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  1. 1. ANNEXURE – I EPC WORK The scope of supply and service is Design, Engineering, Procurement, Construction, Erection, Commissioning, and Testing including civil works for the power plant on EPC basis. Scope of supply & services are as follows. BROAD SCOPE OF SUPPLY Mechanical • One (1) No. Boiler (48 TPH) TRAVELING GRATE type feeding system with all its accessories & auxiliaries. • Complete feed water system for the boilers consisting of Deaerator complete with all accessories and boiler feed pumps with drives including inter connecting piping, Control and Regulating Valves. • Complete air handling draft system with fans, dampers and regulating vanes wherever required. • Complete Fuel Handling System for Coal & Biomass (Soya Stalk + Soya Husk + Wheat Husk & Gram Stalk). • One (1) No. of turbo generator set of rating 10 MW complete with all its accessories & auxiliaries. • Complete Air Cooled condenser with Auxiliary cooling tower 300m3 /hr, FRP type, and all its accessories. 1W+1S. • EOT Crane (15T / 5T) for Turbine House with all its accessories with hoist one each for 15 T & 5T. Hoist shall be provided in ACC and ESP Trafo. • Complete water treatment system for boiler make up and auxiliary cooling tower make up. With HP & LP dozing system. • One (1) No DM water storage tank with valves, fittings and instruments. • Pumps with all its accessories for the complete power plant. • Complete power plant piping system comprising of IBR & Non IBR systems. • All pressure reducing and de-superheating stations.
  2. 2. • Air compressors, air drier and air receivers with all its accessories including Interconnecting piping. One for Instruments/Service and One for Ash handling system. • Flue gas dust collecting equipment consisting of Electro Static Precipitator (outlet emission 50 mg/Nm3) complete with interconnecting ducting and other accessories for TRAVELING GRATE BOILER. • Complete thermal insulation and refractory for boiler, turbine, equipments, piping etc. • Complete chimney for TRAVELING GRATE BOILER. • First fill lubricants and chemicals for commissioning upto 10 lightups. • All the metallic parts which are site fabricated at plant site will be painted with one coat of red oxide and two coats of synthetic Enamel / Epoxy paint. • Spares for two years operation and maintenance. • Special tools and tackle as per the list attached. • Complete services & Potable water distribution system with pumps and interconnecting piping and Storage tank. • Complete Ash Handling System for TRAVELING GRATE BOILER with necessary accessories shall be provided. The Dense phase ash handling system is used to transmit the fly ash from TRAVELING GRATE BOILER to Ash silo. • Effluent Treatment plant (Membrane based technology type as per PCB), adequate drainage system for all power plant equipment, piping up to drain gutter, with dewatering pump. • All hangers, supports, anchors and other pipe fittings for the piping with in the battery limits. • Fire protection system as per factory rules for Fuel storage and BTG Island. • Weigh Bridge (40 tons Pitless Type).
  3. 3. Electrical & Instrumentation  One (1) No of 10 MW, 11KV, 0.8 PF, 50Hz brushless exciter type Synchronous generator along with metering and protection panel.  One no Auxiliary transformer 11KV/415V, 1600 kVA with standard fittings as per standards.  11 KV HT breaker panel with necessary protection, metering and indication.  LTPCC and MCC which includes feeder protection and motor protection.  Lighting system complete, with outdoor mast lighting system. Applicable for two areas. Near to Main plant buildings.  Complete plant / equipment earthing system with earth pit system. Separate earthing for electronic system.  All AC & DC motors required for successful power plant operation  Complete lightening arrester system for Chimney, T.G Alternator and house.  Power, Control and Signal cables for interconnection of all equipment.  Cable tray, termination kits, ferrules and other accessories. All the cabling system shall be above ground.  Cable and its accessories with bolts & nuts.  DC system complete with battery, battery chargers and DC distribution board.  Instrumentation and control system which includes interconnection with protection,  Interlocking, Sequential control system, Annunciation system and data Acquisition system  DG Set – 2 x 500 KVA rating.  Power Evacuation system including one (1) No Power Transformer of capacity 12.5 MVA, 11/132 KV and 132 KV Switch Yard. CIVIL • Power Plant/Station Building/Boiler/ ESP/ AHP control rooms. • Steam Turbine Generator building foundation, Chimney Foundations and all the equipment foundations. • Control Room Building. • TRAVELLING GRATE Boiler up to firing floor. • Air cooled condenser up to operating floor.
  4. 4. • Raw water pump house. • Raw Water Storage tank/Raw water reservoir with PCC lining. Above ground type. • MCC Rooms/ Plant control room/ Switchgear room. • Cable Gallery above ground will be designed for overall plant area. • Pipe Racks shall be above ground only. • Transformer Yard /Switch yard with control room. • Fuel Handling System • Biomass Storage facility • Weigh bridge. • Ash silo foundation will be RCC and Storage will be MS Tank. • Water treatment plant and D.M.water. • Weigh bridge room, Other Tanks & Vessels • Site leveling and grading to required Level not exceeding + or – 250mm. • Internal roads, along with drains all along the road. • Boundary wall, etc. • Construction of ETP Plant in case of Membrane based or Neutralizing pit. • Bachelor’s accommodation. Note: The entire civil design is based on safe bearing capacity of 20 T/m2 at 3 Meter depth. Piping Piping Layout and Isometric Drawings for the following: • Low Pressure piping inside Plant boundary limits. • DM Water piping • Instrument & service air piping • Ash conveying piping • Fire fighting including hydrants and Piping. • Lube Oil System • Aux. Cooling Water System • Steam/Feed Water/Condensate System for Boilers
  5. 5. • Review of Piping System which includes checking calculations for line sizing, strength & stress analysis.
  6. 6. Procurement 1) Preparation of Technical specification for all the plant & equipments. 2) Floating of the technical specification for invitation of bids from the prospective Vendors. 3) Bids shall be invited by the EPC Contractor from prospective Vendors based on the technical specification. 4) EPC Contractor shall obtain necessary clarifications, details, documents, diagrams from the Suppliers for placement of orders. 5) A Techno-commercial discussion with the suppliers shall be arranged for finalization of equipments. 6) EPC Contractor shall issue the final purchase order copies to the supplier Erection & Commissioning The activities includes 1) Prepare & review of Project Implementation schedule and subsequent monitoring. 2) Monitoring site activities, identifying likely delays and necessary corrective measures. 3) Review adequacy of Sub - Contractors resources in respect of Special Tools/ Equipment for site work and adequacy of manpower. 4) Prepare monthly progress report based on the status of the project. 5) Review Monthly Progress Reports covering current construction status, deviations from project implementation schedule and recommend remedial measures to be initiated. 6) Periodic follow up with suppliers for delivery of equipments. 7) Depute respective Engineers (Mechanical, Electrical & Civil) at site for construction, erection & Commissioning of the plant 8) Co-ordinate with all sub-contractors / suppliers for smooth functioning of site activities. PROCUREMENT & CONSTRUCTION CONTRACTOR along with OWNER will witness the equipment guarantee tests which will be conducted by the respective equipment suppliers / sub - contractors and coordinate for issue of acceptance certificates on satisfactory completion of tests. Though it is clearly understood that in case the guarantees are not met, it will be
  7. 7. the responsibility of the contractors to adjust, repair or replace free of cost, the equipment supplied by them and demonstrate the guaranteed performance. Following works are also included in the scope of work of EPC contractor. i. Site development as per Plot layout proposed. ii. Leveling and compaction of plant area for civil construction. Contour plan and trial pits for soil data. iii. Security for the plant and equipments while construction upto commissioning. iv. Water and power requirement for construction will be provided at one point inside plant boundary will be provided by client, the same shall be distributed by Contractor. v. Colony for staff and workers engaged in EPC work. vi. Removal/ disposal of excavated earth generated within the plant area, vii. First filling of lubricants, chemicals and fuel for commissioning. viii. Access area for temporary office, store, stock yard, fabrication area, labour camps. ix. Gate, compound wall with boundary fencing. x. Non plant buildings like administrative building, canteen, security building, etc. Labour and labour laws;- The contractor shall employ labour in sufficient numbers to maintain rate of progress and of quality to ensure workmanship. The contractor shall provide transport, housing, canteen, and payment of wages etc. thereof to the labors in accordance with relevant statutory rules and regulations etc. All labors engaged by the contractor shall have no claim against RIPL in respect of any right or benefit due to them in their employment. Safety and Clearance. The contractor shall take all necessary safety precautions and arrange PPE to prevent loss of human lives, injuries, to personnel engaged by contractor before commencing of the work. The contractor shall insure the workman engaged by contractor against all accidents. Otherwise RIPL will arrange the same on contractors account for contractor manpower. In case of fatal or disability injury accident to any person at the construction site, the victim and/or his/her dependents shall be compensated by the contractor as per the statutory requirements.
  8. 8. Supply part for plant spares:-2 years O & M spares / 1 year mandatory spares shall be provided along with plant material. Spares listed below shall invariably be included. Special Tools for Turbine 1. Rotor Lifting device. 2. Casing Lifting device. 3. Lifting device for diaphragm and diaphragm sleeve. 4. Bearing bush disassembly device. Special Tools for Generator 1. Special tools (shoe plate etc.) for generator rotor threading in / threading out. 2. Lifting and rotating device for generator end cover. Spares for Exciter 1. All necessary input / output cards – 2nos. 2. Diodes / Rectifiers – 2nos. 3. HRC Fuses – 10 nos. Spares for Turbine 1. Spare shaft, impeller, mechanical seals, o rings for each type of Auxiliary oil pump – each 1 nos. 2. Spare seat, gland packing etc. for all types of control values – each 1nos. 3. Lube. Oil filter element – each 1nos. 4. Spare tubes for ( 5% of installed quantity for each) i. Generator cooler ii. Oil Cooler 5. Generator bearing bush – 1 set. 6. Slip ring insulating sleeve – 1 set. 7. Turbine front bearing( Journal ) – One set
  9. 9. Boiler Spares 1. Different types of special material tubes, bends. 2. Anti erosion cover of different types and sizes. 3. Back plate, clamping color, lock plate hooks, claps nail etc. 4. Feed line valve spares for both low load and full load valve. 5. Essential spares for regulating / isolating valves and dampers. 6. Gauge glass spares – One set. 7. Repair kit for gauge glass – Two set. 8. Mechanical seal for BFP – One set. 9. IBR valves (class 1500) – 15 NB – 02 nos. , 25 NB – 02 nos, 40 NB – 02 nos. Electrical Spares (Note* Subjected to OEM standard) 1. Assorted size of HRC fuses for power & control. 2. DC Fuses. 3. Auxiliary contactors of different size and capacity for power & control circuit. 4. Battery charger spares. 5. ESP spare electrode both +ve and –ve and hammers. 6. Shaft insulator – 01 nos. 7. Support insulator – 01 nos. Instruments Spares 1. Impulse tube. 2. Compensating cable. 3. I/P converters. 4. Copper tube fittings. 5. Thermocouples/RTDs. 6. Pressure, Temperature and Flow Indicators.
