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Saraf Agencies Private Ltd.

Pre-Feasibility Report for 1x15 MW Coal Based CPP

at Chatrapur, Dist. Ganjam in Odisha

PRE-FEASIBILITY REPORT FOR 1 x 15 MW COAL BASED CAPTIVE POWER PLANT FOR TITANIUM PROJECT AT CHATRAPUR, DISTRICT GANJAM IN ODISHA I N D E X STUDY AT A GLANCE SECTION–1 : INTRODUCTION AND EXECUTIVE SUMMARY 1.1 Foreword

1.2 Executive Summary

1.3 Justification of the Project

SECTION–2 : BASIC REQUIREMENTS AND SITE FEATURES 2.1 Introduction

2.2 Land Features & Availability

2.3 Water – Requirement, Source, Availability & Conveyance

2.4 Fuel – Source, Availability & Transportation

2.5 Power Evacuation

2.6 Infrastructural Facilities

2.7 Meteorological Details

SECTION–3 : TECHNICAL FEATURES 3.1 Introduction & Basic Design Consideration 3.2 Main Plant & Equipment 3.3 Auxiliary Plant Systems 3.4 Electrical System & Equipment

3.5 Instrumentation & Control System

3.6 Plant Layout


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3.7 Civil Engineering Aspects

3.8 Environmental Aspects SECTION–4 : PROJECT EXECUTION AND IMPLEMENTATION

4.1 Construction Aspects

4.2 Organizational Set-up

4.3 Project Implementation Schedule

4.4 Project Execution

SECTION–5 : ESTIMATION OF PROJECT COST AND TARIFF

5.1 Basis of Estimates

5.2 Phased Fund Requirement

5.3 Project Cost Estimate

5.4 Estimation of Cost of Generation

5.5 Sensitivity Analysis


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LIST OF ANNEXURES & DRAWINGS

SECTION - 1 Annexure -1.1 : Electricity Tariff for Industrial

Consumers in Odisha

SECTION - 2 Annexure - 2.1 : Estimation of Consumptive Water

Requirement (2 sheets) Annexure – 2.2 : Tentative Analysis of Coal

(Imported and Indigenous) Annexure – 2.3 : Climatological Table of Gopalpur Drawing No.14O02-002-DWG-PD-001 : Vicinity Map

Drawing No.14O02-002-DWG-PD-002 : Site Location Map

Drawing No.14O02-002-DWG-PD-003 : Oceanographic Map

SECTION - 3 Drawing No.14O02-003-DWG-PD-001 : Plant Layout

Drawing No.14O02-003-DWG-PD-002 : Mass & Energy Balance Diagram

Drawing No.14O02-003-DWG-PD-003 : Water Balance Diagram

Drawing No.14O02-003-DWG-PD-004 : Single Line Diagram – Electrical System

Drawing No.14O02-003-DWG-PD-005 : Waste Water Management Scheme

SECTION - 4 Drawing No.14O02-004-DWG-PD-001 : Project Schedule for 1x15 MW CPP

Drawing No.14O02-004-DWG-PD-002 : Organization Chart (O&M Team)

SECTION - 5 Annexure - 5.1 : Project Cost Estimate

Annexure - 5.2 : Financial Analysis (14 sheets)

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STUDY AT A GLANCE

General :-

The Project : 1 x 15 MW coal based Captive Power Plant at Chatrapur in Ganjam district of Odisha.

Owner : Saraf Agencies Private Limited

Station Capacity : 1 x 15 MW with provision of expansion in future.

Station Configuration : One(1) Steam Generator supplying steam to a 15 MW Turbine Generator set.

Land (identified for CPP) : 57.3 Acres. Plant Location : At latitude 19° 19’ 48.3” N and longitude

84° 37’ 11.85” E.

Fuel : Option-I : Imported coal from Indonesia.

Option-II : Coal from Talcher coal fields in Odisha.

Daily Fuel Requirement : Option-I : 229 TPD for Indonesian coal. Option-II : 338 TPD with Talcher coal.

Annual Fuel Requirement : Option-I : 0.71 Lakh Te at 85% load factor (Indonesian coal)

Option-II : 1.05 Lakh Te at 85% load factor (Talcher coal).

Fuel Transportation : By sea and thereafter by truck from the port for Indonesian coal.

By road from Talcher mines. Traffic : Option-I : 15 truck load (imported coal) Option-II : 23 truck load (Indigenous

coal) Stack Details : Two months’ storage.


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Coal Handling System : Coal will be transported by truck from

Talcher mine/Gopalpur Port. Coal storage for two(2) months and boiler bunker storage capacity of 12 hours are proposed.

Consumptive Water : Option-I : with wet type cooling – 1.2

cusec. Option-II : with air-cooled condenser –

0.4 cusec. Ash Generation : Option-I : (for imported coal with ash

content @ 14%). FA : 1.19 TPH (Max.) BA : 0.26 TPH Option-II : (for Indigenous coal with ash

content @ 42%). FA : 5.31 TPH (Max.) BA : 1.18 TPH Ash Disposal : BA – Semi-wet extraction and disposal. FA – Dry extraction and in-house

consumption for the main plant. Basic Technical Features : • The basic thermodynamic cycle would

comprise non-reheat, regenerative Rankine cycle with fluidized bed boiler of about 65 TPH and injection type turbine with 3 to 4 extractions to ensure optimum cycle efficiency.

• Condenser cooling deploying wet type

cooling tower or air-cooled system may be adopted.

Power Evacuation : Power shall be supplied to Titanium Project

at 33 kV. However, the CPP shall be connected to grid for provision of supply from grid during exigency and supply to grid in case of surplus.


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Manpower Requirement : 30 persons for O&M.

The Project Management Team for Titanium Project shall also be utilised during CPP construction.

Environmental Aspects : Twin-flue stack will be constructed 78 m

high considering provision of expansion of one more unit and to meet the norms set by MoEF for dispersion of particulate, SOx and NOx.

• Multiple field twin-path electrostatic

precipitators with separation effi-ciency of more than 99.89% is envisaged.

• Waste water quality to be maintained as per Central Pollution Control Board (CPCB) standards and the Ministry of Environment & Forest’s (MoEF) noti-fication. The scheme envisaged would ensure minimum liquid effluent dis-charge from the plant.

• Solid waste in the form of FA would be

utilised in-house.

Infrastructure and Enabling Works :-

Land Development : Contour survey of the plot will be undertaken and levels will be planned. For this study report Main Plant is proposed at an elevation of 28 m above mean sea level (MSL). Highest flood level (HFL) of the area is 27.60 m above MSL.

Project Timeframe : Commercial Operation after 21 months.

Project Cost :-

Capital Expenditure : `92.23 Crore

Capitalised Project Cost : `99.35 Crore

1st Years Tariff : `5.47 per unit.

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SECTION - 1

INTRODUCTION AND EXECUTIVE SUMMARY

1.1 Foreword Saraf Agencies Private Limited (SAPL) is a holding company owning a

group of companies known as Saraf Group companies. The group is well-

diversified, owning and operating large industrial plants. The group is

establishing a Special Economic Zone (SEZ) at Chatrapur in the district of

Ganjam, Odisha and proposes to set up the Titanium Complex to

manufacture various Titanium products like high Titanium slag, Titanium

dioxide pigments, ferro-Titanium, Titanium sponge metal etc.

To optimize the cost of production and attain operational ease, it is proposed

to set up a Captive Power Plant (CPP) for the Titanium Complex. CPP would

use imported/indigenous coal as fuel and capacity of the CPP is proposed as

1 x 15 MW with provision of further expansion.

Accordingly, M/s. Saraf Agencies Private Limited (SAPL) appointed

Development Consultants Private Limited (DCPL) to prepare a Pre-

Feasibility Report (PFR) for the proposed Captive Power Project (CPP) at

village Mayapatna near Chatrapur in Ganjam District, Odisha.

1.2 Executive Summary SAPL intends to set-up a 1x15 MW CPP with provision of one more unit of

similar size at Mayapatna village near Chatrapur in Ganjam district of

Odisha.

About 57.3 acres land on the southern and south-eastern side of the

proposed Titanium project has been earmarked for setting up the CPP. It is

located within SAIL’s acquisition limit. Key features of the land are depicted

below:-


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a. Being located within the SAPL project boundary early start of the

enabling works may be possible.

b. Site is situated at higher HFL.

c. A 20 m wide land corridor connecting site with NH-5 running 500 m

away from the site.

d. Construction power and water are available from proposed Titanium

Project.

The said area is situated at a distance of 10 km from the river Rushikulya,

the source of consumptive water for the CPP. Land for ash storage is to be

identified outside the plant boundary. It is proposed that station would

receive coal from Indonesia. However, possibility of using indigenous coal is

under consideration. In Section-2 of the report, the basic requirements

and site features have been elaborated.

The technical features of the 15 MW set size outlining the design parameters

of main plant and equipment are discussed in Section-3 of the report. A

non-reheat steam cycle with regenerative feed heating arrangement

operating at sub-critical range using fluidized bed combustion technology is

envisaged for the proposed CPP. Condenser cooling deploying wet type

cooling tower is considered in the present study. However, alternately air-

cooled system may be adopted.

Fly ash generated from the station is proposed to be extracted in dry form

and would be consumed in-house main plant. Semi-wet extraction and

disposal for bottom ash is envisaged.

Imported coal would be transported from Paradeep Port by trucks to the

plant site. Alternately, indigenous coal would be transported by truck from

mines (Talcher). A two(2) months’ coal storage is envisaged at site.


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Other auxiliaries and accessories would deploy the state-of-the-art

technology to ensure safe and continuous operation of the units with

minimum unscheduled outages. The project would be implemented on

package basis in such a manner that will lead to shortest gestation period,

obtain firm guarantee on performance and completion schedule and make

investment remunerative. It is expected that the project would be

commissioned within 21 months after ordering of main plant equipment.

A total manpower for the station is envisaged as 30 to compliance of owner’s

own model of manpower deployment. All the above mentioned aspects are

narrated in Section-4 of the report. Tentative project cost estimate and

cost of generation is discussed under Section-5 of the report.

1.3 Justification of the Project In order to achieve the ambitious rate of growth in various industries and to

accelerate development on all fronts both agricultural and industrial –

availability of low priced and reliable power is essential.

