coastal energy private...

COASTAL ENERGY PRIVATE LIMITED

PRE FEASIBILITY REPORTFOR

2000 MW NATURAL GAS BASED COMBINED CYCLE POWERPROJECT

__________, ANDHRA PRADESH

December, 2009

Coastal Energy Pvt. Limited

PRE FEASIBILITY REPORTFOR

2000 MW

NATURAL GAS BASED POWER PROJECT

AT __________VILLAGE,

NEAR KAKINADA TOWN,

___________DISTRICT,ANDHRA PRADESH


CONTENTS

CHAPTER TITLE PAGE NO.

I INTRODUCTION 1

II JUSTIFICATION FOR THE PROJECT AND SITESELECTION

3

III PROJECT SALIENT FEATURES 9

IV BASIC POWER STATION REQUIREMENTS ANDSITE FEATURES

15

V SELECTION OF TECHNOLOGY, PLANTSIZE,CONFIGURATION

19

VI PLANT LAYOUT AND CIVIL ENGINEERINGASPECTS

22

VII MECHANICAL SYSTEMS 24

VIII WATER SYSTEMS 30

IX ELECTRICAL SYSTEMS 33

X INSTRUMENTATION AND CONTROL SYSTEMS 41

XI ENVIRONMENTAL ASPECTS AND WASTEMANAGEMENT

45

XII PROJECT COST ESTIMATES AND COST OFGENERATION

52


LIST OF APPENDICES

APPENDIX NO. TITLEPAGE NO.

1. METEOROLOGICAL DATA 55

2. ANALYSIS OF NATURAL GAS 56

3. TARIFF CALCULATIONS 57


LIST OF EXHIBITS

EXHIBIT NO. TITLE

1. ELECTRICAL SINGLE LINE DIAGRAM

2. WATER BALANCE DIAGRAM

3. PROJECT MILESTONE SCHEDULE


PFR – 2000 MW COMBINED CYCLE POWER PROJECT, KAKINADA, ANDHRA PRADESH 1

CHAPTER IINTRODUCTION

1. __________ group is engaged in developing innovative projects and in providing worldclass services in Infrastructure. This group has a vision to become a dominant player in thissector.

2. __________ group is currently having the following ventures. __________ ENERGY LIMITED: The 220 MW naphtha-based plant in Mangalore is

the world’s largest, and India’s first, barge mounted combined cycle Power plantand is the first medium sized Independent Power Producer (IPP) in Karnatakacommissioned in November 2001. The plant has received ISO 14001 certificationfrom Det Norske Veritas. As the PPA with Karnataka Power TransmissionCorporation was for 7 years which ended in June 2008, the plant is currentlyoperating as a merchant power plant.

__________ POWER CORPORATION PRIVATE LIMITED: The 200 MW Powerplant in Chennai, is the first Independent Power Project in Tamil Nadu and largesttwo stroke stationery engine power plant under one roof in the world, set up in theyear 1998. The plant received ISO 14001 and OHSAS 6001 Certification from DetNorske Veritas and the renowned Dr. M.S. Swami Nathan Foundation Award forEnvironment Protection.

VEMAGIRI POWER GENERATION LIMITED: The latest Power generation projectwith a capacity of 370 MW is at Vemagiri in the East Godavari district of AndhraPradesh, which was commissioned during December 2005. The project wouldprovide power to APTRANSCO.

__________ KAMALANGA ENERGY LIMITED: __________ Kamalanga EnergyLimited (GKEL) has taken up construction of 1000 MW coal fired thermal powerproject near Kamalanga in Dhenkanal Dist. of Orissa state. OSEB has the right topurchase 250 MW of Power generated from this project. Therefore, at anappropriate stage of the Project development, GKEL will be entering into a PowerPurchase Agreement (PPA) with Govt. of Orissa and with neighboring states or withPower Distribution Companies (DISCOMs) for the remaining 750 MW of powergenerated. Any excess exportable power will be sold to the neighboring states or toother bulk consumers through power trading agencies like Power TradingCorporation (PTC).

INTERGEN NV. ACQUISITION: __________ Infrastructure has acquired a 50%stake in InterGen. InterGen has 12 power plants located across the UK, theNetherlands, Mexico, Australia and Philippines, with 8,086 MW of net operationalcapacity (including 428 MW under construction in the Netherlands) and 4,680 MWof assets under development.

EMCO ENERGY LIMITED: __________ Energy has Acquired 100% stake ofEMCO Energy Limited developing 2x300 MW TPP, Warora., Maharashtra based ondomestic coal. 200 MW of generated capacity of the plant tied up MSEDCL.

3. This Group has won two projects awarded by the National Highway Authority of India(NHAI) under the Build, Own and Transfer (BOT) Annuity Scheme.

4. __________ Group is actively participating in the venture of privatization / modernization ofAirports in India.

Proposed Power Project5. __________ Energy Limited (GEL) proposes to install a 2000 MW Natural Gas based

Combined Cycle Power Project in a site at Komaragiri village, near Kakinada town, EastGodavari district, Andhra Pradesh.



6. GEL also intends to enter into a Power Purchase Agreement (PPA) with Govt. of AndhraPradesh and with neighboring states or with Power Distribution Companies(DISCOMs)/private customers for the sale and dispatch of electricity generated from theproject.



CHAPTER IIJUSTIFICATION FOR THE PROJECT AND SITE SELECTION

__________ is an active player in the energy sector and has already established three green fieldPower projects, and has been planning to make a foray into gas based thermal power station.

The demand supply situation in southern and western regions is given below:

• The western region in general and Maharashtra in particular are presently facing severepower shortage as can be seen from Figure IV.1.

• Andhra Pradesh can be an ideal location to supply power to neighboring states likeMaharashtra.

Fig IV.1. Power Supply Position in Western Region :

Source: CEA Monitoring Report-Feb,2009.

The power supply position in Western region as per the Fig IV.1 indicates that there is deficit in theregion. Particularly the state Maharashtra is facing severe power shortages.

Fig IV.2. Power Supply Position in Southern Region :



Source: CEA Monitoring Report-Feb, 2009.

The power supply position in Southern region as per the above Fig IV.2 indicates that there isdeficit in this region also. Andhra Pradesh has got power shortages.Long Term Scenario:Western Region

Southern Region

Source: CEA Monitoring Report-Feb,2009.

It would be evident from the above information that during the end year of 11th plan i.e. 2011-12both the western and southern regions are expected to face a peak shortage of 10.64% and18.76% respectively. The projected shortages will remain even if the benefits from the 11th planschemes that are spilled to the 12th plan are taken into account.

In view of the above, it can be concluded that the proposal for setting up a gas based power plantof 2000 MW (5 X 400MW CCPP Blocks) capacity at Kakinada is fully justified.

__________ has been prospecting for a coastal site for setting up a gas based power station forthe following reasons:



Coastal stations have access to sea water and hence precious sweet waterrequirement would be minimal.

The site is very near to the gas rich Krishna Godavari Basin, popularly known as, KGBasin.

Further, at present __________ has focused on the eastern coast since there is considerabledemand for power in southern region and power can be economically supplied to the western gridalso.

Further, Andhra Pradesh was considered preferable for the following reasons:

Andhra Pradesh and the neighbouring State of Tamil Nadu are likely to experiencepower shortages in future.

Andhra Pradesh can be an ideal location to supply power to neighboring states likeMaharashtra due to the proximity of the site to the western grid.

Four villages Anur, Yellameli, Komaragiri and Pydikonda were identified for setting up a powerplant due to the following reasons:

1. Its close proximity to the gas rich Krishna Godavari Basin, popularly known as, KG Basin.

2. Its direct connections to the National and State Highway network, proximity to NationalHighway No. 5, connecting Chennai-Kolkata, a major South to east Corridor.

3. Its proximity to both the Rajahmundry (1 hour away) and Visakhapatnam Airports.4. The presence of a broad gauge link to the national railway network in close proximity to the

port.

The location of the four sites is shown below:

Sl.No.

GENERAL DATA ANUR YELLAMELI KOMARAGIRI PYDIKONDA



1.0 HOUSES /HABITATION

PRESENCE OF SOMEHOUSES BELONGINGTO FARMERS

NO HOUSES ORSTRUCTURES –PLANTATIONS EXIST

NO HOUSESORSTRUCTURES

NO HOUSESORSTRUCTURES

2.0 STRUCTURES 400kV TRANSMISSIONTOWERS PASSTHROUGH SITE

TWO TRANSMISSIONTOWERS PASSTHROUGH SITE

NOSTRUCTURE

ONE OR TWOTRANSMISSIONTOWERS PASSTHROUGH SITE

3.0� AGRICULTURALACTIVITY

AGRICULTURALACTIVITY

AGRICULTUREEXISTS

AGRICULTURE EXISTS– PALMS, SAGO

FEW PATCHES NEAR TO SEA –SOMEAGRICULTUREEXISTS

� 4.0� OWNERSHIP

4.0

5.0� SITEFEATURES

SITEFEATURES

UNDULATION UPTO3 m

PLAIN FLAT LAND PLAIN FLAT LAND PLAIN FLATLAND

� 6.0� LOCATION

6.0

7.0 FOREST COVER,LOCALREGULATIONS

NO NO NO FORESTCOVER

NO

8.0 CONSTRUCTIONWATERAVAILABILITY

BORE WELLS (TO BEPLANNED)

BORE WELLS (TO BEPLANNED)

BORE WELLS(TO BEPLANNED)

BORE WELLS(TO BEPLANNED)

9.0 NEARESTRAILWAY STATION

SAMALKOT – 13Km SAMALKOT – 13Km SAMALKOT –13Km

KAKINADA-32Km

The site located near Komaragiri village, near Kakinada town, East Godavari district, AndhraPradesh has been selected for the following reasons:

1. No inhabitation in the site.



2. Proximity to the shore which would minimize the sea water pumping distance.3. Its close proximity to the gas rich Krishna Godavari Basin, popularly known as, KG Basin

Hence, setting up a Coastal gas based thermal power project near Komaragiri village, nearKakinada town, East Godavari district, Andhra Pradesh is justified.



CHAPTER III

PROJECT SALIENT FEATURES1. Land:The site is located at Komaragiri village (approximately at 17° 3'5.68"N 82°18'30.38"E), nearKakinada town, East Godavari district, Andhra Pradesh. The site is suitable for installation of a2000 MW Natural gas based combined cycle power project from the following technicalconsiderations:

The required land for setting up 2000 MW (5 x 400 MW CCPP Block) Natural gas basedcombined cycle power project is available. This would be of the order of about 285 acresfor Power Plant, Yard, Switchyard, Water System facilities, Housing Colony and GreenBelt.

The site at Komaragiri is located on the sea shore near Kakinada Nearest railway station isAnnavaram at a distance of about 10 kms from site.

No agricultural activity is present at site. Sea water can be used for condenser cooling system. Desalination plant is envisaged for

sweet water requirement.. The proposed Location map of the project is shown below:

2. WATERClosed cycle condenser cooling water system, using sea water as make-up is planned forthis project. Sea water make-up shall be drawn from the sea. Blow down shall be returnedto the sea after meeting the discharge water temperature norms.Fresh water for Process Makeup is used by using Desalination process.Basic requirement of Sea Water for the project is 12000 m3/hr.

3. Fuel

The natural gas from Krishna Godavari basin will be made available to the power plant.

The maximum total requirement of natural gas for the proposed 2000 MW CCPP (5 blocks of400MW) will be about 10 MMSCMD. Natural Gas would be supplied at the required gaspressure up to the new gas metering station located in the plant site. . The Natural Gas will besupplied at the power plant site through a pipeline .

4. POWER UTILIZATION AND SALE OF POWERSince the plant is proposed to be set up as a merchant plant and with the advent of openaccess system in the electricity sector, electricity can be delivered to customers in variousstates in western and southern regions.

5. POWER EVACUATIONPower generated from the plant is proposed to be evacuated through the followingsubstations:

Proposed PowerPlant site



400 KV PGCIL Chandrapur substation (Maharashtra) located about 465 km fromsite.

400 KV PGCIL Kurnool substation located about 460 km from site.System studies will be required to ascertain the transmission capacity available in theexisting network and to assess the additional Transmission system required to be createdand the cost thereof for evacuating complete power.

The Map showing the Substations is as shown below:

6. MAIN PLANT EQUIPMENT

Name Plate Rating, Availability and plant load factor:The nominal nameplate rating of the proposed Power Project would be 5 x 400 MW.This CCPP would be constructed in 5 blocks of up to 400 MW each. About 94% plantavailability and about 85% PLF are expected out of this plant.

Brief technical Parameters of the Main Plant:

The proposed CCPP 2000 MW would consist of either 5 blocks of 400 MW with eachblock consisting of 2GTG + 2 HRSG + 1 STG in multi shaft configuration or 5 Blocks of400 MW each in either single shaft configuration or multi configuration comprising of 1GTG,1 HRSG and 1 STG.

Possible CCPP Configurations and Technical Parameters:

MANUFACTURER

MODELNO.

