DPR

Suryalakshmi Cotton Mills Limited
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SURYALAKSHMI COTTON MILLS LIMITED RAMTEK, MAHARASHTRA
DETAILED PROJECT REPORT FOR 1 x 25 MW COAL FIRED POWER PLANT
PREPARED BY: RITECHOICE ENERGY AND SYSTEMS ENGINEERING LTD 25,FIRST MAIN ROAD, KASTURIBHA NAGAR ADYAR, CHENNAI-600 020.
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TABLE OF CONTENTS
1. 2. 3. 4. 5. 6. 7. 8. 9. 10. 11. 12. 13. INTRODUCTION SELECTION CRITERIA OF MAJOR UNITS OF CPP FUEL DETAILS TECHNOLOGY CRITERIA UTILITY REQUIREMENT AND INTERCONNECTION LAYOUT FACILITIES SYSTEM DESCRIPTION ENVIRONMENTAL PROTECTION AND WASTE MANAGEMENT PLAN PLANT OPERATION AND MAINTENANCE PROJECT IMPLEMENTATION PROJECT COST ESTIMATE AND COST OF GENERATION APPENDICES DRAWINGS
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Suryalakshmi Cotton Mills Limited 1 INTRODUCTION INTRODUCTION:
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In order to sustain the present level of operation and also to ensure regular and assured growth in the level of operation, the current day industries are constantly reviewing the avenues for expansion, diversifying and optimizing the areas of operation. While growth means augmenting the capacity on main product, ensuring quality power availability, achieving energy conservation and thus reduction in product cost and time coupled with quality improvement also assumes importance. In this scenario, in house power production assumes significance. M/s Suryalakshmi Cotton Mills Limited, Ramtek who are embarking on optimizing and expanding on their denim production coming on line are mainly looking at this aspect seriously. PRESENT GOVERNMENT POLICY: Government of India has announced changes in policy in private power generation wherein it is notified that the power generation is permitted in private industries. The power plant thus installed can be either Independent Power Plant (IPP), or Co-Generation Plant or Captive Power Plant (CPP). The ministry of power has encouraged the various State Electricity Boards to purchase power from IPPs or CPPs who have excess power available to be sold. The modalities of purchase and the cost of purchase are decided by the State Electricity Regulatory Commissions who have been set up in the wake of overall economic and power reforms. In fact, certain states have evaluated cases for permitting third party sale by private parties to overcome the chronic power shortage problems. Ministry of Power and Non Conventional Resources encourage private industries to set up IPPs or CPPs with renewable energy fuels such as bio mass besides process rejects or wastes that have useful heating value in order to mitigate pollution problems. ADVANTAGES OF IPPs / CPPs: The several advantages of setting up IPPs or CPPs are by way of economic benefits that accrue out of the plant such as: The project gives a direct advantage of reliable and quality power for in plant
operation and also for export.
The production cost of the power and the main product shall also reduce due to The excess power sold results in additional monetary benefits for the parent
utilizing the in house generated power. company thus improving the bottom line in operation.
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The project helps the nation in overcoming pollution problems for generating the The project generates additional employment for about 36 persons directly and
same power by going in for better combustion technologies for power production. many more indirectly. PROJECT OBJECTIVES: The proposed power plant is to be set up with the following main objectives: To act as independent in house power plant ensuring power generation using the coal and meet the captive power generation. To sell the excess power thus produced to the Maharashtra State Electricity Board (MSEB) to achieve additional revenue generation. In order to achieve these objectives, SLCM shall ensure the following: Make arrangement for sufficient quantity of fuel for power generation. Make arrangement for start up power. Make arrangement for supplying uninterrupted quantities of make up water for Provide necessary in plant infrastructure. Provide adequate skilled manpower for plant operation and maintenance.
process and cooling purposes.
AUTHORIZATION: SLCM has appointed M/s Ritechcoice Energy & System Engineering Pvt. Limited, Chennai to prepare Detailed Project Report for the installation of 1 x 25 MW Captive Power Plant to study the techno economic feasibility. PROJECT REPORT: The project report is prepared in ten chapters supported by tables, drawings and appendices. The subjects discussed include selection criteria for major units of CPP, fuel details, technology criteria, utility requirement and interconnections, layout facilities, system description, environment protection and waste management plan, implementation schedules, operation and maintenance details, cost estimates of CPP, financial aspects. ACKNOWLEDGEMENT: RESEL thankfully acknowledges the cooperation and assistance received from SLCM during the preparation of this project report.
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SELECTION CRITERIA OF CPP:

SITE SELECTION: The site has been earmarked by SLCM in their manufacturing unit located in Ramtek near Nagpur, where sufficient space is available for installing the mechanical and electrical equipments and also house the fuel yard for storing required quantities of coal LIFE PERIOD This project is expected to provide service for more then 20 years of operation. The plant is expected to function smoothly, unless influenced by external factors. STATUS The company has already earmarked the marked area in their manufacturing unit for the project and is in the process of obtaining the necessary statutory clearances and financial closure from financial institutions. PLANT ELECTRICAL LOADS: The in plant power demand for both the units of the power plant is expected to be about 3000 kW, while the denim plant of the Suryalakshmi group expect to consume on average about 7000 kW for meeting the process demands within the plant where the power plant is located. The additional power shall be exported to the grid through the 220 kV switchyard to be installed in the current scheme. In order to meet the start up power and during emergencies, grid power shall be provided and shall be interconnected to the 415 V PCCs, through the proposed electrical networking. SELECTION OF THERMAL CYCLE: It is proposed to install two coal-fired boilers to generate high-pressure steam. The main fuel being considered is coal and supplemented by agro wastes if available nearby. The effective way of burning the fuels shall be combustion mode only in a Steam Generator. The combustion technology shall be based on fluidized bed combustion that is the most effective way of burning the fuel. More has been discussed on the technology in the chapter covering the technology criteria.
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The steam generated in the boilers will drive two steam turbines each coupled to an electric generator. The power thus produced will be distributed to the plant loads through power distribution system. The exhaust steam from the turbine shall be condensed in an air-cooled condenser. The condensate thus extracted by the condensate extraction pumps shall be fed to the regenerative feed water heating cycle. While the heaters ensure that the feed water to the boiler is heated to the desired levels using the heat available in the extraction steam from the turbine, the deaerator serves the double purpose of removing the oxygen in the condensate before entry to boiler and also to heat the water to a desired level. The steam required for heating is fed by from the LP extraction stage of the turbine for the heaters. This concept of regenerative heating reduces the heat load in the boiler, thus reducing the fuel demand. The overall plant efficiency is also increased due to this concept. The hot water is then pumped into the boiler by high-pressure boiler feed water pumps. The condenser is cooled by air-cooling system. The turbine shall be provided with all necessary auxiliaries such as ejectors, gland steam condensers, ejector condenser etc. A pressure reducing de-superheating station is also envisaged to feed the start up steam requirement for the LP and MP heaters during startup and emergencies. SLCM-ME-005 (R1). SELECTION OF STEAM PARAMETERS AND UNIT SIZE: Higher steam parameters viz. pressure and temperature has enabled to produce higher kWh per kg of steam expanded. Conventionally, manufacturers have looked upon the cycle parameters of 92 ata / 500 Deg C or 110 ata / 515 Deg C for units of this size as the most techno economic viable parameters. Considering the overall impact on the plant efficiency and the fuel consumption parameters, it has been proposed to consider 108 ata / 510 Deg C for this plant at the inlet of the STG. The boiler shall generate steam at 112 ata / 515 Deg C. The boiler shall be designed on atmospheric fluidized bed combustion technology as this the most proven technology for similar fuels for plants up to 200 TPH rating. The turbine shall be designed as an extraction cum condensing turbine to meet the regenerative steam requirement within the plant. The plant shall run on a fully condensing mode as well. The The proposed thermal scheme and heat and mass balance diagrams are shown in drawing nos. 10-SLCM-ME-003 (R1), 10-SLCM-ME-004 (R1) & 20-
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turbine shall be multi stage coupled to an electric generator. The turbine shall be complete with all auxiliaries. GENERAL FEATURES OF THE PROPOSED HWTSDF & POWER PLANT: The following are the salient features of the proposed steam cycle power plant.
Installed capacity of the boiler: Installed capacity of the STG: Estimated average output of the power
plant at normal operating conditions Boiler: Steam Turbine Generator
1 x 120 TPH @ 112 ata / 515 Deg C 1 x 25 MW
1 x 106 TPH@ 112 ata/ 515 Deg C 1 x 25 MW 335 days 85% 90%
No. of days of operation:
Average plant load factor in 1st year:
Average plant load factor in following years: Gross power output on annual basis: Gross power output at 90% PLF and
335 days of operation:
219.0 MU
180.90 MU 21.71 MU 159.19 MU 51.92 MU 107.27 MU*
Auxiliary power consumption: Net power available: Power used in house: Power exported to grid:
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FUEL DETAILS:
FUEL DETAILS: Suryalakshmi Cotton Mills Limited is considering coal as the primary fuel for combustion to raise steam. No special fuel is considered for either start up or low load stability since combustion technology adopted permits stable operation with coal at all loads. SLCM proposes to buy all the coal required in the CPP from M/s Coal Indias western coalfields. ANALAYSIS OF FUELS TO BE CONSIDERED: The proximate analysis of the coal is as follows: Grade of coal: D Fixed Carbon: Volatile matter: Ash: Moisture: Gross Calorific Value: Fuel quantity required: 34% 21% 35% 10% 4000 Kcal/kg 18.50 TPH 148740 TPA The boiler chosen shall be capable of firing the following grade coal as well Grade of coal: Fixed Carbon: Volatile matter: Ash: Moisture: Gross Calorific Value: Fuel quantity required: F 24% 21% 45% 10% 3400 Kcal/kg 21.76 TPH 174950 TPA
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TECHNOLOGY CRITERIA:
TECHNOLOGY CRITERIA: Conventionally, the combustion technologies have been improved over the period of time to meet the disparate fuel availability and achieve better combustion efficiencies. The technologies adopted included: Spreader Stoker technology for sizing ranging upto 100 TPH Pulverized fuel technology for sizing from 200 TPH upwards.
There was no effective technology to fill in the gap. Further, the quality of coal used has been steadily deteriorating in India with a result that high ash content coals with the ash being high abrasive nature has resulted in higher downtime and reduced availability. The Fluidized Bed Combustion (FBC) technology was developed in order to meet the following parameters and to overcome the above addressed problems. To meet the power generation at economical cost To improve the thermal efficiency To comply with current and expected environmental standards.
The FBC technology developed since early 1960s has come to fill in the gap between the above two technologies besides favorably replacing them in similar ranges. The technology offered compact boiler design due to higher heat release rates per Meter Square of combustion bed area. The SOx and NOx generated were also lesser and able to meet the existing pollution guidelines. The FBC technology can be broadly classified into the following categories: Atmospheric Fluidized Bed Combustion (AFBC) Circulating Fluidizing Bed Combustion (CFBC) Pressurized Fluidized Bed Combustion (PFBC) Integrated Gasification Combined Cycle (IGCC)
PROCESS DESCRIPTION: In a fluidized bed technology, the bed is made of inert or live combustible materials. Instead of the bed being in a static state, it is fluidized by admission of under bed pressurized air to create enough turbulence in the bed. This ensures that the bed material is churned well so that the solid fuel articles start behaving as a fluid medium. This fluid behaviour ensures that the fuel is well exposed to combustion and the heat release rate per unit area of bed is higher than the conventional combustion modes. The combustion efficiency is also higher thus ensuring disparate fuels well
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burnt. The fact that under bed combustion air is further supplemented by over bed air to complete combustion, the concept of two stage combustion is achieved thus reducing the level of NOx emission. In the case of high sulphur coals, the bed effectively captures the SOx emission. If required, in bed addition of lime ensures further sulphur capture thus reducing the overall emission of SOx. In the AFBC, the combustion takes place at atmospheric conditions. The circulation rate of the fuel particles elutriated is limited. In the CFBC, the fuel particles are necessarily circulated by admitting higher fluidizing velocities to ensure higher carbon burn up efficiencies and thus combustion efficiencies. However, the circulation means higher power consumption besides special heat transfer disposition. In the PFBC, the combustion takes place under pressurized conditions to make the unit more compact. The IGCC mode involves PFBC but employs combined cycle concept to improve the overall cycle efficiency as in the all the other cases, steam cycle is employed where the cycle efficiencies are limited to about 36%. In order to achieve better fluidization, the fuel particles size shall be restricted to less than 6 mm, with the oversize particles from 6-mm upto 10 mm limited to less than 10% by weight. The fine particles i.e. from 3mm to less than 1 mm shall also restricted to less than 25 to 30% to achieve good combustion results. This means that the fuel preparation plant shall comprise of one or two stage crushing depending upon the raw feed size. SELECTION OF TECHNOLOGY: The AFBC is more proven one especially considering the unit size under installation. In India, BHEL has already installed more than five units based on bubbling AFBC technology for combustion of coal. Although, there are a few more companies for supply of AFBC technologies, The boiler companies that may offer similar technologies are Thermax Babcock Wilcox (TBW), Cheema Boilers, Thermodyne Private Limited with bubbling FBC,.
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UTILITY REQUIREMENT AND INTERCONNECTION:

PLANT UTILITIES: The following plant utilities are required for the continuous running of the power plant. Auxiliary steam for HP heater , Deaerator & LP heater Raw water system Soft water system DM water system Auxiliary cooling water system for turbine and boiler. Evacuation system for power generated Roads and drainages Plant infrastructure such as administrative building, canteen, workshop, laboratory, staff quarters etc. In order to ensure Normal Mode of Operation of the plant, all the above systems are to be incorporated in the system design and integrated with the power plant. The interconnection shall be restricted to roads and drainages, staff quarters etc. AUXILIARY STEAM SYSTEM: The auxiliary steam is required in the HP heater and deaerator. The quantities are as follows: Sl. No 1 2 3 Equipment LP heater Deaerator HP Heater Steam Parameters / unit Pressure Temperature (ata) (Deg C) 17.68 1.65 114 10.03 8.40 215 11.41 31.70 355
Flow (TPH)
The above auxiliary steam requirement is taken from the steam turbine itself and in the case of deaerator the steam is obtained after pressure reduction from 8.40 ata stage. However during start up the steam required for deaerator is fed from a PRDS to be installed in the plant. WATER SYSTEM: The raw water requirement shall be such that the plant shall run without any disturbance even the water supply is affected for three to four days. The make up water requirement for auxiliary cooling water, boiler feed make up water shall be about 10 Cum/hr, since it is proposed to install air cooled condenser to save on precious ground water. This means that the raw water reservoir capacity shall be sized to minimum 500 cum. The raw water shall be drawn from the reservoir to the
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softening plant and the DM plant for supplying the make up quantities required in the system. The water balance is shown in the drawing no. 20-SLCM-ME-006 (R1). ELECTRIC POWER: The electric power demands for running the plant shall be met from within the plant generation itself. The Single Line Diagram is drawn and shown in drawing no. 20-SLCM-EE-001 (R3). The power produced at 11 KV is stepped down to 415 V though the unit transformers. The 415 V switchgear feeds the entire unit requirement. The denim mill demands is also fed through the 415 V switchgear which in turn is being fed by the 11 kV bus through the 11 kV / 415 kV transformer, both the units are being installed in the plant in line with the above single line diagram. The excess power generated is fed to the generator transformer to be stepped up from 11 KV to 220 KV before being fed into the grid. The plant auxiliary demand including HT and LT power is estimated at app.3200 KW while denim mill demand is fixed at 7650 KW totaling the in plant consumption to 10850 KW.
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LAYOUT FACILITIES:
GENERAL: The power plant will be located in the proposed site as shown in the drawing no.00-SLCM-ME-001 (R5) and 00-SLCM-ME-002 (R3). The total area required for the plant is around 10 acres for building and construction areas. A separate fuel storage area is not shown in the layout. LAYOUT OF UNIT: The layout of the unit is the east west direction as shown in the drawing. The boiler is an outdoor type with only canopy over the boiler. The steam turbine is of indoor type located inside a turbine building. The fuel storage bunkers and the fuel feeding system is located in the side of the boiler. The boiler-operating floor will be located at app. 7.0 M elevation ensuring easy access to the bottom ash disposal system. The boiler will be complete with economizer, air heater, Electro static precipitator etc. The BFW pumps shall be located in a separate area above, which is located, the LP heater, the deaerator and the HP heater, in the powerhouse front bay. The condensate lines are drawn from the CE pumps into the feed water storage tank. The make up water is fed to the deaerator directly. The HP heater drain is also fed to the deaerator, while the LP heater drain is led to the condenser hot well. Individual RCC stack of 90 M is provided to evacuate the flue gases from the boiler. The RCC chimney shall meet the Local Pollution guidelines for particulate and SOx emissions. The boiler area will be covered by concrete paving with necessary drains and trenches for cables and pipes. The operating floor of the turbo generator shall be app. 8 M. All the turbine auxiliaries such as drain pumps, air ejectors, lube oil system etc. are located inside the turbine building while the CE pumps and the condensate storage tank are located outside the turbine building. The STG shall be located on RCC foundations designed specially to take care of all static and dynamic loads. The STG building shall be provided with a 30 MT EOT crane for erection and maintenance purposes. The electric and control panels shall be housed insides a control room in the building. The PCCs and MCCs shall be housed inside a separate building. The fuel handling arrangement is located close to the boiler unit as shown in the drawings 10SLCM-ME-007 (R1) & 10-SLCM-ME-008 (R1). The crushers shall be housed inside crusher house. The conveyors are designed as closed system located in the open. The fly ash-handling unit consisting of dense phase ash units will also be located close to the boiler. The ash shall be fed to as ash silo from where it is taken out of the plant.
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The raw water reservoir is located in one corner with the softening and DM plant located nearby. The auxiliary cooling tower and the CW pump house shall also be located nearby to save on water piping. The switchyard shall be located in the other end as shown from where the transmission lines are drawn, as already existing in the plant A separate administrative building will be constructed over the STG building with a provision for lift to carry people. Green belt will be developed inside the premises taking into consideration of the guidelines of environmental authorities. The overall layout of the plant facilities, chimney etc, is proposed taking into consideration the wind directions. However, this needs to be studied further during detailed engineering for possible improvement.
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SYSTEM DESCRIPTION:
Power Plant and Process Description: The process described here applies to a steam cycle process. The plant is rated for 1 x 25 MWe gross output at full load site conditions. The plant is divided into three main parts, fuel handling, and steam generation boiler and steam turbine generator. The main parts include the following major equipment: Fuel handling system including a raw fuel conveying system, fuel preparation unit, and prepared fuel feeding system. One no. 120 TPH Steam generator including stack, deaerator/ feed water tank, feed water system One no. Steam turbine generator (STG) rated for 25 Mwe with air cooled condenser and condenser evacuation system. Balance of plant equipment comprising of Mechanical Material handling plant Air cooled condensers Water treatment plant Various pumps EOT Cranes and hoists HVAC system Compressed air system Fire Protection system Yard piping for water, steam, air etc.
Electrical Unit auxiliary transformers HT switchgear LT switchgear Cables Plant lighting Plant earthing Battery and battery charger Plant intercom
Instrumentation
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Boiler / STG controls and instrumentation. BOP controls and instrumentation. Plant overall supervisory control.
An optimized integration of the above three main parts is a key feature to reach high overall plant efficiency. Design Information: The basic design data and criteria assumed are as follows: Ambient conditions:
Ambient temperature Site elevation Relative humidity
45 Deg C max. / 30 Deg C for design 288 m from MSL 70% max. / 60 % for design
Fuels and additives: Design fuel Coal
Products:
Electricity Steam parameters
1 x 25 MWe
High pressure steam Annual operation: Operation hours Technical life time: Steam cycle plant
112 ata, 51`5 Deg C
8040 hours
20 years
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Suryalakshmi Cotton Mills Limited Steam Generator:
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one No. Fluidized Bed Combustion based Steam generator to generate steam of single pressure, natural circulation type suitable for outdoor installation with the capacity of 120 TPH comprising of SCOPE OF WORK 1.1 Complete engineering and preparation of all required data, drawings, calculations etc., as required for boiler and its auxiliaries. I. I SCOPE OF SUPPLY FOR MAIN BOILER Boiler: Pressure Parts Steam drum with internals. Membrane water wall furnace. Studded Inbed tubes with headers. Down comers and risers. Radiation & convection superheater with inlet, intermediate & outlet headers. Necessary pipings connecting drum and superheater. Forced Flow section with inlet & outlet headers. Boiler integral piping. Feed water system Boiler Feed water pumps (3 Nos.) complete with coupling, base frame and drives arrangement. Feed regulating station for maintaining uniform level of water in steam drum. Parallel flow paths for start up and low load as well as higher loads up to 100% MCR with a stand by flow path of 100% capacity. Feed pump re-circulation flow under low feed pump flow conditions by automatically controlled solenoid valve installed in between feed pump and deaerator. Strainers at the suction of feed water pump. Feed line from deaerator to feed pump suction, feed pump discharge to economiser and from economiser to steam drum. Steam Steam line up to main steam stop valve.
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Suryalakshmi Cotton Mills Limited Drains and Vents Air vent piping. Safety valve exhaust piping up to safe elevation. Boiler drain piping up to blow down tank. Blow down lines from blow off valves to blow down tank. Two nos. blow down tanks (Continuous and Intermittent blow down). Air Pre-Heater Multitubular air pre-heater shell and tube type assembly.
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Ash hoppers at the bottom of Air Pre-Heater with Rotary Air Lock valves for continuous discharge of ash. Air system Forced draft air header and ducting from FD header to Air Pre-Heater. Ducting from Air Pre-Heater to main distribution Header and main air distribution header to individual compartment. Dampers and expansion joints in FD air ducting. Individual dampers at the suction of each compartment. Fuel feeding Coal bunker for 16 hours storage capacity. Fluidized Bed furnace arrangement complete with plenum chamber, air nozzles etc. Secondary Air system. 5 nos. over / under bed fuel feeding system including variable speed drag chain feeders with pneumatic spreaders for evenly spraying of fuel over the entire bed. Flue gas system Flue gas ducting up to the inlet of chimney. Dampers and expansion joint in flue gas ducting from boiler to inlet of chimney. Refractory and insulation Supply of refractory materials. Supply of insulation and cladding materials for vendor equipment. Supports and platform Supporting structure for the boiler, Economiser, Air Pre-heater and ESP from ground level. Supporting structure for air & flue gas ducting.
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Minimum and essential operating platforms with approach stairs / ladders for the equipments supplied by vendor (except concrete firing floor). Supply of foundation bolts required for vendor equipments. Supply of necessary insert plate for vendor equipment supports. Buck stays. Auxiliaries Two nos. FD fans designed for 60% MCR with motors. Two nos. ID fans designed for 60% MCR with motors Two nos. PA fans designed for 100% MCR with motors. Six nos. power cylinders operated regulating dampers for FD, PA and ID fans inlet. Required nos. of power cylinder actuated open / close dampers in fluidizing, secondary and compartment air ducts. Required nos. Rotary Air Lock Valves with gear box and motor for continuous discharge of ash from ash hopper, boiler bank, economiser, air pre-heater and ESP ash hoppers. Sample coolers for feed water, boiler water, saturated steam and superheated steam. Minimum and essential valves and fittings. One no. flow nozzle in steam line. Others Two coats of red oxide primer coating for vendor supplied equipments. Two coats of finish paint after primer. Two copies of boiler O & M manual. Deaerator cum storage tank Deaerator with deaerated water storage tank. Minimum and essential valves and fittings. Saddle support for placement of deaerator on control room top. Level control valve with required isolation. Pressure control valve with required isolation. Feed water piping from deaerator outlet to feed pump suction. Feed water piping from the outlet of level control station to deaerator. Steam piping from the outlet of pressure control station to deaerator. Ladders and staircases. LP & HP Chemical dosing system Skid mounted LP dosing system including motors. Skid mounted HP dosing system including motors. LP dosing piping (including supports) to feed pump suction.
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Suryalakshmi Cotton Mills Limited HP dosing piping (including supports) to steam drum. One no. motorised agitator for each dosing system. Minimum and essential required valves and fittings. II. DUST COLLECTING SYSTEM (Electrostatic Precipitator) One no. ESP having four fields with the following : Slide support to take care of casing thermal expansions. Precipitator casing of 5 mm thick adequately reinforced with access door.
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4 numbers of pyramidal hoppers of 5 mm thick provided with inspection door, ash level indicator, electrical heater, screen plates and outlet flange. 4 numbers of perforated gas distribution screens at inlet and one number of screens at outlet. The GD rapping is envisaged. Emitting system with of spiral type stainless steel electrodes and rapping mechanism. Collecting electrodes of 1.25 mm thick mild steel and rapping mechanism. Outer roof forming a convenient inspection floor on top of each casing. Inlet and outlet funnels of 5 mm thick, stairs and walkways. 4 numbers of mineral oil immersed HVR units of capacity 95 kV / 800 mA designed for outdoor application with microprocessor based controllers. Manually operated lifting and handling arrangement. Integral Auxiliary Control Panel cum LT board (ESP switchgear) of double front, non-draw out type for EC panels and auxiliaries. Necessary interlock system. Heaters for hoppers, support and shaft insulators complete with thermostats. Rotary air lock valve and knife-edge gate valve at the outlet of each hopper. One number of temperature probe in each hopper and a temperature scanner in control room. III. VALVES & MOUNTINGS : Set of IBR & Non-IBR Valves and Mountings not limited to the following: : Main Steam Stop Valve at Secondary SH outlet Instrument Connection Valve on SH O/L header Safety Valve on Sec. SH O/L header Air-Vent Valve on Sec. SH O/L header Auxiliary Steam Valve on Steam drum Air -Vent Valve on Steam drum Instrument Connections Valve on Steam drum Safety Valve on Steam Drum Gauge Glass Cocks assembly with Drain valve 1 No. 2 Nos. 1 No. 2 Nos. 2 Nos. 2 Nos. 2 Nos. 2 Nos. 2 Pairs
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Suryalakshmi Cotton Mills Limited IV Level Indicator/Controller Isolation valve Continuous Blow Down valve Drain Valves on headers Air vent valves on Headers Drum Internals - Baffle plates, Perforated plate, Dry box tray, Steam separator etc. Feed Check Valve on Drum Economizer - Air Vent Valve Eco. Instruments Conn. Valve-I/L & O/L headers 1 Set 1 No. 2 Nos. 2 Nos. 2 Nos. 1 No. 8 Nos. 4 Nos.
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IV. ELECTRICALS V LT MCC consists of switches/relays, fuses for the following equipments supplied by vendor : V. FD /ID/PA fan motors Feed water pump drive Fuel feeder drive Rotary Air Lock valves drive Dosing pump motors Motorized valves and dampers Spare feeders
INSTRUMENTATIONS The instrumentation and control system consisting of microprocessor based controllers and distributed control system architecture (DCS as applicable along with PC based automation system for monitoring and control of the boiler plant from the control room. Local field instruments (not limited to) such as, Thermocouples and compensating cables to measure: Bed temperature Flue gas temperature at free board. Flue gas temperature before & after super heater Flue gas temperature before economiser. Flue gas temperature before multi tubular air pre-heater. Flue gas temperature after multi tubular air pre-heater. Air temperature after multi tubular air pre-heater. Feed water temperature before economiser. Feed water temperature after economiser. Steam temperature at superheater outlet.
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Pressure gauges to measure Steam pressure at steam drum. Steam pressure at SH outlet header. Feed line pressure before feed control valve. Feed line pressure after feed control valve. Inlet and outlet of feed pump pressure. Deaerator pressure. HP & LP dosing line pressure.
Draught gauges to measure Air box pressure. Furnace pressure. Flue gas pressure before bank tube. Flue gas pressure before economiser. Flue gas pressure before and after multi tubular air pre-heater. Air pressure at FD air header. Air pressure at primary air header.
The following measurement loops complete with field mounted primary elements, SMART transmitters interconnecting cables up to central system is provided: Drum pressure Feed water temperature before and after economiser. Steam temperature before and after desuperheater. Main steam pressure, temperature and flow. Combustion air temperature before and after Air preheater. Flue gas temperature at SH inlet SH outlet Economiser outlet AH outlet ID fan inlet
Feed water control valve position feed back. Position feedback of FD / ID fan suction damper. In-situ Zirconia type oxygen analyser complete with probe and electronic
unit to measure O2 in flue gas.
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The following closed loops complete with field mounted measuring elements, SMART transmitters, I/P converters, pneumatically operated control valves / dampers etc. are included in the scope. Master pressure control. SH steam outlet temperature control. Three element drum level control. Combustion control with coal feeding and fuel air control linked with Furnace draught control. Deaerator pressure control. Deaerator level control.
master steam pressure control.
Instrumentation cables from field instruments to junction boxes including junction boxes and from junction boxes to boiler control desk. Necessary painting, corrosion protection and preservation measures as required. Commissioning and two year operation spare parts All consumables such as lubricants, for the first fill. One set of special tools and equipment for maintenance and erection, inspection and repair in steel boxes, including identification and operation instructions as well as equipment for storing dismantled parts during inspection. Complete electrical system including drive motors suitable for area specified, control panel, local push button stations, transformers rectifier set, power & control cables, cabling complete with supports, cable trays, glands, lugs, earthing and lightning protection system for the successful operation of the plant. SYSTEM DESCRIPTION A. BOILER PRESSURE PART The pressure part consists of the following: Steam Drum The boiler is provided with a steam drum. The drum is of fusion-welded construction with welded ellipsoidal-dished ends. The longitudinal end circumferential welds are heat-treated and 100% radiographed during manufacturing. Drums are provided with manhole in each end to access the drum interior. Nozzles and
connections for steam outlet, safety valves, pressure gauges, water level gauges, feed water inlet, continuous blow down, chemical dosing, vent and drains, sampling connections etc. are provided
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on the drum. The steam drum is provided with internals to promote circulation and ensure steam purity. The thickness of the drums is designed based on the requirement as specified under Indian Boiler regulation 1950 with latest amendments. Furnace - Water Wall Tubes
The furnace is of natural circulation, balanced draft design. The fluidised bed combustor is provided with required number of compartments with individual air control system for continuous and nonstop operation of fluidised bed steam generator at varying load conditions. High rate of water circulation in the tubes is maintained so as to ensure the longer tube life. Complete furnace is formed from the panel walls made up from 63.5 mm OD tubes of the carbon steel at pitch of 76.2 / 88.9 mm with finned tubes to reduce the radiation losses and get maximum heat extracted in the furnace. Water wall section is fabricated with welded type panel construction. Necessary supporting system is provided for expansion of components when the unit is in operation. Inbed tubes A separate set of Inbed tubes are provided in the furnace. High rate of water circulation in the immersed bed tubes is maintained so as to ensure the longer tube life. These tubes are of seamless construction having thickness of 6.35 mm. These inbed tubes are provided to control the furnace temperature & reducing the excess air required in FBC. Superheater The Superheater has been designed in two stages pendent type vertically suspended and combined convection and radiation characteristics to achieve rated steam temperature in between 50% to 100% Steam load range. Attemperator of inter stage spray type design maintain the close tolerance of temperature with variation in load range. Steam from the Steam Drum is taken in the primary superheater consisting of 44.5 OD tubes with 4 mm thick with combination of carbon steel and alloy steel T11 material. Interstage attemperator is utilized for the temperature control by injecting water in the intermediate header, and then steam is taken to the secondary SH facing the furnace. Secondary SH is completely Alloy Steel with combination of T11 and T22 material of 44.5 OD and 4.5 to 6.3 mm thick. This arrangement gives fairly flat characteristic with respect to the load. Sufficient mass flow has been maintained for steam so as to reduce the SH metal temperature at lower loads also.
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Suryalakshmi Cotton Mills Limited Economiser
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Economiser is of plain tubular coil type, counter flow and drainable type construction with seamless tube. Water temperature to the inlet of the economizer is 160 to 165 0C.The economiser casing is of MS plates suitably reinforced. The flue gas path is of pressure tight construction. The bolted access doors are provided for inspection and maintenance of the equipment. Note : The Superheater tubes, inbed tubes, water wall tubes, boiler bank tubes, economiser tubes and headers are of Seamless construction. GENERAL Required numbers of fire doors are provided in the furnace and Superheater section at appropriate location for observation, inspection and maintenance. B. B Over / Under Bed Fuel Feeding and Distributing System Boiler is equipped with complete system of fuel transportation from bunker to fluidized bed furnace. Fuel from the bunker reaches the drag chain feeder with gravity and this feeder feeds the fuel in a controlled way to the furnace. The spray air nozzle provided below the feeder, distributes the fuel equally throughout the entire bed. Varying RPM of the feed, which is controlled by electronic variable Frequency drive, regulate the quantity of fuel. Boiler is also equipped with bed material bunker to feed the bed material (either sand or crushed refractory) Fluidised Bed and Ash / Sand Drain System The fluidized bed system is of proven design capable of continuous & reliable operation suitable for firing the specified fuel. The nozzle design permits the fluidizing at lower loads with provision to shut the individual compartments. The bed air nozzle are made of Stainless Steel 304 as per the requirement and tight fitted in the top plate holes of the plenum chamber and a layer of castable lining is applied to further hold the same from the collars. Necessary ash / sand drain system with plate valves is provided in bed section as required, for removal of bed ash / sand. Secondary Air System Secondary air system consisting of multiple high velocity nozzles with air swirlers is provided at required height in the fluidized bed combustor to meet the oxygen requirement and create the turbulence for proper combustion of fines and volatiles. C. AIR PRE-HEATER FUEL FEEDING AND FIRING SYSTEM
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A shell and tube design Air pre-heater is provided with the boiler at the down stream of economiser with gas flow inside the tubes and airflow outside the tubes. This is a multi tubular, counter current flow, self-cleaning design equipment. The air pre-heater is complete with casing duly reinforced, supporting structure, ducting etc. Required access doors are provided for inspection and maintenance. D. DRAFT SYSTEM
The draft system for the boiler is suitable for producing a balanced draft with sub atmospheric pressure conditions in the furnace each sized for 100% MCR firing of the boiler complete with drive motors, couplings etc. required for satisfactory performance of the boiler under rated load conditions. Forced Draft Fans
The boiler is equipped with two numbers of centrifugal type FD fans. The FD fan is of variable speed, horizontal, radial flow with variable inlet guide vanes. Each fan is designed for a minimum discharge capacity of 20% higher than the theoretical air required at 25% excess air at MCR and head 20% higher than the required. The pneumatically controlled damper in suction of FD fan is provided to regulate the air quantity to the furnace. The fan rotor is supported over grease lubricated bearing assembly designed to take care of radial and thrust loads. The fan is complete with drive motor, expansion bellow and ductwork. The impeller of the fan is dynamically balanced for vibration free operation. Induced Draft Fan
The Induced Draft fan is of radial flow type and variable speed machine with suction louvers. The variation of suction louver is controlled by means of pneumatic operating mechanism. The boiler is equipped with two numbers of ID fan. The fan is designed for a minimum discharge capacity of 20% higher than the theoretical air required at 25% excess air at MCR and head 20% higher than the required. The pneumatically controlled damper in suction of ID fan is provided to control the draft of the boiler. The impeller of the fan is dynamically balanced for vibration free operation. Renewable hard-faced wear pads on the impeller blades are incorporated. The fan is complete with motor, expansion bellow and ductwork. The impeller of the fan is dynamically balanced for vibration free operation.
Primary Air Fans
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The boiler is equipped with two number centrifugal type PA fans. The PA fan is of constant speed, horizontal, radial flow with variable inlet guide vanes. The fan is designed for a minimum discharge capacity of 20% higher than the theoretical air required at 25% excess air at MCR and head 20% higher than the required. The pneumatically controlled damper in suction of PA fan is provided to regulate the air quantity to the furnace at secondary level. The fan rotor is supported over grease lubricated bearing assembly designed to take care of radial and thrust loads. The fan is complete with drive motor, expansion bellow and ductwork. The impeller of the fan is dynamically balanced for vibration free operation. E. FLUE GAS CLEANING EQUIPMENT (ELECTROSTATIC PRECIPITATOR)
The precipitator comprises number of dust collecting plates - rows in parallel forming a multi parallel gas path and with discharge electrodes freely suspended within this path. These all are housed in an MS casing complete with Pyramidal type ash collecting hopper. Method of Gas Filtration
A single-phase high voltage current is impressed on the discharge electrodes from a high voltage transformer rectifier unit with control sets. The necessary primary supply voltage and control feed backs for these units are fed from the control panels separately housed nearby containing all necessary control gears for operation of these sets. The gases entering the precipitator, comes under the influence of high static electricity set-up by the high potential difference between the discharge and collecting electrodes. This causes the ash in the gases to get ionized to be driven towards the collecting electrodes and adhere on the surface of collecting electrodes. Thus the dust particles are separated from the flue gas. The clean gases then pass out of the precipitator. The deposited ash is removed from the collecting plates by rapping them on one end at an interval causing the dust to dislodge and to fall into the hopper beneath the collecting fields. Rapping is also applied to the discharge electrode to remove the dust deposited on them due to positively charged particles. The dust, which is precipitated, is collected in the hoppers installed below these arrangements. F. BOILER CASING, SUPPORTING STEEL STRUCTURE, PLATFORMS AND WALK WAYS ETC. Outer casing is provided for boiler, Economiser, Air pre-heater. The casing of the boiler furnace is designed to enclose completely the furnace excluding superheater headers. The outer construction is weatherproof and air tight. The casing is of welded construction but is sectioned to allow easy removal and replacement wherever necessary.
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The supporting steel design, material and fabrication is conform to the applicable provisions of IS standards for use of structural steel. The boiler unit is placed on a self-contained steel framework. All structural steel required supporting the equipment including boiler, economiser, air pre-heater, and ESP and bunker etc. of boiler and its accessories. The boiler is provided with all structural work to support it's accessories and auxiliaries. Platforms, walk ways, stairs etc. is provided to ensure easy and convenient access to all parts of the boiler unit. The supporting steel is designed to carry all live and dead loads applicable to the site, temperature stresses, including load from access platforms, walk ways, stairs, other equipment placement loading. G. BLOW DOWN TANK The steel structure includes columns, base plates, bolts, anchor channels, girders, beams, pipe supports, hangers and other steel necessary for proper supporting
The blow down and drain system for the boiler is provided complete with tank, inter connecting piping, valves, gauges etc. The blow down tank is designed and fabricated as per IS 2825. All the inlet connection to the tank would be tangential and wear plates are also provided to take care of the erosion. The tank is provided with manhole opening and bolted door for easy manipulation. H. CHEMICAL DOSING SYSTEM
LP Chemical Dosing System The feed water contains traces of oxygen due to the incomplete mechanical/thermal deaeration. These traces of oxygen are scavenged by chemical deaeration. Chemicals like sodium sulphite or hydrazine is dosed to the suction header of the feed pump by LP dosing. In LP dosing sodium sulphite reacts with oxygen and forms sodium sulphate or hydrazine react with O2 and forms water and nitrogen. HP Dosing System Scale formation is limited by converting hardness salts to a free flowing sludge. HP dosing is done by carbonate control and phosphate control by addition of sodium carbonate or trisodium phosphate respectively. Other chemicals such as sodium hydroxide carbonate or calcium oxyphosphate can be added. Best result of calcium carbonate or magnesium hydroxide or calcium silicate, magnesium silicate will be available as free flowing sludge where caustic alkalinity is 10 to 15 % of the dissolved solids. OH alkalinity leads to prevention of magnesium phosphate as bad scale by converting magnesium-to-magnesium hydroxide. Sludge conditioner can also be used, if there is no effective means of blow down is available, it is better not to concentrate on internal treatment. I. DEAERATOR AND FEED WATER STORAGE TANK
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Deaerator mounted on the deaerator water storage tank of deaerating capacity 135 tons per hour and feed storage tank of minimum 20 minutes storage capacity is provided. The deaerator and feed water storage tank is located on the top of the control room. The deaerator is of spray nozzle type complete with drains, vents, over flow valve, isolating and by-pass valves for control valves etc. The feed water tank is provided with one fixed support and one moveable support on anti-friction taflon pad. The make up water to the deaerator has to be provided from the DM water line coming from the chemical water treatment at a temperature of 30 0C. The steam is supplied to the deaerator from the steam drum at 8 Kg/cm2a pressure and 240 0C temperature. The oxygen contents after deaeration is 0.01 ppm. The temperature of water is raised from 110 0C to 170 0C by using the auxiliary steam.
J.
BOILER FEED WATER PUMPS
Three-nos. boiler feed water pumps of 50% capacity is provided for the boiler. Two pumps are in operation and other pump standby. The boiler feed pump is operated on a common suction as well as discharge main. Each feed pump is capable of meeting 110% of maximum continuous rating of the boiler. The pumps are of single suction, multi-stage, and centrifugal type complete with drive motor of suitable rating. The feed pump re-circulation under low feed pump flow conditions is automatically controlled by use of a solenoid valve to be installed between the feed pump and the deaerator. This valve is operated in ON/OFF mode based on a pressure switch in the main line. Each boiler feed pump is provided with strainers on the suction side of the feed pump. Feed Regulating Station
The boiler feed regulating station is maintaining continuously uniform level of water in the boiler drum within set limits. Feed regulating station have parallel flow paths suitable for start-up and low load operation as well as high load up to 100% MCR with a standby flow path. All the regulating valves are provided with isolating valves on either side. K. DUCT WORK AND DAMPERS
The required duck work up to chimney with necessary dampers for controlling the flue gas and airflow through the ducting, expansion bellow etc. The air ducting is made out of 4 mm thickness and flue gas ducting from 5 mm thick MS plates. L. INSULATION
All the exposed portions of the boiler, auxiliaries, ducting and inter-connecting piping which operate at a temperature above 600C during normal operation is thermally insulated so that the outer
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surface temperature of the insulating material before application of finishing material shall not exceed the ambient temperature by more than the acceptable limits. The design and installation of all thermal insulation are complete in every way for the service intended and suitable for achieving the desired reduction in heat transmission as well as maintaining the surface temperature within allowable limits. Insulation thickness is suitable for 20 0C temperature differential considering a maximum ambient temperature of 45 0C. Mineral wool insulation material is used for hot service equipment. The insulation is in the form of rocks or slag wool mat with wire netting on both faces. Insulation material for pipes up to DN300 carrying steam, condensate, hot water, hot air, hot flue gases are light resin bonded mineral wool in the form of pipe suction. LRB mineral wool mattress is used for insulating pipe sizes above DN300. M. REFRACTORY
All necessary refractory and setting material is supplied. The refractory bricks are supplied of the best quality consistent with temperature obtained at various zones. The refractory and insulation thickness of all sides of the boiler is such that the temperature of the surface of the casing would be low enough from the point of view of the safety of the operating personnel and also consistent with the permitted heat loses. N. INTER CONNECTING PIPE WORK, VALVES AND FITTING
All necessary inter-connecting pipe work between various units of the boiler along with supporting material to support and anchor the pipeline at regular intervals is also supplied with the boiler. O. scope. MOTOR CONTROL CENTRE Necessary power supply to the incoming, outgoing power cables between MCC to
One set of MCC dust proof, vertical standing is provided with starters for the drives in vendor individual motors are provided. P. INSTRUMENTATION AND CONTROL SYSTEM
Programmable Logic Control System The instrumentation and control system for the fluidized bed combustion boiler unit will be of electronic instruments with pneumatically operating final control elements using the latest state of the art technology namely microprocessor based distributed control system and programmable logic control system along with PC based automation system for monitoring and control of the boiler plant from the control room. The fluidized bed combustion boiler will be provided with necessary field mounted gauges, switches, transmitters, converters and pneumatically operated control valves. The transmitters and
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converters for the open loop and closed loops to monitor and control the various process parameters of the boiler will be of electronic type with signal transmission level of 4-20 mA DC. Microprocessor based single loop controllers will be provided to perform the closed loop functions of the boiler and the following are the major closed loops envisaged for the boiler unit. Three Element Drum level control SH Steam Temp. Control System Combustion Control System Furnace draft control Bed temperature control Deaeration level & pressure control
The transmitters for the open loops to monitor the pressure of the boiler will be directly connected to the open loop indicators mounted on the control panel. All open loop temperature points will be connected to a scanner mounted on the control panel. The various field mounted switches and other control devices shall be wired to the central system to perform the sequencing, protection and interlocking logic of the boiler system including the start / stop facilities for the various drives. The open loop indicators, scanner, recorders and DCS will be provided with serial interface port for connecting to PC based Data Acquisition System. The PC based automation system provided in the control room will be complete with the following : Three (3) nos. PC based Operator station of latest configuration complete with CDROM drive, 4 GB RAM, 320 GB HDD, Keyboard & Mouse, 21 SVGA high-resolution digital colour monitors. One (1) no. 132 column ink jet printer for printing reports. MMI software modules of development and routine version complete with packages for database generation, mimic development, trending, log and reports etc., along with device driver modules for the various sub-system devices such as PLC etc. Job specific application software packages developed for these packages, which include mimic displays, alarm, displays, trending, logs and reports will be provided as part of the automation system. Drum level control (three element control) Three element feed water control system is provided to regulate the quantity of feed water flowing in to the boiler to maintain required water level in the steam drum. Linearised steam flow signal properly compensated for variations in steam pressure and temperature will act as a feed forward signal. Drum level signal compensated for pressure variations (shrink and swell) is transmitted to the drum level indicating control function (DCS) as a measured variable. The measured variable
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signal is compared with the fixed set point in the drum level indicating control function (DCS). The resultant error/ control signal is added with the feed forward steam flow signal, which will act as variable set point for the feed water flow indicating control function. This variable set point is compared with the linearised water flow signal (compensated for temperature variations) in the feed water flow indicating control function (DCS). The resultant error/ control signal will adjust the flow of water flowing in to the steam drum by actuating the feed water flow control valve. Combustion Control The combustion control system is designed to control the load fluctuations and to maintain the constant superheated outlet header steam pressure by controlling the fuel flow and air flow into the furnace. Boiler demand signal is generated by comparing the desired steam pressure and the superheated outlet steam pressure. Fuel Flow Control The boiler demand signal shall act as the Remote Set Point to the Foal Flow Controller. However, to ensure that no fuel rich condition exists under any circumstances, the total airflow signal shall be compared with the boiler demand signal in a low selector and the lower of the two signals shall be used as the Remote Set Point to the Fuel Controller. The total Fuel Flow signal shall be used as a feed back signal to this controller. Air Flow Control The boiler demand signal shall also act as the Remote Set Point to the Air Flow Controller. To ensure that no fuel rich condition exists under any circumstances, the total Fuel flow signal shall be compared with the boiler demand signal in a high selector and the higher of the two signals shall be used as the Remote Set Point to the Air Flow Controller. The output from FIC shall be fed to FD Fan A&B Air Flow Controllers to provide the required flow. Furnace Draft Control Furnace Draft pressure control system will be provided to regulate the furnace draft pressure. The furnace pressure is transmitted to the Furnace Draft Pressure Indicating Control Function (DCS) as a measured variable. The measured variable signal is compared with the fixed set point. The resultant error/ control signal will adjust the ID fan Inlet guide vanes.
Main Steam Temperature Control Steam temperature at the outlet of the final super heater is transmitted to the temperature control function as a measured variable and is compared with the fixed set point. The resultant error/
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control signal is used as variable set point for de-super heater temperature control function (DCS). De-super heater outlet temperature is used as measured variable for this control function. The resultant error/ control signal from the de-super heater temperature control function adjusts the flow of water flowing in to the de-super heater by actuating the water spray control valve. Deaerator Pressure control Deaerator pressure is controlled through a Auxiliary steam supply line Pressure control valve, to maintain the deaerator pressure.
Feed Water storage tank level control Feed tank level is measured through a level transmitter, which gives signal to the mixed make up water line level control valve for control. In case the FW tank level goes very high, the over flow drain valve is automatically opened, by means of a split range control.
Steam Turbine Generator: Multistage, Nozzle governed, Horizontal spindle, two bearings, Impulse bleed cum condensing steam Turbine with: Hydraulically operated Stop & Emergency Valve with integral steam strainer for inlet Hydraulically operated Throttle/Governing valves for inlet steam flow control. Lubrication System Forced feed lubrication system, combined for Turbine, Gearbox and Alternator comprising of: Lube oil tank cum base plate provided with cleaning doors, air breather and AC motor driven vapour extractor. The provision for connecting oil centrifuge is provided. Shaft driven Main oil pump (MOP) AC motor driven Auxiliary oil pump (AOP) with auto cut-in & cut-out facility DC motor driven Emergency lube oil pump (EOP) with auto cut-in & cut-out facility Suction strainers for MOP, AOP & EOP Pressure relief valves for discharge of MOP & AOP lube oil line Oil coolers (1 working + 1 standby) with on-line change-over arrangement Oil filters (1 working + 1 standby) with on-line change-over arrangement Pressure regulating valve to achieve desired lube oil pressure
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Interconnecting lube oil piping Governing System
Electronic governor (Woodward 505) complete with electro-hydraulic actuator, magnetic speed pick-up.
Hydraulic accumulator of bladder type in the turbine control oil circuit to take care of any surges in control oil line and suitably pre-charged with gas.
Control oil filter 10/15 micron size. Control oil pressure-regulating valve to achieve desired control oil pressure in the control oil system. Interconnecting control oil piping. B Safety devices
Over speed trip and alarm Low lube oil pressure trip and alarm Low control oil pressure trip and alarm High thrust wear trip and alarm High exhaust/condenser pressure trip and alarm Manual trip (Hand trip) Remote emergency trip (Solenoid trip) DP across lube oil filters high alarm High Vibration trip thru Vibration Monitoring system for high speed train (Turbine front bearing, turbine rear bearing, turbine thrust bearing, gear box high speed pinion shaft front bearing, gear box high speed pinion shaft rear bearing) Gearbox
Single helical, single reduction Gearbox with hardened & ground gears Couplings
Non-lubricated, steel laminated, flexible type, high-speed coupling and low speed couplings with coupling guards. Accessories
Motorised barring gear arrangement
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NRV, Full flow relief valve and Isolation valve for bleed steam line (loose supply) Gland sealing system complete with: Gland Vent condenser with motor driven air blower Valves and piping within specified battery limits for header line Piping for return line upto condenser hot well complete with strainers, steam trap, valves, drains, vents & isolation provisions.
Common base plate for turbine and gearbox Insulation for Turbine hot parts (lagging & cladding) Set of tools & tackles for maintenance Set of foundation bolts
Condensing System Condensing system comprising of: Turbine exhaust steam duct & steam distribution duct with In-line and hinged expansion joints Rupture disc Steam trap Pressure equalizing pipeline between steam duct & condensate tank Inspection manholes Saddle supports with stiffener rings for steam duct Steam duct water collection system including valves & piping up to condensate storage tank A-frame type finned tube exchanger bundles with G-type embedded finned tubes Condensate collection system with Condensate storage tank 2 x 100% condensate extraction pumps 2 x 100% drain pumps Interconnecting piping up to ejector condenser Steam jet air ejector system complete (skid mounted) comprising Hogging ejectors (1 100%) compete with silencer 2 stage holding ejector (2 x 100%) compete with inter and after condensers Interconnecting piping & motive steam header Structural steel components comprising of Bundle support A-frame, partition wall, fan ring
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Suryalakshmi Cotton Mills Limited -
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Plenum chamber, fan guards, wind wall above fan deck & mechanical equipment maintenance walkway Mechanical equipment comprising of fans, spiral bevel gear box type speed reducer, vibration switches PART-B ELECTRICAL
AC Generator AC Generator shall be complete with following accessories : Brushless exciter Air coolers AVR cum Excitation panel Anti-condensation heaters Twin bearings
Auxiliaries for Generator protection and control Generator protection (Relay) panel Generator control (Metering & synchronizing) panel Generator Vacuum Circuit Breaker (VCB) Panel Lightning arrestor, Surge capacitor and Potential transformer (LA, SC & PT) panel Neutral grounding resistor (NGR) panel Battery Battery charger cum DC Distribution panel
PART-C - CONTROL & INSTRUMENTATION Turbine Dial type pressure gauges for : MOP discharge AOP discharge EOP discharge Gland steam header Gland steam return lines Inlet steam line
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Bleed steam line
Dial type Differential pressure indicator with switch for monitoring DP across lube oil filters Pressure switches for : Lube oil pressure very low trip & alarm Control oil pressure low alarm AOP auto cut-in & cut-out EOP auto cut-in & cut-out
Transparent level gauge for oil tank Dial type temperature gauges for : Turbine bearing oil Gearbox bearing oil Oil cooler inlet & outlet Inlet steam Bleed steam line
RTDs for : Turbine bearing oil Gearbox bearing oil
Condensing system Condenser hot well level control system complete with : Level transmitter Level indicator cum controller Control valves I-to-P converter Air filter regulators
Dial type Pressure gauges for : CEP discharge Motive steam to ejector Condensate to ejector Condensate from ejector First stage ejector condenser Condensate pump discharge
Pressure switches for :
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Condensate header pressure control & CEP auto-start interlock Condenser pressure high trip & alarm
Dial type temperature gauges for : Condensate after hotwell Condensate after inter/after condensers of ejectors Motive steam to ejector Cooling water inlet & outlet Condensate suction Condensate to ejector
Transparent level gauge for condenser hotwell Level switches for : Condenser hotwell level low alarm and CEP dry run interlock Condenser hotwell level high alarm
Pneumatic and impulse piping with fittings for interconnection within battery limits.
Turbine Control cum PLC Panel Turbine control panel shall house the following: Electronic governor SCADA / PLC based turbine safety interlocks and trip logic Remote controls comprising of selector switches, ammeters, push buttons & indicating lamps for : AOP motor EOP motor Air blower motor CEP motors 1 & 2 Barring gear motor Vapour extractor motor
Push buttons for turbine speed raise and lower Turbine remote trip/reset push buttons SCADA / PLC based temperature Monitoring for turbine and gearbox bearing temperature SCADA / PLC based alarm annunciations for Turbine fault monitoring Vibration Monitor
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The panel shall be complete with AC supply & DC supply on /off control switches, indicating lamps and space heater. Stand alone PC with SCADA will provided near the control panel.
Turbine Aux. MCC MCC Panel shall house: DOL starters for : AOP motor Air Blower motor CEP-1 & 2 motors Barring gear motor Vapour extractor motor
Speed indicator and speed raise/lower push buttons. DC motor (EOP) starter panel
DC motor starter panel shall house feeder & control circuit for EOP motor. C Local push button station Local control stations with on/off push buttons for : AOP motor EOP motor Air Blower motor CEP-1 & 2 motors Barring Gear motor Vapour extractor motor Generator Dial type pressure gauge for lube oil - 1 per bearing Dial type temperature gauges for : Bearing oil 1 per bearing Hot air & cold air 1 each per cooler
Temperature sensors for : Winding temperature (embedded RTDs) 4 per phase Bearing oil temperature (duplex RTD) 1 per bearing
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Hot air & cold air 1 each per cooler
Temperature scanner to monitor Generator winding and bearing oil temperature
The steam turbine shall be started, shutdown and normally operated directly from the Central Control Room. All valves, equipment etc, required for the above operations shall be motorized /pneumatic operated as required. Instrumentation has to be provided for safe and satisfactory operation and supervision of the plant. Adoption of the specified scope and design of the control and instrumentation equipment shall be done where needed for matching the special versions and requirements of apparatus and plant equipment. BALANCE OF PLANT: MECHANICAL SYSTEM: Mechanical systems and equipment including the following within the boundary limits: WATER TREATMENT PLANT: Water treatment plant comprising of 3 nos. raw water transfer pumps each rated for 15 cum/hr to feed the system 2 nos. raw water chemical dosage metering pumps to dose chemicals on line, coagulant Pre filtration system with self cleaning filter and cartridge filter. High pressure pumps and motor to feed water to the RO / DM units. Reverse osmosis pressure vessel with membranes for treating the water. Necessary on line instruments to control the system characteristics. Necessary interconnecting piping, fittings and valves Programmable logic controller for controlling the system performance Clean in place (CIP) for the RO membranes and automatic flush unit DM plant for the RO treated water consisting of the following: 2 nos. pre treated water feed pumps Cation bed reactor with suitable free board, complete with proven quality resin. Anion bed reactor with suitable free board, complete with proven quality resin.
and anti scale chemicals.
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Mixed bed exchanger with suitable free board, complete with proven quality resin. Mixed bed scouring air blower (oil free type) with drive motors, base plate, suction air filter, silencer, piping, valves & fittings, foundation bolts & nuts. DM water storage tanks complete in all respects including local instruments, ladder, manhole etc., DM water transfer pumps with drive motor, coupling, base plate, foundation bolts & nuts and other accessories.
Waste Effluent Neutralization System: Two Nos. Neutralizing Pits of RCC construction complete with all necessary equipment including Waste Water Inlet Puddle Pipe and Isolation Valves, re-circulation internal pipes and valves. The chemical waste from the chemical handling area shall be collected in local sumps and transferred to the neutralization pit by sump pumps.
Effluent Disposal System consisting of Two Nos. Effluent Disposal Pumps and Priming arrangement for the Effluent Disposal System including piping up-to the disposal point. Two Nos. (1W +1S) Acid dosing pumps / Caustic dosing pumps for dosing of acid / caustic into Neutralization pit. All Drive motors for Pumps/Blowers/Agitators with Base Plate and coupling, coupling guard etc. for the equipment. Commissioning and two years operating spare parts One set of Special Tools and Equipment for maintenance, inspection and repair in steel boxes including identification and operating instructions. First fill of lubricant shall be included in the scope of supply. All standard equipment and accessories normally included in the supply schedule but not separately listed. Complete electrical system including drive motors suitable for area specified, Motor Control Center, control panel, local push button stations, transformers rectifier set, power & control cables, cabling complete with supports, cable trays, glands, lugs, earthing and lightning protection system for the successful operation of the plant.
WASTE WATER TREATMENT PLANT The wastewater Treatment Plant shall take care of the following requirement Makeup Water Treatment Plant regeneration wastewater and Chemical storage/ Handling area wastewater shall be led into common Neutralization Pit, Neutralized by addition of Acid/ Alkali and led to the wastewater Discharge System. Oil bearing effluent generated from boiler area, STG area, Transformer area, floor washings and Miscellaneous areas, shall be fed to the Oily Waste Water Sump and further treated in a
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Oil/Water Separator. The Waste Oil shall be collected in a Waste Oil Holding Tank and shall be disposed in containers. Oily waste from distillate storage & handling area shall be taken to an Oil Interceptor and shall be discharged to Waste Water Discharge System. Sewage water from Power Plant shall be subjected to treatment system to satisfy the standards prescribed by PCB. Separate Treatment Plants shall be provided for Power Plant. The clear water shall be led to Wastewater discharge system. Provision for storage and distribution of clear water for Horticulture shall also be included in the scope. For requirement of disinfectants at Sewage Treatment Plant Sodium Hypochlorite plant shall be installed. Sludge collected shall be disposed using Trucks. Handling system for loading into Trucks shall be provided Filter Backwash water shall be treated in a Clarifier for Suspended Solid reduction, collected in a Filter Back wash water sump and then pumped into the Waste Water Discharge System after satisfying the standards specified by PCB. The sludge shall be collected in a drying pit and disposed off-site manually. Blow-down shall be quenched with Raw water and fed to Dual Media Filter Inlet along with raw water. Special Waster Water like Acid cleaning of boiler etc. shall be collected and treated for removal of suspended solids, neutralized and let into the Waste Water Discharge system after satisfying the standards. Commissioning and two years operating spare parts. All consumables such as lubricants for the first fill. All necessary painting, corrosion protection and preservation measures as required. All standard Equipment and accessories normally included in the supply schedule but not listed separately. Complete electrical system including drive motors suitable for area specified, Motor Control Center, control panel, local push button stations, transformers rectifier set, power & control cables, cabling complete with supports, cable trays, glands, lugs, earthing and lightning protection system for the successful operation of the plant. Fuel and Ash Handling System The design of the fuel handling system is based on the estimated fuel consumption of the boilers. The coal required for total steam generation from two boilers for full generation of 25 MW works out 18.35 TPH considering coal with GCV 4000 kcal/kg. However, the fuel consumption works out to 21.6 TPH considering coal with GCV 3400 kcal/kg. Accordingly, it has been decided to consider coal handling plant throughout capacity as 60 TPH assuming the plant shall run for two shifts each of duration 6 hours totaling 12 hours of operation. The layout of the coal handling plant is drawn out keeping in mind the overall
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plant layout and space allocated for the new power plant in the rear of the unit. Accordingly the raw and product coal conveyors have been laid up to the boilers. The raw fuel will be manually fed to the underground hopper through a grizzley with opening aperture size limited to 200 mm. The coal is fed by a vibrating feeder onto the raw coal conveyor BC1. Two-stage screening and single stage crushing is envisaged for ensuring proper sizing of coal to be fed into the boiler. The conveyor in turn feeds the vibrating screen located on top of the primary crusher to segregate the undersized coal that is fed directly to conveyor BC3. The oversized coal is then fed into the crusher for crushing. The crushed fuel shall then be fed onto the secondary vibrating screen located below the crusher. The rejects from this vibrating screen is fed to the recycling conveyor BC2 for being fed back to raw coal conveyor BC1. The undersized coal from the vibrating screen is fed to conveyor BC3 and then other product conveyors BC4 to BC6 to the top of the boiler. The recycling concept coupled with two stage screening and crushing ensure proper sizing of the coal. The schematic of fuel handling is shown in drawing no. 20-SLCM-ME-007 (R1) & 20SLCM-ME-008 (R1). The ash collected from under the bed is conveyed by a conveyor system after proper cooling. The ash is conveyed to an ash silo for intermediate storage. The fly ash is conveyed through a dense phase conveying system to a separate fly ash silo. The ash from the silo is then removed from the plant by trucks. Closed Cooling Water System Closed cooling water system comprising of The pipe-work, valves, strainers and all associated equipment for connecting the circulating water inlet and outlet piping with the inlet and outlet branches of the closed cooling water heat exchanger Design Requirements The closed cooling water system is used as a common facility for Steam turbine auxiliaries, boiler auxiliaries & other equipment auxiliary coolers. The system will operate with soft water and the water will be supplied from the soft water storage tank via the filling pump to the closed cooling water expansion tank. All cooling circuit equipment shall be suitable for this duty and shall include Closed cooling water pumps Induced draft-cooling towers with capacity of 200 cum each. The tower will be PVC Cooling water piping from the cold water basin of the cooling tower to the aux. and
construction for design temperature drop of 8 Deg C. tower CW system and back to the cooling tower.
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Make up water piping to take care of the evaporation, blow down and drift losses in Associated piping, strainers, valves, fittings and hangers All instrumentation, alarms and controls
the circuit.
CRANES AND HOISTS Cranes One (1) no. electric overhead travelling crane rated for 30 MT for Turbine Hall comprising of Hoists Manual chain hoist shall be provided for areas with equipment/component to be lifted for erection and maintenance weighing less than 2 Tonnes. Electric hoist shall be provided for equipment/component weighing 2 tonnes and above. The final number of hoists to be supplied will be according to the requirements of the equipment. VENTILATION & AIR CONDITIONING SYSTEM (HVAC) HVAC plant comprising of 1 X 100% Air- water air-conditioning system for administrative building. Unitary Air-conditioning system for Control room, Electronic panel room, UPS room in Powerhouse Building, Water Treatment plant controls room. General ventilation system for STG Hall, Electrical Switchgear room, Cable spreader, pump house etc. Dilution ventilation system for Battery room, fuel oil pump houses. Spot Cooling system STG Hall operating zone. Common equipment and services comprising of The gantries, crane rails and end stops complete with all fastenings The crane bridge with crane drive gear and rail clamps The drive gears for the gantries, (gantry crane) The gangway alongside the runway girders of the turbine hall crane Maintenance platforms and access ladders, wherever applicable The crab with crab drive gear Operator cabin and /or pendant control as required The main lifting gear complete with ropes and hook fittings The auxiliary lifting gear (where required) complete with ropes and hook fittings Slings and shackles The complete electrical equipment
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Hot dip galvanized ductwork. Commissioning and two years operation spare parts All consumable such as lubricants, chemicals, etc. for the first fill. One set of special tools and equipment for maintenance, inspection and repair in steel boxes, including identification and operating instructions as well as equipment for storing dismantled parts during inspection.
All refrigeration machines shall use ozone friendly refrigerant.
COMPRESSED AIR PLANT The instrument and service air system will include two 100 percent oil-free air compressors, connected in parallel, two receivers (total receiver capacity shall be adequate for plant requirements), dual tower dryer, pre- and after-filters, and all necessary valves, fittings and supplies. Extraction air from the gas turbine compressor will provide standby instrument air. Controls will provide for local control and will be monitored by the DCS. The capacity of the system will meet all plant control and service air and instrument air needs. In the event of low air pressure, the service air will be automatically shut off. Cooling water will be provided by the auxiliary cooling water system and isolation valves will be provided to allow the supply of potable water to the compressor package for emergency purposes. Tank and filter drains will be plumbed to plant drains. The compressed air plant shall comprise of 2 x 100% instrument/service air compressor (Oil free) with all auxiliary Moisture separators, lubricating system, anti-vibration equipment, base 2 x 100% air drying plant complete with pre-filter, after-filter(fine filter), etc. 2 x 100% air receiver each for instrument & service air system. Complete piping network including piping from gas compressor, interconnecting equipment such as after-coolers & inter-cooler. plate, intake filters, silencers etc.
piping as required for distribution including compensators, automatic operating devices, supports, fasteners, necessary automatic condensate traps, isolating valves, by pass control valves, fitting etc, including the following particulars items. Common equipment and services shall comprise of All necessary insulation as required. Complete electrical system including drive motors suitable for area specified,
couplings & coupling covers, control panel, local push button stations, transformers rectifier set, power & control cables, cabling complete with supports, cable trays, glands, lugs, for the successful operation of the plant.
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First fill a lubricants & consumables. One set of special tools and equipment for maintenance, inspection and repair in
steel boxes, including identification and operation instructions as well as equipment necessary for storing dismantled parts during inspection. FIRE FIGHTING SYSTEM The fire protection system shall comprise of Hydrant system - For entire power plant block & administration building area Fixed Medium velocity water deluge spray system for cable spreader rooms. Mobile foam system - oil tank (s). Fixed High velocity water spray system - For transformers and turbine lubrication oil tank(s) Wet pipe Sprinkler system for areas in warehouse building storing combustible & flammable material. Fire detection and alarm system for Power block & administration building area. The following equipment & accessories shall be supplied Diesel driven main fire pumps for hydrant network serving of hydrants, water Electric motor driven standby fire pumps for hydrant network serving hydrants Electric motor driven jockey pumps for hydrant network serving of hydrants, water All necessary pump controls complete with all accessories for the abovespray, sprinkler and foam system. water spray, sprinkler and foam system. spray sprinkler and foam system. mentioned pumps. All buried piping and over-ground pipes, fitting ,valves, automatic actuators, supports etc for fire water distribution networks All necessary sign-posting for the water-hydrant ring system including brackets, complete with accessories. All necessary water spray rings, risers, pipes, valves, fittings, spray nozzles , Complete Addressable analogue fire detection system with heat and smoke sprinkler nozzles etc for : detectors for various plant area and fuel tank(s) with necessary cabling, interface panels, controllers, sounders, manual call points, sirens, response indicators, and all necessary hardware and accessories. All necessary electrical equipment like LV switch-gear, LV motors, LV power and control cables, control panels with alarm, PBB and interlocks, necessary DC systems, push
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button stations, cable trays and accessories, cabling, glands lugs, earthing and lightning protection conforming to relevant electrical specifications. Central fire station (if required) as per the stipulation with all mandatory Trailer pump of required capacity for fire brigade use All necessary communication and warning systems inside the fire station. All required fire fighting equipment and accessories inclusive of all safety Water supply tank(s) of adequate capacity for feeding the trailer pumps and fire All necessary wall-mounted/mobile Dry powder extinguishers, CO2 extinguishers All necessary wall or open air retainers for the permanent installation of the All necessary instruction and warning plates All necessary masks and/or other protection devices for optimal protection of the requirements as indicated below shall be provided.
equipment. engines.
equipment
personnel. Common equipment and services comprising of Commissioning and two years operating spare parts All consumable such as lubricants, etc. for the first fill One set of special tools and equipment for maintenance, inspection and repair in
steel boxes, including identification and operating instructions as well as equipment for storing dismantled parts during inspection. Workshop Equipment: The workshop equipment shall comprise of Heavy Duty Lathe Medium Duty Lathe Radial Arm drilling machine Medium Duty Pedestal Grinder Power hacksaw Universal milling machine Light duty pipe bender Marking Table Pneumatic Tools Two-nos. Machine shop measuring Instruments (set) Work benches
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Suryalakshmi Cotton Mills Limited Mobile Compressors Portable Grinding Machine Lever type-shearing machine Vices (fixed) Vices (universal) General Tools and Measuring Instruments Laboratory Equipment: The chemical laboratory equipment shall comprise of Equipment for Water Analysis (a) (b) (c) (d) (e) (f) UV Spectrophotometer Conductivity Meters pH Meters Turbidity Meters Alfloc test kits Jar test apparatus : : : : : : One (1) Two (2) Two (2) Two (2) Two (2) Two (2)
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Equipment for Gas Analysis Two (2) nos. each of the following equipment with all accessories. (a) (b) (c) Three-bulb Orsat apparatus Explosimeter (Combustible gas analysis) Hydrogen purity test apparatus
All tools required for effective servicing and maintenance of above equipment as well as one initial charge of consumables and reagents shall be furnished. ELECTRICAL SYSTEM: The proposed single line diagram is shown is drawing no. 20-SREL-EE-001 (R3). The power generated in the STG at 11 KV is fed to a 11 KV swichgear which feeds the in plant captive power demand and denim plant demand. Accordingly two unit auxiliary transformers are proposed. The various MCCs are the fed by the 415 V switchgear. The voltage levels in the proposed plant will be 11 KV, 50 Hz generation, auxiliary utility voltage at 415 V, 50 Hz for 3 phase and 240 V for single phase and 110 V ac for control supply requirement. The major equipment being supplied are as follows: 11 KV, 13.2 KA 3 sec, 3 phase, 50 Hz, indoor HT switchboard with Al. Single bus arrangement two in-comer breakers rated at 1600 A, five outgoing breakers rated at 630 A
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each two for utility transformers and three for feed pump drives, two outgoing breakers rated at 1250 A each one for denim plant and the other to switchyard, draw out type Bus PT and spare feeders as shown in the SLD with meters feeders and protection & relays. All breaker panels are draw out VCB type. 11 KV UE grade Aluminium cables from alternator terminals to utility transformers primary and generator transformer primary. The cables from HT switchboard outgoing feeders to the denim plant incoming feeder shall also be rated as above. The cables shall be suitably derated to suit underground laying in groups. Two numbers 11 KV / 415 V unit auxiliary transformers rated at 2500 KVA, connection Delta on primary and Star on secondary side, outdoor construction, Off circuit tap changers, Oil Natural and Air cooled type, 415 V, 50 KA, 3 sec, 3 phase, 50 Hz, indoor LT Power Control Center to feed various MCCs as shown in SLD. The breaker ratings shall be as per SLD with metering, protection & relays. The PCC shall have necessary spare feeders. 750 KVA DG set for start up power and emergency power supply generating at 415V, 3 phase. The DG shall be connected to the LT bus as shown in SLD through a bus coupler. The DG set shall be synchrononised with the STG with AMF features. The DG set shall be water-cooled construction. The scope shall include air intake system, exhaust system, fuel oil system, lube oil system etc. This facility is available at site. The transformer secondary shall be connected to the PCC in-comer through a bus duct rated for 4000 A outdoor construction with a short circuit rating of 50 KA for 1 second. Power and control cables with necessary trays. The cables shall of Al conductor, PVC insulated, armoured type. The cables shall be suitably derated for underground laying in a trench in groups. Plant earthing and lightning protection system. Plant Lighting system. The street lighting will be based solar power design. The lights will be stand alone type with solar panels mounted on individual posts. Control power supply system comprising of battery and battery chargers. The battery shall be lead acid type, 220 V / 110 V, 110 Ah rating. The battery charger shall have both boost, float cum boost charge facility. Dc distribution boards with suitable feeders with Two pole MCBs shall be provided. Relay and protection panel including the following but not limited to, Voltage restrained over current relay Earth fault relay Restricted earth fault relay Differential relay
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High speed master relay Over voltage relay Under voltage relay Reverse power relay Reverse reactive power relay Under frequency relay Over frequency relay Rotor earth fault relay Trip circuit supervision relay Negative phase sequence over current relay Directional over current relay
Metering panel including the following but not limited to, Ammeters Voltmeter with selector switch Integrating type KWh meter with reverse lock MWE meter MVAR meter MVA meter Power Factor meter Frequency meter Running Hour meter Microprocessor based Multi point Temperature scanner Energy monitor and recording meter Indicating lamps Audio visual alarms
Synchronizing panel of desk type, with indicating lamps, rotary control switches, digital operation, necessary interlocks, Mimic wiring showing the Power plant scheme, audio visual alarms including the following: Automatic synchronizer with auto voltage and frequency matching. Synchroscope with check synchronizing facility Double frequency meters Double voltmeters Indicating lamps Potential transformers Dead bus relays
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Outdoor type Switchyard: The switchyard for transmitting power to the grid shall comprise of the following, as existing at site and shall be used for the power plant purposes: Power Transformer rated for 25000 KVA, ONAN cooling, primary at 11 KV and secondary at 220 KV, 3 phases, outdoor type, Off circuit load changers, connection as Delta on primary side and Star on secondary side solidly grounded complete with oil conservator, explosion vent, buchholz relay, oil level indicator etc. SF6 type Circuit Breaker rated for 220 KV and 630 A current, outdoor installation, 3 phases with a short circuit rating of 31.5 KVA for 3 seconds, closing coil mechanism motor operated 110 V DC spring charged, electrically released with trip free closing mechanism, IP 55 protection and local mounted control panel. Isolators of outdoor installation rated for 220 KV and 630 A current, with a short circuit rating of 31.5 KVA, motorized operation and suitable for horizontal installation. Outdoor lightning arrestors station type, magnet valve type sealed with pressure relief diaphragm rayed for 120 KV and 10 KA. Outdoor oil filled hermetically sealed porcelain type current transformer rated for 220 KV with primary current of 100/50 A and secondary current of 1 A, with cores of CL 0.5, CL 5P 20 and CL PS and rated burden of 20 VA for CL 0.5 and CL PS. Outdoor oil filled hermetically sealed porcelain type potential transformer, with primary voltage 220 KV and secondary voltage 110 V / 110 V, rated burden 100 VA each. Metering & Relay panel suitable for outdoor switchyard including but not limited to Digital Meters viz. Ammeters Voltmeters with selector switches Integrating type KWh meter with reverse lock MW meter MVAR meter MVA meter Power Factor meter Frequency meter
Indicating lamps LED type as follows but not limited to Breaker ON, OFF, tripped position Aux. DC power supply On
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Aux. DC power supply Failure
Audio Visual alarm annunciation with different tone and having amber indication for DC failure trip Winding temperature high alarm Winding temperature very high alarm Buchholz alarm Buchholz trip All electrical faults & trip
Relay and protection panel including the following but not limited to, IDMT Over current + Inst. Over current relay Restricted earth fault relay Differential relay High speed master relay Over voltage relay Under voltage relay No volt relay Under frequency relay Over frequency relay df /dt relay Trip circuit supervision relay Directional over current and earth fault relay
All the relays shall have suitable multiplication and trip arrangement. All relays shall be digital, microprocessor based except High speed trip relay, trip circuit supervision relay. All relays shall confirm to IS: 3231-1965 or latest. Export / import Metering panel The panel shall house the export / import metering and accessories prescribed by the state electricity board. There shall be two meters each for SEB / IPP having accuracy class 0.2. The panel shall be suitable for outdoor installation.
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Suryalakshmi Cotton Mills Limited Design Requirement of the Coal Handling Plant:
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The supporting structures, gantries etc shall be designed for wind and seismic loads as per relevant Indian standards and as stipulated in the purchase specification. The trestle / tower foundation shall be designed for soil conditions being furnished by the clients. The equipment shall be designed for continuous operation throughout the year. The conveyors / crushers shall normally operate for 12 hours in a day, six hours per shift for 2 shifts in a day. However, the conveyors and crushers shall be designed for round the clock continuous operation. They shall be suitable for operation in a dusty environment. The crusher shall be able to start at full load conditions and shall take the impact of coal dropping from a height of 2 meters. The crusher shall be capable of handling of oversize lumps without any difficulty. The crusher shall be low height, compact in dimension, light in weight for easy and quick installation with minimum support to avoid heavy civil foundation. The speed of the crusher shall be low to avoid fine generation, resulting in low power consumption and minimum wear and tear during the lifetime. Slopes of conveyors where applicable shall not exceed 16 deg. Belt sag between idlers shall not exceed 2%. The design capacity of the conveyors shall be equal or greater than 1.1 x rated capacity. The drive motors, gear reduction unit, high speed, low speed couplings of all equipment shall be rated for 120% of calculated values. This will have to be demonstrated during load trail run. The conveyors shall be so selected such that the normal working tension at specified design load shall not exceed 80% of the maximum allowable working tension. The conveyor shall have to start in full load conditions. The drive unit comprising of drive motors, gear reducer and other components shall be mounted on a common base frame rigid in design. The design shall be modular such that individual components can be taken out for overhaul and maintenance with minimum dislocation of other components. The driving drum shall be clear off the base so that the bottom run of the belt shall not foul with the structure. Necessary access to clear the material falling at the bottom of the driving drum shall be provided. The motors shall be horizontally foot-mounted type as per relevant Indian specifications amended up to date. The speed of raw coal conveyor shall be restricted to 0.6 m/sec while that of crushed coal conveyors be restricted to 1.0 m/sec. The gear reducer shall be of helical type with service factor not less than 1.5. The gearbox shall have a rated life of not less than 50,000 hours. Flexible gear / pin bush couplings shall be used for power transmission between motor, gear reducer and drive pulley. The couplings shall be designed and manufactured to meet the following criteria: By allowing the motor of off-load start By enabling the starting torque to match the drive requirements By acting as a filter to Torsional vibrations
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By acting as torque limiters Automatic take up arrangement of vertical gravity type shall be provided complete with bend pulley, take up pulley, counter weight and other accessories suitable guards with marked up scale attached to the frame to monitor belt stretch. Access / platforms with handrails shall be provided to inspect, repair and maintain the take up arrangement. The arrangement shall be so located as to keep belt tension at a minimum. The bearings shall be of seize resistant type with bore diameter not less than 30 mm for impact and 25 mm for carrying and return idlers. The bearing shall be C3 clearance and dimensions as per relevant IS specifications. The bearing shall be adequately sealed and lubricated for life and life of the bearings shall not be less than 30000 working hours. The carrying idlers shall consist of three rollers of equal lengths. The troughing angle shall be 35 deg. Carrying idlers shall be placed at 1000 mm (maximum) along the conveyor length. The return roller shall be of single roll type and shall be placed at 3000 mm interval (maximum) along the length of the conveyor. Impact idlers at the loading and transfer points shall be designed so as to avoid direct loading impact and damage to the belt. The impact idler shall be placed at not more than 400 mm spacing and a minimum of 6 nos. shall be located at every loading / transfer points. On the carrying side, two sets of self-aligning troughing idlers shall be located at 5 meters spacing from head and tail pulley. The spacing of the intermediate self-aligning idlers shall be 15 meters. On the return side, two sets of self-aligning return idlers shall be located at 10 meters spacing from head and tail pulley. The spacing of the intermediate self-aligning idlers shall be 30 meters. Selfaligning idlers shall be located near the drive and take up pulleys. The self-aligning idlers shall be of direct acting type. All the pulleys shall be lagged with rubber. The lagging shall be bound on the pulleys by hot vulcanizing. The lagging on drive pulley, discharge pulley shall be chlevion V-type herringbone or diamond pattern wherever required. Formed sheet steel decking plates shall be provided throughout the length of the conveyor to protect the bottom belt from spillage. The thickness of the decking plate shall not be less than 3 mm. Suitably located skirt plate shall be provided at the loading points for a distance of 5 meters to prevent spillage. The skirts shall flare slightly upwards from the chutes to prevent the materials from wedging. The contact should be soft but firm which will complete sealing at the transfer / loading points. Wherever required, suitable belt scrapping system should be provided to ensure belt cleaning.
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For emergency stopping of conveyor from any point along the conveyor length, pull cord switches (manual reset type) shall be provided on both sides of the whole conveyor running length. The pull cord rope shall be PVC sheathed GI wire. Belt sway switches shall be located at suitable intervals and near head and drive drums. One number electronic type belt speed-monitoring switch shall be provided for every conveyor to trip the conveyor if the speed falls below a preset value. All switches shall be heavy-duty type, totally sealed and dust and vermin proof. The conveyor belts shall be made of all nylon-nylon, all synthetic material, heavy-duty type, capable of exposure to sun and rain, extreme temperatures from 15 to 50 deg C and relative humidity of 98%. The belting shall be straight ply type and confirm to latest IS codes. The belts shall have sufficient lateral and longitudinal flexibility to match the layout requirements. The belts shall have sufficient impact resistance to ensure safety against high impact loads. The chutes shall be fabricated from 6-8 mm thick steel plates and wherever required be lined with abrasion resistant liners. The cross section of the chutes at any point shall not hinder free flow of material and not result in wedging. The power supply to the proposed plant shall be fed from a motor control center designed to cater to the running demands of the CHP. The operational voltage shall be 415 v +/- 10% @ 50 Hz +/10%. The vendor shall supply the necessary control cables leading up to the control panel to be supplied for safe starting and shut down. The start and stop sequencing shall be incorporated in the control panel and shall be done by a programmable logic controller. The control panel shall be located in the ESP control room located close to the ESP and not far away from the conveyors. There should be additional local start stop facility also for all the conveyors. The motor rating shall be at least 10% more than the peak power consumed to take care of any variations in the performance parameters. The conveyor / crusher house illumination shall be carried out by the Purchaser. The proposed crusher / belt conveyor motors shall be earthed by forming one number earth electrode as per IS 3043 (amended up to date) at a convenient location by 50 x 6 mm GI strip. The Purchaser shall connect this earth electrode to the proposed earth bus. The light fittings / junction boxes and safety switches shall be earthed by auxiliary connection to the earth bus of size 25 x 6 mm GI strip. This earth bus of 25 x 6 mm shall run along the conveyor run and shall be connected to the common earth bus at a suitable location. The lightning protection of the conveyors / crusher house shall be provided by air termination network to separate grounding electrodes by down conductors having suitable test points with minimum 25 x 6 mm GI strips.
