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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

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


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
Document No.:9635-999-NOG-J-001 R ’C’ (Dec.12) Page ii of xi
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

Document No.:9635-999-NOG-J-001 R ’C’ (Dec.12) Page iii of xi


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

Document No.:9635-999-NOG-J-001 R ’C’ (Dec.12) Page ix of xi


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, IV


(+) 17.0 M, (+) 24/25 M, (+) 32.8 M, (+) 38/41 M
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.

Page 2 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

Page 3 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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.

Page 4 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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 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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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:

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. Description Drawing No. Exhibit
No. No.
1. Main Plant Layout Plan at 9635-999-POM-F- 3
EL (+/-) 0.00 m. 001 (Rev. 0)

2. Equipment Layout Plan at 9635-999-POM-F- 4


EL (+/-) (+) 8.5 m, (+) 17.0 m 002 (Rev. 0)
(+) 24 m, (+) 32.8 m, (+)
38/41m

3. Main Plant Cross-Section 9635-999-POM-F- 5


003 (Rev. 0)

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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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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
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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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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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.

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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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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. 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

1.02.00 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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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 660 MW (In case of static


Maximum Continuous Rating excitation system, the
(EMCR) at Generator terminals EMCR output at generator
with Cycle make up of 3% of terminals shall be 660 MW
throttle steam flow and design plus excitation power
condenser pressure. requirement at EMCR).
ii) Turbine throttle steam pressure 247 kg/cm2 (abs)
iii) Turbine throttle Main steam/ 565 O C/593 O C
Reheat Steam temperature.
iv) Variations in rated Steam As per IEC-45.
temperature & pressure
V) Pressure drop in reheat circuit 10% of HPT exhaust
i.e between HPT Exhaust & IPT pressure.
inlet.
vi) Condenser pressure with CW 77 mm of Hg
temperature of 33 Deg C
vii) Turbine speed 3000 rpm
viii Frequency variation range from (+) 3% to (-5%)
rated frequency of 50 Hz (47.5HZ to 51.5HZ)
ix) DM Water make up to thermal 3% of throttle steam flow
cycle under EMCR condition.
x) Final feed water temperature at 287.5 (+/-) 2.5 deg C
100 % TMCR & at EMCR
condition.
xi) Turbine protection against water As per ASME-TDP-1(latest)
induction.
xii) No. of extractions for As per cycle optimization by
regenerative feed water heating the bidder.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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:

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
(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
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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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.

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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
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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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

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 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.
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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.

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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.

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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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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)

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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:

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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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

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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.

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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,
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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

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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
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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. Measures Benefits
No
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 126.00
Plant, CMB etc.) --- abstract civil
cost
6. Ash Management & Utilization 4377.00
Total 12561.00

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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 80,00,000 cum
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.
3 Scarifying the slopes of filling, 75,000 sqm
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.
4 Providing and placing 150mm 75,000 sqm
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS

5 Providing and hand packing the 75,000 sqm


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.
Ground Improvement
1 Installation of sand compaction 16,00,000 RM
piles of 900 mm compacted dia (For Main
with specified c/c spacing as Plant)
shown in the construction
+
drawings, as per specifications
and as directed by the Engineer 4,25,000
including mobilization of all plant, (For Ash
equipment, manpower at site Dyke)
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.
2 Laying of sand blanket over sand 6,50,000 cum
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.

1.03.00 Boundary wall & Fencing


1 Boundary wall 6 Km

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Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS

2 PVC Chain link Fencing 2 Km

1.04.00 Roads, Bridges, Culverts,


Drains, Railway Siding
A Roads
1 Double Lane Bituminous Roads 15 km
(Inside Plant)
2 Single Lane Bituminous Roads 5
with shoulders (Inside Plant)
B Drains in Main Plant
1 Rectangular Concrete Trunk 2 Km
drains
2 Rectangular Concrete Catch 35 Km
drains

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, 48500 MT
fabrication & erection)
3 Electro Forged Gratings 750 MT
4 Stainless steel (ASTM A240 type 180 MT
304 Stainless steel)
5 MS Black Foundation Bolts & 400 MT
Nuts

1.06.00 Piling & Foundation


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

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Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS

1.07.00 General Civil Works


This includes civil and LOT
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

1.08.00 Chimney
275 m Twin flue steel lined 1 No.
RCC chimney with staircase and
elevator.

1.09.00 Enabling Works


1 CHP office cum maintenance 500 Sqm
building
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.

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Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS

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 01 No


servant qtr and garage
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 59 No


Barracks
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 1800 M2


Workshop)
2 Trainees Hostel (40Rooms) 2000 M2
3 Hospital (50 bed general hospital 3000 M2
with support facilities)

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Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS

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 200 M2
the Project)
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 300 M2
12.5Mx 25M))
Area for change room & filtration
plant)
22 Sports Complex (With Grand 1000 M2
Stand & Play Field)
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

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PARAMETERS

1.10.00 Coal Handling Plant


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

1.11.00 Ash Dyke (100 acres) LOT

1.12.00 Ash Handling System LOT


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

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PARAMETERS

1.13.00 CW & MUW System


CW system for the project LOT
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.
1.14.00 Desalination, DM plant, CPU
and effluent treatment
system
Complete RCC structures for LOT
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.
1.15.00 Switchyard Civil/ Structural
Works
Towers & equipment foundations LOT

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PARAMETERS

2.00.00 MECHANICAL WORKS


2.01.00 Steam Generator & 2 Sets Supercritical Boiler
Associated Auxiliaries
Type: a) Supercritical with
Circulation : Drum/once through Single Pass
Draft : Balanced/Forced (tower)/ Double
Pass arrangement
Furnace bottom : Dry/Wet 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 568o C


outlet
4. Temperature at reheater outlet 596o C

5. Exit Flue gas Temp. at chimney later


inlet
6. Efficiency based on later
performance coal at TG rating
2.01.02 Description / Quantity / Spec.
(For Each Set of SG)
1. Main Boiler pressure parts with yes
enclosure, boiler structure
including all platforms, stairs,
walkways, ladders, handrails,
galleries etc. (yes/no)
2. Soot blowing systems with yes
controls (Yes/No)
3. Start-UP Drain Circulation 1 No 1X100% (upto 30%
Pump BMCR)
4. Air preheaters with water Rotary Regenerative,
washing facilities, fire fighting Bisector type
equipments 2 Nos. Primary APH

Page 82 of 153
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PARAMETERS

2 Nos. Secondary APH

5. SCAPHS (nos. per boiler) 4 Nos. Two for PA & Two for
SA
6. Milling plant with feeders, PA To be decided
fans, seal air fans and drive by the
motors. supplier Mill: Vertical spindle
subject to PA Fan: 2X60%
a. Pulveriser
specified Variable Pitch Axial
b. Feeder criteria fans
c. PA Fan 2 Nos.
Seal Air Fans: 2 X
d. Seal Air Fan 2 Nos. 100% Common for all
Mills
7. Draft plant including

a. ID fans axial type with drive 2 Nos. ID fans: 2X60%


motor and accessories. Variable Pitch Axial
fans with drive motor.
b. FD fan axial type with drive 2 Nos. FD fans: 2X60%
motor and accessories. Variable Pitch Axial
fans with drive motor.
8. ESP & ESP accessories with Lot Inlet dust burden - Later
control system Outlet dust burden -
100mg/Nm3
9. Passenger cum goods elevators 2 Nos. Capacity: 1 no. 3000 kg
with all controls for SG and 1 no. 1088 kg
10. Ducting, dampers, expansion 1 Lot
joints etc
11. Refractory, insulation and 1 Lot
cladding
12. FSSS with SADC system 1 Lot

13. Coal and Oil Burners 1 Lot

14. HFO/LDO Pressurization 1 Lot Common for two (2)


System with heaters and other units
accessories including
interconnection with existing
Storage tanks

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PARAMETERS

15. Miscellaneous
1. Spares Lot
2. Maintenance Tools & Tackles Lot
16. Auxiliary boiler with all 1 No. Common for two (2)
associated auxiliaries of 60 units
T/Hr. capacity with rated steam
parameters at SH outlet as
19kg/cm² (gauge) pressure and
250°C temperature.

