thermal power plant(9,11,12)

8/13/2019 Thermal Power Plant(9,11,12)

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Project Management I Report on Feasibility study of Thermal Power Plant (Coal based) 1

Submitted by: CP0911, CP1111 and CP1211, M-Tech CPM, Faculty of Technology, CEPT University, Ahmedabad, India.

1.0. INTRODUCTION

A thermal power station is a power plant in which the prime mover is steam driven. Water is

heated, turns into steam and spins a steam turbine which drives an electrical generator. After it

passes through the turbine, the steam is condensed in a condenser and recycled to where it washeated; this is known as a Rankine cycle. The greatest variation in the design of thermal power

stations is due to the different fuel sources. Some prefer to use the term energy center because

such facilities convert forms of heat energy into electricity .[1] Some thermal power plants also

deliver heat energy for industrial purposes, for district heating, or for desalination of water as

well as delivering electrical power. A large part of human CO 2 emissions comes from fossil

fueled thermal power plants; efforts to reduce these outputs are various and widespread.

2.0. Efficiency

The energy efficiency of a conventional thermal power station, considered as salable energy as a

percent of the heating value of the fuel consumed, is typically 33% to 48%. This efficiency is

limited as all heat engines are governed by the laws of thermodynamics. The rest of the energy

must leave the plant in the form of heat. This waste heat can go through a condenser and be

disposed of with cooling water or in cooling towers. If the waste heat is instead utilized for

district heating, it is called co-generation. An important class of thermal power station is

associated with desalination facilities; these are typically found in desert countries with large

supplies of natural gas and in these plants, freshwater production and electricity are equally

important co-products.
http://en.wikipedia.org/wiki/Power_planthttp://en.wiktionary.org/wiki/prime_moverhttp://en.wikipedia.org/wiki/Steamhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Electrical_generatorhttp://en.wikipedia.org/wiki/Condensationhttp://en.wikipedia.org/wiki/Surface_condenserhttp://en.wikipedia.org/wiki/Rankine_cyclehttp://en.wikipedia.org/wiki/Heathttp://en.wikipedia.org/wiki/Energyhttp://en.wikipedia.org/wiki/Thermal_power_station#cite_note-0http://en.wikipedia.org/wiki/Thermal_power_station#cite_note-0http://en.wikipedia.org/wiki/Thermal_power_station#cite_note-0http://en.wikipedia.org/wiki/District_heatinghttp://en.wikipedia.org/wiki/Desalinationhttp://en.wikipedia.org/wiki/Heating_valuehttp://en.wikipedia.org/wiki/Thermodynamichttp://en.wikipedia.org/wiki/Waste_heathttp://en.wikipedia.org/wiki/Surface_condenserhttp://en.wikipedia.org/wiki/Cooling_waterhttp://en.wikipedia.org/wiki/Cooling_towerhttp://en.wikipedia.org/wiki/District_heatinghttp://en.wikipedia.org/wiki/Co-generationhttp://en.wikipedia.org/wiki/Desalinationhttp://en.wikipedia.org/wiki/Natural_gashttp://en.wikipedia.org/wiki/Natural_gashttp://en.wikipedia.org/wiki/Desalinationhttp://en.wikipedia.org/wiki/Co-generationhttp://en.wikipedia.org/wiki/District_heatinghttp://en.wikipedia.org/wiki/Cooling_towerhttp://en.wikipedia.org/wiki/Cooling_waterhttp://en.wikipedia.org/wiki/Surface_condenserhttp://en.wikipedia.org/wiki/Waste_heathttp://en.wikipedia.org/wiki/Thermodynamichttp://en.wikipedia.org/wiki/Heating_valuehttp://en.wikipedia.org/wiki/Desalinationhttp://en.wikipedia.org/wiki/District_heatinghttp://en.wikipedia.org/wiki/Thermal_power_station#cite_note-0http://en.wikipedia.org/wiki/Energyhttp://en.wikipedia.org/wiki/Heathttp://en.wikipedia.org/wiki/Rankine_cyclehttp://en.wikipedia.org/wiki/Surface_condenserhttp://en.wikipedia.org/wiki/Condensationhttp://en.wikipedia.org/wiki/Electrical_generatorhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Steamhttp://en.wiktionary.org/wiki/prime_moverhttp://en.wikipedia.org/wiki/Power_plant


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3.0.Components of thermal power plant

1. Cooling tower 10. Steam Control valve 19. Superheater

2. Cooling water pump 11. High pressure steamturbine 20. Forced draught (draft) fan

3. transmission line (3-phase) 12. Deaerator 21. Reheater4. Step-up transformer (3-phase) 13. Feedwater heater 22. Combustion air intake5. Electrical generator (3-phase) 14. Coal conveyor 23. Economiser6. Low pressure steam turbine 15. Coal hopper 24. Air preheater7. Condensate pump 16. Coal pulverizer 25. Precipitator8. Surface condenser 17. Boiler steam drum 26. Induced draught (draft) fan9. Intermediate pressure steamturbine 18. Bottom ash hopper 27. Flue gas stack

