al - abbas energy limited -...

SSJD BIOENERGY LIMITED

REQUEST FOR PROPOSAL

FOR

ENGINEERING, SUPPLY, ERECTION AND

COMMISSIONING

OF

12MW BIOMASS POWER PROJECT

JANUARY – 2011

SSJD BIOENERGY LIMITED12 MW Biomass Power Project

INDEXPage No.

SECTION – 1 INSTRUCTION TO CONTRACTORS …………………………………..….… 02

SECTION – 2 GENERAL CONDITIONS OF CONTRACT …………………………..…….… 07

SECTION – 3 PROJECT SITE INFORMATION ……………………………………….…..…

15

SECTION – 4 TECHNICAL REQUIREMENT AND DESIGN CONSIDERATIONS ...…….….. 17

SECTION – 4.1 TECHNOLOGY AND PLANT CONFIGURATION ...……………………….….17

SECTION – 4.2 STEAM BOILER & AUXILIARIES …………………………………………..….…17

SECTION – 4.3 STEAM TURBINE – GENERATOR & AUXILIARIES ………………………… 31

SECTION – 4.4 BALANCE OF THE PLANT EQUIPMENT (MECHANICAL) ……..

………… 41

SECTION – 4.5 BALANCE OF THE PLANT EQUIPMENT (ELECTRICAL) ………………….. 56

SECTION – 4.6 INSTRUMENTATION & CONTROL SYSTEM (I&C)…………………………

67

SECTION – 4.7 GUARANTEES DATA ………………………………………………………...…… 73

SECTION – 5 CIVIL & STRUCTURAL WORKS ………………………………………..………

75

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SECTION – 6 COMMISSIONING AND TESTING …………………………………….………

79

ANNEXURES - ……………………....... 84- 86

SECTION – 1: INSTRUCTIONS TO CONTRACTORS

Preamble

SSJD Bioenergy Limited, (“the Owner”) with its principal office located at Plot # 10-11, Hassan Ali Street, Karachi-Pakistan, under the Alternate Energy Policy, Alternate Energy Development Board (AEDB), Government of Pakistan, intend to construct and operate a power plant on multiple biomass of approximately 12MW in district Mirpurkhas, province of Sindh. The net electrical power will be exported to the nearest grid of Hyderabad Electric Supply Company (HESCO) electrical network.

Invitation for Proposals

The Owner is inviting proposal on turn key basis including civil works from the interested EPC Contractors for designing, manufacturing, furnishing, insuring, delivering to site, storing at site, erecting, commissioning, operating on a trial basis and testing of the equipments and materials for 12MW power generating unit (herein after called “the Project”).

The plant technical description and design considerations with scope of works contained in this document shall be a guideline to enable the Contractors to prepare and submit their proposal complete in all respect for a functional plant. Prior to preparation of this RFP, the Owner has conducted the preliminary site survey, assessed the site conditions, availability of land and

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water supply source for development of the project. A Letter of Interest (LOI) has been obtained from the relevant agency of the Government of Pakistan i.e. Alternate Energy Development Board (AEDB) to undertake the project on fast track.

The Contractors are advised in their own interest to have full understanding of the RFP, plant design consideration, specification of equipments, scope of works that are necessary for a complete functional biomass power plant prior to submission of proposal. Any explanation or clarification desired by the Contractors regarding the meaning or interpretation of the RFP may be requested by e-mailing to the Owner’s designated point of contact. If any explanation or interpretation is necessarily required by Contractors, it may be provided by the Owner subject to availability on best effort basis. No clarification or lack thereof will be a cause of contention at the time of submission of proposal or if and when the Contract is awarded.

An effort has been made to provide sufficient information/data for design, scope of works, services, materials, plant equipment, building and structure, and other essential facilities etc, described in the RFP. Nevertheless, the Bidder will solely be responsible for examination of its completeness and comply with all instructions. Failure to furnish complete information, or submission of a proposal not conforming to RFP, and found substantially non responsive may be rejected.

The Contractors shall submit a firm proposal for the entire EPC work, however the Owner reserve the rights to bifurcate the Contract at the time of contract award for, i)Supply Contract for supply of equipment and machinery together with all necessary items, ii)Service Contract for engineering, supervision, installation, commissioning and testing..

Owner's Rights to Accept any Proposal and to Reject Any or All Proposals

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The Owner reserve the rights to accept or reject complete proposal or part of the proposal at any stage without assigning any reasons thereof whatsoever, without incurring any liability to the Contractors, or any obligation to inform the Contractors of the reasons for such actions. No conditional proposal shall be accepted.

Submission of Proposal

The firm technical and commercial proposal with two identical copies are required to be delivered in person or sent by completent courier services or by registered mail at the address of the Owner or by email, on or before the expiry of twenty (20) days period from the receipt of RFP. The Contractor will submit the Commercial part along with the proposal and the EPC cost break down sheet.

To be addressed to Owner at the following address:

The SSJD Bioenergy Limited, Plot # 10-11, Hassan Ali Street,Off. I.I. Chundrigar Road, Karachi, 74000.Phone: (92-21) 32631017Cell # 0314 - [email protected]

Attention: Mr. Akhlaq UllahVice President (Technologies)SSJD Bioenergy Limited

Language

The proposal and all correspondence shall be written in English language.

Prices

The Contractors will quote firm EPC prices in detail breakdown as per format provided in Annexure, which shall remain valid up to the validity period. Proposal with escalable prices will be rejected as non-responsive. The quoted

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prices shall include the cost for entire scope as per the technical requirements and specifications provided in this document considering all items necessary for a complete functional plant.

Contractors Address

The Contractor shall give its full and proper address at which correspondence may be sent (electronically and by mail) and all notices may be served in connection with this RFP.

Clarification of Proposals

To assist in evaluation of the Proposals, the Owner may, at its sole discretion, require a Contractor to clarify its proposal. The request for clarification and Contractor’s response shall be in writing and no change in the price or substance of the proposal will be sought, offered or permitted.

Evaluation of Proposals

Owner will, in private, undertake a detailed examination and evaluation of proposals. To assist in the examination, and evaluation of proposals, the Owner may ask Contractors for clarification of their proposal, including breakdowns of quoted price. The Owner does not bind itself to award the Contract to lowest or any Contractor, but will take into consideration the quoted price and such other factors as are relevant for complete functional plant. After the Owner is satisfied with the proposal of a Contractor, the Owner will start clarifications/negotiation meetings.

Notification of Award

Following the proposals evaluation process the Owner will hold detailed discussion and make all good efforts to settle all technical, financial, and

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commercial matters to meet lenders requirement, and Power Purchaser that are necessary to incorporate in the Contract. Should such discussion not lead to signing of the contract between the Owner and the Contractor for any reason whatsoever, the Owner shall have all rights to reject such Contractor without any liability of any nature whatsoever. In case negotiations with one Contractor does not culminate in finalizing the contract for any reason, the Owner may, at its sole discretion, invite any other Contractor for negotiations or annul the process at any stage without any liability whatsoever.

The Owner shall at all time have the option and discretion to reject any or all proposals without assigning any reason thereof and without any liability whatsoever. The Contractor (s) shall not be entitled to claim any costs, charges, expenses or damages of any nature by reason of rejection of proposal (s) or annulment of the entire Bidding process.

Decisions conveyed by Owner in respect of its evaluation of the proposals, Award of Contract to a Contractor shall be binding. The Owner decision, in any manner whatsoever, shall not be challenged.

Signing of Contract

Upon finalization of the Contract document, the Contractor will be required to attend the office of the Owner within one (1) week from the date of receipt of notice to Award the Contract, with the power of attorney for signing the Contract Agreement in the form set out in the Contract documents with alterations or additions thereto as may have been mutually agreed upon.

Supplementary Information

(1) The following supplementary information shall be submitted with each copy of the proposal.

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(a) An organization chart of the minimum supervisory staff the Contractor proposes to employ on Facility Site for the performance of the EPC Contract. This chart shall also show the distribution of work for each member of the staff and their respective duration of work at plant site.

(b) A list with complete description of all items of installation equipment and plant proposed to be used in carrying out the EPC Works, indicating the make, type and capacity of all equipment which shall be in complete detail to demonstrate fully that the equipment will meet all the requirements for carrying out the work according to specifications, drawings and the time schedule.SECTION – 2: GENERAL CONDITIONS OF CONTRACT

General Instruction

The designing of the power plant on multiple biomass shall based on best steam power cycle, current state of-the-art technology, current industry trend, highly reliable equipments with built in redundancy and design margin and safety against unplanned outages, all equipments suitable for a thirty (30) years life period.

The Contractor is required to follow international designed approach to engineering and construction, all equipment to be designed and manufactured in accordance with the international applicable codes and standards, state regulations, and Pakistan Standards for environmental control are all adhered to in design, and complies with the emission levels during operation.

The plant design and steam power cycle shall be engineered for optimum thermal efficiency adopting high pressure and high temperature steam parameters, and design conditions specified in this document.

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Contract Agreement

The Contractor shall enter into and execute a Contract Agreement to be prepared and submitted by the Contractor, however the Owner will have the full rights to review and negotiate the terms of the Contract documents and sign the Contract Agreement.

Compliance with Contract

Equipment, materials and services shall be complete in all respects and in strict accordance with the contract. The Contractor shall comply with the codes and standards specified in the Contract Documents which shall be latest revisions of international standards/codes.

Commercial Proposal

The Contractor shall submit commercial proposal in reasonable detail as per Annexure provided in this RFP.

Taxes

The Contractor shall be responsible for all Contractor’s corporate taxes payable under the laws of Pakistan. The tax payable in Pakistan will be in local currency.

Import Duties

Import duties, import permits fees and other charges applicable on import of equipment and materials will be the responsibility of and will be paid by the Owner for all items imported under the Contract. The freight and

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marine insurance cost on all equipment and materials shall be included in the price quoted by the Contractor.

Transportation and Insurance

The Contractor shall obtain all risk insurance for marine and inland transportation (in Pakistan and abroad) including coverage for custom duties without war risk to cover all loss and damage from Contractor’s (Manufacturer’s) warehouse to the site for imported material and equipment.

For the inland transportation of equipment and materials, the Contractor shall arrange and pay for transportation insurance with National Insurance Corporation or any other insurance company of Pakistan which shall cover all risks, i.e. fire, flood, theft, damage due to the exposure, breakages, loss in transit, or through riots, strikes, civil commotion, etc. from the manufacturer’s plant warehouse up to the site, plus ninety (90) days of storage after arrival of each consignment at site.