1. Turbine, Generator, Exciter and 1 Set EMCR power output


660 MW (In case
. Auxiliaries per unit 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 247 kg/cm2 (abs)
Pressure
Turbine MS & HRH 565 deg C/593 deg C
Temperature
Final feed water temperature at 287.5 (+/-)2.5 deg C
100 % TMCR heat rate (HR) &
at EMCR condition.
Condenser pressure with CW 77 mm Hg abs
temperature of 33 deg C
CW Temperature 33 o C / 36 o C
(Design/Maximum)
2. Boiler feed pump with booster pumps couplings, drives and accessories

a. Turbine Driven 2 No 2x50% Capacity


Boiler Feed Pumps
per unit

b. Motor Driven Boiler 2 No 2x30% Capacity


Feed Pumps per
unit

3. Condensate Extraction Pump 3 No 3x50% capacity

Page 84 of 153
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PARAMETERS

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 1 No Sponge Rubber Ball


cleaning system (for each half type
of condenser per Unit)

6. Condenser Air Evacuation 2 No 2x100% capacity.


Pump per Unit

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

10. Central lube oil purification 1 No. Clean and dirty oil tank
system for all units. capacity 1.5 times the
capacity of MOT.
Centrifuge capacity
same as unit
centrifuge.

11. Turbine hall EOT Cranes for all 2 No Main Hook of each
units. crane shall be capable
of lifting at least 105%
of the weight of single
heaviest component/
equipment, including
lifting beam and slings
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PARAMETERS

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.

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PARAMETERS

2.03.00 Piping
1 Power Cycle Piping including LOT Lot for 2 units.
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.
2 Station piping with valves, LOT Lot for 2 units.
fittings etc.

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

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PARAMETERS

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, 92 Nos. M.S. fabricated, 1200 mm
bend & take-up) av. Dia 630 mm
a) Drive pulleys 4 Nos. M.S. Fabricated, 1800 mm
face width, dia 800 mm dia
b) Other pulleys, (Tail, snub, 36 Nos. M.S. fabricated, 1800 mm
bend & take-up) av. Dia 630 mm
7 Drive motors for conveying 12 Nos. HT Motor
system
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
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PARAMETERS

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 Nos. For Raw coal (-)50mm (for
(one 2000 TPH conveyor) (as
each) 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 2 Nos. 2000 TPH rated, ring
drive unit granulators
26 Vibrating Grizzly screen with 2 Nos. 2000 TPH rated
all accessories
27 Vulcanising Machine 2 Nos. (1 no. for 1200 mm belt
width & 1 no. for 2000 mm
belt width)
28 Passenger cum goods 2 Nos. 1 Te capacity (Rack &
Elevator 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 Lot Typical
Package AC
32 Service water system, Potable Lot Typical
Water System and Cooling
water system
33 Mandatory spares Lot Typical
34 Special tools & tackles Lot Typical

35 Vibration Monitoring System 1 Nos. For crusher house


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PARAMETERS

B CHP Electrical and Controls


1 Complete CHP electrical, Lot Typical
control & instrumentation &
associated facilities
2 Main CHP Control Room 1 nos.

3 WT Control Rooms - -

c) CHP Structural & Civil Works

1. a) Double conveyor gallery C.S. 1070 mtrs. Structural steel fab.


2.7m x 6.6 m internal
For 1200TPH (1000 mm Belt
Width)
b) Double conveyor gallery C.S. 100 mtrs. Structural steel fab.
2.7m x 6.6 m internal
For 2000 TPH (1600 mm Belt
Width)
c) On ground double conveyor 450 mtrs. Structural steel fab.
gallery C.S. 2.7m x 6.6 m
internal
For 1200 TPH (1000 mm Belt
Width)
d) On ground double conveyor 140 mtrs. Structural steel fab.
gallery C.S. 2.7m x 8 m
internal
For 2000 TPH (1600 mm Belt
Width)
e) Single conveyor gallery (CS 100 mtrs. Structural steel fab.
2.7m x 4 m)
For 1200 TPH (1000 mm Belt
Width)
f) Single conveyor gallery (CS 200 mtrs. Structural steel fab.
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)
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PARAMETERS

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 Belt Rating : 1600mm
1641 m wide synthetic, cover thick
Belting 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

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PARAMETERS

a) Drive pulleys 1 Nos. M.S. Fabricated, 1800 mm


face width, dia 800 mm dia
b) Other pulleys, (Tail, snub, 6 Nos. M.S. fabricated, 1800 mm
bend & take-up) av. Dia 630 mm
7 Drive motors for conveying 1 Nos. HT motors
system 500 kW

8 Reduction gears 1 Nos. Helical type with integral


hold backs for drives in
Sl.No.7
9 High speed coupling 1 (Scoop-1 Nos. Fluid couplings for drives
Traction-0) 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, Lot Typical
Potable Water System and
Cooling water system
21 Mandatory spares Lot Typical
22 Special tools & tackles Lot Typical

B. CHP Electrical and Controls


1 Complete CHP electrical, Lot Typical
control & instrumentation &
associated facilities
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PARAMETERS

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 400 m
hood over conveyor on ground
c. Open Single conveyor gallery with 200 m Structural steel fab.
hood over conveyor elevated (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 2 Nos. MS, fixed roof type, 2000
suction heater, floor coil heater, Cu M capacity
insulation, cladding, accessories,
instruments etc
2. LDO storage tanks complete with 2 Nos. MS, fixed roof type, 500
all instruments and accessories 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 1 Nos. 6 Cu M
in the pump house area.
5. Condensate Flash Tank 1 No. 6 Cu M
6. Unloading pump motor sets 6 Nos. Twin-screw, 100 Cu M/hr
(HFO/LSHS/HPS)
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. 2 Nos. 20 T/hr
steam
10. Unloading pump suction strainers 18 Nos. 200NB
11. Fuel oil unloading hoses, steam 10 Nos. 75NB-8M Long for HFO
and condensate hoses 50NB-8M Long for Steam
10 Nos. 50NB-8M Long for
Condensate
10 Nos. 75NB-8M Long for LDO

