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CONTENTS
1. INTRODUCTION
5 TECHNICAL WRITE UP
STANDARD PROPOSAL MODULE FOR 3x660 MW COAL BASED THERMAL POWER PLANT
BASED ON SUPERCRITICAL TECHNOLOGY
PIYUSH KUMAR SINHA AUXILIARIES)
MBA Power Management
5.1 MAIN PLANT (STEAM GENERATOR & STEAM TURBINE GENERATOR AND
5.2 BALANCE OF PLANT- MECHANICAL piyushkrsinha@gmail.com 5.3BALANCE OF PLANT ELECTRICAL 5.4BALANCE OF PLANT CONTROL AND INSTRUMENTATION 5.5 CIVIL, STRUCTURAL AND ARCHITECTURAL WORKS 6 BASIS OF OFFER 7 TECHNICAL DATA SHEETS AS PER TENDER SPECIFICATIONS 8 DRAWINGS AND DIAGRAMS
Standard Proposal Module for 3x660 MW Coal based Thermal Power Project
EXECUTIVE SUMMARY Power Crisis has been a long clamor in India and this seems to persist for the coming decade or so. Beyond optimistic illusions, ground realities are too fierce to be accepted. Seeds of improvement are however being planted at all possible arenas broadly Indicating: -
FIGURE 1
The Project Idea springs from one of the reforms Viz. generation of Power. To cater the accelerated need of the country Ultra Mega Power Plants (UMPPs) have been proposed. These are giant power plants of 4000 MW at one place. In addition to these, a number of Mega Power Projects (More than 1000 MW) are also being promoted. The unit size of power plants has also experienced a supercritical shift in technology. Thus focus is on more efficient supercritical units of 660 MW and 800 MW. However considering imported coals as the main fuel, unit size can go up to 1000 MW. As the domestic coal
Standard Proposal Module for 3x660 MW Coal based Thermal Power Project
available for power sector is having very high (40 to 45%) ash content feasibility of higher size units are yet to be examined. Meanwhile after 500MW / 600 MW (subcritical) the next suitable supercritical size was decided 660 MW or 800 MW for coal based thermal power plants. This Project has been based on study and formulation of EPC proposal of 3x660 MW coal based thermal power plant (Super Critical Technology). It also includes plant design basis, scopes of work different packages & technical write up of main plant as well as Balance of Plants. Cost estimation and percentage cost breakup of the Thermal power plant spells out the brief overview of the EPC project cost. 2.0 INTRODUCTION The study shall form the basis for the standard proposal module for the 660 MW project. As the gear of technology is experiencing a critical shift in power sector, India is keen to welcome the Supercritical technology. The first stage of capacity shift is seen to be 660 MW which is being adopted by NTPC and other private sector players for several upcoming projects. The assignment covers supply of complete main plant with BOP package on Engineering, Procurement and Construction (EPC) basis and making standard proposal module of this. EPC work can exclude civil works, coal handling system, ash handling system, external raw water system and water intake system depending upon the projects. The power plant configuration considered for the project shall be having 3 identical units to generate gross power 1980 MW.
Standard Proposal Module for 3x660 MW Coal based Thermal Power Project
1. INTRODUCTION MAJOR EQUIPMENTS:3 units of steam generator, 3 units of steam turbine generator and other associated systems in line with specific tender document taken as reference and as per the scope of work.
