PRE-FEASIBILITY REPORT -...

PRE-FEASIBILITY REPORT

[15 MW COGENERATION PLANT]

Of

M/s CARGILL INDIA PVT LTD.

DAVANGERE

KARNATAKA

Pre-Feasibility Report for 15MW cogen thermal power plant in Devangere, Karnataka

1

INDEX

S.N Item Page Number

1 EXECUTIVE SUMMARY 2

2 INTRODUCTION OF THE

PROJECT / BACKGROUND

INFORMATION

3

3 PROJECT DESCRIPTION 7

4 SITE ANALYSIS 22

5 PLANNNING BRIEF 23

6 PROPOSED INFRASTRUCTURE 24

7 REHABILITATION & RESETTLEMENT

(R & R) PLAN

33

8 PROJECT SCHEDULE & COST

ESTIMATES

34


2

EXECUTIVE SUMMARY

Project 1 x 15 MW Thermal Power Plant

Project name

M/s CARGILL INDIA PVT LTD., KARNATAKA

Location of the project DAVANGERE, Karnataka

Longitude & Latitude 14.450564, 75.789487

Technology Coal fired Thermal Power Plant with Boiler & 15 MW Steam turbine

Fuel Imported / Indian Coal

Source of water River Tunga Bhadra

Water requirement 720CUM

Land envisaged

The proposed power plant will be established in the existing plant premises of 97 acres only. Project Location map and plot layout plan is enclosed as Annexure-1 and III

respectively for your kind reference. Total Project Cost of 15 MW power plant Rs. 9000.0 Lakhs

Project Implementation

16 months from the date of getting environmenta l Clearance , CFE from KSPCB & from the date of

Financial closure


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INTRODUCTION / BACKGROUND

Identification of project and project proponent

Power is the important infrastructure facility and is critical for the development of the economy. For a developing country like India, energy in the form of electricity is necessary and having its own importance. As economy grows the demand of power increases at a faster pace. As on today the demand of power is more than that of power generation. Further to say that it has been estimated by the World Bank that the demand of power will increase nearly twice that at which the economy grows. Power generation and its utilization in the form of electrical energy also reflects the living standard and prosperity of the nation.

If we look into the history of the power generation which was in the hands of few private industries before independence. After independence an act was framed in the year 1948 as Electricity Act 1948. As per this Act, one of the major points is the power generation, transmission and distribution was entrusted to the individual states and separate group has been formed in every state as State Electricity Board apart from the private participation at that moment.

Later on in the mid-seventies the government wanted to speed up the process of capacity addition as the demand was immensely high. Thus the generation, transmission and distribution was entrusted to NTPC, NHPC, PGCIL apart from the existing system of State Electricity Board and others.

A few years later in the year 1990, the act was amended for private participation in the power sector as Independent Power Producers (IPP) in the area of generation, for further boost up to the capacity addition process.

These all attempts of Government helped a lot in adding the capacity and improving the national average of plant load factor and strengthening the distribution network and in many other areas. But, still there is a gap observed between generation and its demand. For bridging this gap government’s efforts are continuous and in this process in the year 2003 lot of reforms took place. This time government wants to encourage more private participation in the energy sector so as to reduce the demand vs. generation gap. This is the back drop for getting good response from private sector to set up plant of various capacity adopting new technologies. With this kind of present power sector scenario for accelerating the capacity addition process it is necessary that the entire sector like state/public/private sector should participate actively.

CARGILL INDIA PVT LTD is India’s largest manufacturer of starch and starch derivatives. The company has plants in Viramgam (Gujarat), Gokak (Karnataka), and Pantnagar (Uttaranchal). Its products include corn starch powder, liquid and powdered glucose, modified starches, glucose D, dextrose monohydrate, maltodextrine, high-maltose corn syrup, and dextrose syrup. These products cater to a number of industries such as food processing, pharmaceuticals, paper, textiles, adhesives, inks, and paints.

CARGILL INDIA PVT LTD is a wholly owned subsidiary of. Roquette Freres (RF) is French Company. RF is the fifth-largest corn-processor and largest producer of polyols (sugar-free sweeteners) globally. It is also a leading global producer of starch derivatives.

M/s CARGILL INDIA PVT LTD is registered under the Companies Act 1956 on 2013. The promoters of CARGILL INDIA PVT LTD are working for manufacturing of Liquid Glucose and Spray dried Malto dextrin from Corn wet milling processs and also having a good background in project implementation. Now company proposed expansion of corn wet milling plant and power will be required for the Corn plant. Now the company proposed to establish new 15 MW thermal power in the existing plant premises


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Need for the project and its importance to the country or region

The power generation sector in India had an installed capacity of 205.34 giga watt as on June 2012. If we look into eleventh five year plan (2007 – 2012), the installed capacity of electricity sector in India is 199.88 giga watt as on end March 2012. This is apart from the captive generation capacity of 31.5 giga watt. Thus, India is the 5th largest power generating country by the end of the 11th five year plan (March 2012). The growth of installed capacity since sixth five year plan is shown in the table below: (all units in MW)

Plan/Year Thermal Nuclear Hydro

(Renewable)

RES (MNRE) Total in

(MW)

End of 6th

Plan

(31.03.85) 27029.70 1095.00 14460.02 0.00 42584.72

End of 7th

Plan

(31.03.90) 43745.57 1565.00 18307.63 18.14 63636.34

End of 2nd

Plan

(31.03.92) 48054.00 1785.00 19194.31 31.88 69065.19

End of 8th

Plans

(31.03.97) 61010.28 2225.00 21658.08 902.01 85795.37

End of 9th

Plans

(31.03.02) 74428.21 2720.00 26268.76 1628.39 105045.96

March, 2003 76762.15 2720.00 26766.83 1628.39 107877.37

March, 2004 77968.53 2720.00 29506.84 2488.13 112683.50

March, 2005 80902.45 2770.00 30942.24 3811.01 118425.70

March, 2006 82410.54 3360.00 23225.77 6190.86 124287.17

End of 10th

Plan

(31.03.07) 86014.84 3900.00 34653.77 7760.60 132329.21

March, 2008 91906.84 4120.00 35908.76 11125.41 143061.01

End of 11th

Plan

(31.03.12) 131603.18 4780.00 38990.40 24503.45 199877.03


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Demand – Supply Gap

Looking into the back ground it is observed that growth of power sector is the major criteria for the economic development of the country. If we look into the capacity addition with respect to year 1950 to the year March 2012 the generation capacity increased from 1713 MW to 199877 MW. Similarly the electricity generation increased from about 5.1 billion kWh to 876.1 billion kWh. At the same time if we see the per capita consumption of electricity which is also increased from 15 kWh in 1950 to about 814 kWh March 2012. However, the country continue to mismatch between demand and supply and experienced energy and peak shortage to the tune of approximately 10.3% during the year 2012.