Typical diagram of a coal-fired thermal power station
http://en.wikipedia.org/wiki/Cooling_towerhttp://en.wikipedia.org/wiki/Control_valvehttp://en.wikipedia.org/wiki/Superheaterhttp://en.wikipedia.org/wiki/Cooling_tower_systemhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Centrifugal_fanhttp://en.wikipedia.org/wiki/Electrical_power_transmissionhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Deaeratorhttp://en.wikipedia.org/wiki/Transformerhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Feedwater_heaterhttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Electrical_generatorhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Conveyorhttp://en.wikipedia.org/wiki/Economiserhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Air_preheaterhttp://en.wikipedia.org/wiki/Condensate_pumphttp://en.wikipedia.org/wiki/Pulverizerhttp://en.wikipedia.org/wiki/Electrostatic_precipitatorhttp://en.wikipedia.org/wiki/Surface_condenserhttp://en.wikipedia.org/wiki/Steam_drumhttp://en.wikipedia.org/wiki/Centrifugal_fanhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Bottom_ashhttp://en.wikipedia.org/wiki/Flue_gas_stackhttp://en.wikipedia.org/wiki/Flue_gas_stackhttp://en.wikipedia.org/wiki/Bottom_ashhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Centrifugal_fanhttp://en.wikipedia.org/wiki/Steam_drumhttp://en.wikipedia.org/wiki/Surface_condenserhttp://en.wikipedia.org/wiki/Electrostatic_precipitatorhttp://en.wikipedia.org/wiki/Pulverizerhttp://en.wikipedia.org/wiki/Condensate_pumphttp://en.wikipedia.org/wiki/Air_preheaterhttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Economiserhttp://en.wikipedia.org/wiki/Conveyorhttp://en.wikipedia.org/wiki/Coalhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Electrical_generatorhttp://en.wikipedia.org/wiki/Combustionhttp://en.wikipedia.org/wiki/Feedwater_heaterhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Transformerhttp://en.wikipedia.org/wiki/Deaeratorhttp://en.wikipedia.org/wiki/Three-phasehttp://en.wikipedia.org/wiki/Electrical_power_transmissionhttp://en.wikipedia.org/wiki/Centrifugal_fanhttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Steam_turbinehttp://en.wikipedia.org/wiki/Cooling_tower_systemhttp://en.wikipedia.org/wiki/Superheaterhttp://en.wikipedia.org/wiki/Control_valvehttp://en.wikipedia.org/wiki/Cooling_tower


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3.1. Functions

1. COAL (fig. 1) Coal is transported from the mine to loading place Loading place into ships Ships to the port Unloaded at the Port Transported through conveyors into bunkers From bunkers into mills (Pulverizes) Powdered, put into furnace and burnt The heat generated is used to heat water, steam, air (fig. 1)

2. CHP Coal handling plant (fig. 2) At the receiving location stock yard or sent to coal bunkers To make sure to generate electricity when you want to, you have to make sure the coal is

in the right place at the right time Typically 15 days stock is maintained at site The stock yard stocks these and helps in times of lean supply from the mines or when

transportation is not available

(fig. 2)

3.

Coal Conveyor (fig. 2) Coal conveyors are used to move coal around efficiently. Coal arriving by train can bestocked for later use or taken straight to the coal bunkers

CHP control room with remote control system helps to ensure that the conveyors take thecoal to the right bunkers


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4. Boiler Coal (fig. 3) Coal bunker supplies coal to pulverizing fuel mills. Each

bunker can hold 1,000 tonnes of coal, and there may besix to eight bunkers per unit

Power station coal is not as lumpy as coal used in thehome. Typically around half of it is less than 12.5millimeters across and 95% is less than 50 millimeters

This when powdered is called 200 mesh cleared. Thatis the powdered coal passes through a sieve with so many holes in square inch area. It is

better than the face powder in terms of size(fig. 3)

5. Stack and Reclaim (fig. 4)

Machines are used to put coal out to thestockpile and reclaim coal from the stockpile

Water is sprayed on coal to stop them fromgetting burnt when in storage yard due tointernal heat up or sun heat

Coal when powdered is heated and being lifted by hot air that is sent into the mills

This goes and burns inside the furnace producing ash and converting the water in the pipelines into steam

(fig. 4)

6. Coal Feeder (fig. 5) The variable speed coal feeder feeds coal from the bunkers to the mill It uses a conveyor to move coal through a fixed gap at a precisely controlled speed Varying the speed controls the amount of coal

supplied to the boilers These are precision bits of equipment that have to

move exact amounts of coal. They can move 40 tonnes of coal in an hour

(fig. 5)