Total installed capacity of the State of Odisha as on March 31, 2013 is

recorded as 6946.33 MW as per CEA published data. During the period of

April 2013 to March 2014, deficit in energy availability and peak demand

has been recorded as 3.3% and 6.9% respectively.

Keeping in view the present uncertainty in the power sector the future

prospect continues to remain black. Moreover the stability and quality of

the power supply from the grid continues to remain suspect. Accordingly it

is advisable for a power intensive project like SAPL’s Titanium Project to go

for captive power generation to remain free from the vagaries of the grid.

Accelerated increase in the power tariff in recent time has been observed in

Odisha. The energy charge for EHT industrial consumers has been raised

from Rs.2.80 per kWh as on April 01, 2010 to Rs.3.95 per kWh as on April

01, 2013. It is expected to continue to rise in future also. Electricity tariff


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for industrial consumers in Odisha from 2010-11 to 2013-14 is enclosed in

Annexure-1.1.

A restriction in availability of grid power shall lead to loss of production and

thus loss in revenue. The indirect effect is far reaching and results in

disruption of work schedule, affects working environment and morale and

increase stress and strain on the equipment.

Thus in the background of increasingly expensive grid power together with

its uncertain availability, it would be logical to consider the proposal for

setting up a Captive Power Plant. The approach is to economise the cost of

finished product by using reliable power generated in-plant.

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Annexure – 2.2

Annexure – 1.1

Sheet 1 of 9





Electricity Tariff for Industrial Consumers in Odisha Retail Supply Tariff effective from 1st April, 2013

Annexure – 2.2

Annexure – 1.1

Sheet 2 of 9





Annexure – 2.2

Annexure – 1.1

Sheet 3 of 9





Annexure – 2.2

Annexure – 1.1

Sheet 4 of 9





Annexure – 2.2

Annexure – 1.1

Sheet 5 of 9





Annexure – 2.2

Annexure – 1.1

Sheet 6 of 9





Annexure – 2.2

Annexure – 1.1

Sheet 7 of 9





Annexure – 2.2

Annexure – 1.1

Sheet 8 of 9





Annexure – 2.2

Annexure – 1.1

Sheet 9 of 9






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SECTION - 2

BASIC REQUIREMENTS AND SITE FEATURES

2.1 Introduction To ensure efficient and trouble-free operation of a thermal power plant

throughout the operating life, selection of a proper site with required

features, infrastructure and inputs, is always the key factor to optimise the

design and cost parameters involved.

From the point of view of locating a coal fired captive thermal power plant,

the features which are considered important are -

a. Availability of suitable land for main plant and auxiliaries and ash

disposal. The plot should be above high flood level.

b. Year-round availability of adequate quality of consumptive and cooling

water from a source within reasonable distance from the site.

c. Road and railway access to the site for ease of transportation of fuel,

construction equipment etc.

d. Population centre at a reasonable distance so as to utilise existing

facilities during initial stages of the project.

e. Suitability of sharing of infrastructure developed for main project/

process plant so that investment requirement for development of the

infrastructure for CPP can be optimised.

f. Proximity to load centre i.e. main project/process plant so that

requirement of transmission line is minimum.

Proposed CPP would comprise 1 x 15 MW coal based unit adjacent to the

proposed Titanium Project at village Mayapatna in Ganjam district of


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Odisha. Infrastructure along with other facilities to be developed for

Titanium Project would be designed for adequate capacity to cater to the

requirements of the proposed CPP. Vicinity map for the proposed project is

enclosed in Drawing No.14O02-002-DWG-PD-001.

2.2 Land Features & Availability The plot of land earmarked for the station is surrounded by village

Mayapatna & National Highway (NH-5) to the north, village Tikirla

Brahmapur to the east, village Kanamana & National Highway (NH-516) to

the south and village Narayanpur & Chonotrapada to the west. Land is

fallow and covered with little patches of bushes. It is surrounded by Kewra

and Cashew trees. It is moderately undulated with reference level varying

from 19 m to 30 m above mean seal level (MSL). Slope of the plot is

directed from south-west to south-east. It is noted that High Flood Level

(HFL) of the area is about 27.2 m above MSL. However, a separate study

needs to be instituted to establish HFL of the area. The plot is covered with

sandy soil with rock outcrops at places. Site is about 2-3 km away from

Bay of Bengal and is beyond coastal regulatory zone. Oceanographic map

of the area is shown in Drawing No.14O02-002-DWG-PD-003. One no.

132 kV transmission line is passing along the eastern boundary outside the

plot.

The plot for ash storage is to be identified outside the plant boundary but

close to the main plant. In Drawing No.14O02-002-DWG-PD-002, site

location map is enclosed.

Features of selected plot : The proposed Thermal Power Plant of 1x15 MW is earmarked to be located

at longitude 19° 19’ 483” E and Latitude 84° 37’ 11.85” N on an identified

plot of land lying on the southern and south-eastern side of the proposed

Titanium Project with a total landmass of 57.3 hectares. The site at


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Chatrapur was prima facie preferred on the basis of following intrinsic

merits :-

a. Being located within SAPL project boundary, land is primarily free

from permanent obstructions which will enable early start of the

construction work.

b. No nallah flowing through or emanates from the area identified for

CPP.

c. The area is well connected by road providing easy access. A separate

approach road from NH-5 to the plot would be provided. A 20 m wide

land corridor has been identified for this purpose.

d. The area is adjacent to the Indian Rare Earths Limited (IREL) plant

from where raw material for the Titanium project should be sourced.

e. A perennial water source i.e. Rushikulya River is located around 10

km from plant site.

f. Construction power and construction water would be available from

proposed Titanium Project.

g. Residential accommodation along with other necessary amenities

would be available in surrounding towns viz. Chatrapur, Ganjam,

Berhampur, Gopalpur etc.

h. No forest or any archaeologically important sites are located in the

vicinity.

The basic requirements for the proposed thermal power project are studied

in the backdrop of the available infrastructural facilities and the requirement

of developing further facilities to ensure compatibility and adequacy.


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2.3 Water – Requirement, Source, Availability & Conveyance

The consumptive water required for the station will be drawn from the

common intake pump house proposed to be constructed on the Rushikulya

River for Titanium Project with necessary augmentation. Though Rushikulya

River is perennial in nature, sustained availability of water in dry season

needs to be ascertained.

Rushikulya River which is 165 km long has a catchment area of 8900 sqr.

km. This area is mainly used for irrigation purpose is the source of drinking

water for the population in the vicinity including Berhampur and Chatrapur

towns besides meeting water needs of existing industries in the vicinity.

There are number of weirs and anicuts on upstream of the river to facilitate

storage of water for irrigation purposes. Hiradharbali anicut is the nearest

one on the river located at around 30 km from confluence with Bay of

Bengal. Various options for meeting water needs of the CPP may be

considered as follows :

a. Meeting both cooling water and other requirements from River

Rushikulya.

b. Meeting cooling water needs from the sea in once-through mode and

other requirements from River Rushikulya.

c. Meeting cooling water needs from the sea in once-through mode and

other requirements also from the sea after desalination.

However, possibility of obtaining water allocation from River Rushikulya

from Water Resources Department (WRD) of Govt. of Odisha should be

explored before proceeding to finalise the water supply arrangement from

the CPP. Detailed studies by specialised agencies would be required in this

regard. For the purpose of the study, sweet river water is considered for

both cooling and consumptive use.


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Total consumptive water requirement for the proposed station size of 1x15

MW is 128 m3/hr when water cooled condenser is considered. Alternatively,

when air-cooled condenser is considered it is 44 m3/hr respectively.

Estimation of the total water requirement is shown in Annexure-2.1.

On the basis of raw water quality available, clariflocculation, filtration and

demineralisation plants would be required and the treatment plants would

be accordingly designed permitting adequate redundancy as well as storage

capacities for different qualities of treated water.

2.4 Fuel – Source, Availability & Transportation Imported coal from Indonesia is considered as fuel for the CPP. Tentative

analysis of coal is given in Annexure-3.2 (2 sheets). Coal from Indonesia

would be transported by sea route to the Paradeep Port at a distance of 260

km from the project area and then brought to the plant by rail/trucks. The

port at Gopalpur (crow fly distance of 2 km from the site) under

construction may be used after it starts its operation.

Based upon the expected imported coal characteristics the maximum daily

coal requirement for the proposed CPP of 15 MW would be about 229 TPD @

MCR and annual fuel requirement is estimated at 0.71 lakh tons per annum

at 85% plant load factor.

Alternately, coal from Talcher coal fields in Odisha may be considered. Coal

would be transported by road from the Talcher coal fields. Approximately,

338 TPD and from Talcher would be required daily. Annual coal

requirement is estimated at 1.05 lakh Te per annum at 85% load factor.

Tentative coal analysis is indicated in Annexure-2.2.


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2.5 Power Evacuation Power will be generated at the CPP at 11 kV. It shall be stepped up to 33 kV

for supply to the Titanium Project. Start-up power and construction power

shall be received at 132 kV and shall be stepped down to 33 kV to feed 33

kV switchyard. Power from the grid will be received from 132 kV Chatrapur

sub-station of OPTCL for which a LILO connection will be taken from the 132

kV transmission line running parallel to the eastern boundary.

2.6 Infrastructural Facilities The access road to the subject plot is proposed to be taken from National

Highway (NH-5) passing through 650 m away from northern boundary of

the plot. Another approach road from NH-516 running about 1.5 km south-

east of the plot may be considered. Nearest railway station is at Chatrapur

at a distance of 2 km from site. Station is situated at a level of 30.165 m

above MSL and falls under East Coastal Railway (ECR). It lies on the double

track electrified BG main line (Howrah-Chennai). Berhampur town is about

22 km west of the site. Nearest airport is at Bhubaneswar (180 km) and

port is at Paradeep (290 km). However, a new port is under construction at

Gopalpur which is about 2 km from the site.

CPP would be able to share some of the infrastructural and construction

facilities to be developed for main plant (Titanium Plant).

Besides, open space will be provided for setting up contractors’ office, stores

and fabrication yard etc. Nearby plots have to be taken rented for setting

up batching plant, labour hutment, other fabrication facilities etc.

