vallur-ii feasibility report

EXECUTIVE SUMMARY

1.00.00 BACKGROUND

A memorandum of understanding was signed on 12th July 2002 between NTPC and Tamil Nadu Electricity Board with an intent to establish and operate 1000 MW coal based Thermal Power Project at Ennore in Tamil Nadu. Subsequently, a Joint Venture Company between NTPC and TNEB, each acquiring 50% share, under the name NTPC TAMIL NADU ENERGY COMPANY Ltd. (NTECL) was incorporated on 23rd May 2003.VALLUR TPP, Stage-I, Phase-I (2x500 MW) is presently under implementation stage.

Recently, on perusal of the General Layout Plan developed during earlier stage for the main plant and facilities, it has been observed that additional one unit of 500 MW could be accommodated within the existing premises of the plant area with certain modifications in the existing layout/systems. The proposal for setting up of one more unit of 500 MW was discussed in detail during 21st Board meeting of NTECL held on 14.09.2007. Accordingly, the issues in respect of coal unloading and transportation arrangement, additional make-up water and land requirement for ash disposal for additional unit of 500 MW were discussed with officials of TNEB & NTECL during the meetings held on 20.9.07 and 6.10.97. It is considered feasible to add one more unit of 500 MW under Stage-I, Phase-II. Accordingly, Feasibility Report to install one more unit of 500 MW under Stage-I Phase – II has been prepared.

2.00.00 PROJECT HIGHLIGHTS

2.01.00 LOCATION

The proposed Stage-I, Phase-II VALLUR TPP shall be located within the existing premises of Vallur TPP. The project is located between Ennore creek and Pulludivakkam village of Ponneri Taluk of Thiruvallur district in Tamil Nadu at a Latitude 130 13’ 45” N and Longitude 800 18’ 05”E respectively. It is located at a distance of about 20 Kms from Chennai city. The nearest railhead, Kathivakkam is at a distance of 1 Km on trunk route section of Southern Railway from the project site. The National Highway exists at a distance of about 14 Kms from project site. The nearest airport, Meenambakkam, is about 36 Kms from the project site.

2.02.00 LAND

About 1184 Acres of land has been acquired/under acquisition for development of Stage-I, Phase –I (2x500 MW) comprising of about 415 acres for plant & associated facilities, 500 acres for ash disposal area, 75 acres for ash based units, 35 acres for corridors, 45 acres for township and about 114 acres of non usable area (112.35 acres of salt pan plot falls under CRZ and another 1.65 acres located across Ennore creek).One unit of 500 MW under Phase-II of the project would be accommodated within

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the plant boundary. However, 140 acres of additional land will be required for ash dyke and ash water pipe corridor and road.

2.03.00 CAPACITY

Stage-I, Phase-I : 2 x 500 MW - Under Implementation

Stage-I, Phase-II : 1 x 500 MW - Present Proposal

2.04.00 MODE OF OPERATION : Base Load

2.05.00 FUEL : Coal

2.06.00 COAL REQUIREMENT, AVAILABILITY AND LINKAGE

Coal requirement for Phase-II, 500 MW capacity of Vallur TPP, Satge-I shall be about 2.52 million tonnes/annum, considering GCV of coal (ash content not exceeding 34%) as 3900 kcal/kg, unit heat rate of 2447 Kcal/kwhr and PLF of 90%. SLC(LT)/MOC is being approached by NTECL for accord of additional coal linkage for Stage-I, Phase-II of the project.

The addition coal unloading and transportation arrangement for the 3rd unit at Ennore port was discussed during the meeting dtd. 6.10.07 wherein it was informed that the capacity of the coal conveyor system at Ennore Port is 16 MTPA. It can be enhanced to 18 MTPA by improving the system. Thus, there will be a deficit in the system to the tune of 2.2 MTPA. Further, TNEB have plans to add 1X500 MW at NCTP, Stage-III and 1X500 MW at ETPS expansion. In view of the above, TNEB stated that one more additional coal berth at Ennore port is required to meet additional the existing conveyor BCN-40A/40B before JNT-50. However, TNEB agreed to meet requirement of 3rd 500 MW unit of NTECL from existing coal berth subject to proportionate sharing of handling cost at the new berth at Ennore Port. Accordingly, no capital cost towards port augmentation facilities have been considered.

2.07.00 COAL TRANSPORTATION The envisaged mode of coal transportation from the coalmines to the power plant is by Indian Railways rakes in BOBR wagons/BOX-N wagons upto the port, thereafter by ships upto Ennore Port and from Ennore Port to the main plant by conveyor system.

2.08.00 COOLING WATER SOURCE, REQUIREMENT, COMMITMENT AND SYSTEM It is proposed to adopt closed cycle re-circulating type CW system for expansion unit similar to phase-I (2X500 MW) of the project by drawing makeup water for the project from intake channel of North Chennai Thermal Power Station. The total make up water requirement for 3X500 MW would be within 7.5 cumecs, already committed by TNEB during minutes of meeting dtd. 24.11.06. Sweet water requirement of the complete project is proposed to be met by provision of desalination plant.

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The plant capacity shall be augmented to take care of this expansion phase also.

2.09.00 STEAM GENERATOR TECHNOLOGY

The Steam Generators (SG) shall be of subcritical, drum type natural / assisted circulation, single/double pass (tower type/two pass type), single reheat, radiant furnace, dry bottom, balanced draft, outdoor type, direct pulverised coal fired with all necessary auxiliaries.

2.10.00 POWER EVACUATION SYSTEM

Power generated from the proposed units shall be stepped upto 400 kV and will be evacuated through Associated Transmission System (ATS) of the project to be implemented by Power Grid Corporation of India Ltd..

2.11.00 BENEFICIARY

Presently it is envisaged that the power generated from the project shall be absorbed by the States/UT of Tamil Nadu, Karnataka, Kerala and Pondicherry. NTECL is taking up with the above beneficiaries for their confirmation for offtake of power from the expansion unit.

2.12.00 PROJECT FINANCING

The proposed debt equity ratio is 70:30. The debt portion is proposed to be financed from Domestic Commercial Borrowings (DCB) and the equity portion will be financed from promoters contribution.

2.12.01 Consequent upon the identification of the NTPC as one of the “Navratna” Companies, the Board of NTPC has inter-alia been delegated the power to establish financial joint ventures and wholly owned subsidiaries in India or abroad with the stipulation that the equity investment of the PSE should be limited to 15% of the net worth of the PSE in one project limited to Rs. 10000 Million. The overall ceiling on such investment in all projects put together shall be 30% of the net worth of the PSE. The total equity contribution of NTPC in NTECL towards Vallur Thermal Power Project, Stage-I, 3x500 MW(Phase-I & II) will exceed Rs. 10000 Million and therefore necessary waival of Govt. of India would be required. Accordingly, GOI would be approached for accord of necessary waival at an appropriate stage.

3.00.00 PROJECT COST

Current Cost (4th Qtr.’ 2007)

(Rs. in Million)

Project Cost including IDC & WCM 26335.51

Cost/MW (incl. IDC & WCM) 52.67

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Cost of Energy

Current Cost (Paise/kWh)

1st full Year opn. Levelised

Fixed : 149.25

Variable : 131.94

Total : 281.00

255.00

4.00.00 ENVIRONMENTAL ASPECTS

The Terms of Reference (TOR) for Environmental Impact Assessment (EIA) study for the project has been finalised and application has been submitted to MOEF for TOR approval in accordance with the revised notification of MOEF dated 14th September, ‘06. After approval of TOR, EIA study would be undertaken. Thereafter TamilNadu State Pollution Control Board shall be approached for conducting Public Hearing and MOEF will be approached for Environmental Clearance.

5.00.00 COMMISSIONING SCHEDULE

The commercial operation (COD) of the expansion unit is envisaged in 42 months from the date of main plant award.

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TABLE OF CONTENT

CHAPTER TITLE PAGE No

1.0 Introduction 1

2.0 Demand Analysis and Justification 3

3.0 Feasibility Studies 8

4.0 Layout Systems 11

5.0 Civil Works 15

6.0 Mechanical Systems 25

7.0 Electrical Systems 47

8.0 Control & Instrumentation Systems 59

9.0 Environmental Aspects 65

10.0 Technical Data & Bill of Quantities 69

11.0 Cost Estimate & Financial Analysis 96

12.0 Project Implementation 99

13.0 Manpower Training & Placement 104

14.0 Operation & Maintenance Philosophy 107

15.0 Marketing Philosophy 119

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LIST OF ANNEXURES

Sl. No

DESCRIPTION Annexure No

1. Summary of Project Capital Cost 1.1

2. Preliminary & Civil Works 1.1.1

3. Mechanical Works 1.1.2

4. Electrical Works 1.1.3

5. Coal Transportation System 1.1.4

6. Phased Fund Requirement 1.1.5

7. Detailed Calculation of IDC 1.1.6

8. Working Capital Requirement 1.1.7

9. Estimate of Cost Of Energy 1.1.8

10.

Cost for Environmental Measures 1.1.9

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LIST OF EXHIBITS

SL No

DESCRIPTION EXHIBIT No

1. Vicinity Plan I

2. General Layout Plan II

3. Main Plant Lay out at EL (+/-) 0.00 m. III

4. Main Plant Equipment Lay out at 8.5M, 16.5M, 23.5M, 31.25M & 35.5M.

IV

5. Main Plant Cross-section V

6. Water Balance Diagram VI

7. Single Line Diagram (Electrical) VII

8. Single Line Diagram (Switchyard) VIII

9. Single Line Diagram (MISC. System) IX

10. Implementation Schedule X

11. Organisation Structure for Corporate Center XI

12. Organisation Structure for Power Project XII

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INTRODUCTION 1.00.00 BACKGROUND

Power development is one of the key infrastructural element for the economic growth of the country. The development of the power sector in the country, since independence has been predominantly through the State Electricity Boards formed in each state under the Electricity (Supply) Act -1948, with responsibility for generation, transmission and distribution of electric power. Central Electricity Authority (CEA) is the nodal agency for centralise planning of generation and transmission system. In the year 1975, through an amendment of the Electricity (Supply) Act, two Central Sector Undertakings namely, NTPC & NHPC were formed with the task, to supplement the efforts of the SEB’s for quicker and greater capacity addition including associated transmission system. National Thermal Power Corporation Ltd., presently known as NTPC Limited was set up in November, 1975 with the objective of planning, promoting and organizing integrated development of thermal power in the country. Since then NTPC has been a key player in the power sector of the country. Subsequently, associated transmission systems were transferred to Power Grid Corporation of India Ltd after its formation in the year 1991.

In recent years, power development has assumed paramount importance in view of its role in rapid development of industry, agriculture and service sector in the country. The installed capacity of the country that was only 1713 MW in 1950 has already grown to around 1,18,419 MW by March, 2005.

The Tamil Nadu Electricity Board (TNEB) is a statutory body formed on 01.07.1957 under the Electricity (Supply) Act -1948 as a successor to the erstwhile Electricity Department of the Government of Madras. Starting with the modest installed capacity of 156 MW (Mega Watt) with annual gross generation plus purchase of 630 MU (Million Units) at the dawn of independence, the TNEB has grown by leaps and bounds with generating capacity of 9512 MW as on 31.3.2005.The distribution network comprises 1,46,823 circuit kilometers of extra high tension (above 33 kV) and high tension (11 kV to 33 kV) lines, 4.77 lakh kilometers of low tension lines.

A memorandum of understanding was signed on 12th July 2002 between NTPC and Tamil Nadu Electricity Board with an intent to establish and operate 1000 MW coal based Thermal Power Project at Ennore in Tamil Nadu. Subsequently, a Joint Venture Company between NTPC and TNEB, each acquiring 50% share, under the name NTPC TAMIL NADU ENERGY COMPANY Ltd. (NTECL) was incorporated on 23rd May 2003.VALLUR TPP, Stage-I, Phase-I (2x500 MW) is presently under implementation stage.

Recently, on perusal of the General Layout Plan developed during earlier stage for the main plant and facilities, it has been observed that additional one unit of 500 MW could be accommodated within the existing premises of the plant area with certain modifications in the existing layout/systems.

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The proposal for setting up of one more unit of 500 MW was discussed in detail during 21st Board meeting of NTECL held on 14.09.2007. Accordingly, the issues in respect of coal unloading and transportation arrangement, additional make-up water and land requirement for ash disposal for additional unit of 500 MW were discussed with officials of TNEB & NTECL during the meetings held on 20.9.07 and 6.10.97. It is considered feasible to add one more unit of 500 MW under Stage-I, Phase-II.

Accordingly, it is proposed to install one more units of 500 MW under Stage-I, Phase-II.

2.00.00 PROPOSAL The present proposal is to implement one more unit of 500 MW based on coal under Phase – II within the existing plant premises.


DEMAND ANALYSIS AND JUSTIFICATION

1.00.00 GENERAL

Vallur TPP, Stage-I, Phase-II (1x500 MW) is being taken up by NTECL primarily to meet the power requirements of Tamil Nadu and States/UTs of Southern Region. The project is expected to start yielding benefits during 11th Plan period.

2.00.00 DEMAND ESTIMATION (11TH AND 12TH PLAN)

The demand scenario has been prepared as per latest publication of Electrical Power Survey (EPS-17) published by CEA and is presented below in table-1. The 16th EPS data has also been tabulated for reference purpose.

Table-1 Demand projections up-to 2012 under EPS

PEAK DEMAND (MW) ENERGY REQUIREMENT (MU)

REGION

(1)

16th EPS

(2)

As per 17th EPS

(3)

16th EPS

(4)

As per 17th EPS

(Forecast)

(5)

NR 49674 48137 308528 294841

WR 46825 47108 299075 294860

SR 42061 40367 262718 253443

ER 15664 19088 90396 111802

ISLANDS 94 88 444 384

ALL-INDIA 157107 157325 975222 968659

As per 17th EPS, the projected demand by 2012 is 157325 MW as estimated in column (3), Table-1 above. It may be noted from the above table that the total peak demand as projected in 17th EPS is very close to the forecast of 16th EPS i.e. the difference is only 218 MW.

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Table-2 Demand projections up-to 2017 under EPS-17th

PEAK DEMAND (MW) ENERGY REQUIREMENT (MU)

REGION

(1)

16th EPS

(2)

As per 17th EPS

(3)

16th EPS

(4)

As per 17th EPS

(Forecast) (5)

NR 69178 66583 429480 411513

WR 61966 64349 395859 409805

SR 56883 60433 354599 380068

ER 20416 28401 117248 168942

NER 4134 3760 20756 21143

ISLANDS 148 136 702 595

ALL-INDIA 212725 223662 1318644 1392066

As per 16th EPS, the projected demand by 2017 was 212725 MW while 17th EPS forecast is 223662 MW as estimated in column (2) & (3), Table-2 above. It may be noted that the total demand as projected in 16th EPS is based on Cumulative Annual Growth Rate (CAGR) of 6.2% while 17th EPS forecast is based on GDP growth of 8-10 %.

3.00.00 SUPPLY ESTIMATION (11TH PLAN) 3.01.00 Actual supply position from 02-03 to 05-06 is presented in Table-3 below:

Table-3 Actual supply position from 02-03 up to Dec.’06

Existing Capacity

Availability Financial year

(1)

(MW)

(2)

Energy (MU) (3)

Ex-Bus PLF (%)

(4)

Peak

(5)

Ex-Bus

(6)

2002-03 107877 497589 52.65 71547 66.32

2003-04 112683 519398 52.62 75066 66.62

2004-05 118425 548115 52.84 77652 65.57

2005-06 124258 578511 53.15 81792 65.82

April'06-Dec.’06 127925 465149 55.49 86425 67.56


It is observed from above that for period up to 2005-06 the average PLF has been from 52.6 to 53.15% while ex-bus peak has been from 65.6% to 66.6%.The average PLF and ex-bus peak availability for period from April’06 to Dec.’06 (the part year) has also been shown in above table for reference. Considering a further improvement in energy and peak both, estimation of energy and peak availability for 11th Plan has been worked out based on the factors of 55% and 70% respectively as majority of capacity addition is planned through large size units. The same is considered while working out availability at the end of 11th Plan as mentioned in Table-4 below:

3.02.00 Capacity addition during 11th Plan

The expected capacity addition in the country during 11th Plan is 78577 MW from under Construction and New Projects. The above capacity addition data has been considered based on the recent assessment by CEA on demand projection and generation Planning.

Table-4 Estimation with the addition of 78557 MW and enhanced performance in 11th Plan

Existing Capacity

at the End of 9th

Plan

Capacity at the End of 10th

Plan

Capacity at the end of 11th Plan

Availability at the end of 11th

Plan

Region

(1)

(MW)

(2)

Addition (MW)

(3)

Total (MW)

(4)

Addition (MW)

(5)

Total (MW)

(6)

Energy

(7)

Peak {col.

(6)*0.7} (MW)

(8) NR 28,092 7407 35,499 22359 57,858 278760 40501

WR 31,374 6293 37,667 19553 57,220 275686 40054

SR 27,099 4145 31,244 14518 45,762 220481 32033

ER 16,191 3080 19,271 17863 37,134 178912 25994

NER 2,241 229 2,470 4284 6,754 32541 4728

ISLAND 49 26 75 - 75 361 53

Total 105046 21180 126226 78577 204803 986741 143362

4.00.00 DEMAND & SUPPLY SCENARIO AT THE END OF 11TH PLAN

Demand & Supply Scenario at the end of 11th Plan with the addition of 78577 MW and enhanced performance in 11th Plan has been worked out and presented in Table-5 below:


Table-5 Demand & Supply Scenario at the End of 11th Plan

Availability at the end of 11th Plan

Demand As per EPS 17th Forecast Region

(1)

Energy (MU)

(2)

Peak (MW

(3)

Energy (MU)

(4)

Deficit/ Surplus

(%)

(5)

Peak

(MW)

(6)

Deficit/ Surplus

(%)

(7)

NR 278760 40501 294841 -5.45 48137 -15.86

WR 275686 40054 294860 -6.50 47108 -14.97

SR 220481 32033 253443 -13.01 40367 -20.64

ER 178912 25994 111802 60.03 19088 36.18

NER 32541 4728 13329 144.14 2537 86.35 ISLANDS 361 53 384 -5.90 88 -40.34

Total 986741 143362 968659 1.87 157325 -8.88

From the above, it is observed that the peak deficit still exists at the end of 11th Plan to the extent of 8.88%.

5.00.00 SUPPLY ESTIMATION (12TH PLAN)

The expected addition in the country during 12th Plan is 86500 MW from New Projects. The above capacity addition data has been considered based on the recent assessment by CEA on demand projection and generation Planning.

Table-6 Estimation with the addition of 86500MW and enhanced performance in 12th Plan

Existing Capacity

at the End of 9th

Plan

Capacity at the End of 10th Plan




(MW )

(1)

Addn. (MW)

(2)

Total (MW)

(3)

Addn. (MW)

(4)

Total (MW)

(5)

Addn. (MW)

(6)

Total (MW)

(7)

Energy {colmn.

(7)*0.55*8.760} (MU) (8)

Peak {colmn. (7)*0.7} (MW)

(9)

105046 21180 126226 78577 204803 86500 291303 1403498 203912.1


6.00.00 DEMAND & SUPPLY SCENARIO AT THE END OF 12TH PLAN

Demand & Supply Scenario at the end of 12th Plan with the addition of 86500 MW and enhanced performance has been worked out and presented in Table-7 below:

Table-7Demand & Supply Scenario at the End of 12th Plan


Demand As per EPS 17th Forecast Region

(1)

Energy (MU)

(2)

Peak (MW

(3)

Energy (MU)

(4)

Deficit/ Surplus

(%) (5)

Peak (MW)

(6)

Deficit/ Surplus

(%) (7)

All India 1403498 203912 1392066 0.821215 223662 -8.83

7.00.00 From the table - 5 & 7, it can be seen that there is overall peak deficit of 8.88% and 8.83% exist in the country in 11th & 12th Plans respectively. Also from table-5, it is seen that Northern Region in particular is expected to face both energy and peak power shortage of (-) 5.45% and (-) 15.86% respectively under 11th Plan.

The National Electricity Policy has set up the goal of adding new generation capacity to not only eliminate energy and peaking shortages but to have a spinning reserve of 5% in the system. Considering the above, Vallur Thermal Power Project (1x500 MW) (Planned to be commissioned in the 11th Plan) is, therefore, justified from demand supply consideration.


FEASIBILITY STUDIES

1.00.00 SITE SELECTION The present site for Vallur Thermal Power Project was selected as the most optimum among a number of alternatives examined during project planning of Stage-I, Phase-I based on the following considerations: Availability of suitable and adequate land Availability of coal and its transportation Availability of water Availability of infrastructural facilities Environmental aspects Road & Railway access A site selection team comprising of members from NTPC and TNEB officials had earlier inspected four alternatives and finalised the present site as the optimal site for setting up of the TPP.

2.00.00 LOCATION AND APPROACH Project Location : District : Thiruvallur, Tamil Nadu Latitude : 13012’ 45’’ N to 13014’30”N Longitude : 80017’ 0’’ E to 800 18’50”E Nearest railway station : Kathivakkam Distance of project site from the railway station

: 1 km

Rail region / zone : Southern Railway Nearest municipal town : Chennai Distance of the municipal town from the Project site

: 20 kms (Approx.)

Nearest commercial airport : Meenambakkam- Chennai Distance of airport from the project site

: 36 kms (Approx.)

Nearest Highway : NH-5 Distance from nearest Highway point to the site

4 kms (Approx.)

Vicinity plan The Vicinity Plan indicating the location of the plant, ash disposal area, colony etc. is placed at Exhibit-I

3.00.00 LAND About 1184 Acres of land has been acquired/ under acquisition for the project for the Srage-I,Phase-I of the project. However, 125 acres of land


for ash dyke and 15 acres of land for ash pipe corridor and road is to be acquired to cater the need of Stage-I,Phase-II.Break up of land is as follows :

Break up of Land Ph-I Ph-II

Plant area including green belt : 415 -

Ash disposal area : 500 125

Ash based units : 75 -

Township : 45 -

Corridors : 35 15

Others(Land area under CRZ includes 1.65 acres plot across Ennore creek )

114 -

Total land : 1184 140 4.00.00 WATER 4.01.00 Source, Requirement and Commitment

It is proposed to adopt closed cycle re-circulating type CW system for expansion unit similar to phase-I (2X500 MW) of the project by drawing makeup water for the project from intake channel of North Chennai Thermal Power Station. The total make up water requirement for 3X500 MW would be within 7.5 cumecs, already committed by TNEB during minutes of meeting dtd. 24.11.06. Sweet water requirement of the complete project is proposed to be met by provision of desalination plant. The plant capacity shall be augmented to take care of this expansion phase also.

5.00.00 FUEL (COAL) Coal Requirement, Availability and commitment

Coal requirement for Phase-II, 500 MW capacity of Vallur TPP, Satge-I shall be about 2.52 million tonnes/annum, considering GCV of coal (ash content not exceeding 34%) as 3900 kcal/kg, unit heat rate of 2447 Kcal/kwhr and PLF of 90%. SLC(LT)/MOC is being approached by NTECL for accord of additional coal linkage for Stage-I, Phase-II of the project. The addition coal unloading and transportation arrangement for the 3rd unit at Ennore port was discussed during the meeting dtd. 6.10.07 wherein it was informed that the capacity of the coal conveyor system at Ennore Port is 16 MTPA. It can be enhanced to 18 MTPA by improving the system. Thus, there will be a deficit in the system to the tune of 2.2 MTPA. Further, TNEB have plans to add 1X500 MW at NCTP, Stage-III and 1X500 MW at ETPS expansion. In view of the above, TNEB stated that one more additional coal berth at Ennore port is required to meet additional the existing conveyor BCN-40A/40B before JNT-50. However, TNEB agreed to meet requirement of 3rd 500 MW unit of NTECL from


existing coal berth subject to proportionate sharing of handling cost at the new berth at Ennore Port. Accordingly, no capital cost towards port augmentation facilities have been considered. The coal cost of Rs.1016.60 / MT including transportation cost of Rs. 501.80 / MT (as considered earlier in case of 2X500 MW) has been considered in FR for COE calculations. Coal Transportation The envisaged mode of coal transportation from the coal mines to the power plant is by Indian Railways rakes in BOBR/BOX-N wagons upto the port, thereafter by ships upto Ennore Port and from Ennore Port to the main plant by conveyor system.

5.01.00 Coal Quality The coal quality considered for FR is as follows:

Washed Coal Raw Coal

Total moisture 15-18% 12-15%

Ash 34+2% 36-46%

GCV (kcal/kg) 3800-4000 3200-3600

6.00.00 RAILWAY SIDING For bringing the equipment and material to the power house through rail route, the existing railway siding of North Chennai Thermal Power Station (NCTPS) is proposed to be used.

7.00.00 CONSTRUCTION WATER Raw water is proposed to be used for meeting the requirement of the project during construction stage. Metro Water Supply Authority (MWSA) has confirmed the allocation of 4 mgd water to the JV project

8.00.00 CONSTRUCTION POWER The requirements of the construction power supply for the project would be met from TNEBs existing source near NCTPS at 33/11 kV level. Necessary overhead lines, 33/11 kV substation/transformers and 11 kV ring main/ LT sub-stations shall be provided as per requirement.


LAYOUT SYSTEMS

1.00.00 GENERAL LAYOUT PLAN The General Layout Plan (Exhibit - II) for the project has been developed taking into consideration various aspects like available land & its shape, ground features & terrain, corridor for outgoing transmission lines, road/rail approaches, prevailing wind direction, the water drawl and the associated pipe corridor. The switchyard orientation has been planned taking into consideration the requirement of power evacuation. The main powerhouse is expanding from west to east, with permanent facilities like service building, located towards west of the main plant and workshop, O&M stores etc. towards east of the main plant, keeping expansion side free for construction activities. The ash slurry/ash water pump house is kept towards south of chimney. The intake/discharge ducts have been routed in the corridor between transformer yard and switchyard and location of CWPH is chosen, so as to minimize the length of CW ducts. Space provision for FGD has been kept towards south of main plant beyond chimney. The natural draft cooling towers have been located considering the safe distances from the switchyard and the main plant. The water treatment plant and the DM water facilities are located close to main plant and towards north-east of main plant. The coal handling plant and the coal stockyard are located towards south of the main plant. The CHP shall have provision for crusher house and stock yard with cross country conveyor from Ennore Port. . 100 M wide peripheral green belt has been identified for this project and also all available vacant space shall be used for plantation.

2.00.00 MAIN PLANT LAYOUT 2.01.00 INTRODUCTION

The main plant building arrangement for the proposed stage of the plant envisages longitudinal disposition of TG set. The main power house will be 117.0 m long and about 42 m wide consisting of TG bay and heater bay, which is in continuation of phase-I of the project. A road is provided along “A” row for handling generator stator. Common Service Building is envisaged at the start of unit # 1 of phase-I, which will cater for phase-II also. An interconnection walkway is also provided between Service Building and operating floor level in AB bay of phase-I for movement of personnel. Reference drawings for Main Plant Layout:

Sl. No.

Description Drawing No. Exhibit No.

1. Main Plant Layout Plan at EL (+/-) 0.00 m.

0261-999-POM-F-001 (Rev. a)

III

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2. Equipment Layout Plan at EL (+/-) (+) 8.5 m, (+) 16.5 m (+) 23.5 m, (+) 31.25 m, (+) 35.5 m

0261-999-POM-F-002 (Rev. a)

IV

3. Main Plant Cross-Section 0261-999-POM-F-003 (Rev. a)

V

2.02.00 DESCRIPTION OF LAYOUT 2.02.01 MECHANICAL AREA

AB Bay The layout envisages AB bay of width 32 m and floors at EL (+/-) 0.00 m, (+) 8.50 m, (+) 16.50 m. The operating floor of the unit is kept at (+) 16.50 m and the mezzanine floor is at (+) 8.5 m. Turbine driven boiler feed pumps (TDBFP) are located at operating floor and motor driven boiler feed pump (MDBFP) is located at mezzanine floor. The AB bay at EL (+/-) 0.0m would house other equipment like vacuum pumps, control fluid equipment, oil equipment for BFP and heat exchangers & pumps for closed cycle DM cooling water system. The three number condensate extraction pumps are to be located in the pit adjacent to turbo-generator raft at approximately EL (-) 4 m. The drain cooler and gland steam condenser are located at local platform or pipe mounted near B-row. Roof of TG hall is envisaged at (+) 37 m. Oil equipment for the Main Turbine is located at 0.0 m.

