khulna thermal power project

DOC.NO. -9635-999-NOG J-001-REV-‘C’ Dec. 2012

BANGLADESH POWER DEVELOPMENT

BOARD (BPDB)

FINAL FEASIBILITY REPORT

KHULNA THERMAL POWER PROJECT (2X660 MW)

BANGLADESH

CONSULTANT CLIENT

NTPC Limited BANGLADESH POWER (A GOVERNMENT OF INDIA ENTERPRISE) DEVELOPMENT BOARD (BPDB)

NEW DELHI DHAKA, BANGLADESH

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KHULNA THERMAL POWER PROJECT (2X660 MW)

EXECUTIVE SUMMARY

1.00.00 BACKGROUND AND INTRODUCTION

The present installed capacity (derated) in June, 2012 is 8,100 MW. Gas based power stations constitute 66.88 % of present generation capacity while coal based power plants constitute only 2.47 %. According to Power System Master Plan (PSMP) 2010 developed by Bangladesh Power Development Board (BPDB), the demand in 2030 will be about 33,000 MW and installed capacity is targeted to reach 38,685 MW. Out of this, coal based generation capacity is expected to be 20,000 MW. BPDB has also carried out generation expansion planning for the period 2012-2016, wherein total additional capacity to be installed by the end of 2016 is 13,154 MW including 1,320 MW proposed at Khulna.

During the visit of Honorable Prime Minister of Bangladesh to India in January 2010, an umbrella Memorandum of Understanding was signed on 11.01.2010 on Energy Cooperation between the two Governments and a Joint Steering Committee (JSC) co chaired by the Power Secretaries of two countries was constituted. In the first JSC meeting, various areas were identified for cooperation between NTPC and Bangladesh Power Development Board (BPDB) which included preparation of FR by NTPC Ltd. for two coal based power plants (at Khulna and Chittagong each of capacities of 1320 MW). The FR for Khulna is to be taken up in first phase and the project is proposed to be implemented as joint venture project between BPDB and NTPC.

MOU was signed with BPDB for implementation of 1320 MW coal based TPP at Khulna in Joint Venture on 30.08.10.

Contract Agreement for FR Consultancy for Khulna project was signed between NTPC and BPDB at Dhaka on 30.09.10.

As per the scope of the consultancy assignment, all the studies/investigations including topographical survey, geotechnical investigations, coal transportation logistic study etc. were to be carried out by BPDB. Survey and geotechnical details at the plant area have been received in Feb.2011.

Draft Feasibility Report (DFR) was submitted to BPDB on 31.03.2011.

Subsequent to submission of Draft FR meeting was held at Dhaka from 30thJuly to 1st Aug.2011 and during the meeting it was decided to review the civil cost mainly for adopting the ground improvement method suitable for Khulna site.

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A team of BPDB officials visited NTPC office at Noida from 26th Sept. to 29th Sept. 2011. During the meeting it was decided to reduce the land area for dredging and filling to 400 Acres instead of 425 acres considered earlier by reducing land area for township to 50 Acres instead of 75 Acres considered in DFR. In order to optimize the quantities for dredging and filling the final finished level was reduced to RL(+) 5.0M instead of RL(+) 5.5M. The method for ground improvement considered in DFR was Stone columns but due to non-availability of required sizes of aggregates, based on BPDB suggestion sand compaction piles have been considered.

Meeting was held in NTPC, New Delhi on 01.11.2011 & 02.11.2011 with BPDB officials and various sensitivity options based on coal cost, coal calorific value, interest rates and equipment cost were worked out and shared with BPDB.

BPDB informed in mid December 2011 that M/s CEGIS, Consultant for Coal Transportation logistics study has collected details and data and the same needs to be discussed and BPDB desired NTPC team to be deputed for this purpose. NTPC team visited BPDB office, Dhaka on 25th -27th Dec.2011.

Consultant report is available and based on available data following is recommended by the Consultant :

The major change as informed by CEGIS would be that cross country coal conveyor from Mongla port to project site would not be applicable as in their recommended option coal from ship would be transferred to barges by literage operation at outer bar and moved directly to project site. As such coal would not be unloaded at Mongla port.

The cost of coal for the recommended option of receipt of coal at jetty at power plant end shall be USD 145 per metric ton. Coal shall be unloaded at jetty at power plant end from barges.

The Draft Feasibility Report for Khulna Thermal Power Project comprising of two units of 660 MW was submitted to BPDB on 30.03.2011.

The Final Feasibility Report (Draft) for Khulna Thermal Power Project comprising of two units of 660 MW was submitted to BPDB on 31.12.2011. The comments received from BPDB on were incorporated in the Final Feasibility Report and same was submitted to BPDB on 20.07.2012. The comments received till 08.11.2012 from BPDB and 11.11.2012 from BPDB/PGCB have been incorporated in present Final Feasibility Report.

2.00.00 PROJECT HIGHLIGHTS

2.01.00 Location and Approach

The proposed project is located in Rampal Upazila of Bagerhat District. The site is bounded by villages Mouzas- Kaigar Daskati, Kapasdanga, of

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Gaurambha Union, Mouzas- Sapmari Katakhali, Baserhula of Rajnagar Union under Rampal Upazila. The plant site is located between latitude and longitude of 22deg. 37’ 0’’ N to 22deg. 34’ 30’’ N and 89deg. 32' 0’’E to 89deg. 34' 5’’E respectively. The site is located 23 Kms. Southward of Khulna City, about 12 Kms. North-eastward of Rampal Upazila Sadar and 14 Kms. North-eastward from Mongla Port. The proposed Khan Jahan Ali Airport is located at a distance of approximately 12 kms from the project site.

2.02.00 Site Selection

The power project site has been selected after examining three alternate sites identified for the project by BPDB. These sites were visited by the joint team of BPDB and NTPC and the present site near Rampal Upazila of Bagerhat District was recommended for setting up the project. This site is on the banks of Possur river, accessible by proposed road connecting Khulna Mongla Highway. Second site near Chumkuri is opposite to Rampal site and is on an island surrounded on all four sides by Possur river and does not have any road access and hence was not found suitable. The third site near Lobanchura is located on the banks of Rupsa river. This site has only about 400 acres fertile and mostly privately owned land, which is not sufficient for locating the power plant.

2.03.00 Capacity : 2x660 MW

2.04.00 Mode of Operation : Base Load

2.05.00 Fuel : Imported Coal

2.06.00 Land Requirement

For Khulna project, about 575acres of land will be required. The same includes 375 Acres for Plant, 50 Acres for Township, 50 Acres for Jetty and about 100 Acres of land for ash disposal (Ash dyke). No major issue is anticipated in acquisition as per discussions with BPDB officials.

2.07.00 Cooling Water Requirement, Source and System

The source of water for the project is saline water drawn from Possur River (about 2 kms), which is primarily back water of sea. Sweet water required for meeting the potable water, plant service water, cycle makeup (DM water) etc shall be produced using Desalination process from sea water. It is proposed to adopt Reverse Osmosis process for Desalination of saline water.

Make up water requirement for this project would be about 9150 Cu.M/hr. It is observed that water in Possur River is having very high silt content. In once through system, huge quantity of water will be required. Desilting of such huge quantity of water would be uneconomical. In cooling tower system, only make up water needs to be provided and can be desilted. Therefore, re-circulating type CW system with cooling towers and open

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intake channel has been envisaged for the project.

2.08.00 Coal Requirement, Availability and Linkage

The coal shall be imported coal having GCV as 6000Kcal/Kg with maximum 15% ash and max 0.6% sulphur for FR purpose the coal shall be imported coal. The daily coal requirement for 2 x 660 MW units shall be about 12920 tonnes based on average gross calorific value of 6000 Kcal/ kg at 100% plant load factor. Annual coal requirement for the project shall be about 4.72 MTPA.

Coal Quality The coal quality for FR purposes has been considered as imported coal and the same is as follows: Proximate analysis

Ash : 15 % GCV (kcal/kg) : 6000 Sulphur 0.6 %

Coal Transportation It is envisaged that coal shall be unloaded from barges at jetty near plant end, as confirmed by BPDB/CEGIS. The envisaged mode of coal transportation considered in FR from Jetty to the power plant is by conveyor system.

Coal Handling System

External Coal Handling Plant

The coal as received by barges at jetty near power plant end shall be unloaded through rail mounted grab bucket type ship unloaders and shall be conveyed to plant end by single stream 2000 TPH capacity conveyor system.

Internal Coal Handling Plant

The coal as received from jetty near plant end through single conveyor shall drop onto two either of vibrating screening feeders and crushers.

An independent coal handling plant is proposed to cater to the two (2) units of 660 MW. Coal handling plant consisting coal conveying system (with 100 % standby parallel stream) along with reclaimers, trippers etc.

2.09.00 Site Development & Civil Aspects

Natural ground levels as per the topographical survey are in the range of (+) 1.15 to 1.35 M above MSL. HFL for cyclone Ayla in 2009 floods as recorded and informed during site visits are (+) 4.47M above MSL. Hence, FGL is proposed as (+) 5.0M above MSL.

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The site is proposed to be raised by dredging & filling ‘river bed material’ from adjoining river Possur or river Maidara. Site is frequently exposed to cyclonic tides. Slope protection measures like ‘Stone Pitching’, ‘Sand/Aggregate Filter’ and ‘Geo-textile’ will be provided.

Ground Improvement

Natural ground as per the Geo-tech data received from BPDB consists of very soft clay up to 5M depth and further soft clay up to a depth of about 15M. Such soft soils offer negative drag on piles as well as very small lateral pile capacities. To achieve sufficient lateral capacities in piles, ground improvement is required. Ground improvement shall cover the entire plant and township area. During meeting BPDB suggested that due to non-availability of required sizes of aggregates, sand compaction piles may be considered and now in revised FR the same is considered.

Approach Road:

Two lane (12M wide) main approach road to plant site is proposed from Khulna-Mongla Highway. This will require about 20M wide corridor to be acquired for about 15 Kms. road length. This road shall be constructed by GOB/BPDB and cost provision for the same is not included in FR costs.

Coal Stock

Coal stock for 90 days is envisaged.

Ash Pond

Ash pond of 100 acres is assumed. Ash dyke will require ground improvement.

2.10.00 Steam Generator Technology

The steam generators shall be super critical once through type, water tube, direct pulverized coal fired, top supported, balanced draft furnace, single reheat, radiant, dry bottom type, suitable for outdoor installation. The gas path arrangement shall be single pass (Tower type) or two pass type. Steam pressure & temp. at Super Heater outlet shall be 256 kg/cm2 and 568 deg. C and temp. at Reheater outlet shall be 596 deg. C.

Boiler design shall be suitable for variable pressure operation from 30% to 100% BMCR with and without 5% throttle margin.

2.11.00 Power Evacuation System

Presently, EHV transmission system in Bangladesh is at 132 kV and 230 kV levels. 400 kV transmission systems have been planned along with the proposed coal based projects at Khulna & Chittagong and gas projects planned at Bibiyana. Part of Dhaka ring main 400 kV transmission network (400 kV line between Meghnaghat and Aminbazar) is under construction by Power Grid Company of Bangladesh (PGCB). To facilitate power transfer between India and Bangladesh, a synchronous interconnection

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through 500 MW HVDC back to back terminal station at Bheramara (Bangladesh) fed from Baharmpur(India) through 400 kV D/C line is under implementation.

The Indian portion 400 kV switching station at Baharampur along with 400 kV D/C line up to Bheramara is under implementation by Power Grid India and Bangladesh portion is being taken up by Power Grid Company of Bangladesh (PGCB).

In view of above and considering present Capacity of Khulna project as 1320MW, the step up voltage level of the project has been considered as 400 KV. Power Generated from each 660MW unit would be stepped up to the evacuation voltage level through suitably rated Generator Transformer.

As per the discussion and communication received from Bangladesh Power Development Board(BPDB)/ PGCB, provision of line bays in generation switchyard for one no.400 kV D/C line (envisaged to connected to Dhaka ring main) and one no. of 230 kV D/C line (envisaged to be connected to Khulna South) is being kept for power evacuation from the project.

The provisions for Power evacuation as considered presently are tentative and shall be reviewed based on finalized ATS of the project by BPDB/PGCB.

2.12.00 Project Cost

Current Project Cost (Incl. IDC & WCM (As on 1st Qtr. 2011) USD 1680.20 Million (145086.0 Million BDT)

Cost per MW USD 1.27 Million (BDT 109.91 Million)

Cost of Energy

• 1st Year 9.84 Cents/kWh (BDT 8.49) • Levelised 9.31 Cents/kWh (BDT 8.04)

2.13.00 Sensitivity Analysis

As desired by BPDB the sensitivity analysis on various suggested options are made and the same is enclosed.

2.14.00 Commissioning Schedule

The COD of first 660 MW unit of Khulna Thermal Power Project will be in 48 months from the Investment approval and second unit after an interval of 6 months thereafter.

2.15.00 Assumptions based on discussion with BPDB and input from Consultant on Coal Transportation logistics study, M/s CEGIS for FR formulation:

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i. All transportation to be made by water ways and the receiving point will be jetty near plant end .

ii. Coal transportation to the power plant is through single stream

conveyor from Jetty near plant boundary to plant.

iii. The landed cost of coal per ton at plant end is considered as US$145 as confirmed by BPDB / CEGIS.

iv. The major change as informed by CEGIS would be that cross

country coal conveyor from Mongla port to project site would not be applicable as in their recommended option coal from ship would be transferred to barges by literage operation at outer bar and moved directly to project site. As such coal would not be unloaded at Mongla port. The length of conveyor from jetty near plant end to plant has been considered as 800 meters and single stream conveyor capacity as 2000 TPH as confirmed by BPDB / CEGIS.

v. Cost of jetty and unloading facilities informed by CEGIS is 30 million

USD and same is considered.

vi. The cost of capital dredging from outer bar to plant site would be borne by Govt. of Bangladesh(GOB). The cost of maintenance dredging from outer bar to Mongla port would be borne by GOB. The cost of maintenance dredging from Mongla port to power plant site shall be booked to the power plant variable cost. The above have been confirmed by BPDB in MOM dated 26-27th Dec.2011, held at Dhaka. Maintenance dredging cost from Mongla port to plant jetty considered is 4 Million USD per year.

vii. From Mongla port to outer bar: 26 Million USD per year( to be borne

by Govt of Bangladesh)

viii. Two lane (12M wide) main approach road will be constructed by the Bangladesh Govt. to cater for heavy transport, trailers, ODC etc from Babur Bazar Point of Khulna Highway to Power Plant Site. Hence, cost provision for the same is not included in FR costs.

ix. Land Land: 400 acres of land will be developed after filling by

dredged material by GoB.

x. BPDB suggested reduction of 40% dwelling units and to replace few dwelling units by providing bachelor accommodation in order to further reduce the cost. The same is incorporated in the revised cost estimate.

xi. The existing ground level shall be raised to RL (+) 5.0 M above

MSL, considering HFL of cyclone Ayla floods (+) 4.47 M above

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MSL, by dredging & filling. Annual lease rent of land for the project is considered in FR as 50000Tk/acre/year as indicated by BPDP.

xii. The cost estimate for Steam Generator, ESP, Ash Handling Plant &

Coal Handling Plant is based on imported coal of GCV – 6000 kcal/kg & max ash content of 15% and max Sulphur 0.6%from Indonesia. Any change in coal source & its quality parameter will impact the cost estimates & tariff calculations.

xiii. Coal stock yard for 90 days consumption is envisaged.

xiv. Ground improvement with sand columns shall be provided for plant,

township & for ash dyke embankment and cost for the same is included in the project cost. However, alternate methods of ground improvement shall be explored at detailed engineering stage.

xv. Many Cement plants exists in the vicinity, 100 % fly ash utilization

has been considered. Also 100% bottom ash utilization has also been considered. However, ash dyke of 100 acres has been provided in FR.

xvi. The project cost is estimated based on the latest awarded cost for

NTPC projects of similar capacities.

xvii. Water in Possur River is having very high silt content. Desilting of huge quantity of water required for once through system would be uneconomical. Therefore, re-circulating type CW system with cooling towers and open intake channel has been envisaged for the project.

xviii. As per the discussion with BPDB/ PGCB, provision of 2 nos. line

bays in generation switchyard (one no.400 kV D/C line envisaged to connected to Dhaka ring main and one no. of 230 kV D/C line envisaged to be connected to Khulna South) is being kept for power evacuation from the project.

xix. Project Financing- Out of total 70% loan, the interest rate for 10% of

loan is considered as 15.5% and for balance 60% as 6.5% as ECA funding. The loan repayment is considered in 10 equal annual installments, with a moratorium period of 5 years, considering single EPC package with ECA funding.

xx. Based on the information received, customs, excise and sales tax is

nil in Bangladesh so no tax is considered in the project cost.

xxi. Cost of Energy- For calculating COE, ROE is considered as 18%. For working capital 3 Months coal stock is considered. Annual lease rent of 50000 Tk /acre/annum and USD 4 million for maintenance, is considered as informed by BPDB.

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TABLE OF CONTENT

CHAPTER TITLE PAGE No

1.0 Introduction 1

2.0 Demand Analysis and Justification 2

3.0 Feasibility Studies 3

4.0 Layout Systems 6

5.0 Civil Systems 10

6.0 Mechanical Systems 22

7.0 Electrical Systems 46

8.0 Control & Instrumentation Systems 62

9.0 Environmental Aspects 70

10.0 Technical Data & Bill of Quantities 74

11.0 Cost Estimate, Financial Analysis 126

11 a Sensitivity Analysis 129

12.0 Project Implementation 132

13.0 Manpower Training & Placement 137

14.0 Operation & Maintenance Philosophy 140

15.0 Marketing Philosophy 152

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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 Civil Aviation Clearance 2

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LIST OF EXHIBITS DESCRIPTION EXHIBIT

No 1. Vicinity Plan I

2. General Layout Plan II

3. Main Plant Layout at EL (+/-) 0.00 M. III

4. Main Plant Equipment Layout Plan at EL(+) 8.5 M, (+) 17.0 M, (+) 24/25 M, (+) 32.8 M, (+) 38/41 M

IV

5. Main Plant Cross-section V

6. Water Balance Diagram VI

7. Single Line Diagram VII

8. 400/132 KV Switchyard Single Line Diagram VIII

9. Implementation Schedule IX

10. Organisation Structure for Power Project X

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1. INTRODUCTION 1.00.00 BACKGROUND

The present installed capacity (derated) in June 2012 is 8,100 MW. Gas based power stations constitute 66.88 % of present generation capacity while coal based power plants constitute only 2.47%. According to Power System Master Plan (PSMP) 2010 developed by Bangladesh Power Development Board (BPDB), the demand in 2030 will be about 33,000 MW and installed capacity is targeted to reach 38,685 MW. Out of this, coal based generation capacity is expected to be 20,000 MW. BPDB has also carried out generation expansion planning for the period 2012-2016, wherein total additional capacity to be installed by the end of 2016 is 13,154 MW including 1,320 MW proposed at Khulna.

Contract Agreement for FR Consultancy for Khulna and Chittagong projects were signed between NTPC and BPDB at Dhaka on 30.09.10.

As per the scope of the consultancy assignment, all the studies/investigations including topographical survey, geotechnical investigations, coal transportation logistic study etc. were to be carried out by BPDB. Survey and geotechnical details at the plant area have been received in Feb.2011.

Draft Feasibility Report (DFR) was submitted to BPDB on 31.03.2011.

Final FR for Khulna project which has been revised taking into account comments of BPDB/decisions as recorded in Minutes of meeting held at Dhaka from 30th July to 1st Aug.2011 , NTPC office at Noida from 26th Sept. to 29th Sept. 2011, NTPC, New Delhi on 01.11.2011 & 02.11.2011 , BPDB office, Dhaka on 25th -27th Dec.2011 alongwith M/s CEGIS, Consultant for Coal Transportation Logistics Study.

In view of the huge power generation capacity requirement of Bangladesh, it is proposed to establish 2x660 MW Khulna Thermal Power Project near Khulna.

2.00.00 PROPOSAL

The present proposal is to install two units of 660 MW Khulna Thermal Power Project near Khulna. The Khulna project is expected to start yielding benefits by 2016-17 onwards.

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2. DEMAND ANALYSIS AND JUSTIFICATION

1.00.00 GENERAL

Khulna TPP, (2x660 MW) coal based plant is being planned as a part of “New Initiative” by Government of Bangladesh/Bangladesh Power Development Board (BPDB) under the Power System Master Plan(PSMP) to mitigate the demand-supply gap in Bangladesh. The present generating capacity in Bangladesh is 8100 MW and among this 66.88 % is gas based and 2.47% is coal based generation. According to PSMP an optimum mix of base load and peak load plants, corresponding to the electricity demand characteristics of Bangladesh is to be installed.

The proposed coal based power plants will meet electricity demand of the country, which will also improve system reliability and reduce load shedding. The proposed project is located in Rampal Upazila of Bagerhat District. The project is expected to start yielding benefits by 2016-2017 onwards.

2.00.00 DEMAND PROJECTIONS

As per annual report of BPDB for the year 2010-2011, the forecasted demand is 6,454 MW with access to electricity only 50% whereas the maximum generation is 4,890 MW and 1,335 MW load shedding at peak hours is common in summer season.

In view of above, and with a vision to achieve 8% projected GDP growth by 2013 and beyond a massive generation expansion program has been adopted by Government of Bangladesh .The Government of Bangladesh has a prepared a generation plan up to 2016 with addition of around 15000 MW during the period 2010-2016.The Khulna (2x 660 MW) is a part of above plan and is expected to be completed by 2016-17.

3.00.00 CONCLUSION:

In view of above, Khulna STPP (2x660 MW) scheduled to be commissioned in 2016-2017, is justified from Demand Supply consideration.


3. FEASIBILITY STUDIES 1.00.00 SITE SELECTION

The power project site has been selected after examining three alternate sites identified for the project by BPDB. These sites were visited by the joint team of BPDB and NTPC and the present site near Rampal Upazila of Bagerhat District was recommended for setting up the project. This site is on the banks of Possur River, accessible by proposed road connecting Khulna Mongla Highway. Second site near Chumkuri is opposite to Rampal site and is on an island surrounded on all four sides by Possur river and does not have any road access and hence was not found suitable. The third site near Lobanchura is located on the banks of Rupsa river. This site has only about 400 acres fertile and mostly privately owned land, which is not sufficient for locating the power plant.

2.00.00 LOCATION AND APPROACH

The proposed project is a coal based thermal power plant with rated capacity of 1320 MW (2x 660MW). The proposed project is located in Rampal Upazila of Bagerhat District. The site is bounded by villages Mouzas- Kaigar Daskati, Kapasdanga, of Gaurambha Union, Mouzas- Sapmari Katakhali, Baserhula of Rajnagar Union under Rampal Upazila. The plant site is located between latitude and longitude of 22deg. 37’ 0’’ N to 22deg. 34’ 30’’ N and 89deg. 32' 0’’E to 89deg. 34' 5’’E respectively. The site is located 23 Kms. Southward of Khulna City, about 12 Kms. North-eastward of Rampal Upazila Sadar and 14 Kms. North-eastward from Mongla Port. The proposed Khan Jahan Ali Airport is located at a distance of approximately 12 kms from the project site.

3.00.00 CAPACITY : 2x660 MW

4.00.00 Mode of Operation : Base Load

5.00.00 FUEL : Coal

600.00 AVAILABILITY OF BASIC INPUTS

6.01.00 Land

For Khulna project, about 575acres of land will be required. The same includes 375 Acres for Plant, 50 Acres for Township, 50 Acres for Jetty and about 100 Acres of land for ash disposal (Ash dyke). No major issue is anticipated in acquisition as per discussions with BPDB officials.

6.02.00 Cooling Water Requirement, Source, Commitment and System

The source of water for the project is saline water drawn from Possur River (about 2 kms), which is primarily back water of sea. Sweet water


required for meeting the potable water, plant service water, cycle makeup (DM water) etc shall be produced using Desalination process from sea water. It is proposed to adopt Reverse Osmosis process for Desalination of saline water.Make up water requirement for this project would be about 9150 Cu.M/hr..

It is observed that water in Possur River is having very high silt content. In once through system, huge quantity of water will be required. Desilting of such huge quantity of water would be uneconomical. In cooling tower system, only make up water needs to be provided and can be desilted. Therefore, re-circulating type CW system with open intake channel & cooling towers has been envisaged for the project.

6.03.00 Coal Requirement, Availability and Linkage

The coal shall be imported coal. The daily coal requirement for 2 x 660 MW units shall be about 12920 tonnes based on average gross calorific value of 6000 Kcal/ kg at 100% plant load factor. Annual coal requirement for the project shall be about 4.72 MTPA. Coal Quality The coal quality for FR purposes has been considered as imported coal and the same is as follows: Proximate analysis

Ash : 15 % GCV (kcal/kg) : 6000 Sulphur 0.6 %

Coal Transportation It is envisaged that coal shall be unloaded from barges at jetty near plant end, as confirmed by BPDB/CEGIS. The envisaged mode of coal transportation considered in FR from Jetty to the power plant is by conveyor system.

Coal Handling System






An independent coal handling plant is proposed to cater to the two (2) units of 660 MW. Coal handling plant consisting of coal conveying system (with 100 % standby parallel stream) along with reclaimers, trippers etc.

6.00.00 CONSTRUCTION WATER

The requirement of construction water for the project would be met by constructing deep tube wells.


4. LAYOUT SYSTEMS

1.00.00 GENERAL LAYOUT PLAN

General Layout Plan for the project is developed and placed at Exhibit-II. General Layout Plan for the project has been developed taking into consideration various aspects like available land & shape, ground features & terrain, corridor for outgoing transmission lines, road approaches, prevailing wind direction, the water drawl and the associated pipe corridor.

The General Layout Plan is prepared in optimum area so as to reduce the quantity of filling by dredging. The switchyard orientation which is proposed as GIS has been planned taking into consideration the requirement of power evacuation. Permanent facilities like Workshop, Permanent stores etc. are located close to the main plant. The ash slurry/ash water pump house is kept towards the chimney and FGD space is kept beyond 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. Considering the soil condition Induced Draft Cooling Towers are proposed and located considering the safe distance from the Main Plant and Switchyard. The water treatment plant and the DM water facilities are located close to main plant. The coal is proposed to come from coal jetty to be constructed at river bank. As coal comes through sea route, three month coal storage is proposed in plant with space for storage of coal upto six months.

