Fuel gas conversion from Liquid & water to gas & water and Control System Upgrade

GE Proposal NO.714283B dt 18th May 2011

Sl no Section Sub Section Customer comments Customer comment

Prices quoted are on lumpsum basis. It was specifically discussed with GE officials to provide
individual / split pricing as discussed during the 14th April meeting and reiterated through mail
dated 13/05/2011. Despite the same the split pricing has NOT been provided. It is requested to
provide the split pricing as per the following:
1) Gas Conversion hardware (without SPRINT) alongwith gas filters:
2) Gas Conversion hardware (with SPRINT) alongwith gas filters:
3) Control system and its upgrade to Micronet +:
a) Complete Hardware with detailing & Specs
b) Softwares (including System 1 as platform + Performance (EMAP+GC) and Vibration
diagnostic modules)
1 Pricing 2
c) EX2100
4) De-Nox system hardware:
5) Complete Manpower cost (should be ALL INCLUSIVE, including travel, out of pocket, etc, etc.)
related to complete activities of engineering, erection, including combustor replacement,
commissioning, trouble shooting, completion of punch list points, performance demonstration:
6) BKPL has 5 combustors meant for Naphtha operation with water injection. These would be
required to be changed to Gas operation with water injection. GE to indicate the prices for :
a) Changing the combustors for Gas operation with water injection (G42)
b) GE to take these combustors and supply NEW combustors
7) Fire and gas detection system design, supply, implementaton and commissioning
 Fuel gas conversion from Liquid & water to gas & water and Control System Upgrade
GE Proposal NO.714283B dt 18th May 2011
Sl no Section Sub Section Customer comments Customer comment

Degradation curves for a standard LM6000PC engine with respect to operating hours:
We have received degradation curve for ISO condition and for 25 ppm NOx on Gas, while all our
discussions during site meeting on 14th Apr11, were centered around BKPL Site and 50 ppm NOx.
In view of above, please provide similar degradation curves [for a) POWER, b) HEAT RATE; c)
EXHUAST ENTHALPY] on GAS and NAPHTHA considering the following:
1(c) DESIGN
1) BKPL Site conditions: Attached in adjacent xls worksheet
2) NOx 50 ppm
3) With Chill (NO Sprint) ON Gas as well as Naphtha
4) With SPRINT (NO Chill, Or Partial Chill as you have considered in the APPS run attached
below) ON Gas as well as Naphtha

GE to specify the relevant design and manufacturing code and standards for all items that are
covered unders scope of supply such as tubes and piping, flanges, vessels, valves, field
4 Pricing 2.1.6
instruments/sensors/cables, softwares, electric cables, cards, panels, computers and other electric
and electronic hardware, etc
 Fuel gas conversion from Liquid & water to gas & water and Control System Upgrade
GE Proposal NO.714283B dt 18th May 2011
Sl no Section Sub Section Customer comments Customer comment

Payment schedule to have successful commissioning and PG test as one of the milestones as
5 Pricing 2.2
discussed during the 14th April meeting. However the same is NOT reflected in the offer.

Completion of technical advisory services is defined as the material completion of installation of the
GE scope of supplied equipments.Completion of TA services to be modified as successful
commissioning, in cluding performance demonstration of the unit in every aspect. This was
6 Pricing 2.2 discussed during the meeting on 14th April but the same is NOT reflected in the offer.
Payment has to be linked with certain milestones achieved for material supplies as well as site
progress achieved. Detailed terms would be discussed during the meeting at RPower Office at
DAKC, Mumbai.
 Fuel gas conversion from Liquid & water to gas & water and Control System Upgrade
GE Proposal NO.714283B dt 18th May 2011
Sl no Section Sub Section Customer comments Customer comment

Depot visit of the engine, whether it is required for SPRINT conversion? There was no mention of
Delivery ,title
this requirement in the original offer or during the 14th April meeting. It is understood that the
7 transfer and risk of 3.1
SPRINT conversion for all the machines at GMR was done at site only. BKPL doesn't intend to
loss
send the machine to depot for SPRINT conversion.

Delivery ,title This is a comprehensive contract to GE which include design, supply, erection and commissioning
8 transfer and risk of 3.2 by ONE party as far as BKPL is concerned. Hence the Title trasnfer of service can be completed
loss ONLY when the successful performance demonstration and handing over the unit has taken place.