NO. OFGTGs/STGs

OUTPUTOF GTG(MW)

OUTPUTOF STG(MW)

GROSSPLANTOUTPU

AUXILIARYPOWERCONSUMPTION



T (MW)

ALSTOM KA 26B 2 + 1 (MS) 480.376 278.979 759.356 16.875 MW

1 + 1 (MS) 240.188 139.915 380.103 8.349 MW

1 + 1 (SS) - - 381.353 8.357 MW

GEENERGY 109 FA 2 +1 (MS) 456.275 256.148 712.423 14.164 MW

1 + 1 (MS) 228.137 129.0 357.142 7.808 MW

1 + 1 (SS) - - 358.291 7.815 MW

SIEMENS V94.3A 2 +1 (MS) 490.436 249.54 739.975 14.056 MW

1 + 1 (MS) 245.218 125.021 370.239 7.749 MW

1 + 1 (SS) - - 371.087 7.754 MW

MHI M701F 2 +1 (MS) 488.199 252.253 740.452 14.489 MW

1 + 1 (MS) 244.10 126.338 370.437 7.796 MW

1 + 1 (SS) - - 371.429 7.802 MW

7. CONSTRUCTION SCHEDULE

In case of single/multi shaft configuration of 400MW CCPP Blocks :

Based on implementation of this project on EPC/Package wise route and expecteddeliveries of main plant and equipment, a schedule of 24 months has beenconsidered for the design, engineering, procurement, construction and testing /commissioning, from the date of placement of order for the first 400 MW CCPP block,followed by next 400MW with a 6 month gap between the two blocks. Similarly theother blocks of 400MW will be commissioned in the gap of 6 months after thecommissioning of previous block. The construction schedule considered is indicatedin Exhibit- 3.

In case of multishaft configuration of 700 MW CCPP Blocks:

Based on implementation of this project on EPC/Package wise route and expecteddeliveries of main plant and equipment, a schedule of 30 months has been



considered for the design, engineering, procurement, construction and testing /commissioning, from the date of placement of order for the first 700 MW CCPP block,followed by next 700 MW with a 12 month gap between the two blocks. Similarly theother blocks of 700MW will be commissioned in the gap of 12 months after thecommissioning of previous block. The construction schedule considered is indicatedin Exhibit- 3.

PROJECT EXECUTION

The proposed project would be implemented on turnkey EPC/Package wise routeincluding switchyard and gas supply pipeline. Hence, the entire construction aids /facilities/management would be a part of EPC/Package wise contract. However__________ would also consider implementation of the project on package wise basis.

8. ENVIRONMENTAL ASPECTS

The proposed plant would be provided with a green belt as per MoEF norms. Therewould be no particulate matter emissions from the proposed project and NOx and SO2emissions would be within the limits specified by MoEF and control measureswill be indicated in the environmental management plan. This is because of the useof clean fuel like natural gas and use of dry low NOx burners in gas turbines. Watereffluents would be treated before disposal to comply with the relevant standards.Hence, the plant would be a fully environmental friendly green plant.

9. CLEAN DEVELOPMENT MECHANISM- PERSPECTIVE

Applicability of the Project under Clean Development Mechanism

The Clean Development Mechanism (CDM) was instituted in 2001, under the KyotoProtocol to enable developed countries to meet their Green House Gas (GHG) reductiontargets at lower cost through project in developing countries.

The proposed Project is gas based and the fuel is a clean fuel compared with Coal.This would result in a net reduction of GHG gases compared with conventional powerproduction (coal) of same capacity. Hence this project is broadly eligible for registrationas CDM project at UNFCCC.

The consideration of CDM revenue is to assess the final viability of the proposed project. The Government of India has constituted the National Clean Development Mechanism

(NMDM) Authority for the purpose of protecting and improving the quality of environmentin tune with the Kyoto Protocol.

The National CDM Authority receives projects for evaluation and approval as per theguidelines and general criteria laid down in the relevant rules and modalities pertainingto CDM. The evaluation process of CDM projects includes an assessment of theprobability of eventual successful implementation of CDM projects and evaluation ofextent to which projects meet the sustainable development objectives, as it would seekto prioritize projects in accordance with national priorities.

The general project eligibility for CDM has been detailed in Chapter-XI.

10. PROJECT COST AND TARIFFThe total project cost excluding IDC and Financing Charges (FC) is indicated inAppendices – 3, for execution of 5 Blocks of 400 MW. The estimated capital cost of theproposed 5 x 400 MW project is Rs.6535.38 Crore excluding interest during construction



(IDC) and financial charges. The cost per MW of installed capacity works out to Rs. 3.85Crore / MW.

The cost of generation for 2000 MW at 85 % PLF works out to Rs.3.28 per kWh for first fullyear of operation with all CCPP blocks in service, considering the return on equity @ 16 %and the landed fuel cost of Rs 10.63/m3 ($6 per MMBTU).

CONCLUSIONFrom techno-economical considerations including the expected CDM revenue, it is feasibleto install a 2000 MW Natural Gas based Combined Cycle Power Plant at the identified siteKomaragiri village, near Kakinada town, East Godavari district, Andhra Pradesh. Theproposed power plant has all the basic requirements essential for installation of thermalpower plant viz., land, water, proximity to existing Natural gas pipe line and powerevacuation facilities.

The power generated from this power plant can be supplied to Andhra Pradesh andneighboring states after studying the power demand and supply situation. In view of this, itis concluded that setting up of a 2000 MW capacity Natural Gas fired Combined CyclePower Project this location Komaragiri village, near Kakinada town, East Godavari district,Andhra Pradesh is viable.

In this respect __________ have already triggered the process of fuel tie-up, applyingvarious clearances/permits etc,

RECOMMENDATIONS

To ensure timely completion of the proposed project, it is recommended that early action onthe following activities may be initiated by GCEPL.

a) To acquire the land required for power plant, colony, cooling water pipe line, liquid fuelstorage systems and approach road.

b) To arrange for Environmental Impact Assessment (EIA) / Environmental Management Plan(EMP) study

c) To arrange for detailed topographic survey of the above land and to firm up actualcoordinates of land acquired.

d) To carryout detailed soil and geo-technical investigations to ascertain load bearing capacityand to conclude type of foundations viz., open type foundations or pile foundations.

e) Discussions with PGCIL and APTRANSCO regarding evacuation of power from theproposed power plant and initiation of Power Purchase Agreement (PPA) and WheelingAgreement with prospective buyers/ utilities.

f) Approval of Civil Aviation Authority for installing 70 m high chimneys.g) Initiate discussions for Financing of the project loan with prospective Indian Financial

Institutions, Foreign Financial Institutions, external commercial borrowing agencies, Indiancommercial banks.

h) Appointment of Owners Engineer (Consultant) for preparation of basic engineering and tofirm up plant technical specifications for tendering Main plant and Balance of plantEPC/Package wise Specifications,

i) Initiate Horticultural studies to establish the best species of plants that can be grown at thesite for developing the green belt.

j) Permission from the Directorate of Industries, Govt. of Andhra Pradesh, for conversion ofland use from agricultural to industrial.



CHAPTER IVBASIC POWER STATION REQUIREMENTS AND SITE FEATURES

1. BASIC STATION REQUIREMENSThe estimated requirements of land, fuel and water for the proposed power plantinstallation of a 4000 MW Combined Cycle Power Plant are presented in Table -IV.1below:

TABLE - V.1Estimated Requirements of Land, Fuel and Water

Land for power plant ofconfiguration comprising 5 blocksof up to 400 MW each.Each block of 400 MW willconsist of 1 Gas Turbines, 1 HeatRecovery Steam Generatorconnected to the exhaust of GasTurbine and 1 Steam turbine.Alternatively the option of using 3Blocks of 700 MW eachconsisting of 2 GT+2 HRSG+ 1ST will also explored.

285 acres of land including main powerplant, switch yard , and land for green beltrequirement

Natural Gas fuel requirement 10 MMSMD

Total process Water requirement Sea Water: about 12,000 m3/hr.

Power evacuation 400 kV switch yard

2. Site Location

The location of the site in the map is as shown in fig. IV.2. The site is located nearKakinada (at a distance of about 40km).

The co-ordinates of the proposed power plant sites are:17° 3'5.68"N, 82°18'30.38"EHowever these coordinates need to be verified and the exact co-ordinates of the PowerPlant site boundary will be obtained by a survey.

3. Connectivity The site at Komaragiri is located on the sea shore near Kakinada. Nearest railway station is

Annavaram at a distance of about 10kms from site. The site is connected by a rural roadwhich will require widening.

The other Railway Station is at Kakinada which is at about 50 km from the proposed site.



The NH 5 is about 21 km from the proposed site.

The photos of the proposed site are as shown in the figures IV.3 (a) and IV.3 (b) in thefollowing page:

Fig: IV. 3 (a) :): Komaragiri Site

Fig: IV. 3 (b) : Road at Komaragiri



4. Details of Plant Site The available land is near the coastline.

Resettlement and Rehabilitation (R&R) No forest land. Very little habitation.

5. Proposed R&R measures:

As there is very little habitation in the land, there will be little or no Rehabilitation &Resettlement requirement. However, __________ through its Corporate SocialResponsibility arm will endeavor to develop the social infrastructure and enhance thequality of life of communities in the villages located around the proposed Power Plant site.Under this program __________ will try to work on the following areas:

Education:__________ will aim to bring quality education to the underserved areas and sections ofthe community in the villages located around the proposed Power Plant site.

Health, Hygiene and Sanitation:__________ will work towards better health and more healthy lifestyles in the communitiesin the villages located around the proposed Power Plant site.

Empowerment & Livelihoods :__________ will endeavor to empower unemployed youth in the villages located aroundthe proposed Power Plant site through skill training and entrepreneurship developmentprogrammes.

Community Development:__________ will endeavor to improve lives & livelihood of the communities in the villageslocated around the proposed Power Plant site through participatory programmes. These



programmes will begin with a thorough study and analysis of the problems of thecommunities. Subsequently, __________ will work closely with the community to overcomethese hurdles.

6. Availability of Water

Sea Water: Closed cycle condenser cooling water system, using sea water as make-up is planned for

this project. Sea water make-up shall be drawn from the sea. Blow down shall be returnedto the sea.

Fresh water for Process Makeup is will be met through Desalination process Fordesalination cooling tower blow down will be usedBasic requirement of Sea Water for the project is 12000 m3/hr.

7. Fuel Source and Transportation:

Natural gas (NG) will be the main fuel for the gas turbines, will be made available fromKrishna Godavari basin depending upon the availability and pricing.

The maximum total requirement of natural gas for the proposed 2000-2100 MW CCPP(5 blocks of 400MW) will be about 10 MMSCMD. Natural Gas would be supplied atthe required gas pressure up to the new gas metering station located in the plant site.The Natural Gas will be supplied at the power plant site through a pipeline.

8. Environmental AspectsThe preliminary investigation reveals that there are no eco-sensitive spots such as nationalparks, wild life sanctuary, and biosphere reserve, historical and cultural sites present withinthe impact zone of the proposed site. However, authentic data need to be collected in thisregard during Environmental Impact Assessment (EIA) studies.



CHAPTER V

1. SELECTION OF TECHNOLOGY, PLANT SIZE, CONFIGURATION

Combined cycle power plant (CCPP) with capacity of 2000 MW comprising five blocks of400 MW each has been considered for the purpose of this report.

Plant Configurations Available in the market for the plant capacity underconsideration

The standard CCPP configurations available currently from the various manufacturersand their ISO output are published in the 'GTW Hand Book 2006'. This book has beenreferred in choosing the selection of the plant configuration for the proposed CCPP. Themodels available from leading gas turbine manufacturers namely Alstom, GeneralElectric (GE), Siemens and Mitsubishi have been considered.

Based on the GT World Handbook 2006 a list of possible configurations with GasTurbines based on advance class technology has been identified for the CCPP.Thepossible plant configurations, the site output, heat rate, etc. for each block of 400MW ispresented in the tables below.

Brief Technical Parameters and Performance of possible CCPP with Advanced Class Gas Turbines (10Blocks of up to 400 MW with 2 GT + 2 HRSG + 1ST in Multi-Shaft Configuration)

Sl.No Manufacturer

CCPPModel

No ofGTs +STs

Performance at ISOConditions

Performance at Site conditions

GrossOutputof theplantMW

GTGOutput

MW

STGOutput

MW

Grossoutputof theplantMW

GTGOutput

MW

STGOutput

MW

GrossHeat

Rate ofthe plantkcal/kWh

(LHV)

(LHV)Efficienc

y%

AuxpowerMW

1 GE 1 x 109 FA 1 + 1 390.80 254.10 141.80 366 233 133 1541 55.81 7.808

2 MHI 1 x M 701F 1 + 1 416.40 273.80 142.60 370.43 244.10 126.33 1531 56.17 7.796

3 SIEMENS

1 x V 94.3A 1 + 1 416.00 278.70 144.35 370.23 245.21 125.02 1524 56.44 7.749

4 ALSTOMPOWER

1 x KA 26-1 1 + 1 424.0* 288.3 380.10 240.18 139.91 1521 56.55 8.349

ADVANCED CLASS GAS TURBINE TECHNOLOGY

Advanced class GT are distinguished from other GT in following respects,a) Turbine inlet temperatureb) Compressor pressure ratioc) High temperature fatigue and corrosion resistance material and metallurgyd) Compressor and turbine blading aerodynamicse) Improved combustion systemf) Improved allied equipment.



Turbine Inlet temperature

Gas turbine Cycle efficiency is directly proportional to turbine inlet temperature andcompressor pressure ratio of gas turbine. Higher the turbine inlet temperature, higheris efficiency of gas turbine cycle and also of the entire combined cycle powerplant. Over the years the manufacturers were successful in bringing the inlettemperature in the range of 1300eC - 1500eC, hence increasing the efficiencyconsiderably.

Compressor Pressure Ratio

As mentioned earlier higher compressor pressure ratio also helps in improving the gasturbine cycle efficiency. Compressor pressure ratio increased from about 10.5 tocurrently about 19 to 23. This is possible due to enhanced compressor rotorstrength for increased torque and temperature generated within the compressor.