Thus, at present India suffers a major shortage of power generation capacity even though it is the 4th largest energy consumer after United States, China and Russia. Further because of its development activities in industrial sector and others the demand will further increase in the next coming years. In general out of the available power spectrum like Hydel, Thermal, Nuclear and others renewable sources the thermal power generation is one of the best option as the low grade coal and water is the main requirement and are available. Even sometimes the coal washery rejects also can be utilized by blending it with low grade coal for which advanced technology is available.

Thus it has been observed from the energy demand and its supply position in the country which is leading to frequent power cuts, load shedding etc due to short fall in capacity addition. The above situation highlights the need for urgent measures to bridge the gap between demand and supply. To achieve this one of the major criteria is to go for rapid capacity addition by installing more and more thermal power station to cater the needs. The historic data of growth rate in demand is another major criteria to enter in the power sector and contribute an incremental addition in power generation.

Imports V/s Indigenous generation

Without enough local suppliers, India turned to China to help bridge a peak power shortage seen as an obstacle to matching its Asian neighbour's double digit economic growth. The sector's scope for growth is huge. India will soon become the world's largest buyer of power equipment, Maira said. It will spend around USD 140 billion on power infrastructure in the five years to 2012, close to half from the private sector, according to the latest Planning Commission estimates.

The electricity sector in India is predominantly controlled by the Government of India's public sector undertakings (PSUs). Major PSUs involved in the generation of electricity include National Thermal Power Corporation (NTPC), Damodar Valley Corporation (DVC), National Hydroelectric Power Corporation (NHPC) and Nuclear Power Corporation of India (NPCI). Besides PSUs, several state-level corporations, such as Tamil Nadu Electricity Board(TNEB) in Tamil Nadu, Maharashtra State Electricity Board(MSEB)in Maharashtra, Kerala State Electricity Board(KSEB) in Kerala, in Gujarat (MGVCL, PGVCL, DGVCL, UGVCL four distribution Companies and one controlling body GUVNL, and one generation company GSEC), are also involved in the generation.


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Inter-state distribution of electricity:

The PowerGrid Corporation of India is responsible for the inter-state transmission of electricity and the development of national grid. The Ministry of Power is the apex body responsible for the development of electrical energy in India. This ministry started functioning independently from

2nd July 1992; earlier, it was known as the Ministry of Energy.

India is world's 6th largest energy consumer, accounting for 3.4% of global energy consumption. Due to India's economic rise, the demand for energy has grown at an average of 3.6% per annum over the past 30 years. In March 2012, the installed power generation capacity of India stood at 199877 MW while the per capita energy consumption stood at 778 kWh. The country's annual energy production increased from about 190 billion kWh in 1986 to more than 876 billion kWh in 2012 (March).

The Indian government has set a modest target to add approximately 88,000MW of installed generation capacity during 12th five year plan. The total demand for electricity in India is expected to cross 950,000MW by 2030. About 76% of the electricity consumed in India is generated by thermal power plants, 20% by hydroelectric power plants and 4% by nuclear power plants. More than 50% of India's commercial energy demand is met through the country's vast coal reserves. The country has also invested heavily in recent years on renewable sources of energy such as wind energy. As of March 2012, India's installed Renewable generation capacity wind power etc stood at 12000 MW approximately. Additionally, India has committed massive amount of funds for the construction of various nuclear reactors which would generate at least 30,000 MW. In July 2009, India unveiled a $19 billion plan to produce 20,000 MW of solar power by 2020.

Electricity losses in India during transmission and distribution are extremely high and vary between 30 to 45%. In 2004-05, electricity demand outstripped supply by 7-11%. Due to shortage of electricity, power cuts are common throughout India and this has adversely effected the country's economic growth. Theft of electricity, common in most parts of urban India, amounts to 1.5% of India's GDP. Despite an ambitious rural electrification program, some 400 million Indians lose electricity access during blackouts. While 80 percent of Indian villages have at least an electricity line, just 52.5% of rural households have access to electricity. In urban areas, the access to electricity is 93.1% in 2008. The overall electrification rate in India is 64.5% while 35.5% of the population still lives without access to electricity. According to a sample of 97,882 households in 2002, electricity was the main source of lighting for 53% of rural households compared to 36% in 1993. Multi Commodity Exchange has sought permission to offer electricity future markets.


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PROJECT DESCRIPTION

Type of the Project:

M/s. CARGILL INDIA PVT LTD. , proposes to establish a new coal based power plant of 1 x 15 MW (Cogeneration power plant).

Location of the project:

The proposed thermal power plant will be established in the existing starch plant premises of Village Belludi & Taluk Harihar, Davangere District, Karnataka. Topographical map showing the location of the Plant site is furnished in Annexure II. The project layout is shown in Annexure II.

Details of the Alternate sites:

No alternative sites have been examined as the proposed Cogeneration plant will be established in the existing starch plant premises. The existing plant has a valid Consent to Operate from KSPCB.

Size or magnitude of the operation:

M/s. CARGILL INDIA PVT LTD., proposes to establish a new coal based power plant of 1 x 15 MW (Cogeneration plant) in the existing plant premises partly for captive requirement and the balance to be exported to the grid.

