5 mw cogeneration plant in ikwo, ebonyi, nigeria mw cogeneration project details.… · turbine:...
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5 MW Cogeneration Plant in Ikwo, Ebonyi, Nigeria
Project Details
21 January 2013
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1. Project Background
Abakaliki Power Plant Limited (APPL) intends to construct a 5 MW rice husk
cogeneration plant. The plant will be located in Ikwo, which is about 60 km far from
Abakaliki, Ebonyi State administrative headquarters. The plant will mainly use rice
husk as fuel. The net available electricity will be supplied to Ebonyi Electric Power
Company Limited (EEPCL) at 11 kV level. EEPCL will supply the electricity to the
following customers:
Ebonyi Agro rice mill
Ebonyi State Government rice mill
Small rice millers
Oferekpe Mega Water Scheme
Nearby community and commercial establishments to the cluster
Steam will be supplied to the modern rice mills in the Ikwo cluster. This project is
supported by Global Environmental Facility (GEF), United Nations Industrial
Development Organization (UNIDO) and Ebonyi State Government.
2. Project Location
The cogeneration plant will be located in the Ikwo cluster which is around 60 km
away from Ebonyi state administrative capital. The plant will be located centrally in
the cluster such that it is closer to the rice mills.
City and region: Ikwo in Ebonyi State
Name of the nearest International
Airport
Murtala Muhammed International Airport,
Lagos
Name of the nearest Domestic Airport Enugu
Distance of the nearest airport 120 km
Travel duration from nearest airport: 1.5 hrs
The following map shows Ebonyi State in Nigeria
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Figure 1: Location map of Ebonyi State in Nigeria
The following map shows the approximate location of the project site in Ebonyi State
Figure 2: Location map of Ikwo in Ebonyi State
Project Location
Ebonyi State
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Figure 3: Detailed location map of the project site
Figure 4: Location of 12 tph, 5 tph rice mills and cogeneration plant in the
cluster
12 tph rice mill 5 tph rice mill
Cogeneration plant site
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3. General Design Criteria
Major Fuel and Cogeneration Plant Capacity
Main fuel used for the cogeneration plant is rice husk. Cogeneration plant will be
designed for 100% rice husk. However, if there is any shortage, rice husk has to be
supplemented with other fuels such as wood waste, cassava rhizome, palm tree
trunks, palm shell, rice straw and any other fuels available in the vicinity which are
not difficult to combust. However it has to be noted that the maximum percentage of
other fuels usage will be restricted as per boiler design. Minimum 20% usage is
recommended.
Boiler and Turbine Technology
Boiler : Travelling grate system or Step grate system
Turbine: Extraction-Condensing steam turbine
Technical Criteria
The cogeneration plant shall be designed according to the following technical
criteria.
Fuel Rice husk
Type of the plant Cogeneration plant (extraction – condensing)
Number of boilers 1 unit
Number of steam turbine generators 1 unit
Gross electrical output 5 MWe (pure power generation mode)
Net electrical output As high as possible
Process steam demand Upto 8 tph @ 5 bar pressure
Estimated annual operating hours Minimum of 7,800 hours
Operational lifetime Minimum of 200,000 hours
When steam is used for rice mills, gross and net electrical output will reduce
according to the steam usage.
4. Cogeneration Plant Concept
This cogeneration plant is first of its kind in Nigeria. There is not enough experience
in Nigeria for operating such a Cogeneration Plant. As of now, there is no biomass
boiler manufacturer in Nigeria. Also there are not much related industries to maintain
and repair biomass power/cogeneration plant in Nigeria. It is very difficult to get
experienced operators and maintenance personnel from Nigeria. Hence, each
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component of the cogeneration plant should be designed/selected in such a way, for
easy operation requiring very minimum maintenance and easy to maintain. Also the
maintenance cost should be as low as possible.
In the event of any failure in any equipment/instruments/parts the entire cogeneration
plant should not be forced to shut-down its operation. The cogeneration plant
operation should not be stalled until the EPC contractor/equipment supplier visit
Nigeria to rectify it. All the equipment/instruments/parts, control systems, etc. shall
be designed in such a way that it will not depend on EPC contractors/equipment
suppliers for rectifying the problems for the re-start of the plant.
5. APPL Scope of Work
Following will fall into APPL scope of work, with the necessary advisory support of
the Contractor. However, the contractor should recommend only the optimum
specifications to avoid high cost to APPL.