High temperature Fatigue and Corrosion Resistance Material and Metallurgy

For sustaining such high temperatures, advanced alloys have been used like Nickel basedalloys like Hastealloy X, RA 333, Nimonic 263 and Incolloy. In terms of Metallurgy themanufacturing (for compressor and turbine blades) has progressed from directionallysolidified (DS) to single crystal (SC) technology. Single crystal technology scores overDS in Creep strength, thermal fatigue and corrosion resistance. Improved bladecooling technology and more advanced thermal barrier coating on blades and otherhot gas paths have also been introduced.

Compressor and Turbine Blading Aerodynamics.

Previous generation of gas turbines used equiaxial blading, i.e. constant two dimensionalprofile over an axis. In advanced GT machines, a full 3D blade profile has been put touse optimizing the entire gas flow path for maximum energy utilization.

Improved Combustion System

There has been quantum jump in combustion technology due to need for reducednitrogen oxides (NOx) and carbon oxide (COx) due to emission limit imposed on GToperation. Of all types of new combustion technology introduced with dry low NOx (DLN),two most prevailing of them are Lean Premixed and Catalytic combustion. Of whichonly lean premixed has found much commercial success. The generations of 25ppm ofNOx emission for GT ranges in 40% to 100% load are presently ensured bymanufacturers. However during Naptha firing, for Nox abatment DM water will be injectedto keep the NOx levels below 50ppm.

Improved Allied Equipment

There has been simultaneous development in seal technology and control system.Seals are used for preventing leakages of air between rotary stage to next static stage(either compressor or turbine). Honeycomb and brush seals which are already used inaero engines have been introduced in some of the advance class gas turbines. Brushseals reduce the leakage loss by over 50% compared to conventional labyrinth sealsthus improving the gas turbine efficiency. More improved control systems for faster andprecise control have been put to use.

ADVANCED COMBINED CYCLE PLANTS

Most modern power plants are a synopsis of advanced gas turbines, improved steamturbines and new generation heat recovery steam generator working in completesynchronization.



Steam turbines are available either as a single shaft /tandem compounding modewith gas turbine or as multi shaft arrangement.

Most HRSG are designed to work in efficient way with steam turbines and are designedto suit individual steam turbines. HRSGs are available in triple pressure (superheatedsteam, reheat and low pressure) steam to be introduced in steam turbine. They couldbe either designed in vertical or horizontal configuration to suit the plant site conditions.

An Overview of Development of Gas Turbine Technology:

Year 1972 1979 1990 2005*

Parameters

Turbine inlet temp, QC 1010 1120 1260 1300-1500

* Compressor pressureRatio 11 14 14.5 19 - 23

Turbine exhaust temp,SC 482 530 582 600

**Cooled turbine bladerows

1st, 2nd rownozzle,1st rowblades

1st, 2nd row nozzle,1st, 2nd row blades

1st, 2nd, 3rd row nozzle, 1st,2nd 3rd, row blades

1st, 2nd, 3rd rownozzle, 1st, 2nd

3rd, row blades

*GT power output at ISO,MW 60 - 80 70 - 105 165 - 240 250 - 334

*Heat rate at ISO, kJ/kwh 11785 10800 10015 9100

*Efficiency of SC, % 31 34 36 39.5

*Heat rate of CC at ISO,kJ / kwh 7750 7380 6750 6000

*Efficiency of CC, % 46 49 53 60

EQUIPMENT AND SOURCING

For the purpose of this report one model from a leading gas turbine manufacturer hasbeen considered for the proposed 4000 MW Project consisting of 10 blocks of up to 400MW.. The detailed plant description, environmental aspects, project cost estimates andcost of energy generation are based on this model in multi shaft configuration. However,the decision on final configuration and make could be made after EPC/Package wisecontract finalisation through international competitive bidding (ICB) route.

CHAPTER VI



PLANT LAYOUT AND CIVIL ENGINEERING ASPECTS

PLANT LAYOUT1. The layout of the plant shall be developed considering the following general principles:

Least disturbance to existing habitation. Flexibility to have future expansion

2. Predominant wind directions as gathered from the recorder data to minimise pollution,fire risk, etc.,

3. Sea water intake from Bay of Bengal.4. Approach road to the power plant from the main road.5. Availability of adequate space for fabrication / construction equipment.6. Availability of adequate space for labour colony during construction stage.7. All facilities of the plant are laid out in close proximity to each other to the extent

practicable so as to minimize the extent of land required. The layout also facilitatescommunication of men and movement of materials between the various facilities bothduring initial construction and also during subsequent plant operation and maintenance.

CIVIL ENGINEERING ASPECTS1. Site Topography and Grade Level

Site terrain is undulating and would need minimal cutting, filling and grading to an extent of1-2 meters and the graded plant elevation would be around 4 M above MSL (information tobe re-confirmed from detailed topography survey). The main plant, auxiliary buildings etc.,would be located at suitably higher level than that of the general grade level.

MAIN POWER HOUSE BUILDINGS

1. Turbine building

Each block of the 400 MW will house 1 GTG and 1 STG. The building is also plannedaccordingly to suit functional requirement.

2. Gas Turbine Generator (GTG) area

Two GTG area is envisaged for each block. Each area would house two GTG.Overhead crane of 100/25 tonnes capacity is envisaged in the turbine building.There would be no intermediate floor in the GTG area.Structural steel columns and rooftruss are envisaged. For external walls, hollow concrete blocks/ brick wall up to about2.5m from ground level and double walled insulated metal sheet cladding up to roof areenvisaged. The roof would be insulated metal sheet supported on steel trusses. Thefloor would have granolithic floor finish with non-metallic floor hardener suitable forheavy duty loading.

3. Steam Turbine Generator (STG) area

One STG area is envisaged for block. Each area (including auxiliary equipment bay)would be 55m wide and 30m long and would house one STG & one GTG. The height ofthe building would be about 28m. No separate crane is envisaged in STG area,One number overhead crane proposed for both the blocks of GTG area will be madeapproachable to STG area also. Structural steel frames and cladding would be similar tothat provided in GTG area. Expansion joint is planned in between two blocks.Internal columns and floor framings, where applicable, would also be of structuralsteel. The turbine generator foundation would be of frame type in RCC.Equipment foundations would be of either block type or frame type depending onheight from the ground and would be suitably isolated from the main building



foundations and super structures. The floor of the STG building would havegranolithic floor finish with non-metallic floor hardener, suitable for heavy dutyloading. All floor and roof in auxiliary equipment area would be of RCC supported onstructural steel framing.

4. Soil Profile and FoundationsDetails will be furnished after the detailed geo-technical investigation of the proposed areais carried out. However the net safe bearing capacity of 25 t/m2 at 3.5 m below the existingground level is assumed and considered for cost estimation purposes.

5. Machine FoundationsAll equipment will be supported on conventional block / framed type RC foundations andwould be separated from the building foundations and superstructure.

6. Roads, Drains & Boundary WallThe roads would initially be of water-bound macadam type with shoulders on either side ofcarriage width. After major construction activities are completed, these would be surfacedwith bituminous carpet. All major roads will be 7.0 m wide and other approach roads will be4.0 m wide. Storm water drains would be provided on either side of the roads. The stormwater drains will be of RCC construction. The storm water drains will be connected to thenearest water body or will be treated suitably and reused for gardening and other purposes.The power plant boundary wall of 3.0 m height with anti-climbing device would beconstructed from locally available stones.

7. Design BasisDead and live loads will be considered as per relevant IS codes and standard engineeringpractices. The basic wind speed of 50 m/s is considered for design of buildings /structures as per IS: 875: Part III. The power plant is located in Seismic Zone III as per IS:1893 and seismic forces will be considered accordingly for the structures / buildings. Alldesigns shall be carried out in SI units and shall be as per relevant IS codes.

8. Sewage DisposalSewage from various buildings will be led to septic tanks located close to the buildings bymeans of CI pipes laid underground. The overflow from septic tanks will be led to thedispersion trenches or soak pits.

9. LandscapingThe various services / utility areas within the plant will be suitably graded to differentelevations. Areas in front of various buildings and the entrance of power plant will belandscaped with ground cover, plants, trees based on factors like climate, adaptability etc.The green belt will consist of native perennial green and fast growing trees. However it is tobe noted that general terrain is rocky in nature and an investigation has to be done toestablish the specific species of plants & trees which can be planted & grow in this area.

CHAPTER-VIIMECHANICAL SYSTEMS

General



1. The proposed 2000 MW combined cycle power plant at Komaragiri village, nearKakinada town, East Godavari district, Andhra Pradesh would comprise five (5) identicalblocks of about 400 MW each. For the purpose of thisreport, one block of 366 MW is explained in detail since the other block is identical. Oneblock of about 366 MW would consist of one gas turbine generator (GTG), having an outputof about 235 MW capacity at site conditions, one heat recovery steam generators(HRSG) and one steam turbine generator (STG) of about 131 MW capacity.

2. The heat content of the exhaust gas from the gas turbine would be recovered from theassociated triple pressure heat recovery steam generator. The steam generated would thenbe expanded in a reheat condensing steam turbine, driving an electric generator.

Combined Cycle Power Plant3. Typical parameters of the one block of about 366 MW combined cycle power plant

with natural gas (NG) firing, are furnished in Table below:

Parameters of 1 Block of 366 MW Combined Cycle Power Plant:Srno

Equipment Units Parameters

1 Gas Turbine Generator 1 no 235 MW2 Steam Turbine Generator 1 no 131 MW3 Gross site output (at 29.2°C)

(with NG firing366 MW

4 Combined Cycle Heat Rate(LHV) with natural gas firing @100% base load

Kcal/Kwh 1541

5 Gas Consumption @ 100% baseload ,site conditions in the GasTurbine

MMSCMD 1.67

6 Heat Recovery Steam Generator 2 No

Heat Recovery Steam Generator Operating Parameters:Srno

Steam Parameters Unit HP HRH+IP LP

1 Steam Generation Kg/sec 78.67 87 11.842 Steam Pressure Bar (a) 125 31 63 Steam Temperature Deg C 565 565 288

Gas Turbine Generator (GTG)

4 The gas turbine would consist of a multistage compressor and a turbine. Thedescription of equipment given below is typical for an advanced class gas turbines byone of the OEM. The description may vary from one OEM's model to another OEM'smodel.

Compressor Section

5. The compressor would be multiple stages (18) axial type, with modulating inlet guidevanes. Interstage air extraction is used for cooling and sealing air for turbine nozzles,wheel spaces and bearings and for surge control during start-up. The compressor rotorconsists of a forward stub shaft with the stage zero rotor blades, a blade and wheel



assembly for stages 1 to 16, and an aft stub shaft with the stage 17 rotor blades. Rotorblades are inserted into the broached slots located around the periphery of each wheeland wheel portion of the stub. The rotor assembly is held together byaxial bolts around the bolting circle. The compressor rotor is dynamically balanced afterassembly and again after the compressor and turbine rotors are mated, prior toassembly into the stator.

6 The airfoil shaped compressor rotor blades are designed to compress air efficiently athigh blade tip velocities. Inlet guide vanes, stationary blades and the rotor blades of thefirst few compressor stages are coated with a corrosion resistant material that protectthe blades against fouling. Alternatively, corrosion resistant materials are used for theblades. These forged blades are attached to their wheels by dovetail connections. Statorblades utilise square bases for mounting in the casing slots.

7 The casing comprises of three major subassemblies the inlet casing, the compressorcasing and the compressor discharge casing. These components, in conjunction with thecompressor stationary blading, form the compressor stator.

8 The primary function of the inlet casing, located at the forward end of the gas turbine, isto direct air uniformly from the inlet plenum into the compressor. The inlet casing alsosupports the number 1 thrust / radial bearing assembly and the variable inlet guidevanes located at the shaft end.

9. The compressor casing contains compressor stages zero to 12. Extraction ports in thecasing allow bleeds to the exhaust plenum during startup and extraction of air to cool theturbine section nozzle. The compressor discharge casing contains 13th through 17thstage compressor stators and one row of exit guide vanes. It also provides an innersupport for the first stage turbine nozzle and supports combustion components.

10. The compressor discharge casing is joined to the combustion wrapper at the flange onits outer most diameter.

11 The casing bore is maintained to close tolerances with respect to the rotor blade tips formaximum aerodynamic efficiencies. All casings are horizontally split for ease of handlingand maintenance.

Turbine Section

12. In the three stage turbine section, energy from hot pressurised gas produced by thecompressor and combustion section is converted to the mechanical energy. The turbinesection consists of the combustion wrapper, turbine rotor, turbine shell exhaust frame,exhaust diffuser, nozzles and diaphragms, stationary shrouds and bearing assembly. Thegas turbine unit would have combustors with NG firing capability. The gas turbines willbe designed to fire natural gas only. The combustion of air and fuel mixture takes place inthe combustors and the hot pressurized combustion gas produced by the compressor andthe combustors would be converted to mechanical energy, i.e., expanded in the gasturbine which would drive on one end the generator and on the other end the axial flowair compressor. The gas turbine would be having a rated speed of 3000 rpm.

13. The gas turbine generator would be provided with lubrication oil system complete withlube oil pumps, lube oil reservoir, and lube oil coolers. The gas turbine generator wouldhave its own starting system, which would use the generator as the starting motor bysupplying it with a variable frequency power supply.

14. The inlet air system would consist of a filter house with self-cleaning pulse jet airfilters, ducting and silencer. The system would draw atmospheric air into the gasturbine compressor unit. An evaporative cooler would also be provided to cool the inlet airentering into the compressor Air intake silencer would be provided to suppress the noise inthe intake air system.