The main gate and material gate for the Titanium project would be used for

the CPP as it is located within the premises of the main plant. Necessary

internal roads for construction purposes will be built. The plot will be

connected from National Highway No.5 by an access corridor.


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2.7 Meteorological Details The nearest meteorological station of IMD is at Gopalpur and the published

climatological table is given in Annexure-2.3. The area falls under Seismic

Zone-III as per IS 1893. The climatological data as available are given

below:-

• Highest temperature : 44 °C

• Minimum temperature : 9.6 °C

• Annual Rainfall : 1265 mm

• Average relative humidity : 80%

• Predominant wind direction : From South-West.

• Maximum wind velocity : 61 kmph.

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Annexure – 2.1

Sheet 1 of 2

Development Consultants Pvt. Ltd.

24, Park Street, Kolkata-700016




Estimation of Consumptive Water Requirement for Water-cooled Condenser for 1x15 MW Coal Based CPP for Titanium Project at Chatrapur in Ganjam District of Odisha

Sl. No.

Consumptive Points DM Water Filtered Water Clarified Water

Raw Water

Remarks

(m3/hr) (m3/hr) (m3/hr) (m3/hr)

1. a. Heat Cycle Make-up b. Chemical Feed

c. Regeneration Requirement

2 1

1

Sub-Total 4 4

2.

a. Potable Water Requirement b. D. G. Set

c. Airconditioning System d. Regeneration & Backwash

1 5

2 1

Sub-Total 13 13

3.

a. Ventilation System b. Service Water c. Seal Water & other misc. requirement

for Ash Handling System d. Coal Handling System (DE/DS)

e. Cooling Tower Make-up Requirement*

10 3 -

5

74

8 m3 to use CTBD 3 m3 to use CTBD * CTBD 13 m3/hr (n=5)

Sub-Total 105 105

4. a. Desludging, Backwash etc.

b. Evaporation loss in reservoir & line loss

6 10

Sub-Total 121

5. a. Design Margin & Contingency

b. Horticulture

7

-

To use CTBD.

GRAND TOTAL : 128 (Say 1.2 Cusec)

Annexure – 2.1

Sheet 2 of 2






Estimation of Consumptive Water Requirement for Air-cooled Condenser

for 1x15 MW Coal Based CPP for Titanium Project at Chatrapur in Ganjam District of Odisha Sl.

No. Consumptive Points DM Water Filtered Water

Clarified Water

Raw Water

Remarks

(m3/hr) (m3/hr) (m3/hr) (m3/hr)

1. a. Heat Cycle Make-up b. Chemical Feed c. Regeneration Requirement

2 1 1

Sub-Total 4 4

2.

a. Potable Water Requirement b. D. G. Set c. Airconditioning System d. Regeneration & Backwash

1 5 2 1

Sub-Total 13 13

3.

a. Ventilation System

b. Service Water c. Seal Water & other misc. requirement

for Ash Handling System d. Coal Handling System (DE/DS) e. Line Loss (ACC)

10 3

4

5 2

Sub-Total 37 37

4. a. Desludging, Backwash etc. b. Evaporation loss in reservoir & line loss

1

2

Sub-Total 40

5. a. Design Margin & Contingency b. Horticulture

4

- To use CTBD.

GRAND TOTAL : 44 (Say 0.4 Cusec)

Annexure – 2.2

Annexure – 2.2





Analysis of Coal Design Parameters

Sl. No.

Particulars Indigenous Coal

(Talcher) Imported Coal (Indonesia)

1. GCV (kCal/kg) 3250 4800

2. Total Moisture (ARB) 10.5% 40%

3. Volatile Matter 21% 43%

4. Ash Content 42% 14%

5. Fixed Carbon 26% 34%

6. Sulphur 0.37% 0.9%

7. Size 50-200 mm (-) 50 mm

8. Hard Grove Index (HGI) 62 56

9. Ash Fusion Temperature (°C) 1150 1390

Annexure – 2.3

Sheet 1 of 2




at Chatrapur, Dist. Ganjam in Odisha Saraf Agencies Private Ltd.

STATION : Gopalpur 43049 LAT: 19 16 N LONG: 84 53 E HT. ABOVE M. S. L. 17 METERS DATA 1951 To 1980

Climatolocal Table of Gopalpur

Mean Temperature Extremes Cloud Rainfall

-- ------ ------------------------------------ --------------------- -------- -------- -------------------------------------- -----

MN SLP DB WB MAX MIN HIGH LOW MAX DT MIN DT RH VP TOT LOW TOT RAINY WET DRY HEAVY DAY WS

-- ------ ------------------------------------ --------------------- -------- -------- -------------------------------------- -----

1 1015.1 20.5 17.8 27.3 16.5 29.5 13.2 32.8 29 10.0 10 75 18.3 1.8 0.5 16.6 0.9 113.2 0.0 84.8 10 9.8

1011.6 24.3 20.5 1946 1899 70 21.4 1.9 0.4 1968 1968

2 1012.8 23.4 20.4 29.2 19.3 32.7 15.6 36.7 13 11.7 09 75 21.7 1.8 0.9 17.7 0.9 197.6 0.0 134.4 14 12.2

1009.3 26.1 23.0 1954 1934 76 25.7 2.3 1.0 1937 1937

3 1010.3 26.4 23.4 30.6 22.3 33.8 18.9 40.0 29 15.6 05 77 26.4 1.8 0.7 16.2 1.0 190.7 0.0 95.8 03 16.6

1006.7 27.4 25.1 1956 1925 82 30.1 2.9 1.2 1940 1957

4 1007.2 28.0 25.7 31.1 24.7 34.1 21.8 38.9 02 18.5 25 82 31.1 2.5 0.6 18.9 1.3 153.8 0.0 133.6 16 21.0

1003.6 27.9 26.2 1940 1967 87 32.7 4.8 1.9 1971 1971

5 1003.1 29.6 27.2 32.3 26.4 35.3 22.5 43.3 18 19.3 06 82 34.0 3.8 1.2 33.8 2.7 331.2 0.0 126.5 20 21.7

999.8 29.5 27.5 1915 1977 85 35.1 5.0 2.0 1940 1940

6 999.4 29.6 27.3 32.3 26.6 36.9 23.5 44.0 12 20.5 10 83 34.3 6.1 2.1 137.4 7.0 405.4 12.2 171.7 25 17.7

996.6 29.7 27.5 1965 1976 85 35.1 6.5 2.6 1914 1891 1914

7 999.6 28.4 26.4 31.0 25.7 34.9 23.2 39.4 04 20.6 16 85 32.9 6.7 2.7 197.9 10.7 545.6 18.3 200.9 23 15.9

997.1 28.7 26.8 1979 1929 86 33.7 6.9 3.2 1936 1911 1936

8 1000.4 28.5 26.4 31.3 25.7 34.1 23.3 37.2 04 18.6 27 84 32.7 6.6 2.6 218.2 11.7 528.8 26.4 229.9 21 13.1

997.8 28.7 26.8 1928 1976 85 33.6 7.0 3.2 1940 1905 1940

9 1003.8 28.5 26.2 31.8 25.4 34.5 23.0 36.7 29 20.6 08 83 32.4 5.9 2.2 206.8 9.8 502.4 40.2 295.4 12 11.4

1000.9 28.9 26.5 1920 1917 82 32.8 6.4 3.0 1914 1959 1968

10 1009.1 27.0 24.7 31.3 23.6 34.0 20.6 36.3 11 16.7 30 83 29.4 4.3 1.9 302.8 9.6 737.6 0.0 510.8 24 10.0

1006.0 28.4 25.3 1957 1897 77 29.7 5.0 2.3 1954 1954

11 1013.2 23.5 20.8 29.7 19.4 32.0 15.8 34.4 02 9.6 30 77 22.5 3.0 1.0 73.3 2.7 572.3 0.0 263.7 19 9.6

1010.0 26.5 22.0 1970 1970 67 23.0 3.5 1.1 1923 1923

12 1015.3 20.5 17.7 27.8 16.4 30.2 13.3 32.2 12 * 10.0 29 75 18.2 2.2 0.3 9.7 0.5 236.5 0.0 105.7 05 9.9

1011.9 24.4 19.9 1951 1902 64 19.6 2.6 0.4 1947 1909

-- ------ ------------------------------------ --------------------- -------- -------- -------------------------------------- -----

YR 1007.4 26.2 23.7 30.5 22.7 38.3 12.4 44.0 9.6 80 27.8 3.9 1.4 1264.6 58.8 2040.9 655.1 510.8 14.1

LY 1004.3 27.5 24.8 79 29.4 4.6 1.9 1936 1920

YRS 30 30 30 30 30 30 30 90 90 30 30 30 20 30 30 100 100 100 27

30 30 30 30 30 30 20

* Occurred More Than Once

Annexure – 2.3

Sheet 2 of 2




at Chatrapur, Dist. Ganjam in Odisha Saraf Agencies Private Ltd.