  10. 10. ANNEXURE – II Steam Generator Units Steam Generators The steam generating system for the power plant will consist of one (1) no. Soya Stalk/Husk, Wheat Husk/ Gram Stalk biomass fired boilers of 48 TPH capacity and all the auxiliaries. The boiler shall be of top supported traveling grate boiler, natural circulation, balanced draft, and membrane wall radiant furnace design with two stage super heaters and inter stage desuperheater designed for burning Soya Stalk / Soya husk / blend of 85% as the principal fuel for Shajapur plant and balance 15% Indian coal grade F. The boiler will be suitable to operate using 100% biomass or 100% coal during emergencies. The steam generator design parameters shall be as follows: I Maximum continuous rating (MCR)(T/hr) 48 for 10 MW II Peak capacity of the boiler as a percentage of MCR capacity % 110 % III Super-heater outlet pressure Ata 67 for 10 MW IV Super-heater outlet temperature (°C) 445 ± 5 V Feed water inlet temperature (°C) 126 VI Excess air (%) Not more than 20 VII Boiler outlet flue gas temperature (°C) 140 (max.) VIII Dust concentration at chimney (mg/Nm3) < 50 (max.)
  11. 11. The analysis of the fuel are furnished below 1) Coal- F grade 2) Soya Husk SI. NO. PARTICULARS UNIT SOYA HUSK (I) Ultimate Analysis: 1) Mineral Matter % 6.67 2) Carbon as C % 41.79 3) Hydrogen as H % 6.34 4) Nitrogen as N % 1.11 5) Sulphur as S % <0.01 6) Oxygen as O (Remainder) % 44.09 (II) Proximate Analysis: 1) Moisture % 8.63 2) Ash % 6.09 3) Voltaile Matter % 75.28 4) Fixed Carbon % 10.00 5) Gross Calorific Value (on dry basis) Kcal/Kg 3360 3) Soya Stalk
  12. 12. Moisture, % Ash,% Sulphur,% Bulk Density (kg/m3 ) Gross Calorific Value (kcal/kg) 7.6 10.5 0.10 300 3830 SI. No. Elemental Oxides (%) SI. No Elemental Oxides (%) 1. Silicon Di-oxide 23.23 7. Sodium Oxide 1.87 2. Aluminium Oxide 6.35 8. Potassium Oxide 12.38 3. Calcium Oxide 26.31 9. Iron Oxide 2.67 4. Magnesium Oxide 19.00 10. Phosphorus Pentoxide 4.62 5. Chromium Oxide 0.19 11. Sulphur Tri-oxide 3.09 6. Titanium Di-oxide 0.29 Ash Fusion Temperature (ºC) Initial Deformation Temperature Softening Temperature Hemi-spherical Temperature Fluid Temperature 1030 1080 1100 1120 Carbon,% Hydrogen,% Nitrogen,% Chlorine,% Oxygen,% 39.1 5.00 2.42 0.25 35.03
  13. 13. Pressure Parts The complete system of boiler pressure parts, covering: • Steam and water drum • Boiler Bank Tubes • Furnace water wall. • Superheated system & system including headers and Down comer pipes, Risers, Blow down & drains piping, HP dosing piping. • Desuperheating system • Economiser system Together with all required headers, integral piping, interconnecting piping, valves, fittings, supports, etc. will be provided. The circulating system essentially comprising of the drums, water walls, furnace tubes, boiler bank tubes, down comers and relief tubes shall be designed to provide an adequate circulation ratio in the system. The down comers and the relief tubes shall be sized and routed to offer minimum pressure drop and to aid the improvement in the circulation ratio. The sizing of the circulation system components shall be adequate to ensure safe circulation ratios even under peak loading conditions. Steam & Water Drum The boiler will be provided with one steam drum and one water drum of fusion welded type. Both the drums will be provided with 2 nos. manhole doors to open inwards. Steam drum is provided with cyclone and screen type separators as drum internals. The drum design pressure shall have a minimum margin of 6% over drum operating pressure. Suitable nozzles with flange of adequate thickness will be provided in the drum to mount the valves and fittings. Provision for blowdown will be given in the steam & mud drum. The drums are provided with semi ellipsoidal (2:1) dished ends. Liberally sized downcomers and risers are provided. The thickness of the drum is arrived based on the requirements as specified under IBR 1950 with latest amendment.
  14. 14. Furnace Water Wall System The Furnace envelope shall be constructed of fully watercooled membrane/fin welded walls and adequately supported. The design shall be such as to prevent distortion of steel work due to thermal expansion. The construction shall be fully gas pressure tight and the furnace shall be strengthened by providing buckstay and tie bar system. The furnace shall be adequately sized for burning the Soya Stalk/Soya Husk having ash percentage of up to 10%. & Coal having ash percentage of upto 40.0%. Necessary supporting / suspension systems will be provided for the complete system for free expansion of components when unit is in operation. Adequate number of inlet and outlet headers, with the necessary stubs, commensurate with the arrangement of the furnace shall be provided. Each of the headers shall have atleast two numbers of handholes for inspection and cleaning. The downcomers, supply pipes and raisers sizing shall be based on the circulation calculations. The water wall panel fin thickness and width shall be such that the fin tip to base temperature differential does not exceed 70 Deg C. Superheater System The superheater (SH) system shall be of two (2) stage design with inter-stage desuperheating to achieve the rated steam temperature over 60% to 100% load range. The superheater shall be of convection or a combination of convection and radiation type. The superheater pressure drop, the inlet and outlet header sizing, arrangement and sizing of their respective inlet and take off connections shall be so as to give minimum unbalance and the tube element material selection shall be based on the actual metal temperature calculations. Bank Tubes The bank tubes are of seamless Carbon Steel construction. The bank design will be of inline arrangement and the tube spacing shall enable easy removal of the tubes in case of any failure. The bank tubes shall be expanded into both the top and the bottom drums and the tubes after expansion shall be bell mouthed. Adequate number of soot blowers will be provided to cover the maximum surface area of the bank. The bank tubes are designed with a single pass arrangement.
  15. 15. Attemperator System The attemperator system, to control the temperature of the final superheater outlet steam temperature, will be provided in between the two stages of the superheaters. The interstage attemperator shall be of the spray type, using the boiler feed water tapped off at the outlet of the boiler feed water pumps, to control the final steam temperature between 60% to 100% MCR load. The desuperheater will be inter stage fixed orifice type. The desuperheating system will be complete with all required spray valve, control valves, bypass regulating valves, piping and supports etc. Economiser The Economiser will be located immediately downstream of the boiler bank. The design will be of bare tube construction with inline, counter flow, and drainable arrangement. The economiser shall be designed for an inlet feed water temperature of 126 Deg C. The economiser shall be arranged such that there is space for the future addition of about 10% of the installed heating surface area without disturbing the existing economiser coils. Air Heater The air heater will be arranged as the last heat recovery section downstream of the economiser. The Air heater will be multitubular recuperative type with flue gas flowing inside the tubes and the combustion air flowing over the tubes. Required access doors, platforms, walkways etc will be provided as required. The Low Temperature bank of the Air-preheater shall be designed to prevent corrosion and the cold end material of the airheater tubes shall be Carbon Steel. FUEL FEEDING SYSTEM & FIRING SYSTEM The firing system will consist of a spreader stoker with continuous ash discharge travelling grate with variable speed drive. The grate assembly will include the keys, air compartments, air seals, tensioning mechanism, rails, lubrication system etc.
  16. 16. The fuels from the conveyor is brought into the storage silo. The fuel from the silo provided for Bio-mass fuels falls through the drum feeder from where it is taken to screw feeder and then to pneumatic distributor for uniform distribution. DRAFT SYSTEM The boiler will be equipped with 2 x 50% MCR FD fan, ID fan and SA fan. The fans (FD & ID Fans) shall be coupled to the motor with variable frequency drive. The fan shall also be provided with power cylinder operated dampers. Wear liners for ID fan on Impeller will be provided. DUCTING SYSTEM All ducts will be rectangular in cross section and will be of welded construction properly stiffened and reinforced. All the air ducts will be fabricated from steel plates of minimum 4 mm thick and all flue gas ducts shall be of minimum 5 mm thick. The duct plate material will conform to IS 226 / IS 2062. ASH SYSTEM The ash from the fluidized bed, the Economiser / Air heater and the ESP shall be discharged through dense phase system to the main ash silo, keeping the plant clean of ash. BED ASH SYSTEM The coarse grained fraction of fuel ash is not discharged from the fluidized bed but is retained as bed ash at about 850°C. Bed ash extraction takes place through discharge pipes from the fluidized bed bottom and conveyed through dense phase system to Ash Silo. FLY ASH SYSTEM Fly ash is collected below the economiser before entering the air heater as well as in electrostatic Precipitator. Fly ash collected below economiser will be at a temperature of approximately 300 deg C whereas the fly ash temperature in electrostatic precipitator will be at 140oC. Fly ash will be disposed off through a separate ash handling plant. Conveyed through dense phase system to Ash Silo. The compressor shall be separately provided for Dense phase system.