15. The exhaust system would exhaust the gas into the atmosphere through the HRSG only.No simple cycle operation is envisaged and hence no bypass stack and associateddampers are being provided. The exhaust system would mainly comprises of ducting. Theheight the HRSG stack would be about 70m above the ground level.

16. A fire detection and carbon dioxide protection system would be provided to protect the gasturbine and its auxiliaries against fire hazard.

17. Provision for optical pyrometry for cross checking the turbine inlet temperature should beconsidered.

Heat Recovery Steam Generator (HRSG)

18 The HRSG proposed is of triple pressure, unfired, forced circulation vertical gas flowtype with a self supporting stack. A condensate preheater to recover the thermalenergy of the hot gas to the maximum extent will be provided apart from thesuperheater, evaporator and economiser sections. HRSG would be provided withinternal thermal insulation, platforms and ladders as required. Feed water and steamsampling arrangements as required would be provided. The vertical HRSG isconsidered inline with the existing unit.

Steam from the HRSGs would be supplied to a condensing type reheat steam turbinethrough main steam piping. High pressure (HP) and low pressure (LP) bypasssystems of 100% HRSG capacity for dumping the HP and LP steam to the condenserduring start up and turbine trip conditions would be provided.

Steam Turbine

19 For the purpose of this feasibility study, reheat, and condensing type steam turbine hasbeen considered. The steam entry to the turbine would be through a set ofemergency stop and control valves, which would govern the speed/ load of themachine. The steam turbine would be complete with lube oil and control oil system,jacking oil system, governing system, protection system and gland sealing steamsystem.

Condensing Equipment and Auxiliaries

20 The steam turbine would be provided with a axial type condenser fixed to the turbineexhaust for condensing the exhaust steam from the steam turbine. The water boxes of thecondenser will be designed for smooth entry and uniform distribution of cooling waterto all tubes. The circulating water connections of adequate size would be providedwith water boxes. 2 x 100 %, (one working and one standby) water ring vacuumpumps would be provided for evacuation of the steam air mixture from the condenser. 2x 100 %, (one working and one standby) condensate extraction pumps (CEP) of verticalcanister type would be provided to pump the condensate from the condenser hot wellinto the deaerator through the condensate preheater of the HRSG.Online tube cleaning for the condenser tubes shall be provided.

Feed Water System

1. A constant pressure deaerator for each block of 400 MW has been proposed for feedwater heating and deaeration of the feed water. The deaerator is provided to remove thedissolved corrosive gases from the feed water. It prevents internal corrosions of boilertubes.The deaerator would be equipped with a feed water storage tank having a minimumstorage capacity of about six (6) minutes under 100% maximum continuous operation ofthe HRSG of one 400 MW Block. The deaerator would be located at asuitable elevation to provide the required net positive suction head for the feed waterpumps.



For each 400 MW block deaerated feed water contained in the feed waterstoragetank would be supplied by 2 x 100% capacity HP - IP feed water pumps and2 x100% capacity LP feed water pumps. The IP feed water would be an inter stage tapoff from the HP feed water pumps. The feed water flow to the HRSG would beregulated through feed water control valves. The HP pumps would be centrifugalmultistage barrel type pumps. The LP pumps would be centrifugal multistage ringsection type pumps. There will be a common BFP Building having all the pumps.

Steam Cycle

2. Steam is generated at three pressure levels, namely high pressure (HP), Intermediatepressure (IP) and low pressure (LP) in the HRSG. While HP steam is admitted to the HPsteam turbine through the HP stop and governor control valves, the IP / reheat steamwould be admitted to IP turbine through the interceptor stop and control valve. The LPsteam would be injected to the IP turbine through the LP interceptor stop and controlvalve. The steam turbine would be a mixed pressure, reheat condensing type.

Cycle Chemical Dosing System3. Phosphate and hydrazine / morpholine dosing systems would be provided to ensure

chemical conditioning of the feed water so as to prevent scale formation and toremove the dissolved oxygen and carbon dioxide present. Phosphate solution would beadded into the HRSG drum directly, while hydrazine / morpholine would be injected into thefeed water at the feed water pumps suction. Dosing of hydrazine / morpholine at thedischarge of condensate extraction pumps will also be carried out. Each systemwould be complete with solution preparation-cum-feed tanks, agitators / mixers,metering pumps, piping, valves and fittings. Piping and equipments (other than steamturbine and HRSG proper) operating at 60°C or above would be thermally insulatedfor energy conservation and personnel protection. After application of thermalinsulation on piping and equipments Aluminium cladding sheet would be provided.

Fuel Gas System4. Natural Gas (NG) would be the main fuel. NG will be received at the plant boundary

from the supplier from its terminal through cross country buried pipeline at the requiredpressure and temperature. The gas supply system will be provided with separatemetering arrangement, filtration and moisture separation facilities.

The gas conditioning system shall be common for both the blocks and would includeseparation equipment for removal of liquid and particulate matter and control stations forpressure reduction for GTs. Gas conditioning system will also have indirect fired waterbath gas heaters for dew point considerations to heat up the in-coming natural gas tocompensate the temperature drop due to expansion at pressure reduction stationlocated downstream of the heaters and as well as to provide about 30°C super heat overhydrocarbon dew point during start-up of gas turbine. Gas will be further heated inwater/gas shell and tube heat exchangers (performance heater) which are provided foreach gas turbine separately, to improve combined cycle efficiency during normal operatingcondition for DLN combustion system. IP economizer outlet water will be used as theheating medium.The gas conditioning module will include one (1) solenoid assisted pneumaticallyoperated emergency shut down (ESD) valve (first safe) with manual inlet and outletisolation valves, one (1)X100% capacity vertical knock-out drum (KOD), two (2) X100% horizontal or vertical filter/separators, two (2) X 100% Dew point heaters,Pressure reducing cum control station with one (1) X 100% for each GTG plus one (1) X100% stream as common standby, one (1) above ground condensate drain tank commonfor KOD and filter/separators, associated piping, valves, instruments, etc. All equipment of



this module will be mounted on common skid and will be located near gas receivingstation terminal point.

Another module covers one (1) X 100% water / gas shell and tube type heatexchanger (performance heater), one (1) X 100% horizontal / vertical coalescing filterseparator for final removal of solid and liquid particles from the gas prior to the inlet of thegas turbine, one (1) above ground condensate drain tank common forperformance heater and coalescing filter and associated piping, valves, instruments, etc.All equipment of this module will be mounted on common skid and will be located near Gasturbine.The condensate drain collected in individual drain tank of each module will bedisposed through a drain pump fitted on each drain tank. A pipeline vent connection willbe provided near gas turbine inlet to vent out entrapped gases during cold start-up of theplant to a cold vent stack. The condensate collected in the tank shall be collected inthe barrels and shall be taken back by the gas seller or shall be sold out. Gas leakagedetection and alarm system will be provided.

A complete manual operated Nitrogen purging system will be provided to purge thepipeline and skid equipment, before charging with fuel gas and also purge theentrapped gas in pipeline and skid equipment while taking-up maintenance jobs /prolonged shutdown.

Compressed Air System

5. The compressed air system would be provided for meeting the plant instrument andservice air requirements of the plant auxiliary systems. For both the blocks, acommon compressed air system consists of 3 x 50% (2 working + 1 stand by) oil freescrew compressors and water cooled type, driven by electric motor, includingintercoolers, after coolers, step up gear box, silencer and other accessories Thecapacity of each compressor will be about 1200 Nm3/ hr with a discharge pressure ofabout 8 bar pressure. Two (2) nos. air drying plant shall also be provided to supplymoisture free air to instruments. Two (2) air receivers of suitable capacity (one forservice air and one for instrument air) with all accessories would also be provided.

Air Conditioning System

6. Inside design conditions of 24.5 ±1.5°C dry bulb temperature and relative humidity notexceeding 60% would be maintained in all air-conditioned areas.

Centralised air-conditioning system is proposed for air-conditioning of the plant newmain control room, electronic cubicle room, shift in-charge engineer's room,maintenance engineer's room, printer room, UPS room, excitation cubicle room and I andC lab.A packaged direct expansion (DX) air conditioning unit consisting of air handling units,galvanized steel sheets (GSS ducts), air distribution system, refrigerant piping, aircooled condensing unit including compressor and condenser fans and all associatedelectrical and instrumentation and controls is envisaged for air-conditioning of the DMplant control room, Chemical lab, SWAS room, Switchyard relay room, Gas stationcontrol room and Switchgear control room. A small area of the stores shall also be airconditioned using window air conditioners to store environmentally sensitiveequipment.

Ventilation System

7. Packaged ambient air handling unit with pre filters, louvers etc. is provided for theventilation of gas turbine and steam turbine generator building. Air is distributed bymeans of galvanized steel sheet ducting, grilles, dampers etc. Gravity type exhaustdampers shall be provided for switchgear room in Control Building. The hot air is



exhausted by means of roof extractor units. Mechanical ventilation is provided forvarious other areas like DM plant bldg., cable vault, AC plant room, CW pump house,BFP building, Air compressor room, Emergency DG set building, and Desalination plantby means of roof extractors / wall mounted exhaust fans as applicable. Battery room isaintained at negative pressure and the exhaust would be ducted. The fans shall bespark proof construction and epoxy painted. Propeller type exhaust fan is provided fortoilets, pantry, store etc. The supply air and exhaust air would be ducted in switchgearbuilding.

Cranes and Hoists

8. Cranes and hoists with all accessories, supporting structure, power supply, safetydevices and controls of required sizes and adequate capacities would be provided tofacilitate the lifting and transporting of various parts of equipment during maintenance orreplacement of the various plant components. Other miscellaneous monorails.Trolleys and hoists required would also be provided. A suitable capacity mobile cranewith adjustable boom length to handle any equipment during maintenance of the plantwould also be provided.

Each block of 400 MW shall be provided with a common EOT crane of about 100/25Tcapacity for maintenance purposes in the turbine hall.

The following miscellaneous cranes and hoists are provided in different areas of theplant

Miscellaneous electrically operated crane ata) CW pump houseb) Feed water pump housec) Air compressor room

Electric hoist at Monorail with electric hoist will be provided in the following area :

a) Chlorination buildingb) Emergency DG buildingc) Stoplog and coarse screen for CW forebay, Clarified and fire water pump housed) DM plant buildinge) Desalination Plant

Monorail with manual hoist will be provided in the areas requiring handling of weight of 500kg or more.



CHAPTER VIIIWATER SYSTEMS

PLANT WATER REQUIREMENT1. The total plant water requirement for the 5 blocks of 400 MW each is indicated below.

Sea Water: about 12000 m3/hr for CW system make-up. Sweet Water: about 350 m3/hr for potable purposes & for production of DM

water for cycle makeup2. Sweet Water is however proposed to be generated through desalination of the CW system

blow down. The proposed scheme of water systems for the 5 blocks of 400 MW is shownin Exhibit - 2. The water systems consists of various sub-systems listed below anddiscussed in the subsequent paragraphs of this chapter :(a) Pre-treatment system(b) Condenser cooling water (CW) system(c) CW Make up water system(d) Auxiliary cooling water (ACW) system (DM Water)(e) Water treatment (Demineralised water (DM) system)(f) Service & potable water system(g) Fire protection system(h) Effluent treatment Plant

Basic requirement of Sea Water for the project is 12000 m3/hr.

3. Supply of Clarified Water to Various Consuming PointsThe required condenser cooling water make-up will be flowing by gravity to the CW pumphouse forebay. Requirement of other consuming points will be pumped by the followingpumps:

(i) DM plant supply pumps(ii) Fire water pumps(iii) Service water pumps.

CONDENSER COOLING WATER (CW) SYSTEM4. Cooling Towers

Natural draught / Induced draught cooling towers are proposed for CW system. The coolingtowers will be designed for a cooling range of 10º C.

5. Cooling Water (CW) Pump house (CWPH)One CWPH for each of the 5 blocks of 400MW is envisaged. Each CWPH will have spaceto install three CW pumps, one maintenance bay and MCC room. For each block of 400MW three (3) CW pumps each of 50% capacity are proposed. These pumps will beinstalled in individual chambers connected to a common CW fore bay. Each pump chamberwill have provision for installing coarse screens and stoplogs. An EOT crane of suitablecapacity will be provided in the pump house for handling the pumps and motors duringmaintenance.

6. CW Blowdown and Make-Up Water Requirements



Make-up water requirement of CW system is obtained as the sum of drift and evaporationlosses from the cooling tower and blow-down from the CW system.A cycle of concentration (COC) of 1.3 has been adopted for CW system. The CW blow-down will be taken from the condenser inlet. The blow down water from the condenseroutlet will be returned to the sea. Part of the cooling tower blow will be used in thedesalination plant for plant potable water requirement.AUXILIARY COOLING WATER (ACW) SYSTEM

7. The ACW system meets the cooling water requirements of all the auxiliary equipment of theGTG,STG and HRSG units such as turbine lube oil coolers, generator air cooler, BFPauxiliaries such as lube oil coolers, working oil coolers, drive motors, etc., condensatepump bearings, sample coolers, emergency DG sets and air compressors.

8. For the ACW system, a closed loop system (CCW) using passivated DM water as a coolingmedium is proposed. The DM water is circulated through the auxiliary coolers by three (3)50% capacity) CCW pumps . The hot water from these auxiliaries is cooled in the plate typeheat exchangers by the circulating water tapped from the main CW circuit and pumped byACW pumps.