TURBINE HALL EOT CRANES Two (2) numbers Electrically Operated Travelling (EOT) crane are envisaged in turbine hall of phase-I of the project and the same shall be used for phase-II for erection and maintenance of turbo-generators (excluding generator stator) and their auxiliaries. The main hook capacity of crane is considered to be 5% over and above the heaviest component/ equipment (including lifting beam and slings etc.) to be handled in TG hall or at least 105 Tonnes (approx.) and the aux. hook capacity shall be 15 Tonnes (approx). Further, the turbine hall EOT crane will have necessary facilities such as lifting beam with swiveling arrangement and slings for erection as well as maintenance of the equipment provided in AB bay.

BC BAY The BC bay of width 10.0m would consist of floors at EL (+/-) 0.00 m, (+) 8.5 m, (+) 16.5 m, (+) 23.5 m/24.5m, (+) 31.25 m, (+) 35.5 m. The BC bay floor at EL (+/-) 0.00 m would house LP/HP dosing system equipment, condensate polishing unit, SWAS room and fire fighting (inert gas) cylinders. The floor at EL (+) 8.5 m would house LP heaters. The HP heaters are to be located at EL (+) 16.5 m. The floor at EL (+) 23.5/24.5 m would house Air Handling units and Ventilation equipment rooms. The floor at EL (+) 31.25 m has been planned for Auxiliary Steam Pressure Reducing De-super-heating Station, Control Station of feed water system


and Cooling Towers for AC system. The Deaerator is to be kept at EL (+) 35.5 m.

BOILER AREA Boiler, air pre-heater, ID/FD/PA fans, ESP, mills and chimney are located with tentative dimensions as indicated in layout drawing. Mills have been located on the side of the Boiler. Approach roads/ passages have been identified on the side of Mill/Bunker bay. Passageways have also been identified between Mill bay & ESP and between ESP & ID fans. Distance of 12 m between C-row (last row of powerhouse columns) and D-row (1st row of Boiler columns), has been kept to facilitate the movement during erection and operation phase of the plant. C-D Bay is also used to route Critical Piping from Boiler to TG set. Two elevators - one for passengers and one for goods have been envisaged for each Boiler. The main conveyor shall be located at the start of the Unit # 1 of phase-I. Two no. coal handling transfer towers shall be provided in boiler area feeding to mill/bunker bays of each unit with cross conveyors. Ash handling facilities such as Ash Slurry Pump House, Control Room / Switchgear room / Transformers, Ash Water Pump House, BA Overflow Water Settling Tanks and Transport Air Compressor House are located along the road behind chimney. All these Ash handling facilities are common for phase-I and phase-II of the project. The ESP/VFD control room for ID fans and MCCs for ESP alongwith air conditioning and ventilation equipment for the same are envisaged to be located in ESP Control Room. ESP Control Room for unit # 3 is located by the side of chimney. Air conditioned space for locating the remote I/O cabinet has been identified in boiler area for steam generator equipment and near first/last row of ESP for ash handling plant equipment.

AIR COMPRESSOR AND CPU Air Compressors for instrument air and service air requirement shall be installed in a separate building in transformer yard near service building. The regeneration facility for CPU is proposed to be located at the start of Unit # 1 near TG bay. All these facilities are common for phase-I and phase-II of the project.

2.02.02 ELECTRICAL AREAS AB Bay: Electrical switchgears and MCCs of the unit are located in the electrical annexe located at the start of unit in AB bay. The 11 kV/ 3.3 kV switchgear along with DC Batteries are to be located at (+) 3.5 m floor elevation. 415 V switchgears, DC distribution board and Battery Chargers are to be located at (+) 12.0 m floor elevation of the electrical annexe. Since all the switchgears are envisaged to have bottom entry cables, two cable spreader rooms have been envisaged, from EL (+/-) 0.00 m to (+) 3.5 m and other from EL (+) 8.5 m to (+) 12.0 m. Boiler MCC have been located in B-C bay at EL (+) 27.0 m with a provision of cable spreader room at EL (+) 23.5 m.


TRANSFORMER YARD/BUSDUCTS/MCCS Three (3) single phase Generator Transformers (GT) alongwith a Unit Transformers (UT), two (2) Unit Auxiliary Transformer (UAT) and one (1) number station transformer (ST) for each of the unit are located in front of A-row in the transformer yard. One number spare Generator Transformer, provided for phase-I shall also be used for phase-II, as shown in the layout drawing has also been provided in transformer yard area. Necessary road has been provided outside A-row for the generator stator handling. Stator handling can be accomplished without disturbing the transformers. Separate rail tracks have been envisaged for handling GTs and STs. Bus ducts have been considered for connecting Unit and Station Transformers to respective 11 kV switchgears. The bus duct from the Unit Auxiliary and Station Transformers to the switchgears inside electrical annexes would be supported below the floor at EL (+) 8.5 m and would drop down to the switchgears from above. DG sets are located in transformer yard in a separate room.

2.02.03 CONTROL AND INSTRUMENTATION The Unit Control Room for the present stage has been envisaged at the start of unit # 3 in B-C-D bay at operating floor level. Control Equipment Room (CER) is envisaged to be unitized and shall be located in B-C-D-E-F bay at operating floor level and in D-E bay at mezzanine floor level. The control room houses the control desk and control station for certain off site facilities also. Air conditioning room for Central Control Room/CER alongwith its MCC has been located in Service Building at E L (+/-) 0.0 m. UPS and C&I batteries are located at 8.5 m of B-C-D bay. SWAS room shall be located at EL (+/-) 0.00 m of BC bay. Necessary cable shafts have been provided at B-row/C-row for routing of power cables in the Electrical Bay and Control Equipment area.


CIVIL SYSTEMS

1.00.00 LAND DEVELOPMENT The project site is having backwaters on its East side namely Ennore creek. The topography of the proposed power plant site is generally sloping towards backwaters. In order to establish the plant formation level, a comprehensive area drainage study was carried out. Accordingly, the plant formation level of RL(+)4.10m has been considered in FR. Since the existing ground levels are generally in the range of RL(+) 1.0m to 1.5m and accordingly filling to raise the ground level shall be necessary. Filling shall be achieved by ash available in the vicinity and other suitable filling material from borrow areas. Following are the formation levels for the various blocks.

Main Plant RL(+) 4.10 m

Cooling Towers RL(+) 4.10 m

Track Hoppers RL(+) 4.10 m

Coal Stacks RL(+) 4.10 m

WTP RL(+) 4.10 m

Switchyard RL(+) 4.10 m

F.O. Area RL(+) 4.10 m

2.00.00 GEOTECHNICAL DATA & FOUNDATION SYSTEM 2.01.00 Geotechnical Investigation

Detailed geotechnical investigation is carried out at the proposed plant and ash disposal area. Based on field data, the strata comprises of very soft to soft highly plastic clay from top surface to 6 – 8m depth with pockets of silt and sand found occasionally. This is underlain by medium to dense silty sand and hard clay alternating layers upto 30m depth. The ground water table is varying from 0.5 to 1.0m below ground level at the time of investigation. Based on the detailed geotechnical investigation data, it is apprehended that the top soil of about 6.0 to 8.0 m is in soft condition and needs ground improvement. The chemicals in ground water are more than permissible limits. Sulphates and chlorides in ground water are 1500 to 3500 ppm & 15000 to 46000 ppm respectively. Based on the soil data, all heavily loaded structures shall rest on pile foundations and lightly loaded structures shall rest on open foundations on improved ground. The same shall be confirmed during detailed engineering. Piles shall be of bored cast-in-situ type with 600mm dia of 140 T capacity and 760 mm dia of 250 T capacity. Pile length shall be of


26 to 28 m for 600 mm dia and 31 to 33 m for for 760 mm dia. Minimum grade of concrete for piles and other foundations shall be M30. The borehole data indicates that a part of top soil strata may cause dragdown force or negative skin friction on piles.

3.00.00 MAIN PLANT BUILDING 3.01.00 Foundation System

1. All major foundations of equipment and structure shall be supported on pile foundation.

2. Turbo Generator (TG), ID, PA & FD Fans shall be supported on a RCC top deck, which shall rest on steel helical spring units and viscous dampers.

For TG foundation, steel helical spring units & viscous dampers shall be supported on an RCC, framed sub-structure. The sub-structure shall be supported on a base-mat. Steel helical spring units & viscous dampers for ID, PA, & FD Fans shall be supported on RCC sub-structure which in turn shall be supported on base raft with piles. The Turbine Driven Boiler Feed Pump(TDBFP) and Motor Driven Boiler Feed Pump(MDBFP) shall be supported on RCC deck which shall rest on steel helical spring units & viscous dampers, which in turn shall be supported on steel beams resting on the main power house columns and the auxiliary columns. The mill foundation shall consist of RCC block supported on pile foundation.

3.02.00 Structural System 1. Main Power House The building shall be multi span framed structures consisting of structural steel columns, beams and trusses. This shall be braced in longitudinal direction and moment resistant in transverse direction. Main power building shall comprise of turbo generator (AB) bay and multi-level heater (BC) bay. Control room shall be located in BC bay & control equimment room shall be located in CD bay of control tower.All platforms and floors shall be supported on structural steel. 2. Mill / Bunker Building Mill / bunker building shall be single span multi-storyed framed structure consisting of structural steel beams, columns and bunkers. The building shall have floors at feeder location and tripper location. Mill and bunker building shall be braced in longitudinal as well as in transverse direction. Hoppers shall be made of steel with stainless steel liner. The bunker shall be of MS . 3. Conveyor Galleries and Transfer Points Overhead conveyor galleries in the main plant (boiler area) shall be of structural steel frame with cladding and roofing. Seal plate shall be


provided for full length. Transfer points and intermediate supporting trestles shall be made of braced steel framed structures. The staircase shall be of external type. 4. Cable and Pipe Racks

(a) Structural steel trestles and galleries with provision of walkway with chequered plate/grating shall be provided for supporting overhead cables and pipes in the main plant and outlying areas. However, for below ground routing, RCC trench with removable pre-cast concrete covers / box culverts shall be provided.

(b) Pipes and cables running along the boiler structure, mill & bunker buildings and ESP structures etc shall be supported on steel beams resting on the steel bracket fixed to the boiler/ ESP / mill & bunker building structures.

(c) Pipes & cable running between boiler and C-row will be supported on the steel girder/beam resting on the steel brackets from C-row columns. These steel girders shall have sliding joint on main powerhouse and fixed / hinged on boiler structure.

(d) Pipes & cable running along C-row will be supported on the steel truss /beam resting on steel frames/brackets from C-row Column.

5. Other Buildings ESP control, CPU regeneration, DG set, air washer and other similar buildings located in power block shall be of framed structure.

3.03.00 Civil Concepts Roof of TG hall shall be provided with colour-coated metal deck sheet over which a RCC layer shall be laid. Further skylight shall be provided for natural light. Roof of other buildings i.e., deaerator, control tower, bunker building, etc, shall be provided with the metal deck sheet and / or RCC depending upon the clear height of the roof. Intermediate floors of all buildings including main powerhouse building shall be provided with cast-in-situ RCC slab. External cladding of all buildings shall have combination of brick work, metal cladding, aluminium composite panel & glazing. For main plant building initial height of 3 m along A-row and C-row and gable ends shall be provided with brick wall followed by colour-coated metal cladding and glazing in combination with aluminium composite panel. Control room area shall have brick wall on external face. Internal partitions shall be provided with glass reinforced gypsum plaster board/ brick wall /decorated veneer in aluminum framework. However control room internal partitions shall be provided with single or double glazing in aluminium framework.


Roof shall be provided with elastomeric membrane or other suitable water proofing treatment. Windows shall generally be of aluminum. Doors of control room and office area shall be of aluminium frame with glazing or particle board panels. Wherever desired (especially for Control room area) large glass panels with automatic door operation and in reflective glass shall be provided. All fire exits shall be provided with fire proof doors. Hollow metal doors shall be provided for switch-gear room, cable vaults etc. Entire area from transformer yard to chimney shall be provided with paving in combination with interlocking concrete blocks and high wearing resistant concrete. In view of proximity of sea all structural steel shall be provided with suitable coating / painting.

3.04.00 Architectural Concepts Main plant building shall be architecturally treated in such a way that it retains a monumental scale and yet, presents a pleasing composition of mass and void with suitable and functionally designed projections and recesses. The overall architectural character of the plant buildings shall be in harmony with the natural character of the environment. Due considerations shall be given to climatic conditions, landscape design, building orientation, interior design. All finishes for floors, walls, ceiling, structural elements, partitions for offices and industrial areas shall be suitable for their aesthetics, durability and functional requirements and shall include the latest building material & technology. Architectural elevations of main plant or other buildings, may have curve, arches or simple straight lined profiles. For natural and uniform distribution of light, roof lights and adequate glazing shall be provided in all buildings.

4.00.00 CHIMNEY One single flue steel lined reinforced concrete chimney(s) shall be provided. The flue gas emission point shall be 275 metres above the plant grade level. The RCC for the chimney shell and other super structure shall be of M-30 grade and for foundation & grade level slab it shall be of M-25 grade. Liner(s) shall essentially be constructed from structural steel and shall be of the hung type (with multiple point liner support) system. The liner(s) shall be provided with resin bonded wool type thermal insulation. The portion of the liner(s) projecting above the chimney roof, however, shall be constructed of shaped acid resisting bricks. Brick liner shall be protected by a reinforced concrete mini-shell also constructed from the roof slab. Suitable expansion joints shall be provided between the steel and the brick liner(s). Internal platforms shall be provided for enabling access to various elevations of the stack and to provide support to the steel liner(s).


There shall be at least one metre working space around the flue(s). External platforms shall also be provided. The structural steel transition inlet ducting shall be bottom supported. This transition ducting shall be suitably profiled from a rectangular shape at the chimney inlet to a circular shape up inside the chimney where it shall be connected to the suspended circular steel liners through suitable (non-metallic) fluroelastomeric fabric expansion joints. Transition ducting shall also be thermally insulated. Internal platforms shall be of structural steel construction. The chimney roof shall, however, comprise of a reinforced concrete slab supported over a grid of structural steel beams. The external platforms shall be of reinforced concrete construction of grade M-30. An internal structural steel staircase, supported from the shell wall, shall be provided for full height of the stack. Suitable embedments shall be provided in the shell wall for this purpose. An internal ladder shall be provided having its support from the concrete shell inside the chimney and shall be provided for a small height, over the last staircase landing, to access the chimney roof through a roof access hatch. External ladders shall be provided on each of the mini-shells over the roof. The flooring panels of the platforms and treads of the staircase shall be of chequered plate construction. Handrails for platforms and staircase shall be of tubular construction. The external portion of the wind shield shall be coated with alternate bands of red and white colours to meet the aviation safety requirements. The mini-shells and the top few meters of the internal surface of the windshield shall be painted for acid and heat protection with bituminous paint. The other components of the chimney include cast iron caps over mini-shells, liner test ports (for continuous pollution monitoring), liner hatches, reinforced concrete roof slab protected for acid and heat protection, grade level slab of reinforced concrete with a metallic hardener floor finish, a large electrically operated grill type roll-up door (with only the bottom small portion of the curtain of solid shutter type) at grade level and personnel access metallic doors at grade level and at all floors, a personnel access hatch in the roof slab, rain water drainage system, flue liner drainage system, roof drain basin, louvers with bird screens for ventilation openings and all gaps in the wind shield, mild steel discrete strakes, painting of chimney shell surfaces and painting/coating of all structural steel work and miscellaneous ferrous components (for a maintenance free life of at least ten years), all finishing works, electrical power, distribution boards, lighting panels, power and control cabling and wiring systems, cable conduits, stair and platform lighting, socket outlets, lightning protection and grounding system, aviation obstruction lighting, communication system and a rack and pinion elevator. The chimney shall have a suitable foundation.


5.00.00 WATER TREATMENT SYSTEMS CIVIL WORKS Capacities of various facilities have been increased to cater for an additional 500 MW unit.

6.00.00 CW & MAKE UP WATER SYSTEM 6.01.00 CW System

The CW system envisaged for the proposed project is closed cycle system with Natural Draft Cooling Towers. The CW system consists of an intake RCC channel, CW pump house, steel lined concrete encased supply & discharge ducts. For the additional unit of 500 MW, the proposed size of the CW channel shall be increased suitably. Further, additional length of the channel shall also be required to be provided emanating from the CT of unit # 3. One additional steel lined concrete encased supply & discharge duct shall also be provided. The proposed CW pump house for the 2 x 500 MW shall house 1 no. additional circulating water pump for additional 1 x 500 MW. Accordingly, one additional pump bay shall be provided. The substructure shall be of RCC grade M-30. Additional trashrack shall be provided in the additional pump bay for arresting trash entering the pump bay. The trash rack shall be provided with anti-corrosive coating. The superstructure of the pump house (for additional pump) shall be of structural steel with metal sheet cladding. The roof of the pump house (for additional pump) shall have permanent steel deck with cast-in-situ RCC laid over it. The additional CW pump shall pump cold water to condenser and hot water from the condenser to the cooling tower through steel lined concrete encased CW duct. The duct shall be 3200 mm internal dia. The steel liner shall be suitably coated / painted internally against corrosion protection due to sea water application. The cold water from cooling tower shall flow by gravity to the CW pump house through RCC open channel (increased size). The grade of concrete for RCC channel shall be M-30.

6.02.00 Make-up Water System The 2 x500 MW pump house is proposed to be increased to cater for additional unit of 1 x 500 MW.

7.00.00 COAL HANDLING SYSTEM 7.01.00 Crusher House

Crusher house shall be of structural steel with permanently colour coated steel sheet cladding. Floors and roof slabs shall be of RCC. Crushers shall be supported on RCC deck slab which in turn will rest on vibration isolation system consisting of springs & dampers. Ironite flooring has been considered for floors. Pile foundation have been considered for column foundations.


7.02.00 Transfer Points Transfer points shall be of structural steel with RCC floors/roof and shall have permanently colour coated steel sheet cladding. Floors shall be provided with ironite finish. Pile foundation are envisaged for column foundations.

7.03.00 Conveyor Galleries Conveyor galleries shall be of structural steel with trestles at regular intervals. These shall have permanently colour coated steel sheets as side & roof cladding. Pile foundation have been envisaged for trestle foundations.

7.04.00 CHP Control Room & MCC Rooms These shall be RCC buildings with brick wall enclosures. Civil & structural works associated with TPs, CH, S/R foundation, stockyard drainage, conveyor galleries, PH & CHP control bldg. are proposed to be included in the scope CHP mechanical package.

8.00.00 FUEL OIL HANDLING SYSTEM The 2 x500 MW facilities are enough to cater for additional unit of 1 x 500 MW.

9.00.00 ASH HANDLING SYSTEM & ASH WATER RECIRCULATION SYSTEM The Civil works involved in ash handling system are as follows:

• Ash Water Pump House.

• Ash Slurry Pump House

• Transport Air Compressor House

• Ash water recirculation Pump House

• Switch gear/MCC and Control Room for all buildings

• Silo area utility building

• Silo foundation

• F A Slurry Trench

• Bottom Ash Slurry Pump House.

• Vaccum pump house/Conveying air compressor house

• Pedestals/Steel Trestles for supporting Ash Slurry Piping and dry fly ash transportation pipe upto silos near plant boundary.

• RCC pedestals for supporting ash disposal pipes

• RCC pedestals for supporting ash water recirculation pipe.

• Bottom ash slurry pipe pedestals

• Miscellaneous works like Transformer Foundation, Fencing, Paving etc.


• Miscellaneous structures/ Foundation for buffer hopper Tower and Collector tank Tower

• Maintenance Road However, these all these facilities are common for both 1x500MW+2X500MW units. All pump houses and other buildings shall have RCC framed structural arrangement with brick cladding & metal deck roofing filled with RCC. For routing of the ash pipes at road crossing local hump / culvert or bridges shall be provided. All super-structure work related to dry ash handling (including silos, buffer hopper, collector tank) and bottom ash handling are included in mechanical package.

10.00.00 ASH DISPOSAL SYSTEM Ash disposal for 2X500 MW + 1X500 MW will be common. For the ash disposal system, about 546 acres of land is available for ash disposal. The land is almost flat. The ash disposal area is planned with a total usable area of about 491acres. The balance 55 acres of land is identified for ash pipe line corridor, toe drain, road around ash dyke, an overflow lagoon and recirculation system facilities. In this project, (assumed to be operating at an average PLF of 90 percent), about 64.62 million cu.m. of ash is expected to be produced in 25 years. However, as per MOEF notification, 100 percent fly ash utilization is to be achieved progressively within 9 years of plant commissioning. This translates to average fly ash utilization of 82% for 25 years of project life. Accordingly, in the design life period of 25 years, about 12.92 million cu.m. of bottom ash and about 9.31 million cu.m. of fly ash (total 22.23 million cu.m) will have to be disposed off. Balance quantity of 42.39 million cu.m. of fly ash (ie 82% of fly ash produced) will have to be utilized. In the available land for ash dyke, 19.46 million cu.m capacity ash pond can be constructed. For this, two storage lagoons and one common overflow lagoon with a dyke of maximum 14.3 M height will have to be constructed. The ash dyke shall comprise of a starter dyke of maximum 8.3 M height and two subsequent raisings of 3.0 M each using ash. In order to cater for balance ash disposal of 2.77M Cu.m additional ash disposal area of about 125 acres needs to be acquired. The ash dyke shall comprise of a starter dyke of maximum 9.3 M height and one subsequent raisings of 3 .0 M using ash. Since location of additional ash disposal area is not known at this stage, it is assumed that the same will be located in 3.0 km radius from the plant. About 15 acres of land will be acquired for ash pipe corridor and road. The decanted water may have higher TSS since land available is less. In view of above entire water shall be re circulated to plant.


In case fly ash utilization as mentioned above is not achieved, then additional land shall be required, depending on the extent of ash utilization. Geotechnical investigation of the ash dyke area indicates that the top layer of existing strata consists of soft clay up to depth of about 4 to 8 m. Hence, for the foundation of ash dyke embankment, stone columns of about 900 dia and about 7.0 M length will be necessary for ground improvement. With this, the maximum height of dyke above ground level up to which dyke can be raised is 14.3 meters. To avoid fugitive ash dust emission and for promoting vegetation cover, the final ash surface will be covered with 300 mm thick earth cover. Coal parameters for ash generation are as follows:

G C V : 3900 K cal/ Kg.

Heat Rate : 2450 K Cal/ KWhr.

Ash content : 34 %

Density of Hydraulically deposited ash

: 1.0 T/ Cu m

Ash generation : (For 3X500 MW)

Total ash production in 25 years

: 64.62 million cu.m

Bottom ash generation : 12.92 million cu.m

Fly ash generation : 51.70 million cu.m

FLY ASH UTILIZATION AS PER MOEF

: 42.39 million cu.m

% utilization : 2.0 %

CAPACITY OF ASH POND A : 19.46 million cu.m

CAPACITY OF ASH POND B : 2.84 million cu.m

11.00.00 ROADS, DRAINS & SEWERAGE 1. Roads All major roads shall be two-lane (7.0/7.5 m wide), with 2.5/2.25 metre wide shoulders on both side. However, approach road to individual buildings and patrol road along plant boundary shall be single lane (3.75 m wide with 1 m wide shoulders on both sides).


2. Drains Drains shall be constructed on both sides of roads and shall be connected to the trunk drain, which finally gets connected to the nearby natural drainage system. All drains shall be of RCC with rectangular section. 3. Sewerage A network of underground sewerage system shall be provided in the plant area. CI pipes shall be used for catch pipes and RCC concrete pipes shall be used for trunk sewage disposal pipes. However, CI pressure pipes shall be used for disposal under pressure.

12.00.00 SWITCHYARD CIVIL WORKS The civil and structural work for switchyard bays shall be provided as per switchyard single line diagram. Towers shall be supported on pile foundations and equipment such as BPI, LA, CT, CVT, CB, isolator etc as shown in switchyard single line diagram shall be supported on isolated/combined foundations or piles as required.

13.00.00 PERMANENT TOWNSHIP A permanent township is being constructed under Stage-I, Phase-I of the project wherein necessary dwelling units, non residential buildings and other bulk facilities are being developed. For the expansion unit, necessary augmentation of dwelling units and other facilities have been proposed.


MECHANICAL SYSTEMS 1.00.00 STEAM GENERATOR AND AUXILIARIES 1.01.00 General

The Steam Generator (SG) shall be drum type (natural or assisted circulation) or sub-critical once through water tube, single/double pass (tower type/two pass type), direct pulverised coal fired ,single reheat, radiant, dry bottom type, balanced draft furnace, suitable for outdoor installation, top supported, having sub-critical steam parameters with all necessary auxiliaries. Boiler design shall also be suitable for variable pressure operation from 30% to 100% BMCR with 15% throttle margin. The main parameters at 100% MCR will be as follows:

1. Main steam flow at superheater outlet

: 1590 T/Hr

2. Pressure at superheater outlet : 179 kg/cm2(abs)

3. Temperature at SH outlet : 540 deg C

4. RH steam flow : 1353 T/Hr

5. Steam temperature at reheater outlet : 568 deg C

6. Feed water temperature at economizer inlet

: 255 +/- 5 0C

1.02.00 Furnace The furnace will be radiant, dry bottom type with tangential or opposed wall firing and enclosed by water cooled and all welded membrane walls. The furnace bottom shall be suitable both for installation of water impounded bottom ash system and submerged scrapper chain conveying system. Spray type attemperator is envisaged to control the superheater outlet temperature for varying loads. The superheater and reheater tubes will be a combination of radiation and convection type. Economizer will be non-steaming type and shall be of modular construction.

1.03.00 Steam Generator Circulation System (For once through boiler)

The steam generator start up system envisages boiler start up drain system with start up drain circulation pump. Separator(s) will be used for start up as well as separating the steam water mixture upto a load of 30% BMCR, above which it will be running dry. Lower part of furnace/ water wall will consist of vertical plain/ rifle tubes or wrap around/ helical tubes. (For Drum type boiler) The steam generator water circulation system shall be either controlled circulation concept or natural circulation concept.


In controlled circulation system, the water circulation shall be controlled through the water circulation pumps so as to make up for reduced available differential head between steam and water owing to high operating pressure of the boiler. Rifled tubing shall be used for water wall tubes in the high heat zones to keep the minimum circulation required at lower loads and limiting the Departure from Nucleate Boiling (DNB). There shall be 3x50% steam generator water circulation pumps, complete with drive motors, high pressure coolers, purge & fill system, emergency cooling system for individual pump. In natural circulation boilers, rifled tubing shall be used in all the high heat zones of the boiler water walls to avoid the onset of DNB. Economizer re-circulation system shall be provided to protect the economizer tubes under startup and low load conditions, for both natural as well as controlled circulation boilers.

1.04.00 Air and Flue Gas System A balanced draft system will be provided. There will be two axial FD fans and two radial ID fans & two (2) pairs of regenerative rotary type bisector air pre-heaters. One pair of air peheater will be used for primary air system & second pair for secondary air system. Four (4) numbers of steam coil air pre heaters -two on primary and two on secondary air system will be provided for start-up, low load operation or abnormal conditions when an increased air inlet temperature is considered desirable to minimize the cold end corrosion of regenerative air pre-heaters.

1.05.00 Fuel Oil Burning System Start-up, warm up and low load (upto 30%) carrying shall be done by heavy furnace oil/HPS/LSHS. Boiler will be so designed that oil firing for flame stabilization will not be required beyond 30% MCR. Necessary pumps, filters and heaters will be provided. For coal firing the entire operation of purging, insertion, air and fuel sequencing removal and blow off shall be automatic. Ignition of heavy oil shall be directly by high energy arc igniters. There shall be light oil (LDO) firing at least in one burner elevation having a minimum capacity of 7.5% BMCR to facilitate a cold start-up of the unit when no auxiliary steam is available for HFO heating and atomization. LDO system shall be sized for 7.5% BMCR capacity for each boiler.