Delivery ,title
9 transfer and risk of 3.3.1 Project time schedule has to be firm ie. 12 months from date of placement of order.
loss

We understand that there are three gas filter skid (one each of a GT) and filters are duplex filters,
complete with isoltation valves, autochangeover valves with manual override, venting and draining
12 Attachment 1 A arrangement and field instrumentation and transmitters for hooking up the required signals (such as
dp, valve positions and torque switches, etc) for monitoring, operation, alarm and control) to the
GTG control system. GE to confirm the same. Also refer sr. no. (2) above for providing the details.

For an improved power output as part of this proposal the seller will fit both turbines with fixed
15 Attachment 1 A
IGVs at -5 degree - Whether the offer is inclusive of these two FIGVs ?
 Fuel gas conversion from Liquid & water to gas & water and Control System Upgrade
GE Proposal NO.714283B dt 18th May 2011
Sl no Section Sub Section Customer comments Customer comment

Heat rate improvement for -5 deg FIGV as compared to 0 deg FIGV if any is to be confirmed by
16 Attachment 1 A
GE. Increased power output without heat rate improvement is not of interest to BKPL

Water injection for Nox abatement-GE has not quoted for new Denox pumps as an optional item as
17 Attachment 1 A requested (It can't be made out of the offer ).It is assumed that existing Nox injection pump can be
reused.GE to specify the injection water pressure requirements

Since buyer owns 5 ruggedized combustors rotable exchange of 5 ruggedized combustors is

included in the offer. BKPL intends to have ONLY one combustor as warehouse standby and
19 Attachment 1 A therefore to have only 4 LM6000PC gas combustors in exchange of 5 ruggedized combustor and the
balance amount can be adjusted in the offer. GE to specify the price for ONE combustor on rotable
exchange to which the overall offer price can be reduced.

No performance guarantees are included in the revised though it was informed during the 14th April
meeting that GE would give the performance guarantees after assessing the latest engine data and
21 Attachment 1 B
applicable degradation. BKPL has already supplied HS data for the GTGs (except 191-101) thru
email dated 04/05/2011.
 Fuel gas conversion from Liquid & water to gas & water and Control System Upgrade
GE Proposal NO.714283B dt 18th May 2011
Sl no Section Sub Section Customer comments Customer comment

1) Redundancy of Critical IO at card level is not mentioned. GE to provide the list of critical IOs as
22 A Attachment 1 C
requested during the 14th April meeting

3) Are On/Off feedback of critical drives considered in the offer? Actual on/off feedback of critical
22 C Attachment 1 C drives are not configured in exisiting system (Generator lub oil pump, Jacking oil Pump, Turning
gear etc). Total 16 no of feed back should be configured.

22 D Attachment 1 C 4) GE to let BKPL know if soft start/stop feature for critical drives can be provided in the HMI.
 Fuel gas conversion from Liquid & water to gas & water and Control System Upgrade
GE Proposal NO.714283B dt 18th May 2011
Sl no Section Sub Section Customer comments Customer comment

EMAP scope of supply should include major equipments such as cooling water, boiler feed and
25 A Attachment 1 D condensate extraction pumps, De-Nox & SPRINT pumps, Chillers, compressors, blowers, Cooling
Tower cells, and transformers, etc

72 hour test run after gas conversion should be a test run to demonstrate performance as per
27 Attachment 1 F
guarantee in addition to proving the reliability as mentioned in the revised offer
 Fuel gas conversion from Liquid & water to gas & water and Control System Upgrade
GE Proposal NO.714283B dt 18th May 2011
Sl no Section Sub Section Customer comments Customer comment

Performnce PDF documents

38
guarantee provided

Scope of Attachment-2
39
Responsibility page 103 and 104

Seller excludes the capability to ‘hot swap’ modules within the control system while the unit is
40 Controls Page 119 running. Any board failures or removal while thecontrol system is operating issues FSLO Fast Stop
Lock Out logic to shut the turbine down.