  17. 17. CHEMICAL DOSING SYSTEM The boiler shall be provided with a common tri-sodium phosphate based High Pressure (HP) dosing system and a hydrazine and ammonia based Low Pressure (LP) dosing system. The HP dosing system shall add the chemical to the boiler water to take care of the ingress of the hardness salts and to increase the boiler water pH. The LP dosing is done to the feed water preferably at the outlet of the deaerator to scavenge the last traces of oxygen and to increase the feed water pH. HP dosing system sizing shall be with one percent (1%) concentration of tri- sodium-phosphate. The tank usable volume shall be on 24 hours basis. LP dosing system sizing shall be with 0.1% concentration. The tank usable volume shall be on 24 hours basis. Each dosing system shall include a stainless steel mixing tank with an electric motor driven agitator. Each system shall have 2x100% capacity, motor driven positive displacement type pumps, with wetted parts made of stainless steel with facility to vary the feed rate. The HP and LP dosing systems shall be mounted on individual skids with their respective tank, pumps along with all required piping, valves, fittings, supports etc. The complete piping for both the HP and LP dosing system from the skid to the respective admission points to the boiler water circuit shall be of type 304 stainless steel. BLOW DOWN TANK A single Blow down tank has been consider for continuous blow down and intermittent blow down as suitable for boiler capacity. The tank shall be fabricated from carbon steel material. ELECTROSTATIC PRECIPITATOR The ESP will have three (3) working fields with collection efficiency of around 99.8%. The outlet dust concentration from the ESP will be limited to 50mg/Nm3. Each ESP will be provided with ash hoppers having capacity suitable for storing ash collected in at least one (1) shift operation of the Boiler at 100% MCR. The Ash Hopper will be provided 2.5 M above the Ground Level. SILENCERS Silencers are to be provided for start up vent value and safety valves.
  18. 18. INSULATION The entire water wall Panels, Economiser casing, Ducts & piping should be insulated by mineral wool of proper thickness reinforced mattresses. There will be usage of PUF type insulation with Clamp on provisions. CLADDING All the insulated area will be cladded by 24 SWG Aluminum sheet. BOILER TRUSS Boiler roof with sides will be covered by G.I. sheets upto Steam Drum. INTER CONNECTION PLATFORM Inter connection platform will be provided between TG Building and Boiler operating floor. STEAM TURBINE This project envisages one (1) no.10 MW Bleed- cum- condensing turbo-generator. The turbine shall be designed for the operation with the inlet steam parameters at 64ata and 440±50 C for 10MW and shall be with uncontrolled extraction steam. a) The turbine shall be horizontal, single cylinder, Multi stage bleed-cum-condensing type for 10MW. All casings and stator blade carriers shall be horizontally split. b) The uncontrolled extraction steam from the turbine shall be delivered to the deaerator. All casings and stator blade carriers shall be horizontally split or otherwise and the design shall be such as to permit examination of the bending without disturbing shaft alignment or causing damage to the blades. The design of the casing and the supports shall be such as to permit free thermal expansion in all directions. The casing shall also permit the inspection of the bearings without dismantling of the casing. The extraction branches shall be located on the lower half of the casing. The low pressure casing shall have a bottom exhaust arrangement configuration and the exhaust casing shall be suitable for connection to the air cooled condenser without air leakage and suitable for maintaining the condenser vacuum. The turbine exhaust hood shall be provided with exhaust water spray system to protect the turbine against excessive temperature due to
  19. 19. windage at no load and low load conditions. The spray system shall be provided with complete spray nozzles, automatic spray control valve, interconnecting piping, all necessary controls, instrumentation and fittings. The turbine shall have solidly forged and machined rotor with integral disks. The rotor after fully machined and bladed shall be dynamic balanced accurately in the shop and shall be given overspeed test under vacuum. None of the critical speeds of the rotor shall fall within the range of 20% above and 20% below the normal running speed of the rotor. The rotor shall be designed to withstand the maximum shock loading that may occur during any power system disturbance. Gland Sealing System The glands shall preferably be of labyrinth type and sealed with steam. The gland packing shall be of 13% chromium stainless steel. The labyrinths shall be of multi-section spring backed type which would allow for any temporary deformation of the rotor shaft without overheating the rotor due to friction. The gland sealing system design shall permit the examination of and replacement, if necessary, of the glands without lifting the upper half of the turbine casing. During the normal operation of the turbine the source of sealing steam will be from the turbine. During the start up of the machine, steam shall be supplied externally for effecting the sealing. Required gland steam condenser with 2x100% capacity AC motor driven exhausters shall be provided. Suction fans shall have one operating fan and one standby fan. All piping and components of shaft seal system shall be sized for 150 percent of the calculated new clearance leakages. Bearings The turbine shall be provided with liberally rated hydrodynamic radial and thrust bearings. The radial bearings shall be split for ease of assembly and of the sleeve or pad type, with steel shell backed, babbitted replaceable pads. These bearings shall be equipped with anti rotation pins and shall be positively secured in the axial direction. A liberal flow of lube oil under pressure shall be supplied to all the bearings for lubrication and cooling. All bearings shall be accessible without having to remove cylinder covers. The metal temperatures of all the bearings shall be monitored by thermocouples with extension right into the white metal layer. Provision shall be made for measuring the temperature of the oil leaving the bearings.
  20. 20. Lubrication and Control Oil System A pressure lubrication and control oil system shall be provided for the turbo generator unit to supply oil at the required pressure to the steam turbine, gear box, generator and governing system. The lubrication oil system shall supply oil to the turbine generator under all the load conditions, including the turning gear operation. The oil system of the turbo-generator shall be designed with adequate redundancy and emergency provisions such that a failure of a single active component will not prevent the safe operation or a safe shutdown of the turbo-generator. The Oil System shall include the following: • One hundred percent (100%) capacity centrifugal/gear type, main oil pump driven by the turbine shaft/low speed gear shaft. A separate AC electric motor driven main oil pump is also acceptable. • One (1) No. of one hundred (100%) capacity AC motor driven auxiliary oil pump of centrifugal type, arranged to cut in automatically if the oil pressure falls to a preset value. This pump shall also meet the requirements during the start up and shutdown. • One (1) DC motor driven, centrifugal type, emergency oil pump of adequate capacity to provide adequate lubrication in the event of a failure of the AC motor driven pump(s). This pump also shall cut in automatically at a pre set value of the oil pressure. The minimum capacity of this pump shall be to ensure a safe shutdown of the turbo generator. • Two 100% capacity (one working and one standby) water cooled oil coolers. • Two 100% duty oil filters arranged in such a way that it is possible to clean one oil filter while the other is in service. The filters and the coolers shall be arranged with continuous flow transfer valves with online changeover system. • Oil storage and settling tank with adequate reservoir capacity, strainers, level indicators with float switches and alarm contacts, vent and oil mist eliminators and vapour exhaust fans. • Flow and temperature indication for oil from every bearing. • Centrifugal oil purifier with drives, interconnecting piping and valves. • Emergency gravity lubricating oil system. The auxiliary oil pumps and the emergency oil pumps shall be arranged to have flooded suction.
  21. 21. Oil Coolers The oil coolers shall be water cooled with a duplex arrangement and changeover valves. The coolers shall be of shell and tube type with removable tube bundle. The cooler shall be constructed in accordance with TEMA class C. The provided surface area shall be adequate to cool the oil with 32 Deg.C inlet cooling water temperature even with 10% of the tubes plugged. The sizing of the coolers shall consider a tube side (water side) fouling factor of 0.0002 Hr. Sq. M Deg.C./Kcal. The water velocity shall be not less than 1.5 M/sec. The coolers shall be amenable for easy inspection and maintenance and cleaning of one cooler while the other one is in service shall be possible. The cooler tubes shall be of copper, and the body and the tube sheets shall be of carbon steel conforming to IS 2062 or equivalent standards. The cooler on both the tube and the shell side shall be designed for a pressure of 5 Kg/Sq.cm (g). Filters Full flow twin oil filters shall be used, for the lube oil, downstream of the coolers and shall be piped in a parallel arrangement with a continuous flow transfer valve filter size shall be 10 - 15 microns nominal for the lube oil. Filter cartridges shall have a minimum collapsing differential pressure of 3.5 kg/sq.m. The minimum design pressure for the filters shall be the maximum discharge pressure of the oil pumps. Differential pressure gauge with alarm shall be provided across the filters. Oil Purifier A centifugal type oil purifier shall be provided for the removal of water, sediments and other oxidation products from the lube oil system on a continuous basis. The purifier shall be a separate complete package, mounted on a skid, complete by itself with drive motor, piping, heaters, valves and fittings. The capacity of the purifier shall be atleast two (2) percent of the rate of normal flow through the reservoir. Feed to the purifier shall be from the drain end of the reservoir and it’s operation shall be independent of the oil system with hose pipe.
  22. 22. Emergency Oil Tank Emergency gravity lubricating system shall be provided to assure the lubrication at the time of emergency due to the failure of the DC operated lube oil pump. This system shall draw lube oil from a overhead tank, under gravity, and shall be designed to supply oil for the coasting down period of the machine. The overhead tank shall be SS lined and the complete piping shall be of SS 304 material. The tank elevation shall be finalized based on the oil pressure requirements at the bearings. The tank shall be suitably designed for at least one hour capacity. Steam Turbine Governing System The turbine governing system shall be electro-hydraulic designed for high accuracy, speed and sensitivity of response. The governor shall ensure controlled acceleration of the turbo generator and shall prevent overspeed without tripping the unit under any operating condition or in the event of maximum load rejection. The governor shall have linear droop characteristics with a suitable range for stable operation and shall have provision for adjusting the droop in fine steps. The governing system shall have the following important functions: • Speed control • Overspeed control • Load control • Inlet steam pressure control The governor shall be configured to incorporate the following controls while operating in parallel with the grid. a) Load set point shall remain unaffected for variation of frequency between 47.5 Hz and 52.5 Hz. b) The turbine inlet steam pressure shall be maintained at the set value by controlling the power export to the grid. c) Turbine vibration monitoring system – is essentially required.