S.No. Scope of Work Contractor’s Role
1. Raw water supply at inlet of raw water
tank
Inlet point to be decided in
consultation with the
Contractor
2. Black start diesel generator Size and specification to be
given by the Contractor
3. Fuel and ash handling vehicles including,
front-end loaders and other vehicles
Size and specification to be
given by the Contractor
4. Rice husk open storage area preparation Necessary advice, plot plan
to be given by the Contractor
5.
Rice husk covered shed (but fuel
handling system preparation inside the
covered shed is under Contractor’s
scope)
Necessary advice, plot plan,
specifications to be given by
the Contractor
6. Plant boundary wall construction Nil
7. Landscaping
Necessary advice, plot plan
and diagrams to be given by
the Contractor
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8. Internal roads and drains besides the
internal roads
Necessary diagrams to be
given by the Contractor
9. Internal roads lighting Nil
10. Non-plant buildings such as stores,
workshops, administrative buildings, etc.
Necessary advice and size to
be given by the Contractor
11.
Non-plant buildings such as weigh
bridge, car sheds, canteen, security
rooms, etc.
Nil
12. APPL site office
Please see below for details
Diesel usage for running the
site office is the responsibility
of the Contractor
13. Security and protection of
Engineers/workers during construction Nil
14. Visa/work permit assistance Fee to be paid by the
Contractor
15. Custom clearance assistance Necessary documentation/fee
by the Contractor
16. Necessary local licenses and permits
Necessary support
documentation will be given
by the Contractor
17. Weighbridge Size and simple specification
to be given by the Contractor
EPC Contractor’s Scope Of Work
The scope of work of the EPC contractor includes, but not limited to the following:
Advice on APPL scope of work including preparation of specifications/drawings/
designs for execution and sub-contracting wherever necessary
Detailed engineering and design including submission of the same for all civil,
mechanical, electrical and instrumentation and control (I&C) requirements of this
cogeneration project.
Boiler and its auxiliaries
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Extraction condensing steam turbine generator and its auxiliaries including
turbine bypass system
All steam piping with necessary pressure reducers/de-super heaters including
extracted steam connection to low pressure (LP) steam header
Air cooled condenser including required structures, fans, controls and
condensate return system
Electrostatic precipitator or any other proven pollution control device
Fuel and ash handling system
Water treatment plant and its auxiliaries
Waste water treatment plant & its auxiliaries
Distributed control system (DCS)
Firefighting system
Overhead crane for powerhouse and required monorails for all large
motors/fans/pumps/ transformers
All required civil works for foundations, buildings, air cooled condenser, chimney,
drains, trenches, etc., unless otherwise stated
All required cabling, piping and earthing within the terminal points
All required utilities to operate the cogeneration plant including water de-
mineralization (DM) plant, uninterrupted power supply (UPS) system, DC power,
compressed air, lighting, etc.
Required plant air conditioning and ventilation systems
Electrical evacuation until inlet of 11 kV switchyard feeders with isolating breaker
and metering. to EEPCL
Other required aspects for the successful completion of the project (all aspects
other than APPL scope of work given above)
6. APPL Support for the Project
Site office and accommodation facilities provided by APPL are as given below:
A 150 square feet office for APPL and another one with the same size office for
the EPC contractor
A 200 square feet common office
Four self-contained single rooms with air conditioning facility. Two for APPL and
the rest for the EPC contractor
Five double rooms with fan. Two for APPL and the rest for the EPC contractor
Two common toilets
Two common bathrooms
Common kitchen and a dining hall
Sitting hall
50 kVA generator with a generator room
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Water tank, stand and water piping
Furnishing for the entire building
7. Government Support for the Project
The selected EPC contractor will receive the following supports from the Ebonyi
State Government:
Tightened security with armed guards
- For construction workers, site engineers
- For the stored equipment/parts
Such security shall be provided until start of cogeneration plant operation
Assistance in getting visa and other licenses and permits
Other inventions/supports wherever required for the smooth function of the
project
8. Commercial Expectations
Warranty
The supplier must ensure the efficient operation of the cogeneration plant and must
include 1 year rolling warranty. 2 year rolling warranty is preferable.