Subsequent to the obtaining of the custom clearance of the consignments at the sea port by the Owner, timely transportation of the said consignments to the site will be the responsibility of the Contractor. The Owner will not be liable for any demurrage on this account.

Sub Contractors

Except where otherwise provided by the Contract, the Contractor shall not appoint any sub-contractor for any part of the works without the prior written approval of the Owner.

Co-ordination with other Contractors

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The Owner reserves the right to let other contractors in connection with the part of the works of this project. The Contractor shall provide reasonable opportunity for the storage of their materials and the execution of their works simultaneously, shall co-ordinate his work with their. On failure to meet this requirement the contractor shall be liable for any resulting damage and expenditure.

Performance Security

The Contractor shall within fifteen (15) days from the date of the issuance of Notice of Award of the Contract, furnish at his cost Performance Security in a sum of 15% of the total Contract price as a guarantee for the due and faithful performance of the Contract.

Guarantee for Material, Workmanship and Performance

The Contractor shall guarantee that the materials and workmanship incorporated into the project are brand new and the best of their respective kinds for the service intended and that all items will be free from inherent defects in design, workmanship and materials, and that all equipment in its several parts will operate successfully at all capacities up to and including the maximum specified load, specified noise levels, heating, stressing of parts, wear and vibration, and that an ample factor of safety is included in every design.

The Contractor’s liability shall not be limited only to the replacement of any defective part or equipment that may develop in the equipment or material of his own work or manufacture or those of his sub-contractor under power use and arising solely from faulty design, materials, or workmanship during the guarantee period but he shall also be responsible for replacement,

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erection and commissioning of such equipment/material which is damaged due to any mishap caused as a result of defective materials/equipment or inadequate workmanship of the Contractor.

Period and Extent of Guarantee

The period of guarantee on all equipment, material and workmanship shall be 12 Months starting from the effective date of provisional Acceptance by the Owner or as expressly stated elsewhere in the contract documents, including …

If during the guarantee period the services of the Contractor’s personnel are required for the rectification or replacement of any defective part of the work due to defective material, design or workmanship, such services shall be made available by the Contractor without charge to the Owner.

Qualification of Equipment/Manufacturers

Manufacturers for all major equipment shall be of international repute, shall have had at least 10 years previous experience in design, manufacture and installation of all major items of equipment and materials selected and proposed for the project in the proposal, and shall have built and placed in successful services not less than three similar size of unit prior to submission of proposal.

Inspection and Testing During Manufacture

The Owner will be entitled at all times during manufacturing to inspect examine and test in the manufacturer works the materials workmanship progress of manufacture and performance of all equipment and materials

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to be supplied under this Contract. All cost towards inspection by the owner authorized representative like cost of air fare, cost of accommodation; out of pocket expenses shall be borne by the Contractor. Provision of at least three (3) trips and fifteen (15) man-days is considered included in the Contract Price for such inspection.

Performance Guarantee Liquidated Damages

If the equipment is unable to ultimately meet its performance guarantees specified in the Contract document as set forth by the Contractor in the Contract Agreement, after the Contractor he has taken all steps to correct the deficiencies, the Contractor will be assessed liquidated damages in accordance with the provision of the Contract. The liquidated damages payable in respect of deficiencies in performance and delay in commissioning shall not exceed 15% of the Contract price.

Note: The Contractor must understand that timely completion of the Project and the performance guarantee level set forth in the Contract Agreement shall be complied in any case for successful operation of the plant over the term of Power Purchase Agreement (PPA).

Familiarization of Owner’s Personal (training)

The proposal price shall include on job training program of Owner’s personal in all aspects of plant operation and maintenance from the beginning of erection until provisional taking over of the plant. The program shall also include familiarization of the Owner’s personal in Contractor’s works and at works of Contractor’s sub suppliers.

The O&M personal required for safe and efficient plant operation and adequate maintenance of various types of equipments installed will be

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provided by the Owner in accordance with the recommendations to be made by the Contractor.

The O&M personal deployed are experienced and qualified for senior and middle levels and fresh graduates from engineering institutes. All persons will have to be trained through different training programs in similar operating plants etc., it is to be ensured that the persons are experienced and trained at the time of commissioning of the plant.

The training proposal should consist of several courses that are generally applied to the power plant personal, special training manuals in English describing all major plant system, maintenance procedures etc. shall be prepared for all trainees. The Contractor shall develop a comprehensive program for submission to the Owner for review and implementation.

About SSJD Group

SSJD group will be the leading independent energy supplier on indigenous fuel and renewable energy in Pakistan. Its aim is providing energy to Pakistan and helping the country to overcome the power crisis. The main focus of SSJD Bioenergy Ltd. is to generate electrical power from alternate energy sources and limit the dependency on foreign fuel resources. Its management team comprises of local and foreign professionals having vast experience of working in the power sector particularly in developing power projects on all kind of technologies. The professional team has also developed several IPP projects in Pakistan and abroad.

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The group being principal sponsor of SSJD Bioenergy Limited has recently commissioned Pakistan’s first private coal-fired power plant of 15 MW and supplying electricity to Karachi Electric Supply Company (KESC) under Sale and Purchase Agreement.

SSJD Group has established a special purpose Company namely SSJD Bioenergy Ltd. (the “Company”) incorporated in 2010 under the laws of Pakistan as a Private Limited Company. The core activity of the Company is to install several multiple biomass based power projects through out Pakistan, produce and sell electricity to the respective distribution companies of the country.

The Company decided to construct its first biomass power generation facility on multiple biomass fuel in district Mirpurkhas, Province of Sindh, and intended to set up a 12MW power plant near Al-Abbas Sugar Mills on fast track basis.

Multiple biomass fuel (bagasse, rice husk, and other biomass) will be consumed as per requirement of the plant without any limitation of interchangeability. The proposed power plant will utilize maximum bagasse as main fuel available from sugar mills located within 50 km radius of the plant Site, and also the other biomass such as rice husk and cotton stalk abundantly available in the area.

About Hyderabad Electric Supply Company (HESCO)

HESCO is responsible for supply of electricity and operating the electrical network in the area of Sindh province except Karachi the largest city of Pakistan which is served by a private utility company. Currently about 1300MW power is being supplied to its consumers through the network.

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Power demand of Sindh province has a severe short fall in peak power demand as well as energy availability. This shortfall in peak power demand and energy demand will widen further in the subsequent years. The network thus requires a substantial addition in power generation capacity to meet the power demand of its rapidly growing industrial, agricultural and other sectors. Purchase of power from this plant will provide economical, eco-friendly power and contribute someway to bridge the gap between power supply and demand.

SECTION – 3: PROJECT SITE INFORMATION

Some information details of the site selected for biomass power plant is given in tabular form;

Site Project Site is located near Mirwah Gorchani town,

Dist. Mirpurkhas, Province of Sindh, adjacent to Al-

Abbas Sugar Mills.Approach to SiteNearest town Mirwah Gorchani Town (2 km from Site).Nearest Grid 132 KV Mirwah Gorchani Grid (3 km from Site)Nearest Railway Station Mirpurkhas Railway Station: (28 km from Site) Nearest Airport Karachi, Port City (260 km from Site)Access Roads Super Highway up to Hyderabad, 145 km from

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Karachi, and then via the metallic road up to Site. Plant

is located off the main road on way to Digri Town.

All equipment and construction materials can easily be

transported to Site by road.Site Elevation 100.0 m above mean sea level Geographical Location Latitude : 69°,15’46* N

Longitude : 25°,15’48* EClimate Tropical -Hot -Humid Seismic Data Zone-ISeismic Intensity Moderate Metrological Data Ambient Temperature (Dry Bulb) a) Extreme Maximum 48 °C

b) Extreme Minimum 5°C

c) Average max. 34.5°C

d) Average min. 12°C

e) Annual Average 30°C

f) Design Wet bulb Temp. 27.5°CRelative Humiditya) Maximum during monsoon (June to October)

84 %

b) Minimum Humidity during summer (February to May)

28 %

c) Design Relative Humidity

60 %

Rainfall a) Average per annum 200 mmb) Tropical monsoon June to October Wind Velocity & Pressurea) Design Wind Speed 120 km/hr Area of Land 16 acre

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Soil Condition EPC Contractor will carry out itself soil investigation

for designing of civil structures and buildings.Safe bearing capacity 14.6 t/m² (from data of adjacent sugar mills)Sub soil water Present Source of water for construction

From existing water course of land

Nearest source of construction material

Stone clips - sand & bricks – Mirpurkhas city

Cement - Direct from the factory

Bricks - Hyderabad/Mirpurkhas cityPower supply during construction

Separate AC 220 volt, 3 phase connection from

HESCO, or self generation by mobile Gen-set.

SECTION – 4: TECHNICAL REQUIREMENT AND DESIGN CONSIDERATIONS

4.1– TECHNOLOGY AND PLANT CONFIGURATION

The power generation facility shall be developed on conventional steam turbine technology designed on multiple biomass fuel. The plant shall comprise of one (1) no. steam boiler with all auxiliaries including efficient flue gas cleaning and handling system, one (1) no. turbo-generator set with all accessories having a nominal gross capacity of 12MW. Balance of the plant equipment shall mainly comprise of steam condensing unit, feed heaters, multi cell cooling tower, circulating water, water treatment unit, and complete balance of mechanical and electrical system in all respect for a functional power plant.

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4.2– STEAM BOILER & AUXILIARIES

The design, manufacturing, supply and installation of boiler on biomass shall be complete in all respects with accessories for safe and reliable operation for firing 100% bagasse as main fuel, and rice husk mix in the ratio of 80% bagasse – 20% rice husk, or 20% bagasse – 80% rice husk, and other biomass such as sugar cane leaf, rice straw, cotton stalk etc. The boiler shall be approximately 50tph evaporation capacity at pressure of 90 ±3% bar and temperature of 530 ±2% °C at superheater outlet and feed water temperature at economizer inlet depending on the design of steam power cycle to achieve final feed water temperature, but not less than 190°C.

The boiler will be single drum with natural circulation balanced draft, and water tube type suitable for outdoor installation. The drum will be fitted with all internals and attachments, nozzle connections and drum suspension/support. The boiler may be top or bottom support design, and provided with all supporting steel structure and platform and galleries staircases. Adequate weather protection is to be provided for instruments and operating personnel. Necessary insulation and cladding of boiler and ducting to limit outside surface temperature to a safe value will be provided.