  23. 23. d) Speed Reducing Gear Unit: Should be provided between turbine shaft & Gen. Shaft. It should be single reduction & double helical type & having factor of safety of at least 1.3. Thermal Insulation and Lagging The steam turbine and the other high temperature parts, including piping supplied, shall be insulated with low conductivity inert material, where required, reinforced by stainless steel wire net between applied layers. The insulation shall be so arranged that it can be removed for access to the flange bolting, control valves and other parts that require periodic maintenance. The insulation shall be designed, such that the outer surface temperature of the insulation does not exceed 20 Deg.C above the ambient temperature. PERFORMANCE PARAMETERS The following gives the performance requirements for the turbo-generator: Sl. No Description Parameters 1. Turbine Type Extractions cum Condensing 2. Inlet Steam Parameters Pressure (Ata) Temperature (0 C) Flow (Kg/Hr) 64 ata 440 ± 5 °C 45000 3. First Extraction Parameters Pressure (Ata) Temperature (0 C) Type Quantity Requirements Minimum (Kg/Hr) 3.82 200+15 4730 4 . Air cooled Condenser Operating Pressure (Ata) 0.18 5. The economical steam rate required at Percentage load (%) 80-100 6. Rating at the generator terminals (MW) 10
  24. 24. 7. Power factor (lagging) 0.8 8. Generation Voltage (kV) 11 9. Ambient temperature for electrical equipment design (0 C) 50 10. Parallel operation with grid SEB 11. Grid Voltage (kV) 132 12. Duty Requirements 8000 Hours/year 13. Atmospheric Conditions Dusty 14. The maximum noise pressure level at 1.0 m distance for any equipment from the equipment surface shall be equal to or less than [db(A)] 85 15. The minimum continuous load at which the TG is expected to operate as a percentage of the MCR load (%) House load. 16. System Frequency (Hz) (All components of the turbogenerator system shall be designed to operate in this frequency range 50 -/+ 5% CONDENSATE SYSTEM (DRY SYSTEM) Condenser shall be of Air cooled condenser, designed for operating with atmospheric air for condensing the exhaust steam from the steam turbine. Condensate from the condensate storage tank will be pumped by one of the two (2) 100% capacity condensate pumps for each circuit through a gland steam condenser, ejector condenser and to the Condensate storage tank in recirculation mode, Excess to deaerator. The gland steam condenser condenses steam from the steam seals of the steam turbine. The gland condenser is a heat exchanger, which directs the condensate to condenser. The operating dumping capacity of the condensers will be 100% of the high pressure steam. The condensate storage tank shall have sufficient margin to provide required suction head for reliable operation of the condensate extraction pumpsets during transient operation conditions. Condensate Extraction Pumps
  25. 25. Two numbers for each circuit of hundred percent (100%) capacity condensate extraction pumps to pump the condensate from the condensate storage tank shall be provided. The pump shall be selected for a normal continuous flow rate equivalent to the maximum steam flow to the condenser under all the operating conditions. The margin on the pump capacity and discharge pressure shall be of minimum 15%, over and above the 100 percent capacity. Both the pumps shall be driven by electric motors and the flow shall be controlled by discharge throttling. The pumps shall be of vertical /horizontal type with mech. seal and shall be supplied complete with all valves, inlet and discharge piping with manifolds. The pump shall be designed to have adequate discharge head for supplying the condensate to the deaerator. DEAERATOR AND CONDENSATE STORAGE TANK One (1) Deaerator for each circuit of deaerating capacity equal to twenty percent (20%) higher than the gross MCR steam generation capacity of the boiler with a deaerated water storage tank of net useful capacity (normal water level to low water level) equivalent to twenty minutes (20 minutes) of MCR generation capacity of the boiler shall be provided. The material of the deaerator, deaerated water storage tank is SA 515 Gr 70/ IS:2002 Gr 2. The deaerator shall be of either spray-cum-tray type or spray type with counter flow of steam and Water. The deaerator and the storage tank shall be complete with all the fittings and mountings like vents, controlled vent, drains, gauge glasses, pressure indicators, relief valve, steam and water inlet and outlet nozzles etc. The complete deaerator pressure and level control systems with all the piping, fittings, valves, control valves, instrumentation etc. shall be provided. Steam (from turbine extraction) shall be supplied at the inlet of the pressure control station. The level control station shall be located at the outlet of the condensate pumps, which pump the water from the feed water storage tank to the deaerator. The condensate from the turbine air cooled condenser and the make up DM water @ 32°C, shall be piped to this feed water storage tank. The tank shall be complete with all the fittings and mountings like the vents, drains, inlet & outlet nozzles, gauge glasses etc. The Condensate storage tank and the deaerator system shall be designed considering the following condensate return and make-up water addition to the condensate storage tank : Condensate from Air cooled - Condenser (approx.) for 10MW: 45 TPH @ 58.1°C DM water from DM water tank for 10 MW: 3.3 TPH @ 32°C.
  26. 26. BOILER FEED WATER PUMPS Two (2) Nos. of 100% capacity boiler feed water pumps, with one operating and the remaining as standby, to supply feed water to the boiler. The feed water pump will take suction from the deaerator. The pump shall be single suction, multi stage centrifugal type with drive motor of suitable rating coupling common base frame, foundation bolts automatic recirculation valves etc. Each feed pump shall be capable of meeting the peak generating capacity of the boiler with a margin of 5%. The design margin on the head shall be 10% of its maximum discharge pressure requirements for the continuous operation of the boiler. The pump shall be coupled to the motor with variable frequency drive. AIR COOLED CONDENSER Technical features of Air Cooled Condenser The finned tube bundles are fixed on a “roof" type structure with an angle of 60 °. Such an Air-cooled condenser is made of cells each cell consists of: – The structure supporting the cells and bundles; No. of cells should be atleast 03. – The finned tube bundles; – The main stream manifold feeding the bundles; – The fan units with drive assembly and protection guards at the bottom of the A frame; Gear box for fan should be with low oil level & vibration protection. – The air inlet rings at an elevated level above the ground in order to provide a sufficient air inlet area; – Condensate extraction pump and Hotwell drain pumps; – Wind wall for prevention of air recirculation. Fin Tube Bundles Finned tubes bundles are rigid, self supporting and designed for handling as a complete assembly with lifting lugs. The main components are:
  27. 27. – The finned tubes – Tube sheet. – C-frame Tube bundles are made of extended surface fin tubes with 4 rows of circular carbon steel tubes wounded with helical tension wrapped LL-shape (Overlapped) OR G Type Embedded fins. Spatiality of LL- Overlpped Type Finned Tube & G Type Embedded fins. LL - Fins are ideally suitable for application upto 160 Deg.C giving increased atmosphere corrosion protection of the base tube .Fin foot is pre-formed into an LL-shape (overlapped LL) and applied to base tube under tension. G type - Fins are ideally suitable for application upto 160 Deg.C giving increased heat transfer than any of the existing technology. As the Fins are embedded in the tube material wall they are mechanically stronger than all other type of fins. The LL-Overlapped fins are the cheaper alternative of more expensive than Extruded G grooved Finned Tubes. Each bundle consists of two section i.e. primary and secondary sections. The steam condenses mainly in primary section while flowing from top to bottom. The balance steam condenses in secondary section while flowing from bottom to top. The non-condensable is extracted from the top of the secondary section through air extraction line. The secondary section works as dephlagmator for air extraction and thus it ensures proper extraction of air from each bundle and ensures effective extraction. The upper tubular plate of primary bundles is fixed to the steam manifold but can freely expand to the bottom according to thermal expansion. Cleaning pump & arrangement should be provided for on-line fins cleaning.
  28. 28. STEAM SUPPLY LINE This consists of – – Carbon steel exhaust steam duct with transition piece, hot well, balance line, expansion bellows and a rupture disc, spring supports. – The steam manifold, located on top of the air-cooled condenser is welded to the bundles in order to prevent air leakage. The manifold can also expand freely with the help of sliding pads. 02 Nos drain boot pump should be provided to remove condensate from duct. AUXILIARY COOLING TOWER In the proposed plant the Auxiliary cooling tower envisaged to cool the water which is used to cool the equipments like Alternator, Oil cooler, Boiler feed pump, ash vessels and the sample cooler. The cooling water is circulated by Auxiliary cooling water circulating pump. ( 2 x 100 % with drive motor, coupling, frame, foundation bolts, suction and discharge valves, NRVs. STEAM EJECTOR UNIT: Should be provided to maintain minimum 0.18 ata exhaust pressure in the condenser and should consist of (a) Hogger Ejector or start up Ejector (b) 02 Nos. service Ejectors, one for service & other as standby (c) Ejector condenser to condense service ejector steam in this condenser.
  29. 29. TECHNICAL FEATURES OF BALANCE OF PLANT (BOP) MECHANICAL SYSTEMS Fuel Handling System a) Biomass - Soya Stalk/ Soya Husk/ Wheat Husk/Gram Stalk The biomass handling system is designed based on the Indian biomass which requires high Handling capacity. The biomass required for TRAVEL GRATE boiler is fed by means of biomass handling system which contains ground hopper, screening unit etc. Requirement of Soya biomass at MCR for the 10 MW power station shall be 11.2 TPH considering GCV as 3500 Kcal/Kg. The raw biomass which is stored in yard is unloaded in the ground hopper by suitable movers by drag belt conveyor, and will be fed into Boiler Bunker. b) Coal The Coal handling system is designed based on the Indian Coal which requires high handling capacity. The Coal required for boiler is fed by means of Coal handling system which contains ground hopper, crushing unit, and screening unit. Requirement of Coal at MCR for the 10 MW power station shall be 12.27 TPH considering GCV as 3200 Kcal/Kg. The ground hopper contains vibratory feeder and conveying belts. The Coal is transferred to crushing unit through belt conveying system. The raw Coal is crushed by crushers to required size. The sized Coal is transferred to screen house for screening. The conveyor will be suitable for 16 hrs design and will be provided with metal detector, Pull cord switches, belt way switches, & hood cover for conveyor both side walk way at each gantry. Ash Handling System The ash handling system envisaged in this project is to collect the ash from Boilers, ESP and conveying it to the Ash silos. The ash is conveyed by means of compressed air. The ash handling system complete with collecting vessels, conveying pipe lines, ash silos.
  30. 30. The Ash Handling system will be designed to meet the following condition: a) Soya biomass Soya biomass Consumption: 269 TPD Ash content in Soya biomass : 10% Total ash collection: 26.9 TPD b) Wheat & Gram Stalk Soya biomass Consumption: 269 TPD Ash content in Soya biomass : 10% Total ash collection: 26.9 TPD c) Coal Coal Consumption : 294 TPD Ash content in coal: 38.63 % Total ash collection: 65.53 TPD In the TRAVEL GRATE boiler the ash collecting areas are Air preheater, Economiser zones. In the ESP the fly ash is collected at field hoppers and it will be transferred to Ash silos. The ash silo shall be equipped with bag filter, ash conditioner and rotary air lock feeder. Water Treatment System The water plays an important roll in the power plant. In the proposed project the raw water is taken from the bore well which are located in various locations at the site. The raw water may contain unwanted foreign matters, suspended solids, dissolved solids and pathogenic contents so the raw water should be treated at RO/DM plant and fed to boiler and softener. In RO/DM plant the raw water is treated at various stages to remove the contaminants in the raw water. The RO/DM plant consists of CLARIFIER- SOFETNER-Multi grade filter, Softener, Ultra filteration, chemical dosing systems, RO systems, mixed bed. The capacity of the DM plant will be 7 M3 /Hr 20 HRS OPERATION.