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7. Primary Air Fan (fig. 6)

Air to blow the coal from the mill to the boiler, called the primary air, is supplied by a large fan driven by a variablespeed motor

When mixed with a stream of air the powdered coal behavesmore like a gas than a solid

Primary air does two jobs heating the coal powder andsecondly lifting it into the furnace through pipelines

(fig. 6)

8. Boiler light-up (fig. 7) Spark plug provides the initial ignition. Light Diesel oil is then fed to the burner and it

catches fire This is followed by heavy furnace oil (HFO) Once a stable flame is established the coal/air mix is

blown through the burner where it lightsspontaneously

The oil are then shut off. Burner position, coal flowand air flow are controlled to achieve desired outputof temperature, pressure and flow and hence theelectricity

At full output 4,000 MW power station can burnmore than 50,000 tons of coal a day (fig. 7)

9. Boiler (fig. 8) To produce steam each boiler converts energy, in the form of coal, into steam The boiler is lined with steel tubing in which pure boiler feed water is turned to steam by

the heat created from the burning of coal Each boiler is as high as 60 mts and weighs about 40,00,000 kg (4000 T) Inside the boiler there is enough steel tubing to stretch the 500 kilometers and they are

joined together by about 20,000 joints

Pressure inside the tubes could be about hundred timesthat of cars wheel pressure

(fig. 8)


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10. Forced Draught (FD) Fan (fig. 9) Each unit shall have two forced draught fans The fans draw warm air from the top of the boiler house

through large air heaters becoming the primary andsecondary air used for the boiler combustion process

The air heater warms the incoming air by transferring heatenergy from the outgoing flue gases.

(fig. 9)11. Air Pre-Heater (APH) The air heaters use the remaining heat energy in the flue gas to heat up the combustion air

for the boiler Efficiency is increased by using this heat that would otherwise go up the chimney. The

air temperature leaving the air heaters is at 300C The air heaters use the remaining heat energy and efficiency is increased by using this

heat that would otherwise go up the chimney

12. Electro-Static Precipitator (fig. 11) Each boiler has 4 passes with 7 fields each containing high

voltage electrodes These attract the dust or ash from the flue gases At regular intervals the electrodes are rapped with motor-

driven hammers and the PFA falls into hoppers below In a year 1,000 MW station may generate 1.5 million ton

of ash (fig. 11) This is one of the ways to clean up the flue gases or smoke sent up the chimney Secondly this ash is used by construction industry for use in building materials (bricks !!,

Cement Fillers)

13. Induced Draught (ID) Fan Two induced draught fans draw gases out of the boiler The gas has already passed through the air heaters and precipitators before it has reached

these fans The heat from the flue gases or smoke is used in the air heaters to heat up the primary and

secondary air


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14. Chimney (fig. 12) The chimney is 275 meters' high and 50,000 tonnes of

reinforced concrete were used to make it It consists of flues each of which serve typically two or three

boilers (two units)

(fig. 12)15. Super heater (fig. 8) The steam produced in the boiler goes to the steam drum and is then piped through the

primary, platen and final super-heaters where it reachesthe outlet temperature of 560C and 160 ksc pressure

At this point in the process they have now turned thewater into a very powerful source of energy

This rotates the turbine to which generator is on the

other end From rotating generator electricity is produced

16. High Pressure Turbine (fig. 13) High pressure steam at 560C and 160 ksc pressure passes through the high pressure

turbine. The exhaust steam from this section is returned to the boiler for reheating before being used in the next section of the turbine set.

The blades in the high pressure turbine are the smallest of all the turbine blades, this is because the incoming steam has very high energy and occupies a low volume. The bladesare fixed to a shaft and as the steam hits the blades it causes the shaft to rotate

17. Boiler Reheater (fig. 14) After expanding through the high pressure turbine the

exhaust steam is returned to the boiler at 360C and 40ksc pressure for reheating before being used in theintermediate pressure turbine

The Reheater reheats the steam from a temperature of360C back to 560C

(fig. 14)

18. Intermediate Pressure Turbine On leaving the boiler Reheater, steam enters the intermediate pressure turbine at 560C

and 40 ksc pressure (1 ksc = 14.22 psi ) From here the steam goes straight to the next section of the turbine set The steam has expanded and has less energy when it enters this section, so here the

turbine blades are bigger than those in the high pressure turbine The blades are fixed to a shaft and as the steam hits the blades it causes the shaft to rotate


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19. Low Pressure Turbine (fig. 15) From the intermediate pressure turbines, the steam continues

its expansion in the three low pressure turbines. The steamentering the turbines is at 300C and 6 ksc pressure

To get the most work out of the steam, exhaust pressure iskept very low, just 50 mille-bar above a complete vacuum

The tip speed of the largest blades with the shaft spinning at3,000 revolutions per minute is 2,000 kmph (fig. 15)

20. Rotor (fig. 16) The shaft that runs through the turbines is coupled to the

rotor, which is a large electromagnet inside a cylinder of

copper windings called the stator The rotor weighs 100 tonnes and rotates at 3,000 revolutions

per minute

(fig. 16)21. Stator

As the electromagnet rotates inside the copper windings, a magnetic field is createdwhich induces a three phase alternating electric current (AC) in the stator windings

Together the rotor and stator are known as the generator.