Super heater section shall be of vertical convection and radiation type and suitably designed to maintain steam temperature of ≥ 530°C over the control range of 50% to 100% boiler load. For steam temperature control, attemperator with provision for spraying water tapped off from feed water piping shall be provided.

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Tubular carbon steel air pre-heater (with gas flow through tubes) to pre-heat the combustion air complete with casing and support will be provided. Corten steel tubes will be provided at the low temperature block to avoid cold end corrosion during boiler start up and part load operation. Air-heater is also provided with air side bypass with motorized damper.

Adequate nos. of heating surface cleaning soot blowers with control shall be provided for superheater, evaporator, economizer and air preheater.

Steel structure and platform for boiler, economizer and air preheater. Grating and handrail platform. All gratings of stairways and platforms shall be galvanized; all structural steel for stairways and platforms as well as handrails, kicking plates and ladders will be painted. For all system equipment that are operated manually, either in normal operation or in the event of incidents/accidents, passages will have an inside height of 2.10 m. frequently used stairways, walkways, and escape routes will be 1m wide.

Biomass Fuel Specification

The analysis of biomass available for firing in the boiler is provided in the table below (for information only)

Ultimate Analysis Unit Bagasse Rice Husk Cotton Stalk

Carbon % 23.25 36.70 39.26

Hydrogen % 3.25 03.00 5.23

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Nitrogen % 0.00 00.40 1.68

Sulphur % 0.00 00.08 0.00

Moisture % 50.00 10.00 10.00

Ash % 1.50 18.80 6.01

Oxygen % 22.00 31.02 37.82

GCV kcal/kg 2272 3350 3925

Design Fuel Mix Specification

The design fuel mix specification is provided in the table below.

Mix 1: 80% Bagasse / 20% Rice huskLHV Moisture Ash Content

kcal/kgweight - %weight - %

188746.52.3

Mix 2: 80% Rice Husk / 20% BagasseLHV Moisture Ash Content

kcal/kgweight - %weight - %

320512.212.5

Biomass Handling – Storage System

The dry biomass storage shed shall be constructed for at least 3 days, RCC construction, steel roofing, open from two ends for movement of truck dumping, shall have biomass storage transfer conveyor with under ground hopper.

The design of biomass conveying system from dry biomass shed to the boiler bunker, fuel feed system including biomass fuel discharging system shall be designed for 20tph biomass handling.

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Biomass Feeding System

The fuel feeding system may consist of arrangement to fire bagasse and/or rice husk fuel mix in the ratio specified above.

Fuel feeding system may comprise of nos. fuel dosing silos (15 minutes storage each) at the inlet of rotary drum feeder equipped with variable frequency drive motors, screw feeders with constant speed drives, pneumatic distributors, and rotary dampers with motor and necessary support structure, motorized isolation gates at the inlet of connecting chutes as per the respective design of the boiler manufacturer.

Furnace Draft System

Furnace draft system shall be designed to ensure a balanced draft with sub atmospheric pressure conditions in the furnace. The system to consist of:

1 x 100% (with 30% excess air) radial, backward curved, simply supported Forced Draft (FD) fans with variable speed drive motors and pneumatic power cylinder operated control mechanism through IGV, necessary base plates, foundation bolts, couplings, bird screen etc. Grease lubrication system for fans bearings.

1 x 100% radial, backward curved, simply supported Induced Draft (ID) fans with variable speed drive motors and pneumatic power cylinder operated control mechanism, necessary base plates, foundation bolts, coupling etc. Blades will be provided with replacement wear liners/hard facing. Grease lubrication system for fans bearings.

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2 x 60% radial, backward curved, simply supported Secondary Air (SA) fan with motors suitable for variable frequency drives and pneumatic power cylinder operated control mechanism, necessary base plates, foundation bolts, coupling etc. Grease lubrication system for fans bearings.

Manually operated isolating damper at the outlet of FD, SA, and ID fans shall be provided.

Necessary air and flue gas ducting with required stiffeners, expansion joints, guide vanes, wherever required, dampers, insulation, cladding and supports. Expansion joints in flue gas ducting and hot air ducting will be of carbon steel. Non metallic bellows will be provided for the cold air ducting and in gas ducting to economizer.

Flue gas cleaning and handling system, ash silos and unloading system shall be designed for maximum ash content of the biomass.

Flue Gas Cleaning and Ash Handling System

Bagasse has maximum 2% ash while rice husk has maximum 18% ash.

Assume that during operation rice husk and bagasse blended in the ratio of 80: 20 will be fired, estimate the maximum ash generated for system design.

The system shall be such that bed ash generated due to combustion of bagasse/rice husk in the boiler is collected in front bed ash hopper and dropped on water submerged belt conveyor which will carry wet ash to the elevated silo. Ash from fine bed ash hoppers will be conveyed by screw conveyor and will be directed to bed ash submerged conveyors. This submerged conveyor will transfer wet ash to next conveyor which will

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convey ash to the discharge storage area, from where the ash to be removed by trailer/truck for further transportation.

Fly ash system design will be sized to handle 90% of the ash produced. The fly ash system shall comprise of flue gas cleaning system either installing ESP or bag filters, dry collection of fly ash shall be through vacuum system and to be discharged to the main fly ash conveyor or independent silos. The silos shall be sized for capacity to store approximate three (3) shift fly ash produced in worst condition. Fly ash collected in various economizer hoppers, air heater hoppers and ESP / bag filter hoppers is conveyed through vacuum conveying system to fly ash silos. Fly ash collected in ash silos will be unloaded into trucks after humidification through dust conditioner and can be transported to cement manufacturing plant or brick manufacturing plant or to ash disposal yard as the case may be.

Steam Piping

Boiler steam piping consisting of all interconnecting piping between the economizer inlet stop valve and the super heater outlet header etc. shall be provided. The design of the piping system shall be based on the international standard. The piping shall be properly supported and provided with necessary tapping for instruments. Necessary supporting materials to support the piping shall be supplied. The correct location of hangers and supports shall be considered for the flexibility analysis. Suitable expansion loops, restraints and anchors shall be provided to limit the stresses within the allowable values.

The material for the piping and fitting shall be properly selected for various services in the boiler integral piping. All integral piping shall be provided with valves, fittings, drains and vents, safety valves, exhaust piping, start-up vent with silencer, blow down system etc. Proper sampling

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facility shall be provided for feed water, super heated steam and blow down water. The system for sampling shall be complete in all respect for monitoring the satisfactory operation of the boiler.

The steam from the superheater outlet of the boiler will be conveyed through special alloy steel piping to a steam pipe of turbine-generator set.

Adequate stop valves, non return valves, drain valves; traps etc. shall be suitably placed in the piping and header. The piping shall be with necessary supports, hangers, etc. Steam flow meter shall be provided to measure the flow of steam from the boiler.

Feed Water Pumps

Two (2) 100% capacity Boiler Feed Pumps (multistage, barrel casing, centrifugal ring section type) with variable speed drive motors and accessories viz. base plates, coupling, coupling guard, automatic recirculation control valves, piping, suction strainer, suction manifolds, balancing leak off lines, foundation bolts, mechanical seals and lift off devices. The pumps will have their suction from the deaerator and deliver the feed water to the boilers, each pump will be provided with a self-contained forced lubricating oil system for supplying oil to the bearings, couplings etc.

Feed Water Control Station shall consist of 1 x 100% pneumatically operated control valve, 1 x 30% pneumatically operated start up valve and 1 x 100% motor operated bypass valve. Motor or manually operated isolating valves for control valves shall be provided, drain valves as required.

Accessories

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One (1) no. continuous blow down (CBD) tank and one (1) no. intermittent blow down (IBD) tank for collecting the continuous and intermittent blow down from the boiler with necessary drain and vent piping, drain valves, level gauges, level control valve including motorized blow down valves, flash steam from CBD tank to deaerator.

Chemical dosing system (mounted on individual skids) with SS mixing tanks, motorized agitators, plunger type pumps, SS piping, valves and fittings. Dosing system will include 2 x 100% dosing pumps, one number SS mixing tank with motorized agitator, SS dosing piping up to steam drum. Dosing system will include 2 x 100% dosing pumps, one number SS mixing tank with motorized agitator, SS dosing piping up to deaerator outlet feed water piping.

Safety Valves

Boiler to be equipped with necessary valves, mountings and fittings including spring loaded safety valves (total 3 nos.) and remote water level indicator, motor operated startup vent valve with motorized isolation valve and one (1) no. electromatic safety valve. Silencers for superheater safety valves and start up vent valve will be provided to limit noise level to 90 dBA at 1 meter distance.

Drains System

Drains should be provided for all pressure stages of the boiler. These drains should be designed to be sufficient for normal operation of the boiler, as well as startup, steady loads up to 100% MCR and shutdown of the boiler.

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All drains and vents should be routed separately to central stations, cascading lines to other pressure stages will not be used to avoid transferring impurities and high mineral concentrations into a lower pressure stage. The nominal diameter for the drain and vent system valves standardized to min. (25mm) or larger.

All drains required for operation of the boiler including those associated with the steam drum level gauges, level alarms and those from each of the economizer and evaporator bank manifolds will be routed to the blow down vessel. Actuators shall be mounted on all valves which have to be operated during startup, shutdown and normal operation of the boiler. All drain control valves used for normal operation shall be doubling isolated, and are to be installed in the immediate vicinity of the flash tank or its inlet header.

Boiler Stack

The stack should be designed and constructed at site for at least 50 m height and manufactured in carbon steel with weather resistance coating.

Welds on Pressure Parts

All pressure parts welds are to be mandatory examination according to ASME code preferably 100% radiographic test.

Codes and Standards

The boiler shall be designed and manufactured in accordance with ASME Boiler and Pressure Vessel Code (BPVC) or Equivalent code. For the design of electric motors IEC standard or Equivalent shall be followed.

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Painting

All steel components which are not provided with thermal insulation and are not galvanized will be given several coats of paint. The colors of the top coats will be agreed upon with the Owner.

Design Conditions

Particulars Units Data Steam evaporation at superheater outlet tph 50

Peak evaporation tph 55

Steam pressure at superheater outlet bar (a) 90 ±3%

Steam temperature at superheater outlet °C 530 ±2%

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Steam temperature control range % 50-100% MCR

Feed water temperature at economizer °C 180-200inlet

Excess air % 20 - 30

Flue gas temperature °C <150leaving air pre-heater

Kind of fuel bagasse/rice husk/cotton stalk

100% bagasseFuel Mix 80% bagasse 20% rice husk

20% bagasse 80% rice husk

cotton stalk as required.