Adequate space provision has been kept in the layout for lay-down and pre-assembly activities, open stores, contractor’s offices and stores etc. Construction offices and storage sheds are located close to the main approach road to the plant. Administration Building is proposed to be located outside the plant boundary near the main approach road.

Tree plantation shall be done in all available space after completion of the project.

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 277 m long and about 48 m wide consisting of TG bay and heater bay.

Service Building is envisaged at the start of unit # 1 of the project. An interconnection walkway is also provided between Service Building and operating floor level in AB bay 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.

9635-999-POM-F-001 (Rev. 0)

3

2. Equipment Layout Plan at

EL (+/-) (+) 8.5 m, (+) 17.0 m (+) 24 m, (+) 32.8 m, (+) 38/41m

9635-999-POM-F-002 (Rev. 0)

4

3. Main Plant Cross-Section 9635-999-POM-F-

003 (Rev. 0) 5

2.02.00 DESCRIPTION OF LAYOUT

2.02.01 Mechanical Area

AB Bay

The layout envisages AB bay of width 36 m and floors at EL (+/-) 0.00 m, (+) 8.50 m, (+) 17.0 m. The operating floor of the unit is kept at (+) 17.0 m and the mezzanine floor is at (+) 8.5 m. Two (2) numbers of Turbine driven boiler feed pumps (TDBFP) are located at operating floor in A-B bay and two (2) numbers of Motor driven boiler feed pump (MDBFP) are located at mezzanine floor in A-B bay. Oil equipments for TDBFP and MDBFP are located at EL 0.0m in A-B bay.

The AB bay at EL (+/-) 0.0 m would house other equipment like vacuum pumps, Seal oil units, PHE’s for DM cooling water system & 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 8.5 m.

2.02.02 Turbine Hall EOT Cranes

Two (2) numbers Electrically Operated Traveling (EOT) crane are envisaged in turbine hall for erection and maintenance of turbo-generators and their auxiliaries. Generator Stator shall be handled with tandem operation of two numbers of Turbine Hall EOT cranes for which necessary arrangements shall be provided. 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. 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.


2.02.03 BC Bay

The BC bay of width 12.0m would consist of floors at EL (+/-) 0.00 m, (+) 8.5 m, (+) 17.0 m, (+) 24 m, (+) 32.8 m, (+) 38/41 m. The BC bay floor at EL (+/-) 0.00 m would house LP/HP dosing system equipment, condensate polishing unit along with RIO room, SWAS room and Central Lube Oil system. The floor at EL (+) 8.5 m would house LP heaters. The HP heaters are to be located at EL (+) 17.0 m. The floor at EL (+) 24.0 m would house cable vault for boiler MCC and Air Handling Units for Air conditioning system. Boiler MCC is located on local floor at EL 28.0M. The floor at EL (+) 32.8 m has been planned for Auxiliary Steam Pressure Reducing De-super-heating Station, Control Station of feed water system, ECW tanks for SG & TG and Cooling Towers for A/C system. The Deaerator is to be kept at EL (+) 38.0 m.

2.02.04 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 rear side of the Boiler. Approach roads/ passages have been identified on both 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 power house columns) and D-row(1strow of Boiler columns), has been kept to facilitate the movement during erection and operation phase of the plant. Two elevators - one for passengers and one for goods have been envisaged for each Boiler.

The main coal feeding conveyor shall be located at the start of the Unit # 1. Ash handling facilities such as High Concentration Slurry Disposal Pump House along with silos, VFD room, AHP Control Room and transformers for the same are located by the side of ID fan of unit # 1. Other Ash handling facilities such as Transport Air Compressor House, Ash Water Pump House, Switchgear room and Transformers are located across the road, behind chimney in ash handling area.

The MCCs and control for ESP along with air conditioning and ventilation equipment for the same are envisaged to be located in ESP Control Room. ESP Control Room for both units is located by the side of respective ESP’s. Air conditioned space for locating remote I/O panels for ash handling system are also identified inside ESP control room building.

2.02.05 Air Compressor and CPU

Air Compressors for instrument air / service air / Mill reject 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 in DM/PT plant area.

2.03.00 Electrical AreasAB Bay:

Electrical switchgears and MCCs of the unit are located in the electrical annexe located at the start of unit in AB bay. The HT switchgear along


with DC Batteries is to be located at (+) 3.5 m floor elevation. LT 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 (+) 28.0 m with a provision of cable spreader room at EL (+) 24.0 m. LAVT & SPPT cubicles shall be located at a local floor in AB bay at EL 5.0M below IP bus ducts. GCB shall also be located at EL 7.5M in AB bay below IP bus ducts.

2.03.01 Transformer Yard / Bus ducts / MCCs

Three (3) single phase Generator Transformers (GT) along with two (2) Unit Transformers (UT) and two (2) Unit Auxiliary Transformers (UAT) for each of the unit are located in front of A-row in the transformer yard. One number startup/standby transformer, common for two units is also located in front of A-row in transformer yard area. One number spare Generator Transformer common for all units as shown in layout drawing has also been provided in transformer yard area. Separate rail tracks in Transformer yard area have been envisaged for handling GTs and STs.

Bus ducts have been considered for connecting Unit and Station Transformers to respective switchgears and interconnections between unit & startup boards. The bus duct from the Unit Auxiliary and startup 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.

2.04.00 Control and Instrumentation

The Common control room for two units has been envisaged between unit # 1 & 2 in B-C-Dx bay at operating floor level. Control Equipment Room (CER) is envisaged to be unitized and shall be located in B-C-Dx-Ex-Fx bay at operating floor level and Dx-Ex-Fx bay at EL (+) 8.5M floor level. The control room houses the control desk and control station for certain off site facilities also.

Air conditioning plant for Central Control Room/CER and UPS/ Charger room, SWAS room along with its MCC has been located in Dx-Ex bay at EL (+/-) 0.0 M between unit 1 & 2. SWAS room shall also be located at EL (+/-) 0.00 M in BC bay. UPS, Chargers, CER and C&I batteries are located at 8.5 M in B-C-Dx bay. Cable Vault for CER, UPS and battery charger shall be located at EL 5.1M and cable vault for CER/CCR shall be located at EL 13.5M in B-C-Dx-Ex-Fx bay. Space for Fire fighting cylinders has been identified in Ex-Fx bay at EL 0.0M in the Control Tower area. Necessary cable shafts have been provided at B-row/C-row for routing of power cables in the Electrical Bay and Control Equipment.


5. CIVIL SYSTEMS 1.00.00 LAND DEVELOPMENT

As per the survey data received, the levels of the natural ground vary between RL (+) 0.75 to RL (+) 1.25M. The HFL of the area is about RL (+) 4.5M. Hence, RL (+) 5.0M is proposed as plant formation level. To achieve the desired formation level dredging from the nearby river and hydraulic filling is proposed in the plant Site.

About 425 Acres of land is proposed to be filled with dredged material for the plant and the township area.

2.00.00 GEOTECHNICAL DATA & FOUNDATION SYSTEM

Available soil data: Geotechnical investigation (prelimanry) has been carried out by Rana Soil Engineering, Dhaka and borelog data, soil description & soil parameters are available.

Based on the available soil data, the sub strata consists of very soft to soft clay from top to about 14 m to 16 m followed by silty sand with traces of clay (10 %) up to 35 m depth, followed by dense to very dense fine sand up to depth of investigation of 60 m. It is mentioned in the report that, the site is inundated by about 1.0 to 2.0 m above existing ground level (EGL).

Standard Penetration Test (SPT) ‘N’ values of the top layer of 14 to 16m (very soft to soft clay) are varying from 1 to 5. Considering this strata, ground improvement is required to be carried out for the entire area of the plant.

Based on the High Flood Level (HFL), a filling of about 4.5 m in the entire plant area has been considered. It is estimated that due to fill alone, the consolidation settlement of sub strata will be about 750 mm.

Considering the above and assuming that the strata would be similar to the above borehole data, pile foundation is envisaged for all main plant structures.

Bored cast-in-situ RCC piles are envisaged for the plant structures. Based on the sub strata and the fill, there will be dragdown force (negative skin friction) on piles. Based on the pile design & considering the effect of negative drag due to settlement of top soft clay of 14-16 m, the capacity of piles are as given below for FR purpose:

Piles shall be of bored cast-in-situ type of 1000 mm, 760mm & 600mm diameter of 325T, 250T & 140T capacity respectively in compression, lateral and pullout capacity for 1000 mm, 600 mm and 760 mm dia pile shall be 7 T, 5.5 T, 4 T and 100 T, 80 T and 50 T respectively after ground improvement. Pile length may vary from 31 to 33 m below COL for 600 mm dia, 34 to 36 m for 760 mm dia and 35 to 37 m for 100


mm dia below COL. However, for FR purpose, minimum pile length of 32 m below Cut Off Level (COL) for 600 mm diameter, 35 m below COL for 760 mm diameter and 36 m for 1000 mm dia may be considered. COL is considered as 4.0 m below Finished Ground Level (FGL). During pile boring, the top soft clay due to high water table, may or may not be able to retain the profile of pile bore. Therefore, a provision of MS permanent liner has been considered for the bored cast in situ piles in the soft clay portion of strata for a length of 15 m from cut-off level. During the actual execution, contractor shall be asked to make trial pile bore without permanent liner, and if the same is found feasible, then M.S. permanent liner item will not be operated.

Lateral capacity of piles

As the top soil is very soft to soft clay, ground improvement for the area is required to be carried out to achieve the lateral capacity of piles.

Ground improvement

Due to the presence of very soft to soft clay, area needs ground improvement. Suitability of various alternative methods such as stone columns, sand compaction piles, PV Drains / wick drains, soil stabilisation etc have been explored. However, based on the detail discussion with BPDB and confirmation of availability of the specified sand, sand compaction piles are considered for FR preparation.

Sand compaction piles of 900 mm dia and 17 m length are considered below Natural Ground Level for FR purpose. Spacing of sand compaction piles is considered as 4.5 m in equilateral triangular pattern for the main power house block area to increase the lateral capacity of piles and for other areas, open foundations on sand compaction piles are envisaged.

Sand blanket of 500 mm thick (for drainage of pore water in clay) shall be provided above the sand compaction piles which will be connected to the nearest drains.

It is desirable to install the sand compaction piles with drainage blanket followed by site levelling/filling, so that the fill will act as surcharge on the soft clay, which will enhance the consolidation process and minimise the post construction settlements.

Dewatering & Sheet piling

As the ground water table is very high and presence of river adjacent to site, cost provision for comprehensive dewatering for deep excavations and provision for sheet piling for structurtes like Track Hopper, Wagon Tippler, pump houses etc may be kept in the FR


Type of cement and grade of concrete

Chemical results of water and soil are not available. Based on the feed back of team visited to site, it is gathered that there will be back flow of the water from sea for almost 8 months in a year and considering the salinity of water, it is proposed to use M30 grade of concrete for all foundation works. Portland Pozzolana Cement (PPC) or Portland Slag Cement or OPC blended with GGBS up to 60% for all foundation works including piles.

The foundation system proposed for main plant as well as other areas will be reviewed on receipt of preliminary / detailed geotechnical investigation data.

Seismic and Wind Design

For seismic analysis PGA has been considered as 0.24g. However, for tender specification / detailed engineering the seismic design parameters shall be based on Bangladesh National Building Code (BNBC).

The wind load parameters have been considered based on wind data as per Indian standard. However, for tender specification / detailed engineering the wind design shall be based on Bangladesh National Building Code (BNBC).

3.00.00 MAIN PLANT BUILDING

3.01.00 Foundation System

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

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.

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 springs and viscous dampers, which in turn shall be supported on steel beams resting on main power house columns and 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 house building shall comprise of turbo generator (AB) bay and multi-level heater (BC) bay. All platforms and floors shall be supported on structural steel.

2. Service Building

Service Building shall be of RCC structural framing. It shall be a separate building near gable end of the main power house.

3. Mill / Bunker Building

Mill / bunker building shall be single span multi-storied 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 mild steel with stainless steel liner. The bunker shall be of Mild Steel.

4. Conveyor Galleries and Transfer Points

Overhead conveyor galleries in the main plant (boiler area) shall be of structural steel frame with cladding and roofing. Transfer points and intermediate supporting trestles shall be made of braced steel framed structures. The staircase shall be of external type.

5. Cable and Pipe Racks

(a) Structural steel trestles and galleries with provision of walkway with 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 girders resting on the steel bracket fixed to the boiler/ ESP / mill & bunker building structures.

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


6. Other Buildings

ESP control, air washer, compressor house 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., de-aerator, TPs etc, shall be provided with the metal deck sheet and / or RCC depending upon the clear height of the roof.

The roof of Bunker building shall consist of Insulated double layer metal sheets with slope in one direction.

Intermediate floors of all buildings including main powerhouse building shall be provided with cast-in-situ RCC slab supported on profiled metal deck sheets. The profiled metal deck sheets shall be fixed to the structural steel beams by means of headed anchor studs arc welded to the steel beams through the metal deck sheet. External cladding of all buildings shall have combination of autoclave aerated concrete block, brick work, metal cladding, aluminum composite panel & structural glazing.

For main plant building initial height of 3 m along A-row and C-row and gable ends shall be provided with autoclave aerated concrete block followed by color-coated metal cladding and structural glazing except for the Generator-Transformer area near ‘A–row’ where RCC Fire wall is provided on A-Row up to a height 600mm above the highest point of the transformer followed by metal cladding.

Control room area shall have autoclave aerated concrete blocks for wall on external face.

Internal partitions shall be provided with 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. 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.


3.04.00 Architectural Concepts

a) Power Plant buildings shall be architecturally treated in such a way so as to merge with the existing structures and the overall impact of the buildings shall be one of aesthetically unified architectural composition having a comprehendible scale, blending tonal values with the surroundings and taking full consideration of the climatic conditions and the building orientation.

b) All buildings and structures shall be architecturally treated in such a way so as to be in complete harmony with the Main Plant Building, surrounding structures and 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.

c) Overall colour scheme of the Main Plant Building and other buildings shall be designed judiciously and in a comprehensive manner taking into account the mass and void of buildings, its facade, equipment, exposed structural elements, piping, trestles, bus ducts, and other service elements.

d) Natural light shall be used to the maximum extent, especially in the form of North Light/sky light and all buildings shall be designed as Energy Efficient Buildings. For adequate light and ventilation, National Building Code of India recommendations shall be followed.

e) All the buildings shall be architecturally designed to meet the National Building Code.

f) During design stage, Technical specification as prepared shall govern the finishes as well as quantity.

g) Human safety factors shall form the basis of design criteria.

h) Service building shall be designed so as to achieve GRIHA (Green Rating for Integrated Habitat Assessment) minimum three or four star rating.

i) All public buildings shall be designed on the principles of providing barrier free environment for physically disabled persons.

j) Overall emphasis shall be on developing eco-friendly architecture, merging with the nature with its own sustainable energy management systems.

4.00.00 CHIMNEY

One twin flue steel lined reinforced concrete chimney shall be provided for the two 660 MW units of the project. The flue gas emission point shall be 275 meters above the plant grade level. The RCC for the chimney shell, other super structure, foundation & grade level slab shall be of M-30 grade.


Liner shall essentially be constructed from structural steel and shall be of the hung type (with multiple point liner support systems). The liner shall be provided with resin bonded wool type thermal insulation. The portion of the liner 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. Internal platforms shall be provided for enabling access to various elevations of the stack and to provide support to the steel liner. There shall be at least one metre working space around the flues. 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 liner through suitable (non-metallic) fluro-elastomeric 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-shell(s) 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-shell(s), 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 DESALINATION PLANT, DM PLANT, CONDENSATE POLISHING PLANT, CHLORINATION PLANT AND EFFLUENT TREATMENT SYSTEM

Complete RCC structures for desalination plant, DM plant, condensate polishing plant, chlorination Plant and Effluent Treatment system shall be of RCC grade M30. All shed shall be generally steel superstructure with sloping MS roof sheeting.

6.00.00 CW & MAKE UP WATER SYSTEM

6.01.00 CW System civil works

CW system for the project consists of CWPH and SACWPH including fore-bays, intake RCC channels, steel lined concrete encased supply and discharge ducts. The CW pump houses for the project shall house either vertical turbine pumps or concrete volute pumps. Substructure of the pump house shall be of RCC grade M-30 and superstructure of structural steel with steel cladding.

The CW pumps shall pump cold water to condensers and hot water from the condensers to cooling towers through steel lined concrete encased CW ducts..

The cold water from cooling towers shall flow by gravity to the CW pump house through RCC open channel. Grade of concrete for RCC channel shall be M-30.

6.02.00 Make-up Water System civil works

Make-up water for the project shall be drawn from Passur river having saline back water. Water will be drawn from the river by constructing an approach channel. Desilting basin and Make-up water pump house shall be constructed on the down steam of this channel. The MuW water pump house shall pump water to desalination Plant and CW channel for


make-up. Silt flushing pump house shall be provided for automatic removal of silt.

The approach channel, desilting basin and silt flushing pump house shall be of RCC grade M-30. Substructure of MuW pump house shall be of RCC grade M-30 and superstructure shall be of structural steel with steel sheet cladding

A switch gear building, control room along with transformers shall be provided on the river bank for feeding electrical power to the MuW pump house and silt flushing pump house. Sub structure and super structure of the switch gear building shall be of RCC grade M-30 with brick wall cladding.

7.00.00 COAL HANDLING SYSTEM

7.00.01 Crusher House

Crusher house shall be of structural steel with permanently colour coated steel sheet cladding. Floor 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 foundations have been considered for column foundations.

7.00.02 TRANSFER POINTS

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

7.00.03 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 foundations have been envisaged for trestle foundations.

7.00.04 STACKER/RECLAIMER FOUNDATIONS

The stacker/reclaimer rails shall be supported on RCC longitudinal beams which in turn will be supported on Pile foundation.

7.00.05 CHP CONTROL ROOM, PUMP HOUSE & MCC ROOMS

These shall be RCC buildings with brick wall enclosures.


8.00.00 FUEL OIL HANDLING SYSTEM

The civil works for the following are to be provided for fuel oil handling system as mentioned below:

Foundation for 2 nos HFO tanks (2500 KL capacity of 18.0m dia & 12m height)

Foundation for 1 nos LDO tanks (500 KL capacity of 7.5m dia & 12m height)

Foundation for 1 no day oil tank (100 KL capacity of 4.5m dia & 6.5m height)

Fuel oil pressurizing Pump House(750 sqm) Fuel oil unloading Pump House Oil Water separator pit Containment wall around the tank area for all tanks. Foundations for pumps, pipe racks, pipe lines etc, miscellaneous

drains. Paving and drains around tanks. Railway unloading& tanker unloading areas.

9.00.00 ASH HANDLING SYSTEM & RECIRCULATION SYSTEM

The Civil works involved in Ash handling & Ash water recirculation systems are as follows:

1. Ash Water Pump House.

2. HCSD Pump House

3. Ash water recirculation Pump House

4. Switch gear/MCC and Control Room for all buildings

5. Silo area utility building

6. Fly Ash Silo foundation & supporting structure

7. HCSD Silo foundation & supporting structure

8. Transport air Compressor house

9. Steel Trestles for supporting Ash Slurry Piping within plant area and dry fly ash transportation pipe pedestals upto silos near plant boundary.

10. RCC pedestals for supporting HCSD pipes including garlanding of ash dykes.

11. RCC pedestals for supporting ash water recirculation pipe.

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


13. Miscellaneous structures including Foundation for settling tank, surge tank, etc.

All pump houses shall have RCC framed structural arrangement with brick cladding & metal deck roofing filled with RCC. All Control room shall be air-conditioned area with false ceiling.

Overhead bridge/ culvert by thrust boring shall be provided for the railway crossing for the ash slurry pipes. For routing of the ash pipes at road crossing culverts/ local humps or bridges shall be provided as per site conditions.

All super-structure work related to dry ash handling (including silos, buffer hopper, and collector tank) and bottom ash handling are included in mechanical package.

10.00.00 ROADS & DRAINS

Double Lane Roads

The double lane roads shall be 12m wide with 7.5m wide bituminous surfacing (black top) and 2.25m wide raised shoulders on both sides of the roads.

Single Lane Roads

All access roads to all buildings/facilities/structures shall be single lane roads 6.75m wide with 3.75m wide bituminous surfacing (black top) and 1.5m wide shoulders on both sides of the roads.

Patrol Roads

All patrol roads along the boundary wall shall be single lane roads with 3.75m wide bituminous surfacing (black top) and 1.5m wide shoulder on one side of the roads.

Drains

Drains shall be constructed on both sides of double lane and single lane roads. Patrol roads along the boundary wall shall have drain on one side of the roads. These drains shall be connected to the trunk drain suitably, which finally gets connected to the drains outside the plant boundary. All drains shall be of RCC with rectangular section.

11.00.00 ASH DISPOSAL AREA

For ash disposal, about 100 acres of land is identified. The proposed land is located adjacent to the plant boundary. The average ground levels on


proposed land is about RL 1.0M. The ash disposal area is planned with a total usable area of about 60 acres for ash storage. The balance 40 acres of land will be occupied by starter dyke storage lagoons & OFL dyke construction, ash slurry pipe line corridor, over flow lagoon, maintenance road all along the periphery of the dyke and recirculation system facilities.

All the above facilities require ground improvement with sand compaction pile and recirculation facilities shall be on piles with ground improvement.

Many Cement plants exists in the vicinity, 100 % fly ash utilization has been considered. Also 100% bottom ash utilization has also been considered. However, ash dyke of 100 acres has been provided in FR.

12.00.00 PERMANENT TOWNSHIP

481 dwelling units are proposed to be constructed for the project. Additional 72 dwelling units and 59 barracks are proposed to be constructed for Security staff and 96 quarters for support staff.


6. MECHANICAL SYSTEM

1.00.00 STEAM GENERATOR AND AUXILIARIES

1.01.00 General

The steam generators shall be supercritical, once through, water tube, direct pulverized coal fired, top supported, balanced draft furnace, single reheat, radiant, dry bottom type, suitable for outdoor installation. The gas path arrangement shall be single pass (Tower type) or two pass type.

Boiler design shall be suitable for variable pressure operation from 30% to 100% BMCR with and without 5% throttle margin.

The main parameters at 100% BMCR will be as follows:

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 for installation of dry bottom ash 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

The furnace will be radiant, dry bottom type with tangential or opposed wall firing and enclosed by water cooled and all welded membrane walls. 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. Main steam flow at superheater outlet 2120T/Hr

2. Pressure at superheater outlet 256 kg/cm2 (a)

3. Temperature at SH outlet 568 oC

4. Steam flow to reheater 1708.2T/Hr

5. Steam temperature at reheater outlet 596 oC

6. Feed water temperature at economizer inlet 293.7 oC


1.04.00 Air and Flue Gas System

A balanced draft system will be provided. There will be two (2) axial type FD fans and two (2) axial type ID fans and two (2) pairs of regenerative rotary type air pre-heaters. One pair of air pre-heater will be used for primary air system & second pair for secondary air system. Four (4) numbers of steam coil air preheaters-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 will be light oil (LDO) firing at least in one burner elevation having a minimum capacity of 7.5% BMCR to facilitate 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 of two (2) boilers.

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.

(a) With 90% mill loading of the working mills, atleast one mill will be spare while firing the design coal at 100% BMCR.

(b) With 90% loading of the working mills atleast one mill will be spare at 100% TMCR load with worst coal firing.

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 by pass 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

Each of 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 150 T/hr. Low capacity auxiliary PRDS will be sized for a minimum capacity of 25 T/hr 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. Each unit will have its own auxiliary steam headers whereas for station services common station auxiliary steam headers taking its tap off from the unit auxiliary PRD stations will also be provided. The provision will also be made for interconnection with future units.

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 each steam generator.

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

The electrostatic precipitators will have parallel gas streams, isolated from each other on the electrical as well as gas side and will be provided with gas tight dampers at inlets and outlets of each stream, so as to allow maintenance to be carried out safely on the faulty stream, while the unit is working Electrostatic precipitator will be provided with microprocessor based programmable type rapper control system and ESP management system to ensure 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 ash levels in the hoppers and trip the ESP in case of high ash levels in the ash hoppers are also envisaged to ensure safety of ESP.


1.11.00 Provision of future installation of Flue Gas Desulphurising system

(FGD)

As environmental norms for the area are not known, norms prevalent for So2 dispersion in India have been considered. Considering sulphur in the coal sourced from Indonesia limited to 0.6%, So2 emission from the plant is envisaged to be controlled by dispersion through tall stack (275 m) to meet the ground SO2 ambient air quality norms. However, provision has been kept in the layout of the plant such that a Flue Gas Desulphurisation (FGD) system can be installed in future, taking flue gas suction from duct after ID fan and feeding the desulphurised flue gases to the chimney with provision for bypassing the FGD system.

1.12.00 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.

1.13.00 Auxiliary boiler

To meet the auxiliary steam requirement for cold start of the unit, a start up auxiliary boiler of 60 T/Hr. capacity, 19 kg/cm² (gauge) pressure and 250°C temperature shall be provided. Auxiliary boiler shall be suitable to generate rated parameter with LDO. Auxiliary boiler shall be connected to auxiliary PRDS system suitably.

2.00.00 TURBINE AND ITS AUXILIARIES

The scope of each TG unit of 660 MW shall broadly cover the Steam Turbine along with its integral systems and auxiliaries like lube oil system, control-fluid system, condensers, 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 and turbine hall EOT cranes.


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. The turbine shall be capable of operating on variable pressure mode as well as constant pressure mode during part load and start up operation. The turbine shall be provided with suitable margins for VWO flow. The steam turbine shall conform to the following design and duty conditions:

I) Output under Economic Maximum Continuous Rating (EMCR) at Generator terminals with Cycle make up of 3% of throttle steam flow and design condenser pressure.

660 MW (In case of static excitation system, the EMCR output at generator terminals shall be 660 MW plus excitation power requirement at EMCR).

ii) Turbine throttle steam pressure 247 kg/cm2 (abs) iii) Turbine throttle Main steam/

Reheat Steam temperature. 565 O C/593 O C

iv) Variations in rated Steam temperature & pressure

As per IEC-45.

V) Pressure drop in reheat circuit i.e between HPT Exhaust & IPT inlet.