1.06.00 Coal Burning System The coal burning system will comprise of coal mills of vertical spindle type which include (a) bowl mills, (b) roller mills, (c) balls & race mills or any approved equivalent. The number and capacities of the mills shall be so selected that while firing the worst and design coals at BMCR/ TMCR, the following spare capacities shall be ensured. 1. With 90% mill loading of the working mills, atleast one mill will be spare

while firing the worst coal at 100% BMCR. 2. With 90% loading of the working mills atleast two mills will be spare at

100% TMCR load with worst coal firing.


3. With 90% mill loading of the working mills, atleast two mills will be spare while firing the design coal at 100 % BMCR.

Coal from raw coal bunkers will be fed into the mills by belt driven gravimetric coal feeders suitable for handling moist coal. There will be two axial P.A. fans for transporting the pulverized coal from mills to burners.

1.07.00 Soot Blowing System Fully automatic, sequentially controlled, microprocessor based steam soot blowing system, complete with provision for individual operation of any soot blower pair, operation and facility to bypass any soot blower, will be provided. The system will have short retractable rotary wall blowers for the furnace and long retractable rotary blowers for the superheater, reheater and economizer.

1.08.00 Auxiliary Steam System The unit will be provided with two auxiliary PRD stations i.e., high capacity and low capacity PRDS taking their steam tap-offs from MS line and CRH line respectively. The high capacity auxiliary PRDS will be designed for a minimum capacity of 100 T/hr. Low capacity auxiliary PRDS will be sized for minimum 20 T/hr. capacity and will be operated during the normal operation of the unit. Auto-change over between the low and high capacity aux. PRDS stations depending on the station auxiliary steam requirement is also envisaged. The unit will have its own auxiliary steam header whereas for station services common station auxiliary steam headers taking its tap off from the unit auxiliary PRD station will also be provided. The provision will also be made for interconnection with units of NTECL Power Project (2X500MW). A high temperature unit header {16 kg/cm² (a) and 310°C} by taking steam from above PRDS station and also a low temperature unit header {16 kg/cm² (a) and 210°C} by taking steam from high temperature unit header through a desuperheater shall be provided.

1.09.00 Elevators One (1) number passenger cum goods elevator of capacity 3000 kgs. & One (1) number passenger elevator of capacity 1088 Kgs shall be provided for the steam generator. Further, one (1) number passenger elevator having capacity of carrying eight (8) persons shall be provided for ESP control room.

1.10.00 Electrostatic Precipitator It is proposed to install high efficiency electrostatic precipitator having an efficiency that limits the outlet emission to 100 mg/Nm3 while the boiler is operating at its MCR, firing worst coal having maximum ash content. The electrostatic precipitators will have four (4) parallel gas streams, isolated from each other on the electrical as well as gas side and will be provided with gas tight dampers at inlets and outlets of each stream, so as to allow maintenance to be carried out safely on the faulty stream, while


the unit is working. ESP specific collection area shall not be less than 200 m2/m3/sec. at 100% BMCR. Electrostatic precipitator will be provided with microprocessor based programmable type rapper control system and ESP management system to ensure the safe and optimum operation of ESP. ESP transformer rectifier sets will use high flash point oil as the cooling medium. The dust collection hoppers at all strategic locations will have a minimum storage capacity of eight (8) hours. The hoppers will have heating arrangements to prevent ash sticking to the sloping sides and down pipes. Level indicators to indicate and trip the ESP in case of high ash levels in the ash hoppers are also envisaged to ensure safety of ESP. In order to limit the particulate emission to specified levels even under contingency such as wide variations in the coal properties etc., it is proposed that installation of Flue Gas Conditioning (FGC) shall also be explored to function in association with ESPs as stipulated above. However, final selection shall be based on techno-economic consideration.

1.11.00 Provision of future installation of Flue Gas Desulphurising (FGD) System Space provision for the FGD system, to be installed in future (if required), shall be kept behind the chimney. The design and layout of steam generator and its auxiliaries will be such that a wet/dry flue gas desulphurisation system can be installed in future, taking suction from duct after ID fan and feeding the desulphurised flue gases back to the chimney with provision for bypassing the FGD system.

1.12.00 Chemical Dosing System Chemical dosing system complete with preparation and metering tanks 2X100% of capacity dosing pumps , connecting piping , valves and fittings will be provided to control the quality of water at the steam generator.

1.13.00 Environmental and Efficiency Considerations In order to meet the environment norms and maintain the sustained efficiency of ESP, it shall be adequately designed with sufficient margins for all operating conditions. The Electrostatic Precipitator Management System (EPMS) in conjunction with opacity monitor shall continuously monitor and maintain the optimum energy level to achieve higher efficiency of ESP. The steam generator shall be designed for low NOx formation by adopting the appropriate burners. The boiler will meet the requirement of sustained high efficiency and availability, high efficiency at part load, flexibility to burn coal within the range specified, quick startup and two shift operation. Furnace shall be sized for burning high ash coal and low flue gas velocities to minimize erosion.

2.00.00 TURBINE AND ITS AUXILIARIES The scope of TG unit of 500MW shall broadly cover the Steam Turbine along with its integral systems and auxiliaries like lube oil system, control-fluid system, condenser, condenser air evacuation system, HP&LP Bypass system, complete regenerative feed heating system, condensate


pumps along with their drives, boiler feed water pumps along with their drives, automatic turbine run-up system, instrumentation and control devices, turbine supervisory instruments, turbine protection and interlock system, automatic turbine testing system.

2.01.00 Steam Turbine The steam turbine shall be tandem compound, single reheat, regenerative, condensing, multi cylinder design with separate HP, separate IP and separate LP casing(s), OR combined HP-IP and separate LP casing(s), directly coupled with the generator suitable for indoor installation. The plant would be designed to operate as a base load station. However, continuous operation under two-shift and cyclic modes during certain periods of the year is also envisaged. The turbine design shall cover adequate provision for quick start-up and loading of the units to full load at a fast rate. Apart from constant pressure operation, the turbine shall also have the facility for sliding pressure operation. The turbine shall be provided with suitable margins for VWO flow. The steam turbine shall conform to the following design and duty conditions:

1 Output under Economic Maximum continuous rating (EMCR) (Guarantee output load) at generator terminals with cycle make up of 3% of throttle steam flow and design condenser pressure.

: 500MW (in case of static excitation system, the EMCR output at generator terminals shall be 500MW plus excitation power requirement at EMCR).

2 Turbine throttle steam pressure

: 170 kg/cm2 (abs)

3 Turbine throttle Main steam/ Reheat Steam temperature.

: 537 oC/565 oC

4 Variations in rated Steam temperature & pressure

: As per IEC-45.

5 Pressure drop in reheat circuit i.e between HPT Exhaust & I PT inlet.

: 10% of HPT exhaust pressure.

6 Condenser pressure Design/ Maximum

: Design later/Max-89 (mm Hg abs)

7 Turbine speed : 3000 rpm

8 Frequency variation range from rated frequency of 50 Hz

: (+) 3% to (-5%)(47.5HZ to 51.5HZ)

9 DM Water make up to thermal cycle under EMCR condition.

: 3% of throttle steam flow


10 Final feed water temperature for heat rate (HR) guarantee point & EMCR condition.

: 253 +/- 5 Deg C

11 Turbine protection against water induction.

: As per ASME-TDP-1(latest)

12 No. of extractions for regenerative feedwater Heating

: As per cycle optimisation by the bidder.

2.02.00 Condenser

Sea water cooled single pass or double pass condenser with Titanium B-338 Gr-II tubes, shall be adopted. The condenser shall be with divided water box construction. It shall be horizontal, surface type with integral air cooling section. Condenser hotwell shall be sized for three (3) minutes storage capacity (between normal and low-low level) of total design flow with the turbine operating at V.W.O condition, 3% make-up, design back pressure. The condenser shall be adequately sized to cater to all the conditions of turbine operation including the abnormal operating conditions such that condenser would not be a bottleneck at any stage of operation. The exact condenser parameters shall be optimised on the basis of site data and most economical combination of cooling surface and circulating water quantity. The condenser shall be designed, manufactured and tested in accordance with the latest applicable requirements of the Heat Exchange Institute(HEI), USA. Provision of separate sponge rubber ball type condenser on-load tube cleaning system for each half of the condenser including ball circulation pumps, strainer, ball monitoring system etc. shall be made.

2.03.00 Debris Filters Two self cleaning type half capacity debris filters at the inlet to each condenser, complete with backwash system, associated piping system, instrumentation & control. Each debris filter should be sized for atleast 60% of the design flow through each condenser.

2.04.00 Air Extraction System Each unit shall comprise of (2x100%) vacuum pumps along with all accessories and instrumentation for condenser air evacuation. The vacuum pumps and accessories shall be used to create vacuum by removing air and non-condensable gases from steam condenser during plant operation. Vacuum pumps shall be of single/two stage liquid ring type with both stages (if two-stage pump is selected) mounted on a common shaft. Vacuum pumps shall be sized as per latest HEI requirements.

2.05.00 Lube Oil System Each turbine generator shall have a complete self contained lubrication oil system. The system shall cater to the lubrication requirements of the


bearings, requirements of turbine turning gear during start-up and shutdown and jacking oil requirement during turning gear operation. In addition, it shall also supply oil to the generator seals under emergency condition. The system shall specifically include the following: (a) Centrifugal / gear type, Main oil pump (MOP) directly driven by

Turbine as per Bidder's standard practice with capacity to cater lube oil for bearings & emergency seal oil requirement. Further, 2x100% AC Aux. oil pumps for start up, shut down of TG unit and as standby to M.O.P. for automatic operation, each pump having capacity to cater to lube oil, jacking oil & turning gear oil requirement.

OR 2x100% AC oil pumps as per Bidder's standard practice with capacity

to cater lube oil for bearings & emergency seal oil requirement. Each pump shall also be capable of start up, shut down of TG unit and stand by to each other for automatic operation to cater lube oil, jacking oil & turning gear oil requirement. However for this alternative, bidder to provide the system to ensure lube oil supply to the turbine generator bearings during complete power failure (including DC supply) for safe coasting down of the turbine generator rotor as per their standard practice.

(b) 1 x 100% DC emergency oil pump for meeting lube oil requirements of bearings during emergency, with automatic starting on low lube oil pressure preset value.

(c) One (1x100%) each AC and DC motor jacking oil pumps shall be provided to lift the rotor at the bearing during turning gear operation.

(d) Each unit shall be provided with an oil tank of sufficient capacity to allow 5 to 8 oil changes per hour (at normal operating level), fitted with non-corrodable strainers, level indicators & necessary manholes. 2x100% duty vapour extraction fans driven by motors shall also be provided.

(e) 2x100% capacity oil coolers shall be provided for cooling the lubricating oil. The cooling medium shall be DM water (condensate quality).

(f) A lube oil purification unit shall be permanently connected to the piping system for each TG unit for purifying 20% of the total oil charge in the system per hour on a continuous bypass basis. Each unit shall be complete, self-contained with centrifuge, explosion-proof motors, motor-driven feed pumps, heaters etc.

(g) A centralised lube oil storage and purification system consisting of a central purifier (capacity and type same as unit purifier), two central oil tanks (each with capacity one half times the capacity of one unit oil tank), two transfer pumps (for dirty and clean oil) shall be provided. This is for storing and purifying oil from unit oil tank and


also for adding new oil to the system and also for transferring the fresh oil to the unit oil tank. In case of maintenance of the unit purification system, this system shall serve as a backup system.

2.06.00 Turbine Control Fluid System For the governing and control system of the turbine a complete self contained control fluid system shall be provided. Fire resistant fluid shall be employed to minimise fire hazards. The system will comprise of : i) A control fluid reservoir of adequate capacity to ensure fluid supply of

acceptable purity. ii) 2x100% AC motor driven pumps to pump the fire resistant fluid from

the fluid reservoir through the system. iii) 2x100% capacity control fluid coolers designed for service with DM

water (condensate quality). A control fluid purifying unit using Fuller's earth shall be provided for each

turbo-set permanently connected to the piping system for purifying at least 2% of the total fluid charge in the system per hour on a continuous bypass basis. 2x100% capacity AC motor driven purification pumps to circulate oil through purification system are envisaged. Necessary filters, strainers, piping, fittings, valves and instruments shall be provided. All the components including piping which are coming in contact with the control fluid shall be of stainless steel.

2.07.00 Gland Steam Sealing System A fully automatic gland sealing steam supply system shall be provided for

the TG set & the turbine drives for BFPs. HP and IP turbine shaft glands will be sealed to prevent escape of steam into the atmosphere and the LP turbine glands will be sealed for preventing leakage of atmospheric air into the turbine. Steam will be used for sealing these spring backed labyrinth glands.

During startup and low loads (say upto 40% load), seal steam will be supplied to the turbine glands from the auxiliary steam header through a seal steam regulating valve. During normal operation (say above 40% load), the HP and IP turbines will be of self-sealing type and under that condition the auxiliary steam source will be cut off and the leak-off steam from HP and IP glands will be used for sealing the LP glands. The excess leak-off steam will go to the condenser. A gland steam condenser will be provided to condense and return to the cycle, all gland leak off steam including that from BFP turbines. A de-superheating type bypass shall be provided during outage of gland steam condenser. 2x100% capacity vapour exhausters shall be provided to remove non-condensable gases from the gland steam condenser. The exhaust gases shall be left above the TG Hall roof level.

2.08.00 Governing / Regulation System The turbine will have throttle or nozzle controlled type governing. The

steam turbine generator unit shall be equipped with an electro-hydraulic


governing system backed up by 100% mechanical-hydraulic or eletro hydraulic control system. The governing system shall be highly reliable and operationally safe and it shall be capable of controlling with stability the speed of the turbine at all power outputs between zero and the specified maximum power output when the unit is operating isolated or the energy input to the steam turbine when the unit is operating in parallel with the other units. The turbine governing system shall be designed for high accuracy, speed and sensitivity of response. The governing system shall limit the over speed of the turbine on loss of full load to value less than 8% of the rated speed. The steady state regulation shall be adjustable within +3% to +8% of the rated speed. The dead band at rated speed and at any power output within the rated output shall not exceed 0.06% of the rated speed.

2.09.00 HP/LP Bypass The HP and LP bypass stations shall be capable of meeting the following

requirements: a) Quick startup of the steam generator from cold, warm & hot

conditions. b) Parallel operation of the bypass with turbine in the event of large

load throw off. c) House load operation followed by complete external load throw-off. d) To keep the steam generator in operation so as to avoid a fire out in

the steam generator following full load rejection. The HP/LP Bypass system shall be sized for about 65% of BMCR steam flow (exact capacity shall be decided later) with rated main steam parameters at upstream of valves. The LP bypass will be sized for steam inlet conditions (pressure and temperature) of HRH line corresponding to about 60% TMCR.

2.10.00 Regenerative Feed Heating Cycle Regenerative feed heating plant shall be designed for all operating

conditions including transients like sudden load throw-off, HP-LP Bypass in Operation, one or two heaters going out of service etc. The condensate from the condenser shall be pumped by the condensate extraction pumps through the train of LP heaters to the deaerator. In deaerator, the condensate shall be heated to saturation temperature and fed to the boiler feed pump, which increases the feed water pressure to suit the steam generator requirements.

Feed water then passes through two trains of 50% capacity HP heaters which raise the feed water temperature to nearly 253 +/-5 deg C (tentative). Finally the feed water is fed to boiler.

2.11.00 HP & LP Heaters Regenerative feed heating cycle shall consist of LP heaters, one drain

cooler, deaerator and HP heaters. The number of LP & HP heaters shall be based on the optimisation of feed heating cycle.


Feed water shall be heated by uncontrolled turbine extraction steam from turbine inter-stage tap-off and cold reheat line in feed water heaters, depending on optimisation of cycle. The deaerator shall normally operate under variable pressure on extraction steam from the turbine. Each feed water heater shall be capable of handling the drains from the preceding heater under operating conditions of the unit.

Heaters shall be arranged for removal from service and bypassing of condensate flow around each heater individually excepting for HPHs. Each train of HPH can be isolated & bypassed and not the individual heater.

The equipment shall be designed in accordance with latest applicable standard/codes of Heat Exchanger Institute, ASME, IBR etc. The feed water heaters shall be of U-tube with all welded stainless steel tubes, surface type, horizontal with integral condensing and drain cooling zones. The HP heaters shall also have de-superheating zone.

2.12.00 Deaerator Horizontal, direct contact spray or spray cum tray type deaerator with a

horizontal feed water storage tank shall be provided. The deaerator shall be capable of deaerating all the incoming condensate and HP heater drains. It shall effectively remove the dissolved oxygen in condensate and completely remove the traces of carbon dioxide. The minimum capacity of feed water storage tank shall be be 6 minutes of BMCR flow between normal operating level and low-low level with a filling factor of 0.66. The deaerator shall operate without any vibration and water hammer during any transients, loss of full load followed by HP-LP bypass coming into operation and at any steady load from 0% to 110% of rated capacity. The deaerator shall be designed to give a dissolved oxygen content not greater than 0.005ml/litre in feed water at the deaerator outlet under all operating conditions.

2.13.00 Boiler Feed Pumps It is proposed to have 2x50% turbine driven (normally working) and 1x50%

motor driven boiler feed pumps per unit with the booster pumps mounted on the common shaft. Each pump shall be designed to give parameters to suit the steam generator requirements such that two feed pumps shall be capable of meeting the full requirement of the boiler turbine unit with the third pump as a standby. Turbine Driven Boiler Feed Pumps (TDBFPs) shall be located at operating floor and the motor driven pump shall be located on mezzanine floor and shall be accessible to turbine house EOT crane for erection and maintenance. The feed pump shall be able to handle feed water of pH. 8.5 to 9.5 and of temperature of about 185 deg.C (tentative). The boiler feed pumps shall be of horizontal, centrifugal type with stiff shaft design. The boiler feed pumps outer casing shall be of barrel type with end removal. The inner pump assembly comprising of shaft, impellers, stage casings shall be capable of being removed and replaced as a unit without disturbing the feed piping. Each feed pump shall be


provided with ON-OFF recirculation control valve to protect the pump under low flow condition. The boiler feed water system shall be designed to operate primarily in an automatic mode over the range of system design loads. The arrangement will provide automatic start-up of the standby Motor driven feed pump under conditions like tripping of running TDBFP's, discharge header pressure low etc.

The feed flow shall be controlled by throttling the control valve of motive steam for drive turbine in case of turbine driven pumps whereas hydraulic coupling shall be utilised to achieve speed control of motor driven pump. Provisions will be made for warm-up of stand by pump, if required.

2.14.00 Condensate Pumps Each unit shall have 3 x 50% capacity motor driven condensate extraction

pumps (two operating and one standby). The condensate pumps shall be vertical canister type, multistage, centrifugal diffuser design with a double suction first stage impeller designed for condensate extraction service having low suction head requirement. The pumps shall be capable of handling the condensate from the condenser together with feed heater drains when the machine is operating at maximum unit output with HP Heaters out with 3% make-up and discharging this quantity through the gland steam condenser, condensate polishing unit and LP heaters to Deaerator. The pump shall have adequate margins on capacity and head to cater for most adverse conditions of operation such as: i) HP&LP bypass in operation. ii) HP heaters out of service and unit operating at its maximum load

during an under frequency operation (i.e. at 47.5 Hz). 2.15.00 Turbine Hall EOT Cranes

No turbine hall EOT crane is envisaged for this stage, however two (2) numbers Electrically operated traveling cranes of stage-I of this project shall be used for erection and maintenance of turbo-generators and their auxiliaries except generator stator.

2.16.00 LP Chemical Dosing System The purpose of LP dosing system is to maintain the pH of condensate and feed water and to effectively deal with residual dissolved oxygen in condensate and feed water. The arrangement shall consist of the total system for dozing hydrazine and ammonia at boiler feed pump suction and on condensate line.

3.00.00 COAL TRANSPORTATION AND COAL HANDLING SYSTEM 3.01.00 COAL TRANSPORTATION

The facility envisaged for receiving coal at JNT-50 from the EPL jetty for 2x 500 MW is adequate for meeting the coal requirement of additional 500 MW unit proposed at Vallur. The long distance conveyors envisaged for 2x 500 MW to transport coal through a series of conveyors up to the power


plant shall also meet the additional coal requirement for 1x500MW. The long distance conveyors shall discharge coal to the drive house located in the power plant. The additional peak daily coal requirement for 1X500 MW units shall be about 8,650 tonnes considering raw coal of GCV of 3400 Kcal/Kg. Accordingly the peak daily coal requirement for 3x500 MW shall be 26,000 tonnes.

3.02.00 COAL HANDLING SYSTEM The coal handling system capacity for 2x500 MW was envisaged as 1600 TPH. This capacity is not adequate to feed the peak daily coal requirement of 3 x 500 MW. It is therefore proposed to increase the capacity of the coal handling conveyors (with in the power plant boundary) to 2400 TPH to cater to the peak daily coal requirements of 3x 500 MW. The coal of (-) 100 mm is received at the power plant through the cross country conveyors of 4000 TPH rated capacity. The as-received coal shall be crushed to -20mm before it is stacked. Therefore conveyors utilized for receiving the coal from the cross-country conveyors and stacking it are proposed for 4000TPH rated capacity. Coal conveyors for reclaiming this stacked coal and further conveying it shall be rated for 2400 TPH capacity. It is also proposed to directly feed the as received coal after crushing by 2x100 % capacity conveyors to the raw coal bunkers of the boilers. Two (2) nos Independent rail mounted stackers of 4000TPH rated capacity are proposed for stacking of coal and two(2) nos independent reclaimers of 2400 TPH rated capacity are proposed for reclaiming of coal from the stockyard. The stockyard can stack up to 7,50,000 tonnes of coal. Double stream conveyors of 2400TPH capacity are proposed for in plant coal handling. The overall operating hours of the coal handling plant shall be 16 hours spread over two shifts per day leaving third shift exclusively for routine inspection and maintenance. The proposed CHP shall cater to the peak daily requirement of coal for both the units in 12 hrs. effective operation. Dust suppression, ventilation system, potable water system and service water system shall be provided throughout the coal handling plant. Sea water shall be used for dust suppression of coal stockyard whereas soft water shall be used for dust suppression at Transfer points, crusher house & for cooling water application of various auxiliaries. A centralized main CHP control room shall be provided to control and monitor the operations of the entire coal handling system.

4.00.00 FUEL OIL UNLOADING AND STORAGE SYSTEM Fuel Oil unloading and storage system shall be designed to handle both heavy oil (HFO/LHS/HPS) and light oil (LDO). Light oil (LDO) shall be used for cold startup and low part load (up to 7.5%) operation of the steam


generator while firing coal. The heavy oil (HFO/LHS/HPS) shall be used for start-up, warm-up and low load (up to 30%) operation of the steam generator while firing coal. Since there is no provision of railway siding within the plant premises. It is proposed to transport both light oil (LDO) and heavy oil (HFO/LHS/HPS) to the power plant by road tankers. The oil will be unloaded from road tankers by gravity into the dedicated unloading header. From there it will be transferred to oil storage tanks through a set of dedicated positive displacement pumps. Provision shall be kept to unload five (5) nos. road tankers for light oil (LDO) and ten (10) nos. road tankers for heavy oil (HFO/LHS/HPS). Since heavy oil (HFO/LHS/HPS) is to be used for start up, warm up and low load operation, the specific oil consumption is assumed to be 3.5 ml/Kwhr. Accordingly storage capacity equivalent to 30 days operation of the ultimate capacity shall be provided. Therefore, Two (2) nos. of fixed roof type storage tanks each of 2100 KL capacity shall be provided for storage of heavy oil (HFO/LHS/HPS). Necessary provision for heating of the unloading header and storage tanks shall be provided. For storage of light oil (LDO) two (2) tanks each of capacity 500 KL shall be provided. A set of pressurizing pumps shall draw the oil from the storage tanks for pumping the oil to the steam generator units. The auxiliary boiler shall be designed for firing light oil (LDO). A separate day oil tank of 100KL capacity for auxiliary boiler shall be provided. Oil shall be drawn from the main LDO storage tanks for feeding to day oil tank by a set of transfer pumps.

5.00.00 ASH HANDLING SYSTEM 5.01.00 General

The bottom ash as well as fly ash resulting from combustion of coal shall be removed in an effective manner. Keeping in view the MOEF stipulations, provision shall be kept to allow ash based industries to take the fly ash in dry form. It is envisaged that washed coal shall be used for the project The capacity of ash handling plant has been decided considering the following parameters: i. Ash content - 45 % ii. Calorific value of worst coal - 2800 kcal/kg. The ash disposal area is located adjacent to the power plant boundary. Ash disposal is proposed in conventional slurry form with provision of simultaneous collection of fly ash in dry form from all the fields of the ESP of all the units.


5.2.5.2 Bottom Ash Handling System Bottom ash is conveyed by using by using intermittently operating jet pumps in conjunction with a water impounded hopper. The jet pumps would convey the bottom ash slurry from water impounded BA hoppers to the slurry sump of the combined ash slurry disposal pump house. Alternatively the bottom ash is conveyed by using continuously operating submerged scrapper chain conveyor. In case ash is disposed using conventional slurry disposal system the bottom ash shall be pumped to the slurry sump of the ash slurry disposal pump house using centrifugal slurry pumps.

5.2.5.3 Fly Ash Handling System Pneumatic conveying system (either vacuum system or pressurized system) shall be employed for conveying fly ash from the electrostatic precipitator hoppers in dry form. The dry ash shall either be taken to buffer hoppers or to the wetting head/collector tank units. The dry ash buffer hoppers and wetting head/collector tank units shall be located adjacent to the ESP. Dry ash from buffer hoppers shall be transported to main storage silos to be located near the plant boundary. The wet system shall be used only in case the ash is to be disposed in wet form. Three numbers of ash storage silos shall be provided. The storage capacity of silos shall be equivalent to 12 hours production of fly ash (based on design coal at full load). The user industries shall take the dry fly ash from the silo either in closed tankers or in open tankers. Silo area shall be provided with fencing, office block, gate complex and passage for entry/exit of vehicles

5.2.5.4 Ash Disposal System The bottom ash slurry and fly ash slurry shall be led to the common slurry sump of the combined ash slurry disposal pump house of Phase-I & Phase-II. The available disposal area of approx. 546 acres is located adjacent to the plant boundary. This area is not sufficient for disposal of ash from 3X500 MW units. Accordingly additional area of approx. 125 acres (Area-B) is to be acquired for ash disposal. For the purpose of FR, this additional area for ash disposal is considered at a distance of 3 km. from the power plant and pipe route length including the pipe length for garlanding is considered as 12 km. There shall be a common ash slurry pump house for the three units with five (5) pumping streams upto the already identified disposal area. Of these five streams, three streams shall be working streams and two streams shall be standby and of the two standby streams, one stream shall be operation standby stream and the other maintenance standby stream. All the pumping streams shall be provided with its individual disposal pipes. No crossover is being envisaged in the disposal piping. To facilitate ash disposal from one unit only 2 lengths of slurry disposal pipelines and additional slurry pumps shall be provided in future as per


requirement. Provision is kept in the FR for future requirement as indicated above.

5.2.5.5 Ash Water System Sea water shall be used for ash sluicing and ash slurry applications. Accordingly it is proposed that the MOC of the equipment, vessels, pumps, pipes & accessories handling sea water & ash slurry shall be suitable for sea water application. However for sealing purpose & cooling of auxiliaries sweet water shall be used. To meet the requirement of the water for ash handling required number of ash water pumps shall be provided which shall take suction from the ash water sump.