Fuel analysis as provided

Dust concentration and boiler outlet <150 mg /Nm³

ESP / Bag filter efficiency > 98%

Stack height 50 m

Ambient air temperature at °C 30 primary FD fan inletRelative Humidity % 60

Earthquake factor 0.1 g

Wind velocity 120 km/hr

Performance Test Code ASME PTC 4.1 1964

(R-1991) by theindirect loss method

Performance Guarantee

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The Contractor shall guarantee the performance values on the following;

- Super heated steam evaporation at MCR : __ tph- Superheated steam temperature at MCR : __ ºC- Feed water temperature at economizer inlet : __ ºC- Ambient air temperature at FD fan inlet : 30/20/10 ºC- Ambient air pressure : 1.003 bar- Flue gas exhaust temperature : __ ºC- Continuous blow down : 1%- LCV Bagasse : 7285 kj/kg- Boiler efficiency at MCR : __%- Biomass consumption : __ tph

Note: No test tolerance on test results shall apply to meet the performance guarantee level specified in the Contract as the performance of this project shall comply with the benchmark of the Tariff determined by the National Electric Power Regulatory Authority, and will operate under a Sale and Purchase Agreement.

Scope

Contractor scope shall be complete in all respect for safe and reliable operation of the steam boiler, but not limited to the following;

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- Detail engineering, manufacturing, supply, erection, commissioning and testing.

- Complete steam boiler and systems including stack, fuel handling and dry storage system, fuel discharge from storage system to intake hoppers, fuel distribution and dozing system, combustion system, ash removal system, chemical dozing equipment, measuring instrument, boiler control system, electric low voltage system, and power cable wiring, refractory and mineral wool insulation as required, aluminium cladding and necessary fixing components, all necessary materials, valves, piping, auxiliary equipments, field mounted instruments, local field junction boxes, cables and cable trays from field instruments up to junction boxes, oxygen analyzer, CO2 analyzer, steam and water analyzer, support structures for monitoring the base channels of all electrical and instrumentation panels. Soot blowers for super heater, evaporator, economizer, and air pre-heater.

- Instrumentation and control system for monitoring control, DCS shall be adopted.

- Boiler start up system with auxiliary burner including igniter and flame scanner.

- Performance test shall be in accordance with the provision of the boiler code.

- Site training of O&M staff. - Supply of recommended spare parts for two years operation and

maintenance.- Special tools and tackle.- Chemicals for chemical cleaning (alkali boil out), flushing oil and first

fill of lubricants and chemicals shall be in the Contractor scope.- Inspection visits by Owner staff at works. - Witness test by Owner staff at works.

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- Detailed designing/engineering for foundation and civil works, cable and drain pits including supports and covers.

- Embedded hardware for boiler and boiler accessories.- Contractor will provide the list of sub venders.

Note: The scope mentioned above may not be conclusive, however the Contractor will include all scope in its offer necessarily required for safe and reliable operation of the steam boiler.

4.3 – STEAM TURBINE – GENERATOR AND AUXILIARIES

One unit of steam turbine rated at 12MW, multistage, impulse-reaction, multiple bleed, full condensing type, single casing, horizontally split, and

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downward flow exhaust design. The turbine shall be designed for main steam parameters of 90 ±3% bar, 530 ±2% °C before emergency stop valve and exhausting steam against normal condenser pressure of about 0.07 bar absolute pressure. The turbine shall be designed to operate at 105% of turbine MCR corresponding to control valve wide open position, and should also operate in stable condition at minimum load of 20% turbine MCR.

Automatic gland sealing system will be provided for the turbine, which will have provision for receiving steam from auxiliary steam header during start-up and low load operation. The steam turbine will be equipped with electro hydraulic governing system ensuring stable operation under any grid abnormal condition.

All auxiliaries as well as necessary protective device and turbine supervisory system will be provided to ensure trouble free, safe, and efficient operation of the turbo-generator set.

The steam turbine will be capable to withstand full load rejection and continue to operate at auxiliary load.

Steam turbine and accessories

The turbine shall generally comprise:- Steam turbine - Emergency stop valve (s) and control valves (s) hydraulically

operated.- Any extraction equipped with isolating and non return valve

(pneumatically operated). - Turbine protective devices.

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- Steam turbine drains system will consist of pneumatic valves for automatic start-up/shut down.

- Reduction gear- Turning device- Piping pertinent to turbine - Insulation materials and laggings- Turbine bed, anchor bolts and nuts etc.

Turbine governing and protective device

- Turbine speed governing equipment- Turbine emergency trip equipment

Lubricating oil supply system

- Lube oil system, for the lubrication of the turbine and generator bearings and for the service of the turbine control and safety system with instrumentation (pressure transmitters, oil level indicators, etc.)

- Oil tank for turbine, generator, and gear box with accessories, filter, level indicator, vents, drain, and with gas extractor.

- Main oil pump driven by turbine shaft - Auxiliary electric A.C. motor driven oil pump with automatic start-up

device. - Emergency D.C. motor driven oil pump with automatic start-up

device- Oil pressure regulating valve- Electrically oil heating device- Duplex oil cooler with change over device- Lubricating oil temperature regulating valve

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- Two full size (100%) oil coolers with change over valves for maximum design cooling water temperature of 40°C, plate or shell and tube type, and transfer valve.

Turbine Oil Purification System

A turbine oil purification system will be provided. This will be a separate package mounted on a skid consisting of centrifuge type oil purifier, indirect oil heater, dirty oil and clean oil pumps and polishing filter. This will be required to condition the turbine oil continuously on bypass mode in order to remove water and other impurities from the system and to maintain the turbine oil at the optimum condition. The purifier operation will be independent of the lube oil system.

Gland Sealing System

The turbine gland sealing system shall include the following: - 1 gland steam condenser- 1 leak-off steam condenser exhauster- 1 seal steam control valve- 1 leak-off steam control valve - Gland steam supply with de-super-heating station to adequately

supply steam to gland steam system including water spray control valve

- Two AC motor driven blowers- Piping, instrumentation, valves and fittings- Interconnecting piping inclusive of thermal insulation with metal

jacketing

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Turbine Control

The turbine control system shall be a stand-alone system handling all essential controls for the turbine-generator set. The function shall include open and closed control loops as well as monitoring, trip/alarm, processing and logging of alarms, trips and events, provide information exchange through interfaced with plant main DCS. The main turbine generator control system shall include:

- Turbine governor- Turbine protection - Turbine automation (control of auxiliary devices)- Generator control (voltage regulator, synchronization, protection) - Turbine and generator monitoring (temperatures, vibrations, alarm

handling etc.)- Color monitor/keyboard operator stations- Interface with plant controls- Turbine controller and the turbine control protection shall be

equipped with CPU redundancy

The control system shall be provided with redundancy for key functions by use of separate sensors and monitors, turbine monitoring board shall have the following;

- Inlet steam pressure and temperature gauge- Extraction steam pressure and temperature gauge (if any)- Lube oil pressure gauge- Control oil pressure gauge- Push button stop for steam turbine- Run light- Push button for emergency shutoff

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- Speed - Load- Journal bearing metal temperature - Thrust pad metal temperature - Differential expansion between shaft and casing at any critical point- Axial expansion of casing from anchor point- Bearing pedestal or shaft vibration - Contacts for annunciators and alarms, as required.

Condenser and Auxiliaries

- Vacuum condenser single pass design and accessories - Gland steam condenser - Condensate pump and accessories- Steam jet air ejector- Starting ejector - Vacuum breaker valve

Spares and Tools

- Manufacturer’s standard spares and tools (list to be provided alongwith proposal)

Technical Data

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Type Multistage, full condensing, impulse-reaction with

reductiongear

Quantity 1 set

Output at generator terminal 12000 KW

Type of governing Electro hydraulic

Speed 3000/1500 RPM

Inlet steam pressure 90 ±3% bar

Inlet steam temperature 530 ±2%ºC

Exhaust steam pressure 0.1 bar (a)

Steam flow (to be specified) ___ tph

Leak of steam ___ tph

Extractions for LP heater

Pressure ___ bar Temperature ___ ºCFlow ___ tphEnthalpy ___ kj/kg

Extractions for Deaerator

Pressure ___ bar Temperature ___ ºCFlow ___ tphEnthalpy ___ kj/kg

Extractions for HP heater

Pressure ___ bar Temperature ___ ºCFlow ___ tphEnthalpy ___ kj/kgThe steam parameter as per boiler design is fixed, however the Contractor may select steam extractions for heating condensate and feed water to a

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temperature of 180°C before economizer inlet of the boiler. The Contractor shall provide heat and mass balance diagram.

Synchronous Generator

The generator shall be designed for nominal rating of 15 MVA, with generation voltage of 11KV, 50 Hz, 3 phase, and at a rated power factor of 0.8 (lagging) and shall be capable to operate within the voltage range of ±10% and power factor range of 0.8 lagging and 0.95 leading.

The generator will be provided with brushless excitation system. The excitation system shall be capable of operation in isolation or in parallel with similar other generators and with the power grid. Generator shall be able to operate with a variation of ±10% in voltage and ± 5% in frequency with combined voltage & frequency variation of 10% absolute. The short circuit ratio of the generator should be 0.5. The generator shall have class F insulation and temperature rise limit to class B insulation and will be air-water cooled, complied with IEC 60034 standards.

The generator cooling system shall be TEWAC design, inlet temperature of cooling water to the air coolers will be 34°C for design purposes, 6 terminals of the generator shall be brought out and 3 shall be shorted and grounded through secondary resistance loaded grounding transformer to restrict earth fault current and to reduce transient over voltage.

The generator shall have over loaded capacity of 110% for one hour in every 12 hours cycle and shall be capable of withstanding 150% of its rated current for 15 sec. after attaining thermal equilibrium at rated load and voltage. The sub-transient reactance (unsaturated) shall be around 20% depending on the short circuit limitation at 11KV. The excitation system shall be

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capable of supplying excitation current of the generator under all conditions of operation of load, voltage and power factor. Rated current and voltage of the exciter shall be at least 120% of normal excitation and at least 110% of no-load excitation voltage with minimum of 150% ceiling.

Generator shall be provided with the following:

a) Static excitation system with excitation transformer, digital duel auto-manual AVR capable of maintaining steady-state terminal voltage within ± 0.5 % of the preset value under all operating conditions.

b) Excitation control cubicle.c) Surge protection equipment.d) Neutral grounding equipment.e) Current and potential transformers.f) Generator control and relay panel.g) Standard instrumentation.h) Air – water coolers. i) Space heaters. j) Slip ring housing complete with open circuit ventilation system.k) Shaft grounding devices.l) Fire detection and fire protection system or devices for the supplied

equipment inside the electrical generator enclosure including first filling of CO2 bottles.