10% of HPT exhaust pressure.

vi) Condenser pressure with CW temperature of 33 Deg C

77 mm of Hg

vii) Turbine speed 3000 rpm viii Frequency variation range from

rated frequency of 50 Hz (+) 3% to (-5%) (47.5HZ to 51.5HZ)

ix) DM Water make up to thermal cycle under EMCR condition.

3% of throttle steam flow

x) Final feed water temperature at 100 % TMCR & at EMCR condition.

287.5 (+/-) 2.5 deg C

xi) Turbine protection against water induction.

As per ASME-TDP-1(latest)

xii) No. of extractions for regenerative feed water heating

As per cycle optimization 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 optimized 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 half of 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 (if applicable).

The system shall specifically include the following:


(a) Centrifugal/gear type, Main oil pump (MOP) directly driven by the turbine as per Bidder’s standard practice with capacity to cater lube oil for bearings & emergency seal oil requirement (if applicable). In addition to above 2 x 100% AC aux. oil pumps for start-up, shutdown of TG unit and as standby to MOP for automatic operation shall be provided. 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.

OR

2x100% AC oil pumps as per Bidder's standard practice with capacity to cater lube oil for bearings & emergency seal oil requirement (if applicable). Each pump shall also be capable of start up, shut down of TG unit normal operation and stand by to each other for automatic operation to cater lube oil, jacking oil & turning gear oil requirement.

(b) 1x100% DC emergency oil pump for meeting lube oil requirements of bearings during emergency, with automatic starting on low lube oil pressure preset value.

(c) 1x100% each AC and DC motor operated 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 centralized 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), one unloading tank, two transfer pumps (for dirty and clean oil) shall be provided. This is for storing and purifying oil from unit oil tanks and also for adding new oil to the system and


also for transferring the fresh oil to the unit oil tanks. 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 minimize 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 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-condensible 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. Steam turbine governing and protection system shall be complete with electro hydraulic governor with suitable back up as per standard practice of the manufacturer. 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 over speed trip value. 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 large 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 and condensate booster 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 287.5 (+/-) 2.5 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 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 and 2x30% 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 Turbine driven feed pumps shall be capable of meeting the full requirement of the boiler


turbine unit with the Motor driven feed pumps as a standby. Turbine driven boiler feed pumps shall be located at operating floor and the motor driven pumps shall be located on mezzanine floor and both 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 210 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 of TDBFP's, discharge header pressure low etc.

The feed flow shall be controlled by throttling the control valve of drive turbine in case of turbine driven pumps whereas hydraulic coupling shall be utilized to achieve speed control of motor driven pumps. 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 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

Two (2) number of electrically operated overhead travelling cranes with associated auxiliaries, along with electrical equipment, control & instrumentation as required and specified shall be provided in the turbine hall for erection and maintenance of turbo-generators and their auxiliaries.


Each crane shall be capable of lifting at least 105% of the weight of single heaviest component/equipment, including lifting beam and slings etc. (as applicable) to be handled in TG hall for erection as well as maintenance of the equipment provided in AB bay. The auxiliary hook capacity shall not be less than 20 Ton.

In addition, it shall also be possible to handle Generator Stator with tandem operation of two Turbine hall EOT cranes for which necessary arrangements shall be provided. In such case, the combined capacity of two EOT cranes shall not be less than the 105% of weight of Generator Stator, including the weight of lifting beam with swiveling arrangement and slings.

3.00.00 COAL TRANSPORTATION AND HANDLING SYSTEM

3.01.00 Coal Transportation The daily coal requirement for 2 x 660 MW units shall be about 12920 tonnes based on average gross calorific value of 6000 Kcal/ kg , 100% plant load factor and 2317.44 Kcal/ Kwh unit heat rate.

The envisaged mode of coal transportation from jetty near plant end to the power plant end is by conveyor system.

3.02.00 Coal Handling System





An independent coal handling plant is proposed to cater for both units. Coal handling plant consisting of 1200 TPH coal conveying system (with 100 % standby parallel stream) along with reclaimers, trippers etc.

Crushed coal from crusher house shall be conveyed to stock yard through parallel stream conveyors each having capacity of 2000 TPH and shall be stacked in stock yard through stackers of 2000 TPH.

Further, reclaimers of 1200 TPH capacity is proposed to convey the crushed coal to boiler bunkers by means of one set of parallel double stream (one working and one standby) of belt conveyors of 1200 TPH capacity.

An interconnection is also provided to convey coal directly from crusher house to boiler bunker.


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 all units in two bunker filling cycles in 12 hrs effective operation.

It is envisaged that imported coal shall be supplied. Coal handling plant shall have crushers for ultimately sizing the coal to (-) 20mm.

Motorised travelling trippers shall be provided to feed crushed coal into the raw coal bunkers of the boilers.

Coal stock for 90 days is envisaged. However, space is available in coal stock yard for six months storage.

Dust suppression and service water system shall be provided throughout the coal handling plant.

A centralized main CHP control room shall be provided to control and monitor the operations of the entire coal handling system.

4.00.00 ASH HANDLING SYSTEM

4.01.00 Ash Handling System

The boiler shall be of dry bottom type. The bottom ash extracted in dry form shall be transported through conveyor to intermediate silo( common for both units) and pneumatically transported to BA silo and mixed with fly ash for final disposal in HSCD slurry form to ash dyke. The fly ash shall be conveyed in dry form from the electrostatic precipitator hoppers. This dry ash is taken to buffer hoppers for its onward transportation in dry form to storage silos near plant boundary for utilization. In case of non utilization, fly ash shall be taken to HCSD system, where in it shall be mixed in agitator tanks for its ultimate disposal in high concentration slurry form to ash disposal area.

4.02.00 Bottom Ash Handling System

Bottom ash is extracted by using a continuously operating dry bottom ash evacuation system. The bottom ash extracted in dry form from each unit shall be crushed in primary and secondary crusher to granular size of less than 6 mm and shall be collected in an intermediate silo( IM silo). BA can be unloaded and transported through trucks from this IM silo. In case of non utilization of BA ash or disposal though trucks, BA from IM silo shall be transported to a BA silo near HCSD pump house. This shall be further mixed with fly ash and disposed off in form of HCSD slurry. Economizer ash shall be handled in dry form through vacuum system. One common buffer hopper and 2 nos (1W+1S). Vacuum pumps are envisaged for 2 x 660MW units for eco ash conveying.


The BA extraction air compressor for conveying BA shall be used for conveying Eco ash also to BA silo near HCSD pump house. This shall be further disposed off in form of HCSD slurry

4.03.00 Fly Ash Handling System

Pneumatic conveying system (either vacuum system or pressure system) shall be employed for conveying of fly ash from the electrostatic precipitator hoppers and APH hoppers in dry form. This dry ash shall be taken to buffer hoppers of each unit. The dry ash buffer hoppers shall be located adjacent to the ESP. Dry ash from buffer hoppers shall be transported either to HCSD silos to be located near the chimney or to storage silos near the plant boundary. The transportation system shall be provided for each unit for transportation from buffer hoppers to the silos. The user industries shall take the dry fly ash from these storage silos either in closed tankers or in open tankers.

Space provision shall be kept near storage silos for installation of dry fly ash classification system, in future, for users for classified fly ash.

4.04.00 Ash Slurry Disposal System

Fly ash , BA & ECO ash slurry disposal

The fly ash collected in HCSD silos near chimney and ECO& BA ash from BA silo shall be mixed with water in an agitator tank at controlled rate to obtain the desired high concentration. This high concentration slurry shall be further pumped to Ash dyke by HCSD pumps. One HCSD pump house is envisaged for 2x660MW units. There shall be Two (2) working streams( one for each unit) and one (1) standby stream of HCSD pumps. All the pumping streams shall be provided with its individual disposal pipes. No crossover is being envisaged in the disposal piping

Ash water system

The major requirement for ash water system shall be met by CW system blow down and plant make up water system.

4.05.00 Ash Water Re-Circulation System

HCSD systems is supposed to have no excess water. However a recirculation system is envisaged for pumping any excess decanted water from Dyke.

Decanted water from ash pond of HCSD pond shall be led to the plant area by using 2 x 100% (30 cum/hr) capacity pumps and the same shall be conveyed through one number carbon steel pipe from ash dyke to plant area. . This water will be used further in the ash handling system.


5.00.00 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.

It is proposed to transport heavy oil (HFO/LHS/HPS) to the power plant by road tankers. The receiving yard shall be designed to unload ten (10) road tankers a time. The oil from road tankers shall be unloaded to unloading header by gravity which shall then be pumped to storage tanks through unloading pumps.

It is proposed to transport light oil (LDO) to the power plant by road tankers. The oil will be unloaded from road tankers by gravity into the unloading header. From there it will be transferred to oil storage tanks through a set of positive displacement pumps. Provision shall be kept to unload five (5) nos. road tankers for light oil (LDO).

For storage of heavy oil (HFO/LHS/HPS) two (2) nos. of fixed roof type storage tanks each of 2000 KL capacity shall be provided. 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.

6.00.00 WATER SYSTEM AND PLANT UTILITIES

6.01.00 Source of Water

The source of water for the project is sea water drawn from Passur River (about 2 kms), which is primarily back water of sea. Sweet water required for meeting the potable water, plant service water, cycle makeup (DM water) etc shall be produced using Desalination process from sea water.

6.02.00 Type of Circulating Water System

Sea water to be used for this project is having very high silt content. In once through system, huge quantity of water will be required; Desilting of such huge quantity of water would be uneconomical. In cooling tower system, only make up water needs to be provided and can be easily


desilted. Therefore, re-circulating type CW system with cooling towers having open intake channel has been envisaged for the project.

6.03.00 Water Consumption

`Make up water requirement for this project would be about 9150 Cu.M/hr It is proposed to adopt Reverse Osmosis process for Desalination of sea water to meet the sweet water requirement of the plant.

6.04.00 Make-up Water System

It is envisaged to provide five (5) Make up water pumps inside the make up water pump house to be located inside water source, from where water shall be pumped to the plant. It is proposed to provide two numbers of pipelines from makeup water pump house to plant end, one upto circulating Water channel and other upto Desalination plant. The pipelines shall be internally lined suitable for handling sea water The pipelines shall be protected against corrosion using suitable external 3LPE coating. Further the pipes shall be protected against galvanic corrosion by providing impressed current type cathodic protection system. The make up water system shall be provided with required instrumentation, interlocks and controls, control panels to facilitate safe & reliable operation. Required Monorail hoists shall be provided for maintenance requirement of stop log gates of make up water pump house. Dosing of Chlorine is envisaged at the discharge of the pump and/ or at the pump suction. EOT cranes of suitable capacity shall be provided to meet the maintenance requirements of pumps and associated equipments.

6.05.00 Circulating Water System

a) Sea water makeup shall be supplied to the cold water channel of CW system. Water from cold water channel will enter into the CW pump house through stoplog gates and trash racks at low velocity. The total water requirement for the condenser and auxiliary cooling is estimated to be about 72000 Cu.m/hr per 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). A common Circulating Water Pump House shall be provided for both the units. Two numbers of CW pumps shall be provided for each unit. CW pump can be of vertical wet pit or Concrete/metallic Volute type. A common standby CW pump shall be provided. Accordingly there would be five (5) numbers of CW pumps.

b) For interconnecting C.W. duct with CW pump, condenser and cooling

towers, steel pipes internally lined with polyurethane would be used.

c) Cooling water requirement for the auxiliary cooling system of each unit would be tapped from the CW pipe at the upstream of condenser and the return water from the circuit would be led to the CW


discharge pipe after condenser. Re-cooled water after cooling tower will be led to the CW pump house through the cold water channel by gravity. CW system blowdown would be drawn from CW pump discharge.

d) Monorail hoists shall be provided for maintenance requirement of

trash racks and gates of CW pump houses. EOT crane of suitable capacity shall be provided in the CW pump house for maintenance of CW pumps and associated equipments.

e) Type of tower : induced draft cooling tower has been considered.

6.06.00 Equipment Cooling Water (ECW) System

a) Closed circuit cooling water system would be adopted for unit auxiliaries of steam generator and turbine generator and common auxiliaries like compressors for various systems. DM water would be used in primary cooling water circuit for cooling of various auxiliaries which in turn shall be cooled in a secondary circuit by circulating water through a set of plate type heat exchangers. The secondary circuit cooling water would be tapped from the CW pipe at the upstream of condenser and the return water from the circuit would be led to the CW discharge pipe after condenser. Re-cooled water after cooling tower will be led to the CW pump house through the cold water channel by gravity. As the pressure required for coolers of SG auxiliaries and TG auxiliaries are different, it is proposed to provide two independent primary circuits i.e one for SG auxiliaries of each unit and one for TG auxiliaries of each unit. However a common secondary cooling water circuit shall be provided.

b) Make up to the primary side closed loop would be from unit DM make up system through overhead tanks.

6.07.00 Water Treatment Systems

Water treatment system of the project comprises of Desalination System, Chlorination Plant, Condensate Polishing Plant and liquid waste effluent treatment system as described below.

6.07.01 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.

6.07.02 Chlorination Plant for CW System

Chlorination plant shall be provided for chlorine dosing in the CW system to avoid the growth of algae and bacteria. CW chlorination system would consist of three (3) numbers of chlorinator-evaporator sets of 100 Kg/hr capacity. Each chlorination system shall be provided with required chlorine tonne containers, instrumentation panels, chlorine leak detectors etc. Complete chlorination plant shall be located indoor. Chlorine leak absorption system as plant emergency measure shall be provided for each of the chlorination plants to neutralize chlorine leakage from the plant. As the project uses sea water, alternative to the proposed gas chlorinators, use of electro-chlorinators shall be studied and if found suitable the same can be implemented.

6.07.03 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.

6.07.04 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 using CW blow down water or plant water make up system.

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.

Water 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.

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, at a distance of 2 Kms (approx), as it has not been identified for this project.

6.07.05 MISCELLANEOUS WATER SYSTEMS

a) Two sets of potable water pumps for plants and colony shall be provided to fill the overhead potable water tank of the plant and as well as to supply potable water to the township/ colony. A pipe network for distribution of potable water for plant shall be provided from the overhead storage tanks.


b) From the treated water storage tanks in desalination plant, required number of service water pumps, air preheater wash water pumps shall be provided to supply service water for the complete plant, including dust suppression water storage tank of Coal Handling Plant and wash water to Air-pre-heaters of Steam Generators. The service water pumps shall also fill fire water storage tanks.

c) In addition to the above, DM water make up system, boiler fill pumping system and HVAC make up system shall also be provided.

7.00.00 Fire Protection System

A comprehensive fire detection and protection system is envisaged for the complete power station. This system shall generally be as per the recommendations of TAC (INDIA)/ IS: 3034 & NFPA- 850.

The following protection systems are envisaged:

i.) Hydrant system for complete power plant covering main plant building, boiler area, turbine and its auxiliaries, coal handling plant, all pump houses and miscellaneous buildings of the plant. The system shall be complete with piping, valves, instrumentation, hoses, nozzles, hose boxes/stations etc.

ii.) Automatic high velocity water spray system for all transformers located in transformer yard and transformers having oil capacity above 2000Ltrs and located within the boundary limits of plant, Main and unit turbine oil tanks and purifier, Oil canal, generator seal oil system, lube oil system for turbine driven boiler feed pumps, boiler burner fronts etc. This system shall consist of QB detectors, deluge valves, projectors, valves, piping & instrumentation.

iii.) Automatic medium velocity water spray system for cable vaults and cable galleries of main plant, switchyard control room and ESP control room consisting of smoke detectors, linear heat sensing cable detectors, deluge valves, isolation valves, piping, instrumentation, etc.

iv.) Automatic medium velocity water spray system for coal conveyors, transfer points, Stacker reclaimer, consisting of QB detectors, linear heat sensing cables, deluge valves, nozzles, piping, instrumentation, etc

v.) Automatic medium velocity water spray system for un-insulated fuel oil tanks storing fuel oil having flash point 65o C and below consisting of QB detectors, deluge valves, nozzles, piping, instrumentation, etc.

vi.) Automatic Foam injection system for fuel oil / storage tanks consisting of foam concentrate tanks, foam pumps, in-line inductors, valves, piping & instrumentation etc.

vii.) For protection of Central control room, Control equipment room, Programmer room, UPS room, etc. Inert Gas extinguishing system as per NFPA-2001 would be opted.

viii.) Fire detection and alarm system - A computerized analogue, addressable type Fire detection and Alarm system shall be provided to


cover the complete power plant. Following types of fire detection shall be employed.

1) Multisensor type smoke detection system

2) Photo electric type smoke detection system.

3) Combination of both multisensor type and photo electric type

smoke detection systems.

4) Linear heat sensing cable detector.

5) Quartzoid bulb heat detection system.

6) Infra red type heat detectors (for selected coal conveyors)

ix.) Portable and mobile extinguishers, such as pressurized water type,

carbon-dioxide type, foam type, dry chemical powder type, will be

located at strategic locations throughout the plant.

x.) CW blow down shall be used for supply of fire water. An alternate

connection from raw water line shall also be provided as a back-up

source for fire water. It is proposed to provide two numbers of Steel

tanks for storage of fire water system. Fire water pumps shall be located

in the fire water pump house and horizontal centrifugal pumps shall be

installed in the pump house for hydrant and spray system and the same

shall be driven by electric motor and diesel engines as per the

regulations of TAC. The water for foam system shall be tapped off from

the hydrant system network.

xi.) For the above fire water pumping station, automatic pressurization

system consisting of jockey pumps shall be provided.

xii.) Complete Instrumentation and Control System for the entire fire

detection and protection system shall be provided for safe operation of

the complete system.

8.00.00 Plant & Instrument Air System

a) For instrument air requirement of main plant and auxiliaries, required numbers of air compressors & Air Drying Plants (ADP) shall be provided. The capacity of compressors and ADP shall be decided based on the requirements of main plant supplier (especially Steam Generator vendor) and other auxiliary plant and data need to be obtained. However for FR purpose it is proposed to provide three (3) compressors (Two working & one standby) each of capacity of 55 NM3/min and Three (3) numbers of Air Drying Plants of identical capacity for instrument air application. The discharge pressure of the compressors shall be such that a delivery pressure of 7.5 kg/cm2 (g) is available at the outlet of ADP. The compressors shall be of oil free screw type/Centrifugal 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.

b) The air drying plants shall be capable of achieving a dew point of (-) 40oC 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.

c) Service air requirements for various systems shall be obtained before project implementation stage to identify the number & capacity of Plant air compressors. However for FR purpose, it is proposed to provide Two (2) numbers of compressors of capacity same as that of instrument air compressors. The compressors shall be same type as that of instrument air compressors.

9.00.00 Air Conditioning System

i) Air conditioning system shall be provided for all those areas which require close control of environment conditions and shall cover the following areas: a) Control tower areas including Control Rooms, Control

Equipment Rooms, Computer and Programmers Rooms, UPS /Battery Charger Rooms, Conference Room, Shift Charge Engineer's Room, Steam & Water Analysis Rooms (SWAS), etc,

b) Switchyard Control Room. c) ESP control rooms. d) Service Building. e) Administration Building. f) Water System Control Rooms. g) DM plant Lab building.

h) Auditorium

i) Any other area which contains control and instrumentation equipment requiring air conditioning or otherwise requires to be air conditioned.

ii) 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 2 Nos. of 225 TR capacity steam powered Vapour Absorption Chillers (VAC) and 1 Nos. of 225 TR capacity screw / centrifugal type chillers as standby units for central control room, control equipment rooms, UPS/Battery charger rooms, ESP control rooms. Chilled water shall be pumped to each area and each area shall be air-conditioned through dedicated air handling units located locally. Air handling units shall be provided with variable frequency drives (VFD).

iii) It is proposed to provide 2 Nos. of 200 TR capacity screw / centrifugal type chillers (1 No. working + 1 No. stand-by) for Service Building. Further, chilled water pumping shall be in two stages, primary chilled water pumps with normal drives and secondary chilled water pumps with variable frequency drives (VFD) shall be provided. AHUs for Service building shall be with VFDs.


iv) It is proposed to provide 2 Nos. of 225 TR capacity screw / centrifugal type chillers ( 1 No. working + 1 No. stand-by) for Administration Building. Further, chilled water pumping shall be in two stage, primary chilled water pumps with normal drives and secondary chilled water pumps with variable frequency drives (VFD) shall be provided. AHUs for Admin building shall be with VFDs.

v) For other areas, where air conditioning heat load is high, of the order of 60-100 TR, central chilled water type air-conditioning plant using screw/scroll chillers shall be provided. For areas where AC load is of the order of 40-60 TR, Direct Expansion (D-X) type Condensing unit or multiple Package Air Conditioners (PAC) units shall be provided depending on the availability of space/ layout etc. Smaller areas which are away from the PACs/central chilling units which may require air conditioning of the order of 5 TR rating shall be served with Split/Packaged air conditioner units as per requirement.

vi) In determining air conditioning load (TR), equipment load, heat load due to solar heat gain, occupancy, lighting and transmission gain shall be considered as per established design practice.

vii) All air conditioned space shall be maintained at 24 deg C +/- (plus or minus) 1deg C 50% +/-(plus or minus) 5% RH.

viii) Further critical areas like Control room, Programmer room, etc which are required to be air conditioned even during failure of normal power supply shall be air conditioned whose drives along with applicable fresh air fans, chilled water pumps, condenser water pumps, cooling tower and AHU shall operate on emergency Diesel Generator sets.

ix) All air conditioned areas shall be supplied with filtered air. Both re-circulated and fresh air shall be filtered separately.

10.00.00 Ventilation System

a) 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.

b) Basically two types 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.

c) The areas to be ventilated by Evaporative Cooling System shall be as follows: 1) All floors of turbine hall including "BC Bay" other than the area

which are air- conditioned 2) Switchgear rooms and cable galleries of main plant 3) Non air-conditioned area of ESP control room

Non air-conditioned areas of ESP building shall be ventilated by Unitary Air Filtration System.


d) All other buildings /areas such as switchgear rooms, pump houses, store, canteen and toilets etc shall be ventilated by mechanical ventilation process using combination of supply air fans and roof exhausters or wall mounted exhaust fans.

e) All evaporating cooling system shall be designed based on 90% saturation efficiency of air washer. Air quantity shall be selected in such a way so as to maintain an inside temperature of 2 deg C below maximum design ambient during summer or a minimum air change rate of 6 to 8 per hour which ever is higher.

f) All mechanically ventilated areas shall be designed to a maximum inside temperature of 3 deg C above maximum design ambient during summer or 20 air change rate per hour (for general area) and 30 air changes rate per hour for switchgear rooms, battery room whichever is higher.

g) All ventilation system shall work on 100% fresh filtered air. h) Turbine hall and electrical switchgear / control rooms shall be

designed for positive pressure ventilation, which shall be achieved with the assistance of roof extractors besides air washer by sizing the exhausters to extract 60-75% of total air delivered by supply air fans. All fuel oil pump houses, battery rooms, kitchens, toilets shall be designed for negative pressure ventilation.

11.00.00 Hydrogen Generation Plant

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. The capacity of the plant to be designed based on the requirement of Generator. Presently it is proposed to provide a hydrogen generation plant of 15 Nm3/hr capacity for the project, with two streams of electrolysers each of capacity 7.5 Nm3/hr with three hydrogen compressors each of 9.375 Nm3/hr capacity along with auxiliaries. Hydrogen generation shall be accomplished by water electrolysis process. The plant shall be designed as per the regulations of the Explosives authority with all the required safety aspects, instrumentation control, including on-line hydrogen purity analyser system and control panel.


7. 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:

2.00.00 POWER EVACUATION

EHV transmission system in Bangladesh is at 132 kV and 230 kV levels. 400 kV transmission systems have been planned along with the proposed coal based projects at Khulna & Chittangong and gas projects planned at Bibiyana. Part of Dhaka ring main 400 kV transmission network (400 kV line between Meghnaghat and Aminbazar) is under construction by Power Grid Company of Bangladesh (PGCB). To facilitate power transfer between India and Bangladesh, asynchronous interconnection through 500 MW HVDC back to back terminal station at Bheramara(Bangladesh) fed from Baharmpur(India) through 400 kV D/C line is under implementation.

The Indian portion 400 kV switching station at Baharampur alongwith 400 kV D/C line up to Bheramara is under implementation by Power Grid India and Bangladesh portion is being taken up by Power Grid Company of Bangladesh (PGCB)

In view of above, and considering present Capacity of Khulna project as 1320MW the step up voltage level of the project has been considered as 400 KV. Power Generated from each of the 660MW unit would be stepped up to the evacuation voltage level through suitably rated Generator Transformer.

As per the preliminary discussion and communication received from Bangladesh Power Development Board (BPDB)/ PGCB provision of line bays in generation switchyard for one no.400 kV D/C line (envisaged to connected to Dhaka ring main) and one no. of 230 kV D/C line (envisaged to be connected to Khulna South) have been kept for power evacuation from the project. The provisions for Power evacuation as considered presently are tentative and shall be reviewed based on finalized ATS of the project by BPDB/PGCB.

The Switchyard Single Line Diagram indicating overall scheme is enclosed at Annexure- A.

2.1.00 Start-up Power Requirement

The start up power of the plant has been envisaged to be drawn from the 230 kV existing PGCB Khulna South substation through the planned transmission line between generating switchyard and Khulna south substation. The 400 kV switchyard and 230 kV switchyard at Khulna thermal power project shall be interconnected through two nos. suitably rated 400/230 kV Inter Connecting Transformer. Presently rating of above ICT has been considered as standard 315 MVA. However, 520 MVA


transformer may be considered during detailed engineering stage based on PGCB/BPDB requirement. The availability of above 230 kV D/C line interconnection from Khulna south substation needs to be ensured matching with the project start up power schedule.

2.2.00 Auxiliary Power Supply Scheme

The plant auxiliary power supply scheme has been evolved with Generator Circuit Breaker along with suitably rated unit transformers associated with each unit. Unit loads shall be fed from the respective unit boards and station loads shall be distributed among various unit/Standby boards suitably to arrive at optimum transformer size. One no. common Start up/Standby transformer has been provided to cater outage of any unit transformers. The overall scheme has been enclosed at Annexure -B

Techno economic analysis was carried out for two alternative schemes Viz GCB with standby and Station Transformer scheme and it is found GCB scheme is techno economically suitable for the coastal project like Khulna.

