Professional Documents
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BOARD (BPDB)
FINAL FEASIBILITY REPORT
KHULNA
THERMAL POWER PROJECT (2X660 MW)
BANGLADESH
CONSULTANT CLIENT
The present installed capacity (derated) in June, 2012 is 8,100 MW. Gas
based power stations constitute 66.88 % of present generation capacity
while coal based power plants constitute only 2.47 %. According to Power
System Master Plan (PSMP) 2010 developed by Bangladesh Power
Development Board (BPDB), the demand in 2030 will be about 33,000
MW and installed capacity is targeted to reach 38,685 MW. Out of this,
coal based generation capacity is expected to be 20,000 MW. BPDB has
also carried out generation expansion planning for the period 2012-2016,
wherein total additional capacity to be installed by the end
of 2016 is 13,154 MW including 1,320 MW proposed at Khulna.
MOU was signed with BPDB for implementation of 1320 MW coal based
TPP at Khulna in Joint Venture on 30.08.10.
Meeting was held in NTPC, New Delhi on 01.11.2011 & 02.11.2011 with
BPDB officials and various sensitivity options based on coal cost, coal
calorific value, interest rates and equipment cost were worked out and
shared with BPDB.
BPDB informed in mid December 2011 that M/s CEGIS, Consultant for
Coal Transportation logistics study has collected details and data and the
same needs to be discussed and BPDB desired NTPC team to be
deputed for this purpose. NTPC team visited BPDB office, Dhaka on 25th -
27th Dec.2011.
The cost of coal for the recommended option of receipt of coal at jetty at
power plant end shall be USD 145 per metric ton. Coal shall be unloaded
at jetty at power plant end from barges.
The Draft Feasibility Report for Khulna Thermal Power Project comprising
of two units of 660 MW was submitted to BPDB on 30.03.2011.
The Final Feasibility Report (Draft) for Khulna Thermal Power Project
comprising of two units of 660 MW was submitted to BPDB on
31.12.2011. The comments received from BPDB on were incorporated in
the Final Feasibility Report and same was submitted to BPDB on
20.07.2012. The comments received till 08.11.2012 from BPDB and
11.11.2012 from BPDB/PGCB have been incorporated in present Final
Feasibility Report.
The power project site has been selected after examining three alternate
sites identified for the project by BPDB. These sites were visited by the
joint team of BPDB and NTPC and the present site near Rampal Upazila
of Bagerhat District was recommended for setting up the project. This site
is on the banks of Possur river, accessible by proposed road connecting
Khulna Mongla Highway. Second site near Chumkuri is opposite to
Rampal site and is on an island surrounded on all four sides by Possur
river and does not have any road access and hence was not found
suitable. The third site near Lobanchura is located on the banks of Rupsa
river. This site has only about 400 acres fertile and mostly privately owned
land, which is not sufficient for locating the power plant.
For Khulna project, about 575acres of land will be required. The same
includes 375 Acres for Plant, 50 Acres for Township, 50 Acres for Jetty
and about 100 Acres of land for ash disposal (Ash dyke). No major issue
is anticipated in acquisition as per discussions with BPDB officials.
The source of water for the project is saline water drawn from Possur
River (about 2 kms), which is primarily back water of sea. Sweet water
required for meeting the potable water, plant service water, cycle makeup
(DM water) etc shall be produced using Desalination process from sea
water. It is proposed to adopt Reverse Osmosis process for Desalination
of saline water.
Make up water requirement for this project would be about 9150 Cu.M/hr.
It is observed that water in Possur River is having very high silt content. In
once through system, huge quantity of water will be required. Desilting of
such huge quantity of water would be uneconomical. In cooling tower
system, only make up water needs to be provided and can be desilted.
Therefore, re-circulating type CW system with cooling towers and open
Coal Quality
The coal quality for FR purposes has been considered as imported coal
and the same is as follows:
Proximate analysis
Ash : 15 %
GCV (kcal/kg) : 6000
Sulphur 0.6 %
Coal Transportation
It is envisaged that coal shall be unloaded from barges at jetty near plant
end, as confirmed by BPDB/CEGIS. The envisaged mode of coal
transportation considered in FR from Jetty to the power plant is by
conveyor system.
Coal Handling System
The coal as received by barges at jetty near power plant end shall be
unloaded through rail mounted grab bucket type ship unloaders and shall
be conveyed to plant end by single stream 2000 TPH capacity conveyor
system.
Internal Coal Handling Plant
The coal as received from jetty near plant end through single conveyor
shall drop onto two either of vibrating screening feeders and crushers.
An independent coal handling plant is proposed to cater to the two (2)
units of 660 MW. Coal handling plant consisting coal conveying system
(with 100 % standby parallel stream) along with reclaimers, trippers etc.
2.09.00 Site Development & Civil Aspects
Natural ground levels as per the topographical survey are in the range of
(+) 1.15 to 1.35 M above MSL. HFL for cyclone Ayla in 2009 floods as
recorded and informed during site visits are (+) 4.47M above MSL. Hence,
FGL is proposed as (+) 5.0M above MSL.
Natural ground as per the Geo-tech data received from BPDB consists of
very soft clay up to 5M depth and further soft clay up to a depth of about
15M. Such soft soils offer negative drag on piles as well as very small
lateral pile capacities. To achieve sufficient lateral capacities in piles,
ground improvement is required. Ground improvement shall cover the
entire plant and township area. During meeting BPDB suggested that due
to non-availability of required sizes of aggregates, sand compaction piles
may be considered and now in revised FR the same is considered.
Approach Road:
Two lane (12M wide) main approach road to plant site is proposed from
Khulna-Mongla Highway. This will require about 20M wide corridor to be
acquired for about 15 Kms. road length. This road shall be constructed by
GOB/BPDB and cost provision for the same is not included in FR costs.
Coal Stock
Ash pond of 100 acres is assumed. Ash dyke will require ground
improvement.
2.10.00 Steam Generator Technology
The steam generators shall be super critical once through type, water
tube, direct pulverized coal fired, top supported, balanced draft furnace,
single reheat, radiant, dry bottom type, suitable for outdoor installation.
The gas path arrangement shall be single pass (Tower type) or two pass
type. Steam pressure & temp. at Super Heater outlet shall be 256 kg/cm2
and 568 deg. C and temp. at Reheater outlet shall be 596 deg. C.
Boiler design shall be suitable for variable pressure operation from 30% to
100% BMCR with and without 5% throttle margin.
2.11.00 Power Evacuation System
The COD of first 660 MW unit of Khulna Thermal Power Project will be in
48 months from the Investment approval and second unit after an interval
of 6 months thereafter.
2.15.00 Assumptions based on discussion with BPDB and input from
Consultant on Coal Transportation logistics study, M/s CEGIS for FR
formulation:
iii. The landed cost of coal per ton at plant end is considered as
US$145 as confirmed by BPDB / CEGIS.
vi. The cost of capital dredging from outer bar to plant site would be
borne by Govt. of Bangladesh(GOB). The cost of maintenance
dredging from outer bar to Mongla port would be borne by GOB.
The cost of maintenance dredging from Mongla port to power plant
site shall be booked to the power plant variable cost. The above
have been confirmed by BPDB in MOM dated 26-27th Dec.2011,
held at Dhaka. Maintenance dredging cost from Mongla port to
plant jetty considered is 4 Million USD per year.
vii. From Mongla port to outer bar: 26 Million USD per year( to be borne
by Govt of Bangladesh)
viii. Two lane (12M wide) main approach road will be constructed by the
Bangladesh Govt. to cater for heavy transport, trailers, ODC etc
from Babur Bazar Point of Khulna Highway to Power Plant Site.
Hence, cost provision for the same is not included in FR costs.
ix. Land Land: 400 acres of land will be developed after filling by
dredged material by GoB.
xi. The existing ground level shall be raised to RL (+) 5.0 M above
MSL, considering HFL of cyclone Ayla floods (+) 4.47 M above
xii. The cost estimate for Steam Generator, ESP, Ash Handling Plant &
Coal Handling Plant is based on imported coal of GCV – 6000
kcal/kg & max ash content of 15% and max Sulphur 0.6%from
Indonesia. Any change in coal source & its quality parameter will
impact the cost estimates & tariff calculations.
xiv. Ground improvement with sand columns shall be provided for plant,
township & for ash dyke embankment and cost for the same is
included in the project cost. However, alternate methods of ground
improvement shall be explored at detailed engineering stage.
xv. Many Cement plants exists in the vicinity, 100 % fly ash utilization
has been considered. Also 100% bottom ash utilization has also
been considered. However, ash dyke of 100 acres has been
provided in FR.
xvi. The project cost is estimated based on the latest awarded cost for
NTPC projects of similar capacities.
xvii. Water in Possur River is having very high silt content. Desilting of
huge quantity of water required for once through system would be
uneconomical. Therefore, re-circulating type CW system with
cooling towers and open intake channel has been envisaged for the
project.
xviii. As per the discussion with BPDB/ PGCB, provision of 2 nos. line
bays in generation switchyard (one no.400 kV D/C line envisaged to
connected to Dhaka ring main and one no. of 230 kV D/C line
envisaged to be connected to Khulna South) is being kept for power
evacuation from the project.
xix. Project Financing- Out of total 70% loan, the interest rate for 10% of
loan is considered as 15.5% and for balance 60% as 6.5% as ECA
funding. The loan repayment is considered in 10 equal annual
installments, with a moratorium period of 5 years, considering single
EPC package with ECA funding.
xx. Based on the information received, customs, excise and sales tax is
nil in Bangladesh so no tax is considered in the project cost.
1.0 Introduction 1
3. Mechanical Works
1.1.2
4. Electrical Works
1.1.3
9. Implementation Schedule IX
Final FR for Khulna project which has been revised taking into account
comments of BPDB/decisions as recorded in Minutes of meeting held at
Dhaka from 30th July to 1st Aug.2011 , NTPC office at Noida from 26th
Sept. to 29th Sept. 2011, NTPC, New Delhi on 01.11.2011 & 02.11.2011 ,
BPDB office, Dhaka on 25th -27th Dec.2011 alongwith M/s CEGIS,
Consultant for Coal Transportation Logistics Study.
2.00.00 PROPOSAL
As per annual report of BPDB for the year 2010-2011, the forecasted
demand is 6,454 MW with access to electricity only 50% whereas the
maximum generation is 4,890 MW and 1,335 MW load shedding at peak
hours is common in summer season.
3.00.00 CONCLUSION:
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3. FEASIBILITY STUDIES
1.00.00 SITE SELECTION
The power project site has been selected after examining three alternate
sites identified for the project by BPDB. These sites were visited by the
joint team of BPDB and NTPC and the present site near Rampal Upazila
of Bagerhat District was recommended for setting up the project. This site
is on the banks of Possur River, accessible by proposed road connecting
Khulna Mongla Highway. Second site near Chumkuri is opposite to
Rampal site and is on an island surrounded on all four sides by Possur
river and does not have any road access and hence was not found
suitable. The third site near Lobanchura is located on the banks of Rupsa
river. This site has only about 400 acres fertile and mostly privately owned
land, which is not sufficient for locating the power plant.
The proposed project is a coal based thermal power plant with rated
capacity of 1320 MW (2x 660MW). The proposed project is located in
Rampal Upazila of Bagerhat District. The site is bounded by villages
Mouzas- Kaigar Daskati, Kapasdanga, of Gaurambha Union, Mouzas-
Sapmari Katakhali, Baserhula of Rajnagar Union under Rampal Upazila.
The plant site is located between latitude and longitude of 22deg. 37’ 0’’ N
to 22deg. 34’ 30’’ N and 89deg. 32' 0’’E to 89deg. 34' 5’’E respectively.
The site is located 23 Kms. Southward of Khulna City, about 12 Kms.
North-eastward of Rampal Upazila Sadar and 14 Kms. North-eastward
from Mongla Port. The proposed Khan Jahan Ali Airport is located at a
distance of approximately 12 kms from the project site.
6.01.00 Land
For Khulna project, about 575acres of land will be required. The same
includes 375 Acres for Plant, 50 Acres for Township, 50 Acres for Jetty
and about 100 Acres of land for ash disposal (Ash dyke). No major issue
is anticipated in acquisition as per discussions with BPDB officials.
The source of water for the project is saline water drawn from Possur
River (about 2 kms), which is primarily back water of sea. Sweet water
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required for meeting the potable water, plant service water, cycle
makeup (DM water) etc shall be produced using Desalination process
from sea water. It is proposed to adopt Reverse Osmosis process for
Desalination of saline water.Make up water requirement for this project
would be about 9150 Cu.M/hr..
It is observed that water in Possur River is having very high silt content. In
once through system, huge quantity of water will be required. Desilting of
such huge quantity of water would be uneconomical. In cooling tower
system, only make up water needs to be provided and can be desilted.
Therefore, re-circulating type CW system with open intake channel &
cooling towers has been envisaged for the project.
6.03.00 Coal Requirement, Availability and Linkage
The coal shall be imported coal. The daily coal requirement for 2 x 660
MW units shall be about 12920 tonnes based on average gross calorific
value of 6000 Kcal/ kg at 100% plant load factor. Annual coal requirement
for the project shall be about 4.72 MTPA.
Coal Quality
The coal quality for FR purposes has been considered as imported coal
and the same is as follows:
Proximate analysis
Ash : 15 %
GCV (kcal/kg) : 6000
Sulphur 0.6 %
Coal Transportation
It is envisaged that coal shall be unloaded from barges at jetty near plant
end, as confirmed by BPDB/CEGIS. The envisaged mode of coal
transportation considered in FR from Jetty to the power plant is by
conveyor system.