6.00.00 WATER SYSTEM AND PLANT UTILITIES 6.01.00 Source of Water 6.01.01 Sea Water is proposed to be used for meeting complete water

requirement of the project. Present environmental regulation permit installation of once thru Circulating Water system for coastal Thermal Power Stations with a stipulation that the temperature of receiving water does not exceed 7°C over and above the ambient temperature. For Phase -II, it is proposed to adopt open re-circulating type CW system as that of in Phase-I of the project by drawing makeup water for the project from intake channel of North Chennai Thermal Power Station. Sweet water required for meeting the potable water, plant service water, cycle makeup (DM water) etc shall be produced thru Desalination process from sea water.

6.02.00 WATER REQUIREMENT 6.02.01 It is proposed to adopt Reverse Osmosis process for Desalination of sea

water. The total sea water makeup for the project is estimated to be of the order of 4600 Cu.m/hr. A preliminary Water balance diagram is enclosed as Exhibit – VI.

6.03.00 Make up Water System 6.03.01 Makeup water pump house is being provided at intake location. Three

numbers (3 x 50% capacity) of vertical, wet pit type makeup water pumps are envisaged for Phase-I of the project. It is proposed to provide additional pump so that discharge capacity of three pumps shall meet the requirement of Phase-I & II. Two pipelines (2 x 50% capacity) from pump house to plant end are presently envisaged for Phase-I of the project and it is proposed to provide one more pipeline to meet the requirement of Phase-II. The pipeline shall be internally lined suitable for handling sea water. The pipes shall be externally protected against corrosion with wrapping & Coating and as well as Cathodic protection System. Sea water shall be supplied to Ash Water sump/tank, Circulating Water channel and Sea water storage tank near Desalination plant. Dosing of Chlorine is envisaged at the discharge of the pump and/ or at the pump suction.

6.04.00 Circulating (CW) Water System 6.04.01 Sea water makeup shall be supplied to cold water channel of CW system.

Water from cold water channel will enter into CW pump house through


Stoplog gates and trash racks at low velocity. Total cooling water requirement for the condenser and auxiliary cooling is estimated to be about 60000 Cu.m/hr for the proposed unit considering temperature rise of circulating water across the condenser of about 10 to 11 deg. C. It is proposed to operate CW system at about 1.5 Cycle of Concentration (COC).

6.04.02 For Phase-I, a common CW pump house is provided with provision of five CW Pumps considering two CW pumps for one unit and a common standby pump. For stations with three or more units, standby pump is not provided as per present design practice. Accordingly space provision shall be kept in CW pump house of Phase-I, for installation of one more CW pump of identical type & parameter as that of Phase-I. However one CW pump motor shall be procured as “Unit Assembly”.

6.04.03 For interconnecting C.W. duct with CW pump, condenser and cooling towers, steel pipes with internal lining lined would be used.

6.04.04 Cooling water requirement for the auxiliary cooling system of each unit would be tapped from the CW pipe at the upstream of condenser and return hot water from the circuit would be led to the CW discharge pipe after condenser. Re-cooled water after cooling tower will be led to CW pump house through cold water channel by gravity. CW System blow-down would be drawn from CW pump discharge.

6.04.05 Considering sea water in the CW system, it is proposed to adopt Cooling Towers of Natural draft type with splash type fill for this project as that of in Phase-I. There would be one (1) number of Natural draft cooling towers for one 500 MW unit. Fill material of cooling tower shall be of PP or PVC.

6.05.00 Equipment Cooling Water System Closed circuit cooling water system would be adopted for steam generator

and turbine generator auxiliaries. DM water would be used in closed circuit, which in turn will be cooled by circulating water in plate type heat exchangers. Two separate set of DM water circuit shall be provided; one for meeting the TG Auxiliaries and another for SG & other Station auxiliaries such as Service air & Instrument Air compressors, Ash Handling Plant compressors, compressors of mill reject system etc. For each unit of TG Auxiliaries, three numbers of 50% capacity DM water pumps shall be provided with 3 x 50% capacity Plate type heat exchangers and for each unit of SG Auxiliary system 2x100% capacity DM Water pumps and 2 x 100 % PHE’s shall be provided. A common Secondary circuit shall be provided with 3 x 50% capacity pumps for each unit. Make up to the primary side closed loop would be from unit DM make up system. For the secondary side, cooling water would be tapped from CW inlet to condenser and discharged into the discharge duct after the condenser.


7.00.00 WATER TREATMENT SYSTEMS Water treatment system of the project comprises of Desalination System,

Chlorination Plant, Condensate Polishing Plant, Ash Water re-circulation system and liquid waste effluent treatment system as described below.

7.01.00 Desalination Plant It is envisaged to adopt Reverse Osmosis (RO) process for desalination of sea water. Sea water is proposed to be collected & stored in a storage tank of RCC construction near Sea water Reverse (SWRO) Osmosis plant. From storage tank, water shall be pumped to SWRO plant. The Desalination system shall be equipped with Water pre-treatment section such as clarification, chemical dosing as per standard practice of the suppliers & filtration. Treated permeate from SWRO shall be stored in Steel tanks which shall be used for plant water requirement such as Service water, HVAC makeup, makeup to the fire water storage tanks, sealing water for vacuum pumps of ash handling plant and Potable water for plant & colony. To produce Demineralized quality water for cycle makeup, it is required to provide a Second (2nd) Stage RO unit and a set of Mixed Bed Ion-exchanger units at the downstream of SWRO plant. Portion of desalinated water from SWRO units shall be treated through 2nd stage RO unit & Mixed (MB) Bed type ion exchanger units to produce DM water required for cycle makeup and DM water shall be stored in DM Water Storage tanks. For regeneration of ion-exchange resins of Mixed bed unit, regeneration systems comprising set of acid tanks and a set of alkali tanks, dosing pumps, acid & alkali unloading pumps, Neutralization pit, effluent disposal pumps etc shall be provided. The capacity of complete system i.e SWRO plant, associated PT System, RO units & MB exchangers shall be designed considering the expansion phase of one unit of 500 MW.

7.02.00 Chlorination Plant for CW System In Phase-I of the project it is proposed to provide chlorination plant is being provided for chlorine dosing in CW system to avoid the growth of algae and bacteria. It is proposed to provide CW chlorination comprising of three (3) numbers of chlorinator-evaporator sets of 100 Kg/hr capacity. Capacity envisaged for Phase-I would suffice for this expansion phase also considering common CW pump house for Phase-I & II.

7.03.00 Condensate Polishing Plant For maintaining the feed water purity, condensate polishing plant shall be provided in the feed water cycle at the downstream of condensate extraction pumps as per the existing practice. The condensate polishing plant shall be of full flow, deep mixed resin bed type. The resins to be used would be strongly acidic cation and strongly basic anion type, appropriate for condensate polishing system. A common external regeneration facility shall be provided. The exhausted charge of resins


from the service vessel shall be hydraulically transferred to the resin separation/cation regeneration vessel for regeneration and reuse. Spare charge of resin shall be kept in the mixed resin storage tank for immediate exchange of resins with the exhausted ones. One additional charge of resin shall be procured for use during start up of the unit. Acid, Alkali & DM Water Storage for regeneration, and Wastewater Neutralisation facilities shall be provided separately for the external regeneration facility.

7.04.00 Ash Water Re-circulation System It is proposed to provide ash water re-circulation system to meet the requirements of environmental authority. Decanted water from ash pond (s) shall be led to the plant area by using 3x50% capacity pumps from the Phase-I ash dyke and 100 % capacity pumps from Phase-II dyke and the same shall be conveyed through internally lined carbon steel pipes from ash dyke to plant area. . This water will be used further in the ash handling system. Further additional make up to the ash water system shall be from fresh sea water makeup. However provision shall also be kept for operating ash water system on “Once Through” mode also. During once thru mode operation, CW system blow down water shall be used

7.05.00 Effluent Treatment System A Central Monitoring Basin (CMB) of RCC construction shall be provided to collect all the plant effluents so that the same may be pumped back to the sea. The liquid effluents shall be collected and treated / recycled generally as per the following design philosophy. A portion of CW blow down water shall be used for dust suppression system of coal stockyard and balance shall be diverted to Central monitoring basin. Provision shall be kept to use CW blow down water for ash handling plant when the system is operating in once thru mode. Ash water system shall be generally operating in re-circulation mode. Blow down if any from the Ash water system shall be led to the CMB Other plant drains /effluent of sea water quality shall be collected and pumped to central monitoring basin. The reject from desalination plant & sludge if any from the pre-treatment section of Desalination Plant shall be pumped to discharged to the Central monitoring basin. Regeneration waste of Demineralization Pant, condensate polishing plant & boiler blow down water shall be pumped to the CMB. Waster from plant service water system and dust suppression system shall be collected from the plant drains and shall be treated through a set of tube settlers to remove suspended impurities. The treated water shall be pumped to the central monitoring basin. Drains from coal stockyard shall be drained to a set of Coal settling pond for removal of coal particles. The treated water shall be led to Central monitoring basin.


All the plant liquid effluents shall be mixed in CMB and quality of the effluent shall be measured & monitored. Through a set of Waste Effluent disposal pumps and piping, the same shall be disposed off from central monitoring basin up to the final disposal point identified for effluents of Stage-I of the project

8.00.00 MISCELLANEOUS WATER SYSTEMS Pipe network for distribution of potable water, service water, HVAC makeup, air pre-heater wash water, CHP dust suppression water etc for expansion phase shall be extended from respective pipe network of Phase-I.

9.00.00 FIRE DETECTION AND PROTECTION SYSTEM A comprehensive Fire detection and protection system is envisaged for the complete power station. This system shall generally conform to the recommendations of TAC (INDIA)/ IS:3034 & NFPA- 850.

9.01.00 The following fire detection and protection systems are envisaged : Hydrant system for complete power plant covering the entire power station including all the auxiliaries and buildings in the plant area. The system shall be complete with piping, hydrants, valves, instrumentation, hoses, nozzles, hose boxes/stations etc. Automatic high velocity water spray system for all transformers located in transformer yard and those of rating 10MVA and above located within the boundary limits of plant, main and unit turbine oil tanks and purifier, lube oil piping (zoned) in turbine area, generator seal oil system, lube oil system for turbine driven boiler feed pumps, etc. This system shall consist of detectors, deluge valves projectors, valves, piping & instrumentation. Automatic medium velocity water spray system for cable vaults and cable galleries of main plant, switchyard control room, CHP Control room and ESP control room consisting of smoke detectors, linear heat sensing cable detectors, deluge valves, isolation valves, piping, instrumentation, etc. Automatic medium velocity water spray system for coal conveyors, coal galleries, transfer points and crusher house consisting of QB detectors, Linear Heat Sensing Cables, deluge valves, nozzles, piping, instrumentation, etc. Automatic medium velocity water spray system for un-insulated fuel oil tanks storing fuel oil having flash point 65 deg C and below consisting of QB detectors, deluge valves, nozzles, piping, instrumentation, etc. Foam injection system for fuel oil / storage tanks consisting of foam concentrate tanks, foam pumps, in-line inductors, valves, piping & instrumentation etc. For protection of control room, equipment room & computer room inert gas system using Inert gas fire extinguishing conforming to NFPA-2000 would be opted.


Fire detection and Alarm system - A computerised analogue, addressable type early warning system shall be provided to cover the complete power plant. Following types of fire detection shall be employed. Multisensor type detection system & Photo electric type smoke detection system. Linear heat sensing cable detector. Quartzoid bulb heat detection system. Infra red type heat detectors. Spot type heat detectors. Portable and mobile extinguishers, such as pressurised water type, carbon-dioxide type, foam type, dry chemical powder type, will be located at strategic locations throughout the plant.

9.02.00 Required Fire tenders. a) Fire water storage, fire water pumping system, Pipe mains of Hydrant

& Spray System shall be common for Phase -I & II. From the fire water mains various water based fire protection system of Phase-II areas shall be extended.

b) Complete Instrumentation and control system for the entire fire detection and protection system shall be provided for safe operation of the complete system.

10.00.00 PLANT & INSTRUMENT AIR SYSTEM To meet the instrument air requirement of Phase-II, Two (2) numbers of instrument air compressors and two numbers of Air Drying Plants shall be provided and the parameters of the same shall be identical as that of Phase-I. The compressors shall be of oil free screw type and shall provide moisture and oil free air. These compressors shall be provided with all the accessories such as suction filters, inter coolers, after coolers, air receivers etc. The air drying plants shall be capable of achieving a dew point of (-)40 deg C at atmospheric pressure. Individual air receiver shall be provided near each air compressor and further Unit air receivers shall be provided near main plant of each unit. To meet the service air requirement of Phase-II, one (1) number plant air compressor of identical capacity & discharge pressure as that of in Phase-I shall be provided The compressors shall be same type as that of instrument air compressors.

11.00.00 AIR CONDITIONING SYSTEM Air conditioning system shall be provided for all those areas which require close control of environment conditions and shall cover the following areas: Control tower areas including Control rooms, Control equipment rooms, Telecommunication rooms, Microprocessor, Computer and programmers


rooms, Data Storage rooms, UPS Rooms, Instrumentation Laboratory and Steam & water analysis rooms, Conference room, Shift Charge Engineer's room, AVR Room and inverter room, Generator Exciter panels room(if applicable), Relay rooms, Switch yard control room including computer rooms, telemetry room, PLCC & Telex room.

Control rooms of plant auxiliary facilities, Water and fuel analysis room etc. Any other area which contains control and instrumentation equipment requiring air conditioning or otherwise requires to be air-conditioned. A common chilled water type Air conditioning plant shall be provided for air conditioning in main plant area of all the units. It is proposed to provide one steam powered Vapour absorption (VAC) chiller per unit (capacity adequate to meet the requirement of one unit) and one screw or centrifugal type chillers as standby units. Chilled water shall be pumped to each area and through dedicated Air handling units located locally each of the area shall be air conditioned. For Service building 3X50% capacity ( 2 nos. VAM + 1 No. Screw /Centrifugal machines) along with associated chilled water, condenser cooling water system, AHUs etc shall be provided. For Administration building it is proposed to provide 2 x 100 % capacity screw chiller shall be provided. For other areas, where air conditioning heat load is small of the order of 5 -15 TR package air conditioners units (PAC units) or Split type/window AC units shall be provided as per requirement. All air conditioned space which are normally manned shall be maintained at 24oC +/- (plus or minus) 1o C 50% +/-(plus or minus) 5% RH and the other areas such as control equipment rooms etc which are not normally manned shall be maintained at 22oC +/- (plus or minus) 1oC and 50% +/- (plus or minus) 5% RH. All air conditioned areas shall be supplied with filtered air. Both re-circulated and fresh air shall be filtered separately.

12.00.00 VENTILATION SYSTEM Ventilation system shall be designed to supply fresh outdoor air and shall be selected for maintaining inside conditions for those areas where close control of temperature is not required, but nevertheless have a stipulated maximum temperature. Basically two type of ventilation systems namely Evaporative cooling system (i.e. air washer system) and dry mechanical system shall be employed in various areas of the plant for the purpose of ventilation. The areas to be ventilated by Evaporating cooling system shall be as follows: All floors of turbine hall including "BC Bay" other than the area which are air conditioned. Switchgear rooms and cable galleries of main plant. Non Air-conditioned area of ESP control room.


Any other areas where equipment heat load is high and requires ventilation by evaporating process. Non air-conditioned areas of ESP building shall be ventilated by Unitary Air filtration system. All other buildings /areas such as switch gear rooms, pump houses, store, canteen and toilets etc shall be e ventilated by mechanical ventilation process using combination of supply air fans and roof exhausters or wall mounted exhaust fans. All ventilation system shall work on 100% fresh filtered air.

13.00.00 HYDROGEN GENERATION PLANT For Phase-I, a hydrogen generation plant has been envisaged in order to fill up high pressure hydrogen cylinders which are required for generator initial fill up and regular makeup required for generator rotor cooling. Hydrogen generation is accomplished by water electrolysis process. Capacity of hydrogen generation plant being provided in Phase-I of the project is 10 NM3/hr with two streams of electrolysers each of capacity 5 NM3/hr & three hydrogen compressors each of capacity 6.25 Nm3/hr along with auxiliaries. For expansion phase of the project no augmentation of capacity would be required.


ELECTRICAL SYSTEMS 1.00.00 ELECTRICAL SCHEME

The basic electrical scheme is indicated in the single line diagram enclosed at Exhibit No.VII , and described as follows: Power Generated from 500 MW unit would be stepped up to the evacuation voltage level through suitably rated Generator Transformer and will be evacuated through transmission lines. Step-up voltage would be 400 kV in line with proposed evacuation voltage of stage-I units (2x 500 MW).

1.01.00 POWER EVACUATION The power evacuation scheme for 2x 500 MW TNEB- NTPC JV Vallure Project has already been finalized in 24th Southern Region standing Committee meeting on Power System Planning held on 18th June 2007 at Bangalore. The Associated Transmission System (ATS) of 2x 500 MW project are as follows: i) LILO of Almathy-Sriperumbudur 400 kV D/C line at Vallure(NTPC

–TNEB JV) Accordingly, provision for 4 nos. of 400 kV line bays have been kept for 2x 500 MW plant for power evacuation purpose. For additional 1x 500 MW unit, the matter shall be once again taken up with PGCIL for finalization of Associated Transmission System (ATS). Presently provisions for two line bays have been kept in plant GIS switchyard. The provision now being kept is thus tentative and it shall be reviewed based on the finalized ATS of the project for evacuation of power from 1x 500 MW unit.

1.02.00 Start-up Power Requirement The start-up power of the plant has been proposed to be availed at 400KV voltage level itself.

1.03.00 All electrical equipments shall be rated for the maximum ambient air temperature of 50 deg.C and relative humidity of 100%.

2.00.00 GENERATOR The main parameters of Generator would be as follows: a) Nominal rating 500 MW b) Rated output 588 MVA c) Power factor 0.85 (lagging)- 0.95 (leading) d) Rated voltage As per manufacturer's Standard e) Speed 3000 rpm f) Short circuit ratio Not less than 0.48


The Generator winding will be wye connected with the phase & neutral terminals brought out for connection to isolated phase bus duct. The star point will be connected to earth through a transformer having the secondary shunted by a resistor. The stator winding of the Generator shall be cooled by means of demineralised water, passing through hollow stator conductor. The core and the stator shall be cooled by hydrogen which in turn shall be cooled in hydrogen coolers designed for DM water. Generator auxiliary system like stator water system, hydrogen cooling system, seal oil system and gas system complete with all accessories shall also be provided The excitation system shall be static / brushless type. Besides the other electrical protections, the Generator shall have the following additional protections/monitoring. - Alkaliser unit - End winding vibration monitor -Online Partial Discharge (PD) Monitoring System

3.00.00 BUSDUCT The connection between the generator and generator transformers shall be through isolated phase bus ducts. The bus duct shall be continuous enclosure, self cooled type and shall be equipped with air pressurization system. The tap off and neutral connection shall also be of isolated phase construction. The bus duct will have on all aluminum construction. The tentative parameters of the generator bus duct are: Voltage rating 21 kV Current rating (main run) 19,000 Amps

Current rating (delta run) 11,000 Amps Current rating (tap off)

Necessary current and voltage transformers shall be provided in the bus duct for generator excitation control, performance testing, metering, protection and synchronization. Surge protection equipment and a generator neutral grounding cubicle with distribution transformer and secondary resistor, will also be provided. The connection between the unit and station switchgear and transformers to unit and station switchgear will be by means of segregated bus duct with aluminum conductor and enclosure.

4.00.00 GENERATOR TRANSFORMER The 500 MW unit shall have three (3) single phase transformers with combined rating of 600 MVA, for the Generator Transformer. These would be OFAF cooled, with an OFF circuit tap changer. The spare considered under 2x 500 MW units shall be used for the additional unit as well.


5.00.00 AUXILIARY POWER SUPPLY SYSTEM The voltages adopted for the AC auxiliary system are: 415 V For motors rated up to 200 kW (Energy Efficient

Motors have been envisaged up to 160 KW.) 3.3 kV For motors above 200 kW and up to 1500 kW. 11 kV for motors rated above 1500 kW

The electrical auxiliary system proposed will derive station supply from 400 kV systems via suitably rated transformers and unit supply via unit transformer connected with the unit. These transformers will feed station and unit boards, which will have a fault rating of 40 kA break & 100 kA make. The scheme is shown in the single line diagram. Interconnection between unit and station boards, between different station boards will be provided to cater for unit or station transformer outage, as shown in the single line diagram.

6.00.00 LOADS AWAY FROM PLANT BOUNDARY Under 2x 500 MW units, loads away from plant boundary such as cross country, make up water, Ash water Recirculation system (AWRS) shall be fed at 33 kV voltage level through cable/over head line from 33 kV miscellaneous switchgear. Same arrangement shall be used for additional 1x 500 MW unit. The overall arrangement is shown in the Single Line Diagram enclosed.

7.00.00 UNIT TRANSFORMER One no. two winding unit transformer with ONAN/ONAF cooling shall be provided with the 500 mw unit. the transformer is sized for the connected unit loads corresponding to the maximum continuous rating of the unit. the transformer will have on load tap changer. the size and details of the transformer are as per the single line diagram/BOQ.

8.00.00 STATION TRANSFORMER The rating and details of these transformers are shown in the single line diagram/BOQ. The transformer will be ONAN/ONAF cooled and shall be OLTC.

9.00.00 AUXILIARY SYSTEM LOADS For meeting the demand of various systems i.e. unit /station auxiliaries, suitable ratings of 2 x 100% feeders shall be provided as shown in the single line diagram. For station auxiliary system one no. 7.5 MVA 11/3.45 kV transformer is augmented with proposed two nos. 7.5 MVA 11/3.45 kV transformer provided under 2x 500 MW.

10.00.00 LT TRANSFORMERS Power distribution at 415 Volts will be catered by 2x100% or 3X50%, LT transformers. All these transformers will be delta connected on the HT side and star connected on the LT side. The LT star point will be solidly earthed. These transformers shall be mineral oil filled for outdoor


installation or epoxy cast resin/resin encapsulated type in case of indoor installation. The transformers rated 1000 kVA and above will be connected with the respective switchgears by the LT bus ducts.

11.00.00 NEUTRAL GROUNDING ARRANGEMENT High resistance neutral grounding with distribution transformer and secondary resistance shall be adopted for neutral grounding of generator. HT systems feeding to motor loads shall be low resistance, non-effectively earthed to limit the earth fault current upto 300 Amps. 33 kV and 415V system shall be solidly earthed. 220V DC system shall be kept ungrounded. Emergency diesel generator shall be ungrounded.

12.00.00 H.T. SWITCHGEAR Switchgears shall be indoor, metal clad draw out type with SF6 or vacuum breakers. Contractors cum fuse units may be used for auxiliaries such as coal conveyors/crushers; ash handling motors, which require comparatively frequent switching. The switchgears shall have Communicable Numerical Relay system for protection, Control, metering and monitoring of the Switchgears. All the relays shall be networked to a dedicated HMI through data concentrator for Monitoring and Supervision of all the breaker panels. All such data shall be linked to DDCMIS as well.

13.00.00 415 VOLT SWITCHGEAR The LT transformers shall feed power to the 415V switchgears, which in-turn would distribute power to various MCC's located at load centres. The 415V system will have duplicate incomer and bus coupling arrangements so that a changeover can be made from either of the two step down transformers to restore power in case of failure of one of the above two transformers. The 415 Volts switch boards shall be indoor, drawout type compartmentalized with air break circuit breakers. The distribution boards, clarifloculator's MCCS, if any, will be with fixed construction. Adequate numbers of AC & DC Distribution Boards are also envisaged for feeding to various loads. The LV switchgears shall have Communicable Numerical relay system for protection, Control, metering and monitoring of the Switchgears. All the relays shall be networked to a dedicated HMI through data concentrator for Monitoring and Supervision of all the breaker panels. All such data shall be linked to DDCMIS as well.

14.00.00 DC SYSTEM The unit will have a 220V DC system comprising of two nos. of Ni-Cad/ Lead acid plante batteries, and two nos. of float cum boost chargers to supply power to DC emergency pumps, emergency lighting, protection, annunciation, indications and control etc. The required level of redundancy would be achieved with the inter connections between these two batteries and chargers. The unit batteries shall be sized for supplying the total DC load of the unit for a period of 30 minutes under a


complete black out condition. Battery for 2x 500 MW plant switchyard shall also be used for additional switchyard requirement under 1x 500 MW.

15.00.00 EMERGENCY POWER SUPPLY SYSTEM For the safe shutdown of the plant under emergency condition and in case of total power failure, diesel generating sets shall be installed for feeding certain essential applications like battery chargers, emergency lighting, essential air conditioning/ventilation and all auxiliaries necessary for barring operation of main and BFP turbines etc. The unit emergency switchgear section shall be fed by one diesel generator of adequate capacity. One no. standby DG set provided earlier for 2x 500 MW unit shall also be used for additional 1x 500 MW unit as indicated in the single line diagram/ BOQ. Cable interconnection shall be provided from DG to respective unit emergency switchgear.

16.00.00 PROTECTIVE RELAYING The necessary protective relaying system according to established norms shall be provided for EHV switchyards, over head lines, generators, transformers, motors, auxiliary system etc., to minimize damage to equipment in case of fault and abnormal conditions. The summary of protection details to be provided for the equipment are given below:

16.01.00 Generator 1. Generator differential protection, 3-pole (87G) high impedance or

biased type having operating time of 25 milli second or lower at 5 times the current setting.

2. 87 GT- Overall differential covering generator and generator transformers and unit auxiliary transformers.

3. Excitation transformer instantaneous and time delayed over current protection on HV side of excitation transformer, if applicable.

4. Accidental back energisation protection closure/flash over of EHV breaker or EHV isolator(96).

5. Stator earth fault protection covering 100% of winding (64G1) working on the principle of low frequency injection method.

6. Stator standby earth fault protection covering 95% of winding (trip) (64G2) with adjustable time delay.

7. Interturn fault protection. 8. Duplicated loss of field protection (40G1&40G2) with under voltage

check feature. 9. Backup impedance protection, 3-pole (21G).


10. Negative sequence current protection (alarm) with I22 t element for trip (46G).

11. Duplicated low-forward power interlocks for generator (37G1&37G2). 12. Two stage rotor earth fault protection (alarm and trip) working on

principle of continuously monitoring rotor insulation value even during machine shutdown period (64 F).

13. Definite time delayed over voltage protection (59G) for alarm and trip. 14. Over fluxing protection (99G&99T) having inverse time characteristic

suitable for matching generator/generator transformer overfluxing capability.

15. Generator under frequency protection with alarm and stage tripping. (81G).

16. Local breaker back up (or breaker failure protection). 17. Pole slipping protection(98). 18. Monitoring of generator VT fuses. In addition, the generator would have winding temperature recorders and instruments for measuring coolant temperature, flow, pressure, conductivity and purity, with alarm and trip contacts as necessary. The protection against stator overheating would be provided by the generator temperature monitoring system. Limiters for stator current,V/f,Rotor current and under excitation would be included in automatic voltage regulator.

16.02.00 Generator Transformer and Overhead Connection Generator-transformer differential protection for individual phase (87T) bias type having instantaneous high set over current elements. Over head line connection differential protection (87HV)covering overhead connections between generator transformer & breaker including HV winding of generator transformer. Back-up earth fault protection on generator transformer HV neutral (51NGT). Bucholz relay, winding temperature ,oil temperature and oil level alarm and trip. Fire protection to trip EHV generator / breaker,exciter field breaker and unit incoming breaker. Accidental back energisation protection closure/flashover of EHV breaker, EHV isolator(96).

16.03.00 Unit Transformer 1. Unit transformer differential protection 3-pole (87UT).Unit transformer

back up over current protection (51UT). 2. Unit transformer L.V. Restricted earth fault and standby earth fault

protection (64 RUT & 51NUT). 3. Bucholz relay, winding temperature, oil temperature and oil level

alarm and trip 4. Fire protection to trip EHV breaker, exciter field breaker and 11kV

unit incoming breaker.