05 Nos.
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PARAMETERS

12. Drain oil pumps to collect the 2 Nos. Single screw, 10 Cu M/hr
drains from the drain oil tank and
pumping it back to the main tank
(HFO/LSHS/HPS)
13. Dirty oil pump for pumping out Dirty 2 Nos. Single screw, 5 Cu M/hr
oil from the oil water separator unit
14. Sump pumps 2 Nos. Centrifugal, 30 Cu M/hr
15. Water pump for pumping out clear 2 Nos. Centrifugal, 30 Cu M/hr
water from the oil water separator
unit
16. Design of oil water separator pit Lot
along with facilities for removal of
water and oily waste
17. Complete fuel oil piping, steam Lot
tracers, condensate piping, valves,
fittings, steam traps, insulation
hangers and supports etc
18. Instrumentation and control system Lot
including instruments, interfacing
with main plant control room,
protection devices
19. Flow meter
For HFO unloading system 1 No. 500 Cu M/hr for
HFO/LSHS/HPS
LDO unloading system 1 No. 50 Cu M/hr for LDO
20. HOT crane in FO unloading pump 1 No. 2 tons
house (Hand operated Monorail
Hoist)

2.06.00 Ash handling System

2.06.01 Bottom Ash Handling System

1 Dry bottom ash hopper 2 Nos 30TPH


Hydraulic power pack, extractor, chain
2 2 Nos 200 bar
drive, chain
Primary and Secondary crushers( 15 TPH (primary- 4nos,
3 8 Nos
clinker grinder) secondary 4 nos)
Conveyor for Dry BA to BA buffer
4 2 nos 100 M length each
hopper

5 Dry bottom ash extraction compressor 1200 m3/hr, 5 kg/cm2,


2 Nos
200 kW
BA Transport air receiver MS 10 mm
6
thk
2 Nos 10 m3

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PARAMETERS

7 Intermediate silo for Bottom Ash 2 Nos 7.5 Tonnes


8
BA Buffer hopper aeration blower and 100 m3/hr, 0.9 kg/cm2, 10
heater along with drive and motor 2 Nos
kW
9 Air lock / Pump tank 4 Nos 5 m3
Rotary segregating valve with
10 8 Nos 300 NB
pneumatic cylinder
Equalizer valve with pneumatic
11 4 Nos 100 NB
cylinder

12 BA dry transportation pipe 250 NB( MS 9.52mm


2000 M
Thick)
13 Chute isolation valve 4 Nos 300 NB
Bottom ash Structural steel silo
14 complete with staircase, structure, 1 Nos 100 T
platforms etc. for HCSD

15
BA Silo aeration blower and heater 400 m3/hr, 0.9 kg/cm2, 10
along with drive motor 1 Nos
kW
16 Target box 1 Nos
Bag filter with pulsing arrangement for
17
BA silo 1 Nos 1500 m3/hr
18 BA Silo vent fan 1 Nos 1500 m3/hr
Rotary feeder with variable frequency
19 3 Nos 100 TPH
drive
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
8 No. 300 NB
operated-alloy CI
Segregating valve-pneumatic
2 No. 250 NB
operated, alloy CI
Extraction pipe as per
IS:1536/BS1211 Class D with 400 m 250 NB
sleeve couplings and fittings.
Liquid seal ring vacuum pump with
2 No. 2000 m3/hr,16 Hg, 50KW
drive and accessories

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Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS

Buffer hopper with alloy CI liners,


1 No. 10T
supporting structure, platform etc.
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
4 No. 300 NB
pneumatic cylinder slide
Equalizer valve with pneumatic
2 No. 100 NB
cylinder
Chute isolation valve 2 No. 300 NB
2.06.03 Ash Water System

Bottom Ash LP water pumps with 100 m3/hr, 20 mWC, 50


1 2 No.
Drive Motor and accessories. KW
FAHP Water Pumps with Drive
100 m3/hr, 80 mWC, 120
2 Motor & Accessories for HCSD 3 No.
KW
pumps
3 PIPES
A. MS PIPES
(i) IS- 3589 LOT
(ii) IS- 1239 HEAVY GRADE 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
a) Suction - Butterfly 3 No. 200 NB
b) Discharge - Butterfly 3 No. 150 NB
c) Check 3 No. 150 NB
iii) Fly ash conditioner booster
water pump
a) Suction - Butterfly 5 No. 150 NB
b) Discharge 5 No. 100 NB
c) Globe 5 No. 100 NB
d) Check 5 No. 100 NB
e) Bottom ash hopper make
2 No. 200 NB
up - Butterfly
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PARAMETERS

iv) Misc. 300 No. 40 to 200 NB


v) Pendant controlled overhead
1 No. 7.5 tonnes
travelling crane
ALT I - Vacuum Conveying
2.06.07
System
1 Chute Isolation Valves-CI 232 No. 300 NB
2 Material handling valve-pneumatic
232 No. 300 NB
operated-alloy CI
3 Segregating valve-pneumatic
34 No. 250 NB
operated, alloy CI
Extraction pipe as per
4 IS:1536/BS1211 Class D with 2000 m 250 NB
sleeve couplings and fittings.
5 Liquid seal ring vacuum pump with 4000 m3/hr,16 Hg, 75
8 No.
drive and accessories KW
10 Nm3/min, 8 kg/cm2,
6 Instrument air compressor with
4 No. 90 KW, Horizontal,
drive and accessories
reciprocating
Instrument air dryer SILICAGEL 10 Nm3/min,
7 4 No.
TYPE
8 Air receiver for instrument air 4 No. 5 m3
FA line for APH. IS: 1536/BS1211
9 Class D with sleeve couplings and 500 m 250 NB
fittings.
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
Material handling valve –
2 pneumatic operated 232 No. 300 NB
(dome/cone/plate/butterfly)
Ash discharge valve – pneumatic
3 232 No. 300 NB
operated
Segregating valve – pneumatic
4 34 No. 250 NB
operated

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PARAMETERS

232
5 Air lock/pump tanks MS 10 mm thk No. 2 m3

6 Extraction pipe, ALLOY CI 1800 m 200 NB


Extraction air compressors 2100 m3/hr, 7 kg/cm2,
7 4 No.
alongwith drive motor etc. 250 KW
Extraction Air Dryer – refrigerant
8 4 No. 2100 m3/hr
type
10 m3/min, 8
9 IA compressor 4 No.
kg/cm2,90KW
10 IA dryer-Silica gel type 4 No. 10 m3/hr
11 Expansion joints 232 No. Metallic bellows -SS
Air receiver
12 i) For instrument air 4 No. 5 m3
ii) For extraction 4 No. 5 m3
FITTINGS
13 i) 45 deg 360 No 250 NB
ii) 90 deg 60 No 250 NB
Pendant controlled overhead
14 1 No 10 T
traveling crane
2.06.08 Dry Fly Ash Transportation
System upto HCSD Silo
Buffer hopper with alloy CI liners,
1 8 No. 20 m3
supporting structure, platform etc.
2 Target Box 8 No.