Process Details (Power Generation Process):

The Power Generation utility uses most commonly encountered Rankine based thermodynamic cycle. The facility generates electricity by producing steam in a steam generator and expanding the steam through a turbine that is coupled to generator. The steam is then passed to process department and around 40 % of the condensed water called condensate will be collected is again heated in the steam.The process parameters to be considered as per the below table:

Sl.No Description Parameters

Case 1 MP Process

LP Process

63 TPH /15 ata / 205 Deg.c

Nil

Case 2 MP Process

LP Process

60 TPH /15 ata / 205 Deg.c

3 TPH /5 ata / 155 Deg.c

Process Condensate return 40 % of process flow with 70 Deg.c

The steam generator (Boiler) requires water and coal. The water system will have pretreatment and demineralization plant. Pretreatment plant initially the water will be processed for removing the sediments and then processed for de-mineralized. The demineralization water is used in steam generator to protect the boiler tube.


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The coal handling system receive the coal inside the plant area by Road/Rail transportation system. The coal handling system then stacks, reclaims, crushes and convey the same to the bunkers near the steam generator. From coal bunkers the steam generator receives the coal for combustion. After combustion in the furnace area the flue gas passes through the steam generator used for producing the steam at required pressure, temperature and quantity. The flue gas after passing though electro-static precipitator where the fly ash in the flue gas gets precipitated and the flue gas then passes through a stack of adequate height as per CPCB norms.

Thus the steam generated at high pressure and temperature comes to steam turbine for expansion. Here the steam turbine converts the thermal energy to rotating mechanical energy. After the work done in steam turbine it goes to process for drying (Recoverable), cooking by direct Injection (non Recoverable) application. After Work done in the Drying application, steam become condensed and will be taken back to boiler as condensate. Apart from exhaust steam, number of steam extractions provided in the steam turbine and the extracted steam is supplied to the low and high pressure feed water heaters for the liquid regenerative heating which improves the thermal cycle efficiency.

The generator which is coupled to the steam turbine converts the mechanical energy to electrical energy. The electrical output will be 11 kV 3 phase 50 HZ. This electricity generated will be evacuated through 33 kV indoor HT panel and related transmission system to take care of entire plant demand and sometimes will be exported to the grid. The total plant system is well supported by the electrical and control & instrumentation systems. Thus, it is helping the operators to direct the plant operation for reliable and efficient production of electrical energy.

Main Plant Equipment:

a) Steam Generator: The steam generator will be designed based on the coal composition to achieve a good furnace management. The rating of the steam generator is: Steam rate : 100Tonnes/hr

Pressure : 110 ata

Temperature : 5400 + 50C

The boiler is of two pass, natural circulation type and this also contains economizer, super heater and other rotating parts as its auxiliary. The units are designed for ease of maintenance allowing operators to minimize the unit down time.

b) Steam Turbine:

The steam turbine will be of No of stages depending upon the suitability of the requirement and will have the parameters as below: Steam Turbine Power Output : 15 MW

Steam Inlet Temperature : 535 0C

Steam Inlet Pressure : 105 ata

The other parameters will be depending upon the type of turbine and will be specified on later stage. The turbine output is 11 kV, 3 phase 50 Hz. The other auxiliaries of the turbine are HP & LP heaters, motor driven boiler feed pump, extraction steam, deaerator like all other conventional type of steam turbines.


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c) Air cooled Condenser :

The air cooled condenser is designed for 0.20 kg/cm2 (a) during 100% TMCR for ambient design temperature of 40 deg C with KL/LL type aluminium type fins and 2 x 100 % horizontal centrifugal condensate extraction pumps.

Coal Handling System:

The coal handling system receives the coal and then crushes and conveys the same to the coal bunker. The coal handling plant receives the coal to a maximum size of 200 mm and after receiving, this coal goes to coal crusher house. Here, in the coal crusher the coal will be reduced from 200 mm size to 6 mm size before it goes for stacking. The coal from the stock yard will be transported to crusher house and other places by way of a conveyor system. The conveyor system consists of firefighting system in the form of fire detection and fire extinguishers

Ash Handling System:

The fly ash in the flue gas will pass through Electro Static Precipitator. Here the flue gas is ionized and the fly ash is then precipitated. The precipitated ash is collected in ESP hoppers. This ash will be sent to either concrete/or MS Silos by vacuum and pressurized system. Thus the collected ash in Silo will be disposed to the cement or brick manufacturing units for their requirement. The entire fly ash disposal will be in accordance with MOEF notification on fly ash utilization & its amendments thereof.

Water Treatment Plant:

The water received at site through a pipe line from the water source with the help of electrical motor driven pumps. The source is identified as River Ghataprabha. The water is treated first for its sediments in pre-treatment plant. Followed by clarifier, pressure sand filters & activated carbon filters. Thus, the total treated water will be used as follows:

1. Boiler water after demineralization

2. Fire water

3. Service water

4. Equipment cooling water

5. Auxiliary cooling water

6. Coal sprinkling water

7. Potable water

The total water requirement for Entire Cogen plant is 1445 KLD. Depending upon the design criteria and the quantity allocation by the state irrigation department reservoir will be constructed inside the plant area for storage of the water. In any case priority will be given to conservation of water, reuse of waste water, boiler blow down water, and other water will be put into reuse as far as possible.

The boiler make-up water will be treated in RO followed by DM plant for demineralization. The DM plant will consist of cation resin beds, de-gasifier towers, anion resin beds and mixed bed exchangers. Acid and alkali handling and storage system will be installed near the DM plant. The RO Reject and DM plant regeneration water will be treated in neutralization pit followed by Evaporator. Thus, the DM water produced in the plant will be stored in tanks for further use.


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Ventilation & Air-Conditioning System

For good environment, for operation and maintenance of the plant as well as for proper functioning of the equipment, controls and accessories, due consideration will be given for Ventilation and Air Conditioning System.

Ventilation System:

The ventilation system envisaged for the plant will achieve the following:

i. Dust–free comfortable working environment.

ii. Scavenging out structural heat gain and heat load from various equipment, hot pipes,

lighting etc.

iii. Dilution of air.

The following areas will be provided with suitable ventilation system, except for the Turbine building which will be provided with evaporative cooling with washed air system all other areas will be with dry ventilation system.