STATION : Gopalpur 43049 LAT: 19 16 N LONG: 84 53 E HT. ABOVE M. S. L. 17 METERS DATA 1951 To 1980

Weather Wind speed % Wind Direction Total Cloud Low cloud Visibility

-- ----------------------------------- -------------- --------------------------- -------------------- ------------------------ ------------------------------

MN PPT HAIL THUN FOG D.STM SQUA 62 61 19 0 N NE E SE S SW W NW 0 0 T-2 3-5 6-7 8 0 T-2 3-5 6-7 8 F8 <1 1-4 4-10 10-20 >20

-- ----------------------------------- -------------- --------------------------- -------------------- ------------------------ ------------------------------

1 1.1 0.0 0.1 0.5 0.0 0.1 0 1 29 1 59 2 0 0 1 2 1 30 5 14 7 5 4 1 26 4 1 0 0 0 0.1 1.1 21.7 7.2 0.9

0 3 27 1 2 4 30 35 19 7 0 0 3 13 9 5 3 1 25 5 1 0 0 0 0.0 0.1 21.9 7.5 1.5

2 1.4 0.0 0.8 1.3 0.0 0.0 0 1 23 4 39 4 1 1 4 13 3 20 15 12 7 5 3 1 18 6 3 1 0 0 0.0 1.3 19.1 7.4 0.2

0 8 20 0 1 2 9 23 39 24 1 0 1 9 8 6 5 0 15 8 4 1 0 0 0.0 0.9 18.0 8.2 0.9

3 1.9 0.0 2.7 0.8 0.0 0.3 0 5 22 4 15 3 1 1 16 34 3 9 18 15 7 5 3 1 20 7 3 1 0 0 0.2 1.9 21.9 6.8 0.2

0 17 14 0 1 1 1 9 40 44 1 1 2 8 8 7 6 2 17 8 5 1 0 0 0.0 1.0 21.6 7.2 1.2

4 3.0 0.0 6.5 0.8 0.0 0.6 0 11 17 2 3 1 1 3 24 52 2 3 11 9 8 7 5 1 22 6 2 0 0 0 0.1 2.5 21.5 5.7 0.2

0 21 9 0 1 1 0 2 32 59 2 1 2 2 4 8 13 3 9 11 9 1 0 0 0.0 1.5 21.8 6.6 0.1

5 4.5 0.0 5.9 0.3 0.1 0.7 0 12 17 2 3 1 3 3 31 47 2 2 8 4 6 10 8 3 17 7 6 1 0 0 0.2 3.0 22.7 4.6 0.5

0 20 11 0 2 1 2 7 34 49 3 1 1 1 5 9 12 4 8 13 9 1 0 0 0.0 2.6 23.0 4.6 0.8

6 11.0 0.0 7.1 0.0 0.0 1.1 0 8 18 4 6 3 3 3 19 45 3 5 13 0 2 6 13 9 10 9 10 1 0 0 0.0 2.8 22.3 4.3 0.6

0 14 15 1 2 2 2 5 25 51 4 4 5 1 1 5 13 10 5 10 14 1 0 0 0.0 2.4 22.3 4.5 0.8

7 15.9 0.0 6.0 0.0 0.0 0.4 0 7 19 5 5 1 1 2 15 52 5 4 15 0 1 4 14 12 6 10 13 2 0 0 0.0 2.3 22.7 5.5 0.5

0 14 16 1 3 2 2 4 21 54 6 4 4 0 1 4 12 14 2 10 17 2 0 0 0.0 1.7 22.0 6.4 0.9

8 16.4 0.0 7.6 0.0 0.0 0.4 0 5 21 5 7 2 1 2 13 43 7 4 21 0 1 5 15 10 5 10 14 2 0 0 0.0 2.0 23.0 5.2 0.8

0 11 18 2 2 1 1 7 22 47 8 4 8 0 0 4 14 13 2 10 17 2 0 0 0.0 2.0 22.2 5.8 1.0

9 13.6 0.0 8.6 0.1 0.0 0.6 0 3 21 6 20 3 2 2 9 25 4 13 22 1 2 7 13 7 7 11 10 2 0 0 0.0 1.6 21.4 5.7 1.3

0 8 19 3 5 3 6 10 24 35 4 4 9 0 1 5 15 9 2 12 14 2 0 0 0.0 1.2 21.0 6.6 1.2

10 11.8 0.0 6.0 0.4 0.0 0.6 0 1 27 3 43 5 1 2 3 6 2 27 11 3 6 8 9 5 11 10 7 3 0 0 0.0 1.6 22.0 5.5 1.9

0 3 25 3 7 11 21 19 20 9 1 2 10 1 5 8 11 6 8 11 10 2 0 0 0.0 1.2 21.9 6.1 1.8

11 3.4 0.0 0.5 0.1 0.0 0.1 0 1 28 1 56 4 1 0 0 1 0 34 4 8 7 6 6 3 19 6 4 1 0 0 0.0 0.8 19.8 7.3 2.1

0 1 28 1 10 18 33 24 7 1 0 1 6 5 8 7 7 3 18 7 4 1 0 0 0.0 0.4 22.3 5.7 1.6

12 1.1 0.0 0.2 0.1 0.0 0.0 0 1 29 1 56 2 0 0 0 0 0 35 7 14 7 5 4 1 27 3 1 0 0 0 0.0 1.0 21.2 8.1 0.7

0 1 30 0 3 14 40 33 7 1 0 0 2 9 9 7 5 1 26 3 2 0 0 0 0.0 0.2 23.2 7.2 0.4

-- ----------------------------------- -------------- --------------------------- -------------------- ------------------------ ------------------------------

YR 85.1 0.0 52.0 4.4 0.1 4.9 0 56 271 38 26 3 1 2 11 27 3 16 11 80 61 73 97 54 188 89 74 14 0 0 0.6 21.9 259.3 73.3 9.9

LY 0 121 232 12 3 5 12 15 24 32 3 2 4 49 59 75 116 66 137 108 106 14 0 0 0.0 15.2 261.2 76.4 12.2

YRS 28 24 29 23 23 23

24 29 23 23 23


3 - 1




SECTION - 3

TECHNICAL FEATURES

3.1 Introduction & Basic Design Consideration Saraf Agencies Private Limited (SAPL) intends to set up 1x15 MW

captive power plant at village Mayapatna near Chatrapur in Ganjam District

of Odisha with coal from Indonesia or Talcher coal fields in Odisha would be

used as prime fuel. It is proposed to implement a single unit station of 15

MW with sub-critical steam parameters. State-of-the-art technology would

be considered for design of the proposed station.

The design of the system and system components for the proposed station

would consider the following basic design parameters :-

• Max./Min. ambient temp. : 44 °C /9.6 °C

• Seismic Co-efficient : As per Zone-III of IS-1893 • Predominant wind direction : From South-west

• Soil bearing capacity : To be investigated.

• Cooling water pressure and : 15-20 MWC, 33 °C (max.)

temperature in condenser cooling circuit • Auxiliary cooling water : 40-60 MWC, 33 °C (max.)

pressure and temperature The proposed CPP comprising of one unit of 15 MW steam generator and

turbine generator would deploy Rankine Cycle for generating steam &

power. Steam Generator with Fluidized Bed Combustion (FBC) technology

has been proposed.

There are two categories of FBC boilers viz. Atmospheric Fluidized Bed

Combustion (AFBC) and Pressurized Fluidized Bed Combustion (PFBC). In


3 - 2




AFBC option, the Fluidized bed is used to generate steam for power

production using Rankine Cycle. PFBC boilers operate at lower pressure and

thus offer the potential of smaller boilers in comparison with AFBC. Thus

AFBC technology would be adopted. For the present study, one 65 TPH

AFBC boiler with 110 ata and 540 °C is envisaged.

3.2 Main Plant & Equipment Station would comprise one(1) no. steam turbine set each of nominal

capacity of 15,000 kW. Load demand for the Titanium Project is not steady

throughout the day. As a metallurgical plant, it also requires minimum

power to avoid stack out condition of the plant. It is proposed that the

Titanium project would float on grid and will draw power during shortfall. In

case of excess generation the power may be evacuated to the discom. To

meet this requirement, and keeping in mind nature of scheduled and

unscheduled outages of steam generator and STG sets, it is proposed that

the steam requirement of TG set shall be met by one(1) no. boiler.

Basic thermodynamic cycle adopted for the power plant would be non-reheat

regenerative Rankine Cycle. To achieve higher overall efficiency and

conservation of energy, regenerative feed heating using bleed steam from

turbine would be adopted. Steam from four(4) extractions would be used

for feed heating in L. P. heater, deaerator and H. P. heaters respectively.

The improvement in cycle efficiency and the resulting saving in fuel cost

justifies the increased investment and maintenance efforts for provision of

one L. P. and two H. P. feed heaters. The mass and energy balance diagram

of the power plant island is shown in Drawing No.14O02-003-DWG-PD-

002.

While deciding on the plant layout, availability of land and the available

infrastructure like road access to the plant, prevailing wind rose, direction of

water supply and power evacuation will be considered to facilitate

construction and for cost effectiveness. The plant layout would also consider


3 - 3




all auxiliaries required for the unit. In Drawing No.14O02-003-DWG-PD-

001, tentative plant layout is shown.

Steam Generator Set The steam generator will be of AFBC type. Study of the mass and energy

balance diagram reveals that the estimated total steam generation required

for each 15 MW TG set is about 59 TPH. Considering a design margin of

8%, the required generation works out to 65 TPH. CPP may be operated

both on island mode or interconnected with grid. However, to optimize

capital cost and energy charge it is proposed to operate the station by

floating on the state grid. The capacity of the boiler will be of 65 TPH. The

station configuration will be 1 boiler (65 TPH) for 1 turbine. Each unit would

be complete with Firing System, Fans and ESP’s. A twin flue gas chimney 78

m high would be provided (considering provision of adding one more unit in

future).

The number and rating of the boilers has been considered as follows : No. of Boiler : One(1)

Capacity of each Boiler : 65 TPH

Steam pressure at Boiler outlet : 110 ata

Steam temperature at Boiler outlet : 540 ºC

Turbine Generator Set The steam turbines would be standard multi-stage, 3000 rpm, tandem

compound, regenerative, condensing, multi-cylinder unit with three(3)

uncontrolled extractions for regenerative feed water heating. The LP turbine

will exhaust against a condenser pressure of 76 mm Hg (abs) and maximum

cooling water temperature of 33 ºC. The unit will be equipped with all

auxiliaries as per good engineering practice.

The steam turbines will be directly coupled to the horizontally mounted,

three phase, two-pole, cylindrical rotor type electric generators and will have

a nominal rating of 15 MW at generator terminal after meeting power


3 - 4




requirement for excitation system. The generation would be operated at

0.85 power factor.

Condensing Equipment & Accessories The function of the condenser is to condense the turbine steam exhaust and

to produce and maintain vacuum as high as possible in order to increase the

enthalpy drop, which can be utilised for increase of power generation in the

turbine.

The condenser will be single-flow box-type surface condenser. It will be

located below the turbine and form an integral part. Each condenser unit

would be transverse mounted and would condense exhaust steam by

circulation of cooling water (inlet temperature 33 ºC max.) in a recirculating

cooling water system using wet type cooling tower. Clarified water would be

the cooling medium in the condenser. Stainless steel heat exchanger tubes

are envisaged. Condenser pressure would be maintained at 76 mm of Hg

(absolute). The heat load of the condenser will correspond to the turbine

operating condition with VWO having 105% MCR steam flow. The

condensate/feed water cycle would also comprise 3x50% capacity motor-

driven, vertical condensate extraction pumps of CAN type construction. The

feed water heating system shall also comprise three(3) 50% capacity motor-

driven boiler feed water pumps.