The coal as received by barges at jetty near power plant end shall be
unloaded through rail mounted grab bucket type ship unloaders and shall
be conveyed to plant end by single stream 2000 TPH capacity conveyor
system.
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Internal Coal Handling Plant
The coal as received from jetty near plant end through single conveyor
shall drop onto two either of vibrating screening feeders and crushers.
An independent coal handling plant is proposed to cater to the two (2)
units of 660 MW. Coal handling plant consisting of coal conveying system
(with 100 % standby parallel stream) along with reclaimers, trippers etc.
6.00.00 CONSTRUCTION WATER
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
4. LAYOUT SYSTEMS
1.00.00 GENERAL LAYOUT PLAN
General Layout Plan for the project is developed and placed at Exhibit-II.
General Layout Plan for the project has been developed taking into
consideration various aspects like available land & shape, ground features
& terrain, corridor for outgoing transmission lines, road approaches,
prevailing wind direction, the water drawl and the associated pipe corridor.
The General Layout Plan is prepared in optimum area so as to reduce the
quantity of filling by dredging. The switchyard orientation which is
proposed as GIS has been planned taking into consideration the
requirement of power evacuation. Permanent facilities like Workshop,
Permanent stores etc. are located close to the main plant. The ash
slurry/ash water pump house is kept towards the chimney and FGD space
is kept beyond chimney. The intake/discharge ducts have been routed in
the corridor between transformer yard and switchyard and location of
CWPH is chosen, so as to minimize the length of CW ducts. Considering
the soil condition Induced Draft Cooling Towers are proposed and located
considering the safe distance from the Main Plant and Switchyard. The
water treatment plant and the DM water facilities are located close to main
plant. The coal is proposed to come from coal jetty to be constructed at
river bank. As coal comes through sea route, three month coal storage is
proposed in plant with space for storage of coal upto six months.
Adequate space provision has been kept in the layout for lay-down and
pre-assembly activities, open stores, contractor’s offices and stores etc.
Construction offices and storage sheds are located close to the main
approach road to the plant. Administration Building is proposed to be
located outside the plant boundary near the main approach road.
Tree plantation shall be done in all available space after completion of the
project.
The main plant building arrangement for the proposed stage of the plant
envisages longitudinal disposition of TG set. The main power house will
be 277 m long and about 48 m wide consisting of TG bay and heater bay.
Service Building is envisaged at the start of unit # 1 of the project. An
interconnection walkway is also provided between Service Building and
operating floor level in AB bay for movement of personnel.
Reference drawings for Main Plant Layout:
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. Description Drawing No. Exhibit
No. No.
1. Main Plant Layout Plan at 9635-999-POM-F- 3
EL (+/-) 0.00 m. 001 (Rev. 0)
AB Bay
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2.02.03 BC Bay
The BC bay of width 12.0m would consist of floors at EL (+/-) 0.00 m, (+)
8.5 m, (+) 17.0 m, (+) 24 m, (+) 32.8 m, (+) 38/41 m. The BC bay floor at
EL (+/-) 0.00 m would house LP/HP dosing system equipment,
condensate polishing unit along with RIO room, SWAS room and Central
Lube Oil system. The floor at EL (+) 8.5 m would house LP heaters. The
HP heaters are to be located at EL (+) 17.0 m. The floor at EL (+) 24.0 m
would house cable vault for boiler MCC and Air Handling Units for Air
conditioning system. Boiler MCC is located on local floor at EL 28.0M. The
floor at EL (+) 32.8 m has been planned for Auxiliary Steam Pressure
Reducing De-super-heating Station, Control Station of feed water system,
ECW tanks for SG & TG and Cooling Towers for A/C system. The
Deaerator is to be kept at EL (+) 38.0 m.
2.02.04 Boiler Area
Boiler, air pre-heater, ID/FD/PA fans, ESP, mills and chimney are located
with tentative dimensions as indicated in layout drawing. Mills have been
located on the rear side of the Boiler. Approach roads/ passages have
been identified on both side of Mill/Bunker bay. Passageways have also
been identified between Mill bay & ESP and between ESP & ID fans.
Distance of 12 m between C-row (last row of power house columns) and
D-row(1strow of Boiler columns), has been kept to facilitate the movement
during erection and operation phase of the plant. Two elevators - one for
passengers and one for goods have been envisaged for each Boiler.
The main coal feeding conveyor shall be located at the start of the Unit #
1. Ash handling facilities such as High Concentration Slurry Disposal
Pump House along with silos, VFD room, AHP Control Room and
transformers for the same are located by the side of ID fan of unit # 1.
Other Ash handling facilities such as Transport Air Compressor House,
Ash Water Pump House, Switchgear room and Transformers are located
across the road, behind chimney in ash handling area.
The MCCs and control for ESP along with air conditioning and ventilation
equipment for the same are envisaged to be located in ESP Control
Room. ESP Control Room for both units is located by the side of
respective ESP’s. Air conditioned space for locating remote I/O panels for
ash handling system are also identified inside ESP control room building.
2.02.05 Air Compressor and CPU
Air Compressors for instrument air / service air / Mill reject air requirement
shall be installed in a separate building in transformer yard near service
building. The regeneration facility for CPU is proposed to be located in
DM/PT plant area.
Electrical switchgears and MCCs of the unit are located in the electrical
annexe located at the start of unit in AB bay. The HT switchgear along
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with DC Batteries is to be located at (+) 3.5 m floor elevation. LT
switchgears, DC distribution board and Battery Chargers are to be located
at (+) 12.0 m floor elevation of the electrical annexe. Since all the
switchgears are envisaged to have bottom entry cables, two cable
spreader rooms have been envisaged, from EL (+/-) 0.00 m to (+) 3.5 m
and other from EL (+) 8.5 m to (+) 12.0 m. Boiler MCC have been located
in B-C bay at EL (+) 28.0 m with a provision of cable spreader room at EL
(+) 24.0 m. LAVT & SPPT cubicles shall be located at a local floor in AB
bay at EL 5.0M below IP bus ducts. GCB shall also be located at EL 7.5M
in AB bay below IP bus ducts.
The Common control room for two units has been envisaged between unit
# 1 & 2 in B-C-Dx bay at operating floor level. Control Equipment Room
(CER) is envisaged to be unitized and shall be located in B-C-Dx-Ex-Fx
bay at operating floor level and Dx-Ex-Fx bay at EL (+) 8.5M floor level.
The control room houses the control desk and control station for certain off
site facilities also.
Air conditioning plant for Central Control Room/CER and UPS/ Charger
room, SWAS room along with its MCC has been located in Dx-Ex bay at
EL (+/-) 0.0 M between unit 1 & 2. SWAS room shall also be located at EL
(+/-) 0.00 M in BC bay. UPS, Chargers, CER and C&I batteries are located
at 8.5 M in B-C-Dx bay. Cable Vault for CER, UPS and battery charger
shall be located at EL 5.1M and cable vault for CER/CCR shall be located
at EL 13.5M in B-C-Dx-Ex-Fx bay. Space for Fire fighting cylinders has
been identified in Ex-Fx bay at EL 0.0M in the Control Tower area.
Necessary cable shafts have been provided at B-row/C-row for routing of
power cables in the Electrical Bay and Control Equipment.
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5. CIVIL SYSTEMS
1.00.00 LAND DEVELOPMENT
As per the survey data received, the levels of the natural ground vary
between RL (+) 0.75 to RL (+) 1.25M. The HFL of the area is about RL (+)
4.5M. Hence, RL (+) 5.0M is proposed as plant formation level. To achieve
the desired formation level dredging from the nearby river and hydraulic
filling is proposed in the plant Site.
About 425 Acres of land is proposed to be filled with dredged material for
the plant and the township area.
Considering the above and assuming that the strata would be similar to
the above borehole data, pile foundation is envisaged for all main plant
structures.
Bored cast-in-situ RCC piles are envisaged for the plant structures.
Based on the sub strata and the fill, there will be dragdown force (negative
skin friction) on piles. Based on the pile design & considering the effect of
negative drag due to settlement of top soft clay of 14-16 m, the capacity of
piles are as given below for FR purpose:
Piles shall be of bored cast-in-situ type of 1000 mm, 760mm & 600mm
diameter of 325T, 250T & 140T capacity respectively in
compression, lateral and pullout capacity for 1000 mm, 600 mm and 760
mm dia pile shall be 7 T, 5.5 T, 4 T and 100 T, 80 T and 50 T respectively
after ground improvement. Pile length may vary from 31 to 33 m below
COL for 600 mm dia, 34 to 36 m for 760 mm dia and 35 to 37 m for 100
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mm dia below COL. However, for FR purpose, minimum pile length of 32
m below Cut Off Level (COL) for 600 mm diameter, 35 m below COL for
760 mm diameter and 36 m for 1000 mm dia may be considered. COL is
considered as 4.0 m below Finished Ground Level (FGL). During pile
boring, the top soft clay due to high water table, may or may not be able to
retain the profile of pile bore. Therefore, a provision of MS permanent liner
has been considered for the bored cast in situ piles in the soft clay portion
of strata for a length of 15 m from cut-off level. During the actual
execution, contractor shall be asked to make trial pile bore without
permanent liner, and if the same is found feasible, then M.S. permanent
liner item will not be operated.
Lateral capacity of piles
As the top soil is very soft to soft clay, ground improvement for the area is
required to be carried out to achieve the lateral capacity of piles.
Ground improvement
Due to the presence of very soft to soft clay, area needs ground
improvement. Suitability of various alternative methods such as stone
columns, sand compaction piles, PV Drains / wick drains, soil stabilisation
etc have been explored. However, based on the detail discussion with
BPDB and confirmation of availability of the specified sand, sand
compaction piles are considered for FR preparation.
Sand compaction piles of 900 mm dia and 17 m length are considered
below Natural Ground Level for FR purpose. Spacing of sand compaction
piles is considered as 4.5 m in equilateral triangular pattern for the main
power house block area to increase the lateral capacity of piles and for
other areas, open foundations on sand compaction piles are envisaged.
Sand blanket of 500 mm thick (for drainage of pore water in clay) shall be
provided above the sand compaction piles which will be connected to the
nearest drains.
It is desirable to install the sand compaction piles with drainage blanket
followed by site levelling/filling, so that the fill will act as surcharge on the
soft clay, which will enhance the consolidation process and minimise the
post construction settlements.
Dewatering & Sheet piling
As the ground water table is very high and presence of river adjacent to
site, cost provision for comprehensive dewatering for deep excavations
and provision for sheet piling for structurtes like Track Hopper, Wagon
Tippler, pump houses etc may be kept in the FR
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Type of cement and grade of concrete
Chemical results of water and soil are not available. Based on the feed
back of team visited to site, it is gathered that there will be back flow of the
water from sea for almost 8 months in a year and considering the salinity
of water, it is proposed to use M30 grade of concrete for all foundation
works. Portland Pozzolana Cement (PPC) or Portland Slag Cement or
OPC blended with GGBS up to 60% for all foundation works including
piles.
The foundation system proposed for main plant as well as other areas will
be reviewed on receipt of preliminary / detailed geotechnical investigation
data.
Seismic and Wind Design
For seismic analysis PGA has been considered as 0.24g. However, for
tender specification / detailed engineering the seismic design parameters
shall be based on Bangladesh National Building Code (BNBC).
The wind load parameters have been considered based on wind data as
per Indian standard. However, for tender specification / detailed
engineering the wind design shall be based on Bangladesh National
Building Code (BNBC).
For TG foundation, steel helical spring units & viscous dampers shall be
supported on an RCC, framed sub-structure. The sub-structure shall be
supported on a base-mat. Steel helical spring units & viscous dampers for
ID, PA, & FD Fans shall be supported on RCC sub-structure which in turn
shall be supported on base raft.
Turbine driven Boiler Feed pump (TDBFP) and Motor driven Boiler Feed
pump (MDBFP) shall be supported on RCC deck, which shall rest on steel
helical springs and viscous dampers, which in turn shall be supported on
steel beams resting on main power house columns and auxiliary columns.
The mill foundation shall consist of RCC block supported on pile
foundation.
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3.02.00 Structural System
(b) Pipes and cables running along the boiler structure, mill &
bunker buildings and ESP structures etc shall be supported on
steel girders resting on the steel bracket fixed to the boiler/ ESP
/ mill & bunker building structures.
(c) Pipes between boiler and C-row will be supported on the steel
girders resting on the steel brackets at the boiler & C-row
columns. These steel girders shall have sliding joint on main
powerhouse and fixed / hinged on boiler structure.
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6. Other Buildings
ESP control, air washer, compressor house and other similar buildings
located in power block shall be of framed structure.