Generator Design Specification

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Rating 15000 KVA

Power Factor (lagging) 0.8

Power Factor (leading) 0.95

KW 12000 KW

Rated Frequency 50 Hz ± 5%

Speed 3000/1500 RPM

Rated Voltage 11KV ± 10%

Cooling System TEWAC/Air

Short Circuit Ratio 0.50

Design Air Temperature 45°C

Insulation Class F

Temperature Class B

Excitation System Static excitation

Efficiency Not < 97.8%

Short circuit current To specify by manufacturer

Short circuit ratio 0.55

Protection IP44

The turbo-generator shall comply with IS-4722/1EC 60034 standard or their equivalent.

Following Generator Data Sheet and Curves to be provided

- Reactive power capability curve- Saturation curves

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- Unbalanced load-time-curve- V-curves- Voltage and Frequency Variation Range- Detail design specification as per attachment

Scope

Contractor scope shall be complete for safe and reliable operation of the steam turbine but not limited to the following:

Scope shall include design, engineering including foundation and structure, manufacture, supply of main equipment and accessories, preparation of shipment, erection, commissioning and testing, supply of foundation bolts, support structures, heat retention material, special tools and wrenches as required for maintenance, flushing oil and first fill of lube/control oil, commissioning spares, staff training at plant site, recommended spares for two years operation & maintenance, and provision for witness test by Owner staff at works. The Contractor shall carryout performance and reliability run (15 days) test of turbo generator set as specified in the Contract document. The turbine-generator manufacturer shall provide the list of sub venders.

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4.4 – BALANCE OF THE PLANT EQUIPMENT (MECHANICAL)

Raw Water Supply

Branch minor canal is the source of raw water supply, and is drawn through water course used for irrigation. A sample raw water quality specification is given in table below.

Source of Water: Canal Water

Sr. No.

Parameter Unit Value

1 Physical Characteristics- pH at 25oC - 8.6- Conductivity µs/cm 534- Total Suspended Solid ppm 771.6- Total dissolved solids ppm 316.5

2 Cation- Calcium Hardness ppm as CaCO3 83.9- Magnesium Hardness ppm as CaCO3 48.2- Sodium + Potassium ppm as CaCO3 126.9- Total Cation 259.0

3 Anions- M-alkalinity ppm as CaCO3 128.0- Chlorides ppm as CaCO3 50.8- Sulphates ppm as CaCO3 81.3- Total Anions 260.1

4 Total Hardness ppm as CaCO3 132.15 P-alkalinity ppm as CaCO3 4.86 Dissolved Silica pm as SiO2 1.7

Note: For water treatment system, the Contractor will carry out its own analysis of sample water and take reasonable margin in the design.

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Raw Water Requirement

The water requirement for power plant operation is computed below and given table below. However the Contractor shall verify itself the requirement as per actual design.

Details of Raw water required

Steam Generating Capacity = 50 TPH Make-up water at 5% = 2.5 TPHSteam Loss = 0.5 TPHDM water make-up = 3.0 TPHDM Plant capacity with20 hours cycle operation = 3 x 24 = 3.6 tph

20Considering 10% margin = 3.96TPHCapacity (say) = 4.0TPHClarified Water RequirementCooling tower design capacity = 2,850 TPHCOC = 3T (Tout – Tin) = 8oCEvaporation + Drift Loss@ 1.5% of 2850TPH = 42.7 TPHBlow Down = 21.3 TPHCooling tower make-up = 64 TPHDM Plant = 4 TPHTotal Clarified Water Requirement= 68 TPH3% loss in clarifier sludge = 2.0 TPHRaw water required for plant = 70 TPH

Note: The above are the estimated values, however the Contractor will verify its own requirement.

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Water Storage Capacity

The water storage reservoir/ tanks and their capacity for the proposed plant are given in table below.

Water storage capacity

Kachaa/ Pakka water reservoir 30000 m³Clarified concrete water tank 1000 m³DM water steel storage tank 60 m³

Water Treatment System

The purpose of the water treatment is to prepare quantity and quality of de-mineralized water needed for operation of the power plant. The de-mineralized water will cover the consumption during the power plant operation including make up water, to cover the waste (continuous blow down, leakages) during the boiler operation.

The water treatment system design shall be based on the raw water analysis given in table below.

Table: Water treatment plant design for the raw water

PH 7.8 to 8.0Total Dissolved Solid 500 ppmTotal Suspended Solids 800 ppmTotal Hardness 400 ppm

The water treatment plant will cater for a) Clarified water make-up for cooling tower.b) Clarified water for service water & fire water.c) DM water for steam power cycle

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Based on the analysis of raw water, two stages water treatment plant is recommended.

a) Pre-treatment stage comprises of raw water pumping system, cascade aerator, clarifier, sludge handling system, and clarified water storage and fire water sump.

b) Demineralisation Streams (DM) to produce quality water for boiler makeup. Two (2) nos. DM streams (1W+1S) each of capacity 4m³/hr are considered. DM Plant consisting of filtration i.e. PSF, ACF exchanger and DM exchanger i.e. cation, anion and mixed bed vessels polishers with regeneration system.

Treated outlet water quality in DM plant shown in table below.

Treated water quality in DM plant

Turbidity < 10 TNU Organic matter TracesPH 7 ± 0.2Silica (SiO2) < 0.02 ppm M.B. outlet at 25°C Conductivity

~0.1

Composition of Water Treatment Plant

In general the water treatment plant consists of the following parts (or equivalent):

- Raw water storage and handling system- Sand and carbon filtration unit (if required)- De-mineralization unit- Regeneration facilities - Chemicals unloading and storage unit - Neutralization of the waste water from the regeneration

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- Power supply system - Control system - PLC

Main and Auxiliary Cooling Water System

The heat of condensing steam removed in a steam condenser and heat from auxiliary cooling circuits is removed by a continuous loop circulating main cooling water system. The warmed water is then cooled by evaporation in contact with ambient air in a cooling tower, and the evaporation heat is dissipated into the atmosphere. Counter flow induced draft cooling tower of 3000 m³/hr capacity will be designed. The wet bulb temperature of 27.5°C and 4.5°C approach may be considered for design of cooling tower having multiple cells. The heat rejection is approximately 26.87 MWt, and cooling water makeup is 65 tph.

Cooling Water Systems

The cooling water systems shall essentially comprise of the following systems:

i) Circulating Water System for supply of cooling water to the condenser.ii) Auxiliary Cooling Water System for supply of cooling water to various auxiliary coolers of steam turbine, turbo-generator, steam boiler, boiler feed pumps, air-compressors, air conditioning plant etc.

i) Circulating Water System

Circulating Water System will be a closed loop water circuit comprising of induced draft counter flow type cooling tower and circulating water pumps with all necessary piping, fittings, and control etc. Circulating water flow through the condenser is estimated to 2650m³/hr. The make-up to the cooling tower will be from the clarified water storage reservoir.

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Three (3) nos. 60% capacity (2W+1S) circulating water pumps for the condenser will be installed in CW pump house.ii) Auxiliary Circulating Water System

For auxiliary cooling water requirements two (2) nos. (1W+1S) 100% capacity pumps will be installed in CW pump house. This cooling water will meet the cooling water requirement of auxiliaries and other equipments. The return hot water will be routed cooling tower for cooling.

Cooling Tower

For cooling hot circulating water and auxiliary cooling water return after condenser and cooling the auxiliaries, induced draft cooling tower of 3000m³/hr capacity may be considered in system design, wet bulb temperature of 27.5°C and 4.5°C approach to be consider for design, cooling tower shall have three (3) nos. cells. The temperature rise of water in condenser and auxiliaries will be around 8°C in normal operation.

To control the built-up of micro-organisms the circulating water will be chlorinated; to prevent scale formation a combine sulphuric acid and propriety phosphonate based anti scale treatment scheme will be used.

Cooling Tower Make up Pumps

Cooling tower make up pumps at 100% capacity (1W + 1S) will be installed in clarified water pump house to supply make up to cooling water sump.

Biomass Handling and Storage

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It is desired that steam boiler to be capable to fire bagasse mixed with rice husk and or in combination of other biomass as available, these consideration should be kept in mind while finalizing the biomass handling plant and storage facility.The biomass handling and storage facility may comprise of truck weighing bridge, truck dumping system, open yard storage of 90 days, dry biomass fuel shed for 7 days. The fuel conveying system design shall be from the dry biomass fuel shed to boiler fuel feeding system including biomass fuel discharging system, storage system and charging system.

Independent provisions for bagasse and rice husk is to be made for feeding to boiler silos or bunker. Combination of mixed or independent biomass firing may be done as per availability.

De-aerator

The feed water system will be provided with a constant pressure spray cum tray type de-aerator with a feed water tank design for minimum 20 minutes effective storage capacity at full load operation, with required piping, valves, fitting, platform, ladders, control and instrumentation, steam nozzle, water inlet outlet nozzles, steam pressure control valves and deaerator level control valve. The feed water tank will have a safety valve to limit pressure increase in the event of malfunction; material of trays will be of stainless steel.

The deaerator will be designed to de-aerate the incoming condensate to keep the oxygen content of the condensate below 0.02 mg/l. During start up pegging steam will be drawn from the auxiliary steam header and during normal operation from turbine bleed.

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Specifications

Maximum outlet capacity 55,000 kg/ hrOperating pressure 3 barFeed water temperature - at deaerator inlet 90°C- at deaerator outlet 130°CHeating steam pressure ~3.5 bar

Maximum oxygen content < 0.02 mg/ml

Steam Condenser and Auxiliaries

The steam condenser shall be of non contact surface type with suitably designed air evacuation and condensing equipments. The condenser shall be divided water box type to allow water side cleaning of the condenser with turbine operating at 60% load, capable of maintaining the required vacuum while condensing steam at the maximum exhaust steam flow of the turbine.

The condenser shall be designed for a working pressure of 4 bar(a), a circulating water flow rate of approximately 2650 m³/hr or corresponding to condense 1.1 times the normal exhaust steam quantity with cooling water inlet temperature of 34°C, and temperature rise of 8°C. The condenser will be of rolled steel construction of body and water chamber, tubes will be of copper-nickel (Cu: 90%, Ni: 10%) alloy and tube sheet will be of carbon steel.