3.3 Auxiliary Plant Systems

Plant Water System As discussed earlier, the sweet water requirement for the entire station is

proposed to be met by water from Rushikulya River located 10 km from the

plant site. With wet type cooling as option, sweet water requirement for

consumptive use for the proposed 1x15 MW station is estimated about 128

m3/hr. As per the available data on river water quality, a cycle of

concentration of 5 is considered in the estimation. As an alternative, Air

Cooled Condenser (ACC) may be used for the water scare region. ACC may


3 - 5




be of direct type or indirect type. For water cooled system, evaporative

cooling is deployed but in case of air cooled system steam (for direct type)

or DM water (for indirect type), primary coolant, would be cooled by

convection and/ or radiation by passing cooled air by the fans. ACC is pitted

with higher condenser pressure and thus loss of generation. Secondly, ACC

is more cost intensive and the revenue cost is marginally higher. On overall

basis, depending on ambient parameters cost of energy 4 to 5% higher.

With loss of generation, marginally higher energy cost air cooled condenser

is deployed in a ‘No Project Situation’ due to inadequate availability of water.

For ACC as option, consumptive water requirement will be around 44 m3/ hr.

With the water quality available, water treatment plant would comprise

clariflocculation, sand bed filtration and demineralization plant. Water

balance diagram is shown in the Drawing No.12O01-003-DWG-PD-003.

Coal Handling System Two(2) types of coal are envisaged for the proposed project. Coal from

Indonesia would be transported by sea and thereafter by truck from the

port. Alternately, coal from Talcher coal fields may be considered for the

CPP. Coal would be stacked with the help of stacker-cum-reclaimer.

Quantity of coal envisaged for the project considering imported coal and

indigenous coal would be 0.71 lakh Te per annum and 1.05 lakh per annum

respectively at 85% load factor. Bunker would have storage capacity of

about 12 hours coal requirement.

Coal Handling System considered for the station is based on the following

assumptions :-

Mode of transportation of coal : Option-1 : By sea and thereafter by truck from port for Indonesian coal.

Option-2 : By road from Talcher

mines for Indian coal. Daily coal consumption with : Option-1 : 224 TPD for Indonesian 85% load factor coal Option-2 : 338 TPD with Talcher coal


3 - 6




Bunker capacity : 12 hours storage

Lump size of incoming raw coal : (-)50 mm

Ash Handling System The Ash Handling System for the proposed 1 x 15 MW CPP would comprise

wet extraction system by jet pumps for Bottom Ash (BA). For fly ash, dry

extraction and conveying under vacuum from hoppers up to Fly Ash

intermediate surge hopper and pressurized conveying of Fly Ash to terminal

ash silo would be envisaged. Ash from the silos would be consumed in

house main plant. Unutilized fly ash, if any, would be disposed in slurry form

to ash disposal area. Bottom ash would be disposed in slurry form to ash

disposal area. An ash disposal area about 3 acres is considered outside the

plant boundary for accommodating four(4) years’ ash generation.

The quantum of ash generation would depend on the plant load factor and

the quality of coal being fed. The capacity of the Ash Handling Plant is

dependent on the design coal parameters. Since both indigenous and

imported coal are envisaged, the ash generation for both the coals will be

different. For imported coal with ash content 14%, fly ash would be 1.19

TPH (max.) and bottom ash would be 0.26 TPH. For coal from Talcher

mines, with ash content of 42%, fly ash generation would be 5.31 TPH

(max.) and bed ash would be 1.18 TPH.

3.4 Electrical Plant & Systems

Generation System

Proposed power plant will have 1 x 15 MW STG units at Chatrapur CPP

generating power at 11 kV level. Generated power will be received at 11 kV

indoor switchgear and further it will be stepped up at 33 kV for feeding to

the titanium plant as well as intake pump house. Single bus bar

configuration will be considered for the 33 kV switchyard with following

circuits:-


3 - 7




Four (4) – 33 kV circuits for outgoing lines for Titanium Plant and Intake Pump House

One (1) - Incoming line from 132 kV sub-station of OPTCL through one

132/34.5 kV interconnecting transformer. One (1) – Power transformer for Stepping-up the generated power

Start-up power for the unit will be received from 132kV Chatrapur

substation through LILO connection as shown in the drawing. The 132 kV

will be stepped down to 33 kV by 10 MVA, 132/34.5 kV transformer for

receiving the power at 33 kV switchyard during unit start-up. These will be

further stepped down to 11 kV to receive power at 11 kV switchgear and

feeding to the plant auxiliaries during starting.

A control room will be located in the switchyard premises to house

switchyard control, metering and protective equipment.

In the powerhouse the generator will be directly coupled to the steam

turbine. The generator will be a two-pole, three-phase unit rated for 15 MW

at 0.8 p.f. lag. 50 Hz. The nominal voltage rating will be 11 kV with

variation of ±5%, 50 Hz -5% +3%, 3-phase. The excitation system will be

brushless type and will be selected for an ideal rate of response, accuracy

and sensitivity during normal as well as transient state of operation.

The generator will be connected to the 11 kV indoor switchgear for receiving

the generated power. Further the generated power will be stepped-up to 33

kV and will feed to 33 kV switchyard. For stepping up one(1) no. 16/20

MVA, 33/11 kV, three phase power transformer is considered. The

transformer will be provided with ONAN/OFAF type cooling. Vector group of

transformer will be YNd11. The connection between transformer low-

voltage terminal to the 11 kV switchgear will be done by Segregated phase

busduct and high voltage terminals of power transformer will be connected

to the 33 kV Switchyard through overhead ACSR conductor.


3 - 8




Power Supply Arrangement to the Unit & Station Auxiliaries Two voltage levels viz. 3300 V and 415 V have been envisaged to supply

power to unit and station auxiliaries. The drives for auxiliary equipment,

having capacity above 160 kW up to and including 1500 kW will be fed from

3.3 kV system. All motors rated 160 kW and lower will be fed from 415 V

system. Suitable HV and LV switchgears, as described below, will be

provided for operation of these motors. Scheme of the electrical power

distribution arrangement to the plant auxiliaries have been shown in

Drawing No.14O02-003-DWG-PD-004.

During normal operating condition of generators, the power supply to

unit/station auxiliaries will be from the 11 kV switchgear through one no.

Unit Auxiliary Transformer (UAT). UAT will be connected to 11 kV

switchgear through Al, XLPE cable and will be rated for 5 MVA, 11 kV/3.45

kV and with ONAN cooling, Dyn1 vector group.

Power requirement for unit start-up will be drawn from 132/33 kV

Switchyard as shown in the attached drawings. One(1) no. Power

Transformer have been envisaged for receiving the power at 11 kV

switchgear and feeding the plant station loads through 11/3.45 kV UAT.

The power supply to unit auxiliaries like ID fan, FD fan, PA fan, BF pump,

CW pump, Mill, CE pump, DMCW pump etc. will be from 3.3 kV Switchgear

fed by UAT.

The station auxiliary loads will also be fed from 3.3 kV Switchgears located

in the powerhouse.

One(1) no. 2.5 MVA, 3.3 kV/433 Volts, 3-phase, 50 Hz, LV auxiliary

transformer will be provided for feeding the LV auxiliary loads. The HV side

of these transformers will be connected to 3.3 kV switchgear by Al, XLPE


3 - 9




cables and the LV side will be connected to the LV Switchgear/Power Control

Centre (PCC) through non-segregated phase bus duct.

Separate 415V MCC shall be provided for turbine auxiliaries. Boiler and ESP

auxiliaries shall be fed from Boiler MCC. All other loads like Coal handling,

Cooling tower, water system, ash handling system shall be fed from Station

Aux. MCC and shall be located suitably.

The 3.3 kV systems will be designed for 40 kA fault level with short-time

rating 3 seconds. The 415 V systems will be designed for 50 kA fault level

with short-time rating 1 second.

Emergency Power Supply System 415V emergency power supply system has been envisaged to provide power

to essential auxiliary loads required to permit a safe shut down of the unit in

the event of a plant blackout. In addition, emergency power will be

provided for auxiliaries and services required for personnel safety and

equipment safety during the blackout. In order to meet the above

requirement One(1) no. 100 kVA diesel generator set will be installed,

considering emergency loads for the unit.

Plant DC System 220V Plant DC system has been envisaged for reliable power supply to those

loads, which are required to function for security, protection and safe

shutdown of plant in the event of failure of normal AC power supply.

One(1) 220 V battery set of adequate capacity will be installed for each unit.

Another battery set of similar capacity will be provided as common standby.

DC power supply system for each unit comprises:

• 220 Volt DC batteries

• Battery charger (float and float-cum-boost charger)

• DC distribution and sub-distribution boards

Battery will be either Lead Acid PLANTE type or Nickel-Cadmium (Ni-Cd)

type and the battery will be sized for one(1) hour back up time subsequent


3 - 10




to tripping of generating units. Separate battery sets will be provided for

132 kV & 33 kV switchyard, coal handling system and plant water system, if

required.

Uninterrupted Power System Two(2) sets of UPS systems of continuous duty have been envisaged to

supply regulated, filtered and uninterrupted 240 V, 50 Hz, single phase

power to critical AC loads during normal as well as emergency conditions.

UPS battery will be sized for at least thirty(30) minutes back up on failure of

normal AC supply. A separate UPS system of continuous duty has been

envisaged for 33 kV switchyard control room.

Control of Electrical System Centralised control system shall be considered for control of electrical

system/equipment. Following controls will be achieved in the central control

room through Plant DCS System.

Control and operation of 33 kV switchyard will be done from switchyard

control room. Accordingly, the 33 kV switchyard will be provided with

complete sub-station automation system with connectivity to plant DCS

system.

DG sets will be controlled from AMF panel in DG room. Remote control

provision will also be provided in plant DCS.

Control panels for service system like coal handling plant, ash handling

plant, plant water system, etc. will be located in the respective control

room.

Protection & Metering System Numerical relays with 100% redundancy will be used for protection of

electrical equipment.


3 - 11




Plant electrical parameters will be metered to the extent for proper

operation and monitoring of plant conditions. Separate check and main

meters will be provided in 132 kV and 33 kV switchyard line for tariff

metering.