16.04.00 Station Transformer 1 Transformer differential protection 3-pole (87T). 2 Back-up over current protection on HV and LV side (51 ST). 3 Restricted earth fault protection(64R)on HV&LV side 4 Back-up earth fault protection on LV side.(51 N) 5 Bucholz relay, winding temperature ,oil temperature and oil level

alarm and trip. 6 Fire protection to trip it's HV side breaker 7 Local breaker back up (or breaker failure) protection for the breaker

on HV side of Tie transformer. 8 Over fluxing protection

17.00.00 ELECTRICAL CONTROL CONCEPT Central Control Room (CCR) The complete control of generators and auxiliary system shall be provided in the DDCMIS system covered under "control and Instrumentation" having Operator Work Station (OWS) / Large Video Screens (LVS). On the operation desk CRT's/Keyboard shall be provided so that operator can control all the breakers via DDCMIS. The control for synchronizing breakers along with other associated devices like incoming/running voltmeter and frequency meters, synchroscope, indicating lamps etc required for synchronization shall be located in a draw out portion on Unit Control Desk. Synchronization facility shall be kept disabled from OWS/LVS. Hardware required for synchronization namely synchro check and guard devices auxiliary PTs, auxiliary relays etc shall be provided as necessary. In addition to the above, the Substation Automation System LAN shall be extended upto Main Plant Control Room to facilitate control of switchyard bay equipment from Main Plant Control Room. A separate workstation shall be provided for this purpose in the Main Plant Control Room. All the data related to switchyard such as line /transformer loadings, alarms and annunciations etc. shall be available on this workstation. Further, the exchange of SOE data between Generator Relay Panels (GRP) and DDCMIS shall be through a communication gateway, eliminating the need of hardwiring of protection signals between GRP and DDCMIS.

18.00.00 CABLES For HT cable, single core and three core XLPE insulated cables with aluminium conductor would be employed. For 415 V and DC systems, single core XLPE insulated cables with aluminium conductor would generally be used for higher current ratings and multicore XLPE/PVC insulated cables with aluminium conductor would be used for lower


ratings. All control cables would be multicore, PVC insulated with copper conductors. The cables shall be laid overhead/ in trenches or directly buried. Inter plant cabling for main routes shall be laid on overhead trestles/pipe racks. The cables laid in EHV switchyards, transformers yards and those buried in earth would be armoured. All other cables would generally be unarmored. These cables would have FRLS properties.

19.00.00 STATION GROUNDING Buried grounding mats employing suitable dia MS rods, shall be provided for EHV switchyards , main plant area, pump house etc, for keeping the step and touch potential within safe limits. All the connections above the ground would be of galvanized steel. Adequate lighting protection would be provided for EHV switchyards, transformers yards, all buildings and chimneys etc.

20.00.00 LIGHTING SYSTEM Adequate lighting arrangement shall be made for the entire power plant employing lighting distribution boards, panels, HPSV, T5 type flourescent and incandescent(only for DC lighting) lighting fixtures, lighting masts etc. Normal lighting of the plant will operate with the station AC supply. About 20% of these fixtures will also have arrangement for being fed from diesel generators on failure of station AC supply. Emergency DC lighting, which will normally be off, would be provided for all strategic locations. 24 V AC supply network in both boiler and turbine areas shall be provided for safe lighting inside enclosed space for maintenance purpose.

21.00.00 SWITCHYARD 21.01.00 Type: Gas Insulated Switchgear (GIS) type.

GIS type switchyard has been considered for the project to combat with the sea pollution in line with the proposed GIS switchyard for 2x 500 MW unit.

21.02.00 Proposed Arrangement for Power Evacuation The proposed arrangements for the project have been shown as per the single line diagram enclosed at EXHIBITS – VIII & IX.

21.03.00 Bus Switching Scheme: It is proposed to adopt the standard Double bus switching scheme for the 400kV GIS switchyard as indicated in the Single Line Diagram.

21.04.00 Salient Features of Main Equipments 1. Insulation Coordination The 400 kV system is being designed to limit the switching surge over voltage to 2.3 p.u. and power frequency over voltage to 1.5 p.u .All the materials/equipment shall perform all its functions satisfactorily without


undue strain under such over voltage conditions. Consistent with these values and protective levels provided by the lightning arrestor. The proposed insulation levels for the various system voltages are as follows :

Sl No

Description Voltage Level

i) Lightning impulse withstand voltage 1425 kVp

ii) Switching impulse withstand voltage 1050 kVp

iii) Maximum fault current 40 kA

iv) Duration of fault 1 sec

As the power plant is located at the sea coast, a minimum creepage of 35 mm per kV has been proposed for the 400 kV outdoor equipments. The connection between Generator transformers to GIS switchyard shall be by overhead lines having a creepage distance of 40mm/ kV for insulator string. 2. Switchyard Equipments

(a) Circuit Breakers Circuit Breakers shall in general confirm to latest edition of IEC IEC 62271-100/IEC 602516 and shall be SF6 type. The circuit breakers shall comprise of three single pole units complete in all respects with all fittings and wiring. Total break time shall not be more than 30 milliseconds. Circuit breakers shall be provided with pre-insertion resistors of 400 ohms per pole to limit the switching surges to value less than 2.5 p.u. with 8 msec insertion time for lines beyond 200 km long.

(b) Isolators Isolators will in general conform to IEC : 60129,IEC-60265 and IEC-60517 and shall be of horizontal centre break type. Isolators and earth switches will be capable of with-standing short circuit current of the system in their closed position. Isolators and earth switches will be properly interlocked and these will be of fail safe type.

(c) Current Transformer Current transformers shall comply with IEC-60044. Different ratios of the current transformers shall be achieved by secondary taps for the 5 secondaries (4 for protection and 1 for metering). The accuracy of the protection cores shall be class PS and for metering cores it shall be 0.2. Current transformer characteristic shall be such as to provide satisfactory performance for burdens ranging from 25% to 100% of rated burden over a range of 10% to 100% of rated current in case of metering CT’s and up to the accuracy limit factor/knee point voltage in case of relaying CTs.


The current transformer shall be of the torroidal core type mounted inside the metal clad switchgear enclosure. The main bus bar conductor inside the gas enclosure shall act as the primary conductor.

(d) Voltage Transformers Voltage transformers shall be capacitance voltage divider outdoor type with electromagnetic units and shall be suitable for carrier coupling for line feeders however the bus voltage transformer shall be of electromagnetic GIS type. They shall in general conform to IEC IEC-60044. Voltage transformers shall be used for protection and metering & respective cores shall be 200 VA and 3P and 100VA and 0.2 respectively. The capacitance of CVT shall be 4400/6600/8800pF depending on PLCC requirements.

(e) Lightning Arrestors Lightning Arrestors shall conform to IEC-60099 in general. They shall be of metal oxide (gap less) heavy duty station class type. They shall be capable of discharging over voltage occurring during switching of unloaded transformers. Lightning arrestors shall be provided near line entrances and transformers so as to achieve proper insulation co-provided with pressure relief devices and diverting ports suitable for preventing shattering of porcelain housings providing path for the flow of rated currents in the event of arrestors failure.

3. Protection of Switchyard Equipment a. Busbar Protection

Each busbar shall be covered with duplicated high speed bus bar protection scheme. Bus bar protection of each bus bar shall operate in two out of two modes so as to achieve better reliability.

b. Breaker Failure Protection All circuit breakers shall be provided with breaker failure protection to take care of stuck breaker condition. If in the event of fault, a breaker fails to trip on receipt of a trip command, the breaker failure protection shall de-energize that particular bus to which the faulty breaker is connected and also send trip impulse to the remote end breaker to isolate the fault.

c. 400KV Transmission Lines Protection Each EHV line shall be provided with duplicated Numerical carrier aided Distance Protections(Main I and II) based on different hardware platforms. Each line shall also be provided with a two stage over voltage protection. Provision of these protections and carrier equipment would be suitably coordinated with Agencies controlling the other ends of the lines.


d. Metering System 0.2 accuracy class Availability based Tariff (ABT) energy meters along with metering master station software for export & import of active and export and import of reactive energy meters shall be provided for each outgoing lines, generator /station transformer feeders. Static meters of 0.2 Accuracy class have been considered for active energy measurement at other locations like for energy accounting/trend analysis.

4. Control Philosophy for Switchyard The control of generators and associated circuit breakers will be provided from DDCMIS through CRT/keyboard to be located in the Unit Control Room. Switchyard Automation System (SAS) shall be provided for 400kV Gas Insulated Switchyard (GIS). Operator Workstation/ Engineering Workstation shall be located in the switchyard control room for control of 400 kV bays (except generator bays). However BPU and BCU shall be located along with 400 KV GIS building in a separate cubicle or in GIS control room. In order to have complete overview (complete graphic display indicating circuit breaker, isolator, MW/MVAR flows, voltage, frequency, tap position, etc.) of switchyard, provision for display in CRTs/large VDUs will be made in Unit Control Room. SA system will be able to fully communicate with the numerical protection system and switchyard equipments to provide at least the following:

i) Dynamic display of switchyard mimic, measurement values, etc.

ii) Interface with energy meters located in bay control units iii) Monitoring ON/OFF status and remote closing/synchronising

of circuit breakers, isolators and earth switches iv) Display of Switchyard alarms, events and trends v) Interlocking functions vi) Sequential Event Recording vii) Communicating with protection relay IEDs for settings and

Disturbance Recording functions

viii) System self supervision

ix) Hard copy printing and other network functions The SAS shall have suitable architecture/communication protocols for future expansion and also provide gateways for remote communication. As already described in control philosophy for CCR, it is also proposed to provide two numbers of OPC compliant gateways in


the station level network such that desired interface with main plant DCS can be achieved. Two (2) more gateways each shall be provided in the station level network for sharing information with RLDCs. These two would communicate through IEC:60870:5:101 standard protocol.

1. Disturbance Recorder (DR) Disturbance recorder shall be provided for all the generators and 400 kV lines. These shall be microprocessor based and shall be used to record the graphic form of instantaneous values of voltage and current in all three phases, open delta voltage and neutral current, open or closed positions of relay contracts and breaker during the system disturbances. It will record prefault and post fault data which are of immense importance in prevent their occurrences. The disturbance recorders for generators shall have the facility of fast scan as well as slow scan feature to allow for transient as well as dynamic performance of the system. All external and internal faults in the DR equipment such as Power supply fail, printer faults, paper exhausting, processor failure, memory failure etc. are required to be indicated by means of light emitting diodes on the front of panels of the equipment or on the front of panel of the restitution unit depending upon the type of DR used. A time synchronizing equipment based on GPS signal shall also be provided for time synchronization.

2. PLCC Power line carrier communication equipment complete for speech transmission line protection and data channels shall be provided for the transmission line at both end of the line. For the purpose of matching of frequency of transmission and receivers at the two ends of the line, the equipment at both ends of the line shall be arranged by the Transmission Agency . Only wave trap and PLCC battery feeders have been considered for cost purposes.

22.00.00 CONSTRUCTION POWER The requirements of the construction power supply for the project would be met from proposed 11 kV arrangement in stage-I.

23.00.00 BLACK START FACILITY No separate dedicated black start facility is being envisaged for this project. The arrangement to get the black start-up power from the Grid shall be as per the RLDC’s startup procedure of the region.

24.00.00 ELECTRICAL LAB EQUIPMENT One set of electrical lab equipment shall be provided for the plant.


CONTROL & INSTRUMENTATION SYSTEMS

1.00.00 GENERAL Since this project is an extension of 2X500MW units of stage-I, running almost concurrently, the C&I system will be designed and procured as that of 3X500MW unit. The function of the Control & Instrumentation System would be to aid the operator in achieving safe and efficient operation of the unit, resulting in cost effective power generation with optimum fuel consumption and reduced emission levels. The C&I system would be of the type which normally relieves the operator of continuous duties and would take pre-planned corrective actions in case of process drift or if unsafe trends or conditions develop in any regime of operation viz. startup, shutdown, normal working and emergency conditions. The design of C&I system would be such as to permit on-line localization, isolation and rectification of fault in the minimum possible time.

2.00.00 CONTROL ROOM CONFIGURATION & LAYOUT Control Room of Unit #3 shall be separate. Programmer’s Room, UPS etc will be at operating floor along with Control Room. The boiler, turbine and generator along with their associated auxiliaries would be controlled and monitored from the Common Control Room. The control system cabinets and equipment would be located in air-conditioned Control Equipment Room (CER) at operating floor. UPS, 24V DC Modular Power Supply and associated batteries would be located at + 8.5 meters below CER. It is proposed to locate Steam and water Analysis System (SWAS) room for the unit at +0.0 meters. The exact locations of these items shall be finalized according to the main plant layout. For Unit #1 & #2 common control room will be there as envisaged.

3.00.00 UNIT CONTROL & MONITORING PHILOSOPHY As per the currently used practices for main plant control, Large Video Screens (LVS) would be provided for all regimes of operation. A Unit Control Desk (UCD) for mounting monitors / Keyboards (KBDs) would also be provided which shall generally be used as a back-up for all regimes of operation. For operation during disturbed/emergency operating conditions in the plant, very very few back-up conventional devices / instruments like hardwired TRIP push button stations, would also be provided on the UCD itself in draw-out sections. The control, monitoring & operation of the off site and auxiliary plants shall be carried out from control desk of the respective plants / combined control rooms. Large scale integration of control systems, unification of various control areas shall be attempted to economise on number of operation and maintenance staffs, inventory etc. in line with recent practices. It shall also be possible to control all the plant auxiliary system with DDCMIS based control system through redundant station wide LAN (envisaged in stage-I already). The center of Stage-II offsite and auxiliary plants if separate, shall also be controlled from the same common C&I system.


For all such plant information, link shall be provided for collections of data in the main plant control room for the information of unit-incharge/shift-incharge etc. through Station Wide LAN.

4.00.00 MEASURING INSTRUMENTS (PRIMARY & SECONDARY) The primary measuring instruments such as transmitters, switches, sensors etc., for the measurement of parameters like pressure, temperature, level, flow etc., would be used. Use of local gauges / switches shall be kept as minimum. Measurements like coal bunker level, coal feeder speed etc., and all other measurement systems required to ensure complete and satisfactory operation would also be included. Microprocessor based vibration monitoring system for monitoring of vibration of major equipments would also be provided. In view of the all round stress on clean environment and environmental monitoring instruments such as SOx, NOx, O2, CO2 and dust emission measurements shall also be provided.

5.00.00 DISTRIBUTED DIGITAL CONTROL, MONITORING & INFORMATION SYSTEM (DDCMIS) In line with current practices, microprocessor based Distributed Digital Control, Monitoring & Information System (DDCMIS) would be provided for the safe, reliable and efficient operation of Steam Generator (SG), Turbine Generator (TG) and Balance of Plant (BOP) and all auxiliaries. It is proposed to use optimum number of two-tier Large Video Screen (LVS) and Monitors for the purpose of control, information and alarm monitoring as mentioned above. Each of the screens would be 100% interchangeable (i.e. control or monitoring or alarming function for any part of the plant can be performed from any Monitor) and would provide complete control, monitoring, supervisory and display functions for control system variables and control system status. Changes in system configuration, tuning constants and similar engineering and maintenance functions would be done from Engineer/Programmer console. Adequate numbers of printers would be provided for logs, reports and alarms. In addition to this, historical data storage and retrieval system would be provided. Alarm Annunciation System and Sequence of Events Recording System (SERS) will be envisaged to be performed in DDCMIS itself. It is envisaged to provide alarm analysis system for this project. Advanced software packages, which result in improving the efficiency of power plant operations such as, heat rate, combustion efficiency, plant life monitoring etc., would be examined and included during specification stage.

6.00.00 SG-C&I SYSTEM The SG –C&I system would generally include the following:


1 Furnace Safeguard Supervisory System for Boiler 2 Secondary Air Damper Control 3 Auxiliary PRDS Control 4 Soot Blower Control 5. Coal Feeder Control, etc. 6. Acoustic steam leakage system (ASLD) 7. Boiler Metal temp, Boiler Drains & Vents including Start up Drains &

vents. 8. Other miscellaneous SG related controls

7.00.00 TG-C&I SYSTEM The TG -C&I system would generally include the following: 1 EHG Control System

2 Automatic Turbine Run Up System (ATRS) 3 HP-LP Bypass Control System 4 Main & BFP Turbine Stress Control System (TSCS) 5 Automatic Turbine Testing System (ATT) 6 Turbine Protection System 7 Main & BFP Turbine Supervisory Instruments (TSI) 8 Generator Auxiliaries Control System 9. TG Area Vents, Drains including start up Drains & Vents 10. Other miscellaneous TG related controls

8.00.00 BALANCE OF PLANT (BOP) C&I SYSTEM The balance of plant C&I system would generally include the following as a minimum: 1 Modulating Control of the Steam Generator

2 Modulating Control of the Feed Water/Condensate Cycle 3 Binary Control of the Auxiliaries of the Steam-Generator (SG) 4 Binary Control of the Auxiliaries of the Turbine-Generator (TG) 5 Control of Electrical System Breakers and Balance Equipment 6 Other miscellaneous controls for common / off-site areas.

9.00.00 COMMON SYSTEM Controls for the following common systems are being envisaged.

9.01.00 ASH HANDLING SYSTEM DDCMIS:


Ash Handling Control System comprising of binary and modulating Controls of dry and wet ash handling system, bottom ash handling system, ash slurry pumps etc.

9.02.00 COAL HANDLING SYSTEM DDCMIS:- Coal Handling Control System comprising of binary and modulating controls,of crushers , conveyers, dust suppression systems etc.

9.03.00 WATER SYSTEM DDCMIS:- Water System Control System comprises the binary and modulating controls of DM plant, CPU Re-generation system, PT plant, Liquid Effluent Treatment system , Cooling Tower system, Ash water recirculation system etc.

9.04.00 MAKE UP WATER SYSTEM DDCMIS:- Make up Water Control System comprises of binary and modulating controls of Make-up water pumps, Raw water pumps etc.

9.05.00 OTHER COMMON SYSTEM DDCMIS:- A Stand-alone common system shall be provided for control and monitoring Of some common system plant like Compressor, CW system, Air conditioning System, Ventilation system etc. and for some station level controls / supervisory functions.

10.00.00 CONTROL AND INSTRUMENTATION FOR PLANT AUXILIARY PACKAGES LIKE FIRE PROTECTION, HYDROGEN PLANT ETC. Programmable Logic Control (PLC)/ Micro PLC based complete and independent Control and Instrumentation System with all accessories, auxiliaries and associated equipment and cables would be provided for the safe, efficient and reliable operation of Hydrogen Generation plant with independent MMI system. Microprocessor based system along with intelligent detectors for Fire Alarm and Protection system and associated cables and accessories. PLC based control and instrumentation systems for Fire water pump house, Foam system pump house and Hydrant Booster pump house. All the above system will be connected to Station LAN. Provision for operation of the above systems through supervisory control.

11.00.00 STEAM & WATER ANALYSIS SYSTEM (SWAS) Recognizing the importance of water chemistry in the power plant a comprehensive Steam And Water Analysis System (SWAS) is envisaged for on line analysis of chemical parameters at all critical points in condensate, feed water and steam cycle.

12.00.00 POWER SUPPLY SYSTEM (UPS & DC SYSTEM) To provide AC & DC power supplies to various C&I systems under SG, TG & BOP C&I systems, following power supply has been envisaged in line with present practices.


Uninterrupted Power Supply (UPS) system to feed AC load like Human Machine Interface (HMI) and peripherals of DDCMIS and SG/TG C&I system, etc. The UPS would consist of chargers, inverters, batteries and distribution boards. Independent 24V DC modular DC power supply systems with Ni-Cd batteries shall be provided for independent control systems. Each set of power supply system shall consist of 2X 100% chargers, 1X100% Nickel-Cadmium batteries for one hour duty, 1X100% DC distribution board for powering the DC load requirement of Contractor’s system. Major Control systems like SG-C&I system, TG-C&I system, BOP-C&I system, CW pump house, Water system etc. shall be provided with two such sets of power supply system. Remote I/O cabinets wherever feasible shall be powered from the nearest power supply system to the extent possible, considering the voltage drop requirements. For other remote I/O cabinets independent power supply modules with sealed maintenance free Ni-Cd batteries, suitable for mounting in remote I/O cabinets shall be provided. Intelligent Battery management system shall be provided for each set of 24VDC power supply system of rating 300 Amps or above and UPS batteries.

13.00.00 CONTROL VALVES, ACTUATORS & ACCESSORIES Control valves would be pneumatically operated in most of the applications. However, for few applications electric/hydraulic actuators would be employed. Electronic microprocessor based positioners shall be provided for pneumatic control valves and dampers.

14.00.00 INSTRUMENTATION CABLES All instrumentation cables including both prefabricated and non-prefabricated type would be with Fire Retardant Low Smoke (FRLS) type Poly Vinyl Chloride (PVC) overall sheath. Multi pair cables of 0.5 sq. mm. shall be used extensively for C&I cables. Wherever required prefabricated cables may also be used. Fiber optic cables shall be provided for Remote I/O bus, CCTV, Station LAN etc.

15.00.00 PUBLIC ADDRESS SYSTEM A central exchange based Public Address (PA) system would be used to provide proper communication throughout the plant (including Coal Handling Plant) with the help of handset stations, loudspeakers, potable handset stations etc. systems shall be integrated with the Stage-I system.

16.00.00 CLOSED CIRCUIT TELEVISION (CCTV) SYSTEM In addition to public address system, to provide security and surveillance of different operating areas in the plant and as an aid to operators Digital Closed Circuit Television (CCTV) system would also be provided.


Adequate number of dome type cameras with facilities like zoom, pan, tilt etc. would be provided at various operating areas. The monitors would be located at control locations such as central control room, operation in-charge room etc. CCTV System shall be interfaced with DDCMIS MMIPIS to portray plant images on the LVS. This shall be integrated with Stage-I system. System shall be common for three units. Only additional no. of cameras for Unit #3 will be added to the Stage-I system.

17.00.00 PROCESS CONNECTION & PIPING Impulse pipes, Instrument air/ Service air headers and pipes shall be provided on as required basis along with all supports. All process transmitters/switch devices would be installed in Local Instrument Enclosures (LIE) in boiler area and in Local Instruments Racks (LIR) in turbine area. LIRs will not be provided for auxiliary plants where grouping of instruments is not feasible.

18.00.00 MAINTENANCE & CALIBRATION EQUIPMENT No separate maintenance and calibration for this stage is required.

19.00.00 PLANT PERFORMANCE ANALYSIS, DIAGNOSIS & OPTIMIZATION SOFTWARE (PADO) PADO for Phase-II i.e. (Unit-3) shall be attempted to be integrated with Unit 1 & 2 PADO system.


ENVIRONMENTAL ASPECTS 1.00.00 INTRODUCTION

NTPC proposes to expand the capacity of Vallur Thermal Power Project by installing one unit of 500 MW under Phase – II in the existing premises of Vallur TPP near Ennore, district Thiruvallur of Tamilnadu.

1.00.01 STATUTORY CLEARANCES

An Environmental Impact Assessment (EIA) report for the Vallur TPP Stage–I (Phase-II) (1 X 500 MW) will be prepared. Application along with EIA report, Executive Summary and FR, will be submitted to Tamil Nadu State Pollution Control Board for Public Consultation. MOEF will be approached for Environmental Clearance after Public Consultation.

2.00.00 POLLUTION CONTROL MEASURES Various pollution control measures proposed to be adopted to minimize the pollution from the power projects are as follows.

2.01.00 Water Pollution The source of water for the project shall be sea. (Bay of Bengal). While raw water after desilting shall be used for cooling, the sea water shall be desalinated for other plant usages such as potable water requirement, generation of D.M water, service water, HVAC system etc. A desalination plant shall be set up at the project for generation of sweet water. An effluent management scheme will be implemented to optimize various water systems so as to reduce intake water requirement as well as effluent discharge. The scheme shall essentially involve collection, treatment and recirculation / disposal of various effluents. The details of water system for the project are described as follows: A closed cycle cooling system with natural draft cooling towers will be provided. Therefore, no thermal pollution is anticipated. Cooling tower blow down shall be used for coal dust suppression and ash handling system. Adequate treatment facilities shall be provided to all the waste streams emanating from the power plant. The D.M. plant regeneration waste will be neutralized, mixed with boiler blow down and led to the inlet of desalination plant. The waste from coal handling plant would be high in suspended solids. A settling pond would be provided and waste from coal stockyard, crusher house, track hopper, transfer points etc; would be routed through this settling pond. The decanted waste from the settling pond would be sent to CMB for further dilution and disposal. For oily wastes, oil water separator would be provided. The separated oil will be removed from the top. The water at the bottom will be brought to CMB through main plant drain. The effluent from coal settling pond, unused cooling tower blow down, ash water blow down, desalination plant reject and underflow from de-silting basin shall be discharged through central monitoring basin(CMB).


The ash effluent shall be brought to a well designed ash disposal area to ensure adequate settling for ash particles. Effluent from ash dump area and blow down from ash water recirculation system shall be brought to CMB. The sewage from plant and township shall be led to sewage treatment plant. It will be provided with appropriate biological treatment system to control BOD and suspended solids. The treated effluent conforming to prescribed standard shall be discharged into the lagoon, leading to sea.

2.02.00 Air Pollution Control System High efficiency electrostatic precipitators (ESPs) will be installed to limit the particulate emission to 100 mg/Nm3. To facilitate wider dispersion of remaining particulates and gaseous pollutants (SO2 and NOx), single-flue chimney of 275m height shall be provided. Space provision has been kept in the layout for retrofitting Flue Gas Desulphurization (FGD) system, if required in future. For the control of fugitive dust emissions within and around the coal handling plant and coal stockyard, dust suppression systems shall be installed. The chimney shall also be provided with facilities for online monitoring of stack emissions.

2.03.00 Noise Pollution The major noise generating sources are the turbines, turbo-generators, compressors, pumps, fans, coal handling plant etc. from where noise is continuously generated. Acoustic enclosures shall be provided wherever required to control the noise level below 90 dB (A). Wherever it is not possible technically to meet the required noise levels, the personnel protection equipment shall be provided to the workers.

3.00.00 SOLID WASTE MANAGEMENT The ash management scheme for ash generated from power plant involves dry collection of fly ash, supply of ash to entrepreneurs for utilization, promoting ash utilization and safe disposal of unused ash. The company will make maximum efforts to utilize the fly ash for various purposes. Unused fly ash and bottom ash shall be disposed off in the ash pond. A blanket of water shall be maintained over the ash pond to control fugitive dust emission. After the ash pond is abandoned, it shall be reclaimed through vegetation.

4.00.00 AFFORESTATION Greenbelt has already been proposed under Stage-I. In addition, large scale afforestation and green belt development activities shall be implemented in all available spaces within and around the main plant and township areas along with the implementation of the project.

5.00.00 POST OPERATIONAL MONITORING PROGRAMME Regular monitoring of different environmental disciplines like air, water, etc. are proposed during Stage-I (Phase-I) and shall be continued for Stage-I (Phase-II) also. The monitoring locations will be finalized in


consultation with state pollution control board. Station will be equipped with all necessary equipment and manpower required for ensuring effective monitoring.

6.00.00 INSTITUTIONAL SET UP An Environmental Management Group (EMG) will be established during Stage-I (Phase-I) and the same shall be responsible for Stage-I (Phase-II) activities also. The EMG shall be equipped with all necessary instrumentation / equipment and manpower required for ensuring effective monitoring. The EMG will interact with State Pollution Control Board for all environmental issues.

7.00.00 ASH UTILIZATION Ministry of Environment & Forest’s Notification on Ash Utilization dated 14-09-1999 and its amendment dated 27-08-03 stipulates that new power stations shall have to utilize ash to the extent of 30% in 3 years of commissioning and to attain 100% utilization by 9th year. NTPC Limited – as a socially conscious utility considers utilization of ash produced at its coal based power station as a thrust area of its activities. Vallur Thermal Power Project, Stage-I, Phase-II (1x500 MW) shall be produced about 2500 tonne of ash per day. At this thermal power plant, various avenues for utilisation of ash in various application areas shall be explored. In order to meet the requirement of MOEF Gazette Notification for ash utilization following actions are proposed: 1. The company shall provide system for 100% extraction of dry fly ash

along with suitable storage facilities. Provision shall also be kept for segregation of coarse and fine ash, loading this ash in to closed / open trucks and also for loading rail wagons. This will ensure availability of dry fly ash required for manufacture of Fly ash based Portland Pozzolana Cement (FAPPC), asbestos cement products; ash based building products and other uses of ash.