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3.04.00 Architectural Concepts
a) Power Plant buildings shall be architecturally treated in such a way
so as to merge with the existing structures and the overall impact of
the buildings shall be one of aesthetically unified architectural
composition having a comprehendible scale, blending tonal values
with the surroundings and taking full consideration of the climatic
conditions and the building orientation.
b) All buildings and structures shall be architecturally treated in such a
way so as to be in complete harmony with the Main Plant Building,
surrounding structures and environment. Due considerations shall be
given to climatic conditions, landscape design, building orientation,
interior design. All finishes for floors, walls, ceiling, structural
elements, partitions for offices and industrial areas shall be suitable
for their aesthetics, durability and functional requirements and shall
include the latest building material & technology.
c) Overall colour scheme of the Main Plant Building and other buildings
shall be designed judiciously and in a comprehensive manner taking
into account the mass and void of buildings, its facade, equipment,
exposed structural elements, piping, trestles, bus ducts, and other
service elements.
d) Natural light shall be used to the maximum extent, especially in the
form of North Light/sky light and all buildings shall be designed as
Energy Efficient Buildings. For adequate light and ventilation,
National Building Code of India recommendations shall be followed.
e) All the buildings shall be architecturally designed to meet the National
Building Code.
f) During design stage, Technical specification as prepared shall
govern the finishes as well as quantity.
g) Human safety factors shall form the basis of design criteria.
h) Service building shall be designed so as to achieve GRIHA (Green
Rating for Integrated Habitat Assessment) minimum three or four star
rating.
4.00.00 CHIMNEY
One twin flue steel lined reinforced concrete chimney shall be provided for
the two 660 MW units of the project. The flue gas emission point shall be
275 meters above the plant grade level. The RCC for the chimney shell,
other super structure, foundation & grade level slab shall be of M-30
grade.
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Liner shall essentially be constructed from structural steel and shall be of
the hung type (with multiple point liner support systems). The liner shall be
provided with resin bonded wool type thermal insulation. The portion of the
liner projecting above the chimney roof, however, shall be constructed of
shaped acid resisting bricks. Brick liner shall be protected by a reinforced
concrete mini-shell also constructed from the roof slab. Suitable expansion
joints shall be provided between the steel and the brick liner. Internal
platforms shall be provided for enabling access to various elevations of
the stack and to provide support to the steel liner. There shall be at least
one metre working space around the flues. External platforms shall also
be provided.The structural steel transition inlet ducting shall be bottom
supported. This transition ducting shall be suitably profiled from a
rectangular shape at the chimney inlet to a circular shape up inside the
chimney where it shall be connected to the suspended circular steel liner
through suitable (non-metallic) fluro-elastomeric fabric expansion joints.
Transition ducting shall also be thermally insulated.
Internal platforms shall be of structural steel construction. The chimney
roof shall, however, comprise of a reinforced concrete slab supported over
a grid of structural steel beams. The external platforms shall be of
reinforced concrete construction of grade M-30.
An internal structural steel staircase, supported from the shell wall, shall
be provided for full height of the stack. Suitable embedments shall be
provided in the shell wall for this purpose.
An internal ladder shall be provided having its support from the concrete
shell inside the chimney and shall be provided for a small height, over the
last staircase landing, to access the chimney roof through a roof access
hatch. External ladders shall be provided on each of the mini-shell(s) over
the roof.
The flooring panels of the platforms and treads of the staircase shall be of
chequered plate construction. Handrails for platforms and staircase shall
be of tubular construction.
The external portion of the wind shield shall be coated with alternate
bands of red and white colours to meet the aviation safety requirements.
The mini-shells and the top few meters of the internal surface of the
windshield shall be painted for acid and heat protection with bituminous
paint.
The other components of the chimney include cast iron caps over mini-
shell(s), liner test ports (for continuous pollution monitoring), liner hatches,
reinforced concrete roof slab protected for acid and heat protection, grade
level slab of reinforced concrete with a metallic hardener floor finish, a
large electrically operated grill type roll-up door (with only the bottom small
portion of the curtain of solid shutter type) at grade level and personnel
access metallic doors at grade level and at all floors, a personnel access
hatch in the roof slab, rain water drainage system, flue liner drainage
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system, roof drain basin, louvers with bird screens for ventilation openings
and all gaps in the wind shield, mild steel discrete strakes, painting of
chimney shell surfaces and painting/coating of all structural steel work and
miscellaneous ferrous components (for a maintenance free life of at least
ten years), all finishing works, electrical power, distribution boards, lighting
panels, power and control cabling and wiring systems, cable conduits,
stair and platform lighting, socket outlets, lightning protection and
grounding system, aviation obstruction lighting, communication system
and a rack and pinion elevator. The chimney shall have a suitable
foundation.
Make-up water for the project shall be drawn from Passur river having
saline back water. Water will be drawn from the river by constructing an
approach channel. Desilting basin and Make-up water pump house shall
be constructed on the down steam of this channel. The MuW water
pump house shall pump water to desalination Plant and CW channel for
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make-up. Silt flushing pump house shall be provided for automatic
removal of silt.
The approach channel, desilting basin and silt flushing pump house shall
be of RCC grade M-30. Substructure of MuW pump house shall be of
RCC grade M-30 and superstructure shall be of structural steel with steel
sheet cladding
A switch gear building, control room along with transformers shall be
provided on the river bank for feeding electrical power to the MuW pump
house and silt flushing pump house. Sub structure and super structure of
the switch gear building shall be of RCC grade M-30 with brick wall
cladding.
7.00.00 COAL HANDLING SYSTEM
Transfer points shall be of structural steel with RCC floors and shall have
permanently colour coated steel sheet cladding. Floors shall be provided
with ironite finish. Pile foundations are envisaged for column foundations.
7.00.03 CONVEYOR GALLERIES
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8.00.00 FUEL OIL HANDLING SYSTEM
The civil works for the following are to be provided for fuel oil handling
system as mentioned below:
Foundation for 2 nos HFO tanks (2500 KL capacity of 18.0m dia &
12m height)
Foundation for 1 nos LDO tanks (500 KL capacity of 7.5m dia &
12m height)
Foundation for 1 no day oil tank (100 KL capacity of 4.5m dia &
6.5m height)
Fuel oil pressurizing Pump House(750 sqm)
Fuel oil unloading Pump House
Oil Water separator pit
Containment wall around the tank area for all tanks.
Foundations for pumps, pipe racks, pipe lines etc, miscellaneous
drains.
Paving and drains around tanks.
Railway unloading& tanker unloading areas.
The Civil works involved in Ash handling & Ash water recirculation
systems are as follows:
1. Ash Water Pump House.
2. HCSD Pump House
3. Ash water recirculation Pump House
4. Switch gear/MCC and Control Room for all buildings
5. Silo area utility building
6. Fly Ash Silo foundation & supporting structure
7. HCSD Silo foundation & supporting structure
8. Transport air Compressor house
9. Steel Trestles for supporting Ash Slurry Piping within plant area
and dry fly ash transportation pipe pedestals upto silos near
plant boundary.
10. RCC pedestals for supporting HCSD pipes including garlanding
of ash dykes.
11. RCC pedestals for supporting ash water recirculation pipe.
12. Miscellaneous works like Transformer Foundation, Fencing,
Paving etc.
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13. Miscellaneous structures including Foundation for settling tank,
surge tank, etc.
All pump houses shall have RCC framed structural arrangement with brick
cladding & metal deck roofing filled with RCC. All Control room shall be
air-conditioned area with false ceiling.
Overhead bridge/ culvert by thrust boring shall be provided for the railway
crossing for the ash slurry pipes. For routing of the ash pipes at road
crossing culverts/ local humps or bridges shall be provided as per site
conditions.
All super-structure work related to dry ash handling (including silos, buffer
hopper, and collector tank) and bottom ash handling are included in
mechanical package.
The double lane roads shall be 12m wide with 7.5m wide bituminous
surfacing (black top) and 2.25m wide raised shoulders on both sides of the
roads.
Single Lane Roads
All access roads to all buildings/facilities/structures shall be single lane
roads 6.75m wide with 3.75m wide bituminous surfacing (black top) and
1.5m wide shoulders on both sides of the roads.
Patrol Roads
All patrol roads along the boundary wall shall be single lane roads with
3.75m wide bituminous surfacing (black top) and 1.5m wide shoulder on
one side of the roads.
Drains
Drains shall be constructed on both sides of double lane and single lane
roads. Patrol roads along the boundary wall shall have drain on one side
of the roads. These drains shall be connected to the trunk drain suitably,
which finally gets connected to the drains outside the plant boundary. All
drains shall be of RCC with rectangular section.
For ash disposal, about 100 acres of land is identified. The proposed land
is located adjacent to the plant boundary. The average ground levels on
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proposed land is about RL 1.0M. The ash disposal area is planned with a
total usable area of about 60 acres for ash storage. The balance 40 acres
of land will be occupied by starter dyke storage lagoons & OFL dyke
construction, ash slurry pipe line corridor, over flow lagoon, maintenance
road all along the periphery of the dyke and recirculation system facilities.
All the above facilities require ground improvement with sand compaction
pile and recirculation facilities shall be on piles with ground improvement.
Many Cement plants exists in the vicinity, 100 % fly ash utilization has
been considered. Also 100% bottom ash utilization has also been
considered. However, ash dyke of 100 acres has been provided in FR.
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6. MECHANICAL SYSTEM
1.00.00 STEAM GENERATOR AND AUXILIARIES
1.01.00 General
The steam generators shall be supercritical, once through, water tube,
direct pulverized coal fired, top supported, balanced draft furnace, single
reheat, radiant, dry bottom type, suitable for outdoor installation. The gas
path arrangement shall be single pass (Tower type) or two pass type.
Boiler design shall be suitable for variable pressure operation from 30% to
100% BMCR with and without 5% throttle margin.
The main parameters at 100% BMCR will be as follows:
1.02.00 Furnace
The furnace will be radiant, dry bottom type with tangential or opposed
wall firing and enclosed by water cooled and all welded membrane walls.
The furnace bottom shall be suitable for installation of dry bottom ash
system. Spray type attemperator is envisaged to control the superheater
outlet temperature for varying loads. The superheater and reheater tubes
will be a combination of radiation and convection type. Economizer will be
non-steaming type and shall be of modular construction.
The furnace will be radiant, dry bottom type with tangential or opposed
wall firing and enclosed by water cooled and all welded membrane walls.
Spray type attemperator is envisaged to control the superheater outlet
temperature for varying loads. The superheater and reheater tubes will be
a combination of radiation and convection type. Economizer will be non-
steaming type and shall be of modular construction.
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1.04.00 Air and Flue Gas System
A balanced draft system will be provided. There will be two (2) axial type
FD fans and two (2) axial type ID fans and two (2) pairs of regenerative
rotary type air pre-heaters. One pair of air pre-heater will be used for
primary air system & second pair for secondary air system. Four (4)
numbers of steam coil air preheaters-two on primary and two on
secondary air system will be provided for start-up, low load operation or
abnormal conditions when an increased air inlet temperature is considered
desirable to minimize the cold end corrosion of regenerative air pre-
heaters.
Start-up, warm up and low load (upto 30%) carrying shall be done by
heavy furnace oil/HPS/LSHS. Boiler will be so designed that oil firing for
flame stabilization will not be required beyond 30% MCR. Necessary
pumps, filters and heaters will be provided. For coal firing the entire
operation of purging, insertion, air and fuel sequencing removal and blow
off shall be automatic. Ignition of heavy oil shall be directly by high energy
arc igniters. There will be light oil (LDO) firing at least in one burner
elevation having a minimum capacity of 7.5% BMCR to facilitate cold start-
up of the unit when no auxiliary steam is available for HFO heating and
atomization. LDO system shall be sized for 7.5% BMCR capacity of two
(2) boilers.
The coal burning system will comprise of coal mills of vertical spindle type
which include (a) bowl mills, (b) roller mills & (c) balls & race mills or any
approved equivalent. The number and capacities of the mills shall be so
selected that while firing the worst and design coals at BMCR/ TMCR, the
following spare capacities shall be ensured.
(a) With 90% mill loading of the working mills, atleast one mill will be
spare while firing the design coal at 100% BMCR.
(b) With 90% loading of the working mills atleast one mill will be spare
at 100% TMCR load with worst coal firing.
Coal from raw coal bunkers will be fed into the mills by belt driven
gravimetric coal feeders suitable for handling moist coal. There will be two
axial P.A. fans for transporting the pulverized coal from mills to burners.
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provided. The system will have short retractable rotary wall blowers for
the furnace and long retractable rotary blowers for the superheater,
reheater and economizer.
Each of the unit will be provided with two auxiliary PRD stations i.e., high
capacity and low capacity PRDS taking their steam tap-offs from MS line
and CRH line respectively. The high capacity auxiliary PRDS will be
designed for a minimum capacity of 150 T/hr. Low capacity auxiliary
PRDS will be sized for a minimum capacity of 25 T/hr and will be operated
during the normal operation of the unit.
Auto-change over between the low and high capacity aux. PRDS stations
depending on the station auxiliary steam requirement is also envisaged.
Each unit will have its own auxiliary steam headers whereas for station
services common station auxiliary steam headers taking its tap off from
the unit auxiliary PRD stations will also be provided. The provision will also
be made for interconnection with future units.
1.09.00 Elevators
One (1) number passenger cum goods elevator of capacity 3000 kgs &
one (1) number passenger elevator of capacity 1088 kgs shall be
provided for each steam generator.
1.10.00 Electrostatic Precipitator
The electrostatic precipitators will have parallel gas streams, isolated from
each other on the electrical as well as gas side and will be provided with
gas tight dampers at inlets and outlets of each stream, so as to allow
maintenance to be carried out safely on the faulty stream, while the unit is
working Electrostatic precipitator will be provided with microprocessor
based programmable type rapper control system and ESP management
system to ensure safe and optimum operation of ESP.
ESP transformer rectifier sets will use high flash point oil as the cooling
medium. The dust collection hoppers at all strategic locations will have a
minimum storage capacity of eight (8) hours. The hoppers will have
heating arrangements to prevent ash sticking to the sloping sides and
down pipes. Level indicators to indicate ash levels in the hoppers and trip
the ESP in case of high ash levels in the ash hoppers are also envisaged
to ensure safety of ESP.