The stator weighs 300 tonnes electricity is generated at over 80 times the voltage in ourhomes

This is stepped up to about 4,00,000 volts and then transmitted

22. Generator Transformer (fig. 17) From the generator the electricity then goes to a

transformer where the voltage is increased to4,00,000 volts before sending it via cables to the

Grid for distribution (fig. 17) Each 1 MW generates about 8 million units and gives

about Rs 2 crores revenue every year . This generatesenough electricity to power around 5,000 avg. homes

(fig. 17)


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23. Condenser (fig. 18) With its useful energy spent in the turbines the steam then

passes to condensers Here it is condensed back into water and pumped back to the

boiler This happens via a series of low pressure and high pressure

feedheaters(fig. 18)

24. Condensate Extraction Pump (fig. 19)(fig. 18)

The condensate water is drawn from the condenser by theextraction pump and sent to the low pressure feed heaters

25. Low Pressure Feed Heaters Feedwater from the condensate extraction pumps passes

through low pressure feed heaters. Steam is used to heat thefeedwater

After the last feedheater, the feedwater is at around 160C.

(fig. 19)

26. Deaerator (fig. 20a) From the low pressure feed heaters the water passes through

the deaerator before going to the high pressure (HP) feedheaters.

(fig. 20a)

27. Boiler Feed Pump The boiler feed pump pumps water into the boiler, overcoming the boiler pressure of 160

bar to achieve it

The pump is driven by a steam turbine or an electric motor It runs at 7,000 revolutions per minute


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28. High Pressure Feed Heaters (fig. 20b) (fig. 20b) With a similar purpose to the low pressure feed

heaters, the high pressure feed heaters are the laststage of feedwater heating before the feedwaterenters the boiler system at the economizer

Feedwater leaving these heaters is at 250C

29. Cooling Tower (fig. 21) The warm river water is taken from the condenser tubes to about a quarter of the way up

the 100 metre high cooling tower where it is dropped through honeycombed plastic packing This breaks the water up into a very fine spray,

increasing the surface area of the water droplets makingit easier to cool

The cooling tower is designed as a natural draughtchimney, drawing cold air from outside through thefalling water

Cool water is collected in pond at the bottom of the cooling tower (fig. 21) From here it is pumped back to the condensers

30. Circulating Water Pumps (fig. 22) The circulating water pumps are used to circulate the

water from the cooling tower to the condenser and backagain

(fig. 22)31. Circulating Water Make-Up Pumps (fig. 23) These pumps are used to supply water for make-up purpose Before going to the cooling Tower the silt is removed in large sedimentation tanks

32. FGD

After passing through the electrostatic precipitators, the boiler flue gas is increased in pressure and then cooled from between 115C-130C to 80C


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It enters the lowest part of the absorber and is further cooled by water used to wash theinlet duct to prevent a build up of solids

The main SO 2 absorption process, and the washing out of any remaining pulverized fuelash, occurs as the gas is scrubbed by the re -circulating limestone slurry

This is taken from the bottom of the absorber and is sprayed downwards from nozzlesarranged at five separate levels in the absorber tower

As a result of the process chemistry, the recirculation slurry becomes predominantlygypsum and a portion is continuously pumped away for gypsum separation and theremoval of water using a hydro-cyclone system

A waste water treatment plant ensures any water from the FGD process returned to theriver meets quality standards set by the regulatory authority

The cleaned flue gas is discharged up the 275 metre high chimney which has been linedwith steel plates/brick lining.

The generated power stepped up to 4 lakh volts is transmitted and handed over todistributors at lower voltages

Finally it is supplied to households at 230 volts and to industries at little higher voltages.

4.1. ADVANTAGE S

The fuel used is quite cheap. Less initial cost as compared to other generating plants. It can be installed at any place irrespective of the existence of coal. The coal can be

transported to the site of the plant by rail or road or sea

It requires less space as compared to Hydro power plants. Cost of generation is less than that of diesel power plants. This plants can be quickly installed and commissioned and can be loaded when compare

to hydel power plant

It can meet sudden changes in the load without much difficulty controlling operation to

increase steam generation

Capital cost in Rupees per Mega watt installed is about 4 crores for hydro, 5.0 crores for

thermal and 5.5 crores for nuclear.