  31. 31. The raw water is fed to CLARIFIER- SOFETNER- Multi Grade Filter (MGF) to remove suspended particles in the raw water. MGF & Softner shall be designed to supply eater to DM / RO as well as to aux. cooling tower. The water from Multi Grade Filter will be passed through the softener for removal of hardness. Minerals like calcium, Magnesium, will be removed in softener with the exchange of sodium. The softener water is fed to cooling water make up requirement and Ultra filtration unit for further treatment. The filtered water is fed into the Ultra filtration system to remove colloidal contents like silica, iron, Aluminium and manganese in water causing fouling, scaling and poor performance of the plant. The treated water from ultra filtration unit is fed to Reverse Osmosis system in which a synthetic semi-permeable membrane is used to separate water from dissolved solids by applying reverse osmosis principle. The water from the RO unit is further passed through the mixed bed unit wherein the total dissolved is further removed with Cation and anion resin in the mixed form to achieve the conductivity less the 1.0 ms/cm. this treated water will be used for boiler feed. The chemicals like HCL, NAOCL and SMBS are dosed with the water at various stages to control ph of water, and de-chlorination. The De mineralized water from RO/DM Plant is stored in DM water tank of 100CUM and the water is fed to Deaerator for Boiler make up and Boiler initial filling by DM water transfer Pump. The water from softener unit is fed to Cooling Tower (or) Auxiliary Cooling tower for cooling water make up. Piping The piping system will complete with Steam piping, Cooling water piping, Compressed air piping, Raw water piping, Condensate piping, Feed piping, Ash conveying piping, DM water piping, Service water and drinking water piping, and Fire hydrant piping. The high pressure steam piping from boiler to turbine line. The steam from PRDS station is fed to ejector; gland sealing and deaerator for initial heating purpose. The Bleed Line from Turbine to Deaerator is low pressure pipings. The water from cooling tower will be circulated to cool the equipments like alternator, oil cooler, boiler feed pump, sample cooler, and ash vessels through cooling water pipe lines. The atmospheric air is compressed by the compressor; the compressed air is used for Instruments and other Service purposes. The instrument air is further treated with dryer to remove moisture in compressed air and store it in a separate reservoir. The service air is stored
  32. 32. separately in another. reservoir. The instrument air is fed to instruments in various locations at site by instrument air piping. The service air is fed to ash conveying vessels and other purposes like cleaning through service air piping. Cranes To handle the main turbo – generator set and its auxiliaries housed in the TG Building, One (1) EOT Crane with the capacity of 15 / 5 Tones will be provided. The crane will move to entire TG floor to handle the equipment during maintenance. In addition hoist should be provided wherever required. Box girders shall be provided with end plates for sealing. Full depth diaphragms or stiffeners shall be furnished at motor supports and below line shaft bearings. Short diaphragms shall be furnished where required to transmit the trolley wheel loads to the web plates. All diaphragms shall bear against the top cover plate. Rotating axle, equalizing end carriages shall be used to distribute the load evenly between the wheels from each bridge girder. End carriage and crab frames shall have built up structural steel members in welded construction to form a rigid box structure and stress relieved as per accepted standards. Safety devices shall also be provided to prevent the trucks from leaving the rails. Bridge shall be driven by two (2) independent driving units comprising of AC electric motors with IP 55 and TEFC, gear box and brakes and shall be placed (arranged parallel to longitudinal shaft) one each near the end carriage on one side of the walkway platform. Each driving unit shall be mounted on a specially designed rigid frame mounted on the bridge girder and removable as a complete system. The trolley frame shall be built up from heavy steel sections welded together to form a rigid one piece frame adequately braced to resist vertical, lateral and torsional strain and support all loads without undue deflection. The hoisting machinery shall consist a separate electric motor for each hoist with a separate self contained, sturdy, automatic, self adjusting specified brakes or other approved type interposed in the hoisting gear train as close to the source of power as possible.
  33. 33. Ventilation and Air conditioning System For proper functioning of the equipment, controls and accessories as well as to provide the right Environment for operation and maintenance of the plant, adequate Ventilation and Air- conditioning system will be provided for the plant as described below. Main control room will be air-conditioned. ESP controls will be located in the main air-conditioned control room. Roof extractors and Wall mounted exhaust fans will be used in TG hall. Battery room (dust proof construction fan & flame proof motor) will be ventilated by exhaust fans. TG hall, A/c Plant room, Cable Gallery. Weigh bridge room. FALSE SEALING will be provided in Main control room. Chemical Laboratory A central chemical laboratory is envisaged for the station. This will have necessary equipment and facilities to test and analyze steam, water, etc. require ensuring satisfactory operation & maintenance of steam generator. Thermal Insulation Insulation will be provided wherever necessary to contain heat loss from the equipment, piping duct and to ensure protection to personnel. Insulation will be held by adequate cleats, wire nets, jacket etc. to avoid loosening. Insulation thickness will be so selected that the covering jacket surface temperature does not exceed the surrounding ambient temperature by more than 15 Deg C. Turbine oil purification system A turbine oil purification system will be provided for the unit consisting of centrifuge type oil purifier, indirect oil heater, dirty & clean oil pumps and polishing filters. This will be required to condition the turbine oil continuously on by pass mode, in order to remove water and other impurities from the system to maintain the turbine oil at the optimum condition. Chimney The Steel chimney is envisaged with this Power Plant for Boiler. The flue gas from boiler contains Sulphur content. If the sulphur is exhausted in the atmosphere it will cause severe environmental problems. So the flue gas should be exhausted at safe height as per Pollution
  34. 34. control board norms. The STEEL Chimney shall be 48 Mtr heights and shall be provided suitable for long life operation. Provision for installing Opacity meter shall be made available with monkey ladder landing platforms & easy ladder upto sampling point. Compressed Air System (Instrument/Service) To cater for the plant compressed air requirements it is proposed to install Air compressor for the instrumentation air system and plant service air system separately. The compressors shall be 1W + 1S for each service. It is rotary, screw type non-lubricating type, complete with inter cooler, after cooler. The compressor will be oil free type. Heavy-duty dry type intake air filter, conveniently located for quick and easy replacement with cyclonic separation and arrangement for pre filter separation. The compressor shall be supplied with adequately designed air cooled radiation type oil cooler and after cooler to take away the heat of compression from the oil. Copper finned tubes shall be used for air cooled versions. The air receiver shall be vertical cylindrical welded construction with elliptical / for spherical dished heads and Auto drain facility. The compressed air drying unit shall be refrigerant type. It shall consist of close-loop refrigerant circuit in which compressed fluid shall be chilled to a controlled temperature and so condensed moisture could be separated out. To prevent freezing of condensed moisture on the refrigerant coils, air/gas should be chilled to a minimum temperature of 2 to 3 Deg.C approximately. The dryers shall be designed for automatic regulation with Auto draining and to adjust themselves to varied load conditions. The regulation system shall consist of an expansion valve in the refrigerant circuit to maintain the flow of refrigerant into the evaporator and Fan control switch to start and stop the condenser fan motor to maintain near constant condenser pressure. The dryers shall be provided with a control system for precise control indications and safety features
  35. 35. Weighbridge Weighbridges are large scales that are usually mounted permanently on a concrete foundation weighing scales that are used to weigh entire vehicles and their contents. By weighing the vehicle both empty and when loaded the load carried by the vehicle can be calculated. The weigh bridge shall be of 40 Ton capacity Pit-less type. The weigh bridge room shall be air conditioned. ELECTRICAL System  All Electrical equipments shall conform to relevant IS/IEC standards and recommendations of IEEE standards.  132/11kv Switchyard in power plant for power evacuation through 12.5 MVA Transformer as per standard Aster design shall be providing to meet MPSEB requirement. The transformer shall be provided with OLTC, with import & export facility.  Fault level at 11 kV is 26.3 kA for three seconds and all bus bars shall be of AL bars.  Fault level at 415 V is 50 kA for one second.  Low voltage motors have class ‘F’ insulation with temperature rise limited to class ‘B’ offering high electrical and mechanical stability.  Motor Control panels comprises of Low voltage Switchgear such as Air circuit breakers, Fuses.  Fuse-Switches, Contactors, Bimetal Overload Relays, Electronic Timers, Motor Starters Pushbuttons and Miniature circuit breakers.  High Voltage switchgear shall be designed for rated voltage and rated power frequency to withstand the short circuit current Breaker shall be Triple pole, single/double break and high speed and Rack out draw type.  Vacuum/SF6 circuit breaker. The circuit breakers shall have three distinct and separate positions on the cradle viz. Service, Test and Isolated with provision for locking the breakers in any of these three positions.  Cables shall be suitable for laying in conduits trays or for direct above ground in both wet and dry locations in cable gallery only. Entire plant shall be free of underground cabling.  The breakers shall be Rack out draw type and provided with protection as per IP-55 standard.
  36. 36.  110VDC system shall be provided with DCDB, Charger and SMF batteries. The DC system for TG application and Electrical Switchyard shall be separate.  240 VAC UPS system shall have 60min backup.  APFC shall have PF improvement of to maintain the overall system PF @ 0.9 ranges. Plant Electrical Systems The Plant Electrical System is covering major equipment such as Generator, Unit Auxiliary Transformer (UAT), Generator Transformer, Breaker panels, MCC, Switchyard, Earthing, lighting and cables, as per approved SLD Generator: The rating of the Generator would be 10 MW at 11 KV. The Generator winding would be star connected with phase and neutral terminals brought to an accessible position. The star point of the Generator would be connected to earth through Neutral Grounding Resistor. Necessary protection for various parameters shall be provided as required. Complete system shall be provided with NGR panel, LAPT panel, Synchronizing panel, Generator protection panel (with one numerical relay of AREVA/ABB/GE make GPR for Generator ) The Generator will be air cooled with Brushless Excitation. Generator would be provided with class-F insulation and temperature rise will be limited to Class-B level to ensure longer life. Following shall be the main parameters of the Generator. • MW rating : 10 MW • Voltage Rating : 11 KV • Rated power factor : 0.80 Lag • Related frequency : 50 Hz • Voltage Variation : ± 10% • Frequency Variation : ± 5% • Unit Auxiliary Transformer (11KV/415V, 1.6 MVA ) One Unit Auxiliary Transformer shall be provided to feed unit auxiliary loads. The Transformer shall be designed to withstand electrical impulses and dynamic stresses. Solid Earthing shall be provided in secondary winding of Transformer. Necessary protection for various parameters shall be provided as required. (As per IP-55).