3.00.00 GENERATOR

The main parameters of Generator would be as follows:

a) Nominal rating 660 MW b) Rated output 777 MVA c) Power factor 0.85 (lag)-0.95 (leading) d) Rated voltage As per manufacturer's Standard (in the

range of 21-24 kV) 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 de-mineralised water, passing through hollow stator conductor. The stator core and the rotor 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


4.00.00 BUSDUCT

The connection between the generator and generator transformers shall be through isolated phase busducts. The busduct 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 busduct will have an all aluminium construction.

The tentative parameters of the generator busduct are:

Voltage rating 21 kV Current rating (main run) 23,500 Amps

Current rating (delta run) 14,000 Amps Current rating (tap off) 2000 Amps

The above data may vary in case of change in Generator Voltage rating.

Necessary current and voltage transformers shall be provided in the busduct 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 will be by means of segregated busduct with aluminium conductor and enclosure.

5.00.00 GENERATOR TRANSFORMER

Each 660 MW unit shall have three (3) single phase transformers with combined rating of 780 MVA, for the Generator Transformer.The transformer would be OFAF cooled.

As per our experience and normal practice in NTPC,because of the adverse feedback of transformer failures due to problems in OLTC due to frequent operation, the most critical link like generator transformers are not being provided with OLTC. Off circuit tap changer are being provided to set the generator transformer at appropriate tap suitable for most of the operating conditions .The voltage variation in plant auxiliary side on account of variation in grid voltage can be catered with OLTC provided at smaller sized unit auxiliary transformers.

However, as per discussion with BPDB/PGCB, since 400 kV system in Bangladesh is evolving grid ,wide range grid voltage variations are expected during light load and peak requirement. In view of above, and to facilitate reactive power exchange depending on grid voltage variations,On Load Tap Changer (OLTC) on generator transformers can be provided as required by BPDB.

6.00.00 GENERATOR CIRCUIT BREAKER

Generator Circuit breaker shall be provided with each unit and shall be metal enclosed free standing type suitable for direct connection to phase


isolated generator busduct in a manner designed to preserve the phase isolated principle. The interrupters of the circuit breaker shall be SF6 or air blast type with suitable continuous and short time current rating. It shall be suitable for frequent operation on load and shall be capable of breaking the maximum fault current (with high DC component) which may flow through it. GCB shall be provided with an earth switch on generator side. One pole of the breaker shall be provided as spare.

7.00.00 AUXILIARY POWER SUPPLY SYSTEM

The voltages adopted for the AC auxiliary system are:

415 V for motors rated upto 200 kW. (Energy Efficient Motors have been envisaged upto 160 KW.)

3.3 kV for motors above 200 kW and upto 1500 kW. 11 kV for motors rated above 1500 kW

The electrical auxiliary system proposed will derive supply from 400 kV systems via suitably rated Unit transformers connected with the unit. These transformers will feed Station and loads, which will have a fault rating of 40 kA break & 100 kAp make. One no. Start up/Stand by transformer of suitable rating has been has been provided for startup requirement or for outage of any unit transformer.

Interconnection between Unit and Station boards will be provided to cater for unit or station transformer outage, as shown in single line diagram. The scheme is shown in the single line diagram.

All electrical equipments associated with above schemes shall be rated for the maximum ambient temperature of 50 deg C and relative humidity of 95% and relative humidity of 100%

8.00.00 LOADS AWAY FROM PLANT BOUNDARY

The scheme for the remote loads away from plant boundary is proposed as per the single line diagram. In order to meet the load of cross country CHP loads and miscellaneous loads it is proposed to install three nos. 16 KVA 11/34.5 kV cross country CHP/Misc transformer. Further the requirement of loads of makeup, colony, AWRS etc shall be met by two nos. 33/11.5 Miscellaneous Service transformers.

Transformers of suitable ratings shall be provided to meet the loads at different voltage levels. These shall be located at the respective load centers.

9.00.00 UNIT TRANSFORMER

02 Nos. two winding Unit transformers with delta connected HV winding and star connected LV winding and having ONAN/ONAF cooling shall be provided with the unit. The transformer is sized for the connected unit loads and station 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.


10.00.00 START UP /STANDBY TRANSFORMER

The rating and details of these transformers are shown in the single line diagram. The transformer will be ONAN/ONAF/OFAF cooled & will have an on load tap changer

11.00.00 AUXILIARY TRANSFORMERS

For meeting the demand of various systems i.e. unit auxiliaries, CHP, station auxiliaries, ash handling, ash water re-circulation system, make up water system etc. suitable ratings of 2 x 100% transformer /feeders shall be provided. All these transformers will be delta connected on the HT side and star connected on the LT side

12.00.00 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 busducts.

13.00.00 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, 415V system shall be solidly earthed. 220V DC system shall be kept ungrounded. Emergency diesel generator shall be ungrounded.

14.00.00 H.T. SWITCHGEAR

Switchgears shall be indoor, metal clad draw out type with vacuum breakers. Contactors cum fuse units may be used for auxiliaries such as coal conveyors/crushers 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.

As per standard metering regulations for generating stations, energy accounting and audit meters are required to be installed at incomer feeders of HT and LT incomer transformer feeder and all HT motors. The accuracy class of all metering meters shall not be inferior to 1.0S. The metering through numerical relays meeting above accuracy class has been considered for above requirements. The above standard conforms to


Indian regulations, however the same can be reviewed based on Bangladesh metering regulations (if any) during subsequent stages.

15.00.00 415 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. All LT motors above 110 KW up to 200 KW shall be breaker controlled and below 110 kW shall be contactor controlled. Microprocessor based MCCBS shall be used for feeder rating of 250 A to 630 A and the feeder rating below 250 A shall be of switch fuse unit type. The LV switchgears shall have Communicable Numerical relay system for protection, Control, metering and monitoring of the Switchgears. All the relays shall be integrated with HT network for common HMI through data concentrator for Monitoring and Supervision of all the breaker panels. All such data shall be linked to DDCMIS as well.

The built in feature of energy metering in the numerical relay shall be used for energy accounting and audit meters as per notified metering regulations.

16.00.00 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 interconnections between these two batteries and chargers. Each of 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. Other Balance of plant systems like AWRS, Ash Silo and CHP shall have separate DC systems as indicated in Bill of Quantity.

17.00.00 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. Diesel Generator (DG) set per unit alongwith one standby DG set common for two units shall be provided as indicated in the single line diagram. Cable interconnection shall be provided from DG to respective unit emergency switchgear.

18.00.00 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 is given below:

18.1.00 GENERATOR

1. Duplicated Generator differential protection, 3-pole (87G1 & 87G2) high impedance or biased type having operating time of 25 milli second or lower at 5 times the current setting.

2. 87GT-overall differential covering generator, 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, GCB 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. Inter-turn 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 I2 t element for trip (46G).

11. Duplicated low-forward power interlock 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. Overfluxing protection (99G&99T) having inverse time characteristic suitable for matching generator/generator transformer overfluxing


capability. Separate relays on either side of generator circuit breaker to be provided.

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

16. Local breaker back up (or breaker failure protection).

17. Generator Circuit Breaker failure protection (50 ZG).

18. Trip Circuit and DC supply supervision relays for Generator Circuit Breaker.

19. Pole slipping protection (98).

20. 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.

One Disturbance/fault recorder (DFR) – microprocessor based shall be provided for each generator. It shall have the facility of fast scan as well as slow scan to record transient as well as dynamic performance of the system.

18.2.00 GENERATOR TRANSFORMER AND OVERHEAD CONNECTION

I. Generator-transformer differential protection for individual phase (87T) bias type having instantaneous high set over current elements.

II. Over head line connection differential protection (87HV) covering overhead connections between generator transformer & 400 KV breaker including HV winding of generator transformer.

III. Back-up earth fault protection on generator transformer HV neutral (51NGT).

IV. Buchholz relay, winding temperature, oil temperature and oil level alarm and trip.

V. Fire protection to trip EHV generator / breaker, exciter field breaker and unit incoming breaker.


18.3.00 UNIT TRANSFORMER

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

2. Unit transformer back up over current protection (51UT).

3. Unit transformer L.V. Restricted earth fault and standby earth fault protection (64 RUT & 51NUT).

4. Bucholz relay, winding temperature, oil temperature and oil level alarm and trip

5. Fire protection to trip EHV breaker, exciter field breaker and 11kV unit incoming breaker.

18.4.00 STARTUP/STANDBY TRANSFORMER

1. 3 winding differential protection 3-pole (87T).

2. Back-up over current protection on HV and LV side (50/51 ST) for ST only.

3. Restricted earth fault protection (64R) on HV& both LV windings

4. Back-up earth fault protection on LV windings (51 N)

5. Buchholz relay, OLTC trouble, cooler trouble 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 station transformer

8. Over fluxing protection (99T)

18.5.00 INTERCONNECTING TRANSFORMER

1. 2 Winding Differential Protection (87T)

2. Restricted E/F Protection (64RT)

3. Directional Back-up O/C and E/F protection on HV and LV (67RYB/N for HV and LV)

4. Back-up neutral E/F protection (51N)

5. Over fluxing Protection (99T)


18.6.00 BUS/LINE REACTOR

1. Reactor differential Protection

2. Reactor restricted earth fault protection

3. Back-up Over current and Earth Fault protection with high set feature

4. Over-fluxing Protection

19.00.00 ELECTRICAL CONTROL CONCEPT

Central Control Room (CCR)

The complete control of generator and auxiliary system shall be provided in the DDCMIS system covered under "Control and Instrumentation" having large video screens. On the operation desk CRT's/Keyboard shall be provided so that operator can control all the breakers via DDCMIS.

The Switchgears shall have Communicable Numerical relay system for protection, Controls, 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 flow shall be linked to DDCMIS as well.

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.

In addition, to the above 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 a back end panel located in CER.

20.00.00 CABLES

For HT cable, single core and three core XLPE insulated cables with aluminium conductor would be employed. For 415V 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.

21.00.00 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.

22.00.00 LIGHTING SYSTEM

Adequate lighting arrangement shall be made for the entire power plant employing lighting distribution boards, panels, HPSV, T5 type fluorescent 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.

23.00.00 SWITCHYARD

23.1.00 Type: GIS

In view of coastal site and marshy land ,Gas Insulated type Switchyard is considered for this project.

Proposed Arrangement for Power Evacuation for the project has been shown as per the single line diagram.

23.2.00 Bus Switching Scheme:

It is proposed to adopt the standard breaker and half switching scheme for the 400 kV switchyard in order to have flexibility in operation and standard advantages of one and half breaker scheme over double bus scheme as follows:


i) In case of one bus bar fault, faulty bus bar tripped. Load redirected to other bus bar, no supply interruption happens.

ii) Bus maintenance becomes much easier, as all the feeder bus

breakers can be tripped and all the feeders remain connected to other bus. No need of transferring all circuits to one bus as done in double bus bar scheme

iii) In case of feeder breaker stuck, only faulty circuit gets

disconnected. All other feeder remains connected through other bus unlike double bus where the entire connected feeder gets tripped.

In double bus with single breaker scheme, in the absence of breaker, whole 660 MW generations will be lost and thereby reducing the revenue. Hence techno economically one and half circuit breaker scheme is proposed for 400 kV generation switchyard. In 220 kV system ,due to outage of single breaker a feeder may be lost and load can be transmitted through other 220 kV feeders as provision of number of lines are kept for n-1 contingency condition

It is proposed to adopt the standard breaker and half switching scheme for the 400kV and double bus scheme for 230 kV GIS switchyard.

23.3.00 Salient Features of Main Equipments

1. Insulation Coordination

The 400 kV system is being designed to limit the switching surge overvoltage to 2.3 p.u. and power frequency over-voltage for both 400 kV & 230 kV to 1.5 p.u. The breakers associated with bus/line reactor shall be suitable for controlled switching. Also to restrict the reactor switching overvoltage, the lightning arrestors associated with 400 kV reactors shall be of 336 kV. All the materials/equipment shall perform all its functions satisfactorily without undue strain under such overvoltage conditions. Consistent with these values and protective levels provided by the lightning arrestor, the proposed insulation levels for the various voltage systems are as follows:

Sl No Description

400 kV 230 kV

i) Lightning impulse withstand voltage 1425 kVp 1050 kVp

ii) Switching impulse withstand voltage 1050 kVp -----

iii) Maximum fault current 40 kA 40 KA

iv) Duration of fault 1 sec 1 sec


2. Switchyard Equipments

(a) Circuit Breakers

Circuit Breaker shall in general conform to latest edition of IEC 62271-100 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.

(b) Isolators

Isolators will in general conform to IEC: 62271-102 (or equivalent Indian Standard) and shall be of horizontal center 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 Transformers

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 metalclad 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.

(f) Reactor

Reactors shall be connected to the 400 kV systems at generation switchyard for reactive load compensation and shall be capable of controlling the dynamic overvoltage occurring in the system due to load rejection. Reactors shall be capable of operating continuously at a voltage of 5% higher than their rated voltage. Shunt reactors shall also limit the power frequency over voltage to the specified limit.

3. Protection of Switchyard Equipment & Outgoing Lines

(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) Line Protection

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) Power Line Carrier Communication

Standard proven Power Line Carrier Communication (PLCC) based system are being provided for distance protection because of limitation of OPGW for line distances involved in case of Khulna STPP. Requirements of repeaters are required for long distances and hence they are not adopted in India and are not proven. In view of it, standard proven PLCC has been provided for distance protection. As regard to data communications, the same can be done


through duplicated OPGW links provided on transmission line by PGCB.

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 Power Grid Company of Bangladesh (PGCB). Only wave trap and PLCC battery feeders have been considered under the present F.R.

(e) Metering System

0.2 accuracy class Availability based Tariff (ABT) energy meters along with metering Master Station and software, for export & import of active and export and import of reactive energy meters shall be provided for each outgoing lines, generator / transformer feeders.

Suitable software for the calculation of Unscheduled Interchange (UI) based on Declared Capacity, Actual generation, Scheduled generation, UI rate etc shall also be provided. Metering system network shall be provided with a suitable gateway for OPC link with the Central OS Control Station (ERP).

Static meters of 0.2 Accuracy class have been considered for active energy measurement at other locations for energy accounting/trend analysis.

23.4.00 Control Philosophy For Switchyard

The control, protection and data acquisition including SOE data for 400 /230 KV switchyard bays shall be accomplished by Substation Automation System comprising of Bay Control Units, Bay protection Units, Operators Workstation, Engineering Workstation, Large Video Screen (LVS) etc.

The SA system will be based on standard communication protocol IEC 61850. The Substation Automation System shall facilitate following functionality:

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

(ii) Monitoring ON/OFF status and remote closing/ synchronizing of circuit breakers, isolators and earth switches

(iii) Display of Switchyard alarms, events and trends (iv) Interlocking functions (v) Sequential Event Recording (vi) Communicating with protection relay IEDs for settings and

Disturbance Recording functions (vii) System self supervision (viii) Hard copy printing and other network functions

DFDR as inbuilt feature of numerical relay shall be provided for all switch yard bays i.e. Generator transformer, reactors and transmission lines. These relays


shall be networked to engineering / DFDR station centrally for data down loading & analysis associated with all the bays. In addition to above, standalone DFDR with slow and fast scan feature shall also be provided for each generator. The Digital Fault Disturbance Recorder (DFDR) system will be a complete automatic digital recording system capable of sensing, acquiring and recording the data, printing and transmitting disturbance records to the analysis units and centrally at Engineering work station provided in the Substation Automation System.

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 redundant gateways along with associated modems shall be provided in the station level network for sharing information with RLDCs through PLCC link. These two would communicate through IEC:60870:5:101 standard protocol. Two more gateways shall also be configured for suitable OPC link with Central OS Control Room.

24.00.00 CONSTRUCTION POWER

The peak power requirements for construction power shall be about 4 MW. The power supply for the project is envisaged to be met from 33kV Mongla substation of PGCB (Approx 20 kMs from proposed site) through two (02) nos. of 33 kV lines. Necessary 33/11 kV substation along with 11 kV ring main/LT sub-stations shall be provided for the required power plant area.

25.00.00 BLACK START FACILITY

The unit size being 660 MW, no black start facility has been envisaged for the plant due to techno –economic reasons.

As per standard philosophy followed for such unit size, the black start power is envisaged to be drawn from the 230 kV existing PGCB Khulna substation through the planned transmission line between generating switchyard and Khulna south substation.

26.00.00 ELECTRICAL LAB EQUIPMENT

One set of electrical lab equipment shall be provided for the plant.


8. CONTROL & INSTRUMENTATION SYSTEM

1.00.00 GENERAL

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 minimum 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 drift in process 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

It is proposed to have air-conditioned Common Control Room for the units at operating floor along with Programmer’s Room. The boiler, turbine and generator along with their associated auxiliaries would be controlled and monitored from the Common Control Room in BC bay (one CCR common for 2 units).. The control system cabinets would be located in air-conditioned Control Equipment Room (CER) at operating floor and 8.5 meters. UPS, 24V DC Modular Power Supply would be located at 8.5 meters in the air conditioned environment. Batteries for UPS & 24 V modular power supply shall be located at 8.5m in air-ventilated environment.

For offsite DDCMIS such as AHP, CHP, Water system , Make-up water system , it is proposed to have air-conditioned control room in their respective areas. The control system cabinets and equipment would be located in respective control rooms.

It is proposed to locate the room of Steam and water Analysis System (SWAS) for the units at +0.0 meters in an air conditioned environment. The exact locations of these items shall be finalized according to the main plant layout.

3.00.00 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. For operation during disturbed/emergency operating conditions in the plant, very few back-up conventional devices / instruments like hardwired TRIP push button, would also be provided on the UCD itself in draw-out sections.

The control, monitoring & operation of the offsite and auxiliary plants shall be carried out generally from LVS/control desk of the respective plants / combined control rooms. Large scale integration of control systems,


unification of various control areas shall be provided to economise on number of operation and maintenance staffs, inventory etc. in line with recent practices. Remote IO’s with

OWS as well as GIU based local operation facility shall also be provided depending on the layout of the control room. DDCMIS shall be provided for offsite areas also and control of any drive of offsite areas can be done from the main plant DDCMIS, subject to proper authorization. For this purpose, for each Sub-area/equipment, a primary operating point and secondary operating point shall be defined based on the process requirements.

For PLC based control system (i.e. H2 generation, Fire Protection) link shall be provided for exchange of data in the main plant control room for the information of unit-in-charge/shift-in-charge etc. through Station Wide LAN.

4.00.00 MEASURING INSTRUMENTS (PRIMARY & SECONDARY)

Primary measuring instruments such as transmitters, sensors etc., for the measurement of parameters like pressure, temperature, level, flow etc., would be used. 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, environmental monitoring instruments such as SOx, NOx, O2, CO2, CO and dust emission measurements shall also be provided.

Measuring instruments for off-site areas such as DM/PT/Chlorination/CPU/AWRS/LWTP and some of the local control cabinets for chlorination system have been envisaged under the respective system.

5.00.00 DISTRIBUTED DIGITAL CONTROL, MONITORING & INFORMATION SYSTEM (DDCMIS)

As already indicated above, 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), Balance of Plant (BOP) including all auxiliaries and common facilities (i.e. offsite plants).

It is proposed to use optimum number of 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 for any part of the plant can be performed from any screen) 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 the 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 provided (as part of PADO which is described later).

Master and slave clock system would be provided to ensure uniform time indication throughout the plant and also for time synchronization among various DDCMIS.

Hart Management system for centralized configuration, maintenance, diagnostics & record-keeping for all electronic transmitters, temperature transmitters and analyzers would also be provided.

5.01.00 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. Boiler Metal temp, Boiler Drains & Vents including Start up Drains & Vents.

7. Other miscellaneous SG related controls

5.02.00 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) including Vibration analysis.

8. Generator Auxiliaries Control System

9. TG Area Vents, Drains including start up Drains & Vents

10. Other miscellaneous TG related controls

5.03.00 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.

5.04.00 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.

5.05.00 COAL HANDLING SYSTEM DDCMIS:-

Coal Handling Control System comprising of binary controls of crushers, conveyers, dust suppression systems etc.

5.06.00 WATER SYSTEM DDCMIS:-

Water System Control System comprises the binary and modulating controls of DM plant, CPU Re-generation system(as per the layout), PT plant including chlorination system, Liquid Effluent Treatment system, Ash water recirculation system etc.

5.07.00 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.


5.08.00 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, Cooling tower, Ventilation system etc. and for some station level controls / supervisory functions.

6.00.00 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 HMI 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.

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

7.00.00 STEAM & WATER ANALYSIS SYSTEM (SWAS)

Water chemistry is life line of the power plant and considering that 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.

8.00.00 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) of BOP C&I DDCMIS and SG/TG DDCMIS 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 for SG C&I, TG C&I, Main plant BOP C&I & CW


system shall consist of 2 sets with each comprising of 2X 100% chargers, 1X100% Nickel-Cadmium batteries for one hour duty, 1X100% DC distribution board (DCDB) for powering the DC load requirement of Contractor’s system.

Other offsite Control systems like AHP, CHP, Water system, Make up water system etc. shall be provided with two sets of 24V DC power supply with each set comprising of 1X 100% chargers, 1X100% Nickel-Cadmium batteries for one hour duty, 1X100% DCDB.

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 along with sealed maintenance free Ni-Cd batteries, suitable for mounting in remote I/O cabinets shall be provided.

Intelligent Battery health management system shall be provided for each set of 24VDC power supply system (rating 300 Amps or above) and UPS batteries.

9.00.00 CONTROL VALVES, ACTUATORS & ACCESSORIES

Control valves and dampers would be pneumatically operated in most of the applications. However, for few applications electric/hydraulic actuators would be employed. Microprocessor based positioners shall be provided for pneumatic control valves and dampers.

10.00.00 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, pre-fabricated cables may also be used. Fiber optic cables shall be provided for Remote I/O bus, CCTV, Station LAN etc.

Instrumentation cables for filed instruments upto field mounted termination units (FTU) for the off-site areas such as DM/PT/ Chlorination/ CPU/AWRS/LWTP have been envisaged under the respective system suppliers and these quantities have not been considered in the annexed BOQ. How-ever Filed cables from (FTU) to respective DDCMIS/Remote IO’s have been considered in the enclosed BOQ.

11.00.00 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/Coal Unloading Area) with the help of handset stations, loudspeakers, portable handset stations etc.

12.00.00 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, IP based 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 HMIPIS to portray plant images on the LVS. Further, high resolution cameras shall be provided during erection and commissioning stage for remote monitoring through Project monitoring Centre (PMC), located at Corporate Centre.

13.00.00 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 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.

14.00.00 MAINTENANCE & CALIBRATION EQUIPMENT

One set of maintenance and calibration equipment has been envisaged. It would consist of calibration equipment required for maintenance of C&I system /devices used in the unit. The exact equipments/ items required for maintenance & calibration shall be procured.

15.00.00 PLANT PERFORMANCE ANALYSIS, DIAGNOSIS & OPTIMIZATION SOFTWARE (PADO)

The PC based online plant Performance Analysis, Diagnosis & Optimization (PADO) system for the station shall be provided. The PADO shall incorporate the complete thermal design model of the unit. The system shall use the measured data from the Distributed Digital Control, Monitoring & Information System (DDCMIS) through appropriate interface.

The PADO system shall provide the following functions in a modular and seamlessly integrated environment, using a common plant model and a dynamically shared database.


i) Performance analysis and monitoring of systems and components.

ii) Emission analysis and monitoring.

iii) System and performance diagnosis

iv) System and performance optimization including set point optimization system.

v) Boiler performance optimization including optimized operation of soot blowing system.

vi) Boiler stress condition analyzer

vii) Interactive water and gas chemistry management system

All the software, hardware, instruments etc. required to implement the above shall be provided by the bidder.


9. ENVIRONMENTAL ASPECTS

1.00.00 INTRODUCTION

An Environmental Impact Assessment (EIA) report for the project has been prepared by BPDB and is under finalization. Project site clearance has already been obtained by BPDB. DOE of Bangladesh has been approached for Environmental Clearance.

2.00.00 POLLUTION CONTROL MEASURES

Various pollution control systems and mitigative measures proposed to be adopted to minimize the pollution from the power project are as follows.

2.01.00 Air Pollution Control System

High efficiency Electrostatic Precipitators (ESPs) will be installed to limit the particulate emission to 100 mg/Nm3 (milligram per normal cubic meter). To facilitate wider dispersion of remaining particulates and gaseous pollutants (SO2 and NOx), bi-flue chimney of 275m height shall be provided. The chimney shall also be provided with facilities for online monitoring of stack emissions.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 and extraction systems shall be installed.

3.00.00 WATER POLLUTION CONTROL SYSTEM

The source of water for the project shall be possur River. While raw water after desilting shall be used for cooling, the possur River 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 waste water treatment system for the project are described as follows:

A closed cycle cooling system with induced 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.

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 Central Monitoring Basin (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 CMB.

The ash effluent shall be brought to a well designed ash disposal area to ensure adequate settling for ash particles. It is proposed to re-circulate the decanted ash water from ash dyke area for its reuse in ash handling system. 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 applicable standard shall be discharged into the Possur river, leading to sea.

4.00.00 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. Equipment will be designed 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 like ear plug/ ear muff shall be provided to the workers.

5.00.00 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 vegetative cover

6.00.00 AFFORESTATION AND GREEN BELT DEVELOPMENT

A green belt has been planned around the main plant area and in available spaces within the main plant area.

7.00.00 POST OPERATIONAL MONITORING PROGRAMME

Regular monitoring of pollutants in different environmental disciplines like ambient air, stack emission, waste water, etc. shall be conducted and the data shall, if required, be submitted to regulatory agencies. The monitoring locations will be finalized in consultation with regulatory agencies. Station will be equipped with all necessary equipment and manpower for ensuring effective monitoring.

8.00.00 INSTITUTIONAL SET-UP

An Environmental Management Group (EMG) shall be set-up at the project site. The EMG shall be equipped with all necessary equipment


and manpower. The EMG will interact with regulatory agencies and other concerned agencies for environmental issues, as and when required.

9.00.00 ASH UTILIZATION PLAN

Many Cement plants exists in the vicinity, best efforts shall be made for maximum utilization of fly ash. Also best efforts shall be made for maximum utilization of bottom ash. However, ash dyke of 100 acres has been provided in FR.