Maintenance and lubrication cost is lower


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4.2. DISADVANTAGES

It pollutes the atmosphere due to production of large amount of smoke and fumes. However, this could create more jobs for a lot of people thus increasing in a good way our

current economic situation which by is failing miserably.

Over all capital investment is very high on account of turbines, condensers, boilers re-heaters

etc .maintenance cost is also high on lubrication, fuel handling, fuel processing.

It requires comparatively more space and more skilled operating staff as the operations are

complex and required precise execution

A large number of circuits make the design complex. Starting of a thermal power plant takes

fairly long time as the boiler operation and steam generation process are not rapid and

instantaneous


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CASE STUDYOn2 x 500 MW Coal based thermal power

plant

near Pipavav, Gujarat, India


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5.0. LOCATION


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5.6. PROJECT COST & COST OF GENERATION

Capital cost Power Plant : Rs. 3333.28 Cr

Port Facility : Rs. 146.32 Cr

Overall project cost Rs. 3479.60 CrProject cost with interest Rs. 4220.83 CrCost of generation Tariff Rs. 2.76/kWh

6.0. MARKET FEASIBILITY

6.1. PROJECT GENESIS

The state of gujarat was 8 th in the list of industrialised state till 1960, it now occupies 2 nd position in terms of output in manufacturing sector.

Due to rapid development power demand has outstripped supply in gujarat.

Gujarat industrial development was concentrated in ahmedabad-baroda-surat belt. Focusis now shifting to saurashtra region owing to increased power requirement.

6.2. SECTOR-WISE TREND OF POWER CONSUMPTION / DEMAND


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6.3. EXISTING POWER SCENARIO IN GUJARAT

DEMAND / SUPPLY POSITION OF POWER IN GUJARAT

YEAR INSTALLED

CAPACITY

DEMAND AVAILABILITY DEFICIT REQUIRED

INSTALLEDCAPACITY TOMEET DEMAND

1994-95 6190 4810 3616 1326 7516

1996-97 6390 5487 4303 2183 8573

1998-99 7408 6258 4757 2372 9778

2000-01 8407 7125 5376 2726 11133

NOTE : ALL CAPACITIES IN MW & MAX. EFFICIENCY OF PLANT = 0.64

6.4. DEMAND vs. SUPPLY TREND IN GUJARAT


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7.0. TECHNICAL FEASIBILITY

7.1. Land requirement

Plant area - 300 ha.

Ash disposal area - 135 ha.

Township area - 30 ha.

Intake pipe route - 4.5 ha.

Other requirement - 10 ha.

Total land requirement - 479.50 Ha.

7.2. WATER REQUIREMENT & AVAILABILITY

Water required for :

cooling water for team condenser cooling of electrical and mechanical equipment make-up water for power cycle ( boiler feed) fire fighting, air conditioning and sanitation potable water for plant & township

There is scarcity of sweet water in the area as ground water is brackish & no river isavailabile, hence proposed to adopt recycling and use of sea water for major use.

Sea water shall be used in proposed desalination plant (2 x 1.5 mgd)

7.3. FUEL REQUIREMENT & AVAILABILITY

Primary fule coal is required at the rate of 8850 mt per day

Coal shall be imported from s.africa/ australia / indonesia through pipavav port.

Pipavav port facilitates navigation of 60000 dwt ships & has unloading facility of 1500t/hr.

Coal transportation to plant site through twin conveyor belt system.

Back up storage of 30 days is proposed at power plant.

Daily requirement of start up & stabilization fuel (hfo) is 80000 lt.


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7.4. INFRASTRUCTURAL FACILITY

Existing facility -

Distance from railway station : 40 km

Distance from nearest state highway (sh-34) : 2.5 km

Proposed facilities

2 lane road from highway to plant site.

Township for accomodating 800 employees equipped with market, school, hospital, postoffice etc.

7.5. POWER EVACUATION

Power generated at the plant shall be evacuated through existing power grid of geb. Geb grid will be connected through 22o kv lines to jetpur substation & sevarkundla lines.

Detailed scheme foe evacuation of exportable power about 915 mw would be drawn up by geb for which agreement is signed with geb.

7.6. SITE SELECTION

Following three sites were indentified for proposed plant :

1. NEAR MUNDRA

2. NEAR VERAVAL

3. NEAR PIPAVAV

*- comparison of salient features of three sites is given in following table


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7.7. COMPARISON FOR SITE SELECTION FOR PROPOSED PLANT

Sr.No.