Performance Guarantees (with Liquidated Damages)
The project owner expects the following performance guarantees:
Project completion within the agreed time
Heat rate
Power output
Availability guarantee for atleast 7,800 hours
Reliability guarantee
Environmental guarantee for particulate emission less than 100 ppm
Noise level guarantee
Insurance
As per international standards
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Bonds, Security
As per international standards
Payment
Progressive payment terms as per international standards
9. Tentative Scoring Mechanism
The following criteria will be applied in selecting the bids:
a) Technical and General
S.No. Criteria Score
1. Compliance with the scope of supply 15
2. Compliance with the technical specifications 10
3. Net power output (for both cogeneration and
power generation mode) 15
4. Specific fuel consumption (for both
cogeneration and power generation mode) 10
5. Overall plant performance 10
6. Operational suitability for Nigerian conditions 10
7. Maintenance suitability for Nigerian conditions 10
8. Experience, track record and international
reputation 5
9. EPC experience in Nigeria and Africa 5
10. Boiler supplier experience in Nigeria and Africa 5
11. Turbine supplier experience in Nigeria and
Africa 5
Total 100
b) Commercial
S.No. Criteria Score
1. Total project cost of overall cogeneration plant 40
2. Detailed breakdown for the total project cost 20
3. Delivery period 10
4. Liquidated damages acceptance 15
5. Warranty period and nature of warranty 15
Total 100
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Selection criteria
Total number of points =200
Criterion Maximum score of points
Technical and General 100
Commercial 100
Note: The above scoring mechanism is tentative. APPL reserves the right to change the scoring mechanism.
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Annexure 1 Nigeria Country Details
S.No. Title Details
1. Population Around 170 million
2. Religion Muslims 50%, Christians 40%, indigenous beliefs 10%
3. Languages English (official), Hausa, Yoruba, Igbo (Ibo), Fulani
4. Literacy Total population – 61.3% Male - 72.1% Female - 50.4% (2010 est.)
5. Government type Federal republic
6. Capital Abuja
7. Independence 01 October, 1960
8. Legal system Based on English common law, Islamic law (in 12 northern states) and traditional law; accepts compulsory ICJ jurisdiction with reservations
9. Judicial branch
Supreme Court (judges appointed by the President); Federal Court of Appeal (judges are appointed by the federal government on the advice of the Advisory Judicial Committee)
10. GDP
GDP (purchasing power parity) - $ 414 billion (2011 est.) GDP (official exchange rate) - $ 240.1 billion (2011 est.) GDP – real growth rate - 7.4% (2011 est.) GDP – per capita (PPP) - $ 2,600 (2011 est.) GDP composition by sector (2011 est.) a) Agriculture - 31.1% b) Industry - 43% c) Services - 26%
11. Inflation rate (consumer prices)
10.8% (2011 est.)
12. Agricultural products
Cocoa, peanuts, palm oil, corn, rice, sorghum, millet, cassava (tapioca), yam, rubber; cattle, sheep, goats, pigs, fish; timber;
13. Industries
crude oil, coal, tin, columbite; rubber products, wood; hides and skins, textiles, cement and other construction materials, food products, footwear, chemicals, fertilizer, printing, ceramics, steel
14. Currency code Naira (NGN)
15. Ports and terminals
Bonny Inshore Terminal, Calabar, Lagos
Source: www.cia.gov
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Exchange Rate
Naira is the official currency of Nigeria. The figure below shows the fluctuations in
the exchange rate of Naira per US dollar for the past one year:
Figure: Exchange Rate of Naira Vs US Dollar
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Annexure 2
Abakaliki Town Details
Abakaliki is the administrative headquarters of the Ebonyi state.
Hotels
Abakaliki Town has numerous hotel facilities with cost ranging from USD 30 to 100
per day.
Security
Abakaliki, Ebonyi is a safe place and do not have any security issues.
In addition to this Ebonyi State Government has pledged to provide complete
security for this project which includes armed security for the following:
For construction workers, site engineers
For the stored equipment/parts
Internet
Abakaliki has good broadband internet facilities at lower rates.
Government support
In addition to providing security, Ebonyi State Government will support the project
by:
Assisting in getting visa and other licenses and permits
Necessary inventions/supports wherever required for the smooth function of the
project
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Annexure 3
Port Details
International Airport
Abuja Airport: Nnamdi Azikiwe International Airport
Lagos Airport: Murtala Muhammed International Airport
Domestic Airports near to site
Enugu airport: About 2.5 hours by road to the cogeneration plant site
Owerri airport: About 4.5 hours by road to the cogeneration plant site
Port Harcourt airport: About 6 hours by road to the cogeneration plant site
Recommended Sea Port
Lagos sea port details can be found in the following link:
http://www.searates.com/port/apapa_ng.htm