Illumination System Suitable illumination system will be provided to facilitate normal operation

and maintenance activities and to ensure safety of working personnel.

Required illumination levels in different areas will be as per standards/code

of practice. Power supply for the illumination system will be derived from

the following sources :

• Normal AC System – to be powered from 415 V normal AC supply • Emergency AC System – to be powered from 415 V emergency DG set

• Emergency DC System – to be powered from 220 V plant DC system

Illumination system will consist of lighting transformers, lighting distribution

boards, indoor & outdoor type lighting panels, different types of lighting

fixtures suitable for different plant areas, lighting cables & wires, etc.

Intercommunication System Two-channel voice communication system with ‘Paging’ mode as well as

‘Private’ mode has been envisaged for plant intercommunication. A

microprocessor based Digital Electronic Private Automatic Branch Exchange

(EPABX) is envisaged for the telephone communication system.

Grounding & Lightning Protection System Comprehensive grounding system will be provided in the power plant which

will be achieved by ground mat buried at one(1) meter depth below ground

and provided with ground electrodes at suitable intervals or as per IEEE80.

All metallic parts of power plant and switchyard equipment/structures will be

connected to the ground mat.

Generator neutral will be high resistance grounded through distribution

transformer and secondary loading resistor. 3.3 kV systems will be high


3 - 12




resistance grounded to limit the fault current to the order of 300 Amp. 415

V power supply system will be solidly grounded. DC system will be

ungrounded.

For grounding of electronic equipment, a separate earthing system totally

isolated from the power equipment earthing mesh risers will be provided.

Lightning protection system will be installed for protecting the buildings/

structures against lightning discharge. This would be achieved by providing

lightning masts/shield wires on stacks, powerhouse building, floodlight

towers, towers in switchyard etc. and connecting them with the ground grid.

3.5 Instrumentation & Control System

Introduction The proposed plant control will be implemented with Distributed Control

System (DCS). DCS will integrate various Closed Loop Control Sub-System

(CLCS), Open Loop Control Sub-System (OLCS) and Monitoring and

Information Sub-System (MIS) for the entire plant including monitoring of

various offsite systems.

Control system will be designed utilising microprocessor based, state-of-art

networking technology to ensure :

a. High system availability and reliability taking into consideration reasonable redundancies at various levels.

b. Extensive diagnostics capability.

c. Low downtime and high meantime between failures.

d. System flexibility and expansion capability.

e. Safety of the equipment, system and operating personnel. System upgradation capability in terms of hardware and software will be

considered.

The control system will be configured to perform the basic functions like,


3 - 13




• Automatic sequencing for the start-up and shutdown. • Regulation functions for various valves and dampers. • Protection of plant system equipment. • Acquisition, display and logging functions. For various offsite plants viz. Coal Handling Plant (CHP), Ash Handling Plant

(AHP), Water Treatment Plant, BMS etc. depending on their criticality of

application, separate stand-alone Programmable Control Systems (PLC)

have been envisaged with redundancy.

Philosophy of Control & Operation The complete Visual Display Unit (VDU) based operation has been envisaged

for the main plant with back-up for a few critical controls.

For ease of operation, the entire plant has been conceptually divided into

the following units.

• Steam Generator Unit • Turbine & Auxiliaries • Offsite Plants An integrated, functionally Distributed Control (both binary/sequential and

modulating) and Data Acquisition System synthesized from one general

family of identical interchangeable hardware has been envisaged for the

plant. The Control System will be real time multi-user and multi-tasking

type. Malfunctioning of any single piece of hardware, a module of software

and loss of power will not jeopardise plant’s safety and will bring the

equipment in fail-safe mode. Uniformity in hardware and software will be

provided throughout the system for simplicity in operation, maintenance and

to minimise spare parts.

The Control and Monitoring System will include the following features : a. All the controllers will be connected to a common high speed (10 MB)

data highway for global distribution and access of data. All data will be available to any point as and when required.

b. The control system will be of open system architecture so that

expansion of the system will be possible by adding extra stations on


3 - 14




the data highway without disturbing the operation of rest of the system.

c. Signal transmission from field to DCS will be normally in the form of

4-20 mA DC/1-5 V DC/T/C/RTD/Pulse/ND/NC contract. d. 1 of 2 logic for critical parameters and 2 out of 3 logic for all trip

circuits will be provided. e. Comprehensive self-diagnostic features will be provided to facilitate

easy fault location upto card/channel level and detection of failure without individually checking each module.

f. Control system and instruments supplied will be of reputed make and

of latest proven design.

Distributed Control System (DCS) Different sub-systems for the DCS shall be as follows :- a. Input/Output Signal Processing b. Closed Loop Control Sub-systems c. Open Loop Control Sub-system d. Data Acquisition Sub-system e. Historical Storage Sub-system f. Performance Calculators Station g. Engineering and Configuring Station h. MMI Sub-system i. Data Highway & Gateway for interfacing with other systems

Scan Times & Response Times The system will fulfil following scan times and response times :- i) Controller cycle time will be within 200-500 msec (adjustable) for

CLCS and DAS and less than 100 msec for OLCS. ii) All analog inputs to CLCS will be acquired and data base updated

within a maximum interval of 250 msec. iii) All remaining analog inputs (4-20 mA, TE), which are not connected to

CLCS but solely used for Data Acquisition System will be scanned and database updated within 500 msec.

iv) Keyboard command to field equipment will be executed in less than 1

sec. under worst loading conditions.


3 - 15




v) Sequence of Events (SOE) system will be integrated within DCS and record the status change of event with time tagging, date and event details with 1 msec resolution.

Displays & Logs A few typical displays and logs have been indicated below :- 1. Real Time Parameter/Status Display 2. Real Time Trend/Historical Trend Graph “Display 3. Alarm Summary Display/printout 4. Start-up Log/printout 5. Synchronisation/Loading log/printout 6. Shift Log/daily log/printout 7. Trip log/printout 8. Operator Control Screens For operation of various controls in CLCS and OLCS, interactive overview

displays, group displays, sub-group displays and individual loop displays will

be provided. All these displays will consist of real time mimic diagram,

control face plates, CLCS, OLCS etc.

System Software The system software will preferably be based on open architecture.

Instruments Measuring Instruments : a. Process Transmitters All the Process Transmitters will be smart type. b. Process Gauge In addition to remote transmitters, process gauges have been

considered in design. These include Pressure Gauge (Bourdon/ Bellows type), Temperature Gauge (mercury filled-in type with SS armoured capillary), Level Gauge (Transparent and Reflex type).

c. Temperature Sensor For high temperature measurement in a relatively high vibration zone,

duplex type thermocouple with SS protecting tube and Magnesium Oxide filling will be provided. Suitable 3-wire resistance temperature


3 - 16




detector will be provided, in general, with SS protecting tube. SS thermowell as per ASME PTC code will be provided as accessories.

d. Process Switches For critical alarm and protection/interlock functions, direct process

switch contacts will be used for better reliability. Switches will be blind type.

e. Flow Elements For measurement of flow of various fluids generally Orifice Plates.

Flow Nozzles, Venturies/Pitot tubes and positive displacement meters have been envisaged.

Steam & Water Analysis System (SWAS) SWAS will be designed for continuous monitoring of steam and water

quality. SWAS will have mainly 2(two) separate sections viz. sample

handling system and dry section.

Vibration & Supervisory Systems In order to monitor and control mechanical health of various machineries,

supervisory measuring instruments will be deployed in important drives and

equipment. For turbines, instruments for measuring various physical

parameters like eccentricity, axial shift, absolute vibration etc. will be

installed. These measuring and supervisory systems will be complete with

sensors, junction box, special cables, transmitters, monitors and

communication capabilities with DCS.

Gas Analysers & Emission Monitoring System a. For combustion quality monitoring and control, signals from various

flue gas analyzers like Oxygen, Carbon Monoxide etc. will be deployed.

b. For monitoring emission from exhaust gas continuous Emission

Monitoring System will be provided for SOx, NOx, solid particles etc. as per regulation. The instruments will be designed, manufactured and tested conforming to API and EPA.


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Final Control Element a. In general, pneumatic type Power Cylinders for Air and Flue Gas path

and control valves have been envisaged for regulating type control purpose.

Control valves will have pneumatic diaphragm actuators, complete

with suitable positioners, air lock valve, position transmitters, I/P converters, limit switches, handwheel etc.

b. For system like governing control etc. depending on manufacturer’s

recommendation, hydraulically controlled final control element will be used.

c. Unless necessitated for the process application for ON-OFF and inching

services, electric actuators will be provided. d. For trip applications solenoid operated valve will be used depending

upon the requirement of the manufacturer.

Control Desk/Cabinet/Enclosures Suitable Operator Console housing CRT, Keyboard, Mouse etc. have been

envisaged. For housing control electronics necessary electronic system

cabinet will be used Instruments and electronics will be so arranged and

grouped that the layout will correspond with realities of the process and will

facilitate operator’s supervision at the same time. Instruments and devices

will be so mounted that the removal and replacement can be accomplished

individually without interruption of services to others.

Cable Necessary cables including data highway cable, instrumentation cable,

compensating cable etc. have been envisaged. Generally cables will be

screened and armoured. For data highway cable, optical fibre may also be

used. All interconnecting cables between two(2) cabinets will preferably be

prefabricated type with suitable prefab connectors at both end.


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Erection Hardware Erection hardware including all process connection and piping materials like

impulse pipe, manifolds, fittings, pneumatic line tubes and pipes along with

necessary fittings, junction boxes, cable accessories like conduits, trays etc.

have been envisaged. Depending on pressure, temperature and type of

process fluid, materials and pressure class of erection hardware will be

selected.

Power Supply & Utilities Normally 24 V power supply will be used for Control System and this will be

driven from battery and battery charger unit with adequate redundancy.

For other applications 240 V AC, 50 Hz uninterrupted power supply will be

made available from UPS complete with voltage and frequency regulators.

Power supply units for the Control System will be distributed cabinet-wise.

Instrument air and service air as required for C&I application will be derived

from sub-headers for instrument air and service air.