Features Mundra Veraval Pipavav

1. Nearby town Bhuj : 62 km Veraval : 27 km Jafrabad : 8.5 km

2. Nearest highway Nh 8a : 82 km Nh 8b :144 km

Sh 31 : 22 km

Nh 8a : 293 km

Sh 34 : 2.9 km

3. New access road to site 7 km 1 km 2.5 km

4. Equipment unloading point Kandla port : 80km

Porbandar

: 230 km

Pipavav port

: 40 km

5. Coal conveyor length to site 9 km 4.8 km 7 km

6. Nearest intake location for sea waterGulf of kutch : 9

kmArabian sea :

3 kmArabian sea 3.5 km

7. Wind/ current

Moderate

Red zone @ 50m/sec

Moderate

Red zone @ 50m/sec

Moderate

Red zone @ 50 m/sec

8. Source of sweet water Throughdesalination plantThrough

desalination plant

Desalination plant +water from narmada &

Dhratrawadi.

9. Source of coal

Indonesia,

South africa

Australia

Indonesia,

South africa

Australia

Indonesia,

South africa

Australia

10.Distance of 400 kv substation & itsdistance from plant Limbdi @ 225 km Jetpur @ 200 km Jetpur @ 125 km

11. Cooling water system & gravityheadIndirect coolingwith 8 m head.

Direct circulationwith 6 km head

Indirect cooling with 22m head

12. Nearest forest boundary Jetpur reserveforest : 2 km

Lodhva : 1km

Dhamrej : 1 km

Kovya reserve

: 3 km

13. Land use Private land Private land Private land marginallycultivated.


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7.8. COST COMPRISON FOR SITE SELECTION

*-note: all figures in crores

SR. NO. FEATURES MUNDRA VERAVAL PIPAVAV

1. Harbour facility 100.05 280.04 22

2.Cost of conveyor

From port to plant @6 cr / km55.8 28.8 43.8

3. Cooling system 143.4 67.0 91.4

4. Roads 1.3 0.2 2.2

5. Land aquisition 6.0 7.2 12.0

6. Cost 400 kv transmission line 450 200 250

Total cost involved 756.45 583.65 422.40

7.9. SITE SELECTION (FINALIZATION) Based on techno commercial feasibility site near pipavav has been selected for construction of

proposed 1000 mw power plant.


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8.0. ENVIRONMENTAL ASPECTS

Main sources of pollution in power plant:

Stacks : discharging particulate matter, toxic gases & heat.

Circulating water blown down from condensercooling circuit- discharging heat, water

with higher salt & chemical concentration added for treatment.

Coal handling plant : coal dust & particulate matter.

Concentrated brine from de salination plant.

8.1. ENVIRONMENTAL MANAGEMENT PLAN

Installation of dust trapping arrangement through electrostatic precipitator with suitablydesigned stack for proper dispersal.

Installation of tall chimneys for dispersion of toxic gases & particulate matter. It also

reduces the heat pollution.

Ash/ solid waste disposal : gainful use of ash in the making of cement & building

industry shall be ensured.

Besides 13o ha. Has been earmarked to disposal of flyash.

Etp installation for treatment of effleunt generated within the plant.

Total cost of pollution control measure : 81.45 cr & recurring cost : 3.55 cr.


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9.0. TECHNICAL FEASIBILITY (Port)

.1. HARBOUR PLANNING AND LAYOUT The harbour is proposed to be constructed along a bay/waterway spanning along N-E.

The available water depth is of the order of 10m. The average width of the channel bounded by the 10m contour line is of the order of 400m.

The length of the channel from the entry point up to the turning circle is of the order of

2000m

The wind direction is predominantly western and most of the wind energy is concentrated

within the band of 45deg. Between W and N-W.

The mean tidal range is expected to be 2.7m and the mean lower tidal range is expected to Be

1.2m Average current of site will be of the order of 1.1knots to 1.3 knots which at high spring

might attain a speed of 3 knots

SIZE and SHAPE of HARBOUR and TURNING BASIN

Location and width of entrance to harbour

Number and orientation of location and docks

Shore connectivity of marine terminal


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2. HARBOUR LAYOUT AND COMPONENTS

3. SELECTION OF DOCK TYPE

4. BERTHING OF SHIP

5. MOORING OF SHIP

6. COAL UNLOADING AND CONVEYANCE

7. UTILITIES AND SERVICES

8. MAINTAINENCE OF BERTHING DOCK AND HARBOUR ZONE

9.1. PROCESS FLOW DIAGRAM AND POWER GENERATION (proposed)


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10.0. CIVIL and STRUCTURAL ASPECTS

1. Plant Level

The general grade of plant level of the plot is approximately 20m above MSL with a

gentle Slope from North to South (The exact grade level will be decided on completion ofsite survey)

By visual investigation, a single terraced level land of the power plant has been

considered At an elevation of 20m above MSL. An average of 0.5m cutting/filling has been considered for grading

2. Soil Characteristics

Soil investigation has not been done yet. Based on the soil characteristics of adjoining

Area in raft/spread footings in foundation have been considered for major plant.