9. A CCW overhead tank of 10 cu.m capacity is proposed to ensure positive suction to theCCW pumps and also serve as the source of make-up to the CCW system.DESALINATION WATER PLANT

10. Desalination water plan will be based Reverse Osmosis technology and will be designed toproduce 350 m3/hr of sweet water required for the Project. Cooling water blow down will besupplied to the desalination plant for producing the sweet water.DM Plant

11. The DM plant will meet the requirements of steam generator (SG) feed water make up,ACW system make-up and plant / colony potable water. It will be designed for a total outputof about 150 m3 /hr of DM water based on SG feed water make up at 3% MCR for 5 blocksof 400 MW. It is proposed to provide three streams in the DM plant, each stream designedfor an output of about 50 m3 / hr with 18 hours productive run time.SERVICE AND POTABLE WATER SYSTEMS

12. Water required for plant washing and air conditioning and ventilation system make-up willbe taken from the service water overhead tank. Water for the service water overhead tankwill be pumped from clarified water storage tank.

13. Requirements of potable water for the power plant would be met from the potable waterpumps in the DM plant which will pump potable water from filter water storage tank to thepotable water over head tank located at a suitable location. Further distribution of potablewater to various consumer points would be by gravity.

FIRE PROTECTION SYSTEM14. This system will consist of the following sub-systems :

(a) Hydrant system covering all areas of the plant gas skid and liquid fuelunloading/storage area.

(b) High velocity water spray (HVWS) system for the protection of generatortransformers, turbine oil tanks, lube oil system equipment, unit auxiliarytransformers ,liquid fuel storage tanks etc.,

(c) Automatic deluge (medium velocity water spray) system for the protection of cablegalleries.

Effluent Disposal System

15. The sources of effluents from the proposed power plant are the following:



• Rejected water from desalination plant

• DM Water Plant

• Cooling Towers blow down

• Heat Recovery Steam Generator (HRSG) blow down

• Plant Area Drains and G T Compressor Wash water

• Plant Oily water drains

The various wastewaters generated in the power plant are handled as given below

a) Sludge from the pre-treatment plant consisting of raw clarifier sludge, DM Water clarifier,sludge pressure sand filter backwash and sludge from clarifier shall be taken to thecommon clarifier sludge treatment system consisting of a thickener and centrifuge.Sludge will be disposed off in the form of cakes. The solid sludge from the centrifuge willbe disposed outside and treated effluents are re-circulated into the system. Hence noliquid effluent is envisaged to flow into the guard pond.

b) DM plant neutralization pit waste shall be pumped to guard pond.

c) HRSG blow down and SWAS room waste will be collected in a common pit from whereit will be pumped to guard pond after quenching with CT blow down water.

d) Cooling Tower blow down from CW system will be sent directly to guard pond. This willbe tapped from the cold side of the cooling water system so as to restrict thetemperature of the same below CPCB limits when it is finally discharged to the sea afterpassing through the guard pond. However a part of this will for quenching of HRSGblow down in the main power block area. Waste back wash water from the side streamfilters will be collected in a sump pit and will be pumped to the guard pond

e) The wastewater from turbine building shall be led to the guard pond. Effluents from theGT Evaporative cooler blow down will be collected in the sump near GTG - STGbuilding. The settled solid sludge will be manually disposed for land filling.

f) Oily water from transformer area shall be collected in a pit. In normal circumstances nooil leakage is envisaged and this waste will be a rare occurrence. Water from thebottom shall be pumped to the oil separator before being transferred to the clarifier. Theoil, if present, is collected in drums.

It has been assumed that the waste streams will only occur during washing period ofapproximately 2 hours in the morning shift. These streams will be treated in an oil waterseparator and lead to a guard pond.

The effluents will be collected in an effluent guard pond sized to collect three to fourhours’ collection of power plant effluents. Dilution water if required will be added in theguard pond to dilute the effluents collected so that the combined quality includingtemperature meets the norms stipulated by pollution control board. The treated effluentsfrom guard pond will be discharged to the sea at a suitable location.

Chemical Laboratory

A separate chemical lab for common for all the five blocks will be provided.



CHAPTER – IXELECTRICAL SYSTEMS

Electrical Generator1. The gas turbine generators will be rated to deliver 233 MW ( at site rating), 0.85

PF lag, 15.75 kV, 3000 rpm, 50 Hz and the Steam turbine generators will be rated todeliver 133 MW (site rating), 0.85 PF lag, 15.75 kV, 3000 rpm, 50 Hz. The generatorswill deliver rated MVA output under +5% variation in voltage and +3% to -5% variationin frequency. The generator winding will be star connected with the phase and neutralterminals brought out. The star point of the generator will be connected to earththrough an earthing transformer, the secondary of which is connected to an earthingresistor.

2. The gas turbine generator will have indirect hydrogen cooled stator core andwindings. Rotors of the machines will be direct hydrogen cooled type. The steamturbine generator will be of Air-Cooled type. The coolers will be adequately sized sothat with one cooler section out of operation for maintenance, the generator cangenerate two-thirds of the rated capacity continuously without exceeding the permissibletemperature rise. Suitable seal oil system shall be provided to prevent the leakage ofhydrogen from the generator casing in case of hydrogen cooled machine.

3. The generator excitation system would be of static or brushless type and would havean automatic voltage regulator to maintain steady generator terminal voltage withinpermissible limits under different load conditions. The voltage regulatorwould also be capable of maintaining stability under transient conditions. Thegenerator windings would be provided with Class-F insulation and temperature rise willbe limited to Class-B. The table provided below indicates the major parameters of thegenerators.

Srno

Generator Parameters GTG STG

1 Voltage rating, kV 15.75 15.75

2 Rated Power factor 0.85 lag 0.85 lag

3 Rated frequency, Hz 50 50

4 Rated Speed, RPM 3000 3000

5 Minimum sub transient reactance onGenerator MVA base

14.5% 14.5%

6 Generator would deliver the ratedMVA output under voltage andfrequency variations as per

EC 60034-3 IEC 60034-3

Generator Bus Duct:

The terminals of the generators will be connected to the respective generatortransformers through Isolated Phase Bus Duct (IPBD) of adequate short circuitwithstand capability. For the gas turbine generators, suitably rated tap-off will beprovided to the unit auxiliary transformer with suitably rated generator circuit breaker



(GCB) provided before the tap-off. The steam turbine generators will be directlyconnected to the Generator transformer. For GTG and STG, suitably rated tap-offwill be provided to surge protection and voltage transformer cubicles. The bus ductswill be pressurized type and will run partly indoor and partly outdoor. The bus ductinstallation will be complete with generator line side and neutral side currenttransformers and line side voltage transformers required for protection and metering.The surge protection equipment consisting of LAs with suitable dischargecharacteristics to suit generator basic insulation level will be provided

Generator Circuit Breaker:

The generator circuit breaker will be inserted in the run of the Gas turbinegenerator main connection to the generator transformer to connect or disconnect thegenerator during the startup or shutdown period of the plant or on generator faultconditions.One generator circuit breaker will be provided for each Gas turbine generatorcomplete with all accessories, a local control panel and following equipment:

- Voltage transformers on both sides of the GCB- Capacitor on generator side before GCB- Earthing switch on both sides of the GCB- Line disconnector- Short circuit switch on generator side before GCB- Surge arrester on generator transformer side- Current transformers on both sides of the GCB.-The rated continuous current and rated voltage will be co-ordinated with the IPB rating.The main current carrying parts will be designed to withstand without damage for aperiod of one second, the effects of a short circuit due to a fault at either the generatortransformer LV side or the generator side.

The generator circuit breaker will consist of ten (10) single pole aluminium enclosedcircuit breakers complete with common base frame, operating mechanism, andlocal control panel for test and maintenance operation, assembled to form a threephase unit. Each pole consists of a circuit breaker, with insulation and are extinguishingmedium by compressed air or SF6.

Generator Transformer

Both Gas turbine generators & steam turbine generators will be connected to 400kVswitchyard through generator transformers. Technical particulars of Generatortransformers are indicated in the table below:

Sl.No

Particulars GTG Transformer STGTransformer

1 Type of cooling ONAN/ONAF/OFAF ONAN/ONAF/OFAF2 OFAF MVA rating 290 190

3 No load voltage ratio kV/kV 15.75/420 15.75/4204 Vector group Ynd1 Ynd15 Percentage impedance on 14 14 (as per existing

its own MVA base units will befinalisedduring detailedengineering)

6 Type of tap changer OLTC OLTC



7 Tap range -10 to +5% -10 to +5%8 Steps on HV side 1.25% 1.25%9 Impulse voltage withstand 1425 kV (peak) 1425 kV (peak)

(1.2/ 50 micro-sec)10 Terminal connection

HV side (for overhead line Bushings Bushingsconnection)LVside(forlPBD Flanges Flangesconnection)

Auxiliary Power supply systemThe proposed auxiliary power supply system is shown in enclosed single line diagram. Variousauxiliaries will be supplied at the following nominal voltages depending upon their ratings andfunctions:

AC Motors , 200 KW and above6.6 kV ±10 %, 50 Hz, ±5%, 3 phase, 3wire, medium resistance earthed

AC Motors, below 200 KW 415 V ±10 % , 50 Hz ±5%,3phase,3wire, solidly earthed

For AC control and protective devices 110V ±10 %, 50 Hz ±5%, 1 phase,AC supply with one lead earthed

For lighting and space heaters 240V ±10 %, 50 Hz ±5%, 1 phase,AC supply with neutral lead earthed

For DC motors, control and protective devices ofElectrical system (GRP, GCP and SRP/SCP)

220V, 2- wire unearthed DC supplyfrom battery / battery charger

For Instrumentation and control system forsteam generator and steam turbine generator

24V DC 2 wire,- ve terminal solidlyearthed. To be derived from UPS.

For services requiring uninterrupted power supply(UPS)

110V, single phase, 50 Hz, ACunearthed supply

Unit Auxiliary transformers (UAT)

Two nos. 100 % unit auxiliary transformer (UAT) will be provided for each block,connected to the respective Gas turbine generator. UATs will be connected to each gasturbine generators through IPBDs. UATs will feed gas turbine generator auxiliaries & steamturbine generator auxiliaries as well as station loads and will be sized to act as standby toeach other in the event of one of them fails. While starting/coasting the unit, the GCBs willbe kept open & the grid supply will be given to unit/station auxiliaries through generatortransformer and unit auxiliary transformer. Once the unit is started, the GCBs will beclosed & the UATs will continue to feed the auxiliaries. In the event of outage of one of theunit auxiliary transformers, the other unit auxiliary transformer of the other block can caterto complete loads of both the blocks. Each unit transformer will feed one section of the6.6kV switchgear.

Service Transformers



Oil filled type, outdoor LT auxiliary transformers of various ratings will be provided tomeet the 415 V load requirements of the power plant. The transformers will be located atdifferent load centres of the proposed power plant feeding the LV switchgear in that area.All LV switchgear will be divided into two sections with incoming feeders from 2x100%rated transformers to have maximum redundancy and reliability in the operations. Therequired number of transformers will be provided depending on service/location of theloads. These transformers will be rated at 2500 / 2000 kVA, 6.6 kV / 433 V with a vectorgroup of Dyn11. They will supply power to the 415 V auxiliaries of the unit and stationloads. The neutral of these transformers will be solidly earthed. The transformers will beprovided with ±5% off-circuit taps in steps of 2.5% on the MV side.

6.6 kV System:

6.6 kV system will be medium resistance earthed with earth fault current limited to about400A. The switchgear will be rated for symmetrical fault current of 40 kA for 1 second.The 6600 V switchgear will comprise draw-out type Vacuum / SF6 circuit breakershoused in indoor, metal-enclosed cubicles and will cater to all 6.6 kV motors and 6.6 kV /433V transformers. The switchgear will be equipped with control, protection, interlock andmetering features as required. All motor feeders will be provided with circuit breakers.

415 V System:

The 415 V, 3 phase, 3 wire power for the 415 V auxiliaries will be obtained from 6.6kV / 433 V service transformers provided in each area. The system will be solidlyearthed. For maximum reliability, duplicate power supplies with auto changeover facilitywill be provided for the essential power and motor control centers. The 415Vswitchgear will be of metal enclosed design with a symmetrical short circuit rating of50 kA for 1 sec. All power and motor control centers will be compartmentalized and willbe of single/double front execution. The circuit breakers will be of air break type.Generally motor starting will be direct on line. All LT motors will be controlled by airbreak, electro-magnetic type contactors provided with ambient temperature compensated,time lagged, hand reset type thermal overload relays, having adjustable setting with built-in single phase preventer backed up by HRC fuses for protection against short circuits.

LV Bus ductsLV bus duct shall be provided for connection between service transformers and theirrespective 415V switchgear. LV bus duct shall also be considered for connectionsbetween other switchgear / MCCs to suit the layout. It shall be of 1.1 kV class non-segregated phase type (NSPBD). The continuous rating of the bus duct shall be same asthe rated current of respective switchgear bus. The short time and momentary currentratings of the bus ducts shall be same as that of associated 415V switchgear. The busconductor shall be of Aluminium alloy grade 63401 as per IS: 5082. The enclosure shallbe rectangular and shall be made of mild steel sheets.

DC System2 X 100 % batteries with 2 x 100 % float cum boost chargers will be provided forSteam turbine generator for each 400 MW block. DC loads of station DC will be fed fromSTG batteries. For GTG load Batteries and Chargers will be supplied by GTG vendor.400kV switchyard DC loads will be fed from 2 x 100 % batteries with 2 x 100 % float cumboost chargers.

Emergency Power Supply

To enable safe unit shutdown during complete A.C supply failure in the station,certainimportant plant auxiliaries will be provided with a reliable A.C power supply througha separate source. For this purpose, one (1) 415V, 1250 kVA,quick starting dieselgenerator set with automatic mains failure (AMF) feature will be provided for each unit.