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The coal handling system shall also include necessary magnetic separators on line in the crusher house to remove iron particles if any before entry to crusher, coal-weighing system to ensure quantity of coal being into the boilers. The coal-weighing system shall be latest state of art system that can withstand dusty working environment and meet accuracy levels accepted by users. SPECIFICATION FOR POWER TRANSFORMER: SCOPE: This specification together with particular Data Sheet intends to cover the design, manufacture, assembly, testing at manufacturers unit, oil immersed, three phase, double wound, out-door type transformer complete with all accessories for efficient and trouble free operation at the project site. Power transformer shall be designed, manufactured and equipped with accessories with applicable Codes and Standards. Design and workmanship shall be in accordance with the best engineering practice to ensure satisfactory performance and service life. Transformer shall be suitable for the design ambient condition temperature of 45 Deg. C. Accessories The following list, but not limited to, the fittings and accessories to be furnished as part of the transformer. 1. Rating and terminal marking plate in stainless steel. 2. Pressure relief devices / explosion vent with double diaphragm. 3. Dial type oil level gauge in conservator. 4. Dial type oil temperature indicator (with capillary tubes and two sets of contact for alarm and trips and maximum temperature indicator.) 5. Thermometer pocket with alcohol thermometer 2 Nos. 6. Filter valves with plug 2 Nos. 7. Sample valves with plug on top and bottom. 8. Oil filling hole with cover. 9. Radiator isolating valves. 10. Inspection cover. 11. Earthing terminals 2 Nos. 12. Lifting lugs. 13. Drain valve with plug. 14. Dehydrating silica gel breather. 15. Conservator drain valve and plug. 16. Air release device.
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Suryalakshmi Cotton Mills Limited 17. Jacking lugs with haulage holes 4 Nos. 18. Bi directional rollers.
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19. Double float buchholtz relays for main tank and OLTC chamber with alarm and trip contacts (with isolating valves). 20. HV end termination with bushing complete. 21. Termination chamber on the LV side, complete with bushings and terminals connection bolts and nuts. 22. Equalizer pipe connection between explosion vent and conservator tank. 23. Marshalling box / kiosk complete with cable glands and cabling between terminals on Marshalling box and various accessories fitted on the transformer. 24. One set of starter and controls for the fans for the forced air cooling of transformer to be joined in Marshalling kiosk along with cubicle illumination and control switch. 25. Lifting handles for the tank cover and conservator. 26. Dial type winding temperature indicator (with capillary tubes and two sets of contacts for alarm and trip and maximum temperature indicator). Completeness of Supply Equipment offered shall be complete in all prospects. Materials or accessories, which might not been specifically mentioned in this specification, but is useful / necessary for satisfactory / trouble free operation and maintenance of the equipment shall be supplied along with the equipment with no extra cost to the Purchaser. All schedules and annexure appended to this specification shall also form part of this specification. The successful Tenderer shall supply all equipment and accessories listed in this specification with such modifications and alterations as agreed upon in writing. Consumable / First charge / Tools & tackles / Documents First filling (including 10 % spare in containers) of transformer oil conforming to IS 335. Special - tools and tackles. All relevant drawings, data and instruction manual (including erection, commissioning and maintenance manuals) Codes and Standards IS 335: Specification for new insulating oils for transformers and switchgear IS 1886:Code of practice for installation and maintenance of transformer. IS 2026: Power transformers Part I Generals.
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Suryalakshmi Cotton Mills Limited IS 2026:Power transformers Part II Temperature rise. IS 2026:Power5 transformers Part III Insulation level and di-electric tests. IS 2026:
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Power transformers Part IV Terminal markings, tapings and connections.
IS 2099:Bushing for alternating voltage above 1000 Volts. IS 3347:Transformer bushings. IS 3639:Power transformers Fittings and accessories. IS 4257:Porcelain bushing for transformers. IS 6600:Guide for loading of oil immersed transformers. IS 8468:ON load tap changer. IS 8478:Application guide for tap changer. IS 10028: Code of practice for selection, installation and maintenance of transformers.
Transformers equivalent to international specifications shall conform to the requirements to the latest edition of the relevant specifications. The transformers shall also conform to the provisions of latest Indian Electricity Rules and to the regulation of statutory authorities. Basic Design The transformer shall be used for supplying power to the various equipment in the plant. The delta connected high voltage winding of the transformer will be connected to the three phase, 50 Hz system. The star connected low voltage winding will be connected to the switchgear. The transformer impedance shall not be less than 10 % to limit the fault level. The neutral of the low voltage winding will be grounded by resistance, with the fault current limited to the full load current of the transformer. The transformer will be located outdoors in a hot, humid, corrosive and tropical atmosphere. The effect of direct sunrays shall be taken into account while designing the transformer. The transformer shall be capable of withstanding the thermal and mechanical effects of short circuits at the terminals of any winding without adverse effects. The transformer shall be oil filled type and designed for natural cooling and forced cooling. The transformer shall be capable of continuous operation at its rated output without exceeding the temperature limit as below (over 50 Deg. C ambient temperature). a) In top oil by thermometer 50 Deg. C
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Suryalakshmi Cotton Mills Limited b) In winding by resistance 55 Deg. C
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The transformer shall be appreciably free from noise and vibration and shall be capable of continuous operation at its rated output under the following conditions. a) b) Voltage variation by +/- 10 % Frequency variation by +/- 3 %
The transformer shall be designed and constructed so as not to cause any undesirable interference in radio or communication circuits. SPECIFIC REQUIREMENTS Transformer Tank The tank shall be of welded construction and fabricated for sheet steel of adequate thickness. All seams shall be properly welded to withstand requisite impact during short circuit without distortion. All welding shall be stress relieved. The tank wall shall be reinforced by stiffner of structural steel for general rigidity. The tank wall shall have sufficient strength to withstand without any distortion the following: 1. 2. Mechanical shock during transportation. Oil filling by vacuum
The tank cover shall be bolted onto the tank with weather proof, hot oil resistant, resilient gasket in between for complete oil tightness. If tank cover is compressible, metallic stoppers shall be provide to prevent over compression. Bushing, turrets, cover of access holes and other devices shall be designed to prevent any leakage of water into or oil from the tank. The tank shall also be provided with sets of bi-directional wheels for rolling the transformer parallel to either center lines. Jacking pads, lifting eyes and pulling lugs shall be provided to facilitate movement of the transformer. All heavy removable parts shall be provided with eye bolt for ease of handling. Manholes of sufficient size shall be provided for access to leads, windings, bottom terminals of bushings and tap. Oil sampling taps shall be provided with valve at top and bottom to collect sample of oil from the tank for testing. To facilitate the oil filtration by stream line filter, suitable inlet and outlet taps with valves at the bottom and at the top of the tank on diagonally opposite corners of the tank shall be provided. The valve at the bottom may be used as drain valve. The bottom drain valve shall be of suitable diameter to drain off 90 % of the oil in ten minutes. The thermometer pocket for top oil temperature measurement by liquid thermometer shall be provided. Marshalling kiosk, boxes etc. shall be weather proof having a degree of protection to IP 54.
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Cooling tubes or radiators shall permit every part of the cooling surface to be cleaned by hand. Radiator tubes shall of good commercial grade low carbon steel of equivalent, with clear bright internal surface and shall be suitably braced to protect them from mechanical shock. Each radiator tank shall be detachable type and provided with oil isolating valves. If any temporary fittings are made in the tank for transporting purposes, instruction and illustrated drawings shall be furnished to facilitate their removal at site before commissioning. The transformer tank shall be filled with a double diaphram type of explosion relief vent at the top with equalizer pipe connection to oil conservator. Explosion relief vent should be located at the top cover and directed in such a way that on bursting of diaphram the oil forced out will not fall on any of the auxiliary equipment of the transformer and other electrical equipment in the vicinity Core and Coil The core shall be build up of high quality, low loss, scale free, non-aging, high permeability grain oriented, cold rolled silica steel lamination with excellent magnetic properties. The lamination shall be insulated from each other materials have high insulating resistance and vast inhibiting property and also capable of withstanding pressure, mechanical vibration and action of heat and oil thus reducing the possibility of sludge formation to a minimum. The core-clamping frame shall be provided with lifting eyes for the purpose of tanking and untanking the core with windings mounted there on and shall have ample strength to take full weight of the core and winding assembly. The core assembly shall be electrically connected to the transformer tank for effective core earthing. All insulating material shall be of proven design. Coil shall be so insulated that voltage stresses are minimum. The windings shall be from electrically copper conductor of high conductivity with suitable Class A insulation. The windings shall be duly sectionalized. Similar coil shall be connected by assessable joints braced (or) welded and finished smooth. Coil assembly shall be securely positioned with spacers pressed board cylinders, barriers and shall be so arranged as to allow circulation of the coil. All leads from the windings shall be suitably supported to prevent injury from vibration (or) short circuit stresses. Guide tube shall be used where practicable. The core and core assembly shall be rigidly braced and fixed on to the tank so that no shifting (or) deformation occurs during transport and installation (or) during short circuits. The end turns of the high voltage windings shall have reinforced insulation to withstand any of the voltage.
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Suryalakshmi Cotton Mills Limited On-load Tap Changer
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The On-load taps shall be provided on the primary side of the transformer to give a constant secondary voltage (on load). The transformer shall be designed to give full rated output at all taps. The winding, including the tapping arrangement, shall be designed to preserve the electromagnetic balance between HV and LV windings at all voltage ratios. The on-load tap changing switch shall be capable of being operated by a remote control panel in the substation. The operating voltage of on-load tap changing equipment and remote control shall be single phase 240 Volts AC supply (or) 415 Volts, 3 phase supply. The equipment shall be so arranged as to ensure that when a step movement (or) any other contingency would result in the movement not being completed approved means shall be provided to safe guard the transformer and its auxiliary equipment. The details shall be explained. The tap changing switch should also be capable of independent manual operation. It shall not be possible to energize electrical / remote operation when the manual operation is in progress. Suitable automatic voltage controls shall be provided to maintain the secondary voltage within the specified variations. The tap changing mechanism and switch shall be able to withstand the frequent switching that may be resulting because of the auto control. The on-load tap changer shall be designed to suit the transformer data. The tap changer shall contain the following: a) Motor drive mechanism. b) c) d) e) f) g) h) Tap position indicator Limiting devices Operation counter. Local / remote selector switch. Over current blocking device. Auto / manual selector. Direction of rotation protection.
The driving motor and electrical control of the motor drive mechanism shall be designed to operate satisfactorily with in the limits of 85 to 110 % of the rated voltage of 415 Volts, 3 phase, 50 Hz / 240 Volts, single phase, 50 Hz as the case may be and 80 to 110 % of the rated DC voltage as mentioned in the Data sheet. Local Tap Changing cubicle A local tap changer cubicle shall be provided for housing motor device mechanism for ON load tap changing at transformer. The tap changing cubicle shall be fabricated with 2.5 mm CRCA sheet
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steel complete wit all wiring, fuses, links, cubicle illumination lamps, and condensation heater with thermostatic control switch, gland plate etc. Remote tap changing cubicle (RTCC) The RTCC shall be indoor Simplex type, free standing, totally enclosed, floor mounting type with rear access door. The panel shall be fabricated from structural steel frame work enclosed on all sides and top by CRCA sheet of steel or aluminium of 2.5 mm thickness. The panel shall be complete with all wiring, fuses, links, illumination lamps with door switch, anti-condensation heater with thermostatic control switch, gland plate etc. The RTCC shall comprise the following, but not limited to: a) b) c) d) e) f) g) h) i) j) k) l) m) n) o) p) Individual / parallel selector switch. Auto / manual selector switch. Raise / lower control switch. Local supervisory selector switch. Tap position indicator (Digital type) Tap changer in local position lamp. Out of step lamp and bell. AVR under voltage lamp. Tap changer temp. lamp. AC supply failure lamp and bell. Alarm / accept / reset lamp test push button. Automatic voltage regulator and associated auxiliary relay. Auto / manual cooler system selector switch. Cooler fan selector switch. Cooler fan ON / OFF indication lamps. In addition to the above the RTCC panel shall be provided with suitable alarm scheme with bell / buzzer / horn for OLTC and cooler control circuits. Insulating oil / Oil conservator. Insulating oil shall conform to the latest revision of IS 335 properly inhibited for prevention of sludging. The necessary first filling of oil shall be supplied for the transformer. 10 % excess oil shall be also provided to take care of wastages in non-returnable containers suitable for outdoor storing. Oil conservation shall be by means of conservator tank. The conservator tank shall be mounted on a bracket fixed on to transformer tank. It shall be provided with a (prismatic gauge) sight glass for
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oil level indication. The back of the gauge shall be tinted yellow enabling clear observation of oil level. The conservator tank shall be connected with the main tank by a pipe through float gas and oil actuated buchholtz relay (having separate sets of contacts for alarm and tripping) with isolating valves at both ends. The conservator tank shall be provided wit dial type level indicator visible from ground level and fitted with low oil level alarm contacts. A weatherproof de-hydrating breather shall be provided with silica gel as the dehydrating agent. Bushing All transformer bushings shall conform to the requirements of the latest revision of IS 2011 and IS 3347. The bushing shall be located so as to avoid adequate electrical clearance between the bushings and also between bushing and ground. The bushing shall be furnished complete with connecting lugs of approved type and size. Terminals / Bus duct The terminals shall be brought out through top side bushings. The secondary terminations shall be brought out to an air insulated disconnecting chamber which inturn is connected to bus duct connection / cable connection with bottom entry forming a weather proof assembly. The bus duct shall be self supporting sheet construction housing. Suitable extension of bus shall be provided incase of cable termination. Neutral of the LV winding connected in star shall be brought out through top side wall bushing to the LV bus duct terminating box through the disconnecting chamber with an arrangement for connection to Purchasers grounding conductor for earthing the neutral. A bushing type CT of protection class PS of suitable ratio shall be provided with LV neutral before the tap off for earthing connection through suitable resistance. The details shall be furnished to the successful Bidder. Each portion of the cable end box shall be provided with 2 Nos. grounding pads suitable for connecting Purchasers aluminium flat. The LV side neutral of transformer shall be earthed through resistance. The neutral earthing resistance shall be outdoor type and will be supplied by others. Transformers manufacturer shall have to coordinate fully with the resistor supplier for making necessary provision to connect the resistor. Thermometers One set of dial type thermometers with a pointer to register the highest temperature attached for oil temperature indication and winding temperature indication shall be supplied and fitted at a suitable point on the transformer so a to be readable at a standing height from ground level. Each two
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separate sets of contact shall be provided, one for alarm and the other for circuit breaker trip on higher temperature for oil and winding. Marshalling Box A cast aluminium dust-tight marshalling box suitable for outdoor use shall be provided. The box shall contain terminal blocks meant for Purchasers control cable connection and all auxiliary devices. The marshalling box shall be provided with a blank end plate for mounting the control cable glands. The fan controls shall be located inside the marshalling box. Wiring Winding and oil temperature indicators, fans control, buchholtz relay contacts and neutral CT provided on the transformer shall be wired up to the terminal blocks inside the marshalling box. Wiring for temperature indicators, fan control, buchholtz relays, contacts shall be done by 2.5 mm, PVC insulated, copper conductor, 660 Volts voltage grade, armoured cables in steel conduit. Wires shall be identified at the termination by numbered plastic ferrules. Not more than 2 wires shall be connected to one terminal. 10 % spare terminals shall be provided. All devices and terminal blocks within the marshalling box shall be clearly identified by symbols corresponding to those used in applicable wiring diagrams. Auxiliary supply all indications, alarm and trip contacts provided shall be suitable for operation on a nominal 220 Volts + 10 % DC. Painting All steel surfaces shall be thoroughly cleaned by sand blasting or chemical agents as required to produce a smooth surface free of scale, rust and grease. All paints shall be carefully selected to withstand tropical heat, rain etc. The paint shall not scale off or crinkle or be removed by abrasion due to normal handling. Steel surface in contact with oil shall be painted with heat resistant, insulating varnish, which shall not react with the oil. After cleaning the external surfaces shall be given coat of high - quality red oxide or yellow chromate primer followed by filler coats. The transformer shall be finished with suitable epoxy paint color, which shall be indicated to the successful Bidder. Special Tools and Tackles The scope shall include a complete and unused set of all special tools and tackles, which are necessary or convenient for erection, commissioning and maintenance and overhauling of any of the equipment provided under this specification. The tools shall be dispatched in separate containers marked with the name of the equipment for which they are intended.
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Suryalakshmi Cotton Mills Limited Spare parts
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The scope shall include item-wise prices of a list of spare parts recommended for 3 years trouble free operation. Noise Levels Cores and tanks shall be properly designed and constructed in order to reduce objectionable noise to a minimum level. Tank rigidity and panel size shall be designed in such a way to reduce the possibility of resonating vibrations to a minimum. Cores shall be designed to avoid the flow of magnetic flux across laminations or at right angles to the grain orientation to reduce the source of objectionable high frequency noise. Efficiency An efficiency of the order of 99 % is expected for the transformer. Should there be a reduction in the above value, Vendor shall justify why the efficiency cannot be improved any further. Inspection Vendor shall provide the Purchaser with advance notification of certain shop inspections as outlined in Purchase Order. The Purchasers representative shall have entry after prior notification by the Purchaser to all Vendor and sub vendor plants where work upon or testing of the equipment is in progress. The Vendor shall keep the following data available for examination by the Purchaser or his representative upon request. a) b) c) d) All specified certification of materials. Purchase specifications for all items. Test data to verify that the requirements of the specifications are being met. Results of quality assurance tests conducted to control deviations from standard requirements at various stages of manufacture, say at winding, core assembly, erection, tanking, fabrication etc. Tests Routine Test During manufacture and on completion, transformer shall be subjected to the routine test as laid down in IS 2026 1977 as amended up to date. The following tests, in addition, shall be performed for each transformer.
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1. After fabrication, each tank fitted with all valves, covers etc. shall be tested for leaks with normal head of liquid plus 0.0352 kg / sq. cm for a period of 12 hours. If any leak occurs, the test shall be conducted again after all leaks have been repaired. 2. The tank shall be subjected to full vacuum for 12 hours. Type Tests Heat run tests shall be performed on the transformer in accordance with relevant standards. Impulse test certificates shall be furnished for similar transformer of same rating. Optional Tests Sound level, partial discharge measurement etc. shall be conducted if required in Purchasers formal order. Six copies of test certificates shall be furnished to the Purchaser for prior approval before dispatch of the equipment for the works. The reports shall furnish complete identification of date including serial number of the transformer. SWITCHYARD EQUIPMENT Technical Requirement The scope of this specification includes: a) Design, manufacture, supply at site, transport from place of storage to erection site, erection, testing and commissioning of 220 kV Switchyard equipment. b) Preparation of all required layout drawings including Switchyard Plan and sections, cable tray layout drawings, lighting layout drawings, earthing layout drawings including earthing mat with calculations of touch and step potentials, architectural drawings of control and relay building etc. Vendor shall also furnish drawings for foundations with supporting calculations, calculations for cantilever strength, lightning protection design etc., for approval. c) Cabling between equipment is included in this specification. Supply and erection of lighting, complete earthing and lightning protection system is also included in this specification. d) All cabling between distribution panel and switchyard equipment, including supply of cables is included in the scope of supply. Supply of 500 terminal Marshalling box to facilitate
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marshalling of cables. Erection, cabling and commissioning of same is part of Vendors scope. Circuit Breaker Circuit breaker shall be electrically interlocked with the associated motor operated Isolators in accordance with the Purchasers switchyard safety interlocking scheme. Any special accessories required for satisfactory operation of the switchyard scheme shall be included in the scope of supply and no claims whatsoever for extra charges on these grounds will be accepted. Circuit breaker shall be provided with two trip coils per pole and tripping shall be suitable for pre-close and post close supervision. Trip coil 2 shall not be connected from trip coil 1 terminal. It shall be wired from other circuits, so that even a loose connection at one coil shall not affect the operation of the other trip coil. Breaker shall be SF6 type and single pressure puffer type only. Each pole shall be provided with independent SF6 pressure monitoring device with minimum two contacts at three independent levels alarm, close lockout and trip lockout. Also independent pressure gauges shall be provided for each pole of the circuit breaker. Necessary steel structures, foundation plates and bolts for mounting the circuit breaker shall be included in the scope of supply. Vendor shall furnish design calculations for the structure and same is subject to Purchasers approval. Tubular structures shall be used for 220 kV breaker. The circuit breaker, along with start-up and essential spares meet all requirements. Vendor shall furnish list of recommended spares required for three years of trouble free operation and quote for the same along with a detailed list of such spares, with item wise prices. Tests Type tests: Vendor shall furnish type test certificates for tests carried out on identical circuit breakers as per latest issue of IEC. Bidders shall also furnish prices for conducting type tests for each breaker as per IEC and same shall be carried out if so desired by Purchaser. Routine tests: The Vendor shall carry out the following site tests: a) Voltage test on control and auxiliary circuits.
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Suryalakshmi Cotton Mills Limited b) Measurement of resistance of the main circuit. c) Mechanical operation tests. d) Measurement of capacitance and tan-delta.
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e) Speed curves with the help of a suitable operation analyzer to determine the breaker contact movement during opening, closing, auto-re closing and trip operation under normal as well as limiting operating conditions. The tests shall show the speed of contacts at various stages of operation, travel of contacts, opening time, closing time, short time between separation and meeting of contacts at break - make operation etc. Specific requirement Vendor shall provide marshalling kiosk for the breaker. Each pole shall have its own local marshalling kiosk and in addition to this a common marshalling kiosk shall be provided. The Vendor will provide the complete terminal diagrams. In addition to, 10 NO + 10 NC contacts shall provide for Purchasers use. Vendor shall provide 2 NO contacts for annunciation of the following: a) b) c) d) e) f) g) Breaker operated Trip coil 1 unhealthy Trip coil 2 unhealthy DC supply fail SF6 gas pressure low SF6 gas pressure low alarm close lockout SF6 gas pressure very low trip lockout
Adequate stud type terminals for the breaker contacts, power supply etc. plus 20% extra terminals shall be provided in each kiosk. The marshalling kiosk and junction boxes shall be with IP 65 degree of protection. Isolators Isolators shall be of the centre break type, suitable for horizontal upright type of mounting. Isolators shall be motor operated. However, it shall be possible to operate them manually in the event of failure of power supply. Earth switch shall be of manually operated type. Isolators shall be interlocked with the associated circuit breaker. Bolt type interlock and any special accessories required on the isolator side for satisfactory operation of scheme shall be included in the scope. The design of auxiliary switches for the isolators shall be such that signaling of closed position shall not take place until the contact system has reached such a position that the rated current and short term currents can be carried safely, signaling of open position shall not take place unless the
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contact system has reached a position of at least 80% of the clear distance of the isolating distance. Isolators shall be provided with 6 NO + 6 NC normal and 2 NO + 2 NC make before break contacts exclusively for the use in the interlock circuit. Isolator and the associated earthing switch shall be electrically interlocked. For the purpose of interlocking 6 NO + 6 NC auxiliary contacts shall be provided for main blades as well as earth switch. Castle key interlock shall be provided for mechanically interlocking the isolator with the associated earth switch. This shall be for manual operation of the isolator. Isolators shall be supplied complete with all associated equipment. Vendor shall furnish all design calculations for the structures and the same is subject to Purchasers approval. Item wise list of recommended spares for three years of trouble free operation, with cost, shall be furnished. The foundation plates and bolts and necessary lattice / tubular steel structure for mounting the isolators shall also be included in the scope. Tests Type test Type test certificates for tests carried out on identical isolators as per latest issue of IEC 60129, shall be furnished. In addition, type test certificates for insulators as per IEC 60068 shall be furnished. Bidder shall also indicate costs for carrying each type test and same shall be carried out if so desired be the Purchaser. Routine test All routine tests as per the latest edition of IEC 60129 shall be carried out and witnessed by the Purchaser / his authorized representative. Lightning Arrester Lightning arrester shall be self supporting and shall be suitable for base mounting on support structure. Surge monitors shall be inserted between the lightning arrester and the earth and shall be provided with a suitable insulating base. The lightning arresters, along with start up and essential spares shall meet all requirements. Item wise list with cost of each of recommended spares for three years of trouble free operation shall be furnished.
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The foundation plates and bolts and the steel structures for mounting the lightning arresters shall also be included in the scope. The Vendor shall furnish the design calculations for the structures for approval. Tests Type tests Type test certificates for tests carried out on identical lightning arresters as per IEC document shall be furnished. Bidders shall also indicate prices for each type test to be carried out with list and shall carry out the same if so desired by Purchaser. Routine tests The Vendor shall carry out all routine tests as per IS and IEC and witnessed by Purchaser / his authorized representative. CVT AND CT The capacitance voltage transformers and current transformers shall have cantilever strength of 600 kgf and shall be complete with terminal connectors as required. The rated voltage factor of CVT shall be 1.2 times of normal voltage continuous and 1.9 times of continuous rating for 30 seconds. The point in CVTs for carrying out tan delta measurement shall be brought out and made accessible at a convenient place outside the CVTs. The capacitance voltage transformers along with start up and essential spares shall meet all requirements. The foundation plates, bolts and the necessary steel structures for mounting the CVTs and CTs are also to be included in the scope of supply. Coupling device for connection to PLCC is also included in the scope of supply. Tests Type tests Type test certificates for type tests conducted on similar current and capacitance voltage transformer as per IS 2705 and IS 3156 respectively shall be furnished. A list of type tests along with prices for conducting each shall also be furnished and type tests, if so desired by Purchaser shall be carried out. Routine tests The Vendor shall carry out all routine tests as listed in IS 2705 (for CT) and IS 3156 (for CVT) and witnessed by Purchaser / his authorized representative.
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Suryalakshmi Cotton Mills Limited Conductor
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Tubular aluminium bus shall be used for the 220 kV switchyard. Moose conductor shall be used for other connections Insulators String insulators shall be provided for bus and lines. Insulators shall be double / single strain as desired from design calculations and shall be accommodated by the Vendor. All routine tests shall be carried out as per relevant IS. Type test charges shall be furnished with a list and type tests shall be carried out if so desired by Purchaser. Clamps and Connectors Tee clamps shall be suitable for connecting single Moose ACSR to single Moose ACSR conductors. Tee clamps shall also be suitable for connecting shield wire to shield wire. Following clamps shall be supplied. Parallel groove clamp. Rigid bus post clamp. Bolted type strain clamp for GS shield wire. Clamp / lug for connecting shield wire to tower earth pad.
Spacer with 250 mm sub conductor spacing and 300 mm sub conductor spacing suitable for Moose conductor shall be included in the scope of supply. Any other type of clamps or connectors required for switchyard shall also be included in the scope of supply. Bidder shall furnish unit prices for the clamps and connectors. Design and performance The switchyard hardware and its accessories shall be designed to meet all requirements specified in this specification viewed collectively. The Bidder shall submit the design and performance data of the equipment offered by filling up the information called for in Data sheet. Bidder shall not leave blank against any item of Data sheet. The cantilever strength of post insulators shall not be less than 600 kg. The equipment shall be designed to withstand short circuit forces as specified in Datasheet. In addition, the equipment shall also be designed to withstand wind pressure. Post insulators shall be of Polycone or solid core type. Stack type insulators are not acceptable. All junction boxes, marshalling kiosks, terminal boxes of equipment etc. shall be fiberglass reinforced poly carbonate material with IP 65 degree protection.
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Layout and performance requirements Vendor shall prepare and submit the plan and sections for 132 kV Switchyard, Control and Relay room, architectural drawings of control and relay room, lighting layouts, cable layouts, earthing layouts, cable sizing calculations, cable schedule and interconnection schedules with all supporting calculations wherever applicable and same are subject to approval by Purchaser. Vendor shall also submit drawings for cable trenches, cable tray layouts, earthing and lightning protection layouts, lighting layouts etc. and all drawings are subject to approval by Purchaser prior to commencement of construction / installation. Hardware material and insulators shall be suitable for hot line washing and maintenance work and suitable measures shall be adopted in design and manufacture and shall be clearly brought out in the bid. Guarantee and Delivery The Bidder shall guarantee that all material, workmanship and performance of equipment and installation shall meet the requirements of this specification and all accompanying standards indicated therein either explicity or implied.
SPECIFICATION FOR 11 kV SWITCH GEAR PANEL Configuration The panels are to control the HT supply to incoming / outgoing feeders and transformers. The panel shall comprise the following. a) b) c) d) e) f) g) 1 No. Incoming Panel from Generator Transformer 2 Nos. Outgoing Panels for Distribution Transformers 3 Nos. for boiler feed pump drives 1 No. for denim plant supply 1 Nos. for switchyard supply 2 nos. spare feeders Draw out type bus PT
11 kV Switch Gear Panel shall be extensible on either sides and fully compartmentalized with separate chambers for breakers, bus bars, current and voltage transformers, relays and Instruments and cable chambers.
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Each cubicle shall be provided with pressure Relief Flap at Top. Circuit breakers shall be horizontal isolated and horizontal draw out type. Circuit breakers shall be suitable for Motor/ Manual Spring charging operation. HT switchgear shall be housed in a separate vertical section for each circuit. 11 kV Switch Gear panel shall be provided with the following: Panel space heater controlled by thermostat with on / off switch and automatically cut in and cut out the heater so as to maintain the interior temperature 5 C above ambient. Cubicle illumination lamp with on / off switch. 2.1 250 V AC, 15 A Plug & socket Current Transformers shall be Epoxy Resin Cast fixed type. Potential transformers are epoxy resin as draw out type. Earth Truck shall be provided with Audio Visual Alarm. CONSTRUCTION FEATURES The metal clad indoor panel shall be made from CRCA sheet steel with 2mm thick for panels & doors and 2.5mm thick for load bearing members folded and braced as necessary to provide a rigid support for all components and shall be compartmentalized with internal metal partitioning/insulated material (epoxy reinforced fibre glass) to provide chambers for Circuit breaker compartment Bus bar compartment CT and cable compartment LT chamber for fixing of necessary instruments, PT withdrawable type along with the truck.
metering and protective equipment
Switchgear should have following additional features: Switchgear shall be tested for internal Arc at 25 kA for 0.1 sec as per IEC 298 All interrupters shall be mounted on a common phase segregated epoxy body for For the smooth withdrawal and fool proof alignment panel should have minimum At rear of the panel perspective poly-carbonate cover should be provided to Annexure AA better insulation and easy replacement. three point guide with two points at bottom and a roller bearing at top inside the panel. inspect cable connections without opening the cover.
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Suryalakshmi Cotton Mills Limited line. BUS BARS Main Bus bars: 1600 A TP Aluminum with PVC heat shrinkable sleeves Current density: 1.4 A / mm2
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Earthing truck shall have PT and Audio-Visual alarm preventing earthing on LIVE
Epoxy cast resin insulator supports which are of non-carbonizing material resistant Supports adequately sized and braced to withstand the short circuit level without Bus bar meeting surface to be tinned and high tensile bolt and spring washers Bus bars housed in a separate chamber, accessible for inspection, only with
to acids, alkalis and non hygroscopic. deformation. provided at all bus bar joints. special tools. EARTHING All non-conducting metallic portions of the equipment connected to the body. Two earth terminals shall be provided on the panel at suitable locations at both Each panel body/frame work to be provided with two distinct and separate Draw out switching units shall have plug in type earthing contact. The earth bus bar on the panel shall be 50 x 6 mm copper run through out the
ends for connection to external earthing flat. earth connections.
full length of the switch board at the bottom. CABLE TERMINATION Entry is from top to receive segregated bus duct for incomer. Cable entry is from bottom through cable trench for outgoing with suitable arrangements to receive XLPE cable with supports. Ample space for connection of cables shall be provided in the switchboard to avoid sharp bends and aiding easy connections. The cable termination arrangement shall be of adequate size and design to receive XLPE cables. Proper cable clamping arrangements will be provided. Detachable gland plates of non-magnetic metal and of adequate thickness shall be provided for the cable entry into the panel. Suitable shrouds shall be provided to prevent accidental contact with live outgoing terminations of other feeders while carrying out maintenance on one feeder.
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Suryalakshmi Cotton Mills Limited INTERNAL WIRING
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Internal wiring and inter-panel wiring for all circuits shall be carried out with 1100/660V Grade Single core, multi strand, PVC insulated copper conductor wire for. a) CT / PT circuits - 2.5 mm2 b) Other circuits -1.5 mm2 The wiring shall be neatly bunched adequately supported and properly routed and terminated in the respective terminals with suitable lugs. There shall not be more than two wires connected at a terminal. Wires shall be identified by numbered ferrules at each end. The ferrules shall be of ring type and non-deteriorating material. TERMINAL BLOCKS Terminal blocks for the LT connections shall be of 660V grade and of adequate current rating. The insulating barriers shall be provided between adjacent terminals. Provision shall be made for label inscription of terminal block. Cables shall never be terminated directly on components. Provision shall be made for CT terminals shorting links, remote on / off push button, remote on/off indication and remote ammeter. 20% spare terminals shall be provided on each terminal block.
LABELS Name plates of approved design shall be made out of anodized aluminum provided to represent circuit designation for each feeder firmly secured with fasteners. PAINTING All metal surfaces shall be chemically cleaned, degreased and pickled in acid to produce a smooth clean surface, free of scale, grease and rust. After cleaning, phosphating and passivation treatment, the surface shall be given two coats of Zinc rich epoxy primer and baked in the oven. After primer it shall be Electrolstatic Powder coated to not less than 50 microns thickness to shade color as decided by Engineer.
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SAFETY INTERLOCKS The following standard safety interlocks shall be provided. The breaker cannot be moved from test to service unless the breaker compartment door is closed. The breaker cannot be closed in between test and service positions and it can be closed only when it is in one of the three positions or when it is fully out of the panel. The breaker compartment door cannot be opened when the breaker is in service position or in between service and test position. The circuit breaker trolley shall be provided with a heavy duty self aligning earth contact which shall make before and break after the main isolating contacts during insertion into and withdrawal from the service position of the breaker. Even in the isolated position positive earthing contact shall exist. Circuit breakers of identical rating shall be interchangeable. TESTS The Circuit Breakers shall be tested in manufacturers premises as per the routine test of relevant IS / BS specification and relevant test certificate should be furnished to the purchaser. Manufacturers should possess CPRI certificates for type tests on CBs. Internal test to be carried out as per I.E.C. TECHNICAL SPECIFICATION FOR LT PANELS. DESIGN SPECIFICATION Voltage ratio Location Feeder Ratings No. of feeders Fault level of system Voltage fluctuation Frequency fluctuation Combined fluctuation Type of construction SCOPE OF WORK 2 Nos. Power Control Centers comprising of 1 x 4000 Amps incoming feeder and necessary outgoing feeders as per SLD. 12 Nos. Motor Control Centers, each comprising of one number incoming feeder and necessary outgoing feeders as per SLD. 415 V Indoor As per SLD As per SLD 50 KA for 1 sec 10 % 5% 10 % Non-draw out
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Suryalakshmi Cotton Mills Limited Two coats of shop painting for all items Commissioning spares Special tools and tackles 2 years operation spares Specification For LT Switch Board:
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L.T. Switch board shall be in the cubicle constructions, totally compartmentalized for indoor installation having extensible Bus Bars and Bus Bars chamber and suitable for 3 phase, 4 wire, 500 V, 50 Hz, A.C. supply with short circuit rating of 50 kA @ 500 V and working at an average atmospheric (Inside Room) Ambient temperature of 40deg.C complete with incoming and outgoing feed controls, relays, tripping devices, interlocks, set of TPN Bus Bars, Metering etc and manufacturing details as specified hereafter and as shown on drawings, all internally connected switchgear and wired for relays, meters H.R.C.fuses etc Bus bars and jumpers to switch above 100 Amps, shall be provided with heat shrinking sleeves and switches below 100 Amps shall be connected by insulated copper wires duly lugged. Colour code shall be observed while shrinking sleeves and while connecting insulated copper wire jumpers to smaller switches Sleeved jumpers shall be brought out from outgoing switches at rear side of the panel in separate compartment for connecting / disconnecting cables without disturbing any other switches or cables. Minimum clearance of any live part, bus bar etc, to sheet steel or between conductors shall not be less than 40 mm Edges of meter or similar items shall be minimum 40 mm. clear of the panel compartments openings. The panel has to be fully compartmentalized i.e. i) ii) Separate compartment for each switch Separate compartment for each connection
iii) Separate metering compartment which can also accommodate relays iv) Lower compartment in incomer cubicle can be used to accommodate relays Micro contact selector switches for Ammeter or voltmeter shall not be used. These shall be robust in construction and of L&T or similar reputed make. Sufficient louvers, protected by brass wire mesh, shall be provided in the panel exterior and even in the compartment member to provide ventilation.
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The shipping width shall not be more than 2.5 meters and door width shall not be more than 750 mm at rear and front of the panels. The cubicle shall have sufficient number of detachable lifting hooks (12mm. MS Round) at top. The compartment size and placement of switches shall be such that, handle of any switch whether in ON or OFF position shall not prevent operation of adjacent switchgear / compartment shutter All switches shall be AC-23-A duty and suitable for cubicle panels. These shall have interlocks and defeat arrangement. The door gasket shall have rectangular gasket section and shall be fixed to the shutter Wiring for metering and relays and indicator circuit shall be with single core, stranded, flexible; PVC insulated copper wires as follows: Potential wiring: 1.5 sq mm Copper Current circuits: 2.5 sq mm Copper Incomer and incomer cable / cables shall have independent column in the panel i.e. outgoing and incoming cables shall have clearly independent compartments. The insulating material shall be Non-Hygroscopic. A 100 watts heater, for use in panel board, shall be provided in each switchgear column with controlling switch, HRC fuse and thermostatic cut-off. All feeders, indicating lamps and fuses for various control circuits, trip circuits, metering and luminous indication shall be provided with approved type and style of nomenclature labels. The feeder legend plates should indicate feeder number, feeder motor rating in kW and feeder name. IS - 4237, IS - 13497, IS - 2147 shall be applicable. Lower 300 mm of cubicles shall have no mountings. The outside of panel shall be painted with Dark admiral Gray Paint (shade no.632 of IS5) and inside of the panel shall be painted in off-white colour. Specially applicable to PCC: All the breakers shall be of utilization category B as per IS 13497. Rated operational voltage of the breaker shall be 500V AC, 50 Hz. The breaker current ratings indicated are the de-rated ratings for continuous operation under the ambient conditions inside the cubicles. The panel builder shall indicate the following in the offer:
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Ambient air temperature expected inside the cubicle with supporting calculations or the data of tests carried out by breaker manufacturer. The temperature for the main current path breaker lower and upper terminals and connected bus bars at these junctions. The material for the main current carrying conductors intend to be used. The specific resistance shall not be higher than the following values: The specific resistance of aluminium bus bar @ 20C - 2.873 ohm / cm3 The specific resistance of copper bus bar @ 30C - 1.8053 ohm / cm3 The bending radius shall not be less than the following: For Aluminium For Copper 2 x Bus Thickness 0.5 X Bus Thicknesses to 1.5 X Bus Thickness Depending upon strength of the material Arrangement to disable electrical operation when manual mode is selected Sheet steel for panel cubicles Load bearing members Gland plates Partitions Shutters ----2 mm thick sheet 3 mm thick sheet 1.6 mm thick sheet 1.6 mm thick sheet
Access shutters for bus compartments and metering & relay compartments shall be hinged on one side and other side shall have self-centering bolts (Operable by screw driver) retained in doors by spring loading washers and cotter pins. Shutter width should not exceed 600 mm For the main breakers there shall be a separate compartment for us jumper from HBB to lower terminals of the breaker. The jumper from bus duct from transformer shall be behind the breaker for facilitating easy maintenance. The first support to bus jumpers after any ACB terminal shall not exceed 250 mm from the breaker terminal center. There shall be no offsetting of buses within this length. No CTs shall be mounted within this 250 mm distance. Protection beside microprocessor based releases on the breakers. Main Breaker:
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1 no. Restricted Earth fault relay (CAG-14 of EE or equivalent with stabilizing resistor complete with 4 nos 2000 / 1 Amp CT, class PS having suitable burden. The CT on neutral will also be placed in the breaker cubicle and neutral grounding will be done at the cubicle only instead of at transformer end. 3 sets of alarm and trip relays type VAA of EE or similar with common hooter for 1 set of alarm and trip by buchholz relay mounted on transformer 1 set of alarm and trip by buchholz relay mounted on transformer for actuation by oil temperature gauge contacts. 1 set of alarm and trip by buchholz relay mounted on transformer for actuation by winding temperature gauge contact. 1 no Inter tripping relay for tripping other breaker (i.e. HV breaker) in case of occurrence of above two types of fault. Outgoing Breakers: No additional protection besides the microprocessor based releases. Metering for all breakers as per SLD. The meters shall be with LED indication flush 96 x 96 mm square flush. The main incoming breaker shall have single phase P.F.meter as above. Luminous Indication by LEDs - 25 mm diameter. The contact resistances will be measured after assembly and these shall be within +5% of the value given by us when clearing the detailed fabrication drawing. For an example for each joint carrying 4000A, the contact resistance and relevant milli volt drop shall be as below: Contact resistance DC Contact resistance AC at 50Hz Milli Volts drop DC Milli Volts drop AC ----1.25 2.44 5 9.78
The cubicle dimensions for breaker part and bus bars shall be as per recommendations of the breaker manufacturer. The bus bars chamber / Trunking shall have sectional area, minimum twenty time that of the total sectional area of phase bus bars The bus bars for PCC shall have phase barriers (SMC sheets or better) through out and shall not be provided with insulating sleeves. These shall have painted colour bands, which shall withstand a temperature of 160C.
SPECIFICATION FOR XLPE CABLE
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Scope This specification covers requirements for the supply of XLPE cables and cable accessories for High Voltage system. Standards The cable shall comply with the latest edition of the following standards. IS:7098 (PART II) - Cross linked Polyethylene insulated PVC sheathed cables, Part II for 3.3 kV up to and including 33 kV. IS:5831 PVC insulation and sheath of electric cables. IS:1753 Aluminium, conductors for insulated cables. IEC:502 Extruded solid electric insulated power cables for rated voltages from 1 kV up to 30 kV. General Construction The cables shall be brand new and in good condition. These shall be suitable for laying in trays, trenches, ducts, conduits and underground buried installation with uncontrolled backfill and possibility of flooding by water. Extra PVC / Rubber and caps for each XLPE cable size shall be supplied. The terminating and straight through joint kits for the cables shall be suitable for the type of cables offered and for storage without deterioration up to 50 0C ambient temperature. Construction Power cables for 11 kV system shall be with Aluminium conductor, XLPE insulated, screened, sheathed, armoured and overall PVC sheathed. The construction of the conductors shall be stranded and compacted circular for all cables. The cables shall be provided with both conductor screening and insulation screening. The conductors shall be provided with non-metallic extruded semi-conducting shielding. The core insulation shall be with cross linked polyethylene unfilled insulating compound. It shall be free from void and shall withstand all mechanical and thermal stresses under steady state and transient operating conditions. The insulation shielding consist of non-metallic extruded semi-conducting compound in combination with non-magnetic metallic screening of copper. The insulation screen shall be strippable without application of heat. The copper screen shall be capable of carrying the single line to ground fault current for a duration of one second. The screen XLPE insulation and insulation screen shall all be extruded in one operation by Triple Extrusion process to ensure perfect bonding between the layers.
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The core identification shall be colored strips or by printed numerals. The inner sheath shall be applied over the laid up cores by extrusion and shall conform to the requirements of Type ST 2 compound of IS: 5831. The extruded inner sheath shall be of uniform thickness of size not less than 0.7 mm for all sizes of cables. For multi core cables, the armouring shall be by galvanized steel strips. Armouring for single core cables shall be with hard-down aluminium round wire of 2.5 mm diameter. The outer sheath for the cables shall be supplied by extrusion over the armouring and shall be of PVC compound confirming to the requirements of Type ST 2 compound of IS: 5831. To protect cable against rodent and termite attack, suitable chemicals shall be added into the PVC compound of the outer sheath. Cable accessories The termination and straight through joint kits for use on high voltage system shall be suitable for the type of cables offered as per this specification. The termination and joints shall be supplied in kit form. The kit shall include all insulating and sealing materials apart from conductor fitting and consumable items. An installation instruction shall also be included in each kit. Owner may consider makes of jointing kits, other than specified items,, if type test certificates accompany the offer. Termination Kits The terminating kits shall be suitable for termination of the cable to an indoor switch gear or to a weather proof cable box of a outdoor mounted transformer / motor. The terminating kits shall preferably be one of the following types or equivalent: Heat shrinkable sleeve type of M/s Raychem. TAPEX of M-seal make using non-linear resistance material for stress grading. PUSH-ON type of CCI make using factory moulded silicone rubber insulators. Cold shrinkable type 3 M Birla. For outdoor terminations, whether shields / sealing ends and any other accessories required shall also form part of the kit. Jointing Kits The straight through jointing kits shall be suitable for under ground buried installation with uncontrolled backfill and possibility of flooding by water. The jointing kits shall be one of the following types.
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TAPEX of M-seal make. TROPOLINK type of CCI make. Heat shrinkable sleeve type of M/s Raychem. Cold shrinkable type 3 M Birla. Testing and Inspection The cables shall be tested and examine at the manufacturers works. All the materials employed in the manufacture of the cable shall be subjected, both before and after manufacture of the cable, to examination, testing and approval by Owner / Consultant Manufacturer shall furnish all necessary information concerning the supply to Owners Inspectors. The Inspector shall have free access to the manufactures works for the purpose of inspecting the process of manufacture in all its stages and he will have the power to reject any wire or other materials which appears to him to be of unsuitable description or of unsatisfactory quality. Cables After completion of manufacture of cables and prior to despatch, cables shall be subjected to type, routine, acceptance and special testes. Type test: The following shall constitute type tests: Tensile test Wrapping test Conductor resistance test Test for armour wires Test for thickness of insulation and sheath Physical tests for insulation Physical tests for PVC sheath, Fire resistance Cold impact Bleeding and blooming
Particle discharge test Bending test Heating cycle test High voltage test
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Suryalakshmi Cotton Mills Limited Routine test Conductor resistance test Partial discharge test High voltage test Acceptance test Tensile test (for aluminium) Wrapping test (for aluminium) Conductor resistance test Test for thickness of insulation and sheath Partial discharge test High voltage test Cable accessories
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Type tests shall have to be carried out to prove the general qualities and design of a given type of termination / jointing system. The type test shall be conforming to the latest IEC 502-2, 466 specifications. The type test certificates shall be submitted along with the offer. Consultant / Owner reserves the right to witness all type tests with sufficient advance notice from Vendor. The test reports for all cables shall be got approved from the Engineer before despatch of the cables. The inner and outer sheath of XLPE cables shall be subjected to all the tests applicable for PVC cables. The test requirements for insulation and sheath of PVC cables shall be as per latest revision of IS:5831. Packing and Marking Cable shall be dispatched in wooden drum of suitable barrel diameter, securely battened, with the take-off end fully protected against mechanical damage. The wood used for construction of the drum shall be properly seasoned, sound and free from defects. Wood preservatives shall be applied to the entire drum. On the flange of the drum, necessary information such as manufacturers name, type, size, voltage grade of cable, length of cable in meters, drum No., cable code, ISI Certification mark, gross weight etc. shall be printed. An arrow shall be printed on the drum with suitable instruction to show the direction of rotation of the drum. Information required with offer
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Catalogue and brochure giving technical and physical details of the cable like current rating, derating factors etc. Type test certificates. Shelf life of cable accessories for the ambient temperature specified in the data sheet attached. INSTRUMENTATION SYSTEM: The instrumentation and control system for the boiler and turbo generator will be electronic and pneumatic final control elements with state of the art Disttributed control system for overall plant control and datalogging. The entire power plant will be controlled from a central control room which houses the DCS panels besides the various TG panels. The boiler controls include but not limited to the following loops: Combustion control with master pressure control 3 element drum level control Superheater temperature control Furnace draft control Deaerator pressure control Deaerator level control Fluidized bed control The turbo generator controls will include: Hot-well level control Gland steam pressure control Pressure and temperature control of aux. PRDS
The various field instruments such as transmitters, switches are connected to the DCS which process the control parameters and send necessary signals to the field for proper control and logic and sequential operation. In order to control the speed of the turbine under fluctuating load conditions, a suitable speed control mechanism viz. governor control will b provided. The speed governing system will limit the over speeding of the turbine on loss of full load so as to avoid tripping by the emergency over speed device. The following features will be incorporated in the governing system:
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Turbine speed control during isolated mode of operation Output power control during parallel mode of operation Process parameter control for limiting the boiler steam pressure and generator Turbine over power limitation condition Turbine over speed limitation condition Turbine emergency stops.
high voltage conditions
The DCS will also oversee the vibration monitoring system at drive and non-drive ends along with axial shift measurement. The bearing and winding temperature elements provided for the turbine and generator will also be connected to the DCS supervisory control. Necessary electrical transducers will be provided to monitor the bus voltage, current, frequency, power and energy as part of electrical distribution system. These transducers will also be connected to the plant DCS. A schematic of the control architecture proposed in the plant is shown in drawing no. 20-SMSL-IE001 (R1). The relevant rules and regulations applicable to the implementation, operation of the facility is as listed below:
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TECHNICAL DATA:
1. BOILER DESIGN BASIS: 1. Installation 2. Steam boiler (Kg/hr.) 3. Steam pressure (Kg/cm2a) 4. Steam temperature (Deg.C) 5. Superheater temperature control range 6. Boiler outlet Flue gas temp. (Deg.C) 7. Water temp. at inlet of boiler (Deg. C) 8. Main Fuel for MCR generation 9. Start up fuel 10. Fuel (GCV) Outdoor 120000 112 515 50 100 % 140 230 100% Coal Coal Coal with GCV options as follows 4000 kcal/kg 3400 Kcal/kg Coal < 6 mm 83 +/- 1.0 % 30 60 30 45 50 415 + 10% 220 + 10% 50 7 (Oil and Moisture free)
11. Fuel sizing 12. Efficiency - Coal 13. Ambient temp. (Deg. C) 14. Relative Humidity (%) 15. Ambient temp. (Deg. C) - Efficiency - Insulation - Electrical 16. Electrical Data - LT Volt (V) - Control Volt (V) - Frequency (HZ) 17. Compressed Air pressure (Kg/cm2)
APPLICABLE CODE: IBR 1950 WITH IT'S LATEST UP TO DATE AMENDEMENT ASME PTC 4.1 FOR EFFICIENCY CALCULATION BY INDIRECT
2. Turbine
STG PERFORMANCE PARAMETERS : : : Multistage Impulse bleed cum condensing 6200 RPM 1500 RPM
Turbine speed Gear box output speed
Performance
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Parameter Turbine Inlet Steam Pressure (ata) Turbine Inlet Steam Temperature (Deg C) Turbine Inlet Steam Flow Maximum (kg/hr) Extraction Pressures (ata) Extraction flows (kg/hr) Extraction Temperatures (Deg C) Exhaust Pressure maximum (ata) Exhaust flow maximum (kg/hr) Electrical Output at Alternator terminals (kWe, 11 kV, 50 Hz) Turbine: Type Casing split Rotor type disks. Shaft seal Rated output power Bearings: - Journal Bearings Type Thrust Bearings Type : : Labyrinth 25000 kWe
108 510 105900 1.65 / 8,4 / 31.7 7.68 / 10 / 11.4 114 / 214 / 357 0.20 76400 25000
: : :
Multistage, impulse, multi stage axial flow bleed cum condensing Horizontal Solidly forged & machined rotor with integral
: :
Tilting pad, forced lubricated Multi segment tilting pad
Governing System: - Speed Governor: Type Model no. / Manu. Name: Inputs Control range Control accuracy Speed regulation Power supply Maximum speed rise NEMA class - Overspeed Governor: Type Tripping speed
: : : : : : : : : :
Electro Hydraulic
505 / Woodward 0 to 110% of rated speed +/- 2 RPM (steady state speed) 4% as droop 110 V DC Less than overspeed setting D Mechanical eccentric trip weight & electric Signal from speed governor 114% of rated speed (Electric) 115% +/- 1% of rated speed (Mechanical)
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Governing oil filter: Element type Oil flow Capacity Oil filtration Capacity
: : :
Micro-felt 35 Liters/minute 10 15 microns
D E F
Governing Valve: Type Emergency Stop Valve: Type Limit switch : : Oil pressure operated type with steam strainer For indication of closed position for inlet steam : bar lifted and Multi valve type
Reduction Gear: : : : : : : Horizontal Single/Double helical, Single reduction AGMA 1.5 6200/1500 RPM 5.5 90 dB(A) at 1.0m Air breather
Gear Box: Type Safety Factor Input /Output speed Ratio Noise Accessory Bearings: H Journal Bearings Type Thrust Bearings Type Couplings: Coupling bet. turbine and gear Coupling bet. gear and gen. Oil system: - Oil: Type of lubrication Oil type Retention time Material of oil reservoir Material of oil piping from Pumps to filters Material of oil piping from Filters to bearings
: : : :
Cylindrical offset Cylindrical offset Diaphragm type Oil contained gear type
: : : : : :
Forced lubrication Servo prime ISO VG-46 5 minutes Carbon steel Carbon steel SS
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Suryalakshmi Cotton Mills Limited Material of oil piping from Bearings to reservoir Main Lube oil pump: Type Operating speed Capacity Driver Discharge pressure Auxiliary Lube oil pump: Type Operating speed Capacity Driver Motor rating Discharge pressure Emergency oil pump: Type Operating speed Capacity Driver Motor rating Discharge pressure Oil cooler: Design code Type Mounting Lube oil filter: Type Mounting Control oil filter: Type Mounting : : : : : : : : : DC motor 11 kW, 110 V 9.0 Kg/cm2g HEI / TEMA Shell and tube fixed tube sheet type Saddle support Gear (positive displacement) 1500 rpm : : : : : : Gear (positive displacement) 1500 rpm : : : : : Gear (positive displacement) 1500 rpm : Carbon steel
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1.1 times of required lube oil flow as minimum AC motor 9.0 Kg/cm2g
1.1 times of required lube oil flow as minimum AC motor 37 kw, 415 V, 3 phase 9.0 Kg/cm2g
: :
Duplex with change over cock Foot
: :
Duplex with change over cock Foot
Oil pressure adjusting valve: Type : Setting pressure
Self acting type
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Suryalakshmi Cotton Mills Limited Lube oil Control oil I ACCESSORIES Turning gear: Type Driver Gland vent condenser: Design code Type Accessory Driver for exhaust fan Motor rating NRV in Bleed Line: Type Material of valve seat : : Check valve SS : : : : : HEI / TEMA Shell and tube fixed tube sheet type Motor driven exhaust fan AC motor 5.5 kW, 415 V, 3 Phase : : Auto engage & auto disengage AC motor : : 1 Kg/cm2g 8 Kg/cm2g
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Isolation valve in Bleed Line: Type Operation End connection Material of stem Material of body & bonnet : : : : : Globe valve Manual through hand wheel Flanged SS-410 ASTM A-216 Gr.WCB
Flow relief valve in Bleed Line Type Operation Material of spring : : : Spring loaded Self actuating Spring steel
Safety devices : J Over speed trip: Type Low lube oil pressure trip: Type Low control oil pressure trip: Type High exhaust pressure trip: Type Hand trip: : : : :
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Suryalakshmi Cotton Mills Limited Type Operation L Solenoid trip: Type Operation : : : :
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CONDENSING SYSTEM Air Cooled Condenser: STEAM JET AIR EJECTORS Operating conditions: Design code Suction medium Type System elements : : : : HEI Air / Vapour Two stage, double element, steam jet ejector Twin stage, 2 x 100% main ejectors Single stage, 1 x 100% start-up ejector 1 x 100% inter /after condensers Condenser top vacuum : 0.2 bar A
Accessories: Steam inlet valve for ejector Steam strainers Air vent plug for water chamber Drain plug for water chamber Suction valve for 1st stage ejector Discharge valve for ejector Foundation bolts and nuts Special tools
CONDENSATE EXTRACTION PUMPS Type : Mounting Operating conditions: Pumping liquid Liquid temperature Capacity : : : :
Centrifugal Horizontal
Condensate water 60 Deg C 90 m3/hr
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Suryalakshmi Cotton Mills Limited Suction pressure Discharge pressure Driver Type Type of bearings Type of seal Type of coupling Type of lubrication Accessories: AC motor with coupling and coupling cover Balance line valve Seal water inlet valve Base plate Foundation bolts & nuts ELECTRICAL AC GENERATOR Design: Type of generator Duty Type of enclosure IP Class Type of cooling Lubrication Type of coupling Rating: Capacity Equivalent power Rated voltage Rated frequency Combined variation voltage & frequency Rated p.f. No. of phases : of : : : +/-5% 0.8 (lag) 3 phase, 3 wire system : ; : 31250 kVA 20500 kW 11 kV +/- 5 % : : : : : : : : : : : : : : : 0.2 bar a 10.0 bar a AC motor (415 V, 3 Phase, 50 Hz) TEFC Anti-friction Mechanical Flexible Oil
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Revolving field, Brushless type, synchronous generator with Brushless exciter Continuous Totally enclosed closed air circulation 54 for generator & 23 for exciter CACW Forced lubrication
Flexible coupling
50 Hz + / - 3%
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Suryalakshmi Cotton Mills Limited No. of terminals Connection Rated speed / No. of pole Short circuit ratio Mounting Insulation Temperature rise Duty Rotation Noise level Terminal box Type of bearing : : : : : : : : : : : : 3 for phase & 3 for neutral Star 1500 rpm / 4 pole More than 0.5 Horizontal Class F (both rotor and stator) Class B limits (both rotor and stator)
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Continuous and suitable for parallel operation To suit driver output 90 dB(A) To suit HT cable connection Sleeve
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Suryalakshmi Cotton Mills Limited TECHNICAL DATA SHEET FOR ELECTRICAL ITEMS SF6 CIRCUIT BREAKER: Type Rated voltage Highest system voltage Continuous rating Rated Frequency Number of poles Application Fault level of system Rated short circuit making current Rated Power Frequency withstand voltage Rated Impulse withstand voltage Rated Operating sequence Creepage distance Rated breaking time Rated closing time Type of Operating mechanism Type test certificates ISOLATOR: Type Rated voltage Highest system voltage Continuous rating Rated Frequency Number of poles Material of moving parts Application Fault level of system Rated Power Frequency withstand voltage Rated Impulse withstand voltage Type of mounting Creepage distance Operating motor: Voltage Frequency Auxiliary contacts Control supply Type test certificates LIGHTNING ARRESTOR: Type Rated voltage Station type, Outdoor, Single pole 220 kV
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Outdoor 220 kV 140 kV 1250 Amps 50 Hz 3 HV side of 25 MVA Transformer 40 kA 100 kA 460 kV (rms) 1050 kV (peak) O 0.3s CO 3min CO 25 mm / kV < 60 ms < 100 ms Energy stored spring mechanism To be furnished
Horizontal, Centre pole rotating, Double Motorized, Outdoor Type 220 kV 140 kV 630 Amps 50 Hz 3 Copper tinned / Aluminium contact HV side of 5.0 MVA Transformer 40 kA 460 kV (rms) 1050 kV (peak) Structural mounting 25 mm / kV 415 Volts, 3 phase 50 Hz 6 NO + 6 NC 220 Volts DC To be furnished
break,
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Continuous system voltage Continuous rating Fault level of system KA rating Rated short circuit making current Creepage distance Accessories Type of mounting Type test certificates CAPACITANCE VOLTAGE TRANSFORMER: Type Rated voltage Highest system voltage Fault level of system Type of mounting Type of cooling Creepage distance VA Burden Class of accuracy Ratio Test certificates
140 kV 198 kV rms 40 kA 10 kA rms 40 kA rms 25 mm / kV Surge counter, connecting cable etc. Structural mounting To be furnished
Outdoor, Single pole 220 kV 140 kV 40 kA Structural mounting Natural 25 mm / kV 100 VA 0.5 for Metering 220 kV / 3 / 110 V / 3 To be furnished
CURRENT TRANSFORMER: Type Rated voltage Highest system voltage Fault level of system Type of mounting Type of cooling Creepage distance VA Burden Ratio Class of accuracy Core 1 Meetering Core 2 Protection Core 3 Protection Outdoor, Single pole 220 kV 140 kV 40 kA Structural mounting Natural 25 mm / kV 20 VA 20 / 1 / 1 / 1 A CL 0.5 CL5P20 CLPS
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MISCELLANEOUS ITEMS: Bus bar Insulators Structural materials Earthing materials Connectors 3" dia., IPS, Aluminium tube Post insulator, 220 kV grade Hot Dip Galvanized 75 x 12 / 50 x 6 mm, GI flat / 40 mm dia MS rod Bolted type, suitable for 3" dia, Aluminium bus bar
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Sl No 1
3 4. 5 6 7 8 9
BILL OF MATERIALS FOR ELECTRICAL SYSTEM Description 2000 A, 500 MVA for 1 sec, Aluminium bus bar, 11 kV Switchgear panel, comprising the following:2000 Amps VCB for incomers - 1 No. 1250 Amps VCB for switchyard - 1 No. 1250 Amps VCB for denim plant - 1 No. 630 Amps VCB for feed pump drives - 3 Nos. 630 Amps VCB for Distribution Transformers - 2 Nos. 630 Amps VCB as spare - 2 Nos Draw out type Bus PT - 1 No. 2000 A, 500 MVA for 1 sec Aluminium bus bar, 11 kV Switchgear Comprising of the following: 1250 amps VCB for incomer - 1 No. 630 amps VCB for Distribution transformers - 3 Nos. Draw out type Bus PT - 1 No. 11 kV XLPE cable 630 sq.mm. x 1 run 3 cores / phase 11 kV isolators 11 kV Current Transformer 2.5 MVA, 11 / 0.433 kV, ONAN, Dyn 11 Distribution Transformers 5 MVA 11 / 0.433 kV ONAN Dyn 11 Distibution transformers for denim plant 433 V 4000 A Non segregated bus duct 433 V PCC panel with Aluminium bus bar, each panel comprising the following:4000 Amps ACB as Incomer - 2 Nos. 4000 Amps ACB as Bus coupler - 1 No. 1600 Amps ACB as Outgoing - 4 Nos. 630 Amps ACB as Outgoing - 4 Nos. 400 Amps ACB as Outgoing - 1 No. 250 Amps MCCB as Outgoing - 4 Nos. MCC panel with Aluminium bus bar, each panel comprising the following:a) 1600 Amps ACB as Incomers b) 630 Amps ACB as Incomers c) 400 Amps ACB as Incomers c) 250 Amps MCCB as Incomer Lighting Distribution Board comprising the following:250 Amps SFU as incomer - 1 No 25 Amps SFU as outgoing - 8 Nos. 5 kVA, 110 Volts UPS 220 Volts, 300 AH Battery, Battery Charger and DCDB LT cabling and cable trays 220 outdoor switch yard comprising of:-
Quantity 1 No
1 No.
1600 meters 1 no. 1 no. 2 nos. 3 nos. 30 meters 1 No
10
12
4 Nos. 4 Nos. 1 no. 4 Nos. 10 Nos
13 14 15 16
1 No 1 set Lot
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25/32 MVA, 11 / 220 kV, ONAN, YNyn0 Evacuation Transformer 220 kV lightning arrester 220 kV isolator with earth switch 220 kV isolator without earth switches 220 kV SF6 type outdoor breaker 220 kV outdoor current transformer 220 kV outdoor potential transformer 220 kV Aluminium tubular bus Miscellaneous equipment viz. insulators Structural material to support above lot 220 kV HT earthing system
1 no. 2 nos. 2 nos. 10 nos. 4 nos. Lot Lot. Lot Lot Lot Lot
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Suryalakshmi Cotton Mills Limited CIVIL ENGINEERING REQUIREMENT:
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This section covers the basic requirement of civil work to be executed for the power plant. During project engineering, more detailed specifications and drawings need to be drawn out depending upon the soil to be decided by soil investigation work. Geo Technical Investigation: The geo technical investigation shall cover the entire area of the power plant. Required field tests such as form test boring tests, drilling through rocks if required, direct load tests, trial pits, tests for dynamic properties, electrical resistivity etc., and necessary laboratory tests shall be conducted to determine the soil and sub soil characteristics required for site preparation and foundation design. Soil investigation shall be carried out at all important foundation locations, buildings etc. A comprehensive investigation report shall be prepared incorporating all data collected and firm recommendations with respect to design input data and guidelines. Equipment Foundations: Turbo generator Foundation The turbo generator foundation is a cast in reinforced frame foundation that consists of top deck slab, beam, and columns and base draft. The base draft shall be extended to a depth that confirms to the allowed soil bearing pressure. The foundation design shall take into considerations all the loads from the machine including dynamic loads as per the turbo generator manufacturers loading data. The design and construction shall confirm to IS: 2974, IS: 456 and IS: 2911, German standard DIN: 4024.VDI 2056 and VDI 2060. The grade of concrete used for the entire foundation shall confirm to M25 as per IS: 456. The HYSD reinforcement steel bars shall confirm to IS: 1786. No dynamic analysis need be done for foundations supporting minor equipment weighing less than one tonne or if the mass of the rotating parts is less than one hundredth of the mass of the foundation. However if such foundations are to be installed in buildings or structures, suitable dynamic analysis is to be carried out. Incorporating suitable vibration isolation system shall control the vibrations. The design of static equipment shall also be done as per above guidelines except that no dynamic analysis is carried out. The grade of concrete shall be minimum M20. The design shall be done by
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Limit State Method. The foundation construction shall allow incorporation of suitable cutouts, embedments and foundation bolts assemblies. Buildings: All buildings shall be designed as per applicable codes and standards. Dead and live loads shall be calculated as per IS: 875. Earthquake loads shall be calculated as per IS: 1893. The design shall confirm to Limit State Method, the grade of concrete shall be minimum M20, the HYSD reinforcement steel bars shall confirm to IS: 1786. Roof design shall be all weather proof and leak proof. Proper drainage shall be constructed and connected to plant storm water drains. The buildings shall be properly ventilated and illuminated as per factory acts. Power House Building: This building locates the Steam Turbine Generator, its auxiliaries, suitable EOT crane, maintenance area, switchgear rooms, air compressor rooms, control room, battery & battery charger room, HVAC system, office etc. The sub structure shall be on concrete shallow foundations, the superstructure shall be of RCC / structural steel framework with concrete cast floor slabs for control rooms, other rooms. External walls shall be 230 mm thick while internal walls shall be 115 mm thick brickwork. The control room shall be fully air-conditioned. Staircases shall be provided for easy access to all areas. Brickwork shall be properly plastered internally and externally with exterior all weatherproof painting. The floor finishes shall met the functional requirement of the operational areas. The floor finishing of battery room shall be acid resistant tile construction. Internal wall & ceiling finishes: Room / Area Switchgear room, Office, AC & Ventilation room Control room Battery room Toilet Entry corridor Wall Plastered OBD Plastered emulsion painted Electrolyte resistant tiles Ceramic tiles Plastered emulsion painted Ceiling Plastered OBD Suspended thermal insulation
acoustic tiles Acid resistant paint Plastered oil painted Plastered oil painted
Non-plant building shall be of shallow concrete foundation, concrete superstructure, AC sheeting roof.
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Suryalakshmi Cotton Mills Limited Switchyard:
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Transformer and other equipment shall be supported on reinforced concrete foundations of minimum M20 grade concrete designed for the allowable soil bearing capacity. An oil drainage pit filled with broken stones shall be provided from which oil can drained out to a soak pit. Firewall shall be provided on threes sides of the transformer wherever required to prevent spread of fire. Fencing and gate shall be provided in the switchyard with proper approach roads. Gravel spreading shall be constructed within the yard. Cable trenches shall be designed and constructed as per requirement. Cooling Tower: The cooling tower basin for collecting the cold water shall be constructed with M25 grade concrete. The raft slab shall be checked for uplift forces considering empty condition of basin with ground water at the maximum level. A minimum factor of safety of 1.2 shall be ensured for such condition and superstructure columns are not constructed. The basin shall be water tight to prevent ground water mixing with cooling water. The superstructure shall consist of columns, beams, hot water distribution basin, cell partition etc. The concrete grade shall be minimum M25. The deck slab for fan shall be minimum 125-mm thk. And shall be sloped to prevent rainwater accumulation. Water proofing admixture shall be added to the concrete. Cable / Pipe trenches: Cable trench wall and base slab shall be cast in situ reinforced minimum grade M20, and HYSD reinforcement steel bars confirming to IS: 1786. Pre cast RC cover slabs shall cover Trenches. Suitable slope shall be provided in the longitudinal direction and connected to plant drain system. Pipe Racks: Pipe rack supporting structure shall be steel columns with interconnecting longitudinal an transverse beams, properly braced. Width and tier of the rack shall be as per functional requirement. Access ladders shall be provided at suitable places. The steel columns shall be resting on RCC pedestals. Roads and pavements:
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All roads within the plant shall be either double lane roads with 6 m black topping and 2.5 m wide shoulders on either sides or single lane roads with 4 m black topping and 1 m wide shoulders on either side. Road geometry and construction shall be as per Indian Road Congress (IRC) or equivalent. Minimum longitudinal slope of the roads shall be 1 in 200 where there are curbs on either side. Slope from crown to edge shall be 1 in 50 generally on straight stretches. Super elevation shall be provided on curves. The sub grade shall be compacted to the levels, falls, widths and cambers as per grade requirement. Sub base will be laid on prepared sub grade. Base and final surfacing shall be of bitumen macadam. Seal coat will also be provided. Pre cast RC kerbs shall be provided on both sides. The rainwater shall be collected in roadside gullies into the plant surface drainage system. Paving area shall be properly graded and compacted to required grade and slopes before providing the base layer. RC paving (grade minimum M20) shall be done in alternate panels not exceeding 3.0 m x 3.0 m in size. Construction joints shall be filled with scaling compound. Surface drainage: All the paved and unpaved areas shall be adequately drained. The surface drainage system shall be designed for surface washings and / or rain / fire water as the case may be. Contaminated area surface drainage shall be collected and discharged through catch pits. The catch pits shall be of RCC construction and shall be covered by CI / MS gratings. Uncontaminated surface drainage shall be constructed through rectangular RCC drains to be connected to open storm water rain. The paved areas shall be sloped towards catch pit drains. Suitable pipe / open Rc culverts shall be provided at all road crossings.
Plumbing and sanitary system: Plumbing and sanitary system shall serve all toilets, showers, bathrooms, kitchen and laundries. All discharge pipes shall be fully vented. All piping within buildings shall be concealed. The design
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and construction shall confirm to relevant Indian standards. All urinals and water closets shall equipped with pop up valves. Sewerage Drainage System: The sewerage drainage system consists of connecting the sanitary waste disposal from different buildings to the septic tank through necessary pipeline. All pipelines shall be of RCC material of minimum size 100 mm at service connection and 200 mm for sewers. Minimum slope in service connection shall be 1 in 40 and 1 in 200 for sewers. All sewers shall be located along the roadways or open spaces. Manholes shall be placed on the top of the head of each sewer, changes in slope, direction or pipe size or at junction of sewers. The maximum distance between the manholes shall be 50 m. Fencing / Compound wall: The plant shall be provided with suitable compound wall / fencing for a height of 2.5 m and steel gates with security rooms all along the boundary of the plant.
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ENVIRONMENTAL PROTECTION AND WASTE MANAGEMENT PLAN: GENERAL:

Any power plant produces pollutants, which if not addressed in the implementation stage can bring in a lot of negative impact on the environment. The selection of combustion technology addresses this aspect to a very great extent. However, even after this step, the power plant still produces pollutants, which are listed below. The protection plan is also elaborated. The major sources of pollution are as follows: Boiler bottom ash and fly ash Effluents from DM plant Blow down water Drains and vents from equipment and piping Floor wash water Sewage from various buildings Fired Boiler flue gases containing suspended particulate matter (SPM), SOx and NOx. Thermal pollution Noise generated due to equipment operation
POLLUTION CONTROL MEASURES: Boiler Ash: The ash in the fuel to be used is brought out as bottom ash and fly ash. The total quantity of ash generated shall be in the range of app. 6 MT to 10 MT per hour, depending upon the coal being fired. The bottom ash constitutes about 20 % while fly ash constitutes about 80%. The ash will be collected in a day silo. The ash shall then be transported out of the plant. The quantum of ash being generated shall be in the range of 144 and 240 TPD respectively for Grade D and E coals. The fly ash is normally sought after by various cement manufacturing units to make pozzalna grade cement. Thus it is proposed to sell all the fly ash to prospective cement manufacturing units. Options are being worked out to install fly ash brick making units to ensure that all fly ash is being consumed inside the plant itself.
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Dust suppression: The dust generated in the fuel storage area shall be suppressed by spraying water on the fuel. Suitable dust extraction systems shall be incorporated in the fuel preparation system. Enough green belt will be developed around the fuel storage area to control fugitive emissions. DM waste water: Minor quantities of acidic effluents generated during regeneration of cation and mixed bed exchangers and alkaline effluent generated during regeneration of anion and mixed bed exchangers of DM plant will be suitably neutralized in a pit. The effluent will be then fed to a balancing tank and mixed with cooling tower blow down. Blow down waters: The blow down from the plant includes blow down water from the steam generator and the cooling tower. The quantity of boiler blow down will be app. 34 cum per day having a pH of 9.5 10.5 at 100 Deg C. This blow down will be mixed with cooling tower blow down. The quantity of CT blow down will be app. 30 cum per day. The quality of water will be as per state pollution control board guidelines for discharging into inland. Residual chlorine in cooling tower blow down will be maintained within acceptable limits. The total quantity of wastewater consisting of CT blow down, boiler blow down and DM plant neutralized effluent shall be app. 78 cum per day. The wastewater will be used for dust suppression, green belt development and ash handling system. There will be no discharge from the plant outside the plant site. Floor wash water: Drains from dusty area will be led to a pit where the dust will be allowed to settle down. Overflow water will be allowed to be set absorbed. Chemistry of water monitored before discharge.
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Sewage from various buildings in the plant: Sewage from the various buildings will be led to a septic tank through separate drains before being discharged into disposing trenches. Fired Boiler flue gases: In the case of fired boiler, an electro static precipitator (ESP) will be installed before ID fan to limit the emission of SPM to less than 50 mg/ Nm3. Sulphur content in the rejects being low, the SOx emission from the boiler will be limited to PCB norms by the process itself. Similarly, NOx emission will be controlled to norms set by PCB. A stack of sufficient height will be installed to control the ground level concentration of SOx in line with PCB norms. Thermal pollution: Heat transmitted from hot components constitutes a pollution problem. In order to dissipate heat properly, plant layout will ensure good air circulation and natural ventilation. Thermal insulation will be provided where the skin temperature is more than 65 Deg C to limit the skin temperature to not higher than 60 to 65 Deg C. In addition, air conditioning systems will be provided in specific areas and man coolers will be provided in hot work spots. The Ventilation and Air Conditioning system shall be so designed that air is conditioned to the following parameters: 25 +/- 1 Deg C dry bulb temperature and 55 +/- 5 % RH in control rooms. Temperature rise limited to 5 Deg above ambient for electric rooms housing switchgear and MCCs. Noise Pollution: The plant and equipment will be designed to ensure that noise generated is limited to PCB norms. The equipment will be provide with noise control measures such as acoustic insulation etc, to ensure noise abatement. The rotating equipment will be properly balanced. Where high noise levels are produced, employees will be provided with ear protection devices.
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Green belt development: Green belt will be developed all around the plant, fuel handling area, administration building etc. The wastewater generated will be used for green belt development and sustenance. The green belt development shall be in line with the guidelines set by CPCB. Post Project Monitoring: As a part of Environment Management Plan (EMP) to be implemented for the power plant as whole, periodic monitoring of air, water, exhaust gases will be done regularly as per PCB norms. Necessary equipment and facilities shall be created to ensure implementation of this plan.
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PLANT OPERATION AND MAINTENANCE:

PLANT OPEARTION: The plant is normally operated as follows: The fired boiler is lighted up and raised to full load and the steam produced will be fed to common header. The steam is then fed to the steam turbine and its auxiliaries. The extraction steam is fed to the regenerative cycle. The electrical load on the steam turbine is increased slowly to reach full load operation. The generator is then synchronized with the system and then the grid. If any load variation occurs either due to in plant disturbance or network frequency due to paralleling, the boiler fuel is controlled and then the turbine mainly due to the boiler thermal inertia. The fired boiler, STG and BOP are controlled from the central room where all the controls are accommodated for start, shut down and configuration changes. The following control system is in place for safe and proper running of the plant: Fuel feeding into the boiler through bunker and chutes, Combustion and flue gas flows Boiler drum level control system Boiler feed water system including deaerator Boiler superheater temperature control system Turbine control system Power evacuation and distribution system Plant water system Plant compressed air system The performance is continuously logged and recorded for analysis and observation. PLANT MAINTENANCE: The operation and maintenance personnel shall carry out the following activities for ensuring preventive maintenance.
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Careful logging of operation data and process for any slow down or detoriation in operation. Carry out walk down check of the plant. Careful control and operation of the plant. Ensure steady operation and avoid rapid fluctuation in load. Regulate routine maintenance including cleaning, lubrication, attend to leakage etc. Prepare and follow maintenance procedures and schedules Conduct periodic plant performance tests including efficiency, vibration, oil testing etc to ensure predicted performance.
Close coordination with manufacturers for speedy repair work where required.
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PROJECT IMPLEMENTATION:
PROJECT SCHEDULE: The successful project implementation means proper project planning, adhering to the planning and timely implementation by qualified expert project team. This results in the stable operation of the plant and ensuring that the cost of production is achieved without much deviation from the projected figures. The project planning shall be carried out in detail by the project management team as soon as the project is conceived and started. SLCM will appoint an external consultant to supervise and assist in the successful implementation of the project. The consultant will also carry out the design and detail engineering and assist in procurement, erection and commissioning supervision activities. The project shall be commissioned in eighteen months from the start of the project and successful financial closure. The broad break up of the project implementation is as follows: Sl. No. 1 2 3 4 5 6 7 8 Description Obtain Statutory Approvals Achieve financial closure Appoint project consultant Finalize major orders Civil works at site Supply of all components Erection activities Commissioning activities Start by Month 1 Month 1 Month 1 Month 1 Month 6 Month 8 Month 8 Month 17 End by Month 3 Month 3 Month 1 Month 6 Month 14 Month 14 Month 16 Month 18 Remarks
STATUTORY APPROVALS: SLCM will apply and obtain all statutory approvals required for the implementation of the project. The major approvals required for the implementation are as follows: Site Selection As Per The CPCB Criteria 2001 DPR, REIA And Public Hearing Site Notification By State Government Apply To Pollution Board For Setting Up The Facility In Requisite Format And Fee, Detail Drawing And Designs Apply To Pollution Board For Consent To Establish Apply To Pollution Board For Consent To Operate Avail The Authorization (Consent To Establish)
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Detail Drawing And Designs Get Approved By MPCB No objection certificate from EB for installation of IPP Approval from state government for water allotment Approval from government for displacement if any
The power plant shall be installed within the main denim plant located in Ramtek near Nagpur and the concerned details shall be furnished to MPCB to obtain the relevant approvals. The detailed project report is completed and shall be subjected to the financial and statutory authorities. Since the power plant lies within the industrial area, public hearing may not be required. Site notification by Government is not required since the power plant rating is not more than 100 MW. SLCM has already applied to state pollution control authorities for statutory clearance and to obtain consent to establish. The consent to operate shall be obtained after the plant is ready for commissioning after erection completion. SLCM has also approached the state electricity board for obtaining no objection certificate for the installation. In order to save for precious ground water resources, SLCM has already planned to install air-cooled condenser. The make up water requirement is normally large for water-cooled condenser applications. The makeup water requirement for boiler and auxiliary cooling tower is nominal and SLCM is confident in obtaining the approval from the state government for water allotment. There is no displacement in this case of installation of power plant and hence this approval from state government is not required. The consultant will assist SLCM in all technical matters at the time of meetings and for submission of documents while processing the various approvals. Soil Investigation and Site Leveling works: Detailed soil investigation work involving bore hole tests and trial pit tests and electrical resistivity tests will need to be carried out to ascertain the soil characteristics including strength parameters. A detailed survey will be done to mark the contour map of the area, which will be the basis for determination of suitable location for the various plant facilities and proper drainage requirement. The proposed layout of the plant as depicted in the drawing already takes into consideration the
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above aspects with due consideration to the existing steel plant layout. SLCM shall carry out the necessary soil investigation tests to ensure optimal design of the civil work in the power plant. Construction Facilities: Construction facilities in the form of power, water, road access, open and covered storage spaces etc, will be provided to facilitate commencement of civil/ structural work and equipment erection. The power requirement during peak construction / erection will be in the order of 750 KVA. SLCM being an existing industry has enough resources for construction water as well power to be allocated to the various vendors involved in the construction of power plant components. Project Implementation: The power plant components have been identified and a detailed PERT chart shall be drawn to facilitate proper and smooth execution of the power plant. The chart is broken into following major activities Carrying out basic engineering work such layout finalization, PID and SLD finalization etc. Preparation of detailed purchase specifications for the various equipment such as boiler, steam turbine and auxiliaries, coal handling plant, ash handling plant, EOT crane, water treatment plant, plant electrics, plant instrumentation and civil work Receiving the various detailed offers, carrying out evaluation studies, and conduct meetings with prospective vendors and finalization of the various orders. Oversee the project execution by the various vendors viz. receiving necessary input information, check and ensure proper interfacing to achieve plant commissioning etc. Match the various schedules to ensure all proactive and reactive works to ensure proper coordination and smooth flow of work uninterrupted. Commission all the equipment in the order as required, to ensure that the plant commissioning is uninterrupted and also meets the required project parameters. Plant Commissioning: The plant commissioning team will consist of representatives from contractor, consultant and client. The staff to be part of the operation team shall be associated from the commissioning stage itself. The responsibility of commissioning and ensuring the predicted and guaranteed performance of the individual packages shall rest with the individual contractors. The plant will be taken over successful performance trials.
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PROJECT COST ESTIMATE AND COST OF GENERATION:

GENERAL: The plant cost comprises of cost of land, cost of developing the land and site, cost of buildings and other civil work, cost of main plant and auxiliaries as erected including taxes, duties, freight and insurance, erection etc., cost of utilities, design, engineering and project management, training, cost of spares, preoperative and preliminary expenses. The total capital cost of the project, which includes all the above heads, the margin money for working capital, interest during construction (IDC) is estimated at Rs. 12806.00 lacs. The break up of the project cost is given below: PROJECT COST ESTIMATE: Sl. No. 1 2 2.1 2.2 2.3 3 3.1 3.2 4 5 6 Description Land and development cost Plant Facilities Buildings and foundations Plant and equipment as erected Design, engineering and project management Total plant cost Other fixed investments Spare parts Preliminary, pre-operative and other expenses Total cost of other fixed investments Contingency @ 5% Margin money @ 25% of working capital Interest during construction (IDC) Total capital cost Cost in Rs. Lacs 0.00 1395.00 9494.00 50.00 10939.00 445.00 76.00 521.00 608.00 106.00 566.00 12806.00
PLANT COST: The land required is estimated at 10 acres and the land is available with SLCM as part of their current plant area. Although the land is reasonably leveled a land development cost of Rs. 100 lacs is considered in the civil construction works refer Appendix I. BUILDINGS AND STRUCTURES: The cost of buildings and structures including land development cost is estimated at Rs. 1395.00 Lacs, the break up details are shown in Appendix I
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Suryalakshmi Cotton Mills Limited PLANT & EQUIPMENT, UTILITIES AND FIXED ASSETS:
Resel
The total cost of the plant as erected works out to Rs. 9494.00 lacs based on offers and discussions held with selected major vendors and also in-house information on similar capacity projects already executed or under execution. The cost is based on indigenous offers only except for air cooled condenser alone that are imported at present. The estimated break up is shown in Appendix II. DESIGN, ENGINEERING & PORJECT MANAGEMNET AND TRAINING: A provision for Rs. 50 lacs is kept for hiring engineering, project management services. SPARE PARTS: A provision of Rs. 445.00 lacs is kept for purchase of spare parts for capital maintenance purposes. The cost is estimated @ app. 5% of the plant & machinery cost. PRELIMINIARY, PREOPERATIVE AND START UP EXPENSES: A provision of Rs. 76 lacs is kept towards preliminary and preoperative expenses in the project implementation. The break up is given below: Break up of the above cost: Sl. No. 1 2 3 4 5 6 7 Description Establishment charges Insurance Travel expense Start up expenses Administration during construction Power during construction Loan processing fee Total Amount in Rs. Lacs 5.00 20.00 10.00 3.00 8.00 10.00 20.00 76.00
CONTIGENCY: A provision of Rs. 608.00 lacs has been made towards contingency, which is app. 5% of the cost of civil, plant and equipment, fixed expenses and IDC. MARGIN MONEY FOR WORKING CAPITAL:
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Although coal is available from nearby the main plant, as per project norms a stock of 0.5 month fuel is considered besides one month of maintenance, administration expenses and 1 month of receivables. This amount is worked out as Rs. 415.0 Lacs out of which 25% is considered as margin money and considered for capitalization. The remaining 75% will be met from short-term bank borrowings. INTEREST DURING CONSTRUCTION (IDC): Based on the assumption that 75% of project cost is taken as loan from financial institutions and based on project cash flow, the interest during construction has been worked out as Rs. 566 lacs. The working is attached as part of the financial sheets enclosed. COST OF POWER GENERATION: The total days of operation of the power plant has been considered as 335 days. Auxiliary power consumption has been computed as 12.5%. Plant load factor has been considered as 85% for 1 st year and 90% for the subsequent years. The cost of generation has been worked out as Rs. 3.04 per unit in the first year of operation considering coal with GCV 4000 kcal/kg. The working of cost of generation for 10 years has been shown in financials attached along with the report. The key assumptions in the working of the cost of generation are listed in Appendix III. The cost of generation has been sub divided into two components viz, fixed and variable costs. The fixed cost includes the interest cost, maintenance cost, administration cost and the cost of depreciation. The variable cost includes primary and secondary fuel cost. The project cost has been raised as 33% equity rounded off to Rs. 43.06 crores and 67% long-term debt rounded off to Rs. 85 crores. The working capital requirement is met out of margin money of 25% and short-term borrowings of 75% from banks. The selling cost of the excess power and denim plant purchasing cost has been assumed as Rs. 4.00 per unit of power sold as per the norms currently prevailing. Based on the above assumptions, the first year revenue mobilization works out to Rs. 59.80 crores while the total expenses work out to Rs. 52.00 crores. Thus the profit before tax works out to Rs.7.80 crores. The project is self-supporting and generates enough profit before tax to pay back the loan amount besides meeting dividend towards equity deployed. Being a captive power project, the project does not attract income tax in the first four year. Thereafter, the project attracts an income tax at the rate of 35% including surcharge. The moratorium period for
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paying the loan installment is one year and the entire loan amount is paid back in nine years thereafter. FINANCIAL HIGHLIGHTS: The financial highlights of the project is presented as follows:
Capital cost of the project Rs. Lacs Debt : equity ratio Equity provision Rs. Lacs Long term loan as debt Rs. Lacs Cost of generation in first year of operation Rs. Internal rate of return
: 12806.00 : 67:33 : 4306.00 : 8500.00 : 3.04 : 13.86%
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RISK AND SENSITIVITY ANALYSIS:

GENERAL: The independent power plant depends upon the following inputs for successful running viz. ample quantities of coal and water. The plants out put viz. Export power needs to be purchased by the state electricity board to ensure smooth revenue generation. However, the revenue viability depends upon the cost of fuel purchased. The assured purchase from the grid also assumes significance. Fuel Availability: The plant is located near the city of Nagpur in the state of Maharashtra. The plant depends upon coal being located in Central India coal terrain. Thus the risk of assured fuel availability is largely mitigated. Having a head start in the area in installation power plant, the cost of fuel can be very reasonably controlled. The average cost of fuel is estimated as Rs. 2200/MT for Grade D coal that is very conservative. The financial calculation also assumes 5% increase in fuel price annually on compound basis. The cost of unit generation for every increase / decrease of Rs. 100/ MT fuel shall be app. Rs. 0.11 / unit. The break-even price of fuel cost in first year will be Rs.3700/MT. Water: The plant is situated in a well-developed Industrial estate and as such water availability is not a criteria. In case water supply is curtailed, the plant can depend on ground water as the same is available in plenty. Air-cooled condenser has already been considered to mitigate the high make up water requirement in the event of usage of water-cooled condenser. Power Purchase: The power shall be purchased by MSEB. Hence the purchase is assured over the tenure of power purchase agreement. The recent electricity act guidelines also encourages third party sale with wheeling charges to grid should a situation arise so. Hence the sale of power is reasonably assured. The sale cost s also considered very conservatively at Rs. 4.00 / unit when the plant is commissioned and ready to sell power. Considering the upcoming demand and also the current gap in supply and demand ensures that the future sale cost will be much more than considered values. Looking at the financial parameters such internal rate of return and debt service ratio, the plant is self-sustainable and should be promoted.
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APPENDIX I:
PARTICULARS OF FACTORY AND NON FACTORY BUILDINGS AND CIVIL WORK:
Sl. No
Description
Const. Type
Concrete qty. Cu.m 1600 900 1200 1200 500 700 500 700 7300
Steel qty. MT
1 2 3 4 5 6 8 9 10
STG & Powerhouse Boiler & auxiliaries Air cooled condensers Fuel handling plant Plant water system Chimney Ash Silo Misc. piperacks and cable trenches Total Structural quantity
RCC with str. RCC RCC RCC with str. Shed with str. RCC RCC RCC Structural
200
Estimated cost: Total RCC quantity 6600 cum. @ Rs. 13000/cu.m. (other than chimney quantity) Total structural steel 200 MT @ app. Rs.50000/MT Site development works Chimney works 700 cum @ Rs 16000/cum Roads and Drainages 7 M wide road 1200 M @ 800 x Rs. 8500 / M 4 M wide road 300 M @ 500 x Rs. 4500 / M Pile foundations 500 @ 500 xRs. 20000 / pile Total cost of civil and structural work (Inclusive of Service Tax component) = Rs.102.00 = Rs. 22.50 = Rs.100.00 = Rs. 1394.50 Lacs = Rs.100.00 = Rs.100.00 = Rs.112.00 = Rs.858.00
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APPENDIX II:
ESTIMATION OF PROJECT CAPITAL COST: Sl. No. 1 2 3 3 4 5 6 7 8 9 10 11 12 13 15 16 18 19 20 21 22 23 24 25 26 27 28 Description Boilers and its auxiliaries STG and its auxiliaries Air cooled condenser and its auxiliaries Cranes and hoists Water treatment plant Cooling tower for aux. cooling ACW and various pumps Fuel handling plant Ash handling plant Air compressor system Fire protection system HVAC system Piping and specialties Workshop facilities Generator transformers Unit auxiliary transformers for power plant & denim plant HT cabling / LT bus duct 11 KV / 415 V switchgears 220 KV switchyard Battery & battery charger Plant lighting system LT Power and control cables / trays Plant earthing system Plant instrumentation and controls with DCS Sub Total Spare parts @ 5% of project cost Civil and structural costs Design and engineering consultancy Grand Total As erected cost in Rs. lacs 3025 1776 1533 47 334 19 19 694 206 12 74 49 103 148 186 201 123 156 581 30 38 113 24 136 9494 445 1395 50 11384
APPENDIX III:
KEY ASSUMPTIONS FOR FINANCIAL ANALYSIS OF 22 MW POWER PLANT: Sl. No. 1 2 3 4 5 6 7 8 9 10 Description Subsidy from GOI Operating hours of power plant / 1st year Project Schedule In Plant Power Consumption Plant Load Factor at optimum prodn. Level in 1st year Plant Load Factor at optimum prodn. Level in subsequent years Fuel used Fuel consumption Sale price to grid / third party Excess power to be sold in 1st year Assumptions / Norms Nil 8040 (335 days) 18 months 12.5% for power plant 85% 90% Coal 18.5/ 21.76 TPH Rs. 4.00 / unit in 1st year 88.09 MU
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Sl.No 1 2 3 4 5 6 7 8 8 9 10 11 12 13 14 15 17 18 19
11 Excess power to be sold from 2nd year onwards 12 Notional cost of fuel 13 Taxes on generation and sale of power 14 Cost of project 15 Debt : Equity ratio Drawing Name 16 Term loan interest 17 Plan Term loan repayment including moratorium Plot 18 Moratorium period Power Plant Layoutinterest payment 19 Mode of 20 Number of quarters of repayment Heat & Mass Balance Diagram Load point No process 21 Annual escalation on fuel cost 22 Annual escalation on O&M cost Heat & Mass Balance Diagram Load point Guarantee 23 Annual escalation on admin. cost Principal Thermal escalation on secondary fuel cost 24 Annual Scheme 25 Annual escalation on unit sale price Schematic Diagram For Water System 26 Depreciation for Civil & Str. / P & M (Book) 27 O & M cost on project cost Plan of fuel handling system 28 Administrative cost on project cost Elevation of fueldevelopment cost considered 29 Land handling system 30 Stock period of fuel considered P&I Diagram for Steam & Water Circuit for boiler 31 Spares on project cost P&I Diagram for Air & Gas Circuit for boiler P&I Diagram for Auxiliary Steam Circuit P&I Diagram for Raw & Treated Water Circuit P&I Diagram for Cooling Water Circuit P&I Diagram for Steam Circuit for Turbine P&I Diagram for Lube Oil Circuit for Turbine Control System Overview & DCS Architecture Single Line Diagram Plant electric distribution Single Line Diagram 220 kV switchyard Legends and Abbreviations
93.82 MU Rs. 2200 per MT Nil Rs. 12806.00 Lacs 67:33 Drawing No 11.5% 9 years 00-SLCM-ME-001 R5 One year Quarterly 00-SLCM-ME-002 R3 36 10-SREL-ME-003 R1 5% 5% 10-SREL-ME-004 R1 5% 20-SLCM-ME-005 R1 5% 5% 20-SLCM-ME-006 R1 15% / 5.28% 2.5% 10-SLCM-ME-007 R1 0.25% 10-SLCM-ME-008 R1 100 Lacs 15 days 10-SLCM-ME-009 R1 5% 10-SLCM-ME-010 R1 10-SLCM-ME-011 R1 20-SLCM-ME-012 R1 10-SLCM-ME-013 R1 10-SLCM-ME-014 R1 10-SLCM-ME-015 R1 20-SREL-IE-001 R1 20-SREL-EE-001 R3 20-SREL-EE-002 R0 30-SLCM-IE-002 R0
List Of Drawings
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Suryalakshmi Cotton Mills Limited