10.00.0 BENEFITS OF ENVIRONMENTAL PROTECTION MEASURES

Following benefits shall accrue due to Environment Protection Measure: Sl. No

Measures Benefits

1. Electrostatic Precipitator (ESP) To clean the exit flue gas

2. Stack of 275m height Dispersion over wider area

3. Cooling Tower Discharge water temperature reduction

4. Desalination plant To produce sweet water from brackish water to avoid exploiting ground water

5. Effluent Management System To minimize effluent

6. Ash Management & Utilization Ash utilization & safe disposal

COST OF ENVIRONMENTAL PROTECTION MEASURES

Broad estimation and impact on project cost due to environment protection measures, are outlined below: Sl. No. Environment Protection Measure Approx.FR provision

(BDT-Million) 1. Electrostatic Precipitator (ESP) 2535.00

2. Stack of 275m height 942.00

3. Cooling Tower 2465.00

4. Desalination plant 2116.00

5. Effluent Management System (Effluent & Sewage Treatment Plant, CMB etc.) --- abstract civil cost

126.00

6. Ash Management & Utilization 4377.00

Total 12561.00


11.00.00 IMPACT ON TARIFF The Environmental Protection Cost has been estimated as BDT 12561 Mln. In US $ it works out to $145.455 Mln. The impact on tariff due to above environmental cost works out as 0.20 BDT per unit in fixed charges, in levelised cost of energy. This includes 0.03 BDT per unit for operation and maintenance of above equipment/measures.

10 A TECHNICAL DATA & BILL OF QUANTITY Sl. No. DESCRIPTION QTY UNIT TECHNICAL

PARAMETERS


1.00.00 PRELIMINARY & CIVIL WORKS

1.01.00 Land Requirement

1 Plant including green belt 375 Acre

2 Ash disposal area 100 Acre

3 Township 50 Acre 4 Coal Conveyor Corridor & Jetty 50 Acre 5 MW Intake 5 Acre 1.02.00 Site levelling works &

Ground improvement

1 Site clearance 18,00,000 sqm 2 Earthwork in filling by dredging

and hydraulic filling for site levelling work within plant / levelling boundary with dredged material by means of Cutter Suction dredgers, pumping through floating and land pipelines including booster pumping if required.

80,00,000 cum

3 Scarifying the slopes of filling, surface dressing, providing and placing 150mm thickness of approved sand filter meeting the technical requirements as per specifications including all leads and lifts rolling the sand with roller.

75,000 sqm

4 Providing and placing 150mm thickness of approved aggregate filter meeting the technical requirements as per specifications including all leads and lifts rolling the aggregate with light hand roller or by mechanical means along the slope, including cost.

75,000 sqm

Sl. No. DESCRIPTION QTY UNIT TECHNICAL PARAMETERS


5 Providing and hand packing the stones (Rip-rap) of 300mm thickness with average weight of each stone about 25 kgs. on the slopes of filling with stones obtained from broken rock of specified quality and size, complete as per specifications and drawings.

75,000 sqm

Ground Improvement 1 Installation of sand compaction

piles of 900 mm compacted dia with specified c/c spacing as shown in the construction drawings, as per specifications and as directed by the Engineer including mobilization of all plant, equipment, manpower at site complete for all types of tests including supply of medium to coarse sand, driving casing, ramming, demobilization after completion of work including shifting of plant and equipment between locations, supply of all necessary materials with any adjunct ancillary works like dewatering, etc. all complete as per technical specifications and directions of the Engineer.

16,00,000 (For Main

Plant) +

4,25,000 (For Ash Dyke)

RM

2 Laying of sand blanket over sand compaction piles including supply of material, compacting upto 85% relative density in layers not exceeding 250mm all complete as per specifications and directions of the Engineer.

6,50,000 cum

1.03.00 Boundary wall & Fencing 1 Boundary wall 6 Km



2 PVC Chain link Fencing 2 Km

1.04.00 Roads, Bridges, Culverts, Drains, Railway Siding

A Roads 1 Double Lane Bituminous Roads

(Inside Plant) 15 km

2 Single Lane Bituminous Roads with shoulders (Inside Plant)

5

B Drains in Main Plant 1 Rectangular Concrete Trunk

drains 2 Km

2 Rectangular Concrete Catch drains

35 Km

1.05.00 Structural Steel – Main plant

1 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.

2 Structural steel (supply, fabrication & erection)

48500 MT

3 Electro Forged Gratings 750 MT

4 Stainless steel (ASTM A240 type 304 Stainless steel)

180 MT

5 MS Black Foundation Bolts & Nuts

400 MT

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 buildings

LOT

1.08.00 Chimney 275 m Twin flue steel lined

RCC chimney with staircase and elevator.

1 No.

1.09.00 Enabling Works 1 CHP office cum maintenance

building 500 Sqm

2 Dozer maintenance Shed 500 Sqm 3 Central workshop 3000 Sqm 4 O&M store 3000 Sqm 5 Canteen 600 Sqm 6 Admin bldg 4000 Sqm 7 Auditorium 600 Sqm 8 Service Bldg 5500 Sqm

1.09.00 Permanent Township

1.09.01 A Residential Buildings

1 Type - A Nil No.

2 Type - B 228 No.



3 Type - C 120 No.

4 Type – D-I 60 No.

5 Type – D-II 72 No

6 Resd. Building Servant Qtrs 72 No

7 Resd. Building Gerrage 72 No

Total DUs 480 No.

HOP Bungalow (including servant qtr and garage

01 No

Total DUs 481 No

Community Garrages 290 No

1.09.02 B Seurity Force Accomodation

1 Type - A 60 No.

2 Type - B 12 No.

3 Type - C - No.

4 Type – D-I - No.

5 Security Force Accomodation Barracks

59 No

Total 131 No.

1.09.03 B Support Staff & Associate Agencies Accommodation

1 Type - A 60 No.

2 Type - B 36 No.

3 Type - C - No.

96

1.09.04 Non-residential Buildings

1 Training Centre (Including Workshop)

1800 M2

2 Trainees Hostel (40Rooms) 2000 M2

3 Hospital (50 bed general hospital with support facilities)

3000 M2



4 Estate Office 350 M2

5 Offices For Union/Association 2x100 M2

6 Guest House 3000 M2

7 Field Hostel 4000 M2

8 Pre-Nursery/Nursery School 1200 M2

9 Hr. Sec. School (Class I to XII) 2x4500 M2

10 Bank 200 M2

11 Post Office 200 M2

12 Telephone Exchange 100 M2

13 Police Station (*As per the need of the Project)

200 M2

14 Shopping Centre 1400 M2

15 Transport Centre 400 M2

16 Petrol Pump 75 M2

17 Club/Welfare Ascn. Club 1x1200 M2

18 Bal Bhawan & Nur. School 600 M2

19 Ladies Club 350 M2

20 Community Centre 1000 M2

21 Swimming Pool (Pool Size 12.5Mx 25M))

Area for change room & filtration plant)

300 M2

22 Sports Complex (With Grand Stand & Play Field)

1000 M2

23 Auditorium 2000 M2

24 Security Force Armoury 250 M2

25 Switchgear/ Substation 600 M2

26 Gas Godown 200 M2

27 Land Development 200000 M2

28 Boundary Wall 2000 M

29 Bulk Water Supply LS

30 Bulk Power Supply LS

31 Bulk Sewage disposal LS



1.10.00 Coal Handling Plant

CHP civil works related to Transfer points, Conveyor galleries and Control room building etc.

LOT LOT

1.11.00 Ash Dyke (100 acres) LOT

1.12.00 Ash Handling System Civil works consists of following

Ash Water Pump House.

Bottom Ash Slurry Pump House

HCSD Pump House

Ash water recirculation Pump House

Switch gear/MCC and Control Room for all buildings

Silo area utility building

Fly Ash Silo foundation & supporting structure

B A Slurry Trench

HCSD Silo foundation & supporting structure

Transport air Compressor house

LOT



1.13.00 CW & MUW System

CW system for the project consists of CWPH and SACWPH including forebays, intake RCC channels, steel lined concrete encased supply and discharge ducts. Make-up water for the project shall be drawn from Rupsa river having saline back water. Water will be drawn from the river by constructing an approach channel.

LOT

1.14.00 Desalination, DM plant, CPU and effluent treatment system

Complete RCC structures for desalination plant, DM plant, condensate polishing plant, chlorination Plant and Effluent Treatment system shall be of RCC grade M30. All shed shall be generally steel superstructure with sloping MS roof sheeting.

LOT

1.15.00 Switchyard Civil/ Structural Works

Towers & equipment foundations LOT

Sl. No. DESCRIPTION QTY UNIT TECHNICAL

PARAMETERS


2.00.00 MECHANICAL WORKS

2.01.00 Steam Generator & Associated Auxiliaries

2 Sets Supercritical Boiler

Type:

Circulation : Drum/once through Draft : Balanced/Forced

Furnace bottom : Dry/Wet

a) Supercritical with Single Pass (tower)/ Double Pass arrangement Once through Balanced Draft Dry Bottom

2.01.01 Major Boiler Parameters

1. Maximum continuous rating 2120 T /hr

2. Pressure at superheater outlet 256 kg/cm2 (abs)

3. Temperature at superheater outlet

568o C

4. Temperature at reheater outlet 596o C

5. Exit Flue gas Temp. at chimney inlet

later

6. Efficiency based on performance coal at TG rating

later

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

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

yes

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

yes

3. Start-UP Drain Circulation Pump

1 No 1X100% (upto 30% BMCR)

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

Rotary Regenerative, Bisector type

2 Nos. Primary APH



2 Nos. Secondary APH

5. SCAPHS (nos. per boiler) 4 Nos. Two for PA & Two for SA

6. 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

a. Pulveriser

b. Feeder

c. PA Fan 2 Nos.

d. Seal Air Fan 2 Nos.

7. Draft plant including

a. ID fans axial type with drive motor and accessories.

2 Nos.

ID fans: 2X60% Variable Pitch Axial fans with drive motor.

b. FD fan axial type with drive motor and accessories.

2

Nos. FD fans: 2X60% Variable Pitch Axial fans with drive motor.

8. ESP & ESP accessories with control system

Lot Inlet dust burden - Later

Outlet dust burden - 100mg/Nm3

9. Passenger cum goods elevators

with all controls for SG

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

10. Ducting, dampers, expansion joints etc

1 Lot

11. Refractory, insulation and cladding

1 Lot

12. FSSS with SADC system 1 Lot

13. Coal and Oil Burners 1 Lot

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

1 Lot Common for two (2) units



15. Miscellaneous 1. Spares

2. Maintenance Tools & Tackles

Lot Lot

16. Auxiliary boiler with all associated auxiliaries of 60 T/Hr. capacity with rated steam parameters at SH outlet as 19kg/cm² (gauge) pressure and 250°C temperature.

1 No. Common for two (2) units

1.

.

Turbine, Generator, Exciter and

Auxiliaries per unit

1 Set EMCR power output 660 MW (In case excitation is other than brushless type, the EMCR output at generator terminal shall be 660 MW plus excitation power requirement at EMCR)

Turbine Throttle Steam Pressure

247 kg/cm2 (abs)

Turbine MS & HRH Temperature

565 deg C/593 deg C

Final feed water temperature at 100 % TMCR heat rate (HR) & at EMCR condition.

287.5 (+/-)2.5 deg C

Condenser pressure with CW temperature of 33 deg C

77 mm Hg abs

CW Temperature (Design/Maximum)

33 o C / 36 o C

2. Boiler feed pump with booster pumps couplings, drives and accessories

a. Turbine Driven Boiler Feed Pumps per unit

2 No 2x50% Capacity

b. Motor Driven Boiler Feed Pumps per unit

2 No 2x30% Capacity

3. Condensate Extraction Pump 3 No 3x50% capacity



per unit

4. HP/LP Bypass System per unit

1 Lot Capacity of the HP/LP bypass system shall be 65% of BMCR steam flow.

5. Condenser on load tube cleaning system (for each half of condenser per Unit)

1 No Sponge Rubber Ball type

6. Condenser Air Evacuation Pump per Unit

2 No 2x100% capacity.

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

8. Debris filter 2 No Self cleaning type of capacity 60% of the total design flow through condenser.

9. Regenerative Feed Heating System (HP & LP heaters)

Number of HP&LP heaters shall be based on optimization of feed heating cycle.

10. Central lube oil purification system for all units.

1 No. Clean and dirty oil tank capacity 1.5 times the capacity of MOT. Centrifuge capacity same as unit centrifuge.

11. Turbine hall EOT Cranes for all units.

2 No Main Hook of each crane shall be capable of lifting at least 105% of the weight of single heaviest component/ equipment, including lifting beam and slings



etc. (as applicable) to be handled in TG hall for erection as well as maintenance of the equipment provided in AB bay. The auxiliary hook capacity shall not be less than 20 Ton.

In addition, it shall also be possible to handle Generator Stator with tandem operation of two Turbine hall EOT cranes for which necessary arrangements shall be provided. In such case, the combined capacity of two EOT cranes shall not be less than the 105% of weight of Generator Stator, including the weight of lifting beam with swiveling arrangement and slings.



2.03.00 Piping

1 Power Cycle Piping including pipes, valves, fittings, expansion joints, Hanger/supports along with necessary Aux. Structure, thermal insulation, spares, flash tanks etc. for main steam, hot reheat, cold reheat, HP/LP Bypass, condensate, extraction, Aux. Steam, feed water, Spray to SHA and RHA, Spray to aux. PRDS and HP Bypass, heater drains & vents, safety valve exhaust and steam drains, vents etc. along with chemical dosing system.

LOT Lot for 2 units.

2 Station piping with valves, fittings etc.

LOT Lot for 2 units.

2.04.00 Coal Handling and Coal Transportation System

A. CONVEYORS AND ACCESSORIES (Mechanical Portion)

1

Belting

I. Belt Rating : 1000mm wide synthetic, cover thick 5/2 mm, av. Belt strength

16863

m

a. 1000/4 FR Grade

II. Belt Rating : 1600mm wide synthetic, cover thick 5/2 mm, av. Belt strength

4300 m a. 2000/4 FR Grade

2 Carrying Idlers 7830 Nos. 35 deg. Trough., 3 roll, 152 mm dia 4 mm thick, 2 deg. Tilt

3 Impact Idlers 234 Nos. As at (2 above,) along with rubber discs

4 Return Idlers 3132 Nos. Double roll 10o trough 152 mm dia, 4 mm shell thick

5 Short support, etc. 938 Te a). MS fabricated 575 Te b) Chute work-20 thk

TISCRAL



520 Mtrs c) 90 lb/yd rail (tripper )

4284 Mtrs d). 105 lb/yd rail (for stacker-reclaimer)

6

Pulleys

a) Drive pulleys 14 Nos. M.S. Fabricated, 1200 mm face width, dia 800 mm dia

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

92 Nos. M.S. fabricated, 1200 mm av. Dia 630 mm




7 Drive motors for conveying system

12 Nos. HT Motor

6 Nos. LT Motor

8 Reduction gears 18 Nos. Helical type with integral hold backs for drives in Sl.No.7

9 High speed coupling 18 Nos. Fluid couplings for drives in Sl.No.7 (all HT drives shall have scoop coupling) (Scoop-12 Traction-6)

10 Low speed coupling 18 Nos. Full geared type for drives in Sl.No.7

11 Brakes 18 Nos. Electro-hydraulic thruster type for drives in Sl.No.7

12 Belt cleaners

a) Internal 15 Nos. V-plough type

b) External 42 Nos. Double bladed spring loaded segmented Type

13 Flap gates 35 Nos. Motorized, M.S. fabricated

14 Rack & Pinion gates 2 Nos. MS fabricated, motorized

15 Rod gates 2 Nos. Manually operated, MS fabricated

16 Safety switches Lot Pull cord, belt sway, zero speed (Typical)

17 Sump pumps - -

18 Belt scales 2 Nos. Electronic type for continuous weighing for 2000 TPH

2 Nos. Electronic type for continuous weighing for 1200 TPH



19 In Line Magnetic Separator 2 Nos. Inline type, 1000 gauss (for 2000 TPH conveyor)

4 Nos. Inline type, 1000 gauss (for 1200 TPH conveyor)

20 Suspended Magnets 2 Nos. 1000 gauss (for 2000 TPH conveyor)

21

Metal detector

2 Nos. (for 2000 TPH conveyor)

2 Nos. (for 1200 TPH conveyor)

22 Coal Sampler Unit 2 (one

each)

Nos. For Raw coal (-)50mm (for 2000 TPH conveyor) (as received) and for crushed coal (-) 20mm for 1200 TPH Capacity (as fired)

23 Travelling Trippers 4 Nos. For 1200 TPH rated capacity)

24 Monorails & hoists Lot Electrical operated hoists, Manual hoists and Chain Pulley Block

25 Coal crusher with complete drive unit

2 Nos. 2000 TPH rated, ring granulators

26 Vibrating Grizzly screen with all accessories

2 Nos. 2000 TPH rated

27 Vulcanising Machine 2 Nos. (1 no. for 1200 mm belt width & 1 no. for 2000 mm belt width)

28 Passenger cum goods Elevator

2 Nos. 1 Te capacity (Rack & Pinion type)

29a. Stacker machine 2 Nos. Slewable type, boom length 41m, 2000 TPH

29b. Reclaimer machine 2 Nos. Bucket wheel type, boom length 41m, slewable 1200 TPH

30 Dust Suppression system Lot Dry Fog and Plain water Dust Suppression (for External & Internal)

31 Ventilation system and Package AC

Lot Typical

32 Service water system, Potable Water System and Cooling water system

Lot Typical

33 Mandatory spares Lot Typical

34 Special tools & tackles Lot Typical

35 Vibration Monitoring System 1 Nos. For crusher house



B

CHP Electrical and Controls

1 Complete CHP electrical, control & instrumentation & associated facilities

Lot Typical

2 Main CHP Control Room 1 nos.

3 WT Control Rooms - -

c)

CHP Structural & Civil Works

1. a)

Double conveyor gallery C.S. 2.7m x 6.6 m internal For 1200TPH (1000 mm Belt Width)

1070 mtrs. Structural steel fab.

b)

Double conveyor gallery C.S. 2.7m x 6.6 m internal For 2000 TPH (1600 mm Belt Width)


c)

On ground double conveyor gallery C.S. 2.7m x 6.6 m internal For 1200 TPH (1000 mm Belt Width)


d)

On ground double conveyor gallery C.S. 2.7m x 8 m internal For 2000 TPH (1600 mm Belt Width)


e) Single conveyor gallery (CS 2.7m x 4 m) For 1200 TPH (1000 mm Belt Width)


f) Single conveyor gallery (CS 2.7m x 5 m) For 2000 TPH (1600 mm Belt Width)


2 Transfer points (Av. Size)

a. Transfer Point TP-1 1. nos 14 x 14 x 15 mtrs (high) (0, 1 floors)

b. Transfer Point TP-2, 3 & 4 3 nos 15 x 10 x 15 mtrs (high) (0, 1 floors)



c. Transfer Point TP-5 1 nos. 10 x 10 x14 mtrs (high) (0, 1 floors)

d. Transfer Point TP-6 1. nos 14 x 14 x 21 mtrs (high) (0, 2 floors)

e. Transfer Point TP-7 1. nos 12 x 12 x 78.5 mtrs (high) (0, 2 floors)

f. Transfer Point TP- 8, 10 2 nos 12 x 12 x 73.2 mtrs (high) (0, 3 floors)

g.

Transfer Point TP-9 1 nos 12 x 12 x 76.2 mtrs (high) (0, 3 floors)

Transfer Point TP-11 1 nos 12 x 12 x 67.7 mtrs (high) (0, 2 floors)

3

Crusher House

1. nos 22 x 18 x 32 mtrs (high) (0, 3 floors)

4 S/R foundation length 1650. mtrs Typical (for 2 stacker reclaimers)

5 Pump Houses 2 nos. Typical

6 Dozer shed 1 Typical

EXTERNAL CHP

A. Mechanical Portion

CONVEYORS AND ACCESSORIES (Mechanical Portion)

1

Belting

1641

m

Belt Rating : 1600mm wide synthetic, cover thick 5/2 mm, av. Belt strength a. 1000/4 FR Grade

2 Carrying Idlers 667 Nos. 35 deg. Trough., 3 roll, 152 mm dia 4 mm thick, 2 deg. Tilt

3 Impact Idlers 6 Nos. As at (2 above,) along with rubber discs

4 Return Idlers 267 Nos. Double roll 10o trough 152 mm dia, 4.5 mm shell thick

5 Short support, etc. 96 Te a) MS fabricated

20 Te b) Chute work-20 thk TISCRAL

6 Pulleys






7 Drive motors for conveying system

1500 kW

Nos. HT motors

8 Reduction gears 1 Nos. Helical type with integral hold backs for drives in Sl.No.7

9 High speed coupling 1 (Scoop-1 Traction-0)

Nos. Fluid couplings for drives in Sl.No.7 (all HT drives shall have scoop coupling)

10 Low speed coupling 1 Nos. Full geared type for drives in Sl.No.7

11 Brakes 1 Nos. Electro-hydraulic thruster type for drives in Sl.No.7

12

Belt cleaners

a) Internal 1 Nos. V-plough type

b) External 2 Nos. Double bladed spring loaded segmented Type

13 Safety switches Lot Pull cord, belt sway, zero speed (Typical)

14 Belt scales 1 Nos. Electronic type for continuous weighing for 2000 TPH

15 In Line Magnetic Separator 1 Nos. Inline type, 1000 gauss (for 2000 TPH conveyor)

16 Metal detector 1 Nos. (for 2000 TPH conveyor)

17 Flap Gates 1 Nos. Motorized, M.S. fabricated

18 Monorails & hoists Lot Electrical operated hoists, Manual hoists and Chain Pulley Block

19 Dust Suppression system Lot Typical

20 Service water system, Potable Water System and Cooling water system

Lot Typical

21 Mandatory spares Lot Typical

22 Special tools & tackles

Lot Typical

B. CHP Electrical and Controls

1 Complete CHP electrical, control & instrumentation & associated facilities

Lot Typical



2 MCC Room 1 Typical

C. CHP Structural & Civil Works

1. For 2000 TPH (1600 mm Belt Width)

a. Open Single conveyor on ground 200 m

b. Open Single conveyor gallery with hood over conveyor on ground

400 m

c. Open Single conveyor gallery with hood over conveyor elevated

200 m Structural steel fab. (Starting at ground level and shall travel up to 34m)

2. Transfer points (Av. Size)

a. Transfer Point TP - A 1 No. 12 x 10 x 40 mtrs (high) (0, 2 floors)

2.05.00 Fuel Oil Unloading System

1. HFO storage tanks complete with suction heater, floor coil heater, insulation, cladding, accessories, instruments etc

2 Nos. MS, fixed roof type, 2000 Cu M capacity

2. LDO storage tanks complete with all instruments and accessories

2 Nos. MS, fixed roof type, 500 Cu M capacity

3. Day Oil tank for Auxiliary Boiler 1 No. MS, fixed roof type, 100 Cu M capacity

4. Drain oil tank to collect oily drains in the pump house area.

1 Nos. 6 Cu M

5. Condensate Flash Tank 1 No. 6 Cu M

6. Unloading pump motor sets (HFO/LSHS/HPS)

6 Nos. Twin-screw, 100 Cu M/hr

7. LDO unloading pumps motor sets 2 Nos. Twin-screw, 50 Cu M/hr

8. LDO transfer pump motor sets 2 Nos Twin-screw, 25 Cu.M./hr

9. Pressure Reducing Station for Aux. steam

2 Nos. 20 T/hr

10. Unloading pump suction strainers 18 Nos. 200NB

11. Fuel oil unloading hoses, steam and condensate hoses

10

10

10

05

Nos. Nos. Nos. Nos.

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



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

2 Nos. Single screw, 10 Cu M/hr

13. Dirty oil pump for pumping out Dirty oil from the oil water separator unit

2 Nos. Single screw, 5 Cu M/hr

14. Sump pumps 2 Nos. Centrifugal, 30 Cu M/hr

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

2

Nos.

Centrifugal, 30 Cu M/hr

16. Design of oil water separator pit along with facilities for removal of water and oily waste

Lot

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

Lot

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

Lot

19. Flow meter For HFO unloading system LDO unloading system

1

1

No. No.

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

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

1 No. 2 tons

2.06.00 Ash handling System

2.06.01 Bottom Ash Handling System

1 Dry bottom ash hopper 2 Nos 30TPH

2 Hydraulic power pack, extractor, chain drive, chain 2 Nos 200 bar

3 Primary and Secondary crushers( clinker grinder) 8 Nos

15 TPH (primary- 4nos, secondary 4 nos)

4 Conveyor for Dry BA to BA buffer hopper 2 nos 100 M length each

5 Dry bottom ash extraction compressor 2 Nos 1200 m3/hr, 5 kg/cm2, 200 kW

6 BA Transport air receiver MS 10 mm thk

2 Nos 10 m3



7 Intermediate silo for Bottom Ash 2 Nos 7.5 Tonnes

8 BA Buffer hopper aeration blower and heater along with drive and motor 2 Nos

100 m3/hr, 0.9 kg/cm2, 10 kW

9 Air lock / Pump tank 4 Nos 5 m3

10 Rotary segregating valve with pneumatic cylinder 8 Nos 300 NB

11 Equalizer valve with pneumatic cylinder 4 Nos 100 NB

12 BA dry transportation pipe 2000 M 250 NB( MS 9.52mm Thick)

13 Chute isolation valve 4 Nos 300 NB

14 Bottom ash Structural steel silo complete with staircase, structure, platforms etc. for HCSD

1 Nos 100 T

15 BA Silo aeration blower and heater along with drive motor 1 Nos

400 m3/hr, 0.9 kg/cm2, 10 kW

16 Target box 1 Nos

17 Bag filter with pulsing arrangement for BA silo 1 Nos 1500 m3/hr

18 BA Silo vent fan 1 Nos 1500 m3/hr

19 Rotary feeder with variable frequency drive 3 Nos 100 TPH

20 Bends (alloy CI/basalt)

21 90 deg 20 Nos

i) 45 deg 20 Nos

22 Screw Conveyors 4 Nos. 25 m length

23 Hydro Mix Dust Conditioner 4 Nos. 100 TPH

2.06.02 ECONOMISER SYSTEM

1 Chute isolation valves 8 Nos. 350 NB

2 Expansion joints 8 Nos. 350 NB

Material handling valve-pneumatic operated-alloy CI

8 No. 300 NB

Segregating valve-pneumatic operated, alloy CI

2 No. 250 NB

Extraction pipe as per IS:1536/BS1211 Class D with sleeve couplings and fittings.