3.6 Plant Layout The area identified for locating the power plant is a virgin plot located within

the boundary of the main plant boundary of Titanium Project of SAPL. The

station conceived to locate one unit of 15 MW would be a captive power unit

with all the auxiliaries. The plant layout of the proposed captive power

station within the identified space adjacent to the Titanium Plant is shown in

Drawing No.14O02-003-DWG-PD-001.

A conventional layout for the boiler and the turbine has been suggested for

the power plant with TG set axis longitudinal to the boilers. The turbine bay

is followed by the heater bay and the electrical bay, the boiler proper,

electrostatic precipitators and lastly the chimney. The main plant area

houses the turbine building, steam generator, 132/33 kV switchyard,


3 - 19




circulating water system, water treatment and DM plant, in-situ receipt,

storage and handling of coal and the ash disposal system.

Unitised concept has been followed in the plant design as far as practicable.

The unloading-cum-erection bay is considered at the beginning of the unit.

The main power block with the switchyard is located on the south of the

plot. On the north-east of the power block is the water treatment facility

which will receive raw water from the raw water reservoir considered to be

located outside the plant boundary. The water from Rushikulya River will be

received by cross-country pipeline through the raw water reservoir

considered outside the plant boundary. It is proposed to deploy wet type

Induced Draft Cooling Towers in the recirculating cooling water circuit. The

cooling towers are located along the wind direction at a suitable location

near the powerhouse building to optimise on length of C.W. piping.

However, alternatively air-cooled condenser may be explored during further

engineering.

A coal storage area has been planned for the station on the west of the

Power Plant location. This would cater more than 2 months’ requirement of

fuel for the station presently considered.

The captive power plant along with the auxiliaries and accessories will be

located within a common security wall of the Complex. The access roads for

the main plant will be utilised for the CPP also.

The Administrative Building for the entire complex would be common and is

located at the entry to the plant. The entry to the Complex will be flanked

by security gate, time office, first-aid centre.

Provision of disposing fly ash by trucks for gainful utilisation from ash silos

located on the eastern side of the plot is kept. The ash truck route has been

provided in the layout.


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3.7 Civil Engineering Aspects

Plant Levels The general grade level of the plot varies from 19 m to 30 m above MSL.

The finished grade level of the plant is envisaged at 28 above MSL. This will

involve cutting and filling for land development. As per prevailing slope

drainage would be directed towards south-east.

Soil Characteristics & Foundations The soil investigation of the plot is yet to be conducted. It was noticed

during reconnaissance visit of the area, the top cover is composed of sand

mixed with clay and rock outcrops are seen. Detailed soil investigation is

necessary for deciding on the type of foundation. For the purpose of the

report pile foundation for main plant building and raft foundation for

auxiliaries and other miscellaneous buildings has been considered.

Seismic Consideration The power station is located in Seismic Zone-III as identified in IS:1893-

1984 of Indian Code of Practice. Analysis and design of structures to resist

the seismic forces are to be carried out accordingly taking into consideration

the factors related to soil characteristics and importance of the structure

together with the basic seismic co-efficient as per provision of Indian Code.

Wind Loading The maximum wind pressure including winds of short duration as specified

in IS-875-1987 (Part-3) will be adopted for the zone where the proposed

power station is located. The site is located in the zone as per above

standard having design wind speed of 61 m/sec. The provision of Indian

Standard Code of Practice IS:875 with appropriate co-efficient for variation

of heights, shape, proximity to sea etc. will be considered during detailed

design.


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3.8 Environmental Aspects The nearest meteorological station of Indian Meteorological Department is at

Gopalpur. The major climatological data of the station have been indicated

earlier. The prevalent wind direction is from south-west.

The area identified for power station falls under Ganjam Coast of Utkal Plain

which is not very wide in this region and appears to be as the main and

erosional surface merging imperceptibly with a narrow belt of marshy land

and sand dunes near the sea shore. The power plant area will be located in

the Rushikulya basin, which is at the foothill of the eastern ghat. The plot

has sandy soil with rock outcrop at places.

There is no forest land, national park, wild life sanctuary, eco-sensitive areas

or archeological sites within 10 km from the site radius. Being 2-3 km away

from the coast line, the plot does not falls under Coastal Regulatory Zone

(CRZ). It is 500 m away from Highway or railway station. The nearest river

Rushikulya is 10km away from the site.

The effect of the on social infrastructure will be note worthy with the

economic spin-off of major investment. There will be overall facelift and

improvement of the surrounding area due to proposed Titanium Project

along with CPP.

A green belt buffer would protect adjoining areas in close proximity to the

ash dump as well as a necessary ash management plan would be adopted in

an environment-friendly manner to contain the fugitive ash emission in the

nearby areas. It is proposed that ash generated from the station would be

consumed by in house use for main project. A zero discharge of waste water

from the plant during normal operation would be attempted. A twin flue gas

chimney is proposed to be constructed with a height of 78 m considering

future provision of adding one more unit.


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The effect of the proposed project an environment would be mitigated in the

following manner :-

• Air pollution : An efficient electro-static precipitator (separation

efficiency of about 99.89%) along with a properly designed boiler would

keep the stack emission of particulate matters within acceptable limits.

With average quality of coal and 6 to 7 field ESP, SPM emission shall be

restricted to 1 kg per hour considering imported coal and 5 kg per hour

considering indigenous coal. The total ground level pollution (SPM)

would be restricted within 50 mg/Nm3.

With average quality of imported coal (sulphur @ 0.9%) SOx emission

would be 172 kg/ hr at MCR.

• Waste water effluent : It is envisaged that the liquid wastes

collected in the guard pond shall be treated and adequate retention

time permitted. The treated waste water from the guard pond would

be recycled to less priority areas for reuse. Attempt would be made to

attain zero discharge of waste water from the plant during normal

operation. Waste water management scheme is depicted in Drawing

No.14O02-033-DWG-PD-005 of the report.

• Solid Waste : The solid waste in the form of coal ash, which will have

to be disposed off in an environmentally accepted manner.

• Noise pollution : Adequate silencing equipment will be provided at

various noise sources to attenuate the noise to acceptable level.

• Green verge : To be developed as per MoEF norms.

The area does not have any large industry in the vicinity and the major

habitation from the proposed plant location is at Chatrapur. The

background pollution level, in terms of SPM, SOx, NOx etc. of the area is as

such well below the prescribed limits of CPCB/MOEF.


3 - 23




Project authority would institute a separate study on Environmental Impact

Assessment (EIA) to ascertain background pollution and identify the effect

of the project on the surrounding environment. As such the plot identified

for the project does not involve any eviction and thus no rehabilitation and

resettlement (R & R) would be involved. Thus, no adverse environmental

impact is foreseen.

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4 - 1




SECTION - 4

PROJECT EXECUTION AND IMPLEMENTATION

4.1 Construction Aspects

General Requirement The proposed power generation plant being developed as a captive unit

would be able to share some of the infrastructural and construction facilities

to be created for the main plant. The layout of various buildings have been

developed considering requirement of basic amenities during construction

stage which may be converted to permanent facilities during plant operation.

Open space will be provided for setting up contractors’ offices, stores and

fabrication yard etc. However, nearby plots have to be rented for setting up

batching plant, outdoor storage, labour hutment, other fabrication facilities.

It has been envisaged that other facilities like administrative office, time

office, security, laboratory, workshop, stores, etc. as available for the

Titanium Project will be utilised during construction stage.

Access to Plant Site The proposed plant will be located within the premises of Titanium Project

within the Special Economy Zone (SEZ). The plant site is located on the

southern side of the Titanium Plant. Necessary internal roads for

construction purposes will be built. The plot will be connected from National

Highway No.5 by a corridor being procured by the project authority.

Rail connection has not been envisaged for the project. The plant layout

envisaged now has a road entry from east to bring in coal other plant

materials. Another road from west is proposed as main entry to the

Titanium Project. These roads will meet necessary requirements for ensuing

movement of ODC/heavy consignment.


4 - 2




Construction Water & Construction Power The construction water (about 25 m3/hr) and construction power (about

1500 kVA) required will be obtained from the centralised network and

distributed throughout the project area. The Titanium Project has an

allocation of 400 m3/day of ground water. Considering the health of the

grid, DG set may be arranged to ensure construction activity.

Construction Equipment It is expected that construction/erection contractors will bring their own

plant/equipment, tools and tackle for construction of the project. A few

construction equipment, viz. bulldozers, pay loaders, mobile crane, winches,

lifting tackle, etc. are however, proposed to be procured by the Titanium

Project authorities which will be loaned to contractors whenever need arises.

These equipment will be later utilised for plant operation and maintenance.

Transport vehicles like cars, jeeps etc. are also proposed to be procured for

use by Owner’s project personnel.

4.2 Organisational Set-up The organizational set-up envisaged for operation and maintenance of the

proposed plant is given in Drawing No.14O02-004-DWG-PD-002.

On completion, the generating station will be under the charge of the

General Manager. The operation and maintenance of the station would,

however, be the direct responsibility of the Manager (O&M) working under

the General Manager. Other functions viz. administration, finance, safety,

legal, medical etc. will be looked after by the establishment of main plant.

The total operating manpower deployment is estimated as 49 in keeping

with the design and operating philosophy.

It is assumed that maintenance staff will be versatile enough to be utilised

throughout the plant wherever needed. The above staffing is based on the

philosophy on minimising the manpower during evening and night shifts and


4 - 3




concentrating on maintenance efforts during the day shifts when the

maintenance supervisory personnel are at the plant actively engaged in

supervision. A minimum number of people, therefore, will be in attendance

during the evening and night shift on the assumption that only temporary

and minor repair will be carried out during these hours. Should major

repairs be necessary during this period, the shift supervisor will have

responsibility of deploying the appropriate maintenance personnel for the

job. It is anticipated that with this method of operation, a large number of

maintenance staff can be avoided.

4.3 Project Implementation Schedule Present indication of the delivery period of major equipment (i.e. boiler and

turbine generator) reveals that it will not be too optimistic to expect that the

one-unit station may be commissioned within 21 months after ordering of

main plant equipment. The project schedule is presented in Drawing

No.14O02-004-DWG-PD-001 enclosed.

It is imperative that the whole procurement should be packaged in such a

manner that will lead to shortest gestation period, obtain firm guarantee on

performance and completion schedule and make investment remunerative.