Note
1.Comments upto Sl number 38 refers to GE offer (714823B) dated June 2011
2.Comments 39&40 refers to GE offer(71823C) dated 13th Sep
 Date :19th Sep 2011
GE feeback BKPL comments based on GE proposal ( Mark VIe )

Split pricing doesn't contain the following info as requested.GE

to provide the same
1. De-Nox system hardware
2 .Mark Vie System
3. Emap
Reflected in the proposal
4. EX 2100
5. Bently 3500
6. Indicative pricing for combustors (BKPL intend to exchange
5 ruggedized combustors in its possession for 4 G42 gas
combustors).The offer should include the net of the exchange
 Date :19th Sep 2011
GE feeback BKPL comments based on GE proposal ( Mark VIe )

The estimated degradation curves GE has submitted can be

considered as good estimates for BSES post-outage The supplied curve is upto major overhaul (50000 hours).What
configuration. Such curves are based on fleet data. will be the expected gain in power and heat rate after major
GE is not in a position to develop new degradation curves overhaul
for engines with 25,000+ hours.

Compliance and certifications are within current GE

Energy Aero Energy design practices and standards. BSES
Motors supplied to be explosion proof.GE to clarify if the
to notify GE if the compliance with additional codes or
instruments provided are intrinsically safe
regulations is requred and Buyer shall list such
requirements
 Date :19th Sep 2011
GE feeback BKPL comments based on GE proposal ( Mark VIe )

On payment milestones for Hardware, Software and

Engineering please refer to 2.2 Payment Schedule Item no.
1.
On payment milestones for Technical Advisory Services:
1) Mobilization It is proposed that some amount to be retained(or a bank
2) Control Panel Energized guarantee in lieu of the same ) for clearing the punch list as well
3) First Fire as warranty issues.
4) Commissioning. Commissioning shall be complete
when the unit is made available to Buyer for commercial
operation. Commissioning completion does not imply the
absence of any punch list or warranty items.

BKPL doesn't agree with item 4 of the comment

See as above, Item 5 (Commissioning completion does not imply the absence of any
punch list or warranty items.)
 Date :19th Sep 2011
GE feeback BKPL comments based on GE proposal ( Mark VIe )

In the 1st revision of the proposal (submitted in March

2011) due to the short timeline the assumption was made
that BSES engines are ready to install the Sprint kit. Drilling of port holes it learnt that can be done at site.GE to
However after carrying out a deep study GE confirms that make necessary arragements in this regard since the gas
BSES engines are NOT Sprint ready. Therefore the port conversion project needs to be completed in 60 days as
holes have to be drilled in the factory. This is due to the mandated by our customer ,the state electricity board
vintage of the units Such mods can not be done on the
field and therefore the depot visit is necessary.

Title to Commissioning TA Services shall pass Buyer upon

Some amount as mutually agreed will be retained for clearing
Commissioning Completion. Commissioning shall be
the punch list as well as warranty issues.Retention can be
complete when the unit is made available to Buyer for
released on submission of a bank guarantee equalling the
commercial operation and Commissioning completion does
retention amount.
not imply the absence of any punch list or warranty items.

Project leadtime between PO acceptance and installation GE to consider further reducing the delivery time to around 10
start of the 1st unit is 12 month. months

Three duplex gas filter skids are part of the scope (one each
GE to confirm if the inlet and outlet valves of gas filter are of
GT).
double block and bleed (for positive isolation).If not please
Please find attached filter schematic drawing for your
make provision for the same
reference - GE gas filter schematic drawing.pdf

Quote modified to include 3 set of /5 deg FIGV kits.

However this shall be subject of future discussions - GE
GE to clarify if existing 0 Deg can be converted to -5 Deg.
will revert back to BSES about the possible guarantees
with 0deg FIGV.

GE feeback
GE is currently investigating whether same/similar
performance estimates can be provided for enginer with 0
deg FIGV as with -5 deg FIGV. GE will revert back by
Tue, June 13.
Date :19th Sep 2011
BKPL comments based on GE proposal ( Mark VIe )
If -5 Deg FIGV can't offer any heat rate improvement BKPL
would retain the existing 0 Deg configuration

GE recommendation is to use new Water Injection pumps, 100 % redundancy required for all the three units.GE to let
one per unit. The new pumps were included in the BKPL know what will be the incremental cost for 100%
previous offering. redundancy

The proposal has been revised to include only 4 combustor

BKPL's intention is to get 4 new combustors against 5
exchanges. As requested by Customer, 4 x NEW
ruggedized combustor it is having.Offer may be revised
combustors are included in the offer (while previous
accordingly
offering was including combustor ROTABLE exchanges).