Turbine building

Air compressor room

DM plant MCC room

Miscellaneous room in power house building like cable spreader room, electrical

switch gear room, battery room, toilet, etc.

Workshop

The steam turbine hall in the power house building will be provided with air washer units and roof with roof mounted axial fans of sufficient capacity to meet the minimum air change requirement and to limit the temperature rise within the acceptable limits. All other building in the plant will be provided with either roof mounted exhaust fans or wall mounted exhaust fans of sufficient capacity to ensure the minimum number of air changes and temperature requirements. The cable spreader room electrical switchgear room, all MCC rooms will be provided with positive ventilation.

Air Conditioning System: Various control rooms in power station, housing a group of sophisticated and precision control panels and desks call for controlled environment for proper functioning and for personnel comfort. The following areas are proposed to be Packaged /Split air conditioned:-

a. Control room, control equipment room/UPS room located in power house

b. Electrostatic precipitator control room

c. DM plant control room

d. Packaged air conditioners will be provided adjacent to respective isolated areas


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Compressed Air Systems:

This system will supply air to the plant in two forms. One is in dry form which is used as Instrument air and another form is with or without drier and is used for service air.

The plant requires number of pneumatic valves for operating and these pneumatic valves required to be operated with the dry instrument air. The minimum air pressure in the line is to be

maintained around 6kgs/cm2 for operating these valves. Hence based on these criteria the design of instrument air will be finalized. The other important point is the valve operation. Stand by arrangements will be made available. Similarly the station service air requirement for normal cleaning, atomizing air medium for warm up of guns and igniters, motive power for burner drive mechanism etc. will be met from separate plant air compressors. This will be identical to the instrument air compressors and would run in same manner with stand by support. The capacity of all the compressors selected is to be of same, so as to achieve interchange ability of units and its parts.

Independent air receiver tanks will be provided for each compressor. Plant service air should have suitable interconnection with the instrument air header for augmenting instrument air supply in case of emergency for instrument air supply.

Fire Protection System:

For protection of the plant against fire, all yards and plant will be protected by any one or a combination of the following systems:-

a. Hydrant system

b. Non-Addressable type Fire detection & alarm system.

c. Automatic High Velocity Sprinkler System

d. Portable and mobile chemical extinguishers

The system will be designed as per the recommendation of Tariff Advisory Committee (TAC) of the Insurance Association of India. For containment of fire and preventing it from spreading in cable galleries, unit-wise fire barriers with self-closing fire resistant doors will be provided. The ventilation systems, if provided in the cable galleries, would be so interlocked with the fire alarm system that in the event of a fire the ventilation system is automatically switched off. Also to avoid spreading of fire, all cable entries/openings in cable galleries, tunnels, channels, floors, barriers etc, would be sealed with non-inflammable/fire resistant sealing material.

Fire Hydrant System (Centralized)

The source of water for the fire water pumps of the hydrant system, water spray and sprinkler system etc, will be taken from dead storage of Raw water storage tank. Two (2) electric motor driven fire water pumps with one (1) diesel engine driven pump as back-up for sprinkler system will be provided in the fire water pump house. These pumps will start automatically in the event of pressure drop in the header. In addition to these jockey pump sets hydro-pneumatic tanks, compressors, pipes and fittings as required will be provided. The hydrant system will feed pressurized water to hydrant valves located throughout the plant and also at strategic locations within the power house. Automatic type water spray (emulsifier) protection system would be provided for the following equipment:


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Grid transformer (11/33kV)

Suitable fire detection system as necessary for all the above mentioned firef ighting system with adequate supervisory circuitry will be provided. In addition to these, adequate number of

portable and mobile (wheel mounted) chemical fire extinguishers of foam, Water CO2 type and dry carbon dioxide type will be provided. Portable units would be placed at strategic locations throughout the plant area. The extinguishers may be used during the early stages of fire to prevent spreading.

Cranes & Hoists:

One electrically operated overhead crane will be put in use in TG hall. The capacity of the crane will be decided based on the design of steam turbine for using it during erection and operation and maintenance. Conventional and special type of cranes required for maintenance of steam generator, auxiliary and turbine generator auxiliary, condenser water box etc maintenance cranes/handling devices of suitable capacities have been considered for all other pump houses and other places as per the requirement. Apart from these mono trails and hoists will be used for lifting heavy motors and other equipment’s of the power house which are not covered by EOT cranes. In some cases suitable rails shall be provided for removal of internal parts such as heat exchanger and other.

Electrical Equipment’s

The design concept of electrical system as a whole is based on the requirements for the safe and reliable performances of steam turbine generator set and the inter connected electrical systems with provision of easy maintenance and over hauling. The design principle and standards delineated herein is generally in compliance latest IEC/IS standards and codes of practice already established in the country. Indian Electricity Rules wherever applicable will be complied.

Auxiliary Power System:

The power supply to power plant auxiliaries will be given from the HT switchgear fed by the auxiliary distribution transformer. Startup power will be taken from EB grid through 33kV MV Panel and Emergency power will be taken from 415V Emergency DG set. The capacity of the Auxiliary distribution transformer is selected on the basis that 100% running load and 30% of intermittent load excluding spare feeder and standby feeder loads. Considering 0.8 power factor for non-VFD load and 0.98 power factor for VFD loads and actual load factor with 10% design margin with due consideration to the starting of largest motor, system fault level, available breaker capacity and voltage regulation requirement. .

Batteries and Battery Charger Equipment

Common Direct Current power supply for protective relays, Emergency Oil pumps, Emergency Lighting will be made along with suitable charger having float cum boost facility. Battery will be SMF / VRLA type.

System Neutral Grounding:

Generator neutral will be grounded through a neutral grounding resistor.

33 kV systems neutral will be solidly grounded.

Other areas 415 V system grounding is envisaged as solidly earthed.


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Grid Transformer:

The output of the generator is connected to the 11KV MV panel. Further connected to 33KV HT panel through generator transformer with cables. The generator transformer is basically designed based on the output of the turbine and the power evacuvation system design and will be finalized accordingly.