Besides this,
PLANNING ,
FUEL POWER
DETAILS,
WATER
ARRANGEMENTS ,
L AYOUT ,
POLLUTION STANDARDS,
LOGISTICS
LOGISTICS ARRANGEMENT , LAND REQUIREMENTS(1.4 MW/Acre for indigenous coal and 0.53 for imported
Standard Proposal Module for 3x660 MW Coal based Thermal Power Project
PROJECT COORDINATION
It is very important at all levels Viz. Engineering, Procurement, Construction, and Start Up. Some Other Important aspects of project management are as follows:-
P LANNING & S CHEDULING D OCUMENT C ONTROL & D ESIGN S UBMISSIONS P RODUCTION C ONTROL & M ANUFACTURE M ATERIAL C ONTROL C ONSTRUCTION M ANAGEMENT S TART U P D OCUMENTATION
I NSPECTION & T ESTING Q UALITY A SSURANCE C OMMISSIONING & T ESTING S ITE M ANAGEMENT & I NSURANCE
Table 1
FIGURE 2
Standard Proposal Module for 3x660 MW Coal based Thermal Power Project
generator. Boiler pressure parts (Economiser, Super Heater, Reheater), Boiler structure Flues , Ducts, Fuel feeding system, Oil system, Combustion equipments( Pf Burners, Igniters, Oil Burners), Boiler auxiliaries( FD , ID, PA Fans, BCP, Air heaters), Cabling, control & monitoring system, Electrical ( HT & LT Motors, Insulation, Refractory), ESP, Milling plant ( Coal Pulverizer)
TERMINAL POINTS: - This is the point of deliveries under mutual agreements between
contractor and owner. E.g. - Raw water, Coal, CW piping, Fuel oil, Civil works, Electrical evacuation, Construction system, Construction power, Roads.
Standard Proposal Module for 3x660 MW Coal based Thermal Power Project
5. BASIS OF OFFER
This is mainly distinction of responsibilities, clarification of scope of works, obligations, schedule of works, vendor list and quality manuals wish can be categorized under following heads: Clarification to tender documents....Doubts are made crystal clear Customer obligation Expectations from customer/ Owner Project scheduleDetail anticipated project completion schedule are submitted Vendor list..Equipments Suppliers list Quality manual....This shall be provided by the Contractor
8. SCHEDULE OF PRICES
Price Schedule (FOB/CIF plus duties & Taxes) is submitted which has details of followings:-
OFF SHORE SUPPLY CONTRACT: - Cost components of foreign & Indian rupees with
marine freight & Insurance, Custom Duty, other taxes & duties.
design and engineering, packing and forwarding, Excise Duty, Central and State Sales Tax, Transportation, entry tax & others.
9. TIME SCHEDULE
Time schedule are given for design, manufacture, delivery at site (FOB portion and Ex-Works portion), equipment erection, commissioning, performance guarantee tests Start and finish.
Standard Proposal Module for 3x660 MW Coal based Thermal Power Project
design, manufacturing and other tolerances including measurement uncertainty with required clarifications(BMCR & TMCR Ratings, Noise Level, Vibration level, other systems as per tender specifications)
Letter of Submission, Company profile, Bid security, Power of Attorney/Letter of Authority, Information forms, Application for bidding, Statement of bidders, Experiences & references, Financial data, Schedules, Un-price, Clarification / Deviation schedule to general conditions of contract & Letter of submission have to be specified in this.
Standard Proposal Module for 3x660 MW Coal based Thermal Power Project
COST BREAK UP Supply Of Main Plant Equipment System Supercritical Boiler Including Auxiliaries Supercritical STG & Auxiliaries Supply of BOP Equipment System Other mechanical Equipment System Electrical Equipment System and C&I Engineering & Project management Erection & commissioning Civil Works Total
COST ( Crore) 3900.0 2500.0 1400.0 2317.4 1467.4 850.0 351.0 352 800 7720.5
26%
4% 4% 9% 86%
Standard Proposal Module for 3x660 MW Coal based Thermal Power Project
LIMITATIONS
There were some limitations with respect to the analysis and data that may affect the accuracy of the results: EPC Proposal depends largely on Bid Requirements so may be some sections may not be as applicable. This is only a rough cost estimate and may differ from prevailing market conditions. As EPC has three models BTG+BOP, Total EPC, STG+BOP, hence scope of work and cost estimation can vary from project to project. Some costs components like Land, Transportation etc. can vary depending on site location.
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Standard Proposal Module for 3x660 MW Coal based Thermal Power Project
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