Please find expected delta performances after the gas The attached performance curves don't indicate any delta
conversion for both Sprinted and non-Sprinted scenario. performance either for power or for heat rate .GE to guarantee
However correction method, related tolerance range and performance both for power and heat rate based on present
test method is still being worked out by GE. engine condition

GE feeback
During the April 14 meeting the discussion was about
LinkNet card redundancy in the MTTB. GE has confirmed
during the meeting, that such redundancy can't be
implemented on BSES unit.
The level of redundancy of the I/O card will be according
to the existing signal redundancy.
This feature is currently not an available design for GE
packages.
See as above.
Date :19th Sep 2011
BKPL comments based on GE proposal ( Mark VIe )
BKPL's requirement is to incorporate redundancy at card level
without doing any modification to the signals (Duplex IO
modules) for GTS and STG.GE to revert back if further should
further clarity on the subject is required
Similar modifications have been implemented at other sites with
Micronet Control System and BKPL intends to have the same
which is very much required by the operator.BKPL will arrange
feed back signals from MCC and GE to incorporate the same
while developing HMIs
Similar modifications have been implemented at other sites with
Micronet Control System and BKPL intends to have similar
options installed while developing the control
system/HMIs.BKPL will wire up the control signal from HMI to
MCC/TCP
 Date :19th Sep 2011
GE feeback BKPL comments based on GE proposal ( Mark VIe )

EfficiencyMap is designed to evaluate and monitor thermal

1. Wherever real time data is not available and the same is
performance of major energy convesion equipment,
known reasonably accurate, whether the same can be entered
including gas turbines, chillers, HRSGs, steam turbine,
manually in Emap
condenser, cooling tower, and any auxiliary boilers. For
2.Bronze Technical Support Agreement (“TSA”) -GE to include
auxiliary equipment, limited calculations based on
technical support for GateCycle as per of the TSA
measured data may be available and archived.

The 72 hour reliability run is supposed to demonstrate that

the upgraded units can be operated normally when
integrated to the plant. BSES shall supply personnel to
carry out performance test according to the test method
provided by GE. GE Field Service representative will be
Performance test to be carried out by GE as per the relevant PTC
on Site to assist while Buyer carries out the performace test
code.GE to arrange all the special instruments required for
(test can be conducted during the 72 hour reliability run).
performance test .BKPL will operate the engine as required and
The pre-outage test shall be carried out tha same way, 1 x
provide the necessary assistance
GE FS Rep will arrive to Site one day prior to the outage to
assist Buyer to the pre-outage test.
The test method for GE performance guarantees is curently
being worked out.
Proposal is updated accordingly.
 Date :19th Sep 2011
GE feeback BKPL comments based on GE proposal ( Mark VIe )

Performance guarantee sheets don't indicate any change of

power or heat rate after gas conversion and SPRINT upgrade.As
discussed GE is requested to evaluate the present performance of
the engine and arrive at guarantee figures for both heat rate and
output.Please bear in mind that BKPL has to submit these data
to our customer to justify the upgrade in terms of engine
performance

1) Remove Ruggedized Liquid Fuel Combustor and Nozzle fuels

injectors & Install Ruggedized Gas Combustor,Fuel Nozzles and
Gas-Water Manifolds.Both works should be part of GE's
scope .BKPL will only remove the engine from skid before
combustor replacement and will install the same back to skid
after the work.Scope to be reviewed.
2) Installation of Mark VI-e related panel inserts in control room
and package located I/O cabinets (MTTB, MGTB). Scope to be
reviewed.

GE to confirm if hot swap feature can be implemented so that

on-line replacement of modules are possible
Date: 12th Oct 2011
GE Comments BKPL COMENTS

SPLIT OF ENGINEERING AND MATERIALS

1. Conversion to gas/water operation (not including Sprint), 3 units
Parts: $ 3,795,240.00
Engineering: $ 615,850.00

2. Mark VIe
Gas Turbine Controls, 3 units: $ 2,776,450.00
Plant DCS total: $ 1,642,790.00
Noted
3. EMAP: $ 326,520.00

4. EX2100 System, 3 units: $ 137,780.00

5. BN3500 and System 1: $ 340,860.00

6. As per point 19
Date: 12th Oct 2011
GE Comments BKPL COMENTS

Post major overhaul, Power and heat rate is expected to regain with
Noted
2-3% of new engine performance levels

Motors in Sprint skid and Water Injection skid are ATEX Zone 2
certified. Noted
Intrinsically safe equipment is not part of the scope of supply.
Date: 12th Oct 2011
GE Comments BKPL COMENTS

Shall be part of commercial discussions once the technical scope is

agreed between the parties.