  37. 37. LTPCC and MCC: LTPCC acts as a Power Distribution Board, which comprises of 4-pole draw out Air Circuit Breaker in its incoming feeder and 3 poles ACB and MCCB in outgoing feeders. Necessary protection such as Earth fault and Over Load Relay shall be provided in all incoming and outgoing feeders. Motor Control panels comprises of Low voltage Switchgear such as AL BUSBAR, Air Circuit Breakers, Fuses, Fuse Switches, Contactors, Bimetal Overload Relays, Electronic Timers, Motor Starters ,Push Buttons, and Miniature Circuit Breakers. The various auxiliaries will be supplied at the following nominal voltages depending upon their ratings and functions: (a) The 415V, 50Hz, 3-phase, 4-wire supply for auxiliaries will be obtained from 11kV/ 415V Transformer through LTPCC. The 415V system will be Solidly Earthed. (b) 230 V, 50Hz, 1- phase AC supply for lighting, Space Heaters, single phase Motors, etc. 11kV HT breaker panel: The 11kV generated voltage from Generator is given to the Indoor HT breaker panel by XLPE (UE) cables. The HT breaker offered is Vacuum Circuit Breaker. The parameter of VCB is given below. Circuit Breaker type: VCB Short Circuit Current: 26.3 kA for 3 sec. The Generator switchboard is housing four breaker panels, one for Generator, one for Auxiliary Transformer, one for Power Transformer and one as spare. All the breakers are provided with necessary protection and metering features. The breaker can be operated by manually or motorized, with trip free Mechanism. Cabling system: The following types of cables will be used: (a) For 11 kV system: 11 kV unearthed grade, stranded Aluminium Conductor, cross linked polyethylene (XLPE) Insulated, PVC inner sheathed, Galvanized single steel wire armored for three core, or Aluminium wire armored for single core and overall extruded PVC sheathed cables.
  38. 38. (b) For Low Voltage System: Power cables of 1100 V grade, stranded Aluminium conductor, PVC insulated, PVC inner sheathed, galvanized single steel wire armour for three core or aluminium wire armour for single core and overall black PVC sheathed Cables conforming to IS:1554. (c) For Control Applications: 1100 V grade annealed high conductivity stranded copper conductor, PVC insulated, PVC inner sheathed armour and PVC outer sheathed control cables conforming to IS:1544. (d) For Instrumentation Applications : Stranded high conductivity annealed tinned copper conductor, PVC insulated, flexible, twisted pair /triplets, individually and overall shielded (for low level analog signals) and only overall shielded for digital signals, PVC inner sheathed, galvanized steel wire armour and overall PVC sheathed cables. Safety Earthing System: The plant safety Earthing consists of a buried grid provided to alternator, transformer and other outdoor areas interconnected with Earthing grids provided in various plant buildings. The buried Earthing grid will be connected to suitably located Earth Electrodes. All metallic conductive parts in the plant buildings which risk accidental contact with a live conductor and cause damage to Equipment and danger to life will be connected to Earthing grid inside the building through earth leads. All equipment is generally earthed at two points for reliability. Main equipments should be earthed with copper strip. Separate earthing shall be provided for electronic instruments. Plant Lighting System: The Lighting system comprises of Lighting Distribution Board which distributes the supply to Main Distribution Board at corresponding Location. The appropriate lighting equipment such as sodium Vapour lamp, High bay lamp, etc will be provided based on the illumination requirement. Control room lighting should be as per IS standard. Out side lighting will be provided with High Mast Tower lighting in Two places.
  39. 39. Switchyard: The power received from the grid is used for running the plant and the power produced by the Turbo Generator is evacuated to the grid. The Switchyard is installed with SF6 circuit breakers, Current Transformers, Potential Transformers, Isolators, Lightning Arrestors, etc., Power Transformer of capacity 12.5 MVA, 132/11 KV is considered for this plant. Instrumentation and Control System The plant will be designed with Distributed Control System (DCS) to co-ordinate and control Boiler, STG and Balance of Plant operation from control room. DM plant and Fuel-Handling Systems shall be controlled from their respective local control panel. Important parameters and status indications of these systems will be made available on the operator station in the control room, Air compressors operation should be covered in DCS scope. Distributed Microprocessor Based Instrumentation: A Microprocessor-Based (DAS) BASED System is proposed to provide a comprehensive integrated instrumentation and control system including the functions of Data Acquisition System (DAS) to operate control and monitor the Steam Generator with its auxiliaries. Steam Turbine Generator with its auxiliaries and utility systems with a hierarchically distributed architecture in view of the following advantages:- • Increased reliability • Better availability • Higher system security • Increased flexibility • Modularity and expandability • Higher maintainability • Drift free control • Lower Power consumption • Lower Operating voltage • Improved man-machine communication with color graphics TFT based control stations • Increased data collection and storage capability • Faster response time
  40. 40. DCS Features: The DCS will include the necessary system and application software to achieve control and monitoring functions and data acquisition functions like logs, reports, trends, curves, performance calculations and historical storage. DCS incorporates the latest technology to provide functionally distributed architecture and reduce the risk associated with the failure of any single control units. They provide hierarchical system structure to facilitate the task of integration, co-ordination and operation of the plant equipment / sub-systems. DCS functions include: (a) Data acquisition for measurement monitoring and control: (b) Historical data logs (Automatic generation of 8 hour report & print) (c) Trending (d) Reporting (e) Data conditioning and processing. (f) Control functions such as: 1. Binary control (open loop control) – on/off logic and protection logic 2. Sequential Control. 3. Analog control – Closed loop control 4. Supervisory control and monitoring functions for plant utilities. (g) Measurement & Monitoring functions (h) Annunciation & Alarm reporting The control system will be provided with 230 V AC UPS (with back up capacity of 60 minutes). Uninterruptible Power Supply (UPS) will be provided to cater the 230 V AC, Single phase, 50Hz,
  41. 41. 2 Wire power supply requirements of the DCS system. The closed loop controls, sequence controls, protection and interlock system will work on +24 V DC voltages. Control Philosophy: The operation and monitoring of the complete plant will be from the control desk /panel located in Control Room. The operator will perform the following operations from the control desk TFTs. (a) Operation of pumps, Fans, Motors associated with the SG, TG, Coal Handling System, Cooling Water System and their Auxiliaries. (b) Operation of all control valves, dampers of the SG, TG and their auxiliaries. (c) Carry out associated control operations with the aid of Plant overview, group display, individual loop display etc., (d) Plant start-up, normal and shutdown operations will be from DCS. In case of DCS Failure, hard-wired back-up operation is envisaged for a safe shutdown of the plant. (e) For safety and reliability, dual redundant sensors will be provided for critical closed/open loop controls. Redundant sensors will be provided with automatic signal selection and rejection features in the DCS. (f) Pre-alarms will be provided whenever necessary to avoid tripping of the equipment, to increase the availability of the plant and to provide adequate information to the operator regarding plant status. Monitoring Instruments: 03 Nos. Monitors 21”, 1 NO. Dot Matrix Printer for reports. (Two as operator station & one as operator cum Engg. station). Standard furniture for DCS operation. They include electromagnetic type indicators, electronic indicators digital display units, drum level Indicator, Ammeters, Voltmeters, Frequency Meters, Power Factor Meters and Energy meter which are essential for starting, loading ,running and shutting down of the unit. Local Instruments: (a) Local instruments will be provided to enable local operators to supervise and monitor equipment/ process.
  42. 42. (b) All transmitters for measurement and control will be electronic type of two wire systems with 4-20 mA DC output-SMART versions (c) All thermocouples will be duplex type and signal transmission through compensating cables (d) All temperature inputs for control will be taken to the system through temperature transmitters. (e) All RTD inputs will be directly wired to Temperature scanner. CIVIL & STRUCTURAL WORKS The main power plant building will be a RCC/ PEB framed structure with brick walls upto roof level. The floor slabs at intermediate levels will be of RCC supported on RCC beams & columns. The roof slabs covering and the MCC room portion of the buildings will be RCC construction whereas the maintenance bay of the TG building will be of Steel roof construction. The structure will be designed to cater for one (1) EOT Crane (15/5 Ton) to handle heaviest load required in handling TG set. The doors and windows will be of metallic frame with glazing to avail natural light. The auxiliary and ancillary buildings will generally be in RCC/Steel framed structure, RCC roof slabs/sheets and brick walls. MCC/PCC room should be on intermediate floor. DESIGN LOADS Design loads for all structures will be determined according to the criteria described below:- i) Dead Loads Dead loads will consist of the weights of the structure and all equipment of a permanent or semi permanent nature including tanks, silos, bins, wall panels, partitions, roofing, piping, drains, electrical trays, bus ducts and the contents of tanks measured at full capacity. ii) Live Loads Live loads will consist of uniform live loads and equipment live loads. Floors and supporting members which are subject to heavy equipment live loads will be designed on the basis of the weight of the equipment in addition to a uniform load of 500 kg/m2, or specifically defined live loads, whichever is greater.
  43. 43. Live loads will be used as follows:- a) Ground Floors Ground floor slabs will be designed for a minimum of 1,500 kg/m2 in all areas. b) Suspended Floors Suspended concrete floor slabs will be designed for a uniform load of 1000kg/m2, except for the following:- i. Control room areas : 1200 kg/m2. ii. Storage areas : Mass of stored material, but not less than 1000kg/m2. iii. Turbine generator : Determined by loads of laydown area major components, but not less than 1,500 kg/m2. Suspended grating / chequered plate floors will be designed for a loading of 500kg/m2 to the supporting members. c) Roof Loads All roof areas will be designed for wind loads as indicated in IS: 875 (Part-3). All roof areas will be designed for imposed loads as per IS: 875 (Part-2) in addition to calculated dead loads. d) Impact Loads Impact loads will be added to other loads for structural components supporting reciprocating or rotating machines, elevators, hoists, cranes, or other equipment creating dynamic forces. The impact loads will be as per IS: 875 (Part-2). e) Pipe Hanger Loads Pipe hanger loads for the major piping systems, such as the main steam, feed water and extraction systems will be specifically determined and located. f) Equipment Loads Equipment loads will be as per Vendor drawings.