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

4 Pressure/Vacuum relief valve 8 No.


8000 m3/hr, 2.5 kg/cm2
5 Transport air compressor with VFD 4 No.
300 KW
Transport Air dryer – refrigerant
6 4 No. 8000 m3/hr
type
7 Air lock/pump tank 16 No. 5 m3

8 Rotary segregating valve with


32 No. 300 NB
pneumatic cylinder slide
9 Equalizer valve with pneumatic
16 No. 100 NB
cylinder

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Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS

10 FA transportation pipe 2500 m 350 NB

11 Chute isolation valve 16 No. 300 NB

12 Buffer hopper aeration blower and 300 m3/hr, 0.9 kg/cm2 ,


4 No.
heater along with drive and motor 15 KW
13 Transport air receiver 4 No. 10 m3 , MS 10 mm thk
Structural steel silo complete with
14 staircase, structure, platforms 2 No. 100 T
etc.(HCSD)
Silo aeration blower and heater 400 m3/hr, 0.9 kg/ cm2
15 along with drive and 3 No.
accessories(HCSD) 25 KW

16 Target box (HCSD) 2 No.


Bag filter with pulsing
17 2 No. 10000 m3/hr
arrangement(HCSD)
18 Silo vent fan(HCSD) 2 No. 10000 m3/hr, 30 mmWC
Hydromix dust conditioner with
19 6 No. 50 TPH, 25KW
drive
Rotary feeder with variable
20 6 No. 50 TPH
frequency drive
Telescopic chute with motorized
21 2 No. 100 TPH
winch
Sump drain pump for silo area
22 2 No. 80 m3/hr, 50 mWC, 20 KW
along with drive motor
23 Bends (alloy CI/basalt)
i) 90 deg 40 No. 300 NB
Pendent controlled overhead
24 1 No. 15 Tonnes
travelling crane
Air Conditioning & Ventilation
2.06.09
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

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PARAMETERS

60 m3/hr, 60bar, 200 kw


1 HCSD Pumps 3 No.
motor (2W + 1S)
2 Seamless MS Pipes 12 Km 150 NB – 12.7 mm thick
30 m3 with 50 KW
3 Agitator tank for HCSD pumps 3 No
Motor
Peristaltic pump complete with
drive, Density measurement,
4 3 LOT One lot for each pump
Pressure transmitters, Pipe loop
piping, shut-off and drain valves .
Pendent controlled overhead
5 1 15 Tonnes
travelling crane
Silo system at Plant boundary
2.06.12
for Ash Utilization
meter
1 FA transportation pipe 4000 350 NB
s
Structural steel silo complete with
2 2 Nos 500T
staircase, structure, platforms etc.
Silo aeration blower alongwith drive 400 m3/hr,0.9 kg/cm2,25
3 3 Nos Kw
motor
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

Hydromix dust conditioner with


7 2 Nos. 100 TPH,25 KW
drive

Rotary feeder with variable


8 4 Nos. 100 TPH
frequency drive
Telescopic chute with motorised
9 2 Nos. 100 TPH
winch
Sump drain pump for silo area
10 2 Nos. 80 M3/hr, 50 MWC, 20 KW
alongwith drive motor
Wash water pumps along with
11 2 Nos. 50 M3/hr, 15 MWC,5 KW
drive motor
Fly ash conditioner booster water
12 3 Nos. 40 M3/hr
pump along with drive motor
7.5 KG/CM2 15 KW
13 Bends (alloy CI/basalt)
90 deg 24 Nos. 350 NB

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PARAMETERS

Pendent controlled overhead


14 1 Nos. 2Tonnes
travelling crane
AWRS system
30m3/hr , 50 MWC,
1 AWRS Pumps 2 nos
50KW
2 MS Pipes 3 Kms 100NB

2.07.00 WATER SYSTEM


2.07.01 Make-up Water System
Makeup Water pumps (for CW 3 nos Each of 3700 M3/hr & 20
System) MWC
Vertical type: Motor rating:
280 KW
Lub.water pumps for Makeup 3 nos Each of 15 M3/hr & 40
Water pumps MWC
Vertical type: Motor rating: 3
KW
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 LOT Impressed current type
make up water pipe from river to system
Plant

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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.

COOLING WATER SYSTEM


2.07.02
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 2 nos 2600 NB size
operated) Valves
Monorail hoist 2 nos 2 tonne
Cooling Towers 2 nos Induced Draft Cooling
Towers;

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PARAMETERS

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 2 nos Each of 1800 M3/hr & 35


Desalination System) MWC
Vertical type: Motor rating:
235 KW
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 5000 M 650 mm dia – 6.3 mm thick
desalination system , 3L-PE coated
Cathodic protection system for the LOT Impressed current type
make up water pipe from river to system
Plant

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PARAMETERS

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.

EQUIPMENT COOLING WATER


2.07.04 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 4 sets Two for one unit
dosing system (SG / TG).
Interconnecting piping, valves,
fittings, instrumentations & control
Interconnecting piping, valves, LOT
fittings, instrumentations & control
Note:
Material of Construction of Pumps, Valves, PHE Plates (Titanium) etc shall be suitable
for handling sea water

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PARAMETERS

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

DESALINATION PLANT
2.07.06
Complete Desalination Plant LOT RO 1st Stage: Net Capacity
including required Pre-treatment : 600 Cu.m/hr
System, chemical Dosing (3 x 200 Cu.m/hr)
Equipments etc. 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.

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PARAMETERS

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 LOT
system for MB Units
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

CONDENSATE POLISHING
2.07.08 PLANT

Condensate polisher vessels 2 sets Each set consisting of 4 x


33% capacity vessel for
each unit
Complete regeneration system LOT ---------
including resins, acid/alkali
storage /day /measuring tanks,
dosing pumps, interconnecting
piping, instrumentation, panels
neutralizing pit, etc.

CHLORINATION PLANT
2.07.09
Electro chlorination Plant for MU 2 sets Electro chlorination system
pumps 15 Kg/hr

Chlorination plant with all 3 sets Each set of Chlorinator &


accessories (CW system) evaporators of capacity 100
Kg/hr, piping,
instrumentation, panels etc
Chlorination plant with all LOT Included as a part of
accessories (Water PT) Desalination PT System

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PARAMETERS

Chlorine leak absorption system (if Gas chlorinators are


for Chlorination plant(CW LOT used for CW System
System)

EFFLUENT TREATMENT
2.07.10 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 1 No. 171 m3/hr & 45 MWC
hydrant Disch. Pr. (motor driven).
8 Booster pumps & Drives for 1 No. 171 m3/hr & 45 MWC
hydrant Disch. Pr. (Diesel engine
driven).
9 Electric motor driven foam conc. 1 No. ----------
Pump along with its drive and all
its accessories
10 Diesel engine driven foam conc. 1 No. ----------
Pump along with its drive and all
its accessories

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PARAMETERS

11 Hydrant & spray system mains Lot ----------


piping, indoor & outdoor
hydrants, hoses, hose boxes,
couplings etc.