The diesel generator will feed to 415V emergency (DG) switchgear. Suitable tie feederswill be provided to 415 V station service switchgears. When the station A.C supply ishealthy, the emergency loads such as lube oil and seal oil pumps, turning gear motor,battery chargers, emergency lights, and essential instrument power supply feeders willbe fed from corresponding service switchgears. When the station A.C supply fails, theDG set will start Automatically and will feed the emergency loads. Necessary logicshould be built in the DCS to reaccelerate only the emergency loads. When the normalA.C supply is restored, these essential loads will be manually changed over to the normalpower supply.Black start facility for the plant has not been envisaged.

Un-Interruptible Power Supply System

110V single phase parallel redundant with static bypass un-interruptible power supplysystem having two (2) sets of rectifiers, inverters along with battery bank (For 1 hourback up) will be provided. The input power supply will be from the 415V serviceswitchgear. Also a standby regulated AC supply will be provided as a back up to theinverters which will be switched on through static switch in case of inverter failure.

Generator, Switchyard Protection and Control:

The selection of the protective scheme will be based mainly on reliability, sensitivityand technical merits. All main protections will be of fast acting type in order to isolate thefaulty system from the healthy system in the shortest possible time, to minimise damageto the equipment and ensure continuity of power supply, if possible. In view of theabove comprehensive Numerical relay will be used for all main protection.

400 kV Switchyard ControlAll breakers and isolators will be controlled from switchyard control panels (SCP) locatedin main control room. Relay panels pertaining to switchyard will be located in theswitchyard relay room, which will be kept locked.

All control operations like closing and opening of circuit breakers and isolators will beperformed from the respective control panels. Discrepancy type control switches willbe provided on the control panel. In addition to the control switches, the control panelsshall consists of the following:1. Mimic of bay layout2. Metering3. Facia annunciation4. Indicating and monitoring lamps

5. Synchronizing facilities, etc.

Cabling SystemPower cables would be selected based on the following criteria:

(a) Continuous circuit current rating(b) De-rating factors for ambient temperature and grouping(c) Short circuit rating of the circuit(d) Voltage dip & Voltage drop

Standardization of cable sizes to reduce inventory

The following types of cables will be used:



For 6.6 kV system

6.6kV unearthed grade, stranded aluminum conductor, cross linked polyethylene (XLPE)insulated, extruded black PVC inner sheathed, galvanized steel wire armoured for threecore or aluminium wire armoured for single core and overall FRLS extruded black PVCsheathed cables conforming to IS : 7098.

For medium and low voltage system

Power cables of 1100V grade, stranded aluminum conductor, cross linked polyethylene(XLPE) insulated, extruded black PVC inner sheathed galvanized steel wire armoured forthree cores or Aluminum wire armoured for single core and overall FRLS extruded blackPVC sheathed cables conforming to IS : 7098.

For control applications

1100 V grade annealed high conductivity stranded copper conductor, PVC insulated,PVC inner sheathed armoured and FRLS extruded black PVC outer sheathed cablesconforming to IS: 1554. Conductor cross section will generally be 1.5mm2. CT, PT andswitchyard control circuits will use 2.5 or 4 mm2 copper conductor cables.

For instrumentation applicationsStranded high conductivity annealed tinned copper conductor, multicore, PVC insulated,flexible, twisted pair / triplets, individually and overall shielded (for low level analogsignals) and only overall shielded for digital signals, PVC inner sheathed, steel wirearmoured and overall FRLS PVC sheathed cables. Conductor cross section will be 0.5mm2.

Individual / pair shielded and overall shielded twisted pair copper cables would be used foranalog signals and overall shielded twisted pair cables would be used for digital signals. Allthese cables are armoured. Overall sheath would be FRLS quality. The size of the wirewould be 0.5mm2 of PVC FRLS, 1.5 mm2 copper control cable would be used for cablingbetween MCC and Control system. Compensating cables will be provided for connectingthe thermocouple inputs to the control system

Cables would be laid in fabricated steel ladder type or perforated type cable trays in thestation and other auxiliary buildings and upper elevations of the steam generator area.Between buildings, the cables would be laid in built-up trenches .Cables to other plantareas located far off from the station building would be laid on overhead racks.

Lighting System

Suitable illumination necessary to facilitate normal operation and maintenanceactivities and to ensure safety of working personnel would be provided. This wouldbe achieved by artificial lighting.

For yard illumination, flood lights would be installed at suitable locations to providethe requisite level of illumination. High mast lighting would be provided for switchyards.Pole-mounted high-pressure sodium vapour fixtures would be used for approach roads.

Generally, fluorescent fixtures would be used for indoor illumination. Acombination of high-pressure sodium vapour and fluorescent fixtures would be used forthe turbine building. For steam generator area and pump houses, high-pressure sodiumvapour lamp fixture will be provided.

The illumination levels at different places would be maintained as per accepted norms.The lighting system would be designed to ensure uniform illumination.

Lighting distribution boards (LDBs) having in built, dry type, 415 V / 433 V lighting



transformers with off circuit tap changer of -5% to +5% insteps of 2.5% with MCCBincomer and outgoing MCBs will be provided at various locations. Lighting panels fittedwith suitably rated ELCB in incomer and single phase outgoing MCB feeders will belocated down stream of these LDBs.

About 80% of the total light fittings would be connected to the normal 240 V AC lightingsupply and the balance 20% to the station emergency bus fed from the DG set in thestation building and steam generator areas.

DC emergency lights are envisaged at strategic points in the power station viz.,nearentrances, staircases, control rooms, etc. These would be fed from 220 V DC system,which would be normally off when AC power is available. These would beautomatically switched on when the normal / emergency AC supply fails. Offsitebuildings will be provided with emergency lights with self-contained batteries (instalites)connected to the mains and will switch on automatically when the supply fails.

Safety Earthing and Lightning ProtectionA safety earthing system comprising buried steel conductor earthing grid would beprovided for the switchyard and other outlying areas. This would be connected to theearth grids in various buildings. The above ground earth grid shall be formed by GIconductor. The buried earth grids would be further connected to earthing electrodes.The selection of earth conductor sizes would be based on the applicable fault levels. Theearth grid shall be interconnected with existing earth grid.

Lightning protection system comprising roof conductors, vertical air termination anddown-comers would be provided for all structures whose calculated risk index requiresprotection as per applicable standards.

Communication System

For effective communication in the plant, public address system, privateautomatic branch exchange system (EPABX), radio paging system, walkie-talkie and P&Ttelephone system with the features described below will be provided:

Public Address System

This system will have paging and party channels comprising handset stations withamplifiers, transmitters, receivers, and loud speakers. This system will facilitate paging,communication and also private conversation as in conventional telephone.

EPABX System

This system will have adequate number of push button type handset stations, centralautomatic telephone exchange, etc. The handsets in the control room would be providedwith priority service facility to enable them to have immediate access to any handset evenif it is already engaged.

P&T Telephones

Necessary number of P&T telephone sets would be provided at strategic locations.

Radio Paging and walkie-talkie SystemsRadio paging and walkie-talkie systems will be provided for mobile communications.These systems will be of particular use during commissioning stage as well assubsequently for convenience during maintenance.

Interface between the EPABX, PA, walkie-talkie and radio paging systems will be providedto enable communication between these systems.



Closed Circuit Television (CCTV)CCTVs shall be provided at Control room, Switchyard relay room, GT/ST areas, Boilerdrums, etc.

Fire Detection / Alarm and Fire Proof Sealing Systems

A fire alarm system would be provided to facilitate visual and audible firedetection at the incipient stage of fire in the power station. This system willcomprise manual call points located at strategic locations in areas which arenormally manned and automatic fire detectors such as optical type smokedetectors / rate of rise of temperature detectors located in plant areas, such ascontrol room, switch gear room, cable vaults, battery rooms, etc., to detect fire at an earlystage.Multi sensor detectors wherever suitable will be used. Linear heat detectors will beprovided for the cable gallery. All fire detection systems will be of analogue addressabletype. Fire proof sealing will be provided for all cable penetrations through walls and floorsto prevent spreading of fire from one area / floor to another. All the cables will be givenfire break coating at regular intervals to minimize the fast spreading of the fire. Acentral fire alarm panel with zone indication facility will be provided and will be located inthe unit control room.

Elevators

One no 8 passenger, 1 m/sec elevator will be provided for control and witchgear building.This elevator will have access to different floors of the control and switchgearbuilding. The HRSG does not require an elevator or lift and hence not provided. Accessstairways will be provided.

Clock SystemA clock system with one Master clock and other slave clocks located at variousstrategic locations of the power plant will be provided. The master clock pulses will alsobe used for synchronizing of reference time based apparatus like Sequence ofEvents Recorder (SOE), Disturbance Recorders and Tariff metering equipment.Synchronizing or Master clock with INSAT reference time using suitable antenna andreceiver is envisaged.



CHAPTER-XINSTRUMENT AND CONTROL SYSTEMS

1 The proposed C and I system would be used for the operation of the power plantequipment from a centralised control room:

Gas Turbine Generator

2 A dedicated C and I system would perform the normal, start-up / shutdown andemergency operations of the GTG and its auxiliaries. It would be designed toperform turbine governing, speed, temperature and load regulation, protectioninterlocks, turbine supervisory functions, monitoring and annunciation ofmalfunctions.

Heat Recovery Steam Generators and Water / Steam Cycle

3 The C and I system would perform the normal start-up, shutdown and emergencyoperations of the HRSG and its associated auxiliaries, feed water and condensatesystems. All the open and closed loop control functions including the major controlslike HP / IP / LP, steam temperature controls, de-aerator level control, hot well levelcontrol and operation of the major pumps such as feed water pumps, condensatepumps would be performed. The interlock and protection system for the HRSGswould operate in coordination with the operational and protective requirements ofGTG, STG and their auxiliaries. The system would also perform the open andclosed loop control functions, monitoring and protection interlocks of condensercooling water system, auxiliary cooling water system and any other balance of plantequipment / system. Non-synchronizing breakers of the electrical system wouldalso be operated. The above controls would be part of the Balance of Plant (BOP)DCS.

Steam Turbine Generator

4 A dedicated C and I system would perform the normal start-up / shutdown andemergency operations of STG and its auxiliaries. It would be designed to performturbine governing, speed, load and frequency control, automatic start-upshutdown, protection interlocks, turbine supervisory functions, automatic turbine run-up system (ATRS) automatic turbine testing (ATT), monitoring andannunciation of malfunctions.

5 The operation and control of the following system would be performed from the PLCbased local panels with a serial link to DCS for monitoring.

- D M water plant and the clarifier system- Air compressors- Effluent Treatment Plant- Fuel gas system along with the metering station

Local Operation:

6 Emergency local stop push button operation will be provided for all motorizeddrives except for solenoid valves.

7 Unit Control Desk



The unit control desk would house the following items:(a) Control CRTs with keyboards to enable the operator to perform plant control and

monitoring functions.(b) Alarm CRT to display the process and system alarms to the operator in a

chronological sequence.The operator stations would be with twenty one inch (21") flat LCD based colourmonitors, which would be fully assignable and functionally interchangeable. Thestations would be supported by the following peripherals (located in the controlroom):(a) Character printer for time activated and on demand logs.(b) Character printers for alarms.(c) Character printer for operator's action.(d) Colour laser printer for copying displays from CRTs and for reports.The operator would perform the following operations from the unit control deskCRTs (console type) through the keyboards:

(a) Operation of pumps associated with the GTG, HRSG, and water-steam cycle,balance of plant, STG and auxiliaries.

(b) Operation of all control valves of the GTG, HRSG, STG and auxiliaries, watersteam cycle and balance of plant.

(c) Plant overview, group display, individual loop display, etc. and carryout associated control operations.

A separate CRT with a keyboard and a colour laser printer would be provided for theShift Charge Engineer. However, the plant operations from this CRT would beinhibited. To enable configuring and programming, the InstrumentMaintenance Engineer would be provided with a separate CRT with a keyboard and acolour laser printer. However, the plant operations from this CRT would be inhibited.

8. Control Room

A Central Control room comprising of Electronic cubicle rooms and OperatingRoom would be provided for the operation and monitoring of the power plant. All plantcontrols will be networked with fibre optic cables This Central control room would belocated in the Electrical and control building. It would house the followingequipment in an air-conditioned environment:(a) One section of unit control desk will house the emergency push buttons for the

STG, GTG and major auxiliaries and Electronic water level indicator of boilerdrums. Another section of the unit control desk will house the operator stations(CRTs) of the GTGs, STG, BOP DCS, Electrical systems and alarm CRTs. Theprinters will be located in a suitable location of the operating room.

(b) C and I system cabinets, electrical auxiliary cabinets, GTG and STGcontrol system cabinets in the electronic cubicle room.

(c) Shift Charge Engineer's CRT with keyboard and printer in the Shift-ChargeEngineer's room.

(d) Maintenance Engineer's CRT with keyboard and printer in the MaintenanceEngineer's room.

(e) Uninterruptible power supplies system (UPS) in the UPS room.(f) Backup panel for operation and monitoring of electrical system separately for

GTG and STG



9. Sequence of Events Recording System

The SER will be integral to DCS with adequate capacity of points for recording thecause of plant trip with a resolution of one millisecond. The system would beprovided with a dedicated printer located in the control room.

10. Analytical Instruments

Adequate number of analytical instruments would be provided for continuousmonitoring of quality of demineralised water, condensate, feed water andsteam. Also gas analyzers for measurement of SO2, NOx, O2, CO and opacity in theflue gas as required to meet the Pollution Control Board's requirements would beprovided. The opacity shall be measured by in-site analysers and the otherparameters shall be measured using a continuos emission monitoring system. Thewater and steam analysers would be located in an air-conditioned room.