  44. 44. g) Access Walkways, Staircase, Handrails and Ladders The walkways will be designed for the dead loads of the structure plus a superimposed live load of 500 kg/m2 uniformly distributed, or a concentrated load of 150 kg at any point, whichever produces the most severe effect. Stair treads will be designed for a distributed load of 225 kg/linear meter of tread width or a concentrated load of 100 kg, whichever produces the most severe effect. Handrail forces will be 100 kg applied outward at the center of the span and vertical between posts. Ladders will be designed to withstand a live load of 100 kg. h) Wind Loads Wind loads for all structures will be based on IS-875 (Part - 3). i) Seismic Loads The seismic risk zone for this site will be determined from the IS:1893-1984. Seismic loading will be used in the design of structures only when they are greater than the computed wind loads. SPECIFICATION: - FOR CIVIL WORK EXECUTION Boundary wall : - Width : 9 inches Height : 2 m from NGL Column center : At every 3m Column size : 6” X 9” Above boundary wall 1 run of barbed wire will be provided on 45* 50 x 50 size angle Plant road : - 6 mts wide 100 mm PCC 150 mm RCC Weigh bridge room : -
  45. 45. Size – 3 mts X 3 mts Two side Aluminium window and one aluminium door. Security Room : - Size : - 3 mts X 3 mts X 3 mts, Two side window and one door. Watch Tower:- 1 x1 Mtr size platform at an elevation of 5 meters from ground level with asbestos sheet roof on tom. Administration building :- Double story. Ground floor – Office room -02 nos, Size - 3 mts X 3 mts X 3 mts with false sealing Hall – 01 no., Size - 6 mts X 12 mts X 4 mts with Urinal and Toilet . First floor – A) Room 02 nos, Size : - 4 mts X 3 mts X 4 mts with attached Toilet and single window. B) Dinning Hall – Size : - 6 mts X 4 mts X 4 mts, window at outside wall. C) Kitchen : - Size : - 3 mts X 3 mts X 4 mts Slab for cooking at 1 mt level. Exhaust fan provision, sink and arrangement for water purifier. Plant Store : - A) A)Room - Size : - 4 mts X 3 mts X 4 mts, 02 Nos side window (glass) B) B)Hall : - Size : - 6 mts X 3 mts X 3 mts, Fixed steel window – Two side. Testing lab : - Size : - 6 mts X 4 mts X 4 mts . Working slab at 1mt level at two sides. Aluminium window and door false sealing. Work-shop:- 15 mtr x 12 mtr size floor with roof at 5 mtr height and suitably covered sides with wide opening for entrance and door. Site Office:- 15 mtr x 20 mtr size shed with asbestos roofing and false ceiling and covered with brick walls to accommodate site staff of both company and contractor.
  46. 46. TG BUILDING : - A) AT 3.5 Mts LEVEL – MCC / PCC / BREAKER ROOM – 6 Mts X 18 Mts. B) AT 6.5 Mts LEVEL – TG HALL – 12 Mts X 18 Mts – CONTROL ROOM – 6 Mts X 15 Mts – OFFICE – 02 NOS – 3 Mts X 3 Mts (Glass partition) C) AT 10.5 Mts LEVEL – Deaerator foundation beam and PRDS System. D) AT 14 Mts LEVEL – EOT crane rail. Rain water harvesting system shall be provided in all the buildings with pits. Suitable area for truck parking shall be developed and provided. Bachelor’s accommodation shall be provided for at least 20 nos. EXTERIOR ARCHITECTURE Doors, Windows / Ventilators Door, Window and Ventilator frames will be made of extruded aluminum, steel, or other tried and proven material which is resistant to the corrosive environment. All windows will be fully flashed and sealed for weather tightness. Equipment Access Doors Large access exterior doors of vertical lift Rolling shutter type with weather seals and wind locks will be provided. Roofs RCC slabs with proper waterproofing will be provided for main TG building and other critical building. Galvanized steel sheets will be provided on the roof of other buildings with water proofing treatments; adequate slopes and roof drainage indicating rainwater down comers. Lighting Lighting fittings and fixtures will be provided for proper illumination in all buildings as per good Engineering practice. Outdoor area shall be provided with Mast lighting tower.
  47. 47. Auxiliary buildings The Power Station with provision for expansion is proposed to be installed in the space earmarked. Land is partly level and therefore no major cutting & filling has been envisaged. Soil is top over hard clay & rocks. The soil bearing capacity will be determined after conducting detailed soil investigation. The precise plant formation level will be finalized after contour survey of the area high flood level and according to the site. The general criteria for various designs will be as follows: – All RCC structures will be designed as per IS:456 and all structural steel structures as per IS 800 and IS 875 and IS 1893 pertaining to wind and earthquake forces. – Mud mat concrete for all foundations shall be of grade M-10 and shall be minimum 75 mm thickness. – Dust load on roofs for any structure will be assumed as 100 kg/m2 in addition to live load. – A surcharge of 1500 kg/m2 at graded level will be assumed for design of all foundations and structures. – Wherever external staircases provided for the buildings etc., the same will be extended up to the roof. In case of non-provision of external staircases, a cage ladder will be provided as an access to the roof. MISCELLANEOUS CIVIL WORKS All Precast cover slabs for trenches will be provided with MS edge protection angles on all sides with epoxy painted (minimum size of angle 50 x 50 x 6 mm). Trench edges will be provided with suitable protection.Civil foundation will take into consideration soil bearing capacity, water table and equipment loading data.
  48. 48. Concrete quality for various works shall be :- – M30 TG chimney and any other special foundation – M20 Station building columns foundation, boiler structural foundations, transformer yard, beams, slabs, pedestals, columns, floors and ancillary building, Air cooled condenser structure etc. – M20 Grade slab and other miscellaneous items – M10 Sub-grade filling, mud/mat plinth protection etc. Suitable Compound Wall with barbed wire fencing, wherever required, will be provided around the power plant for safety and protection of the installation. The ash dump will be identified and located in the close proximity of power station and connected with a road for dumping dry ash from silos in truck. Internal roads have been planned as per the layout for power plant block. The roads shall have drain on one side and street lighting poles on other side. Compound wall with fencing shall be providing based on plot layout . Security points with outpost shall be provided. The civil work in Ash handling system includes construction of Steel silos fly ash. Plant raw water storage tank having two compartments to facilitate maintenance, raw water pump house for conveying water further to DM plant etc. PILE FOUNDATION * Not Required as per SBC data provided by Owner, In case Pile foundation is required the additional cost shall be discussed and mutually arrived. PAINTING: Final painting of steel structure which are site fabricated should be done by single coat of red oxide and two coats of synthetic enamel/epoxy paint shall be in scope of EPC contractor.
  49. 49. ANNEXURE – III TERMINAL POINTS • Raw water tank inlet. • Ground hopper inlet for biomass/ coal. • Up to ash silo outlet. • Drains up to drain pit. • Flue gas at the outlet of the chimney. • Power evacuation up to power plant substation gantry inside boundary limits. • Construction power shall be provided at one point inside plant area. • Construction water shall be provided at one point inside plant area. EXCLUSIONS • Procurement of land and cost thereof. • Transmission line and bay, statutory fees thereof. • Raw water & fuel analysis and the corresponding documents shall be provided by owner to EPC contractor for detailed engineering. • Preparation of environment impact assessment report and related government authorization. • Security for the plant except within the battery limits. • Operation and maintenance of the plant. • Water and power required for construction of the plant as per battery limit. • Fuel storage and its handling beyond the battery limits. • IDC, PRE-op expenses, contingencies, financial services & co-ordination with financial institutions. • Route survey for raw water supply, transmission line , etc. • Legal advice on the work except related to EPC contract. • Getting no objection from electricity board for generation of surplus power and exporting same to grid. • Construction of bore well for construction as well as continuous water supply.
  50. 50. • Obtaining clearances and fees thereof from MOEF / Pollution control board / SEB / Elect. Inspector. • Obtaining permission from ground water authority. • Obtaining clearance for wheeling power from the source to destination. • Raw water intake canal ( or ) pipe line to water reservoir in the power plant. • Future expansion of buildings / foundations. • Any pipe, cabling, instrumentation beyond battery limits. SERVICES AND UTILITIES TO BE PROVIDED BY THE OWNER • Space for operating & main staff during construction and commissioning. • Power required for construction at free of cost. • Power for start up at free of cost. • Water required during construction & commissioning at free of cost. • Project land free of any legal issues. • All or any kind of liaising work related to or what so ever liaising or statuary requirements.
  51. 51. ANNEXURE – IV GENERAL TERMS AND CONDITIONS FOR ENGINEERING, SUPPLY, ERECTION & COMMISSIONING AND HANDING - OVER OF THE PLANT. INTRODUCTION The purpose of this document is to state the conditions that will be diligently followed by the EPC contractor for Engineering and Supplies for “10 MW nameplate capacity plant” supplement with associated auxiliaries for operation as a station with grid connectivity. THE CONTRACT The contract or the contract agreement ( the terms are interchangeable in this context unless otherwise specified ) means the agreement that will be entered into between the EPC contractor and the Owner for execution of works that includes the Commercial conditions of contract, Technical specifications, Letter of award and acceptance, the documents referred to and schedules and drawings annexed to the agreement and those addendums, revisions and change orders agreed to by both parties with express understanding of their inclusion in the agreement as and when such occasion arises at a subsequent date. This part, commercial condition of contract for engineering and supplies (hereinafter contract through out this section unless otherwise mentioned ) shall deal with engineering, design, drawing and supply of equipment, machineries, components and things that will form the plant at the site. Contractor The contractor means the EPC contractor whose offer was adjudged the most suitable and acceptable by the owner for award of contract and whose Letter of acceptance was received for entering into the contract. It includes the legal successors of the contractor but not any assignee.