Equipment and the project cost is estimated on basis of this available data

3.0 Seismic considerations

The power station is located under Zone-IV as per IS: 1893, for which the basic

horizontal Seismic co-efficient is 0.05. Analysis and design structures to resist the seismic forces are to be carried out as per the Provisions of IS: 1893 The applicable importance factors would be duly considered in the detail design


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4.0. Wind Loading

The maximum wind pressure including winds of short duration as specified in IS code

No. 875-1987, for the zone where the power plant is located, will be adopted in design

The site is located in the red zone as per above standard with wind speed of 50m/sec Andthe basic wind pressure for short duration is 150kg/sq.m.

The basic wind pressure along with it variation with heights and with appropriate Co-

efficients for shape of the structures will be considered for design


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10.1. Power House building superstructure

The power house building superstructure will be in

fabricated structural steelwork.

All components will be of welded fabrication and the

field connections will be with high-tensile bolts or

welding as determined in designed stage

The transverse frames will be of rigid type

In the longitudinal direction these rigid transverse

frame will be braced of to resist horizontal forces.

10.2. Civil works for Plant Water System

Circulating cooling water system using cooling tower is considered for condenser as well

As auxiliary cooling of the proposed station using sea water from the gulf of khambat

The sea water intake structure will be located about 3.5kms south of plant size above HFL.

The pump house forebay will be fed by a set of RCC submarine pipe laid on sea bed.

The intake point would be 4/5m above sea bed level and 4/5m below MLLW to ensurereceipt of comparative clean water

The submarine pipe would be suitably covered with ballasts. The intake point of water in seashould be complete without marking buoys.

The intake structure shall be of RCC construction and will house forebay sump chamber, asuitable sand trap, pump room and electrical room

The Discharge line from intake pump house will be buried mild steel gunited line upto the plant

The discharge line shall also have a pressurized flow in order to achieve a minimum velocityof 1.2m/sec to prevent marine growth.

The discharge pipe shall have a diffuser system at the end.


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10.3. Civil works for Coal Handling Plant

Coal from the port will be transported by mean ofconveyor

This conveyor would be constructed owned and

operated by the station Conveyor galleries, supporting trestles, superstructures

of transfer houses shall be fabricated structuralsteelwork

All components will be of welded fabrication with bolted/welded joints for erection and

Assembly in the field Roofing will be of AC sheets. Intermediate floors in transfer houses will be reinforced

concrete supported on structural steel framing Side cladding will be of AC sheets and necessary windows/louvers will be provided for

natural lighting and ventilation

10.4. CONSTRUCTION FACILITIES AND GENERATING PLANT OPERATIONS

10.4.1 Construction of roads

The proposed site is located near the SH-34.

The road is proposed to be built connecting this highway to the plant site.

This road access to the plot is shown in the following figure would form priority for

taking up the project The nearest railway station heads namely at Rajula (14kms) and Pipavav port (140kms)

are connected by meter gauge railway line of the western railways

No provision has been kept for use of the railway system in the present project

Plant machineries and equipment would be transported by sea and road

10.4.2 Construction of building

About 2000 sq. m. of construction office space and 4000 sq. m. of covered storage is proposed to be provided

In addition, open storage spaces, a small garage, yard, toilets etc. along with hostels andresidential units for the staff


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10.4.3 Construction water

The maximum requirement of water is estimated at 80cum/hr for potable and service purposes.

This may be created to by digging tube-wells and having an overhead steel tank

during construction period

10.4.4 Construction power

A GEB distribution is expected to be in operation at site before the beginning of siteactivities

In case of delay in obtaining supply from GEB for construction power, arrangements for providing diesel generating sets of adequate size will be made

10.4.5 Construction Equipments

A number of equipments namely bulldozer, road-roller, crawler and tyre-mounted cranes,tractor-trailors, winches, lifting-tackles etc. are proposed to be arranged by the projectauthorities.

The above may be rented to the contractors as found necessary

An ambulance and fire Bridget vans are made must to be available on the site all the time

10.4.6 Construction Materials

Stone aggregates: Quarries for stone aggregates are available in adjacent areas not farfrom the power station site and the aggregate can be transported by road.

Sand: Coarse to medium sand is available from the river bed within a radius of 15kmsfrom the site and may be transported by road

Bricks: There are number of brick manufacturing agencies in the nearby areas and hencethere should not be any difficulty in getting sufficient quantity of bricks


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11.0. PROJECT IMPLEMENTATION AND MONITORING


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Some of the major packages such as coal handling, Ash Handling, Fuel oil handlingsystem, Cooling towers etc. would be undertaken on a turnkey basis. The contractorswould be entrusted with the design, engineering, manufacture, supply, erection, testingand commissioning for these packages.