LT Bus Duct:

The secondary’s of the LT auxiliary distribution transformers will be connected to the LT power control centres through LT bus ducts. The bus ducts will be non-phase segregated type with aluminum conductor with CRCA enclose. The continuous current rating of the bus ducts is selected considering the full load secondary current of the transformer.

HT and LT Breakers:

The breakers will be provided as per international and national standards. All the breaker capabilities are tied to the rated symmetrical breaking current, which is the value of current that the breaker is required to interrupt at rated voltage and on standard operating duty.

Motor Control Centre and Power Control Centre:

Motor control centres and power control centres will be of sheet steel cubicle and Non draw out type construction (Except ACB) and located for dust proof. The MCC and PCC will consist of vertical sections and each section having separate compartment for individual motors/drives/MCC feeders.

Power and Control Cables:

The HT power cables will have single and three core stranded aluminium conductor respectively, having extruded conductor screen cross linked polyethylene insulation consist of semi conducting layers bare copper screen and phase identification colour coding wrapped with filler core binder type, galvanized steel wire armor and extruded PVC overall sheath. The LT cables are of 1, 2, 3 or 3.5 core normal stranded aluminium conductor having heat resistant PVC insulation colour code wrapped with appropriate filler and core binder and enclosed in galvanized steel wire armour and an extruded PVC sheath.

All the control cables will be multi conductor, colour code with standard copper conductor of various sizes as per the voltage and pre insulated. Instrument cables will be of twisted multi-pa ir colour coded with stranded copper conductor of cross section 1mm2, PVC insulation and PVC outer sheath. The installation/laying of these cables are through trenches or above ground pipe racks etc. depending on the routing. Other Electrical Systems:

Illumination system/General lightning

Normal cum emergency lightning

Emergency DC lightning

Plant DC system

Uninterruptable power supply system

Emergency DG set

Grounding and lightning protection


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33 kV Indoor HT Panel:

33 kV HT panel will be provided for enhancing the power generated and then transported through 33 kV Cable Underground / overhead cable through Cable rack. The generators are connected to 33kV HT Panel through generator transformer. The control, monitoring and operation of the 33 kV Indoor type HT Switch Board will be through a operator interface station in the central control room of the power plant.

C & I Equipment and System:

Distributed control system

The instrument and control system will be provided with a Microprocessor based Distributed Control System (DCS) and a few other analog instruments and control devices. It will perform the functions of monitoring control, alarm, protection and interlock, diagnosing, accident treatment and maintenance guidance of the unit to meet all requirements at various operational conditions. The system will fulfill the following basic functions:

Monitor all major plant functions which are inputs to the DCS.

Provide the operator with a central, universal and instantaneous means to monitor the plant.

Collect and store data for trending of various plant functions. Keep track of various plant

events and record them for historical purposes.

Perform required basic calculations for performance monitoring and optimization.

Produce operating logs for record purposes and post trip review reports.

Provide sequence of events monitoring and reporting.

Perform self-checking and self-diagnosis.

Provide capability to add, delete and modify points from the system from by

means of conventional mode.

According to plant operation process, the distributed digital control system will be divided into three control levels: Unit control level, subsystem control level (function group) and drive control level. The fundamental functions such as control, alarm, monitoring, interlock and protection will be segregated, so that the failure of one does not result in the failure of the other function.

Alarm functions will be realized through CRT video alarms. A few conventional alarm windows are provided for the most critical items. Level of automation Monitoring and control of the unit will be centralized at CRTs and Keyboards. Unit normal operation, emergency treatment and other operation conditions will be performed automatically in the unit control room. Failure at any station will not affect the normal operation of other stations or the communicat ion system. Error checking will be provided to ensure that accepted message is just the same as that was sent. Transmissions of signals between system not located on Plant Island (e.g., coal handling, ash disposal, etc) will be via optical data highways.

Information gathering from the PLC systems located around the plant for different process like water treatment plant, Compressed air system, Fire Protection system etc., has to be made via the suitable communication protocol along with their corresponding physical media. Redundancy and self-diagnosis will be provided for the control system and communication network. The functions of the failed component will be transferred automatically, and bump lessly to the standby processor. The CRT and the alarm printer will display the failure message.


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The corresponding input and output circuits (digital input, digital output, analog input and analog output) are to be housed in the I/O module. All input and output in I/O modules are mutually isolated. Distributed digital Control System will be complete with all safety requirements/redundancy and the following:

VDU Equipment and Printers

Colour CRT

Operators keyboard

Software

Plant Performance supervising

Historical Data Storage and retrieval

System Communication

System Engineering Station

Performance Monitoring Subsystem (PMS)

Alarm Annunciation System

Sequence of Events Recording

System

Turbine Supervisory System

Operational philosophy:

The main plant systems like STG and auxiliaries will be operated through the Operator Console in Central Control Room(CCR). With the exception of auxiliary systems like Fuel handling, Desalination Plant, DM Plant, Compressed Air Plant, chlorination and AC & Ventilation all drives will be remotely operable: from operators console in the central control room.

The envisaged operation mode (Base load with normal fluctuations) will be governed by the C&I system. Unit start up/shutdown process will be performed manually by setting breakpoints associated with the initiation of functional groups, assisted by CRT operating guides. Those auxiliary systems which are not necessary to be managed directly in unit control room will be equipped with complete supervisory instrument and control equipment near the auxiliary system equipment or in a local control room. These systems will be monitored and controlled by PLC’s. Important supervising information will be sent to the DCS system.

All protection functions for plant as well as for individual equipment’s will run automatically without manual interventions by the operators. Also manual operation will be feasible in case of failure of auto system for control loops. The control system will meet the requirement for unit start up and shutdown.

The transfer between automatic and manual modes of operation will be bump less in either direction. The design of control system and related equipment will adhere to the principle of “safe operation” at all system level. “Safe operation” means that loss of signal, loss of Excitation of failure of any component will not cause a hazardous condition while at the same time prevent occurrence of excessive false trips.