  52. 52. Sub Contractor Sub- contractor means the person, firm or company to whom any part of the contract is sub- let by the contractor as per contract or with the written consent of the owner. The contractor remains responsible and liable to all acts of the sub contractor in the same way as it is responsible for its own employees and agents. The term includes Vendor, Sub Vendor and Supplier for this contract who are named in the tender for specific works NOTICE All notices to be given under this contract shall be in writing and in the English language. All certificates, notices or written instructions to be given by each party, owner and the contractor shall be delivered by hand with acknowledgement, or sent by registered post or by speed post and the acknowledgement be collected for records. Notices given by registered post with acknowledgement shall be deemed to have been received on the date of acknowledgement. In case of service of notice by telex, email, facsimile, a hard copy duly signed by the server of notice must reach the receiving party at the address given as under. In all cases electronic communications shall be deemed as Notice, should the receiver duly gives the acknowledgement for it. Otherwise the day of receipt of the hard copy by registered post duly acknowledged shall be considered as day of receipt by the receiving party. Notices shall be effective when received by the recipient. If to Owner (It will be copied to the Owner’s Engineer): Attention : Designation : Address : E-mail : If to Contractor (It will be copied to Contractor’s Rep at Site): Attention : Designation : Address : Fax : E-mail : CONFIDENTIALITY AND NONDISCLOSURE
  53. 53. Confidential Information The owner shall furnish to the contractor information which shall be proprietary in nature and sensitive in character to the extent that it may affect the owner’s development of the project in hand and other ongoing business if disclosed or passed to others. The contractor shall also be preparing documents based on the information of the owner and its principals and in house expertise which if disclosed to others, may jeopardize the development of the owner’s project. All these are “Confidential Information”. The owner and the contractor expressly agree that either party shall not use the confidential information for any purpose other than the contract. Limited Disclosure The contractor expressly agrees that it will ensure that its employees, officers and directors will, take all precautions and measures to ensure that its sub- contractors, vendors, suppliers and others will, hold in confidence the technology, processes and its drawings, designs and other related documents and all information, documentation, data, know-how disclosed to it by the owner and / or prepared specifically for the owner based on the supplied information for the plant and will not disclose to any third party or use any part thereof without the owner’s prior written approval. The contractor also undertakes to disclose confidential information only to those of its employees, sub-contractors and vendors who are engaged in the work on a need to know basis.
  54. 54. Disclosure As Required under Circumstances Confidential Information may be disclosed to (i) a Governmental body pursuant to legal requirements and (ii) to lenders and bankers whose duties reasonably require such disclosure and such parties shall first have agreed not to disclose the relevant confidential information to any other person for any purposes whatsoever. Information Available The restrictions shall not apply, or shall cease to apply, to any part of proprietary information, specifically developed or acquired information for the setting up of this Plant or trade secrets relating to owner’s business that i) is in the public domain ; or ii) was otherwise in the rightful possession of the contractor without any obligation to keep such information confidential, at or prior to the time of the disclosure; or iii) was obtained by the contractor in good faith from a third party entitled to disclosure it. Disclosure required by Law If the contractor is required by Law to disclose certain information in the document or information supplied to it by the owner relating to the plant for execution of this contract, the contractor must promptly give notice to and consult with the owner about the disclosure; and use its reasonable endeavors to minimize any such disclosure. Survival The confidentiality contained herein shall survive the termination or expiry of this agreement. Communication All communications between owner and contractor shall be in English and the copies shall be marked to owner’s engineer and contractor’s site in charge respectively.
  55. 55. REPRESENTATIONS AND WARRANTIES Either party is not in default under any agreement to which it is party or by which it or its property shall be bound, or in any material default of any obligation, which could have a material adverse effect on the ability of the parties to perform their respective obligations under this contract. The parties shall execute and deliver all further documents and instruments, and provide such further assistance that may be necessary or desirable in the reasonable opinion of other party to carry out the provisions of this agreement or to effectuate the purpose or intent of this contract. Representation by the EPC Contractor The contractor represents to the owner as an experienced EPC contractor with wide exposure in such contract execution and has successfully completed plants of comparable size in the past and has technical, commercial and financial resources with adequate in house expertise and supporting manpower for undertaking the assignment. The contractor guarantees and give warranty that the supplies shall conform to the specifications ; all supplies be new, unused and shall be manufactured and produced from materials of appropriate quality and meet the purpose, duty and operational requirements for which they have been supplied throughout their life cycle exhibiting no defects, flaws, faults and failures in use. The best available technology shall be utilized and latest industry practices shall be followed for all supplies and their duties in operation. The contractor undertakes to repair, rectify, replace as a part of its obligation the machineries, components and equipments that are found to be faulty in design, poor in workmanship, deficient in material of construction or such other which affect the operation, safety or deliverance in any manner. The contractor represents that all documents including invoices, billings, waivers, certifications, releases, and reports submitted to owner, government agencies or bodies constituted under law per this contract shall truly reflect the facts about the activities and transactions to which they pertain and contain no material misstatements or omissions. Contractor further represents that all of such documents and reports shall be complete and accurate and understands that owner and other recipients will rely on those documents and reports though acceptance of such reports and documents does not constitute the
  56. 56. agreement of owner with their contents. CONTRACTOR’S DUTIES & OBLIGATIONS WORK SCOPE Works scope means the complete works to be undertaken by the contractor under the contract including engineering, design, drawings, supplies of machineries, equipments, components, assemblies to form the plant equipment at site meeting the specifications and terms given in this document. It is inclusive of such engineering drawings and supplies which are not specified in the documents or the contract but need to be done and supplied for completion of the works in the contract. Design Criteria The contractor shall be responsible for the design of the plant and its detailed engineering including auxiliaries, systems and all things within the battery limit barring exclusions, agreed and acceptable to the owner, which are not in the work scope of the contractor. The contractor has to ensure that the design conforms to and in line with the specifications given in the document and the orders are placed on sub-contractors and the equipments and machineries such as Boiler and Turbo generators, etc need to be designed conforming to criteria laid down for it by corresponding regulatory/statutory body and need to be approved by the inspectorate at Central / State level. Similarly for all such equipments, machineries and components the contractor has to meet the design criteria and seek necessary permission from the constituted bodies as required by law. The contractor shall promptly communicate its plan, action and response from the government and other empowered bodies for such permissions to the owner. Engineering Documents The contractor has to give the owner sets of engineering documents in the form of Drawings, Manuals, Inspection Certificates, Test Repots and such others for the purpose of furnishing information, ordering of components and equipments and dispatch to site etc. These are to be furnished in as much detail as practicable as they form the basis for owner to take a decision and should the information be not sufficient, the owner will ask for more and detailed information. Design drawings will constitute a large portion of all documents and shall need owner’s approval prior to ordering. Approval and acceptance of documents or rejection / conditional approval giving reasons for modification, changes, incorporation / deletion of items or any other shall be done by the owner within reasonable time and the contractor shall be communicated action and return of documents with remarks wherever
  57. 57. applicable. The contractor shall furnish the schedule of supply of engineering documents taking care to give sufficient slack time for their perusal and approval / instruction for further action. Technical Standards & Codes The design, drawings, engineering documents need to conform to the technical standards and codes applicable to them and acceptable to the owner and the authorities in the state of location of the plant and India , dependent upon their respective regulatory bodies for approvals, consents and no objections, need to be sought for the setting up of the plant. The contractor shall plan out and furnish alongside each equipment / component the standards and codes applicable to it and the equivalent followed in India and acceptable to concerned authorities. The contractor shall initiate steps at appropriate time, observing the procedure for filing application, furnishing information and data and making representations and attending meetings for obtaining permissions in time. The contractor is deemed to be fully aware of the statutory bodies, regulations, approval procedures and documentation required for installation of different equipments and machineries forming the plant. DRAWINGS Submission of Drawings The contractor shall submit all drawings, samples, patterns, models in numbers and form as given in the schedule in the program for owner’s approval in writing. They will include all such drawings under the engineering and supplies to the owner. The drawings shall be drawn at a scale that make the drawings legible conforming to ISO/DIN standard and dimensioned in the metric system and supplied in standard sizes. The contractor may use some of non standard drawings for proprietary, patented and special drawings with prior intimation to and permission by the owner. Approval of Drawings All drawings shall be submitted to the owner for approval. Those which need no approval, the owner shall acknowledge and then it will be deemed to be approved. All approvals shall be made on the drawing itself and the reasons for disapproval, conditional approval, wherever applicable, shall be explained in sufficient detail in the covering letter with reference to the drawing and be returned back to the contractor within a reasonable time. All such drawings that need to be modified or corrected shall be done promptly and re- submitted for approval. Delay due to disapproval of drawings shall be entirely to contractor’s account. The contractor shall furnish to the owner three copies (1 original + 2 copies+1CD)
  58. 58. of each drawing for approvals. Contractor’s Responsibility The approval of drawings by the owner is in principle agreement to the basic concepts and conformity to the contract requirements in general. It doesn’t dilute the contractor’s responsibility in any manner. The contractor continues to be responsible for the consequences of errors, discrepancies, omissions, disregard to site situations or oversight of inaccuracies with regard to corresponding drawings for dovetailing and these shall be considered to be contractor’s negligence and all consequences thereof shall be entirely to contractor’s account. The contractor shall enjoy no relief for delay, remedial action or cost incurred for alteration caused by its own mistake in preparation of drawings. Use of Owner’s Drawings The contractor will receive from the owner information including but not limited to the drawings, specifications, technical data, design guidelines and clarifications during the course of award and execution of this contract and the contractor shall develop documentation based upon the information supplied as a part of performance under this contract. All these receipts and developed documents shall be returned by the contractor on completion of this contract and remains the property of the owner. Records of communication and retention of documentation relating to proof of discharge of duties by the contractor which shall be retained by the contractor shall be treated under confidentiality and non-disclosure and survive for the period after completion of the contract and termination.
  59. 59. Drawings of Machines and Equipments The contractor shall supply all the drawings which it prepared or obtained from suppliers which will be required for the purpose of dismantling, assembly, maintenance, spares ordering, troubleshooting or for such other purpose in future. The owner shall not demand the drawings relating to manufacturing practices for the machines or those which are proprietary in nature and can be reasonably assumed to be of no use for the machine or equipment user. Final Drawings The contractor shall compile the whole set of drawings which truly represent the machineries and equipments supplied and as built at site after the changes and modifications they have undergone. The final plant layout and all other drawings on completion shall be prepared and be furnished to the owner under the package “As Built Drawings”. Inspection and Testing Test Observation The contractor expressly offers and vests on the owner the right to access all information relating to plant and machineries at its possession, inspect machines, equipments and materials of construction at different stages of manufacture in contractor, sub-contractor and supplier’s premises and examine and observe the tests. The contractor shall furnish the list of scheduled tests well in advance to the owner for its preparedness to be present at the place of testing on the appointed dates. The owner may communicate in writing to the contractor to go ahead with the test(s) where its representative’s presence is waived for the particular test(s). In such cases the contractor shall send the Inspection Report and Test Results along with its observations promptly to the owner. Presence and deemed presence of the owner in no way relieves the contractor from any of its obligations under this contract.