400 m 250 NB

Liquid seal ring vacuum pump with drive and accessories

2 No. 2000 m3/hr,16 Hg, 50KW



Buffer hopper with alloy CI liners, supporting structure, platform etc.

1 No. 10T

Target Box 1 No.

Bag filter with pulsing arrangement 1 No. 2000 m3/hr

Pressure/Vacuum relief valve 1 No.

Air lock/pump tank 2 No. 5 m3

Rotary segregating valve with pneumatic cylinder slide

4 No. 300 NB

Equalizer valve with pneumatic cylinder

2 No. 100 NB

Chute isolation valve 2 No. 300 NB

2.06.03 Ash Water System

1 Bottom Ash LP water pumps with Drive Motor and accessories.

2 No. 100 m3/hr, 20 mWC, 50 KW

2 FAHP Water Pumps with Drive Motor & Accessories for HCSD pumps

3 No. 100 m3/hr, 80 mWC, 120 KW

3 PIPES

A. MS PIPES

(i) IS- 3589

(ii) IS- 1239 HEAVY GRADE

LOT LOT

B) Valves

i) BALP

a) Suction - Butterfly 2 No. 200 NB

b) Discharge - Butterfly 2 No. 150 NB

c) Check 2 No. 150NB

ii) FAHP water pump


b) Discharge - Butterfly 3 No. 150 NB

c) Check 3 No. 150 NB

iii) Fly ash conditioner booster water pump


b) Discharge 5 No. 100 NB

c) Globe 5 No. 100 NB

d) Check 5 No. 100 NB

e) Bottom ash hopper make up - Butterfly

2 No. 200 NB



iv) Misc. 300 No. 40 to 200 NB

v) Pendant controlled overhead travelling crane

1 No. 7.5 tonnes

2.06.07 ALT I - Vacuum Conveying System

1 Chute Isolation Valves-CI 232 No. 300 NB

2 Material handling valve-pneumatic operated-alloy CI

232 No. 300 NB

3 Segregating valve-pneumatic operated, alloy CI

34 No. 250 NB

4 Extraction pipe as per IS:1536/BS1211 Class D with sleeve couplings and fittings.

2000 m 250 NB

5 Liquid seal ring vacuum pump with drive and accessories

8 No. 4000 m3/hr,16 Hg, 75 KW

6 Instrument air compressor with drive and accessories

4 No. 10 Nm3/min, 8 kg/cm2, 90 KW, Horizontal, reciprocating

7 Instrument air dryer SILICAGEL TYPE

4 No. 10 Nm3/min,

8 Air receiver for instrument air 4 No. 5 m3

9 FA line for APH. IS: 1536/BS1211 Class D with sleeve couplings and fittings.

500 m 250 NB

10 FITTINGS

i) Alloy CI 200x200x150 lateral 384 Nos.

ii) Alloy CI 250x250x250 lateral 72 Nos.

iii) A.lloy CI 250x90 deg elbow 30 Nos.

iv) Alloy CI 250x45 deg elbow 78 Nos.

(OR) ALT-II - Pressure Extraction System

1 Chute isolation valves-alloy CI 232 No. 300 NB

2 Material handling valve – pneumatic operated (dome/cone/plate/butterfly)

232 No. 300 NB

3 Ash discharge valve – pneumatic operated

232 No. 300 NB

4 Segregating valve – pneumatic operated

34 No. 250 NB



5 Air lock/pump tanks MS 10 mm thk 232

No. 2 m3

6 Extraction pipe, ALLOY CI 1800 m 200 NB

7 Extraction air compressors alongwith drive motor etc.

4 No. 2100 m3/hr, 7 kg/cm2,

250 KW

8 Extraction Air Dryer – refrigerant type

4 No. 2100 m3/hr

9 IA compressor 4 No. 10 m3/min, 8 kg/cm2,90KW

10 IA dryer-Silica gel type 4 No. 10 m3/hr

11 Expansion joints 232 No. Metallic bellows -SS

12

Air receiver

i) For instrument air

ii) For extraction

4

4

No.

No.

5 m3

5 m3

13

FITTINGS

i) 45 deg

ii) 90 deg

360 60

No

No

250 NB

250 NB

14 Pendant controlled overhead traveling crane

1 No 10 T

2.06.08 Dry Fly Ash Transportation System upto HCSD Silo

1 Buffer hopper with alloy CI liners, supporting structure, platform etc.

8 No. 20 m3

2 Target Box 8 No.

3 Bag filter with pulsing arrangement 8 No. 4000 m3/hr

4 Pressure/Vacuum relief valve 8 No.

5 Transport air compressor with VFD 4 No. 8000 m3/hr, 2.5 kg/cm2

300 KW

6 Transport Air dryer – refrigerant type

4 No. 8000 m3/hr

7 Air lock/pump tank 16 No. 5 m3

8 Rotary segregating valve with pneumatic cylinder slide

32 No. 300 NB

9 Equalizer valve with pneumatic cylinder

16 No. 100 NB



10 FA transportation pipe 2500 m 350 NB

11 Chute isolation valve 16 No. 300 NB

12 Buffer hopper aeration blower and heater along with drive and motor

4 No. 300 m3/hr, 0.9 kg/cm2 , 15 KW

13 Transport air receiver 4 No. 10 m3 , MS 10 mm thk

14 Structural steel silo complete with staircase, structure, platforms etc.(HCSD)

2 No. 100 T

15 Silo aeration blower and heater along with drive and accessories(HCSD)

3 No. 400 m3/hr, 0.9 kg/ cm2

25 KW

16 Target box (HCSD) 2 No.

17 Bag filter with pulsing arrangement(HCSD)

2 No. 10000 m3/hr

18 Silo vent fan(HCSD) 2 No. 10000 m3/hr, 30 mmWC

19 Hydromix dust conditioner with drive

6 No. 50 TPH, 25KW

20 Rotary feeder with variable frequency drive

6 No. 50 TPH

21 Telescopic chute with motorized winch

2 No. 100 TPH

22 Sump drain pump for silo area along with drive motor

2 No. 80 m3/hr, 50 mWC, 20 KW


i) 90 deg 40 No. 300 NB

24 Pendent controlled overhead travelling crane

1 No. 15 Tonnes

2.06.09 Air Conditioning & Ventilation for AHP

1 Supply air fans 30 No. 10000 m3/hr, 30 mmWC

2 Exhaust air fans 30 No. 7000 m3/hr, 30 mmWC

3 Air conditioner (PAC) 4 No. 16.5 TR

2.06.10 Instrumentation 1 LOT

2.06.11 HCSD System



1 HCSD Pumps 3 No. 60 m3/hr, 60bar, 200 kw motor (2W + 1S)

2 Seamless MS Pipes 12 Km 150 NB – 12.7 mm thick

3 Agitator tank for HCSD pumps 3 No 30 m3 with 50 KW Motor

4

Peristaltic pump complete with drive, Density measurement, Pressure transmitters, Pipe loop piping, shut-off and drain valves .

3 LOT One lot for each pump


1 15 Tonnes

2.06.12 Silo system at Plant boundary for Ash Utilization

1 FA transportation pipe 4000 meter

s 350 NB

2 Structural steel silo complete with staircase, structure, platforms etc.

2 Nos 500T

3 Silo aeration blower alongwith drive motor

3 Nos 400 m3/hr,0.9 kg/cm2,25 Kw

4 Target box 2 Nos

5 Bag filter with pulsing arrangement 2 Nos. 10000 M3/hr

6 Silo vent fan 2 Nos. 10000 M3/hr,30 MMWC

7 Hydromix dust conditioner with drive

2 Nos. 100 TPH,25 KW

8 Rotary feeder with variable frequency drive

4 Nos. 100 TPH

9 Telescopic chute with motorised winch

2 Nos. 100 TPH

10 Sump drain pump for silo area alongwith drive motor

2 Nos. 80 M3/hr, 50 MWC, 20 KW

11 Wash water pumps along with drive motor

2 Nos. 50 M3/hr, 15 MWC,5 KW

12 Fly ash conditioner booster water pump along with drive motor

3 Nos. 40 M3/hr

7.5 KG/CM2 15 KW


90 deg 24 Nos. 350 NB




1 Nos. 2Tonnes

AWRS system

1 AWRS Pumps 2 nos 30m3/hr , 50 MWC, 50KW

2 MS Pipes 3 Kms 100NB

2.07.00 WATER SYSTEM

2.07.01 Make-up Water System

Makeup Water pumps (for CW System)

3 nos Each of 3700 M3/hr & 20 MWC Vertical type: Motor rating: 280 KW

Lub.water pumps for Makeup Water pumps


Discharge Butterfly Valves 3 nos 900 mm dia – Electric motor actuator

Rubber Expansion Joints 3 nos 900 NB

Traveling Water Screens 3 nos Flow/screen 3700 cum/hr

Discharge pipes 60 m 900 NB, 8.8 mm thick

Isolation Butterfly Valves 1 nos 1400 mm dia – Electrical actuator

Recirculation pipeline 50 m 500 NB and 6.3 mm thick

Recirculation Butterfly Valves 1 nos 500 mm NB dia – Motor actuator

EOT Crane for pump house 1 nos 25 Tonne Capacity

Makeup Water Pipes up to CWPH 5000 M 1400 mm dia – 14 mm thick , 3L-PE coated

Cathodic protection system for the make up water pipe from river to Plant

LOT Impressed current type system



Note: a) All the pipes shall be internally lined with Polyurethane (PU). Buried pipes shall be externally protected with 3LPE Coating and Cathodic protection system. For overground pipe, suitable anticorrosive coating shall be provided.

b) Material of Construction of Pumps, Valves, Screens shall be suitable for handling sea water.

2.07.02

COOLING WATER SYSTEM

CW pumps & Drives 5 nos. Capacity 36000 M3 /hr & 27 MWC; Motor rating :3500 KW

Butterfly valves 5 nos. Electro hydraulically operated; Each of size 2600 NB

Rubber Expansion joints 5 nos. Each of 2600 NB

CW discharge pipes 60 M MS pipe; 2600 NB & 18 mm thick

CW system blow down piping 100 M MS pipe; 500 NB & 6 mm thick

CW recirculation pipe line 50 M MS pipe; 1400 mm dia & 14 mm thick

Recirculation valve 1 Butterfly Valve 1400 NB – Motor operated

EOT Crane 1 no. 60 tonne capacity

Interconnecting (Electrically operated) Valves

2 nos 2600 NB size

Monorail hoist 2 nos 2 tonne

Cooling Towers

2

nos Induced Draft Cooling Towers;



Note: a) All the pipes shall be internally lined with Polyurethane (PU).

b) Material of Construction of Pumps, Valves etc shall be suitable for handling sea water.

2.07.03

MAKE UP WATER (DESALINATION SYSTEM)

Makeup Water pumps (for Desalination System)


Discharge Butterfly Valves 2 nos 650 mm dia – Electric motor actuator

Rubber Expansion Joints 2 nos 650 NB

Traveling Water Screens 2 nos Flow/screen 1800 cum/hr

Discharge pipes 60 m 650 NB, 6.3 mm thick

Isolation Butterfly Valves 2 nos 650 mm dia – Electrical actuator

Recirculation pipeline 50 m 400 NB and 6.3 mm thick

Recirculation Butterfly Valves 1 nos 400 mm NB dia – Motor actuator

Makeup Water Pipes up to desalination system

5000 M 650 mm dia – 6.3 mm thick , 3L-PE coated

Cathodic protection system for the make up water pipe from river to Plant

LOT Impressed current type system



Note: a) All the pipes shall be internally lined with Polyurethane (PU). Buried pipes shall be externally protected with 3LPE Coating and Cathodic protection system. For overground pipe, suitable anticorrosive coating shall be provided.

b) Material of Construction of Pumps, Valves, Screens shall be suitable for handling sea water.

2.07.04

EQUIPMENT COOLING WATER SYSTEM

Aux.Cooling Water booster pumps 6 nos Horiz,Centri; Each of 3200 M3/hr & 18MWC Motor rating: 210 KW

DM cooling water pumps (TG) 6 nos Horiz,Centri; Each of 2400 M3/hr & 35MWC Motor rating: 310 KW

DM cooling water booster (SG) 4 nos Horizontal,Centri; Each of 900 M3/hr & 70MWC Motor rating: 230 KW

Plate type heat exchangers (TG) 6 nos 3 x 50% for each unit. (With SS plates)

Plate type heat exchangers (SG) 4 nos 2 x 100% for each unit. (With SS plates)

Chemical storage equipment and dosing system (SG / TG). Interconnecting piping, valves, fittings, instrumentations & control

4

sets Two for one unit

Interconnecting piping, valves, fittings, instrumentations & control

LOT

Note: Material of Construction of Pumps, Valves, PHE Plates (Titanium) etc shall be suitable for handling sea water



2.07.05 5.

MISCELLANEOUS PUMPS

HVAC system makeup pumps 2 nos Hor, Centf; 100 M3/hr & 70 MWC Motor rating: 32 KW

AHP – Seal water Pumps 2 nos Hor, Centf: 100 M3/hr ; Head: 20 MWC; Motor rating: 12 KW

DM water transfer pumps 3 nos Hor, Centf; 100 M3/hr & 70 MWC Motor rating: 32 KW

Service water pumps 2 nos Hor, Centf 130 M3/hr & 70 MWC Motor rating: 35 KW

Air pre-heater wash pumps 2 nos Hor, Centf 400 M3/hr & 110 MWC Motor rating: 160 KW

fBoiler fill pumps 2 nos Hor, Centf 175 M3/hr & 150 MWC Motor rating: 110 KW

Potable water pumps for colony 2 nos Hor, Centf 70 M3/hr & 80 MWC Motor rating: 26 KW

Potable water pumps for plant 2 nos Hor, Centf 30 M3/hr & 50 MWC Motor rating: 7.5 KW

Sump pumps 6 nos Hor, Centf 40 M3/hr & 20 MWC Motor rating: 3.5 KW

j Drainage pumps 4 nos Hor, Centf 40 M3/hr & 20 MWC Motor rating: 3.5 KW

2.07.06

DESALINATION PLANT

Complete Desalination Plant including required Pre-treatment System, chemical Dosing Equipments etc.

LOT RO 1st Stage: Net Capacity : 600 Cu.m/hr (3 x 200 Cu.m/hr) Type of Process : SWRO

2nd stage RO plant LOT Net capacity: 120 Cu.m/hr (2x60 Cu.m/hr) Type of process: RO

c. Permeate water storage tank 3 nos Carbon steel vertical cylindrical type of Capacity : 5000 Cu.m.



d. Potable water storage tank 2 nos Carbon steel vertical cylindrical type of Capacity : 300 Cu.m.

2.07.07

DEMINERALISATION PLANT

Final DM (MB Units) Streams 3 streams Stream Capacity: 60 Cu.m/hr (2W+1S) (Only Mixed Bed Exchangers)

Chemical Storage & Regeneration system for MB Units

LOT

DM Water Storage Tanks 2 nos. Carbon steel vertical cylindrical type of Capacity : 2400 Cu.m.

Complete regeneration system acid/alkali storage /day / measuring tanks, dosing pumps, all interconnecting piping, instrumentation, panels etc

2.07.08

CONDENSATE POLISHING

PLANT

Condensate polisher vessels 2 sets Each set consisting of 4 x 33% capacity vessel for each unit

Complete regeneration system including resins, acid/alkali storage /day /measuring tanks, dosing pumps, interconnecting piping, instrumentation, panels neutralizing pit, etc.

LOT ---------

2.07.09

CHLORINATION PLANT

Electro chlorination Plant for MU pumps

2 sets Electro chlorination system 15 Kg/hr

Chlorination plant with all accessories (CW system)

3 sets Each set of Chlorinator & evaporators of capacity 100 Kg/hr, piping, instrumentation, panels etc

Chlorination plant with all accessories (Water PT)

LOT Included as a part of Desalination PT System



Chlorine leak absorption system for Chlorination plant(CW System)

LOT

(if Gas chlorinators are used for CW System

2.07.10

EFFLUENT TREATMENT

SYSTEM (including civil works)

Coal settling ponds 3 nos. Each of 40 M x 6 M x 3 M (deep)

2.08.00 Fire Detection & Protection System

1 Fire Water Tanks 2 Nos. 2130 m3 effective capacity,

MS Construction

2 Hydrant Pumps & Drives 3 Nos. 410 M3/hr & 105 MWC Disch.Pr.

(Motor Driven)

3 Hydrant Pumps & Drives 1 Nos. 410 M3/hr & 105 MWC Disch.Pr.

(Diesel Engine Driven)

4 Spray Pumps & Drives 2 No. 410 M3/hr & 120 MWC Disch.Pr.

(Motor Driven)

5 Spray Pumps & Drives 2 No. 410 M3/hr & 120 MWC Disch.Pr.

(Diesel Engine Driven)

6 Jockey Pumps & Drives 2 Nos. 75 M3/hr & 105 MWC Disch.Pr.

(Motor Driven)

7 Booster pumps & Drives for hydrant

1 No. 171 m3/hr & 45 MWC

Disch. Pr. (motor driven).

8 Booster pumps & Drives for hydrant

1 No. 171 m3/hr & 45 MWC

Disch. Pr. (Diesel engine driven).

9 Electric motor driven foam conc. Pump along with its drive and all its accessories

1 No. ----------

10 Diesel engine driven foam conc. Pump along with its drive and all its accessories

1 No. ----------



11 Hydrant & spray system mains piping, indoor & outdoor hydrants, hoses, hose boxes, couplings etc.

Lot ----------

12 HVW Spray system for various equipments (Transformers, Oil equipments, Boiler Burner Fronts)

Lot ----------

13 MVW Spray system for coal handling plant (Coal conveyors, TPs & Stacker – Reclaimer Machines)

Lot ----------

14 MVW Spray system for cable galleries

Lot ----------

15 MVW Spray system for fuel oil tanks, Fuel oil pump houses, DG set oil tanks, etc.

Lot ----------

16 Foam injection for fuel oil tanks Lot ----------

17 Inert Gas Extinguishing system for Control/ Control equipment rooms

Lot ----------

18 Analogue addressable fire detection and alarm system including Fire alarm panels, PLC panels, Remote I/O panels, cables, etc.

Lot ----------

19 Fire Extinguishers (Portable & mobile type)

Lot ----------

20 Monorail electric hoist for Fire water pump house

1 No. 5 Tonne

21 Chain pulley block for hydrant booster pump house

1 No. 1 Tonne

22 Chain pulley block for foam pump house

1 No. 1 Tonne



2.09.00 Compressed Air System

1 Air compressors with control panels, instrumentation & all accessories like piping, valves etc

5 Nos. Oil free Screw /Centrifugal type compressors; Each of capacity 55 Nm3/min & disch. Pressure of 8 kg/cm2 (g).

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

3 sets Each of capacity 55 Nm3/min & design outlet dew point of (-) 40oC

3 Air receivers 7 Nos. Nominal Capacity : 10 m3

4 Air receiver for WT plant 1 No. Nominal Capacity : 2 m3

5 EOT crane 1 No. 8 Tonne

2.10.00 Air Conditioning System

1. Centralised A/C System for Main Plant & ESP Control Rooms

I A/C Plant for Main plant building (CCR, CER, UPS room, SWAS, etc.) & ESP control room

1 Lot Central, chilled water type A/C plant mainly comprising of :

2 Nos. 225 TR of Vapor absorption & 1 No. 225 TR of screw/centrifugal type chillers.

Ii Condenser cooling water pumps Lot ----------

Iii Chilled water pumps Lot ----------

Iv AHUs (VFD driven) for control tower area & ESP control room

Lot ----------

V Cooling towers with accessories, etc.

Lot ----------

2. Centralised A/C System for Service Building

I A/C Plant for Service Building 1 Lot Central, chilled water type A/C plant mainly comprising of :

2 Nos. 200 TR of screw type chillers.(1 Nos. working +1 Nos. stand-by)



Ii Condenser cooling water pumps Lot ----------

Iii Primary Chilled water pumps Lot ----------

Iv Secondary Chilled water pumps (VFD driven)

Lot ----------

V AHUs (VFD driven) Lot ----------

vi Cooling towers with accessories, etc.

Lot ----------

3. Centralised A/C System for Administrative Building

i A/C Plant for Administrative Building

1 Lot Central, chilled water type A/C plant mainly comprising of :

2 Nos. 225 TR of screw type chillers.(1 Nos. working +1 Nos. stand-by)

ii Condenser cooling water pumps Lot ----------

iii Primary Chilled water pumps Lot ----------

iv Secondary Chilled water pumps (VFD driven)

Lot ----------

v AHUs (VFD driven) Lot ----------

vi Cooling towers with accessories, etc.

Lot ----------

4. A/C system for Water system control building

1 Lot 2 Nos. 25 TR Air Cooled Condensing unit (scroll/screw), DX Type

5 A/C system for Auditorium Building

1 Lot 2 Nos. 40 TR Air Cooled Condensing unit (scroll/screw), DX Type

6 Split/Packaged air conditioners 10 Nos. 7.5 TR.

7 Split/Packaged air conditioners 20 Nos. 5 TR.

8 Split/Packaged air conditioners 34 Nos. 3 TR.

9 Accessories such as instruments control panel, fire dampers, ducting, diffusers, piping, valves, etc. for complete air-conditioning system

Lot -------------



2.11.00 VENTILATION SYSTEM

1 Air washers (sheet metal construction) for TG building

8 No. 2,50,000 m3/hr capacity.

2 DIDW fans for TG area 8 No. 2,50,000 m3/hr cap.at 75 mmWC.

3 Circulating water pumps 8 No. 250 m3/hr at 30 MWC

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

Lot ---------

5 Unitary air filtration units (sheet metal construction) for ESP building

2 Nos. 75,000 m3/hr capacity

6 SISW centrifugal fans for ESP building

2 Nos. 75,000 m3/hr capacity at 40 mm WC

7 Circulating water pumps 2 Nos. 50 m3/hr & 30 MWC

8 Accessories such as piping, ducting, grills, dampers, valves diffusers, dampers, instrumentation, panels etc for ESP building.

Lot ----------

9 Ventilation System for Misc. Areas comprising of supply & exhaust air fans, roof extractor fans, gravity dampers, etc.

Lot ----------

2.12.00 Hydrogen Generation Plant

Hydrogen Generation Plant 1 No. Plant capacity: 15 Nm3/hr

Two streams of capacity 7.5 Nm3/hr each with H2 gas compressors of capacity 9.375 Nm3/hr & pressure of 160 kg/cm2

(g), with all accessories instrumentation, control panel, piping, manifold, ventilation system etc.

Sl. No. DESCRIPTION QTY UNIT TECHNICAL

PARAMETERS


10 C BILL OF QUANTITIES FOR ELECTRICAL WORKS

3.00.00 ELECTRICAL SYSTEMS

3.01.00 Generator Busduct GENERATOR CIRCUIT BREAKER and Associated Equipment

Isolated phase bus duct

1. 23,500 Amp, main run 366 m single phase run

2. 14,000 Amps, Delta run 258 m single phase run

3. 2,250 Amps, tap off run 203 m single phase run

4. VT & SP cubicles 12 Nos.

5. NG equipments & CTs 2 set

6. Supporting structural steel 100 MT

7. Generator Circuit breaker,23500 A

2 no 2 no + 1 pole spare

3.02.00 Power Transformer/ICT

1. Generator transformer 260 MVA/21 kV/400 kV/3 single phase with off ckt Tap changer and On Line DGA Analyzer

07 Nos.

2. Interconnecting Transformer 400/230 kV,315 MVA ,3 phase ,OLTC ,+/- 10%

02 Nos.

2. 400kV Reactor 1 No. 420kV, 80 MVAR

3. 400 kV line reactor along with NGR & LA

2 Nos. 420kV, 63 MVAR

4. Start up transformer 01 No. 110/55/55 MVA 230 kV /11.5/11.5 kV with OLTC +/-10%

5. Unit transformer 04 Nos. 55 MVA 21 kV /11.5 kV with OLTC +/-10%

6. Miscellaneous Transformer 02 Nos. 11/11.5 kV, 16 MVA

3.03.00 Auxiliary transformers

11/3.45kV Class

1. Unit auxiliary transformer, 16 MVA

04 No.



2. Make up water transformer ,5 MVA at make up water end

02 No.

3. CHP transformers, 7.5 MVA 02 No.

3.04.00 A

L.T. transformer Indoor

1. Unit Service Transformer 08 No. 11/0.433 kV, 2500 kVA

2. Station service transformer 04 No. 11/0.433 kV, 2000 kVA

B Outdoor

1. 11/0.433 kV,2500 kVA Transformers

08 Nos. For ESP,SERVICE

2 11/0.433 kV,2000 kVA Transformers

02 Nos. For adm service


12 Nos. For ASH WATER/ SLURRY/ TAC, /CW SERVICE/SERVICE WATER/CHLORINATION/DESALINATION/FIRE WATER


14 Nos. For CHP,PT, DM, ASH EXTRACTION,FUEL OIL,SWITCHYARD/LOCOSHED/AUX BOILER


08 Nos. For MAKE UP SERVICE/AWRS/WORKSHOP

5. 11/0.433 Kv ,250 KVA 02 Nos FOR CROSS COUNTRY

6. 3.3/0.433 kV,630 kVA Transformers

02 Nos. For RECLAIMER

7. 3.3/0.433 kV,500 kVA Transformers

02 Nos. For STACKER

3.05.00 Neutral grounding resistor

1. 11 kV, 300A 06 No.

2. 3.3 kV, 300A 08 No.