Successful implementation of any project requires the joint participation of

the Owner, the Engineering Consultant, the Vendors and the Contractors.

The Owner plays the most important role in spelling out the objectives,

setting out the time schedules and ensuring the flow of funds. For

implementing the project, the Owner may engage the services of competent

Engineering Consultant to advise and assist in the design, engineering and

procurement of equipment and services and for project management

services required for the project. The Vendors and Contractors in turn,

render the services required from them in the spirit of the specification

prepared by the Engineering Consultant.


4 - 4




4.4 Project Execution

Project Organization The project will be implemented under the overall direction of the Chief

Executive assisted by the Project Department. This department will include

a team of experienced engineers from various disciplines, headed by

discipline leaders.

The Project Department, supported by the Engineering Consultant will be

responsible for the project from its inception to the final commercial

operation of the plant.

In specialised areas, Project Department will need assistance in matters

relating to Real Estate, Legal, Industrial Relations, Security, Purchase &

Finance, Material Management etc. in the process of execution of the

project.

Project Execution Team The principal objective of the project execution team comprising Owners

concerned departments and their Engineering Consultant is to design,

procure, construct and commission the plant within the scheduled time and

cost, ensuring high availability factor of the generation equipment. These

are broadly classified as under.

Basic Design & Planning The basic design parameters firmed up in the Detailed Project Report stage

along with their implications on cost of the project and implementation

schedule form the basic guideline. The component systems and sub-

systems of the Captive Power Plant will be reviewed for compatibility with

each other and conformity with statutory regulations. Cost estimates are

reviewed for comprehensiveness and checked against budgetary quotations

and/or engineered costs of other similar projects. The project schedule is


4 - 5




analysed to find out the critical path and the floats calculated for other non-

critical items.

Engineering Procurement The total project work will be grouped into various system-based work

packages. The grouping will be done in a manner so that the interfaces and

terminal points are clearly and conveniently defined, to minimise

interlinking/inter-phasing problems.

Specifications for each package or item will be prepared by the Engineering

Consultant and these will be finalised after review by the Project

Department.

Pre-award Contract Management The specifications will be prepared indicating broad parameters and basic

technical requirements, along with necessary commercial and contractual

sections. Tenders will be invited for each package or item from selected

technically competent, reliable and financially sound manufacturers/

suppliers. The system of tendering, grouping of equipment and services and

procedure for award of contract will be carefully formulated with the basic

objective of obtaining the most reliable and proven equipment to meet the

technical requirement and parameters and to operate it the desired level of

technical efficiency at the optimum cost. Offers against tenders will be

evaluated by the Engineering Consultant for both technical and commercial

aspects. Based on the Consultant’s recommendation, contract will be

awarded to the selected bidder by Owner’s Project Department.

Post-award Contract Management This function involves expediting and co-ordination of work through constant

follow up with the Contractors in order to ensure timely deliveries of

equipment as per the requirements of the project schedule and conforming

to specification.


4 - 6




Manufacturers’ Level-1 network for delivery schedule for each contract will

be prepared by the Contractor/Supplier in relation to target schedule and

associated activities. Manufacturers’ drawings will then be reviewed by the

Engineering Consultant. Revisions, if required, will be incorporated promptly

by the vendor. Computerised status of activities will be compiled by the

Engineering Consultant at regular intervals during the progress of

engineering, manufacturing and delivery for information of the Project

Department. Quality assurance and physical progress at manufacturer’s

works will be regularly monitored by the Engineering Consultant.

Inspection and expediting engineers of the Engineering Consultant and

Owner will be sent to manufacturers’ works during appropriate stages of

progress, such as, assembly, testing of trial operation of plant and

equipment wherever necessary before giving clearance for despatch.

Arrangements will be made for witnessing shop tests of major equipment by

the Engineering Consultant and/or the Project Department representatives.

Material Management A team of project personnel at site will be entrusted with the responsibility of

receiving, handling and safe storing of the materials under the supervision of

the respective sections. Sequential storing according to erection schedule

will be carried out and records will be maintained.

Construction & Erection For fast implementation of the project, it is envisaged that major packages

will be awarded on total responsibility basis. The Contractors will be

entrusted with design, engineering, manufacture, supply, erection, testing

and commissioning for these packages.


4 - 7




Other packages or items will be executed on supply basis and separate

orders for erection and/or supervision of erection and commissioning will be

issued.

Under the contract agreement, the Contractor will be bound to complete

delivery and/or erection within the specified schedule. All actions will be

taken to keep the target as scheduled. Progress of activities by the

Contractors, their resources and ability to adhere to the quality control will

be supervised constantly. Arrangements will also be made for timely

delivery at site, of drawings and working manuals from the Contractors.

Necessary assistance, if required, will be rendered to each Contractor for

mobilization before commencing erection/construction.

Testing & Commissioning A Testing & Commissioning group including Operation & maintenance

personnel will be deputed by the Engineering Consultant and Owner for

witnessing pre-commissioning checks and final commissioning of various

plant and equipment. A commissioning network and procedure will be

prepared jointly with all concerned which will guide the team for execution of

commissioning activities. Proper documentation of the commissioning

activities will be made for safe and orderly commissioning of the plant.

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5 - 1




SECTION - 5

ESTIMATION OF PROJECT COST AND TARIFF

5.1 Basis of Estimate The project cost estimate prepared and furnished in this section covers the

works cost of the station with prices prevailing in the first quarter of 2014-

15. Cost of main power generating equipment, which constitutes the major

share of the basic power generation project cost, is based on quoted price of

reputed suppliers for similar units for a project of this configuration. Cost of

other major electrical and mechanical plant and equipment have been

arrived at on the basis of similar quotations from reputed manufacturers

and/or cost data for similar equipment procured for other projects.

Civil costs have been estimated in reasonable detail on the basis of

prevailing material and labour rates. Cost of land is not considered in the

estimate as the plot is already available with the Owner.

Estimates have been prepared and presented in the Annexure-5.1

enclosed. No provision has been kept for escalation in the estimate. The

project is located within SEZ area and the supply price is added with other

cost parameters leviable as follows :

• Excise Duty : Not required.

• Sales Tax : 2%

• Freight incl. Transit Insurance : 2.5%

• Erection, Testing & Commissioning : 7% for Mechanical and Electrical equipment, Instrumentation items estimated.

Interest during construction is envisaged on the basis of 12.5% annual

interest rate. Margin money for working capital has been calculated on the

basis of 30 days’ reserve of coal, 60 days’ reserve of fuel oil and one month

O&M expenses.


5 - 2




5.2 Phased Fund Requirement The project schedule shown earlier indicates that the power plant unit will be

commissioned in appropriately 21 months time from the date of placement

of order of main package i.e. boiler and turbine generator unit for the two

units.

Expenses during the first year will consist of land improvements,

construction facilities, approach roads, preliminary investigations, survey,

design and engineering charges, general expenses and advance payment for

the plant and equipment.

Orders for bulk of the civil work will also be placed during this year.

Considerable amount of steel procurement, fabrication and civil work will be

done. Substantial advance payment to other plant and equipment suppliers

will also be given.

Expenditure will be the heaviest during the second year. The major

mechanical and electrical equipment will be delivered and erected during

this period. The erection charges and allied expenditure will also be the

heaviest, during this period.

Bulk of the design and engineering work will be done during the first year

and early part of second year. General overhead charges will be

comparatively low in the first year and distributed proportionately to the

volume of work in the subsequent year.

The estimate of phased capital expenditure and interest for the construction

period has been considered in estimation of interest during construction,

which is capitalised.


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5.3 Project Cost Estimate

The estimated capital expenses for the proposed 1x15 MW CPP have been

detailed in Annexure-5.1. This works out to `922.33 million without

considering interest during construction (IDC) and other financial charges. A

debt to equity ratio of 2:1 is considered. The debt would be financed by

Banks/Financial Institutions and the equity would be generated by project

proponent. The debt portion would attract a long term interest @ 13% p.a.

and working capital loan would be available at an interest rate @ 13% p.a.

On the basis of above the capitalised project cost including IDC works out to

`977.50 million.

5.4 Estimation of Cost of Generation The financial analysis has been worked out on the following options :- 1. Tariff has been calculated considering imported coal. During operation

in future if indigenous coal is linked to the station the tariff would be accordingly worked out.

2. Gross coal calorific value for imported coal is considered as 4800

kCal/kg

3. Delivered cost of imported coal is taken as `4500 per MT. Escalation in fuel supply price is considered @ 6.62% per annum.

4. Effective annual generation as 7446 kWh/kW installed (i.e. plant

utilisation factor 85%). 5. Cost of secondary fuel is considered @ 58000 per KL in the 1st year of

generation. Escalation in fuel oil is considered @ 5.85% per annum. 6. Plant heat rate as 3050 kCal/kWh. 7. Station auxiliary power consumption @ 10% of gross power

generation. 8. The debt equity ratio as 2:1

9. Rate of interest on term loan considered as 13% per annum on long term loan.


5 - 4




10. Loan repayment in equal instalments of ten years is considered

without any moratorium period. 11. Operation and maintenance charges on account of costs incurred in

salary of operating personnel, lubricant, consumables, insurance, etc.

have been adopted @ `20.99 Lakhs per MW of capitalised project cost

in the 1st year of operation. An escalation @ 5.85% is adopted in the estimate.

12. Duty on self-generation has not been considered in the estimate. 13. The captive power plant shall be floating on grid and provision will be

kept to evacuate excess power and vis-à-vis draw power from the grid as per requirement.

14. The start-up power requirement of the captive power plant is

considered 6 MVA. 15. Depreciation has been provided on straight line method as per

guidelines of Central Electricity Authority (CEA), generally @ 5.28% p.a. considering plant life of mother unit.

16. Equity to be raised through Right issue/Preferential allotment of equity

shares to Promoters. 17. Being a captive power plant the entire station will have a consolidated

balance sheet and profit & loss account and hence no tax working have been shown.

18. Return on Equity (ROE) has been considered @ 15% per annum. On the basis of above assumptions, the estimated cost of generation works

out as follows :

Tariff (@ 85% PLF)

• 1st year of full generation : `5.47 per kWh

The detailed financial analysis is furnished in Annexure-5.2 (14 sheets) at

the end of this report.

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