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1.11.00 Provision of future installation of Flue Gas Desulphurising system
(FGD)
As environmental norms for the area are not known, norms prevalent for
So2 dispersion in India have been considered. Considering sulphur in the
coal sourced from Indonesia limited to 0.6%, So2 emission from the plant
is envisaged to be controlled by dispersion through tall stack (275 m) to
meet the ground SO2 ambient air quality norms. However, provision has
been kept in the layout of the plant such that a Flue Gas Desulphurisation
(FGD) system can be installed in future, taking flue gas suction from duct
after ID fan and feeding the desulphurised flue gases to the chimney with
provision for bypassing the FGD system.
The scope of each TG unit of 660 MW shall broadly cover the Steam
Turbine along with its integral systems and auxiliaries like lube oil system,
control-fluid system, condensers, condenser air evacuation system,
HP&LP Bypass system, complete regenerative feed heating system,
condensate pumps along with their drives, boiler feed water pumps along
with their drives, automatic turbine run-up system, instrumentation and
control devices, turbine supervisory instruments, turbine protection and
interlock system, automatic turbine testing system and turbine hall EOT
cranes.
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
2.01.00 Steam Turbine
The steam turbine shall conform to the following design and duty
conditions:
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2.02.00 Condenser
Sea water cooled single pass or double pass condenser with Titanium B-
338 Gr-II tubes, shall be adopted. The condenser shall be with divided
water box construction. It shall be horizontal, surface type with integral air
cooling section. Condenser hotwell shall be sized for three (3) minutes
storage capacity (between normal and low-low level) of total design flow
with the turbine operating at V.W.O condition, 3% make-up, design back
pressure. The condenser shall be adequately sized to cater to all the
conditions of turbine operation including the abnormal operating conditions
such that condenser would not be a bottleneck at any stage of operation.
The exact condenser parameters shall be optimized on the basis of site
data and most economical combination of cooling surface and circulating
water quantity. The condenser shall be designed, manufactured and
tested in accordance with the latest applicable requirements of the Heat
Exchange Institute (HEI), USA. Provision of separate sponge rubber ball
type condenser on-load tube cleaning system for each half of the
condenser including ball circulation pumps, strainer, ball monitoring
system etc. shall be made.
Two self cleaning type half capacity debris filters at the inlet to each half of
condenser, complete with backwash system, associated piping system,
instrumentation & control. Each debris filter should be sized for atleast
60% of the design flow through each condenser.
Each unit shall comprise of (2x100%) vacuum pumps along with all
accessories and instrumentation for condenser air evacuation. The
vacuum pumps and accessories shall be used to create vacuum by
removing air and non-condensable gases from steam condenser during
plant operation. Vacuum pumps shall be of single/two stage liquid ring
type with both stages (if two-stage pump is selected) mounted on a
common shaft. Vacuum pumps shall be sized as per latest HEI
requirements..
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
(a) Centrifugal/gear type, Main oil pump (MOP) directly driven by the
turbine as per Bidder’s standard practice with capacity to cater lube
oil for bearings & emergency seal oil requirement (if applicable). In
addition to above 2 x 100% AC aux. oil pumps for start-up,
shutdown of TG unit and as standby to MOP for automatic
operation shall be provided. Each pump shall also be capable of
start up, shut down of TG unit and stand by to each other for
automatic operation to cater lube oil, jacking oil & turning gear oil
requirement.
OR
2x100% AC oil pumps as per Bidder's standard practice with
capacity to cater lube oil for bearings & emergency seal oil
requirement (if applicable). Each pump shall also be capable of
start up, shut down of TG unit normal operation and stand by to
each other for automatic operation to cater lube oil, jacking oil &
turning gear oil requirement.
(b) 1x100% DC emergency oil pump for meeting lube oil requirements
of bearings during emergency, with automatic starting on low lube
oil pressure preset value.
(c) 1x100% each AC and DC motor operated jacking oil pumps shall
be provided to lift the rotor at the bearing during turning gear
operation.
(d) Each unit shall be provided with an oil tank of sufficient capacity to
allow 5 to 8 oil changes per hour (at normal operating level), fitted
with non-corrodable strainers, level indicators & necessary
manholes. 2x100% duty vapour extraction fans driven by motors
shall also be provided.
(e) 2x100% capacity oil coolers shall be provided for cooling the
lubricating oil. The cooling medium shall be DM water (condensate
quality).
ii) 2x100% AC motor driven pumps to pump the fire resistant fluid
from the fluid reservoir through the system.
iii) 2x100% capacity control fluid coolers designed for service with DM
water (condensate quality).
During startup and low loads (say upto 40% load), seal steam will be
supplied to the turbine glands from the auxiliary steam header through a
seal steam regulating valve. During normal operation (say above 40%
load), the HP and IP turbines will be of self-sealing type and under that
condition the auxiliary steam source will be cut off and the leak-off steam
from HP and IP glands will be used for sealing the LP glands. The excess
leak-off steam will go to the condenser. A gland steam condenser will be
provided to condense and return to the cycle, all gland leak off steam
including that from BFP turbines. A de-superheating type bypass shall be
provided during outage of gland steam condenser. 2x100% capacity
vapour exhausters shall be provided to remove non-condensible gases
from the gland steam condenser. The exhaust gases shall be left above
the TG Hall roof level.
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2.08.00 Governing / Regulation System
The turbine will have throttle or nozzle controlled type governing. Steam
turbine governing and protection system shall be complete with electro
hydraulic governor with suitable back up as per standard practice of the
manufacturer. The governing system shall be highly reliable and
operationally safe and it shall be capable of controlling with stability the
speed of the turbine at all power outputs between zero and the specified
maximum power output when the unit is operating isolated or the energy
input to the steam turbine when the unit is operating in parallel with the
other units. The turbine governing system shall be designed for high
accuracy, speed and sensitivity of response. The governing system shall
limit the over speed of the turbine on loss of full load to value less than
over speed trip value. The steady state regulation shall be adjustable
within +3% to +8% of the rated speed. The dead band at rated speed and
at any power output within the rated output shall not exceed 0.06% of the
rated speed.
a) Quick startup of the steam generator from cold, warm & hot
conditions.
The HP/LP Bypass system shall be sized for about 65% of BMCR steam
flow (exact capacity shall be decided later) with rated main steam
parameters at upstream of valves. The LP bypass will be sized for steam
inlet conditions (pressure and temperature) of HRH line corresponding to
about 60% TMCR.
2.10.00 Regenerative Feed Heating Cycle
Regenerative feed heating plant shall be designed for all operating
conditions including transients like sudden load throw-off, HP-LP Bypass
in Operation, one or two heaters going out of service etc. The condensate
from the condenser shall be pumped by the condensate extraction pumps
and condensate booster pumps through the train of LP heaters to the
deaerator. In deaerator, the condensate shall be heated to saturation
temperature and fed to the boiler feed pump, which increases the feed
water pressure to suit the steam generator requirements.
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Feed water then passes through two trains of 50% capacity HP heaters
which raise the feed water temperature to nearly 287.5 (+/-) 2.5 deg C
(tentative). Finally the feed water is fed to boiler.
2.11.00 HP & LP Heaters
Regenerative feed heating cycle shall consist of LP heaters, one drain
cooler, deaerator and HP heaters. The number of LP & HP heaters shall
be based on the optimisation of feed heating cycle.
The boiler feed pumps shall be of horizontal, centrifugal type with stiff
shaft design. The boiler feed pumps outer casing shall be of barrel type
with end removal. The inner pump assembly comprising of shaft,
impellers, stage casings shall be capable of being removed and replaced
as a unit without disturbing the feed piping. Each feed pump shall be
provided with ON-OFF recirculation control valve to protect the pump
under low flow condition. The boiler feed water system shall be designed
to operate primarily in an automatic mode over the range of system design
loads. The arrangement will provide automatic start-up of the standby
Motor driven feed pump under conditions like tripping of running of
TDBFP's, discharge header pressure low etc.
The feed flow shall be controlled by throttling the control valve of drive
turbine in case of turbine driven pumps whereas hydraulic coupling shall
be utilized to achieve speed control of motor driven pumps. Provisions will
be made for warm-up of stand by pump, if required.
2.14.00 Condensate Pumps
Each unit shall have 3 x 50% capacity motor driven condensate extraction
pumps (two operating and one standby). The condensate pumps shall be
vertical canister type, multistage, centrifugal diffuser design with a double
suction first stage designed for condensate extraction service having low
suction head requirement. The pumps shall be capable of handling the
condensate from the condenser together with feed heater drains when the
machine is operating at maximum unit output with HP Heaters out with 3%
make-up and discharging this quantity through the gland steam
condenser, condensate polishing unit and LP heaters to Deaerator.
The pump shall have adequate margins on capacity and head to cater for
most adverse conditions of operation such as:
ii) HP heaters out of service and unit operating at its maximum load
during an under frequency operation (i.e. at 47.5 Hz).
2.15.00 Turbine Hall EOT Cranes
Two (2) number of electrically operated overhead travelling cranes with
associated auxiliaries, along with electrical equipment, control &
instrumentation as required and specified shall be provided in the turbine
hall for erection and maintenance of turbo-generators and their auxiliaries.
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Each crane shall be capable of lifting at least 105% of the weight of single
heaviest component/equipment, including lifting beam and slings etc. (as
applicable) to be handled in TG hall for erection as well as maintenance of
the equipment provided in AB bay. The auxiliary hook capacity shall not
be less than 20 Ton.
The bottom ash extracted in dry form from each unit shall be crushed in
primary and secondary crusher to granular size of less than 6 mm and
shall be collected in an intermediate silo( IM silo). BA can be unloaded
and transported through trucks from this IM silo. In case of non utilization
of BA ash or disposal though trucks, BA from IM silo shall be transported
to a BA silo near HCSD pump house. This shall be further mixed with fly
ash and disposed off in form of HCSD slurry.
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The BA extraction air compressor for conveying BA shall be used for
conveying Eco ash also to BA silo near HCSD pump house. This shall be
further disposed off in form of HCSD slurry
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5.00.00 FUEL OIL UNLOADING AND STORAGE SYSTEM
Fuel Oil unloading and storage system shall be designed to handle both
heavy oil (HFO/LHS/HPS) and light oil (LDO). Light oil (LDO) shall be
used for cold startup and low part load (up to 7.5%) operation of the steam
generator while firing coal. The heavy oil (HFO/LHS/HPS) shall be used
for start-up, warm-up and low load (up to 30%) operation of the steam
generator while firing coal.
It is proposed to transport heavy oil (HFO/LHS/HPS) to the power plant by
road tankers. The receiving yard shall be designed to unload ten (10) road
tankers a time. The oil from road tankers shall be unloaded to unloading
header by gravity which shall then be pumped to storage tanks through
unloading pumps.
It is proposed to transport light oil (LDO) to the power plant by road
tankers. The oil will be unloaded from road tankers by gravity into the
unloading header. From there it will be transferred to oil storage tanks
through a set of positive displacement pumps. Provision shall be kept to
unload five (5) nos. road tankers for light oil (LDO).
For storage of heavy oil (HFO/LHS/HPS) two (2) nos. of fixed roof type
storage tanks each of 2000 KL capacity shall be provided. Necessary
provision for heating of the unloading header and storage tanks shall be
provided.
For storage of light oil (LDO) two (2) tanks each of capacity 500 KL shall
be provided.
A set of pressurizing pumps shall draw the oil from the storage tanks for
pumping the oil to the steam generator units. The auxiliary boiler shall be
designed for firing light oil (LDO). A separate day oil tank of 100KL
capacity for auxiliary boiler shall be provided. Oil shall be drawn from the
main LDO storage tanks for feeding to day oil tank.
6.00.00 WATER SYSTEM AND PLANT UTILITIES
The source of water for the project is sea water drawn from Passur River
(about 2 kms), which is primarily back water of sea. Sweet water required
for meeting the potable water, plant service water, cycle makeup (DM
water) etc shall be produced using Desalination process from sea water.
Sea water to be used for this project is having very high silt content.
In once through system, huge quantity of water will be required; Desilting
of such huge quantity of water would be uneconomical. In cooling tower
system, only make up water needs to be provided and can be easily
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Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
desilted. Therefore, re-circulating type CW system with cooling towers
having open intake channel has been envisaged for the project.
6.03.00 Water Consumption
`Make up water requirement for this project would be about 9150 Cu.M/hr
It is proposed to adopt Reverse Osmosis process for Desalination of sea
water to meet the sweet water requirement of the plant.
It is envisaged to provide five (5) Make up water pumps inside the make
up water pump house to be located inside water source, from where water
shall be pumped to the plant. It is proposed to provide two numbers of
pipelines from makeup water pump house to plant end, one upto
circulating Water channel and other upto Desalination plant. The pipelines
shall be internally lined suitable for handling sea water The pipelines shall
be protected against corrosion using suitable external 3LPE coating.
Further the pipes shall be protected against galvanic corrosion by
providing impressed current type cathodic protection system. The make up
water system shall be provided with required instrumentation, interlocks
and controls, control panels to facilitate safe & reliable operation.
Required Monorail hoists shall be provided for maintenance requirement of
stop log gates of make up water pump house. Dosing of Chlorine is
envisaged at the discharge of the pump and/ or at the pump suction. EOT
cranes of suitable capacity shall be provided to meet the maintenance
requirements of pumps and associated equipments.