3.06.00 H.T. Switchgear (with numerical relays, networking & metering system)

a) 11 KV,

i) Unit swgr. 99 panels

ii) Standby/start up swgr 17 panels

iii) Colony swgr 13 panels



v) Misc swgr 17 panels

vi) Loose panels 6 panels

c) 3.3KV, 3000/2000 Amp

i) Unit aux. service 99 panels

ii) CHP in Plant 34 panels

iii) CHP/AHP swgr. 19 panels

iv) Make up water(Make up end)

16 panels

3.07.00 Busducts, segregated

i) 11 KV 2500/2000A, 40KA, 100 KAp

800 m

ii) 3.3 KV Bus-duct(2750/1600A)

180 m

iii) Support structure 20 MT

3.08.00 L.T. switchgear LOT

3.09.00 ELECTRICAL EQUIPMENT SUPPLY

A D.C. battery-Ni-Cd/(Lead Acid)

i 220V unit batteries 990 AH/(1500AH Lead Acid)

8 Nos.

ii 220 V, 250 AH switchyard battery/(400AH Lead Acid)

2 Nos.

iii 220 V,90 AH CHP battery/(150AH Lead Acid)

2 Nos.

iv 110V 90 AH AWRS/colony /Ash Silo/MUW (150 AH Lead Acid)

8 Nos.

v. 50 V 360 AH NI-CD(KPL)PLCC battery

2 Nos.

B Battery chargers (float cum boost) for;

i. Unit batteries, 220V, 800 A 4 Nos.

ii. Swyd. Batteries, 220V, 100A 2 Nos.

iii. CHP Batteries, 220V, 50A 2 Nos.

iv. 110 V,30 A AWRS/colony /Silo/MUW

8 Nos.

v. PLCC batteries, 50V, 100A 2 Nos.



C 11KV & 3.3 KV power cables

a) 11 kV grade cable

85 kms

b) 3.3 KV grade cable 42 kms

3.10.00 LT CABLE

1.1KV power cables 550 Kms

1.1 KV control cables 750 Kms

MISC ELECTRICAL

i. Diesel generator sets 3 Nos. 1500 KVA, 415 V

ii. Cabling, earthing & lightning Protection system

Lot

iii. Lighting system Lot

Iv. Electrical lab equipment Lot

3.11.00 Construction power Lot

3.12.00 11 kV Equipment and O/H line for AWRS

Lot

3.13.00 33 kV Equipment and O/H line for MUW on tower

Lot

3.15.00 External Electrification for Township

Lot

3.16.00 Generator-Generator Trf. Unit Protection

2 sets

3.17.00 Start up power Through one no. 230 kV D/C line

3.17.00 Switchyard Equipments.

a) 400 kV GIS SWYD: Equipment rating 40 KA for 1 sec



420 KV, 3000A, 40KA SF6 gas insulated, metal-enclosed, 3-phase, Double Bus Bar System along with SF6 gas insulated Bay modules comprising of SF6 gas insulated circuit breakers, voltage transformers, disconnectors, earth switches, SF6 gas monitoring system, terminal boxes, support structures etc complete in all respect with one & half ckt breaker scheme with six(6) CTs and having following configurations.

(i)

Interconnecting Transformer (ICT)# Tie # GT module, 2500 Amps

Set 01

(ii)

Bus Reactor # Tie # Interconnecting Transformer, 2000 Amps

Set 01

(iii)

Generator Transformer # Tie # Line module alongwith reactor , 3000 Amps

Set 01

Line module along with reactor # Tie # future GT module

Set 01

b) 230 KV GIS switchyard

230, 1600 A, 40 KA SF6 gas insulated, metal-enclosed, 3-phase, Double Bus Bar System along with SF6 gas insulated Bay modules comprising of SF6 gas insulated circuit breakers, voltage transformers, disconnectors, earth switches, SF6 gas monitoring system, terminal boxes, support structures etc complete in all respect with double bus scheme having following configurations



i. Interconnecting transformer bays

sets 02 sets

ii. Start up/stand by transformer bay

set 01 set

iii. Bus coupler bay Set 01 set

iv. Line bays Set

02 sets

Sl. No.

DESCRIPTION UNIT QTY TECHNICAL PARAMETERS

Per Unit Common


10 D BOQ CONTROL & INSTRUMENTATION

1 DDCMIS i) Control System(s) Analog Inputs(4-20mA) Nos 1923 2549 Analog outputs Nos 220 187 Binary Inputs Nos 3192 14623 Binary Outputs Nos 2234 5423 SOE Binary Inputs Nos 664 Calculated SOE Nos 285

Functional groups*

(minimum) Nos 10 17

Control cabinets lot 1 1 Marshalling cabinets lot 1 1 Relay cabinets lot 1 1

No. of Remote I/O

Links Nos 0 22

ii) HMI system(s) HMI Servers Nos 2 10

LVS Nos 12 6 size of LVS is 65 -

70 "

LVS control

units/Workstations Nos 6 6

OWS Nos 4 16

Shift Charge

Workstations Nos 0 1

Station wide redundant

LAN Set 0 1

Station LAN

switch(Redundant) Nos. 0 2

Station wide LAN

server (Redundant) Nos 0 2

Hardware Firewall for

Station LAN Nos 0 2

A4 laser printer Nos 4 24 A3 laser printer Nos 0 2 Dot matrix printers Nos 1 1 Programming station No 1 4

Graphical Interface

Unit Nos 0 21

Matrix KVM switcher Nos 2 0

Sl. No. DESCRIPTION UNIT QTY TECHNICAL PARAMETERS

Per Unit Common


iii) Other Misc. Items

Relays Nos 586 1790 20% Spare Relays Considered Inline With Specifications

HART system(1 PC, 1 color inkjet printer, 1 cabinet with all necessary electronic modules )

Set 1 0

PC stations Nos 3 17 Laptops Nos 0 3 Software Lot 1 5

Master & Slave Clock

System Lot 0 1

Master Clock Nos 0 2 Slave Clocks Nos 10 15

Remote DiagNostics

station Nos 0 1

2 Measuring

Instruments

Flue gas analysers LT O2 Nos 14 HT O2 Nos 2 CO Nos 1 Sox/Nox Nos 2 CO2 Nos 1 OPACITY Nos 1 DP type transmitters No 199 Pressure transmitters No 129 4 Thermocouples No 2

Resistance

temperature Detectors No 2

Impact head type flow

Elements No 2

Vibration Sensors No 106 32 36 Sensors for mill motors has been added.

Key Phasor No 15 5

Vibration Monitors Sets 53 16 Quanities are for two channel monitors.


Per Unit Common


Radar type level

transmitters Nos 15

Single Input DIN-rail mounted Temperature Transmitter

Nos 2

Dual-input Temperature Transmitter With Indicator Nos

2

3 Electrical Power

supply system

UPS-120 KVA Sets (A) 1 (A) : 2 chargers, 2 inverters, 1 bypass source and 1 battery

UPS-10KVA Sets (B) 1 (B) : 1 charger, 1 inverter, 1 bypass source and 1 battery

UPS-25KVA Sets (B) 2

UPS-2KVA Sets (C) 3 (C) : Online UPS with remote monitoring having a battery backup of 30 mins.

UPS-1KVA Sets (C) 9

24 VDC Power supply for Unit DDCMIS (1000Amp)

Sets (D) 2 (D) : set means 2 chargers, 1 battery and 1 DCDB

24 V DC for SA

DDCMIS (175Amp) Sets (D) 2

24 V DC for Common

system (175Amp) Sets (E) 14 (E) : set means 1

charger, 1 battery and 1 DCDB

24 V DC for Common

system (300Amp) Sets (E) 2

24 V DC for Common


24 V DC for Common


24 V DC for Common


24 VDC for Common systems (35 Ampere)

Sets (E) 8


Per Unit Common


4 PCP

PCP material LOT 1

LIE, Type A Nos 16

LIE, Type B Nos 24

LIE, Type C Nos 10

LIR, Type A Nos 7

LIR, Type B Nos 18

LIR, Type C Nos 12

5 Cables

A-2P Meter

1000

The quantity shown are for Two(2) units.

F-4P Meter 147000 F-8P Meter 40000 F-12P Meter 6000 F-16P Meter 3000 F-24P Meter 3000 G-4P Meter 262000 G-8P Meter 33000 G-12P Meter 8000 G-16P Meter 15000 G-24P Meter 9000 G-48P Meter 3000

Laying of instrumentation cables provided by Employer

Meter

530000

Rigid Conduit(1" 25

mm) Meter 8000

Rigid Conduit

2"(50mm) Meter 2000

Flexible

Conduit3/4"(18mm) Meter 7000

Flexible Conduit

1"(25mm) Meter 2000

Cable sub-tray

2"(50mm) Meter 2000

Cable sub-tray

4"(100mm) Meter 4000

Cable sub-tray 6"

(150mm) Meter 1000


Per Unit Common


6 Control desk and

panels

UCD length in CR Meter 7 4 7M for UCD in main CR, 4M for UID

UCD length in other Control Rooms

Meter

18

4 m in WS CR, 4m in CHP CR, 4m in AHP CR, 2m AWRS, 2m AC CR, 2m in Raw water pump house.

LVS panel length in

CR Meter 8400

LVS panel length in other CR's

Meter 9800

4200 m in WS, 2800m in AHP and 2800m in CHP

3PB + 3 LED'S Nos 5

3 PB+4 LEDs for sync

type elec breakers Nos 15

2 PB+ 4 LEDs for sync type Elecl breakers with Numerical relay

Nos 25

2 PB+ 3 LEDs Nos 63 2 PB+ 2 LEDs Nos 17 4 PB+ 4 LEDs 2 2 LED Nos 4 3 LED Nos 5 6 LED Nos 10 1 LED Nos 10 1 PB+4 LED Nos 3 A/M STN Nos Digital Indicators Nos 5 Analog Indicator Nos 5

Trip PB/Emergency

Stop PB's Nos 8 1

With Cover Raise Lower PB Nos 6 Single PB Nos 5 45 Hand Swicthes Nos 8 Mimic Tiles Nos 150 VoltMeters Nos 2 Frequency Meters Nos 2 Synchroscope Nos 1 Release PBs Nos 3 1


Per Unit Common


Acknowledge PBs Nos 3 Test PBs Nos 3 ECP Cabinet lot 1 Furniture lot 1

Incoming voltage

transducer Nos 1

Incoming Frequency

transducer Nos 1

Running voltage

transducer Nos 1

Running Frequency

transducer Nos 1

Check relays Nos 2 Guard relays Nos 2 Auxiliary relay Nos 1 Aux PT 110/110 V Nos 2 Aux PT 63.5/110 V Nos 1

7 SWAS Analysers pH Nos 6

Sp. Cond Nos 7 Flow through type

cell

Cat. Cond Nos 8 Flow through type

cell

Withdrawable cond. Nos 6 Removable type

cell Na Nos 1 Multistream DO2 Nos 3 Silica Nos 2 Multistream HYDRAZINE Nos 2 CHLORIDE ION Nos 0 Turbidity Nos 1

Panels, Valves, fittings etc

Lot 1 Sample cond. panel-1, Analyser panel-1, Chiller unit-1

8 PA system Handset stations

(i) Outdoor wall/columnmounting type

Nos 30 80


Per Unit Common


(ii) Indoor desk topmounting type withextension amplifier

Nos 7 11

(iii)Indoor control deskmounting type withextension amplifier.

Nos 3 1

Loudspeakers

(i) Outdoor Industrial Horn type - (Nos.)

Nos 30 70

(ii) Indoor wall mounted Cone type

Nos 7 11

Portable handset stations

(i) Sockets-(Nos.) Nos 10

(ii) Portable handset sta -tions with plug (Nos.)

Nos 2

Junction boxes Lump sum

Acoustic hoods Nos 8 Master Control unit Nos 1 3

9 CCTV system Cameras Nos 38 143

Network Switch Nos 1 3

Work station with monitor

Nos 1 11

Work station without monitor

Nos 1 3

Database server set # 1 3 # set comprises of primary and standby server

Layer III switch (redundant)

Nos 0 1

10 AAQMS Sox/ Nos 0 4 Nox Nos 0 4 SPM Nos 0 8 CO2 Nos 0 4 PC based Station Nos 0 5

Wireless Communication System

Lot 0 1


Per Unit Common


Meterological Sensors Set 0 1

11 Field marshalling

unit

1024 WAYS Nos 0 9

512 WAYS Nos 0 7

128WAYS Nos 0 6

12 M&C Srd. M/C items Nos. 0 54


11 COST ESTIMATE & FINANCIAL ANALYSIS

1.00.00 GENERAL

The Current Project Cost estimate for Power Station and Facilities (Annexure- 1.1) of 2x660 MW Khulna Thermal Power Project as of 1st Qtr.’2011 is as follows:

(Million US $)

Project Cost excluding IDC & WCM : 1436.97 (124082.40 Mln BDT)

Interest During construction (IDC) : 168.12 (14517 Mln. BDT)

Project Cost including IDC : 1605.09 (138599.40 Mln. BDT)

Working Capital Margin (WCM) : 75.12 (6486.45Mln. BDT)

Project Cost including IDC & WCM : 1680.20 (145086 Mln. BDT)

Cost (Mln. US $ /MW (incl. IDC & WCM)

: 1.27(109.91 Mln. Tk./MW)

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. The cost estimates (Annexure-1.1.1) for most of the packages under this head are as per the rate analysis based on the awarded rates for various ongoing projects of NTPC in eastern region recently opened bid for SG & TG Area civil works including chimney and other offsite building and updated to 1st Qtr.’2011. The latest rates for basic materials and labour prevailing at Khulna site has been considered for each package. The cost estimate for Township has been estimated as per CPWD norms and building cost index of 166 for Khulna.

For dredging and filling rate as received from BPDP is considered.

Land cost is not considered in Project Capital cost, however, land lease rent @ 699 US $ per acre per year is considered for tariff calculations. Cost of approach road is not considered in FR cost.

2.02.00 Mechanical, Electrical & Coal Transportation

Cost estimates for the Mechanical & Electrical Equipment (Annexure - 1.1.2, 1.1.3 ) are based on the award/ bid prices for various ongoing projects of NTPC. The cost estimate is suitably updated to of 1st Qtr.’2011 price level. Customs duty, excise duty and CST is not considered as these are nil in Bangladesh.


2.03.00 Others

The provision for Misc. Tools and Plants, Establishment including Audit & Accounts have been kept @ 0.25% and 3.5 % of the Works Cost respectively.

Pre-commissioning Charges have been kept as 0.50% of Works Cost. To provide for any unforeseen expenditure, 1.5% of the civil works cost and equipment cost has been kept as Contingency.

The provision for Consultancy has been kept as 0.25% 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-1.1.4. 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

Project Financing- Out of total 70% loan, the interest rate for 10% of loan is considered as 15.5% and for balance 60% as 6.5% as ECA funding. The loan repayment is considered in 10 equal annual installments, with a moratorium period of 5 years, considering single EPC package with ECA funding.

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 parallel drawl of equity and debt for Power Plant and Facilities works out to 168.12 Mln. US $ based on weighted average interest rate @ 7.79%. The first unit has been assumed to be commissioned (COD) in 48 months from the date of Main Plant Award and the second unit at an interval of 6 months thereafter.

3.04.00 Working Capital Margin

Working Capital Margin of US $ 75.12 Million 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 : 90 days requirement

ii) Oil cost : 60 days requirement


B) O&M Charges : 30 days requirement

C) Spares : 20% of Annual O&M 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 ( Lease rent US $ 699/acre/year and maintenance dredging at US $ 4 million/year is considered in tariff calculations) :

Cost of Energy (Cents/kWh)

First Full Year Operation : 9.84Cents/kWh(8.49 BDT/kWh)

Fixed Charges : 3.90Cents/kWh(3.38 BDT/kWh)

Variable Charges : 5.93Cents/kWh (5.12 BDT/kWh)

Levelised Cost of Energy : 9.31Cents/kWh(8.04 BDT/kWh)

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

a) Debt:equity : 70:30

b) Return on equity : 18%

c) Drawal of Fund : Parallel drawl of debt & equity

d) Weighted average rate of interest on loan capital :7.79 % per annum

e) Average depreciation : 7% per annum

f) Interest on Working Capital : 13.50% per annum

g) Annual operation : 7446 hours

h) O&M Charges incl. Lease rent : US $ 0.041 Mln/MW

i) Auxiliary power consumption : 6.00%

j) Station heat rate : 2317.44Kcal/kWh

k) GCV of coal : 6000 Kcal/kg

l) Coal price :US $ 145 per MT

(Inc. 25$ for freight charges)

m) Land lease rent : US $ 699 per acre/year

n) Maintenance dredging : US $ 4 million/year

o) Tax holiday : 15 years

p) Corporate tax : 25%

q) Loan repayment : 10 years

r) Taxes and duties:

i) Customs duty = Nil

ii) Excise duty = Nil

iii Sales tax = Nil

iv Works tax/Service tax = 5% on amount more than Tk 3 crore

s) 1 INR = 1.57 Tk

t) 1 USD = 55 INR


SENSITIVITY ANALYSIS

BPDB has suggested to include chapter on sensitivity analysis showing effect on tariff of various parameters namely coal cost, coal calorific value. Same is included as requested by client.

In the base model the project cost has been worked out as 1.27 Million USD/MW, 109.91 MillionBDT/MW. The variables considered for calculation are as tabulated below:-

Description

Unit FR base Model

Total Project Cost Min. BDT/MW 109.91

Mln. USD/MW 1.27

Cost of Energy (Levellised) (Variable)

BDT/kwh

US Cents/kwh

8.04(5.12)

9.31 (5.93)

Coal Cost (Base+Transp) USD/MT 145

Coal GCV Kcal/kg 6000


A) Sensitivity on Coal Cost:

The coal parameters in base model has been considered as USD 145/MT and 6000 Kcal/kg as GCV. The sensitivity has been done for coal cost from USD 165/MT to USD 105/MT. The results are as follows :-

Description

Unit Option 1 FR base model

Option 2 Option 3

Total Project Cost

Min. BDT/MW

110.40 109.91 109.40 108.90

Mln. USD/MW

1.28 1.27 1.27 1.26


BDT/kwh

US Cent/kwh

8.79(5.83)

10.17(6.75)

8.04(5.12)

9.31(5.93)

7.29(4.42)

8.45(5.11)

6.55(3.71)

7.58(4.30)

Coal Cost (Base+Transp)

USD/MT 165 145 125 105

Coal GCV Kcal/kg 6000 6000 6000 6000


B) Sensitivity on Coal GCV:

The coal parameters are coal cost as USD 145/MT and GCV AS 6000 kcal/kg. The sensitivity has been done for GCV of 5200 Kcal/kg. The results are as follows-

Description

unit FR base model

Option 1

Total Project Cost Min. BDT/MW

109.91 110.50

Mln. USD/MW

1.27 1.28


BDT/kwh

US Cents/kwh

8.04(5.12)

9.31(5.93)

8.87(5.91)

10.27 (6.84)

Coal Cost (Base+Transp)

USD/MT 145 145

Coal GCV Kcal/kg 6000 5200


12. PROJECT IMPLEMENTATION

1.00.00 PROJECT SCHEDULE

The Commissioning and Commercial Operation Date (COD) of first unit will be in 48 months from the Investment approval and second unit after an interval of 6 months thereafter.

The implementation schedule is indicated in EXHIBIT X which shows optimum schedule for the project with different milestones shown in bar chart.

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 JV Corporate office 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 JV Corporate office 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 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 (MNW)

A Master Network (MNW), which is the overall programme of project implementation, is finalised by the Monitoring Group in consultation with Engineering, Contracts and Site. The MNW is based on project contract package classification and has about 500 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.

2.02.00 Tendering, Award of Contracts & Engineering Phase

2.02.01 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 project are finalised and documented as part of Revised Cost Estimates (RCE) alongwith the detailed estimates of cost and quantities.

The Engineering 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 accord-ingly 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-à-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 centres, 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.

2.02.02 Contracts Planning, Monitoring and Control

Based on the key event dates identified in the Master Network, detailed plan for pre-award activity upto award of every contract is finalised and monitored vigorously.

When packages are awarded, detailed programme in the form of networks is 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.

2.03.00 Manufacturing, Inspection and Expediting Phase

2.03.01 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.


2.03.02 Quality Assurance

An independent Quality Assurance Group for ensuring the quality during the project engineering, procurement and manufacturing, as well as during material storage is organized 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 Group 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 shall be adopted. Construction Phase and Commissioning Phase

2.03.03 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.

2.03.04 Project Review Team Meeting

A Project Review Team(PRT) headed by the project head with members from various departments at the JV Corporate 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 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 center 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.


13. MANPOWER TRAINING AND PLACEMENT

1.00.00 ORGANIZATION STRUCTURE

Khulna Thermal Power Project is proposed to have a three-tier organization structure consisting of JV Corporate office, the regional Headquarters and Projects. The Organization structures have been placed at Exhibit X JV Corporate office focuses the attention mainly on the formulation of policies, guidelines, development of systems and procedures which need to be adopted by the various responsibility centers. The regional set-up headed by a Regional Executive Director responsible for construction & operation of power stations. The Project General Managers reporting to the Regional Executive Director are accountable for performance in their respective stations.

2.00.00 TRAINING AND DEVELOPMENT

The company should lay 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 institute shall be set up at project.

3.00.00 TYPE OF TRAINING

3.01.00 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. Four types of long-duration training schemes are proposed, to take care of this aspect of training.

Name of Scheme Duration

1) Engineering Executive Training 1-year Scheme

2) Finance & HR Executive Training 1-year Scheme

3) Executive Training Scheme 1-year (Chemistry)

4) Diploma/ ITI Trainees Scheme 1-year

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 can be set up. The institute shall offer general management programme, programme for developing functional knowledge induction and familiarization courses and discussions on subjects of topical interest. The Institute can also undertake applied research, including development of materials and consultancy assignments in the various techno-managerial areas in the Power Sector.

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

Large number of personnel inducted in the various areas of O & M have to be oriented in the operation & maintenance of 200/500 MW units. These programme shall 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 Advanced Training Abroad

To provide necessary exposure on new developments in engineering and management fields, arrangements shall be made for imparting specific need based training abroad in operations and maintenance to personnel down the line.


3.05.00 Employee Development Programme

Short duration programme to develop and upgrade skills and long duration programme to attain higher educational levels shall be formulated for the benefit of personnel at different levels.

4.00.00 Project Training Centers

Khulna Thermal Power Project shall establish training institutes at its project site for providing formal and on-the-job training to various types of trainees like executive trainees, diploma and ITI trainees.


14. 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

Khulna TPP (2x660 MW) is a conveyor fed (from port) coal based station in Bangladesh and will be basically designed to work as base load station.

2.01.02 Design

The design of Khulna TPP (2x660 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.

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 100%

PLF and design 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) Coal bunkers shall be designed to avoid choking /rat holing etc. after

carrying out coal flowability studies


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 90 days full load requirement will be designed at station end. However, space is available in coal stock yard for six months storage.

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

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

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) 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 DCS. 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.


To achieve optimum efficiency, following provisions shall be made:

a) Super heater and Reheater spray shall be taken from the BFP, Kicker stage and Interstage respectively as per pressure requirement. 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.

b) Condenser shall have an 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.

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

d) 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.

e) HP and IP turbine first few stage fixed & rotating blades shall be designed so as to have minimum erosion between Overhauls.

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

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

h) Air Preheaters shall be provided with leakage control/minimizing system for on line seal adjustment.

i) Care shall be taken not to use film type fills in CTs to avoid blockage and efficiency loss.

j) 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.

2.04.0 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) Pressure. /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.

c) Condenser performance with on line instruments: Accurate Condenser measurements (CW inlet/outlet, Hotwell condensate temp, Air suction temp. etc.,) required for η calculations.

d) 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.

e) High temperature O2 probes shall be provided at the furnace exit so as to monitor combustion efficiency. CO2, SOX, NOX monitoring instruments


shall be provided.

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.

2.05.0 DESIGN FOR HIGH RELIABILITY

For high reliability following design considerations are to envisaged:

i) Unit should be designed for a fast 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.


2.08.0 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 training is imparted to all engineers meant for operation and maintenance of 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 Head (O&M) and Project Co-ordinator from Corporate OS.

Training in the areas of operation and maintenance of modern facilities shall also be organized.

2.08.1 TRAINING OF OPERATION ENGINEERS

I) Simulator Training

The operation engineers will undergo extensive training in simulators similar to the unit control room (preferably at the same location). 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 partsbased

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.

4.00.0 COAL SUPPLY MANAGEMENT

Coal shall be sourced from other countries. Coal received at jetty near plant end shall be transported to the station by 1 x 100% conveyor system.

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. As a first step all major auxiliaries shall be provided with energy meters so as to monitor their energy consumption. This shall be integrated to an 'On Line energy Management System'.

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 a thermal cycle with higher efficiency. The boiler shall operate in super critical zone. 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.

d) Running hours of CHP are optimized to reduce specific energy consumption per MT of coal handled.

5.04.0 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.

5.05.0 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,

It can be achieved by the following chemistry control philosophy :

Chemistry Control :

(i) The units are to be operated in Oxygenated treatment (OT) of feed water. (ii) The 100% Condensate to be treated in CPU in hydrogen cycle only.

Therefore a standby 50% treatment facility shall be available all the time. (iii) The make up water should have the following characteristics:

(a) Conductivity less than 0.1 μs/cm,

(b) Silica less than 5 ppb,

(iv) The parameters to be monitored by on-line instruments and core parameters are indicated in Control room with alarm and the limit value. The total chemistry control and monitoring is done by Chemistry expert software to alert and inform operator for desired actions.

(v) Following parameters are to be monitored continuously on-line in water /steam cycle:

(a) Cation conductivity at CEP discharge; CPU outlet;

Feed water and Main steam

(b) Conductivity ---do----

(c) pH at Feed water

(d) Silica at Feed water and main steam

(e) Dissolved Oxygen at Condensate and Feed water

(f) Sodium at Main steam; CEP discharge and CPU

(g) ORP at CEP discharge and Feed water

(vi) The adequate arrangements including nitrogen capping (for dry or wet preservation) shall be provided for proper lay up of the all the water and steam touched system when unit is under shut down.


(vii) The chemical feeding (like ammonia and oxygen) shall be performed by automatic mode.

vii) The WT plant shall be fully automated and to be designed for minimal manual interference. The Utilisation Ozone for water disinfection; use of alternate chemicals such as PAC; and gas transfer membrane system for degasification of deminiralised water etc to be considered.

ix) Cooling water chemistry control to be done by PLC based operation and monitoring.

X) Provision of Chemical laboratory to be made consisting of in climate controlled rooms having adequate instruments for Water, coal, Oil and gas analysis.

5.06.0 OPERATIONAL OPTIMISATION

(a) 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

(b) 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.

(c ) OPC compliance shall be ensured for compatibility with ERP/ other systems.


15. MARKETING PHILOSOPHY

1.00.00 CONTRACTED CAPACITY

The entire available capacity as well as the electricity generated by the Project shall be purchased by BPDB (or its reconstituted successor company under the relevant legislation) as per the Power Purchase Agreement to be entered into between JVC and BPDB, for an initial period of 25 years with a provision of extension thereafter, on mutually agreed terms and conditions, at the relevant point of time.