Experiences engineers will be deputed on site at every stage of progress right fromexcavation or finishing to ensure quality and accuracy or work

11.1. TESTING AND COMMISSIONING

A testing and commissioning group including operation and maintenance personnel

would be deputed for pre-commissioning checks and final commissioning of various plant and equipment.

A commissioning network and procedure would be prepared jointly with all concernedwhich would guide the team for execution of commissioning activities.

Proper documentation of the commissioning activities would be made for safety andorderly commissioning of the plant.

12.0. PROJECT MONITORING CO-ORDINATION AND CONTROL12.1. PROJECT MONITORING INFORMATION SYSTEM:

Progress of each activity at every stage would be physically monitored by respectivesupervising engineers.


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All detailed information would be passed on to the central monitoring cell to keep trackof the work progress.

Similarly, costing of individual items would be monitored and recorded preferably withthe help of software.

Central monitoring cell would monitor the progress and report to the senior executivesfor information and necessary actions

12.2. CO-ORDINATION

Regular meetings would be held at the site amongst representatives of the contractors,consultants and engineers of the respective depts.

Accordingly identification of progress, corrective measure if any, material constraintsetc. would be done, sorted out and leveled up

12.3 REPORTING

Various reports would be generated in regard to the physical and financial progress of the project on monthly, quarterly and yearly basis for forwarding to the various GovernmentDepartments.

Financial institutions as well as for the internal use

Daily progress report of the major items of work, along with their monthly targets, would be reported to the project head.

12.4. FINANCIAL CONTROL

Actual cost records would be regularly monitored against forecasts which would be forwarded toFinance department by the project department on monthly, half-yearly and yearly basis,depending on the actual progress of delivery and erection/construction.


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13.0. FINANCIAL FEASIBILITY and ASPECTS

Foreign loans of the order of 50% of the loan amount of the project cost attract an overall Interest rate of 12.6% per annum and Indian currency load of equivalent amount will

attract Interest @ 18.5% Interest during the construction will be capitalized Equity to be raised from promoters, contribution /public issue/right issues etc. Debt to be sourced from All India financial institutions and overseas sources Total borrowing from the AIFI not to exceed to 40% of the project cost The rate of interest on working capital load would be 18.5% p.a. Terms of repayment of loan with 10 th operating years with no moratorium Price of coal would be Rs. 1683.03/MT. Cost of fuel has been estimated by considering a

station heat rate of 2500kCAL/kWh and designed GCV of fuel as 6720Kcal/kg The delivered cost of fuel oil would be Rs. 7000/KL Working capital to be estimated as per guidelines of CEA The plant load factor to be 68.49%. The annual working hours to be 6000 hours The auxiliary consumption to be 8% & M cost expenses to be @ 2.5%

Depreciation would be provided @ 7.84% as per guidelines of CEA for estimation of book profit and as per WDV method of calculating tax liability

Project Cost Amount (Million)

Preliminary investigation 2.0

Land 2.0

Civil works 527.1

Mechanical works 737

Electrical works 420

Preliminary capital issues expenses 260

Overhead works construction cost 877

Contingencies 39.1

Total 1463.20


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13.1. Estimation cost of generation:

Estimation cost of generation and interest during construction period

Project Cost Amount (Million)

Preliminary investigation 15

Land 119.90

Civil works 3018.80

Mechanical works 23675.05

Electrical works 1915.50

Instrumentation 585.60

Preliminary and capital issues expenses 620.00

Other works cost, construction, management etc. 1916.50

Contingencies 1466.40

Capital Expenses (Power Plant) 33332.80

Capital Expenses (Port facilities) 1463.20

Overall project cost 34796.00

13.2. MEANS OF FINANCING

Source Amount Share of project cost

Equity 12240.00 29%

Forex loan 14777.28 35%

Rupee loan 15190.99 36%

Project cost 42208.28 100%

Total equity 12240.00 29%

Total debt 29968.28 71%

Debt equity ratio 2.33:1 -


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14.0. CONCLUSION

The site selected for construction of a dedicated berth inside the proposed Pipavav Pot harbour zone satisfies all the requirements.

However, capital dredging and subsequent maintenance dredging have to be undertaken tocater the need for the design vessel. Since the desired depth of natural water level is not sufficient.

The harbour may not be available for all weather operations. Amenities such as electricity andwater supply are important challenges to be met prior to the construction phase.

Inspite of these issues the GPPL has shown green signal for this project and agreed toaccommodate the above requirements.


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15.0. REFERENCE

1. GPCL Gujarat Power Corporation Ltd., Ahmedabad, Gujarat.

2. GEB Gujarat Electricity Board

3. Development Consultants Ltd., Ahmedabad, Gujarat.4. GPCB - Gujarat Pollution Control Board, Gandhinagar.

5. GIDB Gujarat Infrastructure Development Board

thermal power plant(9,11,12)

Documents