2008

CONTENTS

STANDARD
PROPOSAL
MODULE FOR 3x660
MW COAL BASED
THERMAL POWER
PLANT

1. INTRODUCTION

2. PROJECT MANAGEMENT PROCEDURES

3. PLANT DESIGN BASIS

4. SCOPE OF WORK, TERMINAL POINTS AND EXCLUSIONS

4.1 SCOPE OF WORK

4.2 TERMINAL POINTS

4.3 EXCLUSIONS

5 TECHNICAL WRITE UP

BASED ON SUPERCRITICAL TECHNOLOGY

5.1 MAIN PLANT (STEAM GENERATOR & STEAM TURBINE

GENERATOR AND

PIYUSH KUMAR SINHA

AUXILIARIES)
MBA Power Management

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: -

POWER SECTOR REFORMS

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

Things to be included in the EPC Proposal

1. INRODUCTION
2. PROJECT MANAGEMENT PROCEDURES
3. DESIGN BASIS
4. SCOPE OF WORK, TERMINAL POINTS & EXCLUSIONS
5. BASIS OF OFFER
6. TECHNICAL DATA SHEETS
7. DRAWINGS & DIAGRAMS
8. SCHEDULE OF PRICES
9. TIME SCHEDULE
10. PERFORMANCE GUARANTEE SCHEDULE
11. COMMERCIAL BID

Brief Descriptions of these are as follows:-

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,

DETAILS,

PLANNING ,

FUEL
POWER

EVACUATION ARRANGEMENTS, WATER REQUIREMENTS , PLANT LAYOUT, POLLUTION ,

WATER

ARRANGEMENTS ,

L AYOUT ,

POLLUTION STANDARDS,

LOGISTICS

LOGISTICS ARRANGEMENT , LAND REQUIREMENTS(1.4 MW/Acre for indigenous coal and 0.53 for imported

coal including MGR & cooling tower) are given in introduction.

2. PROJECT MANAGEMENT & PROCEDURES

MANAGEMENT APPROACH
Define sequence of work and establish project organization.
Staff the organization, required communications & equipments.

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

M ANAGEMENT I NFORMATION S YSTEM

D OCUMENT C ONTROL & D ESIGN

S UBMISSIONS

P ROCUREMENT & F IELD C ONTRACTING

P RODUCTION C ONTROL & M ANUFACTURE

I NSPECTION & T ESTING

M ATERIAL C ONTROL

Q UALITY A SSURANCE

C ONSTRUCTION M ANAGEMENT

C OMMISSIONING & T ESTING

S TART U P D OCUMENTATION

S ITE M ANAGEMENT & I NSURANCE

Table 1
Project organization Structure - Office

FIGURE 2

3. PLANT DESCRIPTION & DESIGN BASIS

This is mainly detailed description of all important equipments(Steam generator, Steam
turbine & generator, Water system, Fire protection system, Compressed air system, Fuel oil
handling system, Air condition & ventilation system etc) their technical specifications and
manufacturing parameters. Please go through main project report for more details.

Standard Proposal Module for 3x660 MW Coal based Thermal Power Project

4. SCOPE OF WORK, TERMINAL POINTS & EXCLUSIONS

SCOPE

OF S TEAM

GENERATOR : - Followings equipments come under the scope of steam

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)

SCOPE OF WORK : MECHANICAL

Water system, CHP & AHP, Effluent treatment plant, Fire protection system, Air
conditioning & Ventilation system, Cranes & hoists, Turbine auxiliaries, Compressed air
system, Power cycle piping, Fuel oil systems, Chemical laboratory & equipment, Pumps,
Auxiliary boiler

SCOPE OF WORK : E LECTRICAL

Evacuation & distribution system, Main generation system, Emergency power, Transformers
Switchyard, Isolators & circuit breakers, Cabling & illumination, Earthing & lightning
protection, Control protection & metering system, Plant communication system

SCOPE OF WORK : CONTROL & INSTRUMENTATION

Distributed control system, Programming logic controllers, Control & instrumentation for
STG & auxiliaries, Steam water & analysis system, Continuous emission monitoring system,
Centralized vibration monitoring system, Plant security & surveillance system, Plant LAN
work, Testing & calibration system, Air & weather monitoring system.

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.

EXCLUSIONS: - This is mainly distinction of responsibilities, clarification of scope of works,

obligations, schedule of works.

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

6. TECHNICAL DATA SHEETS

These are all technical data of all equipments supplied and installed with their capacities.
Please go through main project for detailed technical specifications.