As per point 5
Date: 12th Oct 2011
GE Comments BKPL COMENTS

GE will deliver the both the LP and HP hardware for

SPRINT but only the LP Sprint will be commissioned per the client's
request.  Should the client later request the HP to be commissioned,
a depot visit will be necessary in order to do the necessary drilling to
the casing.  the HP hardware and software will then be installed at
extra cost to the client.

As per point 5

Considering hardware / software lead times, delivery time is 12

months, including upgrade of plant control system to Mark Vie.
However, GE will expedite as much as possible upon PO acceptnace.

Inlet and outlet valves of the gas filter are double block and bleed.
The block and bleed system is bleeding to the atmosphere.

N/A, existing 0 Deg FIGV can be kept

Date: 12th Oct 2011
GE Comments BKPL COMENTS

Removing the -5 deg FIGV kit will reduce price by $ 398,100.00

(three units)

Water injection pump skid redundancy is feasible. GE will revert

back with pricing within a week time.
Note: GE experience shows that only customers with very strict NOx
level restrictions are interested in the purchase of duplex water
injection skids.

4 x New Combustors can be offered at a price of $ 2,907,730.

Buyback value can be discussed during commercial discussions.
4 x Rotable Combustors exchange (assuming rotable exchange) can
be offered a price of $ 1,254,000
Buyer shall revert back about the preferred option

Seller experience shows that the switch in fuels will not cause
differences in the turbine performance.
Without the Sprint system:
Seller grants to maintain the same level of performance as before the
conversion.
With the Sprint system:
Seller grants to maintain the same level of performance as before the
gas conversion, while maintaining higher T2 than without the Sprint
(Buyer will be able to save aux power)
Date: 12th Oct 2011
GE Comments BKPL COMENTS
The level of redundancy of the I/O card will be according to the
existing signal redundancy. If customer doesn’t have redundant
sensors then customer doesn’t need redundant cards. For example
customer do have T3 redundancy - so we split the sensors on
different cards. GE has quoted dual controllers as part of
redundancy.

Feature is feasible if customer can provide the signals. Additional

hardware and HMI software modifications will have to be
considered for this additional feedbacks.
Price estimate of this feature is $ 36,900. Customer shall revert back
which control system is the preferred option (Micronet Plus or Mark
VIe) and GE will finalize pricing accordingly.

Feasible if customer is wiring the signals. Additional hardware and

HMI features can be added.
Price estimate: covered above under point 22C. Customer to revert
back which control system is the preferred option (Micronet Plus or
Mark VIe) and GE will finalize pricing accordingly.
Note: start/stop feature shall be active for maintenance purposes only
and not during normal unit operation, due to safety concerns (the
control system shall overwrite the manual start/stop input)
Date: 12th Oct 2011
GE Comments BKPL COMENTS

1. Provision for Manual entry can be given, however, Seller does not
recommend manual entry of critical data which is used for doing
online calculation, since the calculation frequency is around 10 mins
and it is tough to enter the data that frequently which can lead to
inaccuracy of result. If the data is not critical like Gas Composition it
can be entered manually whenever there is a change.
2. Please clarify request. The GateCycle version that we include in
EfficiencyMap is only for EfficiencyMap calculations and it is not
available to the end-user for any modification.

Concept is OK, however GE wishes to discuss further the details of

the performance test and test evaluation.
Date: 12th Oct 2011
GE Comments BKPL COMENTS

As per point 21.

1) Typo by GE.
Correct wording sounds 'Install Standard Gas Combustor,Fuel
Nozzles and Gas-Water Manifolds'
Combustor exchange is GE Scope
2) Please clarify concern

Redundancy provided at CPU level so Hot

Customer to clarify at which level the hot swap feature shall be swapping feature should be at CPU
implemented. The dual CPUs offered have failover feature. level.i.e,. We can able to replace the CPU
while m/c is running.
252