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Control Philosophy

Mode of plant operation Centralized

Type of control Automatic

Mode of control system Distributed digital control system

System controlled and monitored by DCS Steam generated and its auxiliaries

Triple modular Redundant (TMR) or Turbine generators and its auxiliaries.

Dual redundant fail safe system BMS, T.G Protection (control &

Aux) Standalone control system with Critical

signals Interfaced to DCS for Monitoring purpose

only

BMS, T.G Protection (control &

Cooling water system

Electrostatic precipitator

Firefighting system

Air compressor system

WTP and DM Plant

Air-Condition ing and ventilation system.

Analyzers and Sampling System

Analytical instrument will be provided for continuous monitoring of steam, condensate, feed water and flue gas quality. A centralized analyzer room for steam/ condensate/ feed water sampling will be provided at a suitable location. The room will house (i) Dry section comprising electronics / transmitters for analyzers, (ii) Wet Section housing different steam processing equipment and measuring cells. This concept would minimize the maintenance effort and assure trouble free operation of analyzers. The electronic signal for Dry section will be hooked with DCS system.

Field Instruments:

Adequate number of local instruments will be provided to guide the local operator in his activities. All electronic transmitters will have IP-65 enclosure, all local indicators will have IP-55 enclosure and all pneumatic instruments will have IP-55 enclosure. All local instruments will be mounted at a convenient height of about 1.5 meters above ground or platform. For pressure, flow, level and differential pressure measurement, electronic transmitter with and output of 4-20 mA DC will be provided. All transmitters will be of SMART type. For temperature measurement in the range of 0-3000 C Platinum resistance thermometer will be used and in the range of 3000 C to 14000 C, thermocouple will be used. All T/C and RTD will be of duplex type. All control valves will be provided with valve positioned, local position indicator, limit switches, hand wheel, isolating and bypass valves. Wherever necessary, position transmitter for remote indication will be provided. Various switches for temperature, pressure and level as per requirement will be provided for alarms/ Trips.

Control of Electrical Equipment:

All interlocks, feedback signals and analog valves like voltage current, power etc., associated to one switchgear element within the MCC will be processed in the DCS. The DCS will issue control command to switchgear via interposing relays, which will be considered part of DCS.

Power Supply & Instrument Air Supply:

Power Supply System: The C&I system will be supplied with a 240 VAC uninterrupted power supply.


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Instrument Air Supply:

The C&I will be supplied with adequate instrument air supply from compressor, air dryer

assembly. Moisture and oil free instrument air at 8kg/cm2 and minus 400 C dew point will be used.

Civil Works:

General:

The type of foundation will depend upon the soil load bearing capacity and type. However, for all heavy equipment foundations and building foundations foundation of suitable type and capacity will be considered. For others Suitable of foundations can be considered. It is proposed to adopt RCC framed structure for the power house building. The floor slab will be cast-in-situ reinforced concrete. The cladding shall be of Brick/solid/Hollow block work with architectural finishes. Steel doors, window and rolling shutters, would be used for the plant building the floor finishes would be as required for the various uses.

The roads in the plant area would be of adequate thickness and width as per requirement of different areas. It is proposed to have WBM roads during construction stage and the same would be finished with bituminous surface at completion stage. Adequate plant roads/culverts. Grading and drainage shall be provided. The plant layout has been made in such a manner that adequate space is available for power block, Boiler house, storage yards, etc.

Power Block Area:

The building will be multi span framed structures consisting of structural RCC columns, beams and trusses. Main power house structure will be based in longitudinal direction and moment resistant in transverse direction. Main power building will comprise of turbo generator (AB) bay and multi level heater (BC) bay. All platforms and floors will be supported on RCC structures.

Conveyor Galleries & Transfer Points:

Overhead conveyor galleries in the main plant (Boiler area) will be of structural steel frame with cladding and roofing. Seal plate will be provided at road crossing. Transfer points and intermediate supporting trestles will be made of braced steel framed structures. The staircase will be of external type.

Plant Buildings:

Roof of TG hall will be provided with steel truss and colour coated metal sheet. Further skylight will be provided for natural light. Control room building will have brick wall on external face. Roof will be provided with electrometric membrane or other suitable water proofing treatment. Windows will be of aluminium. Doors of control room and office area will be of aluminium frame with glazing or particle board, wherever desired large glass panels with automatic door operation and in reflective glass will be provided. All fire exits will be provided with fire proof doors.


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Cable & Pipe Racks:

Structural steel trestles and galleries will be provided for supporting over head cables and pipes in the main plant and outlying areas. However, for blow ground routing. RCC trench with removable pre-cast concrete covers/box culverts will be provided. Pipes and cables supporting structure running along the boiler structure and ESP structures etc will be supported from steel bracket fixed to the boiler/ESP structure. Pipes and cable rack structures on C-row will be supported from steel brackets/from C-row column/frames.

Other Buildings:

ESP /AHS control room and WTP MCC room shall be of RCC framed structures.

Coal Handling Plant:

The civil works for coal handling system including crusher house and reclaim hopper (RH) other items will be provided. The reclaim hopper will be of Steel structure. The coal stockpile will be provided with drains all around (Strom water) and properly designed drainage system to be considered for fuel stack yard area. Transfer tower will be of structural steel framed structures supported on ECC pedestals. At ground level it will be provided with RCC paving inside the structures and 1 m wide plinth protection all around.

Crusher house (CRH) structures to be completely in RCC. At ground level it will be provided with RCC paving inside the structure and 1m wide plinth protection all around. Hand railing will be provided at all floors. Staircase will be provided as per requirement. Crushed coal stockpile area, excavating or filling of earth up to the required level will be done.

Non-Plant Buildings: (By Customer)

The Existing administrative building shall be renovated and shall be centrally air conditioned. All internal partitions shall and partially glazed in wooden frames. Canteen, Dining room for senior executives shall be air conditioned. Fire station building will be of RCC framed structure and side wall will be of brick/solid/hollow block masonry. Service building dormitory will be of RCC framed structure and plastered brick/solid/hollow block masonry. The watch towers at all corners of the plant boundary will have RCC elevated platform with roof. The security shed building will be of RCC framed structure and side wall will be of brick/solid/hollow/block masonry.