2.00.00 TARIFF

Sale of Power shall be at the Ex-Bus of the Project. Tariff payable to JVC by BPDB for the Project shall be decided by JVC based on Norms agreed upon in the Power Purchase Agreement signed between BPDB and the JV Company. Tariff payable by BPDB to JVC shall comprise of two-part viz. the Fixed charge and the Energy charge. Tariff determination shall be based on the Capital cost of the Project, Normative Availability, Normative O&M charges, Normative Operating Parameters and agreed Norms of inventory / fuel stock etc.

The tariff payable to JVC will be denominated in foreign and local currencies, depending on the currency in which the costs are incurred. All foreign currency payments will be denominated either in US Dollars or in Euro or a combination thereof.

3.00.00 PAYMENT SECURITY

The payment mechanism in the form of LC (“Letter of Credit”) shall be included in the Power Purchase Agreement. The terms and conditions of which are:

It shall be irrevocable standby LC on sight without any certification from BPDB.

LC shall be valid for a period of one year and shall be renewed annually by the issuing bank immediately prior to the relevant expiry date for further periods of 1 (one) year each until the last day of the term under the Power Purchase Agreement.

It shall be automatically and immediately reinstated to the full LC amount on any drawal thereon.

The amount of LC shall cover 105% of the monthly billing (including capacity charges and energy charges) to be adjusted every quarter based on the projected monthly billing.


In the event of payment default by BPDB to JVC under the Power Purchase Agreement, the JVC shall be paid its dues through a Government of Bangladesh guarantee as per the provisions of Implementation Agreement.

4.00.00 ARRANGEMENT FOR DRAWAL OF POWER

Sale of Power shall be at the Ex-bus of the Project at 400KV. Evacuation of electricity beyond this point shall be the responsibility of BPDB.

ANNEXURE-1.1

SUMMARY OF PROJECT CAPITAL COST (CURRENT COST)

PROJECT: Khulna TPP Stage I (2 x 660 MW)

S.No. Item Description

1.0 Preliminary & Civil Works

1.1 1.2

Land & Civil Construction Works Physical Contingency

Sub-Total 1.0

2.0 Plant & Equipment

2.1 2.2 2.3

2.4 2.5

3.0

Mechanical Equipment Electrical Equipment Coal Transportation System

Misc. Tools & Plants Physical Contingency

Sub-Total 2.0

Works Cost (1.0+2.0)

Pre Commissioning Expenses

4.0 Project Management

4.1

4.2 4.3

5.0

6.0

Establishment incl. Consultancy, Audit & Accounts Training of O&M Staff Losses on Stocks

Sub-Total 4.0

Project Cost excl. IDC (1 to 4)

Interest During Construction (IDC) a) Interest Charges b) Financing Charges

Project Cost incl. IDC (1 to 5)

CostlMW (Exc/. WCM)

Working Capital Margin (WCM)

Project Cost incl. IDC. & WCM (1 to 6)

CostlMW (Incl. IDC & WCM)

(I Qtr.,2011)

ANNEXURE- 1.1.1

ANNEXURE- 1.1.2 ANNEXURE-1.1.3

11 /9/2012

(US$ in Millions)

Total

440.79 6.61

447.41

824.1 4 89.27

0.00

3.39 13.75

930.55

1377.95

6 .89

51.67

0.36 0.09

52.13

1436.97

168.12 162.50

5.62

1605.09

1.22

75.12

1680.2

1.27

Page 1 of 14

002813

Text Box

User

Typewriter

3.6% of Project cost(excl IDC

User

Typewriter

User

Typewriter

Edited by Foxit Reader Copyright(C) by Foxit Corporation,2005-2010 For Evaluation Only.

User

Typewriter

(I Qtr-2011)

PROJECT: Khulna TPP Stage -I ( 2 x 660 MW) (US $ in Mn)

Sl. Item Description Total

No.

1 Survey & Soil Investigation 0.18

2 Land 0.00

3 Site Levelling & Infrastructure (

including US $ 1.45 Mn towards Civil

works of ETP )

24.29

4 Permanent Township 44.55

5 Main Plant Civil incl Chimney 305.98

6 CW & Make Up Water System 29.14

7 Ash Dyke- First 9 years 27.56

8 Miscellaneous 9.09

TOTAL 440.79

CIVIL WORKS(CURRENT COST)

002813

Text Box

Annexure - 1.1.1

ABSTRACT COST ESTIMATE

Mechanical Works (CURRENT COST)

:JROJECT Khulna TPP Stage I (2 x 660 MW)

SI. No.

Item Description

1 SG with Associated aux. Incl. ESP

2 Turbine Generator with Assoc. aux.

3 Coal Handling System including Jetty

4 C & I incl. DAS

5 Ash Handling System & AWRS incl. ETP

6 CW Pumps incl. Makeup Water Sys.

7 Cooling Towers incl. Civil Works

8 Desalination Plant

9 Chlorination System

10 Station piping & Fuel Oil Handling System

11 Fire Detection and Protection System

12 Air Conditioning & Ventilation

13 Workshop & Lab. Equipment

14 Diesel Generator

15 Fuel Oil Handling system

TOTAL

. ANNEXURE- 1.1.2

(I Qtr,2011)

ANNEXURE-1.1 .2

(US$ in Millions)

Total

394.54

206.99

105.79

6.91

23.13

10.45

28.54

24.52

1.73

10.25

4.43

3.01

0.41

0.86

2.57

824.14

Page 3 of 14

ABSTRACT COST ESTIMATE Electrical Works

(CURRENT COST) (I Qtr,2011)


SI. Item Description No. A ELECTRICAL SYSTEM

2

3

4

5

6

7

8

Generator Bus Duct

Gen. Circuit Breaker

Generator, Stn.,L T Outdoor & Indoor Transformer

H T Switchgear

L T Switchgear

H T Power Cables

L T Power, Control & Instrumentation Cable

Cabling, Earthing & Stn. Lighting, & Battery

SUB TOTAL (A)

B SWITCHYARD

9

10

11

12

400 Switchyard

Reactor 400 kV

Battery & Charger

Construction Power, & Ex. Electrification

SUB TOTAL (B)

C COMPUTER & SATE LITE COMMUNICATION FACILITIES

13 Computer Facilities

14 Satellite Communication System

15 Common Facilities

SUB TOTAL (C)

TOTAL

ANNEXURE- 1.1 .3

(US$ in Millions)

...................................................... ----Total

2.35

3.11

17.90

4 .07

4.10

0.93

2.75

5.66

40.86

34.91

2.50

1.22

7.12

45.75

0.97

0.95

0.74

2.66

89.27

page 4 of 14

KhulnaTPP

Year Ending

Tariff Computation in US $

Annual Fixed Cost

Effective Tax Rate

Pre Tax Return on Equity (%)

Return on Equity

Interest on Loan Capital

Depreciation

Oil Cost

Interest on Working Capital

Land lease payment

0& M Expenses (Unit I)

0& M Expenses (Unit II)

Total Fixed Cost

Energy Charge

FC/unit)

VC/unit)

Tariff

Levelised Tariff

First Full Year Tariff

0.018

1.00 0.297

1.00 0.297

9.31

9.84

M" ":ml~ @r~'~' -~-~~W"'.'W" ,,' ~"

In U5.;$ G,ents%

31-Mar-13 31-Mar-14 31-Mar-15 31-Mar-16 31-Mar-17

0.00% 0.00% 0.00% 0.00% 0.00%

18.00% 18.00% 18.00% 18.00% 18.00%

108.34

105.49

132.61

6.70

49.86

5.47

49.02

457.49

685.10

3.96

5.93

9.89

31-Mar-18 31-Mar-19

0.00% 0.00%

18.00% 18.00%

758.40 866.75

665.51 745.75

975.14 1,098.75

46.91 53.61

354.37 405.64

38.26 43.72

196.07 196.07

147.05 196.07

3,181.72 3,606.38

4,795.70 5,480.80

3.94 3.90

5.93 5.93

9.87 9.84

A _~ A

KhulnaTPP $

Year Ending 31-Mar-20 31-Mar-21 31-Mar-22 31-Mar-23 31-Mar-24 31-Mar-25 31-Mar-26 31-Mar-27


Annual Fixed Cost

Effective Tax Rate 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%

Pre Tax Return on Equity (%) 18.00% 18.00% 18.00% 18.00% 18.00% 18.00% 18.00% 18.00%

Return on Equity 866.75 866.75 866.75 866.75 866.75 866.75 866.75 866.75

Interest on Loan Capital 660.21 574.66 489.12 403.57 318.03 232.48 146.94 61.39

Depreciation 1,098.75 1,098.75 1,098.75 1,098.75 1,098.75 1,098.75 1,098.75 1,098.75

Oil Cost 53.61 53.61 53.61 53.61 53.61 53.61 53.61 53.61

Interest on Working Capital 403.68 401.71 399.74 397.77 395.80 393.83 391.86 389.89

Land lease payment 43.72 43.72 43.72 43.72 43.72 43.72 43.72 43.72

0& M Expenses (Unit I) 196.07 196.07 196.07 196.07 196.07 196.07 196.07 196.07

0& M Expenses (Unit II) 196.07 196.07 196.07 196.07 196.07 196.07 196.07 196.07

Total Fixed Cost 3,518.86 3,431.35 3,343.83 3,256.32 3,168.80 3,081.29 2,993.77 2,906.26

Energy Charge 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80

FC/unit) 3.81 3.71 3.62 3.52 3.43 3.34 3.24 3.15

VC/unit) 5.93 5.93 5.93 5.93 5.93 5.93 5.93 5.93

Tariff 9.74 9.65 9.55 9.46 9.36 9.27 9.17 9.08

Levelised Tariff

First Fun Year Tariff

Khulna TPP _. __ • "-.-"--"'<. •• __ . _. __ .... _ ..... -'*'-.-



Annual Fixed Cost

Effective Tax Rate 0.00% 0.00% 0.00% 0.00% 6.25% 25.00% 25.00% 25.00%

Pre Tax Return on Equity (%) 18.00% 18.00% 18.00% 18.00% 19.20% 24.00% 24.00% 24.00%

Return on Equity 866.75 866.75 866.75 866.75 924.53 1,155.66 1,155.66 1,155.66

Interest on Loan Capital 9.31

Depreciation 1,098.75 1,098.75 524.66 34.54 34.54 34.54 34.54 34.54

Oil Cost 53.61 53.61 53.61 53.61 53.61 53.61 53.61 53.61



0& M Expenses (Unit I) 197.87 197.87 197.87 197.87 197.87 200.27 200.27 200.27


Total Fixed Cost 2,854.89 2,847.28 2,259.97 1,758.58 1,817.69 2,056.69 2,059.24 2,059.24

Energy Charge 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80

FC/unit) 3.09 3.08 2.45 1.90 1.97 2.23 2.23 2.23

VC/unit) 5.93 5.93 5.93 5.93 5.93 5.93 5.93 5.93

Tariff 9.02 9.01 8.38 7.84 7.90 8.16 8.16 8.16

Levelised Tariff


" _ • .A

KhulnaTPP

Year Ending 31-Mar-36 31-Mar-37 31-Mar-38 31-Mar~39 31-Mar-40 31-Mar-41 31-Mar-42 31-Mar-43


Annual Fixed Cost

Effective Tax Rate 25.00% 25.00% 25.00% 25.00% 25.00% 25.00% 25.00% 25.00% Pre Tax Return on Equity (%) 24.00% 24.00% 24.00% 24.00% 24.00% 24.00% 24.00% 24.00%

Return on Equity 1,155.66 1,155.66 1,155.66 1,155.66 1,155.66 1,155.66 1,011 .21 144.46 Interest on Loan Capital

Depreciation 34.54 34.54 34.54 34.54 34.54 34.54 27.07 1.09

Oil Cost 53.61 53.61 53.61 53.61 53.61 53.61 46.91 6.70



0& M Expenses (Unit I) 200.27 200.27 203.87 203.87 203.87 203.87 152.90


Total Fixed Cost 2,059.24 2,059.24 2,063.06 2,066.89 2,066.89 2,066.89 1,804.07 254.01

Energy Charge 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 4,795.70 685.10

FC/unit) 2.23 2.23 2.23 2.24 2.24 2.24 2.23 2.20

VC/unit) 5.93 5.93 5.93 5.93 5.93 5.93 5.93 5.93

Tariff 8.16 8.16 8.17 8.17 8.17 8.17 8.16 8.13

Levelised Tariff

First Fun Year Tariff

A nf.4

ANNEXURE- 1.1

SUMMARY OF PROJECT CAPITAL COST (CURRENT COST)


S.No. Item Description

1.0 Preliminary & Civil Works

1.1 1.2

Land & Civil Construction Works Physical Contingency

Sub-Total 1.0

2.0 Plant & Equipment

2.1 2.2 2.3

2.4 2.5

3.0

Mechanical Equipment Electrical Equipment Coal Transportation System

Misc. Tools & Plants Physical Contingency

Sub-Total 2.0

Works Cost (1.0+2.0)

Pre Commissioning Expenses

4.0 Project Management

4.1

4.2 4.3

5.0

6.0

Establishment inc!. Consultancy, Audit & Accounts Training of O&M Staff Losses on Stocks

Sub-Total 4.0

Project Cost excl. IDC (1 to 4)

Interest During Construction (IDC) a) Interest Charges b) Financing Charges

Project Cost incl. IDC (1 to 5)

CosttMW (Excl. WCM)

Working Capital Margin (WCM)

Project Cost incl. IDC. & WCM (1 to 6)

CosttMW (Incl. IDC & WCM)

(I Qtr.,2011)

ANNEXURE-1.1.1

ANNEXURE-1.1.2 ANNEXURE-1.1.3

11/9/2012

(BOT in Millions)

Total

38062.61 570.94

38633.55

71164.49 7708.39

0.00

292.33 1187.46

80352.67

118986.22

594.87

4461 .94

31.40 7.85

4501.19

124082.28

14517.01 14031.88

485.13

138599.29

105.00

6486.61

145085.9

109.91

Page 1 of 14

002813

Text Box

(I Qtr-2011)

PROJECT:Khulna TPP Stage -I ( 2 x 660 MW) (BDT in Mn)

Sl. Item Description Total

No.

1 Survey & Soil Investigation 15.70

2 Land 0.00

3 Site Levelling & Infrastructure (

including BDT 126 Mn towards Civil

works of ETP )

2097.52

4 Permanent Township 3847.13

5 Main Plant Civil incl Chimney 26421.37

6 CW & Make Up Water System 2516.08

7 Ash Dyke- First 9 years 2379.81

8 Miscellaneous 785.00

TOTAL 38062.61

CIVIL WORKS(CURRENT COST)

002813

Text Box

Annexure - 1.1.1

ABSTRACT COST ESTIMATE

Mechanical Works (CURRENT COST)

;)ROJECT Khulna TPP Stage I (2 x 660 MW)

S!. No.

Item Description

1 SG with Associated aux. Inc!. ESP

2 Turbine Generator with Assoc. aux.

3 Coal Handling System including Jetty

4 C & I inc!. DAS

5 Ash Handling System & AWRS inc!. ETP

6 CW Pumps inc!. Makeup Water Sys.

7 Cooling Towers inc!. Civil Works

8 Desalination Plant

9 Chlorination System

10 Station piping & Fuel Oil Handling System

11 Fire Detection and Protection System

12 Air Conditioning & Ventilation

13 Workshop & Lab. Equipment

14 Diesel Generator

15 Fuel Oil Handling system

TOTAL

ANNEXURE- 1.1.2

(I Qtr,2011)

ANNEXURE-1 .1.2

(BOT in Millions)

Total

34068.53

17873.35

9135.36

596.76

1996.88

902.28

2464.43

2117.46

148.99

885.32

382.92

260.15

35.80

74.10

222.16

711 64.49

Page 3 of 14

ABSTRACT COST ESTIMATE Electrical Works

(CURRENT COST) (I Qtr,2011)


SI. Item Description No. A ELECTRICAL SYSTEM

2

3

4

5

6

7

8

Generator Bus Duct

Gen. Circuit Breaker

Generator, Stn.,L T Outdoor & Indoor Transformer

H T Switchgear

L T Switchgear

H T Power Cables

L T Power, Control & Instrumentation Cable

Cabling, Earthing & Stn. Lighting, & Battery

SUB TOTAL (A)

B SWITCHYARD

9

10

11

12

400 Switch yard

Reactor 400 kV

Battery & Charger

Construction Power, & Ex. Electrification

SUB TOTAL (B)

C COMPUTER & SATELITE COMMUNICATION FACILITIES

13 Computer Facilities

14 Satellite Communication System

15 Common Facilities

SUB TOTAL (C)

TOTAL

ANNEXURE-1 .1.3

(BDT in Millions)

Total

202.53

268.47

1545.35

351 .84

354.19

80.07

237.38

488.58

3528.42

3014.09

216.19

105.66

614.50

3950.43

83.52

81 .80

64.21

229.53

7708.39

page 4 of J4

KhuInaTPP

Year Ending

Annual Fixed Cost

Effective Tax Rate

Pre Tax Return on Equity (%)

Return on Equity


Depreciation

Oil Cost

Interest on Working Capital

O&M Expenses

0& M Expenses (Unit I)

0& M Expenses (Unit II)

Total Fixed Cost

Energy Charge

FC/unit)

VC/unit)

Tariff

Levelised Tariff


1.00 0.257

1.00 0.257

8.04

8.49

IN BDT PER UNIT

31-Mar-13 31-Mar-14 31-Mar-15 31-Mar-16 31-Mar-17

0.00% 0.00% 0.00% 0.00% 0.00%

18.00% 18.00% 18.00% 18.00°/', 18.00%

93.55

91.09

114.51

5.79

43.06

0.21 0.22 0.23 0.24 0.26

42.33

395.04

591.58

3.42

5.12

8.54

31-Mar-18 31-Mar-19

0.00% 0.00%

18.00% 18.00%

654.88 748.44

574.67 643.96

842.03 948.77

40.51 46.29

306.00 350.27

0.26 0.26

169.31 169.31

126.98 169.31

2,747.41 3,114.11

4,141.09 4,732.67

3.40 3.37

5.12 5.12

8.52 8.49

1 ..... f A

Khulna TPP

Year Ending 31-Mar-20 31-Mar-21 31-Mar-22 31-Mar-23 31-Mar-24 31-Mar-25 31-Mar-26 31-Mar-27 Annual Fixed Cost

Effective Tax Rate 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% Pre Tax Return on Equity (%) 18.00% 18.00% 18.00% 18.00% 18.00% 18.00% 18.00% 18.00%

Return on Equity 748.44 748.44 748.44 748.44 748.44 748.44 748.44 748.44

Interest on Loan Capital 570.09 496.22 422.35 348.48 274.62 200.75 126.88 53.01

Depreciation 948.77 948.77 948.77 948.77 948.77 948.77 948.77 948.77 Oil Cost 46.29 46.29 46.29 46.29 46.29 46.29 46.29 46.29


O&M Expenses 0.26 0.26 0.26 0.26 0.26 0.26 0.26 0.26

0& M Expenses (Unit I) 169.31 169.31 169.31 169.31 169.31 169.31 169.31 169.31

0& M Expenses (Uni t II) 169.31 169.31 169.31 169.31 169.31 169.31 169.31 169.31

Total Fixed Cost 3,038.54 2,962.97 2,887.40 2,811.83 2,736.26 2,660.69 2,585.12 2,509.55

Energy Charge 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67

FC/unit) 3.29 3.21 3.13 3.04 2.96 2.88 2.80 2.72

VC/unit) 5.12 5.12 5.12 5.12 5.12 5.12 5.12 5.12

Tariff 8.41 8.33 8.25 8.17 8.08 8.00 7.92 7.84

Levelised Tariff


2of4

Khulna TPP

Year Ending 31-Mar-28 31-Mar-29 31-Mar-30 31-Mar-31 31-Mar-32 31-Mar-33 31-Mar-34 31-Mar-35 Annual Fixed Cost

Effective Tax Rate 0.00% 0.00% 0.00% 0.00% 6.25% 25.00% 25.00% 25.00% Pre Tax Return on Equity (%) 18.00% 18.00% 18.00% 18.00% 19.20% 24.00% 24.00% 24.00°Ic,

Return on Equity 748.44 748.44 748.44 748.44 798.33 997.92 997.92 997.92 Interest on Loan Capital 8.04

Depreciation 948.77 948.77 453.04 29.83 29.83 29.83 29.83 29.83 Oi1 Cost 46.29 46.29 46.29 46.29 46.29 46.29 46.29 46.29


O&M Expenses 0.26 0.26 0.26 0.26 0.26 0.26 0.26 0.26

0& M Expenses (Unit I) 170.86 170.86 170.86 170.86 170.86 172.94 172.94 172.94

0& M Expenses (Uni t II) 169.31 170.30 170.30 170.30 170.30 170.30 171.62 171.62

Total Fixed Cost 2,465.20 2,458.63 1,951.49 1,518.53 1,569.58 1,775.95 1,778.15 1,778.15

Energy Charge 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67

FC/unit) 2.67 2.66 2.11 . 1.64 1.70 1.92 1.92 1.92

VC/unit) 5.12 5.12 5.12 5.12 5.12 5.12 5.12 5.12

Tariff 7.79 7.78 7.23 6.77 6.82 7.04 7.05 7.05

Levelised Tariff


30f4

Khulna TPP


Annual Fixed Cost

Effective Tax Rate 25.00% 25.00% 25.00'Yo 25.00% 25.00% 25.00% 25.00% 25.00%

Pre Tax Return on Equity (%) 24.00% 24.00% 24.00% 24.00% 24.00% 24.00°/', 24.00% 24.00%

Return on Equity 997.92 997.92 997.92 997.92 997.92 997.92 873.18 124.74


Depreciation 29.83 29.83 29.83 29.83 29.83 29.83 23.38 0.94

Oil Cost 46.29 46.29 46.29 46.29 46.29 46.29 40.51 5.79


O&M Expenses 0.26 0.26 0.26 0.26 0.26 0.26 0.26 0.26

0& M Expenses (Unit I) 172.94 172.94 176.04 176.04 176.04 176.04 132.03

0& M Expenses (Unit IT) 171.62 171.62 171.62 173.60 173.60 173.60 173.60 43.40

Total Fixed Cost 1,778.15 1,778.15 1,781.46 1,784.76 1,784.76 1,784.76 1,557.81 219.33

Energy Charge 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,141.09 591.58

FC/unit) 1.92 1.92 1.93 1.93 1.93 1.93 1.93 1.90

VC/unit) 5.12 5.12 5.12 5.12 5.12 5.12 5.12 5.12

Tariff 7.05 7.05 7.05 7.05 7.05 7.05 7.05 7.02

Levelised Tariff


A "f A

EXHIBITS

I PLAN KHULNA TPP (2X660 MW)

BANGLADESH PROJECT CODE :9635

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I a " ., II I, !I II II It i: a! II

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400 kV GIS SWYD.

FUTURE UNE UNE'IV UNE,m

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QUAD CONDUCTOR UNE'II UNEfi

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OVERHEAD CONNECTION

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230kV GIS SWYD.

UNEfi UNE'II I ... ture line boys

230KV BUS-I

IFOR FR PURPOSE ONV

- D836-DDD-POB-J-DOl

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EXHIBIT - VII

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Activity ID

Activity Description Mth fromMP Order

KH005 Investment Approval

0

KH010 Main Plants Award (SG and TG)

0

KH020 Start of Piling & Foundation

4

KH030 Start of Boiler Erection

14

KH040 Start of Condenser Erection

26

KH050 Start of TG Erection 28

KH060 Boiler Hydro Test 32

KH070 Readiness of C&I forBoiler Light Up

38

KH080 TG Box Up 39

KH090 Boiler Light Up 39

KH100 Steam Blowing Start 41

KH110 TG on Barring 41

KH120 Commissioning of Unit # 1

44

KH130 COD Unit # 1 48

KH140 Commissioning Unit# 2

50

KH150 COD Unit # 2 54

1 1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18 19 20 21 22 23 24 25 26 27 28 29 30 31 32 33 34 35 36 37 38 39 40 41 42 43 44 45 46 47 48 49 50 51 52 53 54 55 56 57 58 59 60 61 62 63 64 65 66 67Month

Investment Approval

Main Plants Award (SG and TG)

Start of Piling & Foundation

Start of Boiler Erection

Start of Condenser Erection

Start of TG Erection

Boiler Hydro Test

Readiness of C&I for Boiler Light Up

TG Box Up

Boiler Light Up

Steam Blowing Start

TG on Barring

Commissioning of Unit # 1

COD Unit # 1

Commissioning Unit# 2

COD Unit # 2

NTPC LIMITED

KHULNA TPP (2x660 MW) - BANGLADESH

IMPLEMENTATION SCHEDULE

Date Revision Checked Approved

11.03.11 REV 0 (ISSUED FOR FR)

24.03.11 Rev 01 (CORRECTED AS ADVISED BY ENGG)

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Stamp

~ ( BOARD OF DIRECTORS • u • ~ \ CHAlRMAi" ) 0 ~ 0 CHIEF EXECUTIYE OFFICER ~

----------------------------r ---------------------------r

GE~T£RAL ::\U.XAGER

OPER\ TID);" & l\L\Ii"\rffEl\"...\.l'OCE )

:\L"\ TERIALS PL\.. "\')ril~G CO:"STRUCTION F~' A." CE .. ~ HUi\L\N RES. EQ'LlP1UE:\, :\L\... "AGDIEl\'T &SYSTDIS A CCOLl\1S DE\LOP:\IENT ERECTION

TECHi\"ICAL SER\lCES

l\lATh" POWER ( CW SYSTE:\I) ( OFFSITES) TOWNSHIP ) WORKS HOUSE ACCT.

L ( '!ECH. ( ELECr) (C &I 'YORKS ( CO:\"TRACTORS ACCT.

(o.'"St1.TA.'<1 ORGAL'lSATIO:\' STRUCTERE OF

I~I N TPC LLi'dITED

(A G("'~r1Il/It'1II of I I/di D Et/ftrpriu)

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Text Box

KHULNA THERMAL POWER PROJECT (2X660 MW), BANGLADESH

sksehgal

Text Box

KHULNA THERMAL POWER PROJECT (2X660 MW), BANGLADESH

sb042140

Text Box

JV CORPORATE OFFICE

khulna thermal power project

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