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standard practice of the suppliers & filtration. Treated permeate from
SWRO shall be stored in Steel tanks which shall be used for plant water
requirement such as Service water, HVAC makeup, makeup to the
fire water storage tanks, sealing water for vacuum pumps of ash handling
plant and Potable water for plant & colony. To produce Demineralized
quality water for cycle makeup, it is required to provide a Second (2nd)
Stage RO unit and a set of Mixed Bed Ion-exchanger units at the
downstream of SWRO plant. Portion of desalinated water from SWRO
units shall be treated through 2nd stage RO unit & Mixed (MB) Bed
type ion exchanger units to produce DM water required for cycle makeup
and DM water shall be stored in DM Water Storage tanks. For
regeneration of ion-exchange resins of Mixed bed unit, regeneration
systems comprising set of acid tanks and a set of alkali tanks, dosing
pumps, acid & alkali unloading pumps, Neutralization pit, effluent
disposal pumps etc shall be provided.
For maintaining the feed water purity, condensate polishing plant shall be
provided in the feed water cycle at the downstream of condensate
extraction pumps as per the existing practice. The condensate polishing
plant shall be of full flow, deep mixed resin bed type. The resins to be used
would be strongly acidic cation and strongly basic anion type, appropriate
for condensate polishing system. A common external regeneration facility
shall be provided. The exhausted charge of resins from the service vessel
shall be hydraulically transferred to the resin separation/cation
regeneration vessel for regeneration and reuse. Spare charge of resin
shall be kept in the mixed resin storage tank for immediate exchange of
resins with the exhausted ones. One additional charge of resin shall be
procured for use during start up of the unit. Acid, Alkali & DM Water
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Storage for regeneration, and Wastewater Neutralisation facilities shall be
provided separately for the external regeneration facility.
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b) From the treated water storage tanks in desalination plant, required
number of service water pumps, air preheater wash water pumps shall
be provided to supply service water for the complete plant, including
dust suppression water storage tank of Coal Handling Plant and wash
water to Air-pre-heaters of Steam Generators. The service water
pumps shall also fill fire water storage tanks.
c) In addition to the above, DM water make up system, boiler fill pumping
system and HVAC make up system shall also be provided.
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7. ELECTRICAL SYSTEMS
1.00.00 ELECTRICAL SCHEME
The basic electrical scheme is indicated in the single line diagram
enclosed at Exhibit No. VII, and described as follows:
2.00.00 POWER EVACUATION
EHV transmission system in Bangladesh is at 132 kV and 230 kV levels.
400 kV transmission systems have been planned along with the proposed
coal based projects at Khulna & Chittangong and gas projects planned at
Bibiyana. Part of Dhaka ring main 400 kV transmission network (400 kV
line between Meghnaghat and Aminbazar) is under construction by Power
Grid Company of Bangladesh (PGCB). To facilitate power transfer
between India and Bangladesh, asynchronous interconnection through
500 MW HVDC back to back terminal station at Bheramara(Bangladesh)
fed from Baharmpur(India) through 400 kV D/C line is under
implementation.
The Indian portion 400 kV switching station at Baharampur alongwith 400
kV D/C line up to Bheramara is under implementation by Power Grid India
and Bangladesh portion is being taken up by Power Grid Company of
Bangladesh (PGCB)
In view of above, and considering present Capacity of Khulna project as
1320MW the step up voltage level of the project has been considered as
400 KV. Power Generated from each of the 660MW unit would be stepped
up to the evacuation voltage level through suitably rated Generator
Transformer.
As per the preliminary discussion and communication received from
Bangladesh Power Development Board (BPDB)/ PGCB provision of line
bays in generation switchyard for one no.400 kV D/C line (envisaged to
connected to Dhaka ring main) and one no. of 230 kV D/C line (envisaged
to be connected to Khulna South) have been kept for power evacuation
from the project. The provisions for Power evacuation as considered
presently are tentative and shall be reviewed based on finalized ATS of
the project by BPDB/PGCB.
The Switchyard Single Line Diagram indicating overall scheme is enclosed
at Annexure- A.
2.1.00 Start-up Power Requirement
The start up power of the plant has been envisaged to be drawn from the
230 kV existing PGCB Khulna South substation through the planned
transmission line between generating switchyard and Khulna south
substation. The 400 kV switchyard and 230 kV switchyard at Khulna
thermal power project shall be interconnected through two nos. suitably
rated 400/230 kV Inter Connecting Transformer. Presently rating of above
ICT has been considered as standard 315 MVA. However, 520 MVA
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transformer may be considered during detailed engineering stage based
on PGCB/BPDB requirement. The availability of above 230 kV D/C line
interconnection from Khulna south substation needs to be ensured
matching with the project start up power schedule.
2.2.00 Auxiliary Power Supply Scheme
The plant auxiliary power supply scheme has been evolved with
Generator Circuit Breaker along with suitably rated unit transformers
associated with each unit. Unit loads shall be fed from the respective unit
boards and station loads shall be distributed among various unit/Standby
boards suitably to arrive at optimum transformer size. One no. common
Start up/Standby transformer has been provided to cater outage of any
unit transformers. The overall scheme has been enclosed at Annexure -B
Techno economic analysis was carried out for two alternative schemes Viz
GCB with standby and Station Transformer scheme and it is found GCB
scheme is techno economically suitable for the coastal project like Khulna.
3.00.00 GENERATOR
The main parameters of Generator would be as follows:
a) Nominal rating 660 MW
b) Rated output 777 MVA
c) Power factor 0.85 (lag)-0.95 (leading)
d) Rated voltage As per manufacturer's Standard (in the
range of 21-24 kV)
e) Speed 3000 rpm
f) Short circuit ratio Not less than 0.48
The Generator winding will be wye connected with the phase & neutral
terminals brought out for connection to isolated phase bus duct. The star
point will be connected to earth through a transformer having the
secondary shunted by a resistor.
The stator winding of the Generator shall be cooled by means of de-
mineralised water, passing through hollow stator conductor. The stator
core and the rotor shall be cooled by hydrogen which in turn shall be
cooled in hydrogen coolers designed for DM water. Generator auxiliary
system like stator water system, hydrogen cooling system, seal oil system
and gas system complete with all accessories shall also be provided.
The excitation system shall be static / brushless type.
Besides the other electrical protections, the Generator shall have the
following additional protections/monitoring.
- Alkaliser unit
- End winding vibration monitor
-Online Partial Discharge (PD) Monitoring System
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4.00.00 BUSDUCT
The connection between the generator and generator transformers shall
be through isolated phase busducts. The busduct shall be continuous
enclosure, self cooled type and shall be equipped with air
pressurization system. The tap off and neutral connection shall also be of
isolated phase construction. The busduct will have an all aluminium
construction.
The tentative parameters of the generator busduct are:
Voltage rating 21 kV
Current rating (main run) 23,500 Amps
Current rating (delta run) 14,000 Amps
Current rating (tap off) 2000 Amps
The above data may vary in case of change in Generator Voltage rating.
Necessary current and voltage transformers shall be provided in the
busduct for generator excitation control, performance testing, metering,
protection and synchronization. Surge protection equipment and a
generator neutral grounding cubicle with distribution transformer and
secondary resistor, will also be provided. The connection between the unit
and station switchgear and transformers will be by means of segregated
busduct with aluminium conductor and enclosure.
5.00.00 GENERATOR TRANSFORMER
Each 660 MW unit shall have three (3) single phase transformers with
combined rating of 780 MVA, for the Generator Transformer.The
transformer would be OFAF cooled.
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isolated generator busduct in a manner designed to preserve the phase
isolated principle. The interrupters of the circuit breaker shall be SF6 or air
blast type with suitable continuous and short time current rating. It shall be
suitable for frequent operation on load and shall be capable of breaking
the maximum fault current (with high DC component) which may flow
through it. GCB shall be provided with an earth switch on generator side.
One pole of the breaker shall be provided as spare.
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10.00.00 START UP /STANDBY TRANSFORMER
The rating and details of these transformers are shown in the single line
diagram. The transformer will be ONAN/ONAF/OFAF cooled & will have
an on load tap changer
11.00.00 AUXILIARY TRANSFORMERS
For meeting the demand of various systems i.e. unit auxiliaries, CHP,
station auxiliaries, ash handling, ash water re-circulation system, make up
water system etc. suitable ratings of 2 x 100% transformer /feeders shall
be provided. All these transformers will be delta connected on the HT side
and star connected on the LT side
12.00.00 LT TRANSFORMERS
Power distribution at 415 Volts will be catered by 2x100% or 3X50% LT
transformers. All these transformers will be delta connected on the HT
side and star connected on the LT side. The LT star point will be solidly
earthed. These transformers shall be mineral oil filled for outdoor
installation or epoxy cast resin/resin encapsulated type in case of
indoor installation.
The transformers rated 1000 kVA and above will be connected with the
respective switchgears by the LT busducts.
13.00.00 NEUTRAL GROUNDING ARRANGEMENT
High resistance neutral grounding with distribution transformer and
secondary resistance shall be adopted for neutral grounding of generator.
HT systems feeding to motor loads shall be low resistance, non-effectively
earthed to limit the earth fault current upto 300 Amps, 415V system shall
be solidly earthed. 220V DC system shall be kept ungrounded.
Emergency diesel generator shall be ungrounded.
14.00.00 H.T. SWITCHGEAR
Switchgears shall be indoor, metal clad draw out type with vacuum
breakers. Contactors cum fuse units may be used for auxiliaries such as
coal conveyors/crushers which require comparatively frequent switching.
The switchgears shall have Communicable Numerical Relay system for
protection, Control, metering and monitoring of the Switchgears. All the
relays shall be networked to a dedicated HMI through data concentrator
for Monitoring and Supervision of all the breaker panels. All such data
shall be linked to DDCMIS as well.
As per standard metering regulations for generating stations, energy
accounting and audit meters are required to be installed at incomer
feeders of HT and LT incomer transformer feeder and all HT motors. The
accuracy class of all metering meters shall not be inferior to 1.0S. The
metering through numerical relays meeting above accuracy class has
been considered for above requirements. The above standard conforms to
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Indian regulations, however the same can be reviewed based on
Bangladesh metering regulations (if any) during subsequent stages.
15.00.00 415 VOLT SWITCHGEAR
The LT transformers shall feed power to the 415V switchgears, which in-
turn would distribute power to various MCC's located at load centres. The
415V system will have duplicate incomer and bus coupling arrangements
so that a changeover can be made from either of the two step down
transformers to restore power in case of failure of one of the above two
transformers. The 415 Volts switch boards shall be indoor, drawout type
compartmentalized with air break circuit breakers. The distribution boards,
clarifloculator's MCCS, if any, will be with fixed construction.
Adequate numbers of AC & DC Distribution Boards are also envisaged for
feeding to various loads. All LT motors above 110 KW up to 200 KW shall
be breaker controlled and below 110 kW shall be contactor controlled.
Microprocessor based MCCBS shall be used for feeder rating of 250 A to
630 A and the feeder rating below 250 A shall be of switch fuse unit type.
The LV switchgears shall have Communicable Numerical relay system for
protection, Control, metering and monitoring of the Switchgears. All the
relays shall be integrated with HT network for common HMI through data
concentrator for Monitoring and Supervision of all the breaker panels. All
such data shall be linked to DDCMIS as well.
The built in feature of energy metering in the numerical relay shall be used
for energy accounting and audit meters as per notified metering
regulations.
16.00.00 DC SYSTEM
The unit will have a 220V DC system comprising of two nos. of Ni-Cad/
Lead acid plante batteries, and two nos. of float cum boost chargers to
supply power to DC emergency pumps, emergency lighting,
protection, annunciation, indications and control etc. The required level
of redundancy would be achieved with the interconnections between these
two batteries and chargers. Each of the unit batteries shall be sized for
supplying the total DC load of the unit for a period of 30 minutes under a
complete black out condition. Other Balance of plant systems like AWRS,
Ash Silo and CHP shall have separate DC systems as indicated in Bill of
Quantity.
17.00.00 EMERGENCY POWER SUPPLY SYSTEM
For the safe shutdown of the plant under emergency condition and in
case of total power failure, diesel generating sets shall be installed for
feeding certain essential applications like battery chargers, emergency
lighting, essential air conditioning/ventilation and all auxiliaries necessary
for barring operation of main and BFP turbines etc. The unit emergency
switchgear section shall be fed by one diesel generator of adequate
capacity.
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One no. Diesel Generator (DG) set per unit alongwith one standby DG set
common for two units shall be provided as indicated in the single line
diagram. Cable interconnection shall be provided from DG to respective
unit emergency switchgear.
18.00.00 PROTECTIVE RELAYING
The necessary protective relaying system according to established
norms shall be provided for EHV switchyards, over head lines,
generators, transformers, motors, auxiliary system etc., to minimize
damage to equipment in case of fault and abnormal conditions. The
summary of protection details to be provided for the equipment is given
below:
18.1.00 GENERATOR
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18.3.00 UNIT TRANSFORMER
3. Unit transformer L.V. Restricted earth fault and standby earth fault
protection (64 RUT & 51NUT).
4. Bucholz relay, winding temperature, oil temperature and oil level alarm
and trip
5. Fire protection to trip EHV breaker, exciter field breaker and 11kV unit
incoming breaker.