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The maximum heat load for condenser design will be corresponding to turbine operating at 105% turbine MCR steam flow, 3% makeup.

The cooling water for the condenser will be supplied from the cooling tower basin through circulating water pumps installed in CW pump house.

Two (2) 100% capacity steam jet air ejectors including start up ejector shall be provided to maintain the vacuum in the condenser by expelling the non-condensable gases. Following are condenser and auxiliaries;

- Vacuum condenser - Gland steam condenser - Condensate pump and accessories- Steam jet air ejector- Starting ejector - Vacuum breaker valve

Condensate Water System

The condensate water system consist of 2 x 100% capacity (1 operating and 1 stand-by) motor driven condensate extraction pumps to discharge the condensate from the condenser hot well to de-aerator. The condensate will pumped through air ejector condenser, gland steam condenser, and LP heater and then to the de-aerator. A condensate recirculation pipe line to steam condenser shall be provided in the condensate pipe line.

HP / LP Heater

The heater will be provided to heat the condensate and feed water by extraction steam from turbine. The heaters will have both drain cooling and de-superheating zones in addition to the normal condensing zone as

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necessary. All heaters will have individual bypass valve in order to allow isolation and maintenance. 1 x 100% capacity drip pump will be provided to re-circulate the drain of LP heater into condensate discharge line with all necessary piping, valves (including drain and vent valves), and fittings.

Steam and Water Analyzer System (SWAS)

The sampling system package shall consist of the following:-

- Feed water- Steam drum water - Saturated steam - Superheated steam - Condensate from surface condenser

Auxiliary Steam Supply

Saturated steam will be used for gland sealing, steam jet air ejector, and deaerator heating. Steam from the drum will be taken to reducing station, after reducing the pressure, steam will be supplied to the point of use.

Chemical Feed System

To keep up the plant availability it is necessary to adjust certain chemical conditions in the steam water cycle in order to minimize corrosion, scaling and deposits. Chemical feed system will comprise hydrazine and phosphate dozing system which will be supplied complete in all respect.

Laboratory and Testing Facilities

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A chemical laboratory with necessary testing equipments and facilities to test and analyze steam, water, oil, fuel etc. will be provided.

Raw Water - Clarified Water System

Raw water reservoir of adequate capacity will be constructed, two (2) nos. ~ 85 m3/hr capacity pumps (1W+1S) with necessary valves, fittings, piping, and control shall be provided to draw water from the raw water reservoir to the clarifier.

One clarified water covered concrete storage tank of having approx. 1000m3 capacity is proposed to be constructed to store the clarified water. A number of suitable capacity pumps will be provided in clarified water pump house to draw water for DM plant supply, service water, cooling tower make up. Fire fighting pumps will also draw water for fire fighting requirements.

Water Treatment System

The de-mineralization system will produce quality water for use as boiler feed water comprising of cation, anion, and mixed bed with regeneration unit. It shall be provided to produce and store make up water of required quality and quantity during unit operation and shut down periods.

The capacity of the DM plant shall be 2 x 4 tph with storage capacity of 60 m3. The clarified water at the inlet of DM plant will be delivered at a pressure of 3.0 bar (g). The treated water at the outlet of the DM plant will be delivered at a pressure of 3.0 bar (g) to storage tank. Operation of the DM plant will be PLC based.

Final design of the DM plant should be taken after detailed analysis of the raw water available for use.

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The quality specifications after treatment will achieve the following:Hardness (ppm) : NilChloride : NilSilica as SiO2 : < 0.02 ppmIron as Fe : < 0.01 ppmConductivity at 20°C : < 0.2 mhosPH at 20°C : Between 5 – 9

Compressed Air System

Two (2) nos. (1 working +1 stand by) reciprocating air compressor for instrument air and service air of suitable capacity at 8.4 kg/cm² (g) pressure will be installed for compressed air system. The compressor will be medium speed non-lubricated, oil free, reciprocating or rotary screw type 2-stage equipped with suction filter, inter-cooler and after-cooler with moisture separator, air receiver, drive motor with V-belt transmission etc.

Provision will be kept to supply plant air from the air receiver to the instrument air system. The instrument air drying system will consist of two (2) identical desiccant drying towers of suitable capacity at a pressure of 8.4 kg/cm² and individual air receivers to absorb pressure pulsations for supply of instrument air to utility. Normally one of the dryer will be in service while the other one will be under regeneration. A completely automatic control system will sequentially control the driver system to ensure timely regeneration and service to provide dry air at the outlet at all times.

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Ventilation and Air Conditioning System

The main power plant building ventilation system will be provided to exhausted hot air through roof extractors. Various rooms, switchgear rooms etc. will be ventilated by means of the fans or by extending duct system wherever possible. Control room in turbo generator building housing main controls (DCS) for boilers and turbo generator, laboratory, and offices shall be air conditioned with suitable capacity of air conditioning system.

Control room of water treatment plant will be provided with adequately sized split air conditioners.

Neutralization & Waste Water Treatment System

All the effluents of the power plant during normal operation shall be treated to meet the requirement of NEQS for liquid effluent discharge. Waste water from the regeneration process of water treatment plant, boiler blow down with a pH in the range of 9.5 to 10.5 at a temperature of 100°C (maximum 0.5 tph), and cooling tower blow down will be collected in neutralizing basin and after neutralization will be pumped out to main effluent discharge terminal point.

The capacity of the neutralization basin shall be such that all effluent shall be taken up and neutralized. There shall be two (2) pumps for discharge each of 100% capacity, one pump in operation and one standby, capable to empty the basin in one hour.

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After treatment effluent will achieve as follows:

1. Temperature increase ≤ 3ºC2. PH value 6 – 93. Bio-chemical oxygen demand (BOD) at 20ºC ≤ 80 mg/l4. Chemical oxygen demand (COD) ≤ 150 mg/l5. Total suspended solids (TSS) ≤ 200 mg/l6. Total dissolved solids (TDS) ≤ 1000 mg/l

Sewage from various buildings is to be drained to septic tank and the sewage water will be sent to dispose off on land by providing disposing trenches. Sludge will be removed periodically and disposed off as land – fill at suitable places.

Strom water drain harvesting system is to be provided in the plant area.

Fire Protection System

Main plant, transformer area, switchyard, bagasse/rice husk storage yard etc. are protected by combination of hydrant system. Automatic sprinkler system, automatic fixed foam system, high velocity spray system, apart from portable and mobile fire extinguishers will be provided at strategic locations. The systems are to be designed as per the recommendation of applicable standards.

Automatic fire alarm system with portable CO2 foam type extinguisher shall be provided.

Suitable fire detection system would also be provided at cable vault, unit control room and other MCC rooms etc. to detect outbreak of fire at an early stage.

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In addition to these, adequate number of portable and mobile (wheel mounted) fire extinguishers of soda acid type and carbon dioxide type will be provided at suitable locations.

Crane and Hoist

To handle the maximum heavy weight to be lifted for maintenance of turbo-generator set 15 ton capacity traveling crane (EOT) with main and auxiliary hooks will be installed in the turbine hall. Some small hoist and lifting devices of suitable capacity will also be provided in the CW pump house and work shop.

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4.5 – BALANCE OF THE PLANT EQUIPMENT (ELECTRICAL)

Electrical System

The scheme for electrical system of the plant will be based on 3 phase, 11KV, 50 Hz, 0.8 power factor, single generator of rated gross capacity at 12MW. The output of the generator will be connected via the generator circuit breaker to 11KV bus bar. The synchronization of the generator will be done to connect the generator with the 11KV bus bar by auto/manual synchronizing device.

Metering, Control, and Synchronization Panel

For metering, control, and synchronization of turbo generator with the grid system, generator metering and synchronization panel will be provided in the main control room which will have the facility for metering of various generator electrical parameters. The panel will mainly consist of the following:

- Metering for generator & exciter - Control switches - Push buttons - Synchronizing components- Trouble annunciation of generator etc.

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Synchronizing panel will have facility for auto/ manual synchronization of breakers (synchronizing points). The equipment for this purpose will include following:-

- Auto synchronizer - Check synchronizing / guard relay - Necessary voltage sensing relays - Double frequency meter- Synchro-scope etc.- Breaker selector switch - Auto/ manual switch

Provision for synchronizing through DCS may also be built in the design.

11KV is the voltage levels for generator design and export of power to the purchaser grid system. 415-230volts is the voltage level for all motors and small auxiliaries load, 220volts for DC supply system, and 220 volt AC, 24 volt DC for control system.

Auxiliary power supply through 3 MVA, 11 KV/0.415 KV will be designed for AC voltage variation of ±10%, frequency variation ±5%. DC auxiliary’s voltage variation of -15% to +10% of 220 volts.

Controls and protection relays will be micro processor based and centralized in a central control room, multifunction numerical type relays with redundant features will be used as far as possible for the protection of generator, transformers, 11KV, 0.415KV volts systems.

Generator Circuit Breaker (GCB)

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The generator shall be controlled through 3 single poles, 12 KV, SF6 draw out type, circuit breaker integrated into the single phase encapsulated bus duct between the tee-off connection to the unit auxiliary transformer and generator. The breaking capacity of the same shall be selected on the basis of short circuit current rating on 11KV side. The following equipment is mounted on the common base frame:

- The three poles of the circuit breaker- Motor-operated sliding-type series dis-connector - Potential transformer - Surge capacitors- Operating mechanism- Control cabinet

Auxiliary Transformer

The transformer will serve to supply power to the auxiliary loads. The transformers with switchgear and protections shall be as per the following specification.

Transformer ratings : 3 MVA Cooling : ONANRatio : 11KV/0.415KVHighest system voltage : 12KVFrequency : 50 HzTaps and range : Off circuit tap changer +7.5% to -7.5% in steps of 2.5% Voltage vector : dyn 11Cooling : ANInsulation Class : FNeutral earthing : NGR

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The transformers shall have the following protection to isolate the equipment whenever there is any fault.

- Over current and earth fault relay- Differential relay - Restricted earth fault protection at HV side- Buchholz relay- Winding and oil temperature indicators

415 Volt Low Voltage Switchgears

415 volt switchgear shall be metal enclosed, vertical, single/double front, draw-out type, suitable for indoor installation, with degree of protection IP-54 as per IS: 13947. Three phases 4-wire system shall be provided for 415 volt switchgear/ MCC.

The incomers, bus ties and motors of 100 KW and above shall be controlled by circuit breakers having earth fault relay. Switch fuse, contactor and overload relay shall control other feeders with single phasing preventer for motor feeders and switch fuse/MCCB for other feeders.