12 HVW Spray system for various Lot ----------


equipments (Transformers, Oil
equipments, Boiler Burner
Fronts)

13 MVW Spray system for coal Lot ----------


handling plant (Coal conveyors,
TPs & Stacker – Reclaimer
Machines)

14 MVW Spray system for cable Lot ----------


galleries
15 MVW Spray system for fuel oil Lot ----------
tanks, Fuel oil pump houses,
DG set oil tanks, etc.
16 Foam injection for fuel oil tanks Lot ----------
17 Inert Gas Extinguishing system Lot ----------
for Control/ Control equipment
rooms

18 Analogue addressable fire Lot ----------


detection and alarm system
including Fire alarm panels,
PLC panels, Remote I/O panels,
cables, etc.
19 Fire Extinguishers (Portable & Lot ----------
mobile type)
20 Monorail electric hoist for Fire 1 No. 5 Tonne
water pump house
21 Chain pulley block for hydrant 1 No. 1 Tonne
booster pump house
22 Chain pulley block for foam 1 No. 1 Tonne
pump house

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PARAMETERS

2.09.00 Compressed Air System


1 Air compressors with control 5 Nos. Oil free Screw /Centrifugal
panels, instrumentation & all type compressors;
accessories like piping, valves Each of capacity 55
etc Nm3/min & disch.
Pressure of 8 kg/cm2 (g).
2 ADP with panels, 3 sets Each of capacity 55
instrumentation, all accessories Nm3/min & design outlet
like piping, valves & electronic dew point of (-) 40oC
dew point meters
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 1 Lot Central, chilled water type
(CCR, CER, UPS room, SWAS, A/C plant mainly
etc.) & ESP control room 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 Lot ----------
tower area & ESP control room
V Cooling towers with Lot ----------
accessories, etc.
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)
Page 109 of 153
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PARAMETERS

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


Iii Primary Chilled water pumps Lot ----------
Iv Secondary Chilled water pumps Lot ----------
(VFD driven)
V AHUs (VFD driven) Lot ----------
vi Cooling towers with Lot ----------
accessories, etc.
3. Centralised A/C System for Administrative Building
i A/C Plant for Administrative 1 Lot Central, chilled water type
Building 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 Lot ----------
(VFD driven)
v AHUs (VFD driven) Lot ----------
vi Cooling towers with Lot ----------
accessories, etc.
4. A/C system for Water system 1 Lot 2 Nos. 25 TR Air Cooled
control building Condensing unit
(scroll/screw), DX Type
5 A/C system for Auditorium 1 Lot 2 Nos. 40 TR Air Cooled
Building 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 Lot -------------
instruments control panel, fire
dampers, ducting, diffusers,
piping, valves, etc. for complete
air-conditioning system

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PARAMETERS

2.11.00 VENTILATION SYSTEM


1 Air washers (sheet metal 8 No. 2,50,000 m3/hr capacity.
construction) for TG building
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, Lot ---------
ducting, grills, dampers, valves,
diffusers instrumentation, panels
etc for TG building.
5 Unitary air filtration units (sheet 2 Nos. 75,000 m3/hr capacity
metal construction) for ESP
building
6 SISW centrifugal fans for ESP 2 Nos. 75,000 m3/hr capacity at
building 40 mm WC
7 Circulating water pumps 2 Nos. 50 m3/hr & 30 MWC
8 Accessories such as piping, Lot ----------
ducting, grills, dampers, valves
diffusers, dampers,
instrumentation, panels etc for
ESP building.
9 Ventilation System for Misc. Lot ----------
Areas comprising of supply &
exhaust air fans, roof extractor
fans, gravity dampers, etc.
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.

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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 2 no 2 no + 1 pole spare
breaker,23500 A
3.02.00 Power Transformer/ICT
1. Generator transformer 260 07 Nos.
MVA/21 kV/400 kV/3 single
phase with off ckt Tap
changer and On Line DGA
Analyzer
2. Interconnecting Transformer 02 Nos.
400/230 kV,315 MVA ,3
phase ,OLTC ,+/- 10%
2. 400kV Reactor 1 No. 420kV, 80 MVAR
3. 400 kV line reactor along 2 Nos. 420kV, 63 MVAR
with NGR & LA
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, 04 No.
16 MVA

Page 112 of 153


Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS

2. Make up water transformer 02 No.


,5 MVA at make up water
end
3. CHP transformers, 7.5 MVA 02 No.
3.04.00 L.T. transformer
A 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 08 Nos. For ESP,SERVICE
Transformers
2 11/0.433 kV,2000 kVA 02 Nos. For adm service
Transformers
2. 12 Nos. For ASH WATER/ SLURRY/
TAC, /CW
11/0.433 kV,1600 kVA
SERVICE/SERVICE
Transformers WATER/CHLORINATION/DE
SALINATION/FIRE WATER
3. 14 Nos. For CHP,PT, DM, ASH
11/0.433 kV,1000 kVA EXTRACTION,FUEL
Transformers OIL,SWITCHYARD/LOCOSH
ED/AUX BOILER
4. 08 Nos. For MAKE UP
11/0.433 kV,630 kVA
SERVICE/AWRS/WORKSH
Transformers OP
5. 11/0.433 Kv ,250 KVA 02 Nos FOR CROSS COUNTRY

6. 3.3/0.433 kV,630 kVA 02 Nos. For RECLAIMER


Transformers
7. 3.3/0.433 kV,500 kVA 02 Nos. For STACKER
Transformers
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

Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12) Page 113 of 153


Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS

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 16 panels
up end)
3.07.00 Busducts, segregated
i) 11 KV 2500/2000A, 40KA, 800 m
100 KAp
ii) 3.3 KV Bus- 180 m
duct(2750/1600A)
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 8 Nos.
AH/(1500AH Lead Acid)
ii 220 V, 250 AH switchyard 2 Nos.
battery/(400AH Lead Acid)
iii 220 V,90 AH CHP 2 Nos.
battery/(150AH Lead Acid)
iv 110V 90 AH AWRS/colony 8 Nos.
/Ash Silo/MUW (150 AH
Lead Acid)
v. 50 V 360 AH NI- 2 Nos.
CD(KPL)PLCC battery
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 8 Nos.
/Silo/MUW
v. PLCC batteries, 50V, 100A 2 Nos.

Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12) Page 114 of 153


Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS

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 Lot
Protection system
iii. Lighting system Lot
Iv. Electrical lab equipment Lot
3.11.00 Construction power Lot
3.12.00 11 kV Equipment and O/H Lot
line for AWRS
3.13.00 33 kV Equipment and O/H Lot
line for MUW on tower
3.15.00 External Electrification for Lot
Township

3.16.00 Generator-Generator Trf. 2 sets


Unit Protection
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

Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12) Page 115 of 153


Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS

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.
Interconnecting Transformer
(i) (ICT)# Tie # GT module, Set 01
2500 Amps
Bus Reactor # Tie #
(ii) Interconnecting Transformer, Set 01
2000 Amps
Generator Transformer # Tie
(iii) # Line module alongwith Set 01
reactor , 3000 Amps
Line module along with
reactor # Tie # future GT Set 01
module
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

Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12) Page 116 of 153


Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS

i. Interconnecting transformer sets 02 sets


bays
ii. Start up/stand by transformer set 01 set
bay
iii. Bus coupler bay Set 01 set
iv. Line bays 02 sets
Set

Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12) Page 117 of 153


Sl. DESCRIPTION UNIT QTY TECHNICAL
No. 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* Nos 10 17
(minimum)
Control cabinets lot 1 1
Marshalling cabinets lot 1 1
Relay cabinets lot 1 1
No. of Remote I/O Nos 0 22
Links

ii) HMI system(s)


HMI Servers Nos 2 10
LVS Nos 12 6 size of LVS is 65 -
70 "
LVS control Nos 6 6
units/Workstations
OWS Nos 4 16
Shift Charge Nos 0 1
Workstations
Station wide redundant Set 0 1
LAN
Station LAN Nos. 0 2
switch(Redundant)
Station wide LAN Nos 0 2
server (Redundant)
Hardware Firewall for Nos 0 2
Station LAN
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 Nos 0 21
Unit
Matrix KVM switcher Nos 2 0

Page 118 of 153


Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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 Set 1 0
color inkjet printer, 1
cabinet with all
necessary electronic
modules )
PC stations Nos 3 17
Laptops Nos 0 3
Software Lot 1 5
Master & Slave Clock Lot 0 1
System
Master Clock Nos 0 2
Slave Clocks Nos 10 15
Remote DiagNostics Nos 0 1
station

Measuring
2 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 No 2
temperature Detectors
Impact head type flow No 2
Elements
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.

Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12) Page 119 of 153


Sl. No. DESCRIPTION UNIT QTY TECHNICAL
PARAMETERS
Per Unit Common

Radar type level Nos 15


transmitters
Single Input DIN-rail Nos 2
mounted Temperature
Transmitter
Dual-input 2
Temperature
Transmitter With
Indicator Nos

Electrical Power
3 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
UPS-25KVA Sets (B) 2 inverter, 1 bypass
source and 1
battery
UPS-2KVA Sets (C) 3 (C) : Online UPS
UPS-1KVA Sets (C) 9 with remote
monitoring having
a battery backup of
30 mins.
24 VDC Power supply Sets (D) 2 (D) : set means 2
for Unit DDCMIS chargers, 1 battery
(1000Amp) and 1 DCDB
24 V DC for SA Sets (D) 2
DDCMIS (175Amp)
24 V DC for Common Sets (E) 14 (E) : set means 1
system (175Amp) charger, 1 battery
24 V DC for Common Sets (E) 2 and 1 DCDB
system (300Amp)
24 V DC for Common Sets (E) 2
system (275Amp)
24 V DC for Common Sets (E) 2
system (125Amp)
24 V DC for Common Sets (E) 7
system (75Amp)
24 VDC for Common Sets (E) 8
systems (35 Ampere)

Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12) Page 120 of 153


Sl. No. DESCRIPTION UNIT QTY TECHNICAL
PARAMETERS
Per Unit Common

4 PCP
PCP material LOT 1

LIE, Type A Nos 16


LIE, Type B 24
Nos
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 The quantity shown
are for Two(2)
1000 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 Meter
instrumentation cables
provided by Employer 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 2000
2"(50mm) Meter
Cable sub-tray
4"(100mm) Meter 4000
Cable sub-tray 6"
(150mm) Meter 1000

Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12) Page 121 of 153


Sl. No. DESCRIPTION UNIT QTY TECHNICAL
PARAMETERS
Per Unit Common

Control desk and


6 panels
UCD length in CR Meter 7 4 7M for UCD in
main CR, 4M for
UID
UCD length in other Meter 4 m in WS CR, 4m
Control Rooms in CHP CR, 4m in
AHP CR, 2m
18
AWRS, 2m AC CR,
2m in Raw water
pump house.
LVS panel length in Meter 8400
CR
LVS panel length in Meter 980 4200 m in WS,
other CR's 0 2800m in AHP and
2800m in CHP
3PB + 3 LED'S Nos 5
3 PB+4 LEDs for sync Nos 15
type elec breakers
2 PB+ 4 LEDs for Nos 25
sync type Elecl
breakers with
Numerical relay
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 Nos 8 1
Stop PB's 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

Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12) Page 122 of 153


Sl. No. DESCRIPTION UNIT QTY TECHNICAL
PARAMETERS
Per Unit Common

Acknowledge PBs Nos 3


Test PBs Nos 3
ECP Cabinet lot 1
Furniture lot 1
Incoming voltage Nos 1
transducer
Incoming Frequency Nos 1
transducer
Running voltage Nos 1
transducer
Running Frequency Nos 1
transducer
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 Lot 1 Sample cond.


etc panel-1, Analyser
panel-1, Chiller
unit-1
8 PA system
Handset stations
(i) Outdoor wall/column Nos 30 80
mounting type

Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12) Page 123 of 153


Sl. No. DESCRIPTION UNIT QTY TECHNICAL
PARAMETERS
Per Unit Common

(ii) Indoor desk top Nos 7 11


mounting type with
extension amplifier
(iii)Indoor control desk Nos 3 1
mounting type with
extension amplifier.
Loudspeakers
(i) Outdoor Industrial Nos 30 70
Horn type - (Nos.)
(ii) Indoor wall Nos 7 11
mounted Cone type
Portable handset
stations
(i) Sockets-(Nos.) Nos 10
(ii) Portable handset Nos 2
sta
-tions with plug (Nos.)
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 Nos 1 11
monitor
Work station without Nos 1 3
monitor
Database server set # 1 3 # set comprises of
primary and
standby server
Layer III switch Nos 0 1
(redundant)

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 Lot 0 1
Communication
System

Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12) Page 124 of 153


Sl. No. DESCRIPTION UNIT QTY TECHNICAL
PARAMETERS
Per Unit Common

Meterological Sensors Set 0 1

Field marshalling
11 unit
1024 WAYS Nos 0 9
Nos
512 WAYS 0 7
128WAYS Nos 0 6

12 M&C
Srd. M/C items Nos. 0 54

Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12) Page 125 of 153


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 & : 1.27(109.91 Mln. Tk./MW)
WCM)

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.

Page 126 of 153


Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

Page 127 of 153


Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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

Page 128 of 153


Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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 BDT/kwh 8.04(5.12)


(Levellised) (Variable)
US Cents/kwh 9.31 (5.93)

Coal Cost (Base+Transp) USD/MT 145

Coal GCV Kcal/kg 6000

Page 129 of 153


Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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 Option 2 Option 3


model

Total Project
Cost

Min. 110.40 109.91 109.40 108.90


BDT/MW

Mln. 1.28 1.27 1.27 1.26


USD/MW

Cost of Energy BDT/kwh 8.79(5.83) 8.04(5.12) 7.29(4.42) 6.55(3.71)


(Levellised)
(Variable) US 10.17(6.75) 9.31(5.93) 8.45(5.11) 7.58(4.30)
Cent/kwh

Coal Cost USD/MT 165 145 125 105


(Base+Transp)

Coal GCV Kcal/kg 6000 6000 6000 6000

Page 130 of 153


Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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 Option 1


model

Total Project Cost Min. 109.91 110.50


BDT/MW

Mln. 1.27 1.28


USD/MW

Cost of Energy BDT/kwh 8.04(5.12) 8.87(5.91)


(Levellised) (Variable)
US 9.31(5.93) 10.27 (6.84)
Cents/kwh

Coal Cost USD/MT 145 145


(Base+Transp)

Coal GCV Kcal/kg 6000 5200

Page 131 of 153


Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

Page 132 of 153


Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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
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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.
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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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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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.
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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.

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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.

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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.

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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

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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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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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

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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
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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.

Page 148 of 153


Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

Page 149 of 153


Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
(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

Page 150 of 153


Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

Page 151 of 153


Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

Page 152 of 153


Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
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.