Construction Facilities:

Construction site office, storage area open and temporary workshop, garage, yard toilet etc are proposed. Sufficient area will be earmarked for various contractors to build their own facilities.

Roads

All roads in the plant area will be well designed bitumen roads. The main roads from the plant entry up to the main plant area 6 M wide with 1.0 m wide berm to accommodate large truck movement. All other main road will be 6m wide with 1 m wide berm on either side.

Secondary road will be 4.0m wide with 1.0m berm. The crown of the roads will be minimum 200mm above FGL. The final finished road will have of 1 in 60. Camber on top of water bound macadam surface will be 1 in 40.


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Paving:

Boiler, ACC, WTP and transformer areas will be paved with RCC slab 100mm thick in grade M15 and 230mm thick rubble soling will be provided below the paving. Higher thickness as required will be provided in area of vehicles movement.

Drainage:

Surface drainage will be designed based on the maximum rainfall intensity prevalent in the area over last 10 years. Building will be provided with plinth protection all around, sloped towards side drains. The side drains will be connected at the main drains on either side of the roads.

For pipe drains, concrete pipe class NP2 confirming to IS: 458 will be used. However for road crossing, class NP3 pipe will be used. If sufficient clearance cannot be provided between the top of pipe and road top, the pipe will be encased in PCC/RCC. For the process rain, catch pits will be provided at the source location and they will be interconnected buried RCC/CI pipelines and connected to waste water treatment plant.

Environmental Aspects:

To evaluate the effect of the proposed project on the surrounding environment, various factors such as effect on population in the vicinity, type of land use, possible emissions from various sources would be taken into consideration. The major environmental considerations due to burning of this fossil fuel:

Particulate Matter from the stack Gases like SOX, NOX, CO etc. from stack Fugitive emissions. Solid waste in the form of ash Liquid effluents from DM plant, cooling tower blow down, boiler blow down, filter

backwash, etc. Noise level generated due to steam generator and other rotary equipment’s during plant

operation. Hazardous waste in the form of used batteries, waste oil.

Pollution Monitoring & Control Equipment’s:

All required latest environmental protection measures will be provided in the proposed power plant. A separate Environmental management cell will be formed to look after the various aspects of pollution under the Environmental Management Plan established during the Plant Commissioning and Operation Phase. The major environmental protection equipment’s/syste ms are:

Electro Static Precipitator: During the process of combustion of coal, ash will be liberated in the form of particulate matter. In order to control the particulate matter from the flue gases coming out of the boiler a high efficiency electrostatic precipitator will be provided, where the flue gas will be ionised and the fly ash particles will be precipitated on to the electrodes and after periodic rapping, the particles will get collected in a hopper. The outlet particulate emission will

be less than 50 mg/Nm3.The collected fly ash will then be transported to Silos pneumatically for further disposal.

Control of SO2 emissions: Adequate stack height will be provided as per CPCB norms for effective dispersion of sulphur dioxide emissions into the atmosphere. MS stack will be provided based on the SO2 emission during the process of combustion of coal.


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Control of Fugitive Emissions: sources of fugitive emissions include unloading areas of coal, coal transfer points, coal conveying, vehicular movement, etc. In order to control the fugitive emissions the following measures will be provided.

IDENTIFIED SOURCE OF

FUGITIVE EMISSION

MITIGATION MEASURE

Coal transportation Covered trucks

Unloading of coal Dust suppression system

Coal Handling Plant Dust extraction system with bag filters

Coal transfer points Dust extraction system with bag filters

Coal conveying Covered conveyers to prevent flying of dust during conveying

Ash handling & storage Fly ash will be stored in silos.

Vehicular movement All internal roads will be made pucca

Ash disposal: The maximum ash generation will be around 57.1 TPD for Imported Coal or 171.3 TPD for Indian Coal. Of this quantity 20% is bottom ash and 80% is fly ash. The fly ash will be collected in dry form in silos constructed of either concrete or of mild steel. For collecting the fly ash in these silos the proposed plant will have vacuum and pressurizing system. The fly ash collected in silo in this process will be disposed to cement industries/ brick manufacturers. Fly Ash generated will be carried pneumatically into the silo, The Fly ash utilization will be in accordance with the MOEF notification of fly ash utilization. Fly ash will be given to cement plants/brick making units. Bottom ash will be used as bed material, given to brick making units.

Liquid effluent from water treatment plant & others: The liquid effluents mainly consist of CT blow down, Boiler blow down, DM plant regeneration water, filter backwash, etc.

To control and reduce this, a neutralizing pit will be provided in the plant, where the DM water effluents and boiler water will join. In the pit the pH value will be maintained by adding chemicals, acid/alkalies. The discharge of this neutralizing pit will join with the Plant Effluent and thereafter this will be used for the dust suppression in coal handling plant, dust suppression on roads, ash conditioning and for plantation.

Noise Level: The noise levels for all the equipment will be maintained as per the MOEF norms, OSHA standards. The major area of noise is steam generator & turbine. Acoustic enclosure will be provided to STG. Greenbelt will help in further attenuating the noise levels.

Green Belt (By Customer) : Adequate green belt will be developed as per CPCB guidelines in and around the plant area, avenue plantation along internal roads .Plantation near coal stock area and ash disposal area will be proposed for arresting the fugitive emission to certain extent. The plants will be selected in consultation with local DFO to suit to the native species in the area.


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Raw material required (Fuel requirement):

Following is fuel requirement for the proposed 15 MW thermal power plant:

S.N Fuel GCV

(Kcals/ kg)

Quantity

(TPD)

Source Method of

transportation

1 Imported Coal OR 4140 on AR 571 Indonesia By sea route, rail and road covered trucks

2 Indian coal 3970 on AR 580 SCCL,

Telangana By rail and road

covered trucks

Water requirement and its source:

Water required for the proposed 15 MW power plant will be met from Ghataprabha River. Total water requirement for proposed 15 MW power plant will be 1,445 KLD.

Employment generation:

The proposed project creates employment to 200 people during construction and existing staff are adequate for operation of the proposed project.