Circuit breakers shall be of air-break type with symmetrical breaking capacity of 25 KA. Bus bar shall be aluminium or copper PVC sleeved jointed shrouded and rated for 2000 Amps, as required with total temperature limited as per relevant Standards.

Microprocessor-based multi-function energy meters non-volatile memory will be provided on 11KV side at generator terminals, 11KV side of auxiliary transformer, and out going export feeders for energy billing. The energy meters will have accuracy class 0.5.

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All 11KV/0.415 KV feeders connected to main switchgear buses will be equipped with multi-functional microprocessor based feeders management devices having protection and metering facilities alongwith ports for interface with plant DCS system.

All feeders will be provided with conventional indicating and metering instruments.

The motor control centers (MCC) units within the plant shall be designed to have spare capacity for any extra connection in future.

Electric Drive Motors

All motors for auxiliaries shall be 3 phase, 50 Hz, squirrel cage, induction type operating at nominal voltages of 415 volts while small motors shall be 230 volt. Motor rating shall be selected at least 1.10 times the maximum duty point power requirement.

Variable frequency drives shall be provided for ID, FD and SA fan motors and all biomass drum feeder/extractor motors, with a provision of by-passing the drive for maintenance/service.

All motors shall be energy-efficient type, conforming to IS: 12615. Motors rated above 30 KW shall have efficiency higher than 92% and high power factor (at least 0.88). Motor insulation shall be class-F for all motors (with temperature rise limited as for class-B insulation) and minimum class-B insulation for LT motors. Motor shall have IP-55 enclosure (with IPW-55 enclosure/canopy for outdoor motors) and shall be designed for direct-on-line starting with as low starting current as possible.

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For motors above 30 KW rating, single-phase 240 VAC space heaters shall be specified and below 30 KW winding heating is envisaged.

Generator and Transformer Protection

The protection relays shall be of numerical type, of 16-bit microprocessor based intelligent relays, thereby maintenance free, will be provided for protection of main equipment such as generators, unit auxiliary transformer and large motors.

Following protections are proposed for the various equipments against faults: Turbine Generator : Generator differential protection

100% Stator earth fault protection 80-90% Stator earth fault protection Loss of excitation Negative phase sequenceReverse powerOver –voltage Under –voltage Under/over frequency Over current relays Backup impedance Stator winding temperature high

Auxiliary Transformers : HV over current LV over current & earth faultBuchholz alarm & TripWinding temperature high alarm & TripOil temp high alarm & trip

11KV feeders : Over current & Earth fault

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220V DC system : Earth fault (Alarm only) Under voltage

11KV Bus System – Interconnection with the Grid System

The 11KV bus bar of the power plant shall be indoor installation designed for nominal capacity of 2500Amps with the provision of incoming generator breaker, earthing material, surge arresters, PTs panel, outgoing feeder panels, auxiliary transformer panel. Breakers shall be rated at 15KV, 2500 Amp, 25KA short circuit current (as per WAPDA specification) for generator, 15KV, 650 Amp, 25KA short circuit current for auxiliary transformer, 15KV, 2500 Amp, 25KA short circuit current for outgoing feeders.

The plant auxiliary supply will receive startup/emergency power from the power purchaser grid through 3MVA, 11KV/0.415KV auxiliary transformer connected with 11KV bus system.

The power export shall be through outgoing 11KV overhead line to the power purchaser grid system. The outgoing panels will be provided with Billing and Backup Metering System i.e. import/export kWh meter with MDI + KVArh, 0.5 accuracy class.

Automatic synchronizing and power control unit via speed governor shall be envisaged in the design/supply, the unit shall be capable for reverse synchronizing of the generator with the outgoing lines in case of disconnection of the generator with the grid system, maintain stable power condition on the generator.

Control Room

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There will be a centralized control room at the operating floor of turbine-generator building in which control panels for the steam boiler, steam turbine, generator, generator circuit breaker, auxiliary power supply, and 11KV out going circuits shall be housed.

Control room shall also house the DCS equipment and protection panels for generator, unit auxiliary transformer, and fire alarm control panel.

DC System

Plant DC supply system essentially caters for control, monitoring, protection, alarm, annunciation, spring charging and operation of all circuit breakers, DC motor driven emergency lube oil pump, and emergency lighting.

The system shall comprise of 220V or 110 volt DC, 300 Amph lead acid, maintenance free, accumulator battery with one (1) main float cum boost charger and one (1) standby float cum boost charger and DC distribution boards using switchgear units in incomer and in other outgoing feeders.

Grounding

Plant grounding grid shall be provided for grounding of electrical equipment, building steel, exposed metal structures, maintaining step and touch potentials within safe limits to protect personnel caused by ground fault currents and lightning discharges. The plant grounding grid shall in no way be interconnected with the grounding grid of existing sugar mills.

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Separate grounding bus, independent of station grounding bus, shall be provided for electronic systems like governor control panel, UPS etc.

Grounding conductors and accessories shall be designed to carry the maximum fault current for one second. Ground conductor shall be of MS conductor of circular cross section. Ground conductor shall be sized to take into account the corrosion allowance for a period of 30 years.

Lighting

Lighting fixtures shall be provided suitable for 240 volt AC for normal and emergency lighting and 220 or 110 volt DC for back-up emergency lighting.

Supply for AC lighting shall be obtained from 415V, 3 phase, 4 wire, 50 Hz, bus of main lighting distribution board which will receive power from 415V switchgear.

Suitable number of sub-distribution boards/lighting panels, located in various plant areas, will be fed from main lighting distribution board. Incomers and outgoing feeders of LDBs/LPs/sub DBs shall be provided with HRC fuses for short circuit protection.

Ten (10) percent of total lighting fixtures in the plant shall be connected to the Emergency AC lighting system which shall be fed from emergency switchgear.

The type of lighting fixtures and the illumination levels envisaged for the various areas are as follows:

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Out door lighting will be automatically switched on and off through photo electric controlled switches.

Communication System

Complete set of telephone system shall be provided for communication between users of the system at different location throughout the power plant area. The telephone system shall use a modern, digital storage program exchange fully modular design, and it includes the main distribution frame.

The telephone system shall consist of PABX System with 48V DC power supply. The system shall consist of the Private Automatic Branch Exchange (PABX), Main Distribution Frame (MDF) and cable network. The system would accomplish the telephone exchange for intra plant subscribers in whole plant of the power plant and link to the public telephone network, shall have the following features.

Digital stored program exchange Subscriber lines to the public telephone network Central PABX unit with main distribution frame Uninterruptible power supply (UPS) 10 pcs. Desk/wall type telephone sets. 4 pcs. Telephone sets with sound shielding hood for noisy areas. 4 pcs. Telephone sets- weather-proof design for out doors use.

Emergency Power Supply

The plant auxiliary supply buses shall be designed to receive startup power/emergency power from the 11KV plant bus through 3 MVA, 11KV/0.415KV auxiliary transformer.

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In the event of plant black out due to total grid shutdown and for safe shutdown of the unit, the emergency diesel generator shall start automatically to provide the essential loads of the power plant.

Diesel engine driven generator of 250 KVA rating connected to 415 volt bus arrangement shall be envisaged in the scheme. The DG set will be arranged to start automatically up on failure of normal power supply.

The diesel generator shall be installed in a container which provides the required weather and sound protection. The container is provided with the local control panel and all main electrical auxiliary devices for the diesel generator set. The arrangement of the equipment shall allow easy access for maintenance and inspection of all components.

The emergency diesel will be started by an electrical starter. The entire starting system is installed inside the container and includes a set of nickel cadmium batteries and battery charger. The fuel oil tank for 5 hours of full load operation is provided. The engine is equipped with an emergency stop button and engine speed governor, fuel and lubrication oil filters with replaceable elements and an oil line bypass system.The brush-less three phase synchronous generator is of the self-excited type with a self-regulating three-phase synchronous revolving field. The generator is equipped with a complete excitation system capable of supplying excitation current to the generator under all output conditions (from no load to full load) and capable of maintaining constant generator voltage.

Technical Specification:Genset : 250 kVA/200 kW Rated voltage : 0.415 kVPower factor : 0.8

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Frequency : 50 Hz

4.6 – INSTRUMENTATION & CONTROL SYSTEM (I&C)

For this biomass power plant, DCS shall be adopted as the automatic control system, realizing unit central control of boiler, turbine and generator.

Main monitoring and control systems are;

- DAS : Data acquisition system;- MCS : Modulating control system;- SCS : Sequence control system;- FSSS : Furnace safety supervisory system;- ECS : Electric control system;

Such systems as ash-blowing system, composite water pump house and biomass fuel conveying system shall all be under the control of DCS, and be monitored in the central control room. The chemical water treatment programmed control system shall also be in DCS.

Design Philosophy

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The design philosophy for control and instrumentation shall be through state of art microprocessor based Digital Control System (DCS), monitoring and information system for the entire main plant covering the total functional requirements of modulating control, sequence control, interlocks & protection, monitoring, alarm, data logging, fault analysis etc.

The design of the control system and related equipment shall adhere to the principle of ''fail safe" operation at all system levels (i.e.) the loss of signal, loss of power or failure of any component should not cause a hazardous condition; and at the same time prevent occurrence of false trips and provide reliable and efficient operation of the plant under dynamic conditions and attainment of maximum plant availability.

Normal supervision and control of the boiler i.e. either start or shut down will be performed through DCS from the central control room. Protection and interlocking for boiler is also provided.

Boiler shall be capable of control and operation based on biomass fuel with the following.

Major system functions include:

i. Boiler purge ii. Grouped initiation of ignition and shutdown iii. Main fuel trip (MFT) conditioniv. First out annunciationv. Safety interlockingvi. Alarm abnormal conditions

Some of the major close loop boiler controls are described below:

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a. Furnace pressure control. b. Combustion & bed temperature control. c. Drum level control. d. Deaerator level control. e. Deaerator steam pressure control. f. SH steam temperature control. g. Soot blower steam pressure control

Some of the major open loop boiler controls are described below:

a. Combustion furnace Biomass feeding Primary air fan (variable speed) Recirculation gas fan (variable speed) Grate hydraulic pump unit Grate ash airlocks and screw conveyor Ash conveyor main discharge

b. Steam boiler Feed water pumps Ash conveyors

c. Flue gas cleaning plant Ash conveyors ID fan (variable speed)

Monitoring of major balance of plant will be performed through DCS. However control & operation of off site packages such as cooling water system, water treatment system etc. will be provided from DCS with remote I/O & local operating station.