11. Vibration Monitoring System

A vibration monitoring system complete with transducers and remotemonitors is envisaged for monitoring the bearing vibrations of GTG, STG, MVdrives like high pressure boiler feed pumps, condensate extraction pumps andcondenser cooling water pumps. The bearing vibrations would be measured andmonitored in both X and Y directions for each bearing.

12. Final Control Element Actuators

All final control elements of regulating type (control valves) will have actuators ofpneumatic type as well as motorised type. All actuators would be sized so that thefinal control elements would operate properly even when the upstream pressureis 110% of maximum value. Pneumatic actuators would be provided with air failurelock and remote release, limit switches, adjustable minimum and maximum stops,local position indicators, positioners, electronic position transmitters andsolenoid valves in accordance with the system requirement.

13. Local InstrumentsThe proposed local instruments are as follows:

(a) Adequate number of local instruments would be provided to enable localoperators to supervise and monitor equipment/process.

(b) All transmitters for measurement and control would be of electronic type two- wiresystem with 4-20 mA DC output.

(c) All the thermocouples and RTDs would be duplex type and the signaltransmission of thermocouple would be through compensating cables. Thetemperature elements would be wired to the corresponding cards in the DCS andhence temperature transmitters are not envisaged.

14. Air Supply for Pneumatic Equipment

Non-lubricated dry instrument air at a pressure of 5-7 kg/sq.cm (g) would bedrawn from the instrument air header for various instrument auxiliaries. Allpneumatic equipment, which requires air supply, would be provided with an air-filterregulator.

15. Power Supply

An uninterrupted power supply (UPS) would be provided to cater to the 230 V AC,single phase, 50 Hz, 2 wire power supply requirements of the C and I systems.

16. Cables

The proposed C and I cables are as follows:



(a) Overall shielded twisted pair copper cables would be used for digital signals.For analogsignals individual and overall shielded cables will be used and for RTD's TRAID cableswill be used. All these cables would be armored. These cables will be providedwith PVC insulation, PVC inner sheath, GI wire armouring & over all FRLS PVCsheath. The size of the wire would be 0.5 sq.mm.

(b) The interconnecting bus of the distributed system would be as permanufacturer's standard.

(c) The communication bus of the distributed system would be as permanufacturer's standard.

(d) Any other special cables will be included in the respective vendor's scope.

17. Tubes and Fittings:

Proposed C and I pipes and tubes and fittings are as follows:(a) All pipes mounted instruments, pipes and fittings of appropriate material would be

used. For all high pressure and temperature services (above 62 bar or 425°C), twoisolating valves of NB 25 size would be used. For level and flow instruments, NB 25size isolating valves would be used. For other services and measurements, NB15size valves would be used.

(b) For remotely located instruments like transmitters, tubes and fittings ofappropriate material and rating would be used. Open type transmitter racks wouldbe provided to group and mount all pressure, flow and level transmitters.Junction boxes would be provided for termination of all field switches like pressure,temperature and for the transmitters.

18. Master clock system

A stand-alone master clock system with suitable time format is envisaged forsynchronizing with the control system of GTG, STG, balance of plant DCS and PLCsystem of utility plants.

19. EarthingSeparate electronic earthing system with dedicated earthing pits for each controlsystem would be envisaged.

20. SparesAdequate essential and recommended spares are proposed for the complete C and Iequipment.



Chapter – XI

ENVIRONMENTAL ASPECTS AND WASTE

MANAGEMENTThe environmental impact of the proposed 2000 MW combined cycle power plant, covering thefollowing aspects is presented in this chapter:

(a) Site features(b) Air pollution(c) Water pollution(d) Thermal pollution(e) Noise abatement(f) Pollution monitoring and surveillance systems

Air Pollution

The expected air pollutants from a combined cycle power plant are:

(a) Sulphur dioxide in flue gas

(b) Nitrogen oxides in flue gas

Natural gas (NG), which is the main fuel proposed in the gas turbines, is a clean fuelwithout any constituent to generate the particulate matter in flue gas. Hence, therewould be no particulate matter in the flue gas of the combined cycle power plant.

S.No Pollutant TimeWeightedAverage

Concentration in Ambient Air(2009) New

Industrial,residential,Rural and OtherArea

Ecologically SensitiveArea(notified byCentral Government)

1 Sulphur Dioxide (SO2)µg/m3

Annual* 50 2024 Hours** 80 80

2 Nitrogen Dioxide (NO2),µg/m3

Annual* 40 3024 Hours** 80 80

3 Particulate Matter (Size lessthan 10 µm) or PM10 µg/m3

Annual* 60 6024 Hours** 100 100

4 Particulate Matter (Size lessthan 2.5 µm) or PM2.5 µg/m3

Annual* 40 4024 Hours** 60 60

5 Ozone (O3)µg/m3

8 Hours** 100 1001 Hour** 180 180

6 Lead (Pb)µg/m3

Annual* 0.50 0.524 Hours** 1.0 1.0

7 Carbon Monoxide (Co)mg/m3

8 Hours** 02 021 Hour** 04 04

8 Ammonia (NH3) Annual* 100 µg/m3 100 µg/m3

24 Hours** 400 µg/m3 400 µg/m3

9 Benzene (C6H6)µg/m3

Annual* 05 05



10 Benzo(a)Pyrene(BaP)-particulate phase only, ng/m3

Annual* 01 01

11 Arsenic (As)ng/m3

Annual* 06 06

12 Nickel (Ni)ng/m3

Annual* 20 20

In case of NG firing there would not be any emission of sulphur dioxide, as NG is free of anysulphur content. The only pollutant in the flue gas would be oxides of nitrogen (NOx). Typicalvalues of NOx in the flue gas would be less than 50 ppm (15% oxygen volume dry basis) andthis would be achieved by the use of low NOx dry type hybrid burners in the gas turbines. Thevalues of NOx would be about 25 ppm, but for guarantee purposes a value less than 50 ppmwould be considered as stipulated by CPCB. However since Naptha/HSD is planned as a standby fuel, during liquid fuel firing the expected NOx value after water injection will be around 50ppm.

The height of each HRSG stack will be 70m and would meet the Ambient Air Quality (AAQ)limits as stipulated in the Table above.On line monitors would be used to constantly monitor oxides of nitrogen, sulphur dioxide (if any)in the flue gas and in case of excess amount of any pollutant, suitable corrective action wouldbe taken. In view of the above mentioned provisions, the installation of the combined cyclepower plant would not have any significant impact on the ambient air quality.

Water Pollution

The sources of effluents from the proposed power plant are the following:oWater treatment planto Blow down of cooling towero Reject from Desalination Planto Heat recovery steam generator (HRSG) blow downo Plant area drainso Plant oily water drainsoG T compressor Wash water

Water Treatment Plant Waste

This will include DM plant regeneration waste and filter backwash waste water. The wastefrom the DM plant is generated from the regeneration of the ion exchange units andalso from the backwash of filters. The waste from the regeneration of ion exchange units



will mainly consist of trapped cations and anions present in the raw water. The waste fromthe filter backwash will mainly consist of suspended solids and turbidity. The above waste willbe led to the DM plant neutralizing pit where it will be neutralized by acid/ alkali additionand pumped through neutralizing pumps to guard pond. The quantity of waste from watertreatment plant (D M plant regeneration waste and filter backwash) will be about 530 m3/day.

Cooling Tower Blow DownIn order to maintain the CW system cycle chemistry within desired limits certain quantity ofwater is blown down from the CW system. This is termed as cooling tower blow down, whichwill have the quality of CW system make up water with the cycle of concentration taken intoconsideration. The quantity of CW blow down will be about 9000 m3/hour. Out of this around1400 M3/hour will be consumed by desalination plant and the remaining will be lead to guardpond. The cycles of concentration is considered as 1.3.

HRSG Blow Down

Blow down is done from the boiler drums to maintain the concentration of salts withinallowable limits. This blow down is also led to the guard pond. The quantity of boiler blow downwill be about 9000 m3/hr.

Plant Area Drains

The oil sewer will collect drain water from main plant area and such other areas from wherethere are possibilities of contamination by oil and fed to an oil / water separator. From the oil /water separator the clear wastewater will be discharged to the guard pond, while the oilywaste sludge will be collected separately and disposed off in drums. The quantity of plantdrains will be about 30 m3/day.

Thermal PollutionThe combined cycle power plant envisages installation of unfired heat recovery steamgenerators to utilize the heat content of the exhaust gas from the gas turbines. Thetemperature of the flue gas at the HRSG stack exit would be about 98 °C.

Installation of HRSG to recover heat from the gas turbine exhaust gas would enablereduction of the temperature of the exhaust gas to the lowest possible value therebyreducing the thermal heat discharge into the atmosphere.

Noise AbatementAll the equipment in the power plant would be designed to have a total noise level notexceeding 85-90dB(A). Generally the manufacturers of the gas turbine generatorsindicate the following noise level values:

(a) 85 dB (A) at a distance of 1.5 m from the gas turbines(b) 65 dB (A) at a distance of 120 m from the gas turbines

The gas turbine generators would be housed within an acoustic enclosure which in turn willbe located in closed buildings. This would considerably reduce the transmission of noise fromthe gas turbine generators to the outside environment. The inlet air and exhaust gas streamswould be provided with silencers for noise reduction. Generally there would not be anyoperators near the gas turbine generator on a continuous basis. However, maintenancepersonnel working within the gas turbine generator building would be provided with adequateprotection against noise. The steam turbine generator would also be housed in a closedbuilding thereby reducing the transmission of noise to the outside environment.



An integrated approach shall be taken to control noise emission

(a) Design and layout of building to minimize transmission of noise, segregation of particularitems of plant and to avoid reverberant areas.

(b) Specification of permissible noise levels for bought-out items.

(c) Choice of materials for civil construction

(d) Acoustic design of building

(e) Use of lagging with attenuation properties on plant components / installation of soundattenuation panels around the equipment.

If the requirements stated above are not met within the basic design of the plant they shall beachieved by suitable means of noise control, which shall conform to the following requirements:

(a) The noise control system shall, as far as possible, be designed to form an integral part of theplant.

(b) The abatement system shall, wherever practicable, be applied to the source of excessivenoise rather than to the entire item or component.

(c ) If above means are not adequate and enclosures are used for noise abatement, close fittingenclosures shall be provided.

Noise in Control Areas:

(a) Control Rooms

The noise levels in control rooms will be such that intelligible speech communication isalways possible and mental concentration is not hindered.

(b) Other Control AreasThe noise levels in other control areas shall be such that intelligible conversation(telephone and person-to-person) is possible and operator fatigue is minimized.

(c) Station Noise CriterionThe criterion for environmental noise is that the design of the station and its componentsshall not exceed, in any continuous mode of operation, the level stipulated by MOEF and/or Pollution Control Board at the nearest plant boundary.

Gaseous Fuel Vents and Liquid CondensateAll the gas lines and gas scrubber vent connections would be terminated at a safe height ofabout 2m above the roof level. The vent lines would be terminated with flame arrestors. Thecondensate if found, will be removed from the fuel gas in the scrubber would be collected in acollection tank and disposed suitably.

Pollution Monitoring and Surveillance System

A well-defined environmental monitoring programme would be instituted with trained andqualified staff that would monitor the ambient air as well as stack gas quality to ensure that thequality of effluents is maintained within the permissible levels. The stack of the heat recoverysteam generator would be provided with suitable ports to monitor the flue gas quality from thestacks. Suitable analysers will be provided for exhaust gas quality analysis. The quality ofthe blow down water from the heat recovery steam generator drums and the otherwatereffluents from the plant would be analysed on a daily basis or as required toensure that effluents are maintained within the permissible levels.



Some of the facilities that would be used for sampling and analysis are:

(a) High volume samplers(b) Gas monitoring kit(c) PH meter(d) Spectro-photometer.(e) Wind vane and anemometer.

Impact of Pollution / Environmental DisturbancesThe proposed combined cycle power plant would require less land area compared tosimilar capacity fossil fuel fired power plants and would use a clean gaseous fuel. NOx andSO2- emissions would be minimum and there would be no particulate matter emission. Thewater effluents would be treated before disposal to satisfy the standards stipulated under theWater (Prevention and Control of Pollution) Rules as well as the State Pollution ControlBoards. Hence, it is considered that there would be no adverse impact on either the air or thewater quality in and around the proposed power plant site.The Project attracts Consent for Establishment and Consent for Operation from MaharashtraPollution Control Board and Environment Clearance from the Ministry of Environment andForests (MOEF) considering natural gas as the main fuel and Liquid Fuel such as Naphtha/HighSpeed Diesel would be used as standby fuel.

CLEAN DEVELOPMENT MECHANISM- PERSPECTIVE

Applicability of the Project under Clean Development Mechanism

The Clean Development Mechanism (CDM) was instituted in 2001, under the Kyoto Protocolto enable developed countries to meet their Green House Gas (GHG) reduction targets atlower cost through project in developing countries.

It is designed as an element of the sustainable development strategy allowing industrializedcountries investing in "clean" projects in developing countries also to gain emission credits.These credits are given in the form of certified emission reductions (CERs) which areexpressed in tons of carbon dioxide equivalent. The financing country can use these units tooffset its own emissions of greenhouse gases during a given period, or sell them to anothercountry. It can also bank them for use during a subsequent period.National CDM Authority in IndiaThe Government of India has constituted the National Clean Development Mechanism (CDM)Authority for the purpose of protecting and improving the quality of environment in terms of theKyoto Protocol.