2. The company shall make efforts to motivate and encourage entrepreneurs to set up ash based building products such as fly ash bricks etc.

3. NTPC has set up Fly ash brick manufacturing plant at various thermal power stations and fly ash bricks produced are being utilised in construction activity. For Stage-I, Phase-II construction works fly ash bricks shall be manufactured from ash produced in Stage-I, Phase-I to meet the requirement.

4. To promote use of ash in agriculture/ wasteland development – show case project shall be taken up in the vicinity of power stations.

5. Mining authorities will be persuaded to identify and allot abandoned mines for back filling with ash.

6. All government/ private agencies responsible for construction/ design of buildings, development of low lying areas, construction of road


embankments etc. within 100 kms of the plant area shall be persuaded to use ash and ash based products in compliance of MoEF’s Gazette Notification.

With all the efforts mentioned above - it is expected that fly ash generated at the thermal power stations shall be utilized in the areas of cement, concrete and asbestos cement products manufacturing, bricks manufacturing, road construction, mine filling etc. However, in order to prepare realistic road map for 100% Ash Utilization, a detailed market study shall be carried out. Based on recommendations of the study, detailed Road Map for 100% Ash Utilization in line with MOEF Gazette Notification shall be prepared and submitted to regulatory authorities.

8.00.00 CLEAN DEVELOPMENT MECHANISM (CDM) It is proposed to adopt sub-critical boilers with enhanced reheat steam temperature from conventional value of 540 oC at boiler re-heater outlet to 568 oC. This would result in improvement of gross heat rate by about 14.00 Kcal/KWh. thereby reducing the coal consumption per unit of electricity generation and consequent reduction in CO2 emissions. Since the change would be an improvement over conventional steam parameters used in India for similar size of units, it calls for change in certain material and design of intermediate pressure steam turbines, thereby, increasing the investment cost. However, improvement in heat rate (14.00 Kcal/ KWh) would result in reduction in coal consumption per unit of electricity generation and consequent reduction in CO2 emissions. Hence, Vallur Thermal Power Project, (1x500 MW) is likely to fulfill the requirements of CDM additionally.

9.00.00 ENVIRONMENTAL COST A cost provision of Rs. 4568.79 Million has been kept towards the environmental measures.


TECHNICAL DATA AND BILL OF QUANTITIES

SL NO DESCRIPTION QTY UNIT TECH. PARAMETERS

1.00.00 PRELIMINARY & CIVIL WORKS

1.01.00 Land Requirement

Land ( Additional Ash Disposal Area)

140 Acre

1.02.00 SITE CLEARANCE , LEVELLING AND GROUND IMPROVEMENT

1 Site clearance 2,80,000 M2

2 Earth work in filling with ash obtained from ash pond area with 95% compaction (Lead 16 kms)

3,00,000 m3

3 Earth work in filling with earth obtained from borrow area outside plant boundary with 95% compaction (Lead 25 kms)

1,60,000 m3

4 Earth work in filling with gravels 1,20,000 m3

5 Rip rap 7,300 M2

6 Ground Improvement Lot

1.03.00 ROADS, BRIDGES, CULVERTS, DRAINS, RAILWAY SIDING A Roads 1 Double Lane Cement Concrete

Roads (Outside Plant) 3.5 km

2 Double Lane Cement Concrete Roads (Inside Plant)

1 km

3 Single Lane Bituminous Roads (Inside Plant)

2 km

4 Single Lane Bituminous Roads with shoulder (Inside Plant)

1 km

5 Bridges LS B Drains 1 Rectangular Concrete Catch

drains 15 Km

1.04.00 BOUNDARY WALL & FENCING 1 Boundary wall

2 Km

1.05.00 STRUCTURAL STEEL Misc. Str. Steel

Document No.: 0261-999-NOG-J-001 R ’b’ Page 69 of 120


Document No.: 0261-999-NOG-J-001 R ‘a’ Page 70 of 120

Fabrication & erection of Misc. Structural Steel for Main power house A-B-C bay, Control towers, structure around TG, Mill/ Bunker building, Conveyor Galleries etc.

1. Structural steel (supply, fabrication & erection)

17500 MT

2. Electro Forged Gratings 200 MT 3. Stainless steel 60 MT 4. MS Black Foundation Bolts &

Nuts 152 MT

5. Misc. Items LS 1.06.00 PILING & FOUNDATION

All foundations like TG, Boiler, BFP, PA,FD/ID fans, coal mills etc.

Lot

1.07.00 GENERAL CIVIL WORKS

This includes civil and architectural works coming in the Main Plant area comprising of : TG Bay hall, Electrical/ Control bay, Control Tower, BC&CD bays, Mill/Bunker building, Conveyor Galleries & Transfer points, Cable & pipe rack & Ancillary Buildings a)Air washer room b)Compressor house c) D.G. set building d) ESP control room building

Lot

1.08.00 CHIMNEY 275 m single flue steel lined

RCC chimney with staircase and elevator

1 No.



1.09.00 PERMANENT TOWNSHIP Residential Buildings Lot 10 % over and above

Stage-I, Phase – I requirement.

1.10.00 Ash Dyke

a The ash dyke of max. 14.3 m height will have to be constructed, over 546 acres of land and shall comprise of starter dyke of 8.3 m height and 2 subsequent raisings of 3 m each using ash.

Lot For both phases (Ph-I & II)

b Additional ash dyke of max. 12.3 m height will have to be constructed, over 125 acres of land and shall comprise of starter dyke of 9.3 m height and one subsequent raising of 3 m using ash.

Lot For balance disposal requirement of Phase-II

1.11.00 Ash Handling System

1 Ash Slurry Pump House 1 No. 2 Ash Water Pump House 1 No. 3 Ash slurry Pipe Trench 310 M 4 Ash Slurry Pipe Supports 8 Km

Common for 2X500 MW +1X500 MW

5 Recirculation Pump House 1 No. For 1X500 MW 6 Recirculation Pipe Supports Lot For 1X500 MW 7 Air Compressor House 1 No. 8 Foundation for Fly Ash Silos 3 No. 9 Bottom Ash Slurry Pump House 2 No. 10 Silo area utility building 1 No.

Common for 2X500 MW +1X500 MW

1.12.00 CW System

Civil works related to CW Pump House, Fire & Service Water Pump House, Forebays, Stoplogs, Trash racks etc.

1.12.01 Part-I (C.W. System) 1 CW Pump House 1 No.

Capacities of various facilities of 2X500 MW have been increased to cater for additional 1X500MW



2 CW intake and discharge ducts (200 mm & 1700 mm dia steel lined and encased)

4000 MT

1.12.02 Part-II (Make-up Water System) 1 Make up water pipeline Lot 2 Desilting basin 1 No. 3 Make-up Water Pump House 1 No.

Capacities of various facilities of 2X500 MW have been increased to cater for additional 1X500MW

1.13.00 Water Treatment Plant Construction of DM Water Pump

House, DM plant building, Regeneration building, Chlorination plant building, Neutralising pit, DM Water and Condensate water tank foundations, pipe rack foundations, Chemical house of PT plant & other associated works

No separate water treatment plant. Capacities of various facilities of 2X500 MW have been increased to cater for additional 1X500MW

1.14.00 Fuel Oil Handling System

Construction of pump house, pedestals and other associated works.

No separate system. Capacities of various facilities of 2X500 MW have been increased to cater for additional 1X500MW

1.15.00 Switchyard Civil/ Structural Works

Towers & equipment foundations

Lot



2.00.00 MECHANICAL WORKS

2.01.00 Steam Generator & Associated Auxiliaries

1 Set Sub-critical, Natural/ assisted circulation, Drum type or once through with Single Pass (tower type) or Double Pass arrangement; direct pulverized coal fired, balanced draft, single reheat, radiant, dry bottom, suitable for outdoor installation.

2.01.01 Major Boiler Parameters

i. Maximum continuous rating 1590 T /hr

ii. Pressure at superheater outlet 179 kg/cm2 (abs)

iii. Temperature at superheater outlet

540 oC

iv. Temperature at reheater outlet 568 oC

v. Exit Flue gas Temp. at chimney inlet

later

vi. Efficiency based on performance coal at TG rating

later

2.01.02 Description / Quantity / Spec. (For One Set of SG)

i. Main Boiler pressure parts with enclosure, boiler structure including all platforms, stairs, walkways, ladders, handrails, galleries etc. (yes/no)

yes

ii. Soot blowing systems with controls (Yes/No)

yes

iii. Boiler Circulation Pump 3 No. 3 X 50%

iv. Air preheaters with water washing facilities, fire fighting equipments

2 2

No. No.

Rotary Regenerative, Bisector type Primary APH Secondary APH

v. SCAPHS (nos. per boiler) 4 No. Two for PA & Two for SA



vi. Milling plant with feeders, PA fans, seal air fans and drive motors.

To be decided by the supplier subject to specified criteria

Mill: Vertical spindle PA Fan: 2X60% Variable Pitch Axial fans Seal Air Fans: 2 X 100% Common for all Mills

vii. Draft plant including a. ID fans radial type with variable

frequency drive and associated controls.

b. FD fan axial type with drive

motor and accessories.

2

2

No. No.

ID fans: 2X60% Radial fans with Variable Frequency Drive and associated controls. FD fans: 2X60% Variable Pitch Axial fans with drive motor.

viii. ESP & ESP accessories with control system

Lot Inlet dust burden - Later Outlet dust burden - 100mg/Nm3 (At BMCR/ Worst Coal firing)

ix. Passenger cum goods elevators with all controls for SG

2 No. Capacity: 1 no. 3000 kg and 1 no. 1088 kg

x. ESP Control Room Elevator 1 No. Capacity: 8 persons

xi. Ducting, dampers, expansion joints etc

1 Lot

xii. Refractory, insulation and cladding 1 Lot

xiii. FSSS with SADC system 1 Lot

xiv. Coal and Oil Burners 1 Lot

xv. HFO/LDO Pressurization System with heaters and other accessories including interconnection with existing Storage tanks

Lot

xvi. Miscellaneous 1. Spares 2. Maintenance Tools & Tackles

Lot

2.02.00 TG & Auxilia

2.02.01 Turbine, Generator, Exciter and Auxiliaries

1 Set EMCR power output 500 MW (In case excitation is other than brushless

ries



type, the EMCR output at generator terminal shall be 500 MW plus excitation power requirement at EMCR)

Turbine Throttle Steam Pressure 170 Kg/cm2(abs) Turbine MS/ Reheat steam

Temperature 537 deg C/565 deg C

Final Feed Water Temperature at

EMCR condition. 253+/-5 deg C

Condenser pressure

As optimized by the bidder.

CW Temperature (Design/Maximum)

Design later/36 deg.C

2.02.02 Turbine driven Boiler Feed Pumps with booster pumps, couplings, drives and accessories.

2 No (2x50%) capacity

2.02.03 Motor Driven Boiler Feed Pump with booster pumps couplings, drives and accessories.

1

No (1x50%) capacity.

2.02.04 Condensate extraction pump 3 No (3x50%) capacity. 2.02.05 HP/LP bypass system 1 Lot Capacity of e HP/LP

bypass system shall be 65% of BMCR steam flow .

2.02.06 Condenser on load tube cleaning system for each half of condenser

1 No Sponge Rubber Ball type.

2.02.07 Condenser Air Evacuation Pump 2 No (2x100%) capacity. 2.02.08 Regenerative Feed Heating

System (HP & LP heaters) Number of HP & LP

heaters shall be based on optimization of feed heating cycle

2.02.09 Deaerator 1. No. Storage Tank capacity of 6 minutes of BMCR Flow between normal operating level and low low level.

2.02.10 Debris filters 2 No Self cleaning type of capacity 60% of the design flow through each condenser.

2.02.11 Central lube oil purification 1 Nos Clean & Dirty oil tank

th

.



system. capacity 1.5 times the capacity of MOT. Centrifuge capacity same as unit centrifuge.

2.03.00 IN PLANT COAL HANDLING SYSTEM

(3x500 MW, capacity revised from 1600 TPH to 2400 TPH)

1. Belting 9500 M

1800mm wide synthetic, cover thick 5/2 mm av. Belt strength 1250/4 FR grade

7400 M 2200mm wide synthetic, cover thick 5/2 mm av. Belt strength 1250/4 FR grade

2. Carrying Idlers

3705 No 35 deg. Troug., 3 roll, 152 mm dia 4 mm thick, 2 deg. Tilt (for 1800 mm belt width)

2925 No 35 deg. Troug., 3 roll, 152 mm dia 4 mm thick, 2 deg. Tilt (for 2200 mm belt width)

3. Impact Idlers

125 No As at (2) with rubber discs (for 1800 mm belt width)

125 No. As at (2) with rubber discs (for 2200 mm belt width)

4.

Return Idlers 1550 No

Single roll/ Double roll 10o trough 152 mm dia, 4 mm shell thick (for 1800 mm belt width)

1170 No. Single roll/ Double roll 10o trough 152 mm dia, 4 mm shell thick (for 2200 mm belt width)

5. Technological structure 1700

Te

1)MS fabricated



1000

900

3200

Te

mtr

mtr

2)Chute work-20 thk TISCRAL 3)90 lb/yd rail (for trippers) 4)105 lb/yd rail (for stacker reclaimer)

6. Pulleys

a)

Drive pulleys

18 No. M.S. Fabricated, 2000 mm face width, av. dia 1000 mm

11 No M.S. Fabricated, 2400 mm face width, av. dia 1000 mm

b) Other pulleys, (Tail, snub, bend & take-up)

108 No. M.S. fabricated, 2000 mm face width, av. dia 800 mm

66 No M.S. fabricated, 2400 mm face width, av. dia 800 mm

7. Drive motors

i) HT motors

27 No.

1000KWx2 800KWx2 450KWx1 380KWx1 350KWx8 300KWx3 230KWx4 180KWx4 200 KWx2

ii) LT Motors

2 No.

125 KW X 2

8. Reduction gears 29 No. Helical type with integral hold backs for drives in Sl.No.7

9. High speed coupling 29 No. Fluid couplings for drives in Sl.No.7 (27nos. Scoop cplg., 2 Nos. traction cplg)

10.

Low speed coupling 29 No. Full geared type for drives in Sl.No.7



11. Brakes 29 No. Electro hydraulic

thrustor type for drives in sl.No.7

12.

Belt cleaners

Internal

29 No. V-plough type

External 29 No. Double bladed spring loaded segmented Type

13. Flap gates 25 No. Motorized, M.S. fabricated

14. Rack & Pinion gates 2 No. MS fabricated, motorized.

15. Rod gates 2 No. Manually operated, MS fabricated

16.

Safety switches Lot

Pull cord, belt sway, zero speed (Typical)

18. Belt scales 2 No. Electronic type for continuous weighing for 2400 TPH

19. Magnetic separator 2 No. Inline type, 1000 gauss (for 2400 TPHconveyor)

2 No. Inline type, 1000 gauss (for 4000 TPH conveyor)

21. Metal detector 2 No. (for 2400 TPH, 1800 wide conveyor)

1 No. For 4000 TPH , 2200 wide conveyo

22. Samplers 1 No. For Raw coal (-) 100mm 4000TPH conv.

1 No. For crushed coal (-)20mm coal 2400TPH conv.

23.

Travelling trippers 6 No. For 2400 TPH rated capacity conv

- fixed tripper 8 No. -do-

24. Monorails & hoists Lot Electrical operated

r



25. a) crushers with complete drive unit

2 No. 2000 MTPH, Ring granulators Input -100 mm output -20 mm

b) Vibrating screening feeder with all accessories

2 No. Mech, 2000 TPH

26. Vulcanising Machine 2 No. -for 1800 mm wide belt

2 No. -for 2200 mm wide belt

27. Passenger cum goods lift 2 No. 1Te capacity (Rack & Pinion type)

28.a) Stacker mach 2 No. Traveling type, boom length 41m, 4000 TPH capacity

b) Reclaimer machine 2 No. Traveling type, boom length 41m, 2400 TPH capacity

29.

Dust Suppression system and dust extraction system

Lot -DS –plain water fine spray type -DE-- wet scrubber type - Dry fog system

30. a) Ventilation system

Lot Typical

b) Service water system

Lot Typical

c) Drinking water system Lot

Typical

31. Mandatory sp

Lot Typical

32. Special tools & tackles

Lot Typical

33. Vibration Monitoring System 1 No. For crusher house

2.04.00 FUEL OIL UNLOADING & STORAGE SYSTEM , 3 X 500MW

(Common for Phase- I & II)

1 Unloading pump motor set (HFO/LSHS/HPS)

3 No. 50 Cu M/hr

2 HFO storage tanks complete with suction heater, floor coil heater, insulation, cladding, accessories, instruments e

2 No. 2100 Cu M

3 PRDS station for Aux. steam 2 No. 15 T/hr

ine

ares

tc



4 Fuel oil unloading hoses, steam and condensate hoses

10

10

10

05

No.

No.

No.

No.

75NB-8M Long for HFO 50NB-8M Long for Steam 50NB-8M Long for Condensate 75NB-8M Long for LDO

5 LDO unloading pumps motor set 2 No. 50 Cu M/hr 6 LDO storage tanks complete with

all instruments and accessories 2 No. 500 Cu M

7 Unloading pump suction strainer 10 No. 200NB 8 Drain oil tank to collect oily drains

in the pump house area. 1 No. 6 Cu M

9 Drain oil pumps to collect the drains from the drain oil tank and pumping it back to the main tank (HFO/LSHS/HPS)

2 No. 10 Cu M/hr

10 Sump pumps 2 No. 30 Cu M/hr 11 Design of oil water separator pit

along with facilities for removal of water and oily waste

Lot

12 Complete fuel oil piping, steam tracers, condensate piping, valves, fittings, steam traps, insulation hangers and supports etc

Lot

13 Instrumentation and control system including instruments, interfacing with main plant control room, protection devices

Lot

14 Flow meter For HFO unloading system LDO unloading system

1

1

No.

100 Cu M/hr for HFO/LSHS/HPS 50 Cu M/hr for LDO

15 HOT crane in FO unloading pump house (Hand operated Monorail Hoist)

1 No. 2 tonnes

16 Dirty oil pump for pumping out Dirty oil from the oil water separator unit

2 No. 5 Cu M/hr

17 Water pump for pumping out clear water from the oil water separator unit

2

No.

30 Cu M/hr

18 Condensate Flash Tank 1 No. 2 Cu M 19 Day Oil tank for Auxiliary Boiler 1 No. 100 KL,



20 2 No 25 Cu.M./hr

2.05.00 ake up Wat em (For

1. 4 No Vertical wet pit type Cap : 4700 Cum/hr Head : 35 mWC Motor : 575 KW

2. Butterfly Valv 4 No 900 NB – Motor operated

3. Rubber Expansion Joints 4 No 900 NB

4. Traveling Water Screens 4 No Flow / Screen:4700 Cum/hr

5. Discharge pip 80 M 900 NB ; 10 mm thk

6. Recirculation pipe line 30 M 600 NB; 6.3 mm thk

7. Recirculation 1 No 700 NB - Motor operated

8. EOT Crane 1 No 10 Tonne Capacity

9. 12000 M Buried MS Pipe : 900 NB; 10 mm thk

10. solation Valv 6 No 900 NB – Motor operated

11. 3 No Each of 15 Kg/hr

2.06.00 CIRCULATING WATER SYSTEM (for 3 x 500 MW)

a) CW pumps & Drives 6 Sets Vertical wt pit or CV type Cap: 31,000 M3 /hrHead: 28.5MWC; Motor rating: 3100 KW

b) Unit Assemb W Motor 1 Motor rating: 3100 KW c) Butterfly valves for CW Pumps 6 Nos Electro hyd. Operated

2200 mm NB Size d) Rubber Expansion joints 6 Nos 1800 mm NB e) 1 No 50 T Capacityf) Duct Interconnecting Valves 3 Nos Motor operated; 2200

mmNB g) 60 M 2200 mm; 20 mm thk h) CW system blow down piping 30 M 600 mm NB; 6.3 mm thk i) line 50 M 1200mm NB; 12 mm thk j)

System 1 No 1200 NB – Motor

operated k) Cooling Towers 3 Nos Type: NDCT

LDO transfer pump motor sets

M3x500 MW) Makeup Water pumps & Drives

er Syst

es

es

valve

es

ly of C

Makeup Water Pipes

I

Electro Chlorination

EOT Crane

CW discharge pipes CW recirculation pipe Recirculation valve for CW



Fill : Splash type Capacity : 60000 cu.m/hr Range: 11 deg C W.B.T: 27.2 deg C Cold Water temperature : 32.5 deg C RH :60%

2.07.00 a) ps 3 Nos Horizontal Centrifugal

type Cap:2500Cum/hr; Head : 18 m WC

b) m)

3 Nos Horizontal Centrifugal type Cap:1300Cum/hr; Head :35 mWC

c) DM cooling water booster pumps (SG System)

2 Nos Horizontal Centrifugal type Cap:1250Cum/hr; Head: 70 mWC

d) Plate type heat exchangers (TG System)

3 Nos 3 x 50% for each unit.

e) Plate type heat exchangers (SG System)

2 Nos 2 x 100% for each unit

f) Chemical storage equipment and dosing system

2 Sets Two per Unit

g) Interconnecting piping, valves, fittings, instrumentation & controls

LOT

2.08.00 MISCELLANEOUS PUMPS (for 3 x 500 MW) a) HVAC makeup pumps& drives 2 Nos Horizontal Centrifugal

type Cap: 100 M3

Head: 60 MWC;

b) AHP – Seal water Pumps 2 Nos Horizontal Centrifugal type Cap: 120 M3

Head: 20 MWC; c) Service water pumps 2 Nos Horizontal Centrifugal

type Cap: 230 M3/hr ; Head: 80 MWC;

EQUIPMENT COOLING WATER SYSTEM (for Phase – II) Auxiliary cooling water pum

DM cooling water booster pumps (TG Syste

/hr ;

/hr ;



d) Air pre-heater wash pumps 2 Nos Horizontal Centrifugal type Cap: 450 M3/hr ; Head: 110 MWC;

e) Boiler fill pumps 2 Nos Horizontal Centrifugal type Cap: 175 M3/hr ; Head: 150 MWC;

f) Condensate Transfer Pumps 3 Nos Horizontal Centrifugal type Cap: 300 M3/hr ; Head: 70 MWC;

g) DM water Make-up pumps 4 Nos Horizontal Centrifugal type Cap: 85 M3/hr ; Head: 65 MWC;

h) Potable water pumps 2 Nos Horizontal Centrifugal type Cap: 70 M3/hr ; Head: 100 MWC;

2.09.00 DESALINATION PLANT (for 3 x 500 MW) a) Complete Desalination Plant

including required Pre-treatment System, chemical Dosing Equipments etc

LOT Type of Process : RO 1st Stage SWRO: Capacity : 3 x 275 Cu.m/hr 2nd Stage RO Capacity: 3 x 85 Cum/hr

b) Permeate Water Storage Tanks 3 Nos Vertical cylindrical Steel Tanks each of capacity 5000 Cum

2.10.00 DM PLANT a) s 3 Nos Capacity : 75 Cum/hr

each b) 3 Nos Vertical cylindrical Steel

Tanks each of capacity 1200 Cum

2.11.00 a) Chlorination plant (CW system) 3 Sets Cap of each Set: 100

Kg/hr b) Chlorine leak absorption system

for Chlorination plant(CW System)

1 Set

2.12.00 CONDENSATE LISHING PLANT (for 3 x 500 MW) a) Condensate polisher vessels & 6 Nos Cap: 640 M3/hr each

Final DM (MB Units) Stream

DM Water Storage Tanks

CHLORINATION PLANT (for 3 x 500 MW)

PO



all accessories b) Complete regeneration system

incl resins, acid/alkali storage /day /measuring tanks, dosing pumps, interconnecting piping, instrumentation, panels etc.

LOT

c) DM water storage tank for CPU Regeneration

2 Nos Capacity 450 cum each

2.13.00 EFFLUENT TREATMENT SYSTEM (for 3 x 500 MW) a) em LOT Coal Slurry Settling

Ponds:4 Pumps : 3 noTank & Piping : Lot

b) LOT Waste water pit :1 Waste water pumps:3 Tube settlers: 2 @200M3/hr Treated water tank :1 Effluent water pumps:3 Piping : Lot

c) Central Monitoring Basin 1 No RCC of 600 Cum d) Final Disposal Pumps 2 Nos Horizontal Centrifugal

type Cap: 4500 M r ; Head: 25 MWC; Motor: 425 KW Materials suitable for Sea Water

e) Final Disposal Piping 4000 M MS pipe of 1400 mm dia & thickness 10 mm with Polyurethane lining

2.14.00 FIRE DETECTION AND PROTECTION SYSTEM (for 3 x 500 MW) a) 3 Nos

b) Hydrant pumps & drives 1 Nos Horizontal Centrifugal type Cap: 410 M3/hr ; Head: 88 MWC; Diesel Engine

c) Spray pumps & drives 1 Nos Horizontal Centrifugal type Cap: 410 M3/hr ; Head: 120 MWC; Diesel Engine

Coal slurry treatment syst

Waste Service Water treatment system

s

3/h

Hydrant pumps & drives



d) Spray pumps & drives 1 Nos Horizontal Centrifugal type Cap: 410 M3/hr ; Head: 120 MWC; Diesel Engine

e) Jockey pumps & drives

2 Nos 75 M3/hr & 100 MWC (Motor Driven)- Vertical pumps

f) Hydrant Booster Pumps 1 No Cap :170 Cum/hr 50 mWC

g) Hydrant Booster Pumps

1 No Cap :170 Cum/hr 50 mWC Diesel Engine driven

h) Hydrant & spray system mains piping, indoor & outdoor hydrants, hoses/boxes , couplings, etc

LOT

i) HVW Spray system for various equipments

LOT

j) MVW Spray system for coal handling plant

LOT

k) MVW Spray system for cable galleries

LOT

l) MVW Spray system for fuel oil tanks

LOT

m) Foam injection system for fuel oil tanks

LOT

n) Inert Gas Extinguishing system for Control/ Control equipment rooms

LOT

o) Analogue addressable fire detection and alarm system incl. all the panels, cables etc.

LOT

p) Fire Extinguishers (Portable & mobile type)

LOT

2.15.00 AIR COMPRESSORS (for 3 x 500 MW) a) Air compressors with control

panels, instrumentation. & all accessories like piping, valves etc

8 Nos Oil free Screw type Cap: 35 NM3

Pressure: 8 Kg/Sqcm

b) ADP with panels, instrumentation, all accessories like piping, valves & electronic dew point meters

5 Nos Oil free Screw type Cap: 35 NM3

Pressure: 8 Kg/Sqcm

/min

/min



c) Air receivers 11 Nos Cap : 10 Cumd) Air receiver for WT plant 1 No Cap :2 Cum

2.16.00 AIR CONDITIONING SYSTEM (for 3 x 500 MW)

a) A/C Plant for Main Plant building

(For CER etc) 4 Nos VAM type : 2 nos

Cap : 400 TRScrew chillers : 2 nos Cap: 400 TR

b) A/C Plant for Service building

3 Nos VAM type : 2 nos Cap: 200 TR Screw chillers : 1 nos Cap: 200 TR

c) AC Plant for Administration building

2 Nos Screw chillers : 2 nos Cap: 300 TR

d) lding 2 Nos DX type: 2 nos Cap : 75 TR

e)

LOT

f) ting etc for various LOT

g)

LOT

2.17.00 VENTILATION SYSTEM (for 3 x 500 MW)

a) Air washers for TG building 12 Nos Cap : 200000 CMH with DIDW fans sheet metal construction

b) Circulating water pumps 12 Nos 200 Cum/hr @ 35 mWC c)

AC plant SWYD control bui

Split type ACs/ Window type ACs & PAC s for Miscellaneous areas

AHUs, Ducareas

Cooling towers, pumps , piping, valves etc

All accessories such as piping, ducting, grills, dampers, valves, diffusers instrumentation, panels etc for TG building.