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In addition emergency trip push buttons shall also be provided for safe shut down of power plant.

Turbine and Generator along with their major auxiliaries would be accomplished from a Central Control Room (CCR). From the CCR, operators would start-up, load, unload, release for remote dispatch, Shutdown and monitor the steam generator, turbine and other auxiliaries of the plant. The principal functions of the DCS are as follows:

- Provide the control of the Boiler (SG) & steam turbine generator (STG).

- Provide control of the steam generator, main steam cycle, steam and water cycle.

- Provide control of combustion air, burner ignition, and flame management.

- Receive input signals that represent the status of process variables and equipment status; condition the signals; and utilize them for control, protection, monitoring, status display, annunciation and SER.

- Provide the output signals to modulate and control the final devices, such as control valves, control drives, dampers and pumps.

- Provide alarm logging and sequence-of-events recording (SER) capability with 1 ms resolution.

- Provide plant start-up, loading, auto synchronization and shutdown. - Perform information processing functions including logging and

printout of historical data, trend displays, elapsed time monitoring, and totalization of fuel and energy usage and generation.

- Provide a means to coordinate the load control of the prime movers in response to remote dispatch load change requests.

- Status of all drives, pumps, tanks, etc should also be available in central control room.

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The operator shall be able to control the equipment via the station operator's consoles in the central control room.

Upon synchronization, the unit will be loaded in anyone of the following ways:

- Manual loading by the operator.- Automatic loading to pre-select load set points initiated manually by

the operator through boiler-turbine coordinated control loop. - All emergency trip or runback action shall be fully automated. No

operator action is envisaged for any protection related logics under routine operation and running of the plant.

- Alarm and data acquisition shall be on-line continuous function. Operator's action shall be limited to accepting the alarm and recognizing the malfunction or upset parameters of any equipment or drives.

AC and DC Power Supply for Control and Monitoring System

The power supply for the control and monitoring systems takes into account the following guidelines:

The total requirement of control and instrumentation power supply is fed from 240V AC industrial graded parallel redundant UPS. 240V AC UPS supply is fed 10 MMI. 24V DC supply requirement for DCS cards/transmitters etc is met through 240V AC UPS and AC/DC converters:

a. Ability to use the normal power supply available in the plant.b. High degree of reliability and availability to ensure that under no

condition does the supply to the control system of the plant fail.

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c. Back up power to be available for the control when the main electric supply in the plant may not be available.

d. To provide regulated and clean power sources for the Micro-processor based control and monitoring systems.

e. Synchronization of the redundant AC sources to ensure that any transfer to back-up supply does not cause damage to the sensitive computer equipment.

The central supply to Micro-processor based control systems cannot have any breaks as this leads to the loss of memory and consequent halting of the systems. Therefore a non-break supply is ensured for such systems. In order to ensure 24V DC no-break supply, 24V DC redundant system is used, consisting of redundant 240VAC UPS supply/24VDC converter for each cubicle (mounting within cubicle).

The distribution of AC and DC loads for the control and monitoring systems are done as follows:-

- The DC supply is envisaged for the auto-control system, interlock, protection and sequencing and annunciation systems.

- Other system toads are taken on the AC supply through UPS.

For the AC portion of the loads, the use of completely 100% redundant charger cum inverter system is envisaged with 50% load sharing. However the battery bank for the system would be 100% capacity batteries only. The 50% load sharing envisaged also ensure that there is increased margins in the inverters to blow branch fuses. The equipment included for the UPS for such a scheme is given below. UPS is located in AC room:

Description Qty. / Unit

1. 100% capacity float-cum-boost chargers - 2

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2. 100% capacity static inverters - 23. 100% capacity static switches - 24. Manual by pass switch - 1 5. 60 min backup VRLA/SMF batteries with - 1 20 years life.6. Step down transformer - 2 (415V, three phase to 240V, single phase)7. Voltage Stabilizer - 1 8. AC Power Distribution Boards - 2

4.7 – GUARANTEES DATA

The Contractor will optimize the steam power cycle to achieve best efficiency and provide guarantees of performance values on fuel mix i) 80% bagasse – 20% rice husk, ii) 80% rice husk – 20% bagasse.

Performance Guarantees

- Fuel : Fuel mix- Gross power output : __ kW- Plant auxiliary load and losses : __ kW- Net power output for export : __ kW - Boiler efficiency : __%- Steam cycle efficiency : __%- Net efficiency : __ %- Net heat rate : __ kj/kWh- Specific biomass consumption : __ kg/kWh

Performance Values are based on the following

- Ambient Conditions : __

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- LCV of fuel : __ kcal/kg- Exhaust Steam Pressure : __ bar a- Exhaust Steam Temperature : __ °C - Exhaust Steam flow : __ tph- Cooling water flow : __ tph- Cooling water temperature rise : __ °C- Stack Exhaust Temperature : __ °C- Feed Water Inlet Temperature to Economizer : __ °C

Emission Guarantees

SOx : 200 mg/Nm³NOx : 500 mg/Nm³CO : 650 mg/Nm³Particulate Matter : 100 mg/Nm³

Note: No test tolerance shall apply to the performance guarantee as this project is governed under the Sale and Purchase Agreement.

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SECTION – 5: CIVIL & STRUCTURAL WORKS

The scope of civil works shall, but not limited to, soil investigation, foundation design of the main power block i.e. boiler, turbine hall, control room, diesel generator, pump house, cooling tower, water treatment plant, and other affiliated constructions. Other construction works for non-industrial purpose building and structure shall include, office building, guard house, security posts, main gate, guest house, access roads, pavements, boundary wall, parking area, and security fence. The scope of works shall also include all necessary civil works required for other equipment e.g. fire fighting, earthing, plant area lighting, building lighting, installation of all embedded materials, conduits, switchboxes etc. complete in all respect.

The main power plant building shall be a structural steel framed structure with silicon modified polyester coated galvalume steel sheet roof and side cladding, and RCC floors, the electrical bay shall be provided with RCC slab roof with suitable water proofing treatment. The structure will be designed to cater for one no. bridge crane to handle the heaviest load for handling turbo-generator maintenance and other equipment.

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The doors and windows shall be of steel metallic frame conforming to (Industrial Building) with 5 mm thick float glass glazing to avail natural light.

The general criteria for various civil engineering designs shall be as follows:

All RCC structures shall be designed as per IS:456 and all Steel structures as per IS:800 or approved equal standards.

Design loads for buildings and structures including wind loads shall be as per IS: 875 or equal standards.

A surcharge load of 1000 kg/m² at grade level shall be assumed for design of all foundations and structures, located in the vicinity of vehicular movement area.

Live load on platforms and floors for all structures shall be considered as min. 500 kg/m² in addition to any dead loads from permanent equipment etc, local area for stationing of heavy loads such as generator rotor will be strengthened to meet the loading requirement of the equipment supplier.

All buildings/structures shall be provided with cast iron rain water down pipes of minimum 100mm dia as higher size as per design requirement, plinth protection and drainage system connected to main storm water drains, Parapet wall, hand rails shall be provided on all accessible roofs for a height (maximum) of 1000 mm.

All floors of power plant building shall have ironite or equivalent floor hardening treatment topping except turbine hall operating floor, control room, battery room, offices and toilets. Turbine building, shall have heavy duty mosaic tile floor, offices and toilets shall have ceramic floor tiles

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control room shall vitrified ceramic tiles and battery room and neutralizing pit shall have acid proof floor and wall tiles. All tiles shall be of approved make and shall conform to relevant latest codes. Minimum thickness of mosaic/ceramic tiles shall be 20 mm. Toilets shall be provided with minimum 6 mm thick ceramic wall tiles for full height.

All precast cover slabs for trenches shall be provided with MS edge protection angles on all sides (minimum size of angle 50 x 50 x 6). Trench edges shall also be provided with edge protection angle protection.

All structural steel columns shall be encased in M-20 grade PCC from Base plate level to finished floor level.

All culverts at road crossings shall be designed for class "A-A" or Class A whichever gives worst effect loading as per IRC6 (latest) standards in addition to surcharge specified elsewhere.

All conveyor gallery trestles shall be in structural steel construction using Rolled Steel section. The trestle legs shall be encased in concrete for a height of 3.5m, and provided with anticorrosive Epoxy paint.

Civil foundation shall be designed consideration soil bearing capacity as derived from test, water table, dead; live and dynamic loading as applicable shall be followed.

Concrete quality for various works shall be:

- M30 TG and any other special foundation higher grade- M25 Station building columns foundation, boiler structural

foundations, transformer yard, beams, slabs, pedestals,columns, floors, etc,

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- M20 Grade slab, Drains, Plinth protection and other miscellaneous

items,- M10-1:3:6 Sub-grade Filling, mud mat etc.

Asphalted roads with minimum 50 mm thick asphalt concrete topping + seal coat type B or 15 mm wear coat of 6M and 3.5 M width with 1.5m wide hard shoulders will be laid over 150 mm thick water bound macadam base laid over 230 mm thick stone sub-base, connect the main plant road.

All structural steel works shall be painted with epoxy paint of approved manufacture with minimum three coats over two coats of approved primer to provide protection against the corrosive bagasse laden atmosphere.

All concrete surfaces, above ground level shall be provided with water based concrete penetrating water/epoxy corrosion inhibitor and shall be applied as per manufacturer's instruction.

Inside wall of the building shall be painted with acrylic emulsion plastic paint oil based distemper paint over prepared base of oil bound distemper and colour /white waste, as required as per Owner's approval.

Battery room walls and DM plant trenches and neutralizing pit shall be provided with acid proof tiles. Battery room walls and roof shall be provided with acid resistant paint.

Clarified water reservoir having two compartments with central partition wall in RCC construction shall be built up. Sides of the reservoir will be either of earth embankment or in RCC construction as per the availability of space. If earth embankment is used then it should be lined with PVC film to avoid water loss by seepage.

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SECTION – 6: COMMISSIONING AND TESTING

General

After completion of erection and/or installation work, and before being put into operation of the steam boiler, turbo generator, condenser, motors, pumps, heaters, fans, piping, valves, and all other mechanical and electrical equipment and materials shall be thoroughly cleaned and inspected, under the supervision of the engineer appointed by the Owner, for correctness and completeness of installation and acceptability for placing in operation.

The Contractor will be responsible for the equipment operation during the period commencing with Tests-On-Commissioning and extended through Trial Operation and all Performance Tests. During this period, the Contractor shall furnish the supervisory operating personnel