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SITE ANALYSIS

Connectivity:

COMPONENT DESCRIPTION

Road

Rail Harihar Railway Station: 8.0 KM

Air port

Hubli Airport : 148.0 KM

Sea Port

Land use:

The present use of the land is Industrial.

Topography:

The topography of the land is more or less flat without undulations.

Existing land use pattern:

The following is existing land use of the plant site

ITEM AREA IN ACRES

Process plant

Raw material & Finished product storage

Offices & Amenity space New Power plant

Farm land & Greenbelt Road (Present & proposed)

Parking area

Open area

Total

Soil Classification:

The soil in the site is red soil.

Climatic data from secondary sources: The prevailing climate is known as a local steppe climate. There is not much rainfall in Gokak all year long. This location is classified as BSh by Köppen and Geiger. The temperature here averages 25.3°C. About 150 mm of precipitation falls annually. The driest month is January. There is 0 mm of precipitation in January. In October. With an average of 29.1 °C, April is the warmest month. At 22.6 °C on average, December is the coldest month of the year. The variation in annual temperature is around 6.5 °C.


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PLANNNING BRIEF

Planning concept:

The proposed project is establishment of 15 MW Cogeneration power plant. The generated power will be used for captive use in Maize Processing plant. Whenever surplus power available, we will export to Grid.

Population Projection:

Unskilled Man Power required for the proposed Project will be met from the local villages. Qualified semi-skilled man power requirement will be met from local villages.

Land use planning:

The following is the land use planning of the proposed 15 MW Cogeneration power plant area:

S.NO. LAND USE AREA IN ACRES

1 Plant area : 0.96

2 Water Reservoir : 0.50

3 Internal roads : 1.20

4

5 Raw material storage &

CHP

: 0.80

6 Greenbelt : 1.80

Total : 5.56

Note: The above figures of the land use planning are approximately and will be projected exactly while preparing the detailed project report and designed based reports.

Amenities/ Facilities:

Facilities like canteen, rest room and indoor games facilities are already exists in existing plant hence the same will used for this plant.


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PROPOSED INFRASTRUCTURE

Industrial area:

The following is list of major plant and machinery that will be installed in the proposed project:

a) Steam Generator

b) Steam Turbine

c) Air cooled Condenser

d) Coal Handling System

e) Ash Handling System

f) Water Treatment Plant

g) Ventilation& Air-Conditioning System

h) Compressed Air Systems

i) Fire Protection System

j) Cranes & Hoists

k) Auxiliary Power System

l) Grid Transformer

m) Power and Control Cables

n) Tariff metering bay

o) Coal Handling Plant

p) Environmental Monitoring& Control Equipment’s

q) Ash Silo

Residential area (Non-Processing area):

Facilities like canteen, rest room and indoor games facilities has already been provided in the existing Plant. No other additional facilities are proposed.

Greenbelt:

Total 1.80 Acres of Green belt will be developed in the proposed project.

Social Infrastructure: Social infrastructure will be developed as per need based study in the villages.

Connectivity:

COMPONENT DESCRIPTION

Road 400m to SH-25 and 4.1 Km to NH-4

Rail 7km

Air Port 140km


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Drinking water management:

The workers at the plant during construction will be provided with water for their requirement and for the construction activities. The construction labour will be provided with sufficient and suitable toilet facilities to allow proper standards of hygiene. These facilities would preferably be connected to a septic tank and shall be maintained properly to have least environmental impact. Drinking water required for the workers will be sourced from ground water resources.

Sewage system:

Domestic waste water generated will be treated in septic tank followed by subsurface dispersion.

Industrial waste management:

The effluent generated will be cooling tower blow down, DM plant regeneration waste water and sanitary waste water. D.M. Plant regeneration water will be treated in neutralization tank. Treated effluent along with Plant treated effluent will be utilized for dust suppression in CHP, ash conditioning and for greenbelt development. No effluent will be discharged out of the plant premises.

Solid Waste management:

Solid waste generated from the proposed power plant will be Fly ash and same will be given nearby Cement manufacturing units/brick manufacturing units. Ash disposal will be in accordance with norms.

Power requirement & supply / sources:

The generated power will be evacuated by 33 kV lines. To this extent the switch board of 33 kV will be located in the plant TG building and thereafter it will be transported through 33 kV lines to the nearest point of Karnataka State Electricity Board Sub-station. Depending upon the situation the company will enter into power purchase agreement either with SEB or third party. The power required for the industry will be used as auxiliary consumption from power generated.

Electrical distribution will be considered as per enclosed single line diagram with required

terminal points between purchaser and bidder.


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7.0 REHABILITATION & RESETTLEMENT (R & R)

PLAN

No rehabilitation or resettlement plan is proposed as there are no habitations in the Plant site.


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8.0 PROJECT SCHEDULE & COST ESTIMATES

The project proposed will be implemented in 16 months from the date of getting the Environmental Clearance and CFE from KSPCB. Latest technology will be selected depending upon the various technical criteria and environmental aspects. It is proposed to execute the project by engineering procurement and construction basis either in two packages or single package i.e. BTG as one package and BOP (Balance of plant) in another package. To ensure the quality control team of engineers in respective disciplines will be deployed either by direct appointment or by deploying consultant engineers. Necessary help will be extended to contractors/associates for initial mobilization ad during the project execution.

Testing & commissioning group including operation and maintenance will be deputed for pre- commissioning checks and final commissioning of various plants. The project networks will be prepared for project monitoring with the help of EPC agency and owner engineers.

S.N PARTICULARS AMOUNT (Rs. In Lakhs)

1 Land : NIL

2 Land Development & Civil Works :

3 Plant & Machinery :

4 Preliminary & Pre-Operative Expenses :

5

Margin Money for Working Capital

& Contingency

:

Total :

MEANS OF FINANCE

1 PROMOTERS : 100%

2 TERM LOANS : NIL

Total : 100%


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Annexure I

Project Location map


36

Annexure -II Project site on toposheet


37

Annexure –III – Plot Layout map


38

Annexure –IV Water balance diagram

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