LOT

d) Central unitary air filtration system for ESP & VFD building

6 Nos Cap : 35000 CMH with SISW fans

e) SISW centrifugal fans for ESP & VFD building

6 Nos Cap : 35000 CMH with SISW fans

f) Circulating water pumps 9 Nos 25 Cum/hr @ 40 mWC g) All accessories such as piping,

ducting, grills, dampers, valves diffusers, dampers, instrumentation, panels etc for ESP & VFD building.

LOT

h) Ventilation System for Misc areas LOT



2.18.00 ASH HANDLING SYSTEM , (1x500 MW)

2.18.01 Bottom Ash Handling System Alternative-I (Jet Pump System)

a. Three V -Type water impounded Hoppers, Complete with Supporting Structure and Accessories

1 No. 462 m3

b. Clinker Grinders with Drive (gear box and fluid coupling), support structure and accessories(suitably lined for sea water use)

6 No. 70 TPH

c. Jet Pumps (suitable for sea water use)

6 No. 70 TPH

d. Basalt lined piping and valves for Bottom Ash Slurry Transportation Pipe

3 Km. 250 NB (ID of basalt liners)

e. Flushing Apparatus for Economiser Ash Hoppers and associated Pipe-Work (suitably lined for sea water use)

8 No.

f. BA overflow tank (suitable for sea water application i.e. MS with concrete lining.)

1 No 120 cu m

g. BA overflow water pumps (slurry duty) (suitable for sea water use)

2 No 350 cu m/hr, 15 MWC

h. Overflow water piping and valves(suitable for sea water use)

Lot

2. Alternative-II (Submerged Scrapper Chain Conveyor System) a. Dry Type Bottom Ash (BA)

Hopper Complete with Supporting Structure & Accessories

1 No. 250 m3

2 No. 75 TPH or

b. Submerged Scrapper Chain Conveyor assembly. (all the components such as chain, scrapper bar, links etc which are in contact with sea water shall be suitable for sea water duty)

4 No. 38 TPH

c.

Clinker Grinders with Drives and Supporting Structure(suitably

2 No. 75 TPH or



lined for sea water use) 4 No. 38 TPH d. Flushing Apparatus for

Economizer Ash Hoppers & associated Pipe- Work(suitable for sea water use)

8 No.

e. Horizontal Bottom Ash Slurry Pump with Drives(suitable for sea water use)

3 No. 275 m3/hr, 25 mwc

f. Basalt lined piping and valves for BA slurry Transportation Pipe Line

2 Km. 200 NB (ID of basalt liners)

g. Cast Iron Liners (20 mm Thick) for B.A./Economizer Slurry Trench and BA Sump Sluicing Nozzles & Associated Piping & Valves(suitable for sea water use)

Lot

h BA overflow tank (suitable for sea water application i.e. MS with concrete lining.)

1 No 120 cu m

i BA overflow water pumps (slurry 2 No 350 cu m/hr, 15 MWC

j verflow w piping and able for sea water

Lot

k Monorail Hoist for BA Slurry se

1 No. 2T capacity

2.18.02 Fly Ash Handling System

1 Alternative-I (Vacuum conveying System)

a. Mechanical Vacuum Pumps with drives &accessories.

8 No. 3000 m3/hr, 15” Hg vacuum

b. Cast Iron Pipeline with Fittings Spool Pieces etc. alongwith Valves

1 Km. 250/300 NB

c. Wetting Head/Collector Tank Towers with Air Washer, Supporting Structure and all Accessories (Wetting head to be suitably lined for use of sea water)

8 No. 60TPH

d. Buffer Hopper with Supporting Structure and all Accessories

4 No. MS, 25 m3 CAPACITY

e. Instrument Air Compressor with 2 No. 7.5 m3/min @8kg/cm2

duty) (suitable for sea water use)

Ovalves(suituse)

Pump Hou

ater



Drives Heater/Air Drying Pant & Accessories

f. ESP Hopper Aeration Blowers with Drives, Heaters and all Accessories

2 No. 100 m3/hr. @ 5 MWC

g. Buffer Hopper Aeration Blowers with Drives, Heaters and all Accessories

2 No. 75 m3/hr. @ 5 MWC

2. Alternative-II (Pressure conveying System)

a. Air Lock/Pump Tanks 160 No. b. Bellow Type Expansion Joints 160 No c. Air Compressor with Drive & Air

Drying Plant and Accessories 5 No. 40 m3/min. @ 4.0

Kg/cm2 d. MS Pipe Line with Fittings &

Spool Pieces alongwith Valves 1.5 Km. 150/200 NB

e. Buffer Hopper with Supporting Structures and Accessories

4 No. 20 m3

f. Wetting Head/Collector Tanks along with Supporting Structure and all Accessories

8 No. 60 TPH

g. Instrument Air Compressor With Drive Heater/Air Dryer and accessories

2 No. 8.5 m3/min @8kg/cm2

h. ESP Hopper Aeration Blower With Drive, Heater And All Accessories

2 No. 100 m3/hr @ 5 mwc

k Semi EOT crane for Conveying air compressor house

1 No. 3 T capacity

2.18.03

Dry Fly Ash Transportation & Storage System

a Transport air compressors complete with drive motor and accessories

3

No. 9950 m3/hr. @ 7 bar (g)

b Air lock/ pump tank at outlet of buffer hopper

8 No. 5 cu mtrs

c C.I. ash piping 3 Km. 300 NB d Structure steel silos 1 No. 1700 T e Dry ash unloader 1 No. 100 TPH f Hydromix dust conditioner 1 No. 100 TPH g Vent filter & accessories 1 No. h Telescopic chute 1 No. 100 TPH i Silo Aeration Blowers with

Drives, Heaters and all 1 No. 450 m3/hr. @ 7 MWC



Accessories 2.18.04 Combined Ash Slurry Disposal

System

1. For Jet pump system and SSC system

2 No. 1300 m3/hr, 48 MWC for Jet pump option

a. Combined Ash Slurry Disposal Pumps with Drives and accessories (5 Pumps are with Fluid Coupling & Gear Box and balance with belt drive)

2 No. 1050 m3/hr, 48MWC for SSC option

450 NB (ID) for Jet pump option

b. Cast Basalt lined slurry disposal pipe lines with bends, fittings, Valves etc. (MS shell of 6 mm thick with 20 mm thick basalt lining)

9 Km.

400NB,(ID) for SSC option

b1 Cast Basalt lined slurry disposal pipe lines with bends, fittings, Valves etc. (MS shell of 6 mm thick with 20 mm thick basalt lining) Note : For ash disposal to additional area

12 Km. 450 NB (ID) for Jet pump option 400NB,(ID) for SSC option

c. Semi-EOT Crane 10 tonne capacity 2. Sump Pumps a. Sump Drain Pumps with Drives

and accessories for Combined Ash Slurry Pump House (suitable for sea water use)

2 No. 20 m3/hr,10 MWC

b. Sump Drain Pumps with Drives for BAPH (SSC System) (suitable for sea water use)

3 No. 20 m3/hr. 10 MWC

2.18.05 Ash Water System

1. For Jet Pump System (Alternative-I)

Note : All the water pumps shall be suitable for sea water application ie casing made of 18% Ni CI D2 type and impeller shall be of ASTM A351 CF8M

a. Bottom Ash LP Water Pumps with Drives and accessories

1 No. 400 m3/hr, 30 MWC

b. Fly Ash HP Water Pumps with Drives and accessories

1 No. 700 m3/hr, 65 MWC



c. Ash Water Piping Complete with Bends and Valves (Piping and valves shall be suitable for sea water application and shall be of SS/ HDPE or MS with PU coating.)

Lot

2. Submerged Scrapper Chain Conveyor System (Alternative-II)

Note : All the water pumps shall be suitable for sea water application ie casing made of 18% Ni CI D2 type and impeller shall be of ASTM A351 CF8M

a. Bottom Ash LP Water Pumps with Drive and accessories

1 No. 480 m3/hr, 30 MWC

b. Fly Ash HP Water Pumps with Drive and accessories

1 No. 750 m3/hr, 65 MWC

c. BAHP Water pump with Drive and accessories

1 No. 160m3/hr, 40 WC

d. Ash Water Piping Complete with Bends and Valves (Piping and valves shall be suitable for sea water application and shall be of SS/ HDPE or MS with PU coating.)

Lot

2.18.06 Painting of structures and equipments suitable for corrosive environment due to coastal power station.

Lot

2.19.00 ASH WATER RECIRCULATION

SYSTEM (For 3x500 MW)

i) Decanted ash water pumps 3 No Horizontal Centrifugal type Cap: 1600 M r ; Head: 30 MWC; Motor: 190 KW Materials suitable for Sea Water

ii) Decanted ash water pipes 4000 M MS pipe of 800 mm dia & thickness 8 mm with Polyurethane lining

iii) Decanted Ash Water Pumps (Future)

2 No Horizontal Centrifugal type

M

3/h



Cap: 1200 M r ; Head: 45 MWC; Motor: 180 KW Materials suitable for Sea Water

iv) Decanted ash water pipes (Future)

6000 M MS pipe of 500 mm dia & Thickness 6 mm with Polyurethane lining

3.00.00 ELECTRICAL SYSTEMS

3.01.00 Generator busduct and Neutral grounding equipment

3.01.01 Isolated phase busduct a), Main run (Single phase run)

179 M 19000 Amp

b), Delta run (Single phase run) 79 M 11000 Amps c) Tap off run (Single phase run) 45 M 1600 Amps d) Other Misc item, accessories

like CT’s, Bends, flexible

3/h

joints, connectors etc.

Lot

Set t

3.02.00 Generator/Unit/Tie Transformers

Generator transformer 3 No /420kV/√3 single

Unit transformer with OLTC +/-10%

1 No

Station transformer with OLTC 1 No 0/40/40 MVA,

3.03.00 Auxiliary transformers, 11/3.45KV Class

) Unit auxiliary transformer b) Ash Handling/CHP service

transformer

1 No

e) VT & SP cubicles 3 f) NG equipments & CTs 1 Se

g) Supporting structural steel

50 MT

200 MVA Gen Vphase With +/- 5% off ckt tap changer 45 MVA Gen V /11.5 kV

+/-10%

8400/11.5/11.5 kV

a 2 No 16 MVA 7.5 MVA



3.04.00 er (Indoor)

Unit Service Transformer 2 No VA, 11/0.433KV tation service transformer, L.T. Transformer (outdoor)

a) ESP & Ash water/ TAC service transformer

6 No

b) Vacuum pump house Ash handling transformer

2 No

c) AWRS Service Transformer (for AWRS - B)

2 No

3.05.00 H. T. switchgear (with orking

& metering system)

a) 33 kV 33 kV loose panel

b) 11 kV swgr i) Unit swgr Panel ii) Station swgr 22 Panel

Unit Auxiliary Switchgear 36 Panel witchgear P i) Make up Water Switchgear

1 Panel

3.06.00 Phase segregated Bus ucts

i) 11kV segregated Bus Ducts

400 M A, 100 KAp

0

iii) Other accessories for bus duct connection, terminations bends etc.

Lot

3.07.00 ar & Bus Duct

Lot

3.08.00 ding Resistor

i) 300 A, 11 kV 3 No ii) 300 A, 3.3 kV

3 No

L.T. transform

2000 KS 2 No 2000KVA, 11/0.433 kV

1600 KVA, 11/0.433 kV 1000 KVA, 11/0.433kV 1000 KVA, 33/0.433kV

numerical relays, netw

2 No

30

c) 3.3 kV

i)ii) Ash Plant S 15 anel

ii

D

2500A, 40K

ii) 3.3 kV Bus Duct 60 M 3000/2500A, 40KA, 10KAp

L.T. switchge

Neutral Groun



3.09.00 DC Battery and Charger

a) D.C. battery (Ni-Cd) i) Unit Batteries 2 No AH teries

(Float cum Boost)

ii) AWRS Batteries

2 No

3.10.00 Power Cables

11kV Grade XLPE 11.5 Km ii 3.3kV Grade XLPE 20.5 Km

3.11.00 rade Power & Control Cables

a) Power Cables 230 Km les

225 Km

3.12.00 DG V

ical Protection & metering for Generator,

r Transformer b) Disturbance, recorder for

1 Set

3.13.00 Cabling, arthing and Lighting Protection

L

3.14.00 Lighting System L t

3.15.00 Construction power

Lot

3.16.00 Overhead Line

33 kV S/C O/H Line 15 ii) Isolator 4 No iii) Lighting Arrestor

12 No.

220 V, 990

ii) AWRS Bat

2 No 110 V, 80 AH

b) Battery chargers

i) Unit Batteries 2 No 220 V, 990 AH 110 V, 30 A

i) HT Cable

) 1.1 kV G

b) Control Cab

Sets

1 No 1250 kVA, 415

a) Numer

Generato

1 Set

generator

E

ot

o

11 kV Ring Main

33 kV Equipment &

i) Km 3 Pole, 400 A



3.17.00 er Supply Arrangement

L

3.18.00 Switchyard A

ys b) Generator Transformer Bay 1 No ) Station Transformer Bay

4.00.00 CONTROL & N

ffsite Plant

Lot it of

Township Pow ot

420 kV, 2500 A, 40 KGIS switchyard

a) Line Ba 2 No Complete in all respect

c 1 No

INSTRUMENTATIOTotal Plant C&I System (For

Main Plant & Ofacilities)

One set for each unplant & one set main

common for off-site areas

COST ESTIMATE & FINANCIAL ANALYSIS

1.00.00 GENERAL The Current Project Cost estimate for Power Station and Facilities (Annexure- 1.1) of Vallur TPP, Phase-II (1x500MW) as of 4th Qtr.’2007 is as follows:

(Rs. in Million)

Project Cost excluding IDC : 23006.07

Interest During construction (IDC) : 2696.34

Project Cost including IDC : 25702.41

Working Capital Margin (WCM) : 633.10

Project Cost including IDC & WCM : 26335.51

Cost/MW (incl. IDC & WCM) : 52.67 2.00.00 BASIS OF COST ESTIMATE 2.01.00 Preliminary & Civil Works

Various items of packages covered in the cost estimates are based on the scope of work defined in Technical Data & Bill of Quantity (Chapter- 10). The cost estimates (Annexure-1.1.1) for most of the packages under this head are based on the awarded rates for various ongoing projects of NTPC and suitably updated to current price level i.e. as of 4th Qtr.’2007.

2.02.00 Mechanical, Electrical & Coal Transportation

Cost estimates for the Mechanical & Electrical Equipment System (Annexure - 1.1.2, 1.1.3) are based on the award/ bid prices for various ongoing projects of NTPC suitably updated to current price level i.e. as of 4th Qtr.’2007. Considering the project as mega power project, no Customs Duty and Excise Duty have been considered for packages to be awarded on international competitive bidding basis. Excise Duty and CST have been considered on the indigenous packages.

2.03.00 Others

The provision for Establishment including Audit & Accounts have been kept 1.0 % of the Works Cost.

Pre-commissioning Charges have been kept as 0.50% of Works Cost. To provide for any unforeseen expenditure, 3% of the civil works cost and equipment cost has been kept as Contingency.

Lumpsum provisions of Rs 20.00 Million and Rs 5.00 Million have been kept for training of O&M staff and losses on Stocks respectively.


The provision for Consultancy has been kept as 1.00% of the Works Cost.

3.00.00 FINANCIAL ANALYSIS

3.01.00 Phased Fund Requirement

Anticipated phasing of required funds for power plant & facilities is shown at Annexure-1.1.5. This is based on the following considerations:

The schedule of design, procurement, fabrication and installation activities as per project master network, the terms of payment stipulated in the contract documents of similar equipment executed for other projects.

3.02.00 Project Financing

The proposed tentative financing plan with a debt-equity ratio of 70:30 is as given below: Foreign

Component Domestic

Component Equity : - 30% ECB Loan : - Domestic Commercial Borrowings/Bonds

: - 70%

Interest Rate : 11.50 % The equity component shall be met out of the internal resources.

3.02.01 Consequent upon the identification of the NTPC as one of the “Navratna”

Companies, the Board of NTPC has inter-alia been delegated the power to establish financial joint ventures and wholly owned subsidiaries in India or abroad with the stipulation that the equity investment of the PSE should be limited to 15% of the net worth of the PSE in one project limited to Rs. 10000 Million. The overall ceiling on such investment in all projects put together shall be 30% of the net worth of the PSE. The total equity contribution of NTPC in NTECL towards Vallur Thermal Power Project, Stage-I, 3x500 MW(Phase-I & II) will exceed Rs. 10000 Million and therefore necessary waival of Govt. of India would be required. Accordingly, GOI would be approached for accord of necessary waival at an appropriate stage.

3.03.00 Interest During Construction

Based on the phased fund requirement and considering the project being financed from loan and equity in the ratio of 70:30 and the equity and loan components being drawn simultaneously (Rs 3500 million equity as upfront). IDC for Power Plant and Facilities works out to Rs 2696.34 Million based on weighted interest rate @ 11.50%. The unit has been assumed to be commissioned (COD) in 42 months from the date of Main Plant Award. Details are given at Annexure- 1.1.6.


3.04.00 Working Capital Margin

Working Capital Margin of Rs. 633.10 Million (Annexure-1.1.7) has been provided, which is 25% of the Working capital requirement, and the same is calculated on the following basis:

A) Fuel Expenses i) Coal cost : 60 days requirement ii) Oil cost : 60 days requirement

B) O&M Charges : 30 days requirement

C) Spares : 1% of project cost

D) Receivables : 60 days requirement

3.05.00 Tariff Calculation

The 1st full year Costs of Energy (COE) & Levelised Cost of Energy at discounted rate of 12% for 25 years for the project has been worked out as follows:

Cost of Energy (Paise/kWh)

First Full Year Operation

TOTAL P/kWh 281.00

Fixed Charges P/kWh 149.00

Variable Charges P/kWh 132.00

Levelised Cost of Energy P/kWh 255.00

The above have been worked out based on the following assumptions:

a) Return on equity : 14% b) Weighted average rate of interest on loan capital : 11.50 % per annum c) Average depreciation : 3.60% per annum d) Interest on Working Capital : 12.75% per annum e) Annual operation : 7008 hours f) O&M Charges per MW : Rs 12.32 Lakhs g) Auxiliary power consumption : 7.5% h) Station heat rate : 2450 Kcal/kWh i) GCV of coal : 3900 Kcal/kg j) Coal price : Rs.1862.40 per MT Details are given at Annexure- 1.1.8.


PROJECT IMPLEMENTATION 1.00.00 PROJECT SCHEDULE The expansion unit shall be commissioned (Synchronization on coal) in 39

months from the Main Plant Award and Commercial Operation Date (COD) in 42 months from the date of Main Plant Award.

The implementation schedule of Vallur TPP, Phase-II (1x500 MW) is indicated in EXHIBIT No - X which shows optimum schedule for the project with different activities shown in bar chart. The zero date of the project has been reckoned from Main Plant Award. Activities like evaluation of tenders, commercial negotiations, finalisation of contract and placement of orders have been shown from the date of investment approval to the placement of main plant order.

2.00.00 PROJECT MANAGEMENT The major phases of the project during its implementation are classified as

under:- - Design and engineering phase

- Tendering and award phase - Manufacturing - Inspection and expediting - Construction/erection phase, and - Commissioning phase The methodology adopted for executing the project is elaborated below.

2.01.00 Planning Phase 2.01.01 Contract packaging

The entire project work is broken into well defined contract packages. Major aspects considered in packaging are:- 1. The packages formed are compatible considering the prospective

bidders which ensure adequate competition in bidding and consequent procurement at optimum cost.

2. The packages formed include such combinations of equipment and services that can be advantageously engineered for the preparation of specifications for bid documents and subsequent product design including manufacture/construction drawings.

3. The packages formed are mutually exclusive as well as collectively exhaustive.

4. The number of packages and their sizes are optimum for effective implementation.

5. It is possible to clearly define the responsibility for a package to individual engineering coordinator.


6. The terminal points of each package are clearly defined and proper tie ups of these points between packages ensured.

The packages are also classified as Corporate Centre packages and site packages. All contracts involving high capital cost, long equipment delivery periods or requiring intense engineering coordination and specialised engineering and procurement knowledge come under the classification of Corporate Centre Packages. For all the contracts identified on the above basis and defined in the form of a Project Contract Package list, the planning and control starts from the pre-award contract planning stage, i.e. from the preparation of specifications upto the stage the equipment/materials are delivered to the respective sites.

The development of contract packages is initiated at the stage when the Feasibility Report is being considered for Government approval. The contract packages are developed before finalisation of the Master Network programme of the project to ensure that Master Network heads are developed in accordance with the list of contract packages for better monitoring and control.

2.01.02 Master Project Implementation Programme-Master Network A Master Network (MNW), which is the overall programme of project

implementation, is finalised by the Corporate Monitoring group in consultation with Engineering, Contracts and site. The MNW is based on project contract package classification and has about 300 activities. It identifies the key milestone dates for each package in the areas of engineering, procurement, manufacturing, dispatch, construction, erection, testing and commissioning. The date of order of the main plant equipment is the zero date of the Master Network. The MNW forms the basis of all detailed physical scheduling for all contract packages.

3.00.00 TENDERING, AWARD OF CONTRACTS & ENGINEERING PHASE 3.01.00 Engineering, Planning, Monitoring and Control

The basic engineering studies are initiated as soon as Feasibility Report has been submitted and all major technical parameters of the projects are finalised and documented as part of Revised Cost Estimates (RCE) alongwith the detailed estimates of cost and quantities. The Engineering Services plan and schedule the project engineering activities within the time frame specified for the engineering milestones in the finalised Master Network. The engineering programme at Level-2 accordingly shows the dates for data availability, tender drawing release, specification release, bid evaluation and construction drawing release, etc. The schedule drawn up by each engineering discipline also takes into consideration the assistance from external engineering consultants that can be advantageously supplemented to the internal resources depending upon the complexity of an equipment system, the need for inducting latest available technology, the large quantum of fairly simple engineering work, etc. The engineering manpower resources are then allocated depending upon the priorities in the schedule of each engineering discipline.


Departmental reviews are conducted by Project Engineering Coordinators to evaluate the work actually performed vis-a-vis detailed schedules. Corrective actions within the scope of the discipline heads are identified and the plans updated. The Engineering status appraisal from the heads of different engineering disciplines is then reviewed to check the various areas of specification release, bid evaluation, drawing releases, etc. against the target Level-2 programme dates. If any delay is expected to affect the schedule of other control centers, the corrective action to rectify the situation by either re-allocating priorities of internal resources or by seeking the assistance of external engineering agencies is resorted to.

3.02.00 Contracts Planning, Monitoring and Control Based on the key event dates identified in the Master Network, detailed plan for pre-award activities up to award of every contract is finalised and monitored vigorously. When packages are awarded, detailed programme in the form of networks are tied up with the contractor to clearly indicate the owner’s obligation and the supplier’s responsibilities. The owner’s inputs in terms of land availability, construction power/ water availability, civil fronts etc. while that of the contractor’s in terms of drawing submission, manufacture, supply, transportation, erection and commissioning is clearly brought out in the programme. Contract coordinators of each package evaluate the progress for each work package against the schedules drawn up. Such evaluation indicates the causes of delay, if any, in meeting the schedules and suggests actions to be taken for rectifying this delay. Monthly progress reports on identified reporting heads reflecting the corrective actions to be taken in areas of delay are regularly submitted.

4.00.00 MANUFACTURING, INSPECTION AND EXPEDITING PHASE 4.01.00 Inspection and Expediting To expedite supplies from the vendors, expediters are posted at works of

major equipment suppliers. Expediting visits are also arranged periodically to the works of other suppliers to ensure that the work progresses as per schedules. The manufacturing programme and the quality plans finalised at the time of contract award are utilised by the expediters/inspectors for monitoring the manufacturing and quality status. Specified reports at regular intervals are submitted indicating the areas of schedule variances, if any, their likely impact on delivery schedules and any recommendations given to the contractor and/or suggestions for improvement in supply.

4.02.00 Quality Assurance An independent quality assurance group for ensuring the quality during the project engineering, procurement and manufacturing, as well as during material storages is organised in the Corporate Office. Before the award of any contract the QA deptt. discusses with the prospective contractors and finalizes mutually acceptable inspection programme and detailed quality plans. In the post-contract stage, the inspection reports generated


by the inspectors are reviewed to evaluate the quality status with respect to the specified levels and necessary coordination of all actions necessary to ensure the achievement of the required quality levels. The quality plans after discussions and finalization with the contractor form a part of the contract document. There is a close inter-action amongst Engineering, Contract Services, Inspection, Expediting and Quality Assurance groups and the project site in arriving at the quality plan and manufacturing and delivery programme. To ensure that only technically competent parties are awarded the contract, including those for major civil works, a system of pre-qualification of contractors, based on their technical competence, financial capabilities, past performance is adopted by NTPC. The enlistment of contractors has been of great help in executing projects in the desired manner and construction schedule have generally been adhered to without much delay.

5.00.00 CONSTRUCTION PHASE AND COMMISSIONING PHASE 5.01.00 Construction Planning, Monitoring and Control

Site activities start progressively with the award of identified packages. As earlier mentioned, based on the Master Network schedule (level-1 network), during the award, Level-2 networks are finalised, keeping in view the interface events needed to be realised. Execution group at site starts interaction with the contractors/vendors soon after the receipt of the Letter of Award to establish the site office. Based on the L-2 network, site Field Engineering Group also starts interaction with Central Engineering Group to get the required drawings in the sequence in which they are needed for continuous work for the next six months.

5.02.00 Project Review Team Meeting A project review team headed by the project head with members from various departments at the Head Office and site is constituted for every project to review the progress of project on a monthly basis. The meeting of the team is conducted every month. This is chaired by the project head and attended by different departments of Head Office and site. The meeting reviews both pre-award and post-award progress of each package. In pre-award review the progress in award of packages is reviewed and corrective measures are identified. Decision is taken to reduce/eliminate the effect of delay, wherever the award is delayed, so that project completion schedule is adhered to. In post award progress review major problems such as non-availability of desired drawings, clarifications, documents from various disciplines of corporate engineering group, non-receipt of required materials from various vendors, reasons for the same, remedial measures initiated, impact of such delays on the project progress and delay in placement of awards are taken up for decision in the project review team meeting.


Interface problems among engineering, contracts and site affecting project execution are also reviewed and appropriate decisions taken to expedite the release of drawings, materials and such other requirements. Budgetary review is also done during this meeting and shortfall, if any, identified and responsibility centre fixed to get the commitment. After every PRT meeting, the Chief Executive of the company is apprised of the critical issues that emerge during the PRT meeting by putting up an exception report. Chief Executive also takes a review meeting as per requirement based on criticality.


MANPOWER TRAINING AND PLACEMENT

1.00.00 ORGANIZATION STRUCTURE NTECL shall have a two-tier Organization Structure consisting of corporate center and site. The organization structures have been placed at EXHIBIT-XI & XII respectively. The corporate center focuses its attention mainly on the formulation of policies, guidelines, development of systems and procedures, which need to be adopted by the various responsibility centers. The project’s Business Unit Head reporting to the Chief Executive Officer at Corporate Centre shall be accountable for performance of the station.

2.00.00 TRAINING AND DEVELOPMENT NTECL has laid stress on Training and Development as one of the main measures for improving the performance of its employees. To achieve this a string of modern and well-equipped training institutes of the Promoting Companies shall be utilised.

3.00.00 TYPE OF TRAINING 3.01.01 Pre-Employment Training

Pre-employment training aims at providing requisite skills and confidence to the personnel, who enter the organization as fresh trainees at different induction levels. Three types of long-duration training schemes are in vogue in the parent company shall take care of this aspect of training. Sl. No.

Name of Scheme

Duration (Year)

1. Engineering Executive Training Scheme 1 2. Finance and Human Resources Executive

Training Scheme 1

3. Chemistry Executive Training Scheme 1 3.02.00 Post-Employment Training

Post-employment training provides opportunities to personnel at various levels of the organization hierarchy to take up higher responsibility and skills and also to reorient them to keep pace with the advancement in thermal power technology. This package basically has three components viz. Management Development, Specialized Training and Employee Development.