Page 153 of 153


Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Edited by Foxit Reader
Copyright(C) by Foxit Corporation,2005-2010
For Evaluation Only.
ANNEXURE-1.1

SUMMARY OF PROJECT CAPITAL COST


(CURRENT COST)

PROJECT: Khulna TPP Stage I (2 x 660 MW) (I Qtr.,2011) (US$ in Millions)

S.No. Item Description Total

1.0 Preliminary & Civil Works

1.1 Land & Civil Construction Works ANNEXURE- 1.1.1 440.79


1.2 Physical Contingency 6.61

Sub-Total 1.0 447.41

2.0 Plant & Equipment

2.1 Mechanical Equipment ANNEXURE- 1.1.2 824.1 4


2.2 Electrical Equipment ANNEXURE-1.1.3 89.27
2.3 Coal Transportation System 0.00
2.4 Misc. Tools & Plants 3.39
2.5 Physical Contingency 13.75

Sub-Total 2.0 930.55

Works Cost (1.0+2.0) 1377.95

3.0 Pre Commissioning Expenses 6 .89

4.0 Project Management

Establishment incl. Consultancy, Audit &


4.1 3.6% of Project cost(excl IDC 51.67
Accounts
4.2 Training of O&M Staff 0.36
4.3 Losses on Stocks 0.09

Sub-Total 4.0 52 .13

Project Cost excl. IDC (1 to 4) 1436.97

5.0 Interest During Construction (IDC) 168.12


a) Interest Charges 162.50
b) Financing Charges 5.62

Project Cost incl. IDC (1 to 5) 1605.09

CostlMW (Exc/. WCM) 1.22

6.0 Working Capital Margin (WCM) 75.12

Project Cost incl. IDC. & WCM (1 to 6) 1680.2

CostlMW (Incl. IDC & WCM) 1.27

11 /9/2012 Page 1 of 14
Annexure - 1.1.1

CIVIL WORKS
(CURRENT COST)

(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 ( 24.29


including US $ 1.45 Mn towards Civil
works of ETP )

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
ANNEXURE-1.1 .2

ABSTRACT COST ESTIMATE

Mechanical Works
(CURRENT COST)
. ANNEXURE- 1.1.2
(I Qtr,2011)
:JROJECT Khulna TPP Stage I (2 x 660 MW) (US$ in Millions)

SI. Item Description Total


No.

1 SG with Associated aux. Incl. ESP 394.54

2 Turbine Generator with Assoc. aux. 206 .99

3 Coal Handling System including Jetty 105.79

4 C & I incl. DAS 6.91

5 Ash Handling System & AWRS incl. ETP 23.13

6 CW Pumps incl. Makeup Water Sys. 10.45

7 Cooling Towers incl. Civil Works 28.54

8 Desalination Plant 24.52

9 Chlorination System 1.73

10 Station piping & Fuel Oil Handling System 10.25

11 Fire Detection and Protection System 4.43

12 Air Conditioning & Ventilation 3.01

13 Workshop & Lab. Equipment 0.41

14 Diesel Generator 0.86

15 Fuel Oil Handling system 2.57

TOTAL 824.14

Page 3 of 14
ANNEXURE- 1.1 .3
ABSTRACT COST ESTIMATE
Electrical Works
(CURRENT COST)
(I Qtr,2011)
PROJECT: Khulna TPP Stage I (2 x 660 MW) (US$ in Millions)
......................................................----
SI. Item Description Total
No.
A ELECTRICAL SYSTEM

Generator Bus Duct 2.35

2 Gen. Circuit Breaker 3.11

3 Generator, Stn.,LT Outdoor & Indoor Transformer 17.90

4 H T Switchgear 4 .07

5 L T Switchgear 4.10

6 H T Power Cables 0.93

7 L T Power, Control & 2.75


Instrumentation Cable

8 Cabling, Earthing & Stn. Lighting, & Battery 5.66

SUB TOTAL (A) 40.86

B SWITCHYARD

9 400 Switchyard 34.91

10 Reactor 400 kV 2.50

11 Battery & Charger 1.22

12 Construction Power, & 7.12


Ex. Electrification

SUB TOTAL (B) 45.75

C COMPUTER & SATE LITE COMMUNI-


CATION FACILITIES
13 Computer Facilities 0.97

14 Satellite Communication System 0.95

15 Common Facilities 0.74

SUB TOTAL (C) 2.66

TOTAL 89.27

page 4 of 14
M" ":ml~ @r~'~' -~-~~W"'.'W" ,,' ~"

KhulnaTPP In U5.; $ G,ents%

Year Ending 31-Mar-13 31-Mar-14 31-Mar-15 31-Mar-16 31-Mar-17 31-Mar-18 31-Mar-19

Tariff Computation in US $

Annual Fixed Cost

Effective Tax Rate 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%

Return on Equity 108.34 758.40 866.75


Interest on Loan Capital 105.49 665.51 745.75
Depreciation 132.61 975.14 1,098.75
Oil Cost 6.70 46.91 53.61
Interest on Working Capital 49.86 354.37 405.64
Land lease payment 0.018 5.47 38.26 43.72
0& M Expenses (Unit I) 1.00 0.297 49.02 196.07 196.07
0& M Expenses (Unit II) 1.00 0.297 147.05 196.07

Total Fixed Cost 457.49 3,181.72 3,606.38

Energy Charge 685.10 4,795.70 5,480.80

FC/unit) 3.96 3.94 3.90


VC/unit) 5.93 5.93 5.93
Tariff 9.89 9.87 9.84
Levelised Tariff 9.31
First Full Year Tariff 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

Tariff Computation in US $

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 _. _ _ • "-.-"--"'<. •• __ . _. __ .... _ ..... -'*'-.-

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

Tariff Computation in US $

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
Interest on Working Capital 388.80 388.70 375.49 364.21 365.54 371.01 371.16 371.16
Land lease payment 43.72 43.72 43.72 43.72 43.72 43.72 43.72 43.72
0& M Expenses (Unit I) 197.87 197.87 197.87 197.87 197.87 200.27 200.27 200.27
0& M Expenses (Unit II) 196.07 197.87 197.87 197.87 197.87 197.87 200.27 200.27

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
First Full Year 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

Tariff Computation in US $

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
Interest on Working Capital 371.16 371.16 371.38 371.60 371.60 371.60 323.85 45.32
Land lease payment 43.72 43.72 43.72 43.72 43.72 43.72 38.26 5.47
0& M Expenses (Unit I) 200.27 200.27 203.87 203.87 203.87 203.87 152.90
0& M Expenses (Unit II) 200.27 200.27 200.27 203.87 203.87 203.87 203.87 50.97

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)

PROJECT: Khulna TPP Stage I (2 x 660 MW) (I Qtr.,2011) (BOT in Millions)

S.No. Item Description Total

1.0 Preliminary & Civil Works

1.1 Land & Civil Construction Works ANNEXURE-1.1.1 38062.61


1.2 Physical Contingency 570 .94

Sub-Total 1.0 38633.55

2.0 Plant & Equipment

2.1 Mechanical Equipment ANNEXURE-1.1.2 71164.49


2.2 Electrical Equipment ANNEXURE-1.1.3 7708.39
2.3 Coal Transportation System 0.00
2.4 Misc. Tools & Plants 292 .33
2.5 Physical Contingency 1187.46

Sub-Total 2.0 80352.67

Works Cost (1.0+2.0) 118986.22

3.0 Pre Commissioning Expenses 594.87

4.0 Project Management

Establishment inc!. Consultancy, Audit &


4.1 4461 .94
Accounts
4.2 Training of O&M Staff 31.40
4.3 Losses on Stocks 7.85

Sub-Total 4.0 4501.19

Project Cost excl. IDC (1 to 4) 124082.28

5.0 Interest During Construction (IDC) 14517.01


a) Interest Charges 14031.88
b) Financing Charges 485.13

Project Cost incl. IDC (1 to 5) 138599.29

CosttMW (Excl. WCM) 105.00

6.0 Working Capital Margin (WCM) 6486.61

Project Cost incl. IDC. & WCM (1 to 6) 145085.9

CosttMW (Incl. IDC & WCM) 109.91

11/9/2012 Page 1 of 14
Annexure - 1.1.1

CIVIL WORKS
(CURRENT COST)

(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 ( 2097.52


including BDT 126 Mn towards Civil
works of ETP )

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
ANNEXURE-1 .1.2

ABSTRACT COST ESTIMATE

Mechanical Works
(CURRENT COST)
ANNEXURE- 1.1.2
(I Qtr,2011)
;)ROJECT Khulna TPP Stage I (2 x 660 MW) (BOT in Millions)

S!. Item Description Total


No.