SURYALAKSHMI COTTON MILLS LIMITED RAMTEK, MAHARASHTRA

DETAILED PROJECT REPORT FOR 1 x 25 MW COAL FIRED POWER PLANT

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited 1 INTRODUCTION INTRODUCTION:

operation and also for export.

Suryalakshmi Cotton Mills Limited

process and cooling purposes.

Suryalakshmi Cotton Mills Limited

SELECTION CRITERIA OF CPP:

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited

1 x 120 TPH @ 112 ata / 515 Deg C 1 x 25 MW

No. of days of operation:

Average plant load factor in 1st year:

180.90 MU 21.71 MU 159.19 MU 51.92 MU 107.27 MU*

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited

UTILITY REQUIREMENT AND INTERCONNECTION:

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited

Ambient temperature Site elevation Relative humidity

Fuels and additives: Design fuel Coal

Electricity Steam parameters

112 ata, 51`5 Deg C

Suryalakshmi Cotton Mills Limited Steam Generator:

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited

unit to measure O2 in flue gas.

Suryalakshmi Cotton Mills Limited

master steam pressure control.

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited Economiser

Suryalakshmi Cotton Mills Limited

Primary Air Fans

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited

BOILER FEED WATER PUMPS

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited

Interconnecting lube oil piping Governing System

Motorised barring gear arrangement

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited -

Suryalakshmi Cotton Mills Limited

Bleed steam line

RTDs for : Turbine bearing oil Gearbox bearing oil

Pressure switches for :

Suryalakshmi Cotton Mills Limited

Suryalakshmi Cotton Mills Limited