3.03.00 Management Development In recognition of the vital role that the management development has to play in the growth of the power sector, a Power Management Institute has been set up by NTPC, one of the Promoting Companies. The institute offers General Management programs, programmes for developing functional knowledge, induction and familiarization courses and


discussions on subjects of topical interest. The Institute also undertakes applied research, including development of materials and consultancy assignments in the various techno-managerial areas in the Power Sector. The services of this/other institute shall be utilised for development of NTECL employees.

3.04.00 Specialized Training Activities The specialized training activities, besides providing special skills, also strive to acquaint the employees with the latest technology around the world. This package of training includes the following areas:

3.04.01 Orientation of Power Plant Operations A large number of personnel inducted in the various areas of O&M have to be oriented in the operation & maintenance of 500 MW unit. These programmes include in plant operations, training in the power stations and study visits to manufacturers works.

3.04.02 Training Under-Contract Packages Training of the Company’s personnel by the suppliers has been provided for under different contractual agreements. Executives are being trained under this scheme to assimilate and build up in-house expertise in the contemporary technology intensive areas.

3.04.03 Training of Erection Personnel to Switch Over to O&M As a part of the total manpower strategy, 15 to 20% of the erection manpower will have to be switched over to operation and maintenance as and when the units come into the operation. These personnel, depending upon their level will be given appropriate training for their placement in the O & M position. The training apart from providing opportunities for career growth to individuals will go a long way involving the problem of erection personnel being rendered surplus, when project activities come to an end.

3.04.04 Simulator Training NTPC 500 MW training simulator commissioned at Korba is a dynamic training device for demonstrating plant operational concepts and the application of problem solving logic. This facility has a complete range of capabilities to train personnel in the various specialized aspects, particular to a power plant. This facility shall be utilised for development of NTECL employees also.

3.04.05 Advanced Training Abroad To provide necessary exposure on new developments in engineering and management fields, arrangements have been made for imparting specified need based training abroad in operations and maintenance to personnel down the line.


4.00.00 EMPLOYEE DEVELOPMENT PROGRAMS Short duration programme to develop and upgrade skills and long duration programs to attain higher educational levels have been formulated for the benefit of personnel at different levels.

5.00.00 INSTITUTIONAL SET- UP Training and development infrastructure facilities available at the corporate and projects of Promoting Companies shall be utilised for development of NTECL employees also.


OPERATION & MAINTENANCE PHILOSOPHY

1.00.00 GENERAL The purpose of this section is to broadly outline the operation and maintenance philosophy to be adopted for this project. This will act as a useful input for basic as well as detailed engineering of the project so that all required provisions for optimum operation and maintenance of this plant are made during the engineering stage itself.

2.00.00 OPERATION PHILOSOPHY 2.01.00 OVERALL REQUIREMENT 2.01.01 Base Load Station

Vallur TPP, Stage-II ( 1 x 500 MW) is a sea port fed coal based station and will be basically designed to work as base load station.

2.01.02 Design The design of Vallur TPP, Stage-II (1 x 500 MW) will cover adequate provision for the following:

a) Capability of rapid unloading from full load to no load under controlled conditions in not more than 20 minutes to minimize turbine cooling.

b) Capability to achieve full load within 30 minutes after synchronising subsequent to an 8 hour shutdown (overnight).

2.01.03 House Load Operation The main plant, auxiliaries as well as all associated systems and controls will be designed to permit house load operation, without shutting down the unit in the event of sudden loss of load demand due to tripping of transmission lines or other grid disturbances. It should also be designed for part load operation on consistent basis.

2.01.04 Participation in Load Frequency Control The design of main plant control systems will permit participation of variable pressure operation and two shift operation in load frequency control in the event of system disturbances.

2.02.00 DESIGN FOR HIGH UNIT AVAILABILITY 2.02.01 General

High availability of the unit and all associated auxiliaries and sub-systems is one of the main O&M objectives for ensuring high PLF and low partial loading. This objective will be implemented by adopting the following principles : - a) Use of equipment and systems whose design performance and high

availability has been fully established by a considerable record of successful operation for similar service conditions in coal fired utility power stations.


b) Use of only field proven design concepts and conservative designs. c) Special consideration for proper approach ease of operation and

maintenance while selecting the equipment and while finalizing the location and layout plans.

d) Strict implementation of quality assurance norms during design, manufacture as well as installation and commissioning stage.

e) Strict compliance with NTPC approved commissioning documentation, comprising of Standard Checklists, Testing Schedules and Commissioning Schedules etc., forming a part of commissioning documents for the project.

f) Easy accessibility and maintainability of the equipment shall be the prime consideration during selection of the same.

g) Approachability of equipment for easy operation shall be considered during detailed engineering stage.

2.02.02 Sizing of Critical Equipment-Margins & Standby Provision of adequate margins will be made while sizing all-important auxiliaries and sub-systems to ensure operation of the unit under the worst conditions and after normal wear. The following aspects will be kept in view: a) The unit as a whole shall be able to generate at 105% of the name

plate rating on a sustainable basis to meet the requirement of the grid.

b) Each major equipment ( fans, BFP’s, CEP’s, CC pumps, ECW pumps, CW pumps etc) will be capable of meeting 60% of Boiler MCR requirements. However, while sizing adequate range-ability and turndown capability will also be provided for proper operation of related control systems.

c) The unit and equipment control system shall be designed in such a way that the unit will survive the loss of a major equipment and continue to operate at a lower load.

d) The number and size of mills will be so selected that with worst coal at BMCR one mill will be spare. With worst coal at TMCR and also with design coal at BMCR two mills will be spare.

2.02.03 Coal Handling Plant The design and sizing of coal handling plant has an important bearing on station plant load factor. Hence, the following steps will be taken while designing the coal handling plant so as to ensure high PLF for the stations: a) CHP shall be able to meet the daily coal requirement considering

105% PLF and worst coal. b) Adequate standby capacity will be provided in the coal handling

plant and for crushers so that outage of a single crusher or other


equipment will have no effect at full load operation of station with worst coal.

c) CHP evacuation rate shall match with coal transportation system unloading rate such that there is no detention of loaded coal rake at the track hopper terminal.

d) Adequate number of properly designed suspended magnets and online magnetic separators, Metal Detectors will be provided to segregate magnetic and non-magnetic materials respectively.

e) To minimise the dust nuisance in CHP area, effective dust suppression system shall be provided in track hopper, bunker floor, transfer points and stockyard. Dust extraction system shall be provided in the crusher house.

f) Effective provision shall be made for accurate and reliable measurement of incoming coal and coal consumed by each unit.

g) In order to take care of unforeseen disruption in coal supplies, coal

stockyard equal to 30 days full load requirement will be designed at station end.

h) In order to avoid flooding of underground portions, all conveyor

galleries shall be over-ground except track hopper and connected conveyors.

i) Coal bunkers shall be designed to avoid choking /rat holing etc. after

carrying out coal flowability studies. j) Provision of blending of different types of coal shall be kept while

designing CHP so as to feed coal to bunkers within reasonable quality range.

2.03.00 DESIGN FOR EFFICIENT OPERATION The basic and detailed engineering of the project will be done so as to help in achieving high standard of operational performance especially with respect to efficiency & Heat Rate. This may include the following key indices. a) Low auxiliary power consumption b) Low make-up water consumption c) No oil support above 40% MCR operation with adjacent mills and any

combination of elevations. d) Optimum efficiency and heat rates for the units and their sub-system

by achieving design parameters.


Provision will be made for accurate and reliable measurement of coal receipt, coal consumption per unit, oil receipt and oil consumption per unit, total D.M. Water production and make-up water consumption per unit, generator output, auxiliary power consumption, flue gas oxygen content etc. These values will be fed to Information System (IS) and daily reports regarding receipt, consumption and stock position will be prepared. Adequate provision of sequence controls, safety interlocks and protection, automatic modulating controls and operator guidance messages through CRT will be made to assist the operators in safe and efficient operation of these units. Provision will be made for on-line performance calculations for the unit and major sub-systems in DAS. On line CRT display of heat rate penalties due to deviation of key parameters from the design values will be provided by HMI. Provision shall be made to monitor power being exported from the station.

2.03.01 To achieve optimum efficiency, following provisions shall be made :

a) Spray water for reheater steam shall be tapped from feedwater line after the high pressure heaters to take advantage of the gain due to feedwater heating. However, to compensate for the passing of spray control valves due to excess spray water pressure, multistage or equivalent valve shall be used before spray control valves.

b) Air preheaters and Milling system including hot air system shall be designed to achieve maximum permissible mill outlet temp. to achieve better pulverisation and combustion.

c) Condenser shall have a on line tube cleaning system. Provision shall also be made to supply condenser with clean & suitably chemically treated water to avoid fouling in condenser tubes and for proper functioning of the tube cleaning system.

d) High pressure feedwater heaters shall be designed for negative TTD to gain maximum heat from extraction steam.

e) Optimum heat transfer in boiler shall be monitored and effected by installing a boiler cleanliness monitoring system. Intelligent soot blowing using the above should be a part of the system.

f) HP and IP turbine first few stage fixed & rotating blades shall be designed so as to have minimum erosion between Overhauls. If required, coating shall be provided on turbine blades for preventing solid particle erosion.

g) Turbine shall be provided with high and sustained efficiency seals, with proven record of satisfactory performance.

h) Large equipments like ID fans shall be provided with variable frequency drive to reduce power consumption during part load operation.


i) Air Preheaters shall be provided with leakage control/minimizing

system for on line seal adjustment. j) Care shall be taken not to use film type fills in CTs to avoid blockage

and efficiency loss. k) ESPs and associated Flue gas treatment equipments shall be

designed to achieve parameters better than latest environmental norms for chimney gas without flue gas conditioning.

2.04.00 Instrumentation for efficiency monitoring a) Flue gas exit temp. measurement shall be done using multiple

thermocouple sensing from different points of a grid in the cross section of duct.

b) Pr. Helium Detector/Temp. measurement instruments at HP & IP turbine inlet and outlet, all extraction lines, drip lines and heater inlet/outlet feedwater line are required to be of very high accuracy to provide accurate temp. Press measurement for correct cylinder efficiency and heater performance calculations condenser performance with on line instruments. Condenser measurements to be accurate to η calculation

CW inlet/outlet Hotwell condensate temp. Air suction temp. c) Flue gas sampling provision at Air Preheater inlet and outlet shall

be of multiple probe type for collecting samples from different points in a grid across the cross section.

d) High temperature O2 probes shall be provided at the furnace exit so as to monitor combustion efficiency.

Instrumentation for Reliability : Main turbine/ Generator, BFP-TD shall be having on line performance & vibration based diagnostic system. Accuracy of the on-line instruments used for absolute pressure/differential pressure, temperature for determining cylinder efficiency, heater performance, condenser performance shall be of 0.2% class or equivalent.

2.05.00 DESIGN FOR ABT REQUIREMENT Under ABT regime, following further operating conditions are required to be taken care of : a) there are 96 time blocks in a day of 15 mins. each and there may

be a requirement of changing Unit load with change in frequency in each block.

b) Unit may have to be kept under reserve shut down and brought back fast as per grid demand.


c) Very high availability target (> 80%) to be met for full fixed charge recovery.

d) Minimum Partial Loading. To meet such extended requirements, following design considerations are to be met ; i) Unit should be designed for a faster ramp up/ Ramp down rate

without effecting undue thermal stresses. ii) Mills shall be designed so that they can be started and loaded fast

to meet the above requirement. iii) Unit shall be capable of meeting the requirement of fast start up

and quick loading till full load. iv) Steam generator, Turbine generator and their auxilliaries shall be

designed to run with satisfactory performance from one overhaul to another without requiring any major shutdown.

2.06.00 OPERATION MANAGEMENT SYSTEM (OMS) The operation of this project will be optimized by implementing Operation Management System of NTPC. This system covers clear definition of responsibilities of all key executives including shift-in-charge, AGM/DGM (Operation), AGM (O&M)/GM etc. and lays down the procedure for detailed analysis of O&M problems. It also covers the system of daily reporting to Corporate Office and monthly operation review team (ORT) meetings.

2.07.00 OPERATION REVIEW TEAM (ORT) MEETINGS. The following important aspect will be covered during the monthly ORT meetings: a) Review of actual performance of the station and each unit vis-a-vis

targets and norms for key operating parameters like generation, availability and deviations on heat rate, specific coal/oil consumption, make-up water consumption, auxiliary power consumption etc.

b) Review of specific O&M problems of the project and progress of corrective actions.

c) Review of external constraints like coal supply problems, power evacuation problems and other related difficulties.

d) Review of commercial and financial performance. e) Review of house keeping standard. Proper implementation of OPMS and regular ORT meetings are expected to help in achievement of high standard of plant operation.

2.08.00 TRAINING OF O&M PERSONNEL Since O&M cadre for this project is likely to be largely based on fresh engineering graduates, considerable importance has to be given to training of O&M personnel so that the required skills in various


specialised disciplines could be created in the shortest possible time. It is therefore very important to ensure that all engineers meant for maintenance first unit so that they could become fully familiar with their area of work (O & M Deptt. Is to be set up at least 24 months prior to synchronisation of unit). This will be achieved by: a) Study of O&M Manuals and Drawings. b) Review / Preparation and finalization of commissioning

documents. c) Supervision of pre-commissioning and commissioning activity. d) Preparation of documents for maintenance management

system. e) Participation in actual maintenance work in similar NTPC

project. f) Participation in annual overhauling work in one NTPC project. g) Training at manufacturer’s works in specialised

areas/simulator/other utilities. This on-the-job training activity will be co-ordinated by AGM (O&M) and Project Co-ordinator from Corporate OS. Training in the areas of operation and maintenance of modern facilities shall also be organised

2.08.01 TRAINING OF OPERATION ENGINEERS i) Simulator Training The operation engineers will undergo extensive training in the running units of NTPC projects and on replica simulator at Simulator Training Institute, Korba/Sipat. This training will be so designed as to fully equip the operators with the requisite know how and confidence to effectively handle all plant upsets and crisis situation which are likely to arise in a plant. ii) Training at manufacturers Works and other Utilities The operation engineers will undergo extensive training at manufacturers work for familarisation and for design/testing aspects. They will also be imparted training in the running units of other utilities also where new technologies have already been adopted by these utilities and our organisation is in the process of absorbing these technologies.

2.08.02 TRAINING OF MAINTENANCE ENGINEERS Maintenance engineers will undergo extensive training at other stations of NTPC, and other utilities. They will also be imparted training at manufacturers work for familarisation and for design/testing aspects.


3.00.00 MAINTENANCE PHILOSOPHY 3.01.00 MAINTENANCE MANAGEMENT SYSTEM

The maintenance of this project will be carried out as per the maintenance management system of NTPC, which has been evolved in consultation with BEI, UK and is presently being followed in NTPC projects. This system aims at maximizing the availability of generating units while ensuring minimum maintenance cost and safety of plant and personnel. The maintenance management system shall aim to have no break down from overhaul to overhaul. The maintenance management system covers organizational structures, preventive maintenance schedules, predictive maintenance detailed work specification covering all maintenance jobs, permit to work system, long term maintenance planning, safety aspects etc. This system provides for daily maintenance planning meeting for about 30 minutes for finalizing maintenance schedule for next 24 hours and resolution of interface problems between departments. These meetings are supplemented by meeting of HODs for half an hour daily to accelerate the decision-making process and to lay down the priorities and guidelines for maintenance work during the next 72 hours.

3.02.00 SPARE PARTS MANAGEMENT SYSTEM The primary objective of spare part management system will be to ensure timely availability of proper spare parts for efficient maintenance of the plant without excessive build-up on non-moving inventory. The spare parts management system will cover the following aspects: a) Proper codification of all spares and consumable. b) Spare parts indenting and procurement policy. c) Criteria for ordering of mandatory and recommended spares. d) Judicious fixation of inventory levels and ordering levels for

spare parts based on experience in similar projects. e) Development of indigenous sources/in house capability for

imported spare parts. f) Development of more than one source wherever practicable.

3.03.00 AVAILABILITY OF O&M MANUALS a) All contracts will include provision of 8 sets of “DRAFT” O&M

Manuals to be supplied by vendor within 12 months from the date of LOA.

b) The draft O&M Manuals will be reviewed by project engineering group / corporate engineering and corporate OS to ensure completeness and proper coverage. The final manuals will incorporate all NTPC comments.

c) Schematic diagrams, P&I diagrams, wiring diagrams, cable schedule, valve schedules , pipe schedule etc shall also be submitted by vendor.


d) “FINAL” O&M Manuals ( 15 sets prints and 3 CD ROMs), which will be distributed to all concerned as per the approved distribution policy of the company, will be available to all concerned at least 18 months prior to synchronisation of unit to avoid problems in preparation of commissioning document as well as proper installation & commissioning of equipment.

3.04.00 SPECIAL TOOLS AND TACKLES All contracts will include the provision for supply of two unused sets of all special tools and tackles which are required for installation, Commissioning and proper maintenance of plant and equipment. These two sets of special tools and tackles will be handed over to O&M department within one (1) month of commissioning of the first unit. Suitable lifting tools and tackles shall be provided for carrying out maintenance with full safety. Quick erect scaffolding for boiler furnace and set of sky climber shall also be part of special tools and tackles. Pneumatic tools, roller support in turbine rotors shall also be arranged.

4.00.00 COAL SUPPLY MANAGEMENT The minimum requirement of coal will be based on operating norms. However, the monthly requirements will be finalised through Coal Supply Agreements. In order to meet the actual requirements of the project, the mines will keep a provision for 10% increase or decrease in supplies from the agreed average level. The coal loading and handling plant at Mine and coal handling plant of NTPC will be designed to meet the peak requirement on daily basis with adequate reserve capacity to take care of normal breakdowns and maintenance requirements.

5.00.00 ENERGY CONSERVATION ASPECTS 5.01.00 INTRODUCTION

All consumers of electricity, irrespective of their power demand, are required to become conscious about energy conservation and should think of ways and means to optimise their energy consumption. But it is all the more very important for a power plant, which happens to be one of the biggest consumer of electricity, to think of reducing its own power consumption.

5.02.00 SELECTION OF STEAM PARAMETERS AND FEED HEATING CYCLE Thermal efficiency of the Cycle can be improved by raising main steam parameters (pressure and temperature), introducing reheating of steam at a suitable stage of expansion, improving condenser Vacuum and optimimizing regenerative feed water heating arrangement. Improvement in thermal efficiency means saving in fuel burnt in boiler and also


significant saving in power consumption of plant auxiliary equipment in turn an effort towards energy conservation. The thermal cycle parameters shall be optimised for this range of unit rating by selecting parameters of Main steam temperature, pressure, reheat steam temperature and condenser pressure to provide an optimum thermal cycle. The cycle employs regenerative feed water heaters thereby ensuring optimum turbine heat rate. The losses through flue gas have been kept to a minimum.

5.03.00 COAL HANDLING PLANT Coal Handling Plant for feeding coal to the Boiler Bunkers has been envisaged with the following major features to minimize the consumption of energy: a) Coal handling plant layout shall be finalized with very less number of

conveyers in order to minimize the total coal-conveying path. b) Crusher house height shall be reduced preventing un-necessary

conveying of coal to higher elevations. c) For dust control at coal transfer points dust suppression system shall be

provided exclusively for reducing the energy consumption levels to almost nominal values compared to dust extraction system, which are restricted to crush house only.

5.04.00 MONITORING OF KEY PARAMETERS The following critical parameters/systems shall be monitored regularly to keep them in line with design values and to achieve optimum efficiency: i) Boiler water and steam pressures. ii) Boiler water and steam temperatures. iii) Boiler water and steam flows. iv) Percentage of flue gas oxygen provided by a grid of probes and

excess air. v) Combustion air and flue gas side draft loss. vi) Exit gas temperatures at different sections. vii) Fuel and combustion air flows. viii) Superheat and reheat spray flows. ix) Boiler flame intensity from scanners as well as flame monitors. x) Condenser vacuum xi) Soot blower operation. xii) Unburnt carbon in ash. xiii) Oxygen & Carbon mono oxide in flue gas, provided by a reliable on-

line measurement. xiv) PF fineness and coal quality (as fired)


xv) CW inlet and CW outlet temperatures. The above list is not exhaustive. Any deviation in the parameters shall be corrected at the earliest. However, efficiency test as envisaged shall be carried out regularly to ascertain the efficiency gaps.

5.05.00 CHEMISTRY Continuous monitoring and control of water and steam purity in the plant cycle will further improve the heat transfer rate in heat exchanger tubes, reduce the erosion of power cycle equipment and damage due to carry over. EPRI study reports a cost to benefit ratio of over 1:1200 for steam & water quality systems which is indicative of the importance of this system. The on-line parameters are being monitored for steam & water analysis as follows: a) Specific conductivity ( Boiler water, condensate, feed water and steam

at different locations) b) Silica (Boiler water)/ steam c) Cation conductivity (condensate, feed water and steam different

locations) d) pH ( Boiler water,) e) Hydrazine( feedwater/) f) Sodium in steam, condensate and CPU outlet h) Dissolved Oxygen in condensate and feed water after deaerator i) Phosphate in boiler water j) Conductivity monitoring of hotwell water k) Conductivity of cooling water (after condenser) Besides the above, the trending and alarm of above parameters to be provided in control room and chemical laboratory To control all chemical parameters full flow condensate purification system preferably in deep mixed bed ( 2x50%) configuration shall be provided after CEP. Provision shall be made for wet preservation scheme in pre-boiler and boiler sections including nitrogen capping arrangement.

5.06.00 OPERATIONAL OPTIMISATION Automatic controllers are provided for plant optimization. The unit capacity controller shall set load demand keeping the safety of the equipment inherent. The main controllers used for optimum performance of the whole plant are as follows: a) Unit Capacity Controller

i) Boiler Capacity Controller


ii) Turbine Capacity Controller b) Combustion Control

i) Coal flow ii) Air flow

c) SH/RH Steam temperature controller d) Chemical dosing controller

i) Hydrazine ii) Ammonia iii) Phosphate

e) Main steam pressure controller f) FW flow Controller (Drum level)

i) Low range ii) High range

g) Deaerator level h) Hot well level i) HP/LP bypass j) PA header In addition to above, HMI is programmed to carryout on-line performance calculation like unit/turbine gross/net heat rate and efficiencies of boilers/Turbines/all major auxiliaries and thus giving immediate feedback to the management for analysis by unit performance improvement & optimisation. IS system also has provision for different logs.


MARKETING PHILOSOPHY

1.00.00 ALLOCATION OF POWER NTPC has formed a 50:50, Joint Venture Company with Tamil Nadu Electricity Board (TNEB) under the name and style of “NTPC Tamil Nadu Energy Company Ltd. (NTECL)”. The Joint Venture Company, NTECL is establishing a generating station at Ennore namely Vallur TPP near Chennai in the State of Tamil Nadu for supply of power to Tamil Nadu and its neighboring States. The capacity of Vallur Thermal Power Project is now being expanded to 1500 MW by adding another unit of 500 MW capacity as Phase-II of this project. The power from this expansion project (500 MW) capacity as Phase-II of this project. The power from this expansion project (500 MW) shall be utilized by Tamil Nadu and shall also be offered other states of the Southern Region. Tamil Nadu being JV partner and home state has shown interest for 75% of power from this expansion phase also in line with 750 MW of tentative allocation from Stage-I (2X500 MW) for this project. The allocation will further be subject to the beneficiary States/State Electricity Boards/Corporations/Distribution Utilities concluding the Power Purchase Agreement (PPA) with NTECL and would be subject to the beneficiaries ensuring compliance with the financial and commercial terms (including LC coverage) of the PPA. This includes opening/enhancing the letter of credit of the requisite amounts for the power being allocated to them and timely payment. In case of failure of the beneficiaries adhering to the conditions mentioned above, NTECL may shut off or restrict power supply and also reallocate the power in case beneficiaries default in payment or if they do not open LCs of an adequate amount in favour of NTECL.

2.00.00 ARRANGEMENTS FOR DRAWAL BY SEBS The power-generated from this station would be supplied into the EHV grid at the 400 kV bus bars of the station. The transmission of power from the project to various states is through Regional Transmission System of Power Grid. The transmission of this project would be implemented by Power Grid Corporation of India Ltd. for evacuation of power from this project and through SEBs transmission system.

3.00.00 TARIFF The tariff shall be notified by CERC or any other competent authority under Electricity Act, 2003 or any other Act/Regulation enacted by the Govt. of India from time to time as per directives/guidelines/tariff policy issued by Government of India. Through the tariff, NTECL would recover the Fixed Charges consisting of O&M charges, Depreciation, Interest on Loan, Return on Equity, Interest on Working Capital, Taxes, if any, and the fuel charges alongwith the Fuel Price Adjustments as fuel charges. The tariff would be applicable for the capacity and energy supplied at the EHV buses of the station, which would be fully accounted for through Regional


Energy Accounts prepared by the Regional Power Committee/Regional Load Dispatch Center or any other competent authority as defined as per Electricity Act, 2003. The losses beyond the bus bars of the station would be shared by various beneficiaries to ensure that NTECL is paid for all its energy sent out as metered at bus bar of power station.


FEASIBILITY REPORT

VALLUR THERMAL POWER PROJECT,

STAGE-I, PHASE-II (1 x 500 MW)

NTPC - TAMIL NADU ENERGY COMPANY LTD.

(A Joint Venture Company between NTPC and TNEB)

CONSULTANT :

NTPC Limited (A GOVERNMENT OF INDIA ENTERPRISE) NEW DELHI

DOC.NO. - 0261-999-NOG J-001-REV-a NOVEMBER, 2007

ANNEXURES

EXHIBITS

ANNEXURE- 1.1

SUMMARY OF PROJECT CAPITAL COST(CURRENT COST)

(MEGA)

PROJECT: Vallur STPP Phase II (1 x 500 MW) (IV Qtr,2007) (Rs. in Millions)Sl. Capital CostNo. Item Description Annexure No. FC IC Total

1.0 Preliminary & Civil Works

1.1 Land & Civil Construction Works Ann. No.1.1.1 0.00 6461.27 6461.271.2 Physical Contingency 0.00 193.84 193.84

Sub-Total 1.0 0.00 6655.11 6655.11

2.0 Plant & Equipment

2.1 Mechanical Equipment Ann. No.1.1.2 2781.75 10627.19 13408.942.2 Electrical Equipment Ann. No.1.1.3 0.00 1047.68 1047.682.3 Coal Transportation System Ann. No.1.1.4 0.00 0.00 0.002.4 Spares 171.89 488.97 660.862.4 Misc. Tools & Plants 0.00 0.002.5 Customs Duty 0.00 0.002.6 Excise Duty 0.00 0.002.7 Central Sales Tax 383.46 383.462.8 Service Tax 0.00 0.002.9 Physical Contingency 88.61 376.42 465.03

Sub-Total 2.0 3042.25 12923.72 15965.97

Works Cost (1.0+2.0) 3042.25 19578.83 22621.08

3.0 Pre Commissioning Expenses 113.11 113.11

4.0 Project Management

4.1 Establishment incl. Consultancy, Audit & Accounts 452.42 452.42

4.2 Training of O&M Staff 20.00 20.004.3 Losses on Stocks 5.00 5.00

Sub-Total 4.0 477.42 477.42

Project Cost excl. IDC (1 to 4) 3042.25 20169.36 23211.61

5.0 Interest During Construction (IDC) Ann. No.1.6 0.00 2561.53 2561.53a) Interest Charges 0.00 2478.24 2478.24b) Financing Charges 0.00 83.29 83.29

Project Cost incl. IDC (1 to 5) 3042.25 22730.89 25773.14

Cost/MW (Excl. WCM) 51.55

6.0 Working Capital Margin (WCM) Ann. No.1.7 633.70 633.70

Project Cost incl. IDC. & WCM (1 to 6) 3042.25 23364.59 26406.84

Cost/MW (Incl. IDC & WCM) 52.81

1 US$ = 38.48

vallur-ii feasibility report

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