7. Local breaker back up (or breaker failure) protection for the breaker on
HV side of station transformer
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18.6.00 BUS/LINE REACTOR
For HT cable, single core and three core XLPE insulated cables with
aluminium conductor would be employed. For 415V and DC systems,
single core XLPE insulated cables with aluminium conductor would
generally be used for higher current ratings and multicore XLPE/PVC
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insulated cables with aluminium conductor would be used for lower
ratings. All control cables would be multicore, PVC insulated with copper
conductors.
The cables shall be laid overhead/ in trenches or directly buried. Inter
plant cabling for main routes shall be laid on overhead trestles/pipe racks.
The cables laid in EHV switchyards, transformers yards and those buried
in earth would be armoured. All other cables would generally be
unarmored. These cables would have FRLS properties.
21.00.00 STATION GROUNDING
Adequate lighting arrangement shall be made for the entire power plant
employing lighting distribution boards, panels, HPSV, T5 type fluorescent
and incandescent (only for DC lighting) lighting fixtures, lighting masts etc.
Normal lighting of the plant will operate with the station AC supply. About
20% of these fixtures will also have arrangement for being fed from diesel
generators on failure of station AC supply. Emergency DC lighting, which
will normally be off, would be provided for all strategic locations. 24 V AC
supply network in both boiler and turbine areas shall be provided for safe
lighting inside enclosed space for maintenance purpose.
23.00.00 SWITCHYARD
In view of coastal site and marshy land ,Gas Insulated type Switchyard is
considered for this project.
Proposed Arrangement for Power Evacuation for the project has been
shown as per the single line diagram.
23.2.00 Bus Switching Scheme:
It is proposed to adopt the standard breaker and half switching scheme for
the 400 kV switchyard in order to have flexibility in operation and standard
advantages of one and half breaker scheme over double bus scheme as
follows:
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i) In case of one bus bar fault, faulty bus bar tripped. Load redirected
to other bus bar, no supply interruption happens.
ii) Bus maintenance becomes much easier, as all the feeder bus
breakers can be tripped and all the feeders remain connected to
other bus. No need of transferring all circuits to one bus as done in
double bus bar scheme
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2. Switchyard Equipments
(b) Isolators
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switching of unloaded transformers. Lightning arrestors shall be
provided near line entrances and transformers so as to achieve
proper insulation co-provided with pressure relief devices and
diverting ports suitable for preventing shattering of porcelain
housings providing path for the flow of rated currents in the event of
arrestors failure.
(f) Reactor
Each busbar shall be covered with duplicated high speed bus bar
protection scheme. Bus bar protection of each bus bar shall operate
in two out of two modes so as to achieve better reliability.
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through duplicated OPGW links provided on transmission line by
PGCB.
For the purpose of matching of frequency of transmission and
receivers at the two ends of the line, the equipment at both ends of
the line shall be arranged by the Power Grid Company of
Bangladesh (PGCB). Only wave trap and PLCC battery feeders have
been considered under the present F.R.
Static meters of 0.2 Accuracy class have been considered for active
energy measurement at other locations for energy accounting/trend
analysis.
The control, protection and data acquisition including SOE data for 400
/230 KV switchyard bays shall be accomplished by Substation Automation
System comprising of Bay Control Units, Bay protection Units, Operators
Workstation, Engineering Workstation, Large Video Screen (LVS) etc.
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shall be networked to engineering / DFDR station centrally for data down loading
& analysis associated with all the bays. In addition to above, standalone DFDR
with slow and fast scan feature shall also be provided for each generator. The
Digital Fault Disturbance Recorder (DFDR) system will be a complete automatic
digital recording system capable of sensing, acquiring and recording the data,
printing and transmitting disturbance records to the analysis units and centrally at
Engineering work station provided in the Substation Automation System.
The unit size being 660 MW, no black start facility has been envisaged for
the plant due to techno –economic reasons.
As per standard philosophy followed for such unit size, the black start
power is envisaged to be drawn from the 230 kV existing PGCB Khulna
substation through the planned transmission line between generating
switchyard and Khulna south substation.
26.00.00 ELECTRICAL LAB EQUIPMENT
One set of electrical lab equipment shall be provided for the plant.
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8. CONTROL & INSTRUMENTATION SYSTEM
1.00.00 GENERAL
The function of the Control & Instrumentation System would be to aid the
operator in achieving safe and efficient operation of the unit, resulting in
cost effective power generation with minimum fuel consumption and
reduced emission levels. The C&I system would be of the type which
normally relieves the operator of continuous duties and would take pre-
planned corrective actions in case of drift in process or if unsafe trends or
conditions develop in any regime of operation viz. startup, shutdown,
normal working and emergency conditions. The design of C&I system
would be such as to permit on-line localization, isolation and rectification
of fault in the minimum possible time.
2.00.00 CONTROL ROOM CONFIGURATION & LAYOUT
As per the currently used practices for main plant control, Large Video
Screens (LVS) would be provided for all regimes of operation. A Unit
Control Desk (UCD) for mounting monitors / Keyboards (KBDs) would also
be provided. For operation during disturbed/emergency operating
conditions in the plant, very few back-up conventional devices /
instruments like hardwired TRIP push button, would also be provided on
the UCD itself in draw-out sections.
The control, monitoring & operation of the offsite and auxiliary plants shall
be carried out generally from LVS/control desk of the respective plants /
combined control rooms. Large scale integration of control systems,
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unification of various control areas shall be provided to economise on
number of operation and maintenance staffs, inventory etc. in line with
recent practices. Remote IO’s with
OWS as well as GIU based local operation facility shall also be provided
depending on the layout of the control room. DDCMIS shall be provided
for offsite areas also and control of any drive of offsite areas can be done
from the main plant DDCMIS, subject to proper authorization. For this
purpose, for each Sub-area/equipment, a primary operating point and
secondary operating point shall be defined based on the process
requirements.
For PLC based control system (i.e. H2 generation, Fire Protection) link
shall be provided for exchange of data in the main plant control room for
the information of unit-in-charge/shift-in-charge etc. through Station Wide
LAN.
4.00.00 MEASURING INSTRUMENTS (PRIMARY & SECONDARY)
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engineering and maintenance functions would be done from
Engineer/Programmer console.
Adequate numbers of printers would be provided for logs, reports and
alarms. In addition to this, historical data storage and retrieval system
would be provided.
Alarm Annunciation System and Sequence of Events Recording System
(SERS) will be envisaged to be performed in DDCMIS itself. It is
envisaged to provide alarm analysis system for the project. Advanced
software packages, which result in improving the efficiency of power plant
operations such as, heat rate, combustion efficiency, plant life monitoring
etc., would be provided (as part of PADO which is described later).
Master and slave clock system would be provided to ensure uniform time
indication throughout the plant and also for time synchronization among
various DDCMIS.
Hart Management system for centralized configuration, maintenance,
diagnostics & record-keeping for all electronic transmitters, temperature
transmitters and analyzers would also be provided.
The balance of plant C&I system would generally include the following as
a minimum:
1. Modulating Control of the Steam Generator
2. Modulating Control of the Feed Water/Condensate Cycle
3. Binary Control of the Auxiliaries of the Steam-Generator (SG)
4. Binary Control of the Auxiliaries of the Turbine-Generator (TG)
5. Control of Electrical System Breakers and Balance Equipment
6. Other miscellaneous controls for common / off-site areas.
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5.08.00 OTHER COMMON SYSTEM DDCMIS:-
Water chemistry is life line of the power plant and considering that a
comprehensive Steam And Water Analysis System (SWAS) is envisaged
for on line analysis of chemical parameters at all critical points in
condensate, feed water and steam cycle.
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system shall consist of 2 sets with each comprising of 2X 100% chargers,
1X100% Nickel-Cadmium batteries for one hour duty, 1X100% DC
distribution board (DCDB) for powering the DC load requirement of
Contractor’s system.
Other offsite Control systems like AHP, CHP, Water system, Make up
water system etc. shall be provided with two sets of 24V DC power supply
with each set comprising of 1X 100% chargers, 1X100% Nickel-Cadmium
batteries for one hour duty, 1X100% DCDB.
Remote I/O cabinets wherever feasible shall be powered from the nearest
power supply system to the extent possible, considering the voltage drop
requirements. For other remote I/O cabinets independent power supply
modules along with sealed maintenance free Ni-Cd batteries, suitable for
mounting in remote I/O cabinets shall be provided.
Intelligent Battery health management system shall be provided for each
set of 24VDC power supply system (rating 300 Amps or above) and UPS
batteries.
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Handling Plant/Coal Unloading Area) with the help of handset stations,
loudspeakers, portable handset stations etc.
Impulse pipes, Instrument air/ Service air headers and pipes shall be
provided on as required basis along with all supports.
All process transmitters devices would be installed in Local Instrument
Enclosures (LIE) in boiler area and in Local Instruments Racks (LIR) in
turbine area. LIRs will not be provided for auxiliary plants where grouping
of instruments is not feasible.
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i) Performance analysis and monitoring of systems and components.
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9. ENVIRONMENTAL ASPECTS
1.00.00 INTRODUCTION
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and disposal. For oily wastes, oil water separator would be provided. The
separated oil will be removed from the top. The water at the bottom will
be brought to CMB through main plant drain. The effluent from coal
settling pond, unused cooling tower blow down, ash water blow down,
desalination plant reject and underflow from de-silting basin shall be
discharged through CMB.
The ash effluent shall be brought to a well designed ash disposal area to
ensure adequate settling for ash particles. It is proposed to re-circulate the
decanted ash water from ash dyke area for its reuse in ash handling
system. The sewage from plant and township shall be led to sewage
treatment plant. It will be provided with appropriate biological treatment
system to control BOD and suspended solids.
The treated effluent conforming to applicable standard shall be discharged
into the Possur river, leading to sea.
4.00.00 NOISE POLLUTION
The major noise generating sources are the turbines, turbo-generators,
compressors, pumps, fans, coal handling plant etc. from where noise is
continuously generated. Equipment will be designed to control the noise
level below 90 dB(A). Wherever it is not possible technically to meet the
required noise levels, the personnel protection, equipment like ear plug/
ear muff shall be provided to the workers.
5.00.00 SOLID WASTE MANAGEMENT
The ash management scheme for ash generated from power plant
involves dry collection of fly ash, supply of ash to entrepreneurs for
utilization, promoting ash utilization and safe disposal of unused ash. The
company will make maximum efforts to utilize the fly ash for various
purposes. Unused fly ash and bottom ash shall be disposed off in the ash
pond. A blanket of water shall be maintained over the ash pond to control
fugitive dust emission. After the ash pond is abandoned, it shall be
reclaimed through vegetative cover
6.00.00 AFFORESTATION AND GREEN BELT DEVELOPMENT
A green belt has been planned around the main plant area and in
available spaces within the main plant area.
7.00.00 POST OPERATIONAL MONITORING PROGRAMME
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and manpower. The EMG will interact with regulatory agencies and other
concerned agencies for environmental issues, as and when required.
9.00.00 ASH UTILIZATION PLAN
Many Cement plants exists in the vicinity, best efforts shall be made for
maximum utilization of fly ash. Also best efforts shall be made for
maximum utilization of bottom ash. However, ash dyke of 100 acres has
been provided in FR.
10.00.0 BENEFITS OF ENVIRONMENTAL PROTECTION MEASURES
Following benefits shall accrue due to Environment Protection Measure:
Sl. Measures Benefits
No
1. Electrostatic Precipitator (ESP) To clean the exit flue gas
2. Stack of 275m height Dispersion over wider area
3. Cooling Tower Discharge water temperature
reduction
4. Desalination plant To produce sweet water from
brackish water to avoid exploiting
ground water
5. Effluent Management System To minimize effluent
6. Ash Management & Utilization Ash utilization & safe disposal
Page 72 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
11.00.00 IMPACT ON TARIFF
The Environmental Protection Cost has been estimated as BDT 12561
Mln. In US $ it works out to $145.455 Mln. The impact on tariff due to
above environmental cost works out as 0.20 BDT per unit in fixed charges,
in levelised cost of energy. This includes 0.03 BDT per unit for operation
and maintenance of above equipment/measures.
Page 73 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
10 A TECHNICAL DATA & BILL OF QUANTITY
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS
Page 74 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS
1.08.00 Chimney
275 m Twin flue steel lined 1 No.
RCC chimney with staircase and
elevator.
5 Type – D-II 72 No
3 Type - C - No.
2 Type - B 36 No.
3 Type - C - No.
96
Page 82 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS
5. SCAPHS (nos. per boiler) 4 Nos. Two for PA & Two for
SA
6. Milling plant with feeders, PA To be decided
fans, seal air fans and drive by the
motors. supplier Mill: Vertical spindle
subject to PA Fan: 2X60%
a. Pulveriser
specified Variable Pitch Axial
b. Feeder criteria fans
c. PA Fan 2 Nos.
Seal Air Fans: 2 X
d. Seal Air Fan 2 Nos. 100% Common for all
Mills
7. Draft plant including
Page 83 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS
15. Miscellaneous
1. Spares Lot
2. Maintenance Tools & Tackles Lot
16. Auxiliary boiler with all 1 No. Common for two (2)
associated auxiliaries of 60 units
T/Hr. capacity with rated steam
parameters at SH outlet as
19kg/cm² (gauge) pressure and
250°C temperature.
Page 84 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS
per unit
10. Central lube oil purification 1 No. Clean and dirty oil tank
system for all units. capacity 1.5 times the
capacity of MOT.
Centrifuge capacity
same as unit
centrifuge.
