Corporation (26.00%).

Sector Power Generation

Project(s) Site Location Right bank of the river Barakar, Nirsa – cum – Chirkunda

block, District Dhanbad, Jharkhand

Project(s) Capacity 1050 MW (2 X 525 MW)

Salient Features

The Project includes 2 Units of 525 MW each with total nominal capacity of 1050MW. The plant will use 4.864 million metric tons per annum (MMTPA) of domestic coal as fuel and 55 cusecs water from Maithon Reservoir. The project is 74:26 joint ventures between Tata Power and Damodar Valley Corporation (DVC). The Project Power will be evacuated through 400kV lines by PGCIL to benefit the States of Jharkhand, Bihar, West Bengal, Delhi, & Punjab.

India’s first public private partnership TATA Power: DVC 74: 26 at Maithon is committed to deliver quality power at most competitive price. It is the zero discharge plant at Maithon site.

Plant Capacity: Maithon Project was originally envisaged as a 4 x 250 MW or a 3 x 350 MW

thermal power plant. However, the Ministry of Power, Government of India (MoP) while

approving Tata Power as joint venture partner in MPL had requested Tata Power and DVC to

examine alternative unit size of 2 x 500 MW units. MPL invited bids for 4X250MW, 3X350 MW

and 2X500 MW configuration and based on the past performance in other plants and the

advantages in terms of operational parameters (heat rate, area & staff requirements) has

chosen 2 X 525 MW configuration as it is technically more acceptable as compared to a 2 X

500 MW.

Share Holders Project Equity

Tata Power: DVC 74 : 26

Debt :Equity 70 : 30

Power Evacuation Through 400kV Power grid Transmission links - Double circuit Maithon- Maithon line - Double circuit Maithon – Bokaro line

Power Purchase Agreements

DVC -300MW Punjab- PSEB- 300 MW Delhi- NDPL -300 MW West Bengal- WBSEB-150 MW

Coal Linkage 1.7 MTPA from BCCL – FSA executed. 1.9 MTPA from CCL- LoA Received

Water 55 cusecs from DVRRC, Maithon Reservoir

The BTG Package was executed by M/S BHEL. The other major Package Executors being:

M/S Simplex Infrastructures Pvt Ltd - General Civil Works

M/S L&T - Induced Draft Cooling Tower

M/S Tecpro Systems Ltd - Coal Handling System

M/S Macawber Beekay Pvt Ltd - Ash Handling System

M/S L&T -ENGP - Plant Electrical Systems

M/S BGR - DM Water Systems

M/S Voltas - LP Piping & PWS Electrical

Steam Generator: The BHEL Make steam generator (SG) is a pulverized coal fired SG

with assisted circulation and drum type design. The SG is of two pass type design, radiant,

single reheat, balanced draft, semi-outdoor type, rated to deliver superheated steam at

optimum pressure and temperature. The Specification for the Steam Generator are as

follows:

Rated Steam Flow - 700T/Hr

Boiler Design Pressure - 210Kg/cm2

Super heater outlet pressure - 191.3Kg/cm2

Super heater outlet temperature - 540°C

Re-heater outlet temperature - 540°C

Total Heating Surface Area - 50800m2

Steam Turbine: The BHEL Make steam turbine generator (STG) is rated for 525 MW

maximum continuous output at generator terminals. Steam turbine is a three cylinder reheat,

extraction and condensing turbine. The specification for the Steam Turbine is as follows:

Gross Power Output - 525MW

(At 100% TGMCR)

Turbine Cycle Heat Rate - 1962 Kcal/Kwh

(At 100% TGMCR) Maximum Load - 546.7MW

(Under VWO Condition)

HP Turbine - Single Flow,17 Reaction Stages

IP Turbine - Double Flow,12 Reaction Stages per flow

LP Turbine - Double Flow,6 Reaction Stages per flow

Challenges Faced: Flavor of Maithon Green Field Project

Maithon Project can be a perfect example of the challenges to be faced in a Greenfield

Project. The majority of the local mass in Maithon Consisted of Farmers and farm workers

whose first reaction to the project was hugely negative in the initial stages of the project.

They were also incited by the local politicians with vested interests to protest against the

project. This resulted into mass protests at site including forced and fierced resistant even up

to the extent of attacking MPL Employees. “Band-Pradarshan & Dharna”, Road & Gate

Blockage , Threatening to the Contractors etc were a common phenomenon witnessed and

challenges faced by the Maithon Project during its entire construction phase. The Security

Team along with the entire Team Maithon had a tough time overcoming the local protests.

Protest by the local villagers and security on High alert.

Agitation & Road Blockade by Villagers of Purni

Agitation by the PAP s

Procession and Strike called by the Villagers

Violent Protests leading Site Activities to a Halt

The battle was won by putting tireless efforts in coordinating and bringing harmony between

the project team and the local community. Key concerns, needs and expectations of the

villagers were focused upon and all efforts were made in winning the hearts of the local.

Frequent meetings were held amongst with the government officials & the various groups of

local villagers. R&R package acceptable to the locals were finalized and the interests of the

stakeholders were aligned for execution of the project.

Despite all odds and prevailing politically unstable conditions which also resulted into

insufficient support from the Govt. Officials , Maithon Project became the first successful

green field project of the Jharkhand State.

Journey Of Maithon Phase I Project (from Greenfield Project

to 2X525 MW Power Plant)

By Feb 2008, the land acquisition process was completed and an area of 1100 Acres was

acquired by DVC and handed over to MPL for the construction of the Project. The Ground

Breaking Ceremony (Bhoomi Poojan) was conducted at site where the villagers, authorities

and Officials from Tata Power & MPL came together to give the Project a Kick-start.

Project initiated with whole-hearted support from Villagers & Land Losers

Bhoomi Poojan being performed by local Villagers Local Daily reporting the news

Maithon Bhoomi Poojan

Commencement of Site works in Mar’08

Curious Locals watching machinery at work

Excavation Job under Progress

Site Infrastructure in the initial Phase Of Project

Temporary Arrangement For First-Aid at site

First Porta-Cabin At site

Job Progress in 2008

Erection Of First Boiler Column

ESP#1 Column Erection Started

TG I Raft

Chimney Raft

Progress Review At Site

Job Progress in 2009

Unit#1 Boiler Drum Erection

Job Progress in 2010

BTG Area

Raw Water Intake Area

Job Progress in 2011

Unit#1 Steam Blowing under progress

Unit Synchronisation

Unit on Full Load

Maithon………As of Now!

During the project, members of the execution team had to face numerous setbacks and

challenges on many occasions. With consistent efforts and hard work put together into the

Project by all the Stakeholders, the TATA POWER’S Greenfield Power Project got finally

transformed into 2X525 MW Power Plant.

Unit#1 (525 MW)

: Synchronization on 28th March 2011

: Full Load on 30th June 2011

: COD on 1st Sept 2011

Unit#2 (525 MW)

: Synchronization on 17th March 2012

: Full Load on 23rd March 2012

: COD on 24th July 2012

Raw Water Intake

IDCT and CW Pump House

400KV Switchyard

Stacker-Cum- Reclaimer

View In Front Of Technical Building

Maithon Power: View across Barakar River