The National CDM Authority receives projects for evaluation and approval as per the guidelinesand general criteria laid down in the relevant rules and modalities pertaining to CDM. Theevaluation process of CDM projects includes an assessment of the probability of eventualsuccessful implementation of CDM projects and evaluation of extent to which projects meet thesustainable development objectives, as it would seek to prioritize projects in accordance withnational priorities.

The National CDM Authority may recommend certain additional requirements to ensure that theproject proposal meets the national sustainable development priorities and comply with the legalframework so as to ensure that the project is compatible with the local priorities and stakeholdershave been duly consulted.



The Authority ensures that in the event of project proposals competing for same source ofinvestment, projects with higher sustainable development benefits and which are likely to succeedare accorded higher priority.

The Authority also carries out the financial review of project proposals to ensure that the projectproposals do not involve diversion of official development assistance in accordance with modalitiesand procedures for Clean Development Mechanism and also ensure that the market environmentof the CDM project is not conducive to under-valuation of Certified Emission Reduction (CERs)particularly for externally aided projects.

The Authority carries out activities to ensure that the project developers have reliable informationrelating to all aspects of Clean Development Mechanism which include creating database onorganizations designated for carrying out activities like validation of CDM project proposals andmonitoring and verification of project activities, and to collect, compile and publish technical andstatistical data relating to CDM initiatives in India.Host Country ApprovalEligibility CriteriaThe project proposal should establish the following in order to qualify for consideration asC D M project activity:

Additionalities:Emission Additionality: The project should lead to real, measurable and long term GHG mitigation.

The additional GHG reductions are to be calculated with reference to a baseline.

Financial Additionality: The procurement of Certified Emission Reduction (CERs) should not be

from Official Development Assistance (ODA).

Sustainable Development IndicatorsIt is the prerogative of the host Party to confirm whether a clean development mechanism project

activity assists it in achieving sustainable development. The C D M projects should also be

oriented towards improving the quality of life of the poor from the environmental standpoint.

Following aspects should be considered while designing CDM project activity:

Social well-being: The CDM project activity should lead to alleviation of poverty by generating

additional employment, removal of social disparities and contribution to provision of basic

amenities to people leading to improvement in quality of life of people.

Economic well-being: The CDM project activity should bring in additional investment consistent

with the needs of the people.

Environmental well-being: This should include a discussion of impact of the project activity onresource sustainability and resource degradation, if any, due to proposed activity; bio-diversityfriendliness; impact on human health; reduction of levels of pollution in general;



Technological well being: The CDM project activity should lead to transfer of environmentallysafe and sound technologies that are comparable to best practices in order to assist in upgradation of the technological base. The transfer of technology can be within the country as wellfrom other developing countries also.

BaselinesThe project proposal must clearly and transparently describe methodology of determination of

baseline. It should confirm to following:

• Baselines should be precise, transparent, comparable and workable• Should avoid overestimation•The methodology for determination of baseline should be homogeneous and reliable• Potential errors should be indicated• System boundaries of baselines should be established• Interval between updates of baselines should be clearly described• Role of externalities should be brought out (social, economic and environmental)• Should include historic emission data-sets wherever available• Lifetime of project cycle should be clearly mentioned

The project proponent could develop a new methodology for its project activity or could use one of

the approved methodologies by the C D M Executive Board. The project proposal should

indicate the formulae used for calculating GHG offsets in the project and baseline scenario.

The following natural gas based power projects have already obtained the host country approval:

(i) Sintex 7.5 MW natural gas based cogeneration project, Gujarat

(ii) 155 MW gas based combined cycle power plant by ESSAR

(iii) Natural gas based 445 MW combined cycle power plant by Konasema gas power Ltd.

(iv) 721 MW combined cycle power plant by ONGC Tripura Power Corporation Ltd.

In order to avail CDM benefit, Project Concept Note (PCN) and Project Design Document (PDD)

as per the standard format need to be prepared separately.



CHAPTER XII

PROJECT COST ESTIMATES AND COST OF GENERATION

BASIS OF COST ESTIMATES

1. The Project would be executed either by EPC contract route or by few LSTK packageroutes by negotiation with prospective bidders. Cost estimate break up includes the cost ofGas Turbine generators and auxiliaries, Steam Turbine generators and auxiliaries, HeatRecovery Steam Generators and auxiliaries, water systems, control and instrumentationsystem, electrical system and Balance of Plant required for the power plant within thebattery limits of the power plant. The cost of land, pre commissioning costs, overheads andpre-operative expenses, interest during construction and financing costs are added toarrive at the total project cost.

COST OF LAND

2. The cost of the land for the plant to be acquired from private owners and Govt. agencieshas been estimated based on a rate of Rs.5 lakhs per acre.The project cost is based on the following assumptions:1. Non-plant buildings such as gatehouse, warehouse, and site offices and other

infrastructures required during the construction period2. Cost of site grading for areas like SG /TG area, switchyard, cooling tower area,

liquid fuel storage area and other non-service areas3. Boundary wall and anti climbing fencing for the area proposed to be acquired for the

power plant:(g) Cost of transmission system has been included in the Project cost.(h) Cost of spares for mechanical and electrical equipment is considered in project

cost.(i) Taxes and duties have been considered as per prevailing rates.(j) Price escalation has not been considered during the execution period of the Project.

INTEREST DURING CONSTRUCTION PERIOD

3. The interest on loan during construction (IDC) has been calculated based on a debt-equityratio of 70:30.Since IDC can be capitalized, the overall project outlay includes this amount.

PROJECT COST4. The total project cost excluding IDC and Financing Charges (FC) is indicated in

Appendices – 3, for execution of 5 Blocks of 400 MW. The estimated capital cost of theproposed 5 x 400 MW project is Rs.6535.38 Crore excluding interest during construction(IDC) and financial charges. The cost per MW of installed capacity works out to Rs. 3.85Crore / MW.

TARIFF



5. Power Purchase Agreement(s) with the MSEB / its DISCOMs and/or others like PTC areexpected to be executed on long term basis (say 25 or 30 years from the date ofcommercial operation of the power plant).

6. The cost of generation for 2000W at 85% PLF out to Rs. 3.28 per kWh for first full year ofoperation with all CCPP blocks in service, considering the return on equity @ 16% and thelanded fuel cost of Rs 10.63 / m3 ($ 6 PER MMBTU).

FIXED CHARGES

7. The items of cost forming a part of the fixed charge component are :(a) Interest on loan becoming due during the year(b) Return on equity(c) Interest on balance of working capital(d) Depreciation(e) Operation and maintenance charges(f) Income Tax.

VARIABLE CHARGES

8. The variable charge component of the tariff includes the cost of primary fuel which isnatural gas. Based on Central Electricity Regulatory Commission (CERC) norms, thefollowing are considered while computing the annual running cost for periods beyond theinitial stabilization period:(a) Annual cost of Fuel Gas



APPENDICES



APPENDIX – 1

METEOROLOGICAL DATA

1.0 Location of plant site : Komaragiri village near Kakinada town,

East Godavari district, Andhra Pradesh.

2.0 Co-ordinates of site. :(17° 3'5.68"N 82°18'30.38"E), (Tentative)

3.0 Climatic Conditions

3.01 Temperature (Mean Monthly Parameters)

Mean of daily maximum

temperature

: 32.4 ° C (in the month of June)

Mean of daily minimum

temperature

: 23.9° C (in the month of January)

3.02 Relative Humidity : Relative humidity maximum and around89% and minimum during winter around66%.

3.02 Rain fall : Annual rainfall is around 1113 mm.

3.03 Wind Speed Mean : Wind from SW and S. The mean wind speedis usually about 9.6 kmph.

4.0 Seismic Conditions : The proposed site is located in seismiczone-III as per the Seismic Zone mappingdone by Indian Meteorological Department

5.0 Elevation above mean sea : About 20 m above the mean sea level



APPENDIX – 2

ANALYSIS OF NATURAL GAS

Following is the typical analysis of Natural Gas produced in the KG basin.

Component Unit CompositionValue

Methane % Mole 99.475Ethane % Mole 0.1180Propane % Mole 0.0226i-Butane % Mole 24.4 PPMn-Butane % Mole 46.2 PPMi-Pentane % Mole 12.1n-Pentane % Mole 13.5n-Hexane % Mole 74.3 PPMn-Heptane % Mole --n-Octane % Mole ---n-Nonane % Mole ---n-Decane+ % Mole --Hydrogen % Mole --Oxygen % Mole --

Carbon Dioxide% Mole

0.2040Nitrogen % Mole 0.1679Calorific Value,Superior, Dry

Kcal/m39027

Calorific Value,Inferior, Dry

Kcal/m38128



Appendix- 3

INPUT DETAILSSR.NO. PARTICULARS UNIT VALUE

1 Installed Capacity kw 20000002 Station Operating Heat Rate (LHV) kcal/kwh 18003 Auxiliary Power Consumption % 3.04 Fuel Cost in 2012-13 Rs per M3 10.630186725 Fuel Cost Variation Factor 1.056 Lower Calorific Value of Gas Kcal/m3 9435

7Project Cost (excluding IDC but including Financingcharges @ 0.25% of Loan) Rs. in Crores 6546.40

8 Total Project Cost with IDC Rs. in Crores 7676.939 Debt : Equity Ratio % 75/25

10 Debt Amount Rs. in Crores 5757.6911 Rupee Term Loan (RTL) Rs. in Crores 5757.6912 RTL Payment Period years 1213 Equity Rs. in Crores 1919.2314 Domestic Long Term Interest Rate % 11.515 Interest Rate on WC Borrowings % 10.5

16Annual O&M Cost including Insurance for the year 2011-12 Lakhs/MW/Year 16.54

17 O&M Cost Escalation Factor 1.0518 Depreciation Rate % 619 Cost per MW Rs. In Crores. 3.838



Sl Item Cost in Rs

no Crores1 Land 28.502 Site Development 5.703 GTG AND STG Package (Imported) 1817.004 HRSG & Balance of plant (indigenous) 2934.80

5 Civil works 250.00

6Freight, Insurance, Duties and Taxes (item 6(i) + 6 (ii) +6(iii) + 6 (iv)) 717.06i) Imported @ customs duty 18.62% ) 338.33ii)Indigenous Cost x 8.24% Excise duty[(item 4 x 8.24%] 241.83iii)2% CST [(item 4 + 6 (ii)) x 2%] 63.53iv)2.5% Freight & Insurance [(item 4 x 2.5%] 73.37

7 TOTAL including taxes and duty 5468.86Imported Total 2155.33Indigenous Total 3313.53

8 Erection testing and commissioning ( i + ii ) 250.00i) Imported 168.00ii)Indigenous 82.00

9 Initial / Spares (i+ ii) 218.75i) Imported @ 4% of item 7 (imported) 86.21ii)Indigenous @ 4% of item 7 (indigenous) 132.54

10Total Cost including erection & spares (sum of items1,2,5,7,8 and 9) 6221.81

11 TOTAL EPC COST 6221.81

12 Colony Development cost 0.00

13 Sea Water supply system (incl in item 4 & 5) 0.00

14 Fuel Oil System - Not Applicable 0.00

15Non EPC Bldgs + Misc works & Non EPC Site development+ Electricals 0.00

16 Project insurances @0.8% of items 11, 12 &15 49.77



17 TOTAL NON EPC COST (sum of items 12,13,14,15,16) 49.77

18 Initial Project development cost 4.50

19 Design & Engg and establishment @ 2.5% of item 11 155.55

20 TOTAL COST ( sum of items 11,17,18 and 19) 6431.63

21Establishment / Construction Supervision (covered insl.no.18 & 19) 0.00

22 Start-up fuel and power 100.00

23 Operator's training 3.75

24 Development expense (covered in sl no.18) 0.00

25 Legal expense (covered in sl no.18) 0.00

26 Contingencies on works 0.00

27Project cost excluding IDC, escalation and financingcost 6535.38



Tariff Calculation

1.0 GENERATION 1st Year 2nd Year1.1 Plant Installed Capacity kw 2000000 20000001.2 Annual Plant Load Factor (PLF) 0.85 0.851.3 Annual Gross Generation Mkwh 14892.0 14892.01.4 Auxiliary Power Consumption Mkwh 446.8 446.81.5 Units Sent Out Mkwh 14445.2 14445.2

2.0 FUEL CONSUMPTION2.1 Plant Operating Heat Rate Kcal/kwh 1800 18002.2 Annual Gas Consumption M M3/yr 2841.0811 2841.08112.3 Gas Cost in First full year Rs./M3 10.62.4 Assumed gas Cost Rs./M3 10.6 11.22.5 Annual gas Cost Rs. in cr. 3020.12 3171.132.6 Annual Fuel Cost Rs. in cr. 3020.12 3171.13

3.0 FIXED COST3.1 Interest on Loan / Debt Rs. in cr. 662.13 606.963.2 Interest on Working Capital Rs. in cr. 96.30 98.453.3 O&M Expenses Rs. in cr. 330.80 347.343.4 Return on Equity Rs. in cr. 307.08 307.083.5 Depreciation Rs. in cr. 460.62 460.62

3.6Less CDMrevenue(@8USD/CER) Rs in cr 135 135

3.7 Total Fixed Cost Rs. in cr. 1722 16853.8 Fixed cost/unit Sent Out Rs./kwh 1.19 1.17

4.0 VARIABLE CHARGES4.1 Annual Fuel Cost Rs. in cr. 3020.12 3171.13

4.2 Variable cost/unit Sent Out Rs./kwh 2.09 2.20

5.0TOTAL FIXED & VARIABLECOST Rs. in cr. 4742.12 4856.13

6.0 GENERATION COST Rs./kwh 3.28 3.36

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