7. DRAWINGS & DIAGRAMS

All drawings are supplied wherever required. Namely Plot Plan, PIDs (Process N
Instrumentation Diagrams), Turbine Cycle Scheme, Water & Steam System Scheme, Coal
Handling System Flow Diagram, Fly Ash Handling System, Bottom Ash Handling and Slurry
System etc.

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.

ON SHORE SUPPLY CONTRACT:-

Includes Ex-works price of equipments including

design and engineering, packing and forwarding, Excise Duty, Central and State Sales Tax,
Transportation, entry tax & others.

ON SHORE SERVICES CONTRACT:- Includes Scope of services, mentioning design and

detail engineering, project management services, erection, testing and commissioning ,
clearing, forwarding of Offshore supply of goods at Indian port, transportation and transit
insurance, performance Guarantee tests, training and service tax & other duties.

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

10. PERFORMANCE GUARATEE SCHEDULE

This has to be given for all units of power plant and auxiliaries in respect of all items based
on specified design and parameters mainly specifying the followings:-

PERFORMANCE GUARANTEE UNDER LIQUIDATE DAMAGE: - Value inclusive design,

manufacture & other tolerances with required clarifications. (Gross STG Power Output,
Total Auxiliary Power Consumption, Gross unit heat rate, Station Heat rate, SGMCR etc.)

PERFORMANCE GUARANTEE UNDER CORRECTION:-

This contains Value inclusive

design, manufacturing and other tolerances including measurement uncertainty with

required clarifications(BMCR & TMCR Ratings, Noise Level, Vibration
level,
other
systems as per tender specifications)

11. COMMERCIAL BID

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 ESTIMATION & CLEARANCES FOR 3x660 MW TPP

Sr.
No
100
200
300
401
401
401
402
403
404
404
404
404
405
406
407
408
409
410
411
500
501
505
600
700

Preliminary cost Estimate for 3x 660 MW TPP

COST
% Cost
( Crore )

Preliminary investigation & survey

Civil Works
Mechanical Works
Main Plant
Steam generator with associated auxiliaries
Turbo generator with associated auxiliaries
Coal handling Plant
Ash Handling Plant
Water System
Sea Water Intake including intake piping and outfall
Water treatment plant( Desalination & DM)
Cooling tower including pumps
LP & CW piping including valves, specialities and fittings
Air conditioning system and ventilation system
Fire protection system
Cranes/ Hoisting Equipments
Compressed air System
Miscellaneous Equipments, tanks, Piping, Insulation etc
Sub Total
GRAND TOTAL MECHANICAL
Electrical Works
Electrical cost AS PER ROW
Cost of transmission line & plant instrument & control
Lumpsum
Total works Cost ( Prelims+ civil + mech+ elec+ C& I)
EPC Project Cost

2.5
800.0
5367.4
3900.0
2500.0
1400.0
480.0
260.0
540.0
200.0
180.0
160.0
65.0
20.0
60.0
10.0
13.0
19.4
5367.4
5367.4
350.0
300.0

200.0
2.85%
7019.9 100.00%
7019.9 100.00%

COST
( Crore)

COST BREAK UP
Supply Of Main Plant Equipment System
Supercritical Boiler Including Auxiliaries

2500.0

Supercritical STG & Auxiliaries

1400.0

Supply of BOP Equipment System

Other mechanical Equipment System

1467.4

Electrical Equipment System and C&I

850.0

Engineering & Project management

Erection & commissioning
Civil Works
Total

0.04%
11.40%
76.46%
55.56%
35.61%
19.94%
6.84%
3.70%
7.69%
2.85%
2.56%
2.28%
0.93%
0.28%
0.85%
0.14%
0.19%
0.28%
76.46%
76.46%
4.99%
4.27%

% Total cost
(9023 Crores)

3900.0

43%

2317.4

26%

351.0

4%

352

4%

800

9%

7720.5

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

Suggestions & Recommendations

Growing economies always need a proportional need for power. Country like
India has a required growth in power sector close to 15 %. In order to match
the accelerated need of country, there is urgent need is to take the challenge to
squeeze the time and cost required to complete a coal based power project. If
some more R&Ds could fetch some reductions in total EPC costs and could
increase operating efficiencies, it would be a great relief to fund hungry power
projects.
We should go for large size projects which are more efficient and less
polluting than several smaller units. One more field which needs to be
prioritized is Risk management and project management that play a very
crucial role in carrying out such big projects.
BIBLIOGRAPHY
www.cea.nic.in , Report on land Requirement
http://powermin.nic.in/, Report on Generation
www.ntpc.co.in , Generation & Plants
http://www.worldenergy.org/ ,
www.bhel.com
www.power.alstom.com
www.google.com
http://en.wikipedia.org/

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