11. Turbine hall EOT Cranes for all 2 No Main Hook of each
units. crane shall be capable
of lifting at least 105%
of the weight of single
heaviest component/
equipment, including
lifting beam and slings
Page 85 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS
Page 86 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS
2.03.00 Piping
1 Power Cycle Piping including LOT Lot for 2 units.
pipes, valves, fittings, expansion
joints, Hanger/supports along
with necessary Aux. Structure,
thermal insulation, spares, flash
tanks etc. for main steam, hot
reheat, cold reheat, HP/LP
Bypass, condensate, extraction,
Aux. Steam, feed water, Spray
to SHA and RHA, Spray to
aux. PRDS and HP Bypass,
heater drains & vents, safety
valve exhaust and steam drains,
vents etc. along with chemical
dosing system.
2 Station piping with valves, LOT Lot for 2 units.
fittings etc.
Page 87 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS
3 WT Control Rooms - -
EXTERNAL CHP
A. Mechanical Portion
Page 91 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS
1. HFO storage tanks complete with 2 Nos. MS, fixed roof type, 2000
suction heater, floor coil heater, Cu M capacity
insulation, cladding, accessories,
instruments etc
2. LDO storage tanks complete with 2 Nos. MS, fixed roof type, 500
all instruments and accessories Cu M capacity
3. Day Oil tank for Auxiliary Boiler 1 No. MS, fixed roof type, 100
Cu M capacity
4. Drain oil tank to collect oily drains 1 Nos. 6 Cu M
in the pump house area.
5. Condensate Flash Tank 1 No. 6 Cu M
6. Unloading pump motor sets 6 Nos. Twin-screw, 100 Cu M/hr
(HFO/LSHS/HPS)
7. LDO unloading pumps motor sets 2 Nos. Twin-screw, 50 Cu M/hr
8. LDO transfer pump motor sets 2 Nos Twin-screw, 25 Cu.M./hr
9. Pressure Reducing Station for Aux. 2 Nos. 20 T/hr
steam
10. Unloading pump suction strainers 18 Nos. 200NB
11. Fuel oil unloading hoses, steam 10 Nos. 75NB-8M Long for HFO
and condensate hoses 50NB-8M Long for Steam
10 Nos. 50NB-8M Long for
Condensate
10 Nos. 75NB-8M Long for LDO
05 Nos.
Page 93 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS
12. Drain oil pumps to collect the 2 Nos. Single screw, 10 Cu M/hr
drains from the drain oil tank and
pumping it back to the main tank
(HFO/LSHS/HPS)
13. Dirty oil pump for pumping out Dirty 2 Nos. Single screw, 5 Cu M/hr
oil from the oil water separator unit
14. Sump pumps 2 Nos. Centrifugal, 30 Cu M/hr
15. Water pump for pumping out clear 2 Nos. Centrifugal, 30 Cu M/hr
water from the oil water separator
unit
16. Design of oil water separator pit Lot
along with facilities for removal of
water and oily waste
17. Complete fuel oil piping, steam Lot
tracers, condensate piping, valves,
fittings, steam traps, insulation
hangers and supports etc
18. Instrumentation and control system Lot
including instruments, interfacing
with main plant control room,
protection devices
19. Flow meter
For HFO unloading system 1 No. 500 Cu M/hr for
HFO/LSHS/HPS
LDO unloading system 1 No. 50 Cu M/hr for LDO
20. HOT crane in FO unloading pump 1 No. 2 tons
house (Hand operated Monorail
Hoist)
Page 94 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS
15
BA Silo aeration blower and heater 400 m3/hr, 0.9 kg/cm2, 10
along with drive motor 1 Nos
kW
16 Target box 1 Nos
Bag filter with pulsing arrangement for
17
BA silo 1 Nos 1500 m3/hr
18 BA Silo vent fan 1 Nos 1500 m3/hr
Rotary feeder with variable frequency
19 3 Nos 100 TPH
drive
20 Bends (alloy CI/basalt)
21 90 deg 20 Nos
i) 45 deg 20 Nos
22 Screw Conveyors 4 Nos. 25 m length
23 Hydro Mix Dust Conditioner 4 Nos. 100 TPH
2.06.02 ECONOMISER SYSTEM
1 Chute isolation valves 8 Nos. 350 NB
2 Expansion joints 8 Nos. 350 NB
Material handling valve-pneumatic
8 No. 300 NB
operated-alloy CI
Segregating valve-pneumatic
2 No. 250 NB
operated, alloy CI
Extraction pipe as per
IS:1536/BS1211 Class D with 400 m 250 NB
sleeve couplings and fittings.
Liquid seal ring vacuum pump with
2 No. 2000 m3/hr,16 Hg, 50KW
drive and accessories
Page 95 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS
Page 97 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS
232
5 Air lock/pump tanks MS 10 mm thk No. 2 m3
Page 98 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS
Page 99 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
Sl. No. DESCRIPTION QTY UNIT TECHNICAL
PARAMETERS
2.07.05
5. MISCELLANEOUS PUMPS
HVAC system makeup pumps 2 nos Hor, Centf; 100 M3/hr &
70 MWC Motor rating: 32
KW
AHP – Seal water Pumps 2 nos Hor, Centf: 100 M3/hr ;
Head: 20 MWC; Motor
rating: 12 KW
DM water transfer pumps 3 nos Hor, Centf; 100 M3/hr &
70 MWC Motor rating: 32
KW
Service water pumps 2 nos Hor, Centf 130 M3/hr & 70
MWC Motor rating: 35 KW
Air pre-heater wash pumps 2 nos Hor, Centf 400 M3/hr &
110 MWC Motor rating: 160
KW
fBoiler fill pumps 2 nos Hor, Centf 175 M3/hr &
150 MWC Motor rating: 110
KW
Potable water pumps for colony 2 nos Hor, Centf 70 M3/hr & 80
MWC Motor rating: 26 KW
Potable water pumps for plant 2 nos Hor, Centf 30 M3/hr & 50
MWC
Motor rating: 7.5 KW
Sump pumps 6 nos Hor, Centf 40 M3/hr & 20
MWC
Motor rating: 3.5 KW
j Drainage pumps 4 nos Hor, Centf 40 M3/hr & 20
MWC
Motor rating: 3.5 KW
DESALINATION PLANT
2.07.06
Complete Desalination Plant LOT RO 1st Stage: Net Capacity
including required Pre-treatment : 600 Cu.m/hr
System, chemical Dosing (3 x 200 Cu.m/hr)
Equipments etc. Type of Process : SWRO
2nd stage RO plant LOT Net capacity: 120 Cu.m/hr
(2x60 Cu.m/hr)
Type of process: RO
c. Permeate water storage tank 3 nos Carbon steel vertical
cylindrical type of Capacity :
5000 Cu.m.
CONDENSATE POLISHING
2.07.08 PLANT
CHLORINATION PLANT
2.07.09
Electro chlorination Plant for MU 2 sets Electro chlorination system
pumps 15 Kg/hr
EFFLUENT TREATMENT
2.07.10 SYSTEM (including civil works)
1 DDCMIS
i) Control System(s)
Analog Inputs(4-20mA) Nos 1923 2549
Analog outputs Nos 220 187
Binary Inputs Nos 3192 14623
Binary Outputs Nos 2234 5423
SOE Binary Inputs Nos 664
Calculated SOE Nos 285
Functional groups* Nos 10 17
(minimum)
Control cabinets lot 1 1
Marshalling cabinets lot 1 1
Relay cabinets lot 1 1
No. of Remote I/O Nos 0 22
Links
Measuring
2 Instruments
Flue gas analysers
LT O2 Nos 14
HT O2 Nos 2
CO Nos 1
Sox/Nox Nos 2
CO2 Nos 1
OPACITY Nos 1
DP type transmitters No 199
Pressure transmitters No 129 4
Thermocouples No 2
Resistance No 2
temperature Detectors
Impact head type flow No 2
Elements
Vibration Sensors No 106 32 36 Sensors for mill
motors has been
added.
Key Phasor No 15 5
Vibration Monitors Sets 53 16 Quanities are for
two channel
monitors.
Electrical Power
3 supply system
UPS-120 KVA Sets (A) 1 (A) : 2 chargers, 2
inverters, 1 bypass
source and 1
battery
UPS-10KVA Sets (B) 1 (B) : 1 charger, 1
UPS-25KVA Sets (B) 2 inverter, 1 bypass
source and 1
battery
UPS-2KVA Sets (C) 3 (C) : Online UPS
UPS-1KVA Sets (C) 9 with remote
monitoring having
a battery backup of
30 mins.
24 VDC Power supply Sets (D) 2 (D) : set means 2
for Unit DDCMIS chargers, 1 battery
(1000Amp) and 1 DCDB
24 V DC for SA Sets (D) 2
DDCMIS (175Amp)
24 V DC for Common Sets (E) 14 (E) : set means 1
system (175Amp) charger, 1 battery
24 V DC for Common Sets (E) 2 and 1 DCDB
system (300Amp)
24 V DC for Common Sets (E) 2
system (275Amp)
24 V DC for Common Sets (E) 2
system (125Amp)
24 V DC for Common Sets (E) 7
system (75Amp)
24 VDC for Common Sets (E) 8
systems (35 Ampere)
4 PCP
PCP material LOT 1
5 Cables
A-2P Meter The quantity shown
are for Two(2)
1000 units.
F-4P Meter 147000
F-8P Meter 40000
F-12P Meter 6000
F-16P Meter 3000
F-24P Meter 3000
G-4P Meter 262000
G-8P Meter 33000
G-12P Meter 8000
G-16P Meter 15000
G-24P Meter 9000
G-48P Meter 3000
Laying of Meter
instrumentation cables
provided by Employer 530000
Rigid Conduit(1" 25
mm) Meter 8000
Rigid Conduit
2"(50mm) Meter 2000
Flexible
Conduit3/4"(18mm) Meter 7000
Flexible Conduit
1"(25mm) Meter 2000
Cable sub-tray 2000
2"(50mm) Meter
Cable sub-tray
4"(100mm) Meter 4000
Cable sub-tray 6"
(150mm) Meter 1000
7 SWAS
Analysers
pH Nos 6
Sp. Cond Nos 7 Flow through type
cell
Cat. Cond Nos 8 Flow through type
cell
Withdrawable cond. Nos 6 Removable type
cell
Na Nos 1 Multistream
DO2 Nos 3
Silica Nos 2 Multistream
HYDRAZINE Nos 2
CHLORIDE ION Nos 0
Turbidity Nos 1
10 AAQMS
Sox/ Nos 0 4
Nox Nos 0 4
SPM Nos 0 8
CO2 Nos 0 4
PC based Station Nos 0 5
Wireless Lot 0 1
Communication
System
Field marshalling
11 unit
1024 WAYS Nos 0 9
Nos
512 WAYS 0 7
128WAYS Nos 0 6
12 M&C
Srd. M/C items Nos. 0 54
A) Fuel Expenses
i) Coal cost : 90 days requirement
ii) Oil cost : 60 days requirement
In the base model the project cost has been worked out as 1.27 Million
USD/MW, 109.91 MillionBDT/MW. The variables considered for
calculation are as tabulated below:-
The coal parameters in base model has been considered as USD 145/MT and
6000 Kcal/kg as GCV. The sensitivity has been done for coal cost from USD
165/MT to USD 105/MT. The results are as follows :-
Total Project
Cost
The coal parameters are coal cost as USD 145/MT and GCV AS 6000
kcal/kg. The sensitivity has been done for GCV of 5200 Kcal/kg. The results
are as follows-
The major phases of the project during its implementation are classified as
under: -
Short duration programme to develop and upgrade skills and long duration
programme to attain higher educational levels shall be formulated for the
benefit of personnel at different levels.
a) The unit as a whole shall be able to generate at 105% of the name plate
rating on a sustainable basis to meet the requirement of the grid.
c) The unit and equipment control system shall be designed in such a way that
the unit will survive the loss of a major equipment and continue to operate at
a lower load.
d) The number and size of mills will be so selected that with worst coal at
BMCR one mill will be spare.
2.02.03 Coal Handling Plant
The design and sizing of coal handling plant has an important bearing on
station plant load factor. Hence, the following steps will be taken while
designing the coal handling plant so as to ensure high PLF for the stations:
a) CHP shall be able to meet the daily coal requirement considering 100%
PLF and design coal.
c) Coal bunkers shall be designed to avoid choking /rat holing etc. after
carrying out coal flowability studies
The thermal cycle parameters shall be optimised for this range of unit rating by
selecting parameters of Main steam temperature, pressure, reheat steam
temperature and condenser pressure to provide a thermal cycle with higher
efficiency. The boiler shall operate in super critical zone. The cycle employs
Page 147 of 153
Document No. 9635-999-NOG-J-001 R ’C’ (Dec 12)
regenerative feed water heaters thereby ensuring optimum turbine heat rate. The
losses through flue gas have been kept to a minimum.
5.03.00 COAL HANDLING PLANT
Coal Handling Plant for feeding coal to the Boiler Bunkers has been envisaged
with the following major features to minimize the consumption of energy:
a) Coal handling plant layout shall be finalized with very less number of
conveyers in order to minimize the total coal-conveying path.
b) Crusher house height shall be reduced preventing un-necessary conveying
of coal to higher elevations.
c) For dust control at coal transfer points dust suppression system shall be
provided exclusively for reducing the energy consumption levels to almost
nominal values compared to dust extraction system, which are restricted to
crush house only.
d) Running hours of CHP are optimized to reduce specific energy consumption
per MT of coal handled.