1 SG with Associated aux. Inc!. ESP 34068.53

2 Turbine Generator with Assoc. aux. 17873.35

3 Coal Handling System including Jetty 9135.36

4 C & I inc!. DAS 596 .76

5 Ash Handling System & AWRS inc!. ETP 1996.88

6 CW Pumps inc!. Makeup Water Sys. 902.28

7 Cooling Towers inc!. Civil Works 2464.43

8 Desalination Plant 2117.46

9 Chlorination System 148.99

10 Station piping & Fuel Oil Handling System 885.32

11 Fire Detection and Protection System 382 .92

12 Air Conditioning & Ventilation 260.15

13 Workshop & Lab . Equipment 35 .80

14 Diesel Generator 74 .10

15 Fuel Oil Handling system 222.16

TOTAL 711 64.49

Page 3 of 14
ANNEXURE-1 .1.3
ABSTRACT COST ESTIMATE
Electrical Works
(CURRENT COST)
(I Qtr,2011)
PROJECT: Khulna TPP Stage I (2 x 660 MW) (BDT in Millions)

SI. Item Description Total


No.
A ELECTRICAL SYSTEM

Generator Bus Duct 202.53

2 Gen. Circuit Breaker 268.47

3 Generator, Stn.,L T Outdoor & Indoor Transformer 1545.35

4 H T Switchgear 351 .84

5 L T Switchgear 354.19

6 H T Power Cables 80.07

7 L T Power, Control & 237.38


Instrumentation Cable

8 Cabling, Earthing & Stn . Lighting, & Battery 488.58

SUB TOTAL (A) 3528.42

B SWITCHYARD

9 400 Switch yard 3014.09

10 Reactor 400 kV 216.19

11 Battery & Charger 105.66

12 Construction Power, & 614.50


Ex. Electrification

SUB TOTAL (B) 3950.43

C COMPUTER & SATELITE COMMUNI-


CATION FACILITIES
13 Computer Facilities 83.52

14 Satellite Communication System 81 .80

15 Common Facilities 64.21

SUB TOTAL (C) 229.53

TOTAL 7708.39

page 4 of J4
KhuInaTPP IN BDT PER UNIT
Year Ending 31-Mar-13 31-Mar-14 31-Mar-15 31-Mar-16 31-Mar-17 31-Mar-18 31-Mar-19
Annual Fixed Cost

Effective Tax Rate 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%

Return on Equity 93.55 654.88 748.44


Interest on Loan Capital 91.09 574.67 643.96
Depreciation 114.51 842.03 948.77
Oil Cost 5.79 40.51 46.29
Interest on Working Capital 43.06 306.00 350.27
O&M Expenses 0.21 0.22 0.23 0.24 0.26 0.26 0.26
0& M Expenses (Unit I) 1.00 0.257 42.33 169.31 169.31
0& M Expenses (Unit II) 1.00 0.257 126.98 169.31

Total Fixed Cost 395.04 2,747.41 3,114.11

Energy Charge 591.58 4,141.09 4,732.67

FC/unit) 3.42 3.40 3.37


VC/unit) 5.12 5.12 5.12
Tariff 8.54 8.52 8.49
Levelised Tariff 8.04
First Full Year Tariff 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
Interest on Worki ng Capital 348.57 346.87 345.17 343.47 341.77 340.07 338.37 336.67
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
First Full Year 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
Interest on Working Capital 335.73 335.64 324.23 314.49 315.64 320.36 320.49 320.49
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
First Full Year Tariff

30f4
Khulna TPP

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'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
Interest on Loan Capital
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
Interest on Working Capital 320.49 320.49 320.69 320.88 320.88 320.88 279.64 39.13
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
First Full Year Tariff

A "f A
EXHIBITS
I PLAN
KHULNA TPP (2X660 MW)
BANGLADESH
PROJECT CODE :9635
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Activity Activity Description Mth from Month
ID MP Order 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 67
KH005 Investment 0 Investment Approval
Approval

KH010 Main Plants Award 0 Main Plants Award (SG and TG)
(SG and TG)

KH020 Start of Piling & 4 Start of Piling & Foundation


Foundation

KH030 Start of Boiler 14 Start of Boiler Erection


Erection

KH040 Start of Condenser 26 Start of Condenser Erection


Erection

KH050 Start of TG Erection 28 Start of TG Erection

KH060 Boiler Hydro Test 32 Boiler Hydro Test

KH070 Readiness of C&I for 38 Readiness of C&I for Boiler Light Up


Boiler Light Up

KH080 TG Box Up 39 TG Box Up

KH090 Boiler Light Up 39 Boiler Light Up

KH100 Steam Blowing Start 41 Steam Blowing Start

KH110 TG on Barring 41 TG on Barring

KH120 Commissioning of 44 Commissioning of Unit # 1


Unit # 1

KH130 COD Unit # 1 48 COD Unit # 1

KH140 Commissioning 50 Commissioning Unit# 2


Unit# 2

KH150 COD Unit # 2 54 COD Unit # 2

NTPC LIMITED Date Revision Checked Approved


11.03.11 REV 0 (ISSUED FOR FR)
KHULNA TPP (2x660 MW) - BANGLADESH 24.03.11 Rev 01 (CORRECTED AS ADVISED BY ENGG)

IMPLEMENTATION SCHEDULE
(
~ BOARD OF DIRECTORS
JV CORPORATE OFFICE

•u

~
0
\ CHAlRMAi" )
~
0
~
CHIEF EXECUTIYE OFFICER
----------------------------r ---------------------------
r
KHULNA THERMAL POWER PROJECT (2X660 MW), BANGLADESH

GE~T£RAL ::\U.XAGER

OPER\ TID);" & l\L\Ii"\rffEl\"...\.l'OCE )

:\L"\TERIALS PL\.."\')ril~G C O:"STRUCTION F~' A." CE ..~ HUi\L\N RES. EQ'LlP1UE:\,


:\L\..."AGDIEl\'T &SYSTDIS A CCOLl\1S DE\LOP:\IENT ERECTION

TEC Hi\"ICAL
SER\lCES

l\lATh" POWER ( CW SYSTE:\I) ( OFFSITES) TOWNSHIP ) WORKS


HOUSE ACCT.

( '!ECH. ( ELECr) (C &I 'YORKS ( CO:\"TRACTORS


L
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) KHULNA THERMAL POWER PROJECT (2X660 MW), BANGLADESH