5.05.0 CHEMISTRY
Continuous monitoring and control of water and steam purity in the plant cycle
will further improve the heat transfer rate in heat exchanger tubes,
It can be achieved by the following chemistry control philosophy :
Chemistry Control :
(i) The units are to be operated in Oxygenated treatment (OT) of feed water.
(ii) The 100% Condensate to be treated in CPU in hydrogen cycle only.
Therefore a standby 50% treatment facility shall be available all the time.
(iii) The make up water should have the following characteristics:
(a) Conductivity less than 0.1 μs/cm,
(vi) The adequate arrangements including nitrogen capping (for dry or wet
preservation) shall be provided for proper lay up of the all the water and
steam touched system when unit is under shut down.
vii) The WT plant shall be fully automated and to be designed for minimal
manual interference. The Utilisation Ozone for water disinfection; use
of alternate chemicals such as PAC; and gas transfer membrane
system for degasification of deminiralised water etc to be considered.
ix) Cooling water chemistry control to be done by PLC based operation and
monitoring.
(a) Automatic controllers are provided for plant optimization. The unit capacity
controller shall set load demand keeping the safety of the equipment
inherent.
The main controllers used for optimum performance of the whole plant are as
follows:
a) Unit Capacity Controller
i) Boiler Capacity Controller
ii) Turbine Capacity Controller
b) Combustion Control
i) Coal flow
ii) Air flow
c) SH/RH Steam temperature controller
d) Chemical dosing controller
i) Hydrazine
ii) Ammonia
iii) Phosphate
e) Main steam pressure controller
f) FW flow Controller (Drum level)
i) Low range
ii) High range
2.00.00 TARIFF
Sale of Power shall be at the Ex-Bus of the Project. Tariff payable to JVC
by BPDB for the Project shall be decided by JVC based on Norms agreed
upon in the Power Purchase Agreement signed between BPDB and the
JV Company. Tariff payable by BPDB to JVC shall comprise of two-part
viz. the Fixed charge and the Energy charge. Tariff determination shall be
based on the Capital cost of the Project, Normative Availability, Normative
O&M charges, Normative Operating Parameters and agreed Norms of
inventory / fuel stock etc.
11 /9/2012 Page 1 of 14
Annexure - 1.1.1
CIVIL WORKS
(CURRENT COST)
(I Qtr-2011)
PROJECT: Khulna TPP Stage -I ( 2 x 660 MW) (US $ in Mn)
2 Land 0.00
8 Miscellaneous 9.09
TOTAL 440.79
ANNEXURE-1.1 .2
Mechanical Works
(CURRENT COST)
. ANNEXURE- 1.1.2
(I Qtr,2011)
:JROJECT Khulna TPP Stage I (2 x 660 MW) (US$ in Millions)
TOTAL 824.14
Page 3 of 14
ANNEXURE- 1.1 .3
ABSTRACT COST ESTIMATE
Electrical Works
(CURRENT COST)
(I Qtr,2011)
PROJECT: Khulna TPP Stage I (2 x 660 MW) (US$ in Millions)
......................................................----
SI. Item Description Total
No.
A ELECTRICAL SYSTEM
4 H T Switchgear 4 .07
5 L T Switchgear 4.10
B SWITCHYARD
TOTAL 89.27
page 4 of 14
M" ":ml~ @r~'~' -~-~~W"'.'W" ,,' ~"
Tariff Computation in US $
Effective Tax Rate 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
Pre Tax Return on Equity (%) 18.00% 18.00% 18.00% 18.00% 18.00% 18.00% 18.00%
A _~ A
KhulnaTPP $
Year Ending 31-Mar-20 31-Mar-21 31-Mar-22 31-Mar-23 31-Mar-24 31-Mar-25 31-Mar-26 31-Mar-27
Tariff Computation in US $
Effective Tax Rate 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
Pre Tax Return on Equity (%) 18.00% 18.00% 18.00% 18.00% 18.00% 18.00% 18.00% 18.00%
Return on Equity 866.75 866.75 866.75 866.75 866.75 866.75 866.75 866.75
Interest on Loan Capital 660.21 574.66 489.12 403.57 318.03 232.48 146.94 61.39
Depreciation 1,098.75 1,098.75 1,098.75 1,098.75 1,098.75 1,098.75 1,098.75 1,098.75
Oil Cost 53.61 53.61 53.61 53.61 53.61 53.61 53.61 53.61
Interest on Working Capital 403.68 401.71 399.74 397.77 395.80 393.83 391.86 389.89
Land lease payment 43.72 43.72 43.72 43.72 43.72 43.72 43.72 43.72
0& M Expenses (Unit I) 196.07 196.07 196.07 196.07 196.07 196.07 196.07 196.07
0& M Expenses (Unit II) 196.07 196.07 196.07 196.07 196.07 196.07 196.07 196.07
Total Fixed Cost 3,518.86 3,431.35 3,343.83 3,256.32 3,168.80 3,081.29 2,993.77 2,906.26
Energy Charge 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80
Year Ending 31-Mar-28 31-Mar-29 31-Mar-30 31-Mar-31 31-Mar-32 31-Mar-33 31-Mar-34 31-Mar-35
Tariff Computation in US $
Effective Tax Rate 0.00% 0.00% 0.00% 0.00% 6.25% 25.00% 25.00% 25.00%
Pre Tax Return on Equity (%) 18.00% 18.00% 18.00% 18.00% 19.20% 24.00% 24.00% 24.00%
Return on Equity 866.75 866.75 866.75 866.75 924.53 1,155.66 1,155.66 1,155.66
Interest on Loan Capital 9.31
Depreciation 1,098.75 1,098.75 524.66 34.54 34.54 34.54 34.54 34.54
Oil Cost 53.61 53.61 53.61 53.61 53.61 53.61 53.61 53.61
Interest on Working Capital 388.80 388.70 375.49 364.21 365.54 371.01 371.16 371.16
Land lease payment 43.72 43.72 43.72 43.72 43.72 43.72 43.72 43.72
0& M Expenses (Unit I) 197.87 197.87 197.87 197.87 197.87 200.27 200.27 200.27
0& M Expenses (Unit II) 196.07 197.87 197.87 197.87 197.87 197.87 200.27 200.27
Total Fixed Cost 2,854.89 2,847.28 2,259.97 1,758.58 1,817.69 2,056.69 2,059.24 2,059.24
Energy Charge 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80
" _ • .A
KhulnaTPP
Year Ending 31-Mar-36 31-Mar-37 31-Mar-38 31-Mar~39 31-Mar-40 31-Mar-41 31-Mar-42 31-Mar-43
Tariff Computation in US $
Effective Tax Rate 25.00% 25.00% 25.00% 25.00% 25.00% 25.00% 25.00% 25.00%
Pre Tax Return on Equity (%) 24.00% 24.00% 24.00% 24.00% 24.00% 24.00% 24.00% 24.00%
Return on Equity 1,155.66 1,155.66 1,155.66 1,155.66 1,155.66 1,155.66 1,011 .21 144.46
Interest on Loan Capital
Depreciation 34.54 34.54 34.54 34.54 34.54 34.54 27.07 1.09
Oil Cost 53.61 53.61 53.61 53.61 53.61 53.61 46.91 6.70
Interest on Working Capital 371.16 371.16 371.38 371.60 371.60 371.60 323.85 45.32
Land lease payment 43.72 43.72 43.72 43.72 43.72 43.72 38.26 5.47
0& M Expenses (Unit I) 200.27 200.27 203.87 203.87 203.87 203.87 152.90
0& M Expenses (Unit II) 200.27 200.27 200.27 203.87 203.87 203.87 203.87 50.97
Total Fixed Cost 2,059.24 2,059.24 2,063.06 2,066.89 2,066.89 2,066.89 1,804.07 254.01
Energy Charge 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 5,480.80 4,795.70 685.10
A nf.4
ANNEXURE- 1.1
11/9/2012 Page 1 of 14
Annexure - 1.1.1
CIVIL WORKS
(CURRENT COST)
(I Qtr-2011)
PROJECT:Khulna TPP Stage -I ( 2 x 660 MW) (BDT in Mn)
2 Land 0.00
8 Miscellaneous 785.00
TOTAL 38062.61
ANNEXURE-1 .1.2
Mechanical Works
(CURRENT COST)
ANNEXURE- 1.1.2
(I Qtr,2011)
;)ROJECT Khulna TPP Stage I (2 x 660 MW) (BOT in Millions)
Page 3 of 14
ANNEXURE-1 .1.3
ABSTRACT COST ESTIMATE
Electrical Works
(CURRENT COST)
(I Qtr,2011)
PROJECT: Khulna TPP Stage I (2 x 660 MW) (BDT in Millions)
5 L T Switchgear 354.19
B SWITCHYARD
TOTAL 7708.39
page 4 of J4
KhuInaTPP IN BDT PER UNIT
Year Ending 31-Mar-13 31-Mar-14 31-Mar-15 31-Mar-16 31-Mar-17 31-Mar-18 31-Mar-19
Annual Fixed Cost
Effective Tax Rate 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
Pre Tax Return on Equity (%) 18.00% 18.00% 18.00% 18.00°/', 18.00% 18.00% 18.00%
1 ..... f A
Khulna TPP
Year Ending 31-Mar-20 31-Mar-21 31-Mar-22 31-Mar-23 31-Mar-24 31-Mar-25 31-Mar-26 31-Mar-27
Annual Fixed Cost
Effective Tax Rate 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00% 0.00%
Pre Tax Return on Equity (%) 18.00% 18.00% 18.00% 18.00% 18.00% 18.00% 18.00% 18.00%
Return on Equity 748.44 748.44 748.44 748.44 748.44 748.44 748.44 748.44
Interest on Loan Capital 570.09 496.22 422.35 348.48 274.62 200.75 126.88 53.01
Depreciation 948.77 948.77 948.77 948.77 948.77 948.77 948.77 948.77
Oil Cost 46.29 46.29 46.29 46.29 46.29 46.29 46.29 46.29
Interest on Worki ng Capital 348.57 346.87 345.17 343.47 341.77 340.07 338.37 336.67
O&M Expenses 0.26 0.26 0.26 0.26 0.26 0.26 0.26 0.26
0& M Expenses (Unit I) 169.31 169.31 169.31 169.31 169.31 169.31 169.31 169.31
0& M Expenses (Uni t II) 169.31 169.31 169.31 169.31 169.31 169.31 169.31 169.31
Total Fixed Cost 3,038.54 2,962.97 2,887.40 2,811.83 2,736.26 2,660.69 2,585.12 2,509.55
Energy Charge 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67
2of4
Khulna TPP
Year Ending 31-Mar-28 31-Mar-29 31-Mar-30 31-Mar-31 31-Mar-32 31-Mar-33 31-Mar-34 31-Mar-35
Annual Fixed Cost
Effective Tax Rate 0.00% 0.00% 0.00% 0.00% 6.25% 25.00% 25.00% 25.00%
Pre Tax Return on Equity (%) 18.00% 18.00% 18.00% 18.00% 19.20% 24.00% 24.00% 24.00°Ic,
Return on Equity 748.44 748.44 748.44 748.44 798.33 997.92 997.92 997.92
Interest on Loan Capital 8.04
Depreciation 948.77 948.77 453.04 29.83 29.83 29.83 29.83 29.83
Oi1 Cost 46.29 46.29 46.29 46.29 46.29 46.29 46.29 46.29
Interest on Working Capital 335.73 335.64 324.23 314.49 315.64 320.36 320.49 320.49
O&M Expenses 0.26 0.26 0.26 0.26 0.26 0.26 0.26 0.26
0& M Expenses (Unit I) 170.86 170.86 170.86 170.86 170.86 172.94 172.94 172.94
0& M Expenses (Uni t II) 169.31 170.30 170.30 170.30 170.30 170.30 171.62 171.62
Total Fixed Cost 2,465.20 2,458.63 1,951.49 1,518.53 1,569.58 1,775.95 1,778.15 1,778.15
Energy Charge 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67
30f4
Khulna TPP
Year Ending 31-Mar-36 31-Mar-37 31-Mar-38 31-Mar-39 31-Mar-40 31-Mar-41 31-Mar-42 31-Mar-43
Annual Fixed Cost
Effective Tax Rate 25.00% 25.00% 25.00'Yo 25.00% 25.00% 25.00% 25.00% 25.00%
Pre Tax Return on Equity (%) 24.00% 24.00% 24.00% 24.00% 24.00% 24.00°/', 24.00% 24.00%
Return on Equity 997.92 997.92 997.92 997.92 997.92 997.92 873.18 124.74
Interest on Loan Capital
Depreciation 29.83 29.83 29.83 29.83 29.83 29.83 23.38 0.94
Oil Cost 46.29 46.29 46.29 46.29 46.29 46.29 40.51 5.79
Interest on Working Capital 320.49 320.49 320.69 320.88 320.88 320.88 279.64 39.13
O&M Expenses 0.26 0.26 0.26 0.26 0.26 0.26 0.26 0.26
0& M Expenses (Unit I) 172.94 172.94 176.04 176.04 176.04 176.04 132.03
0& M Expenses (Unit IT) 171.62 171.62 171.62 173.60 173.60 173.60 173.60 43.40
Total Fixed Cost 1,778.15 1,778.15 1,781.46 1,784.76 1,784.76 1,784.76 1,557.81 219.33
Energy Charge 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,732.67 4,141.09 591.58
A "f A
EXHIBITS
I PLAN
KHULNA TPP (2X660 MW)
BANGLADESH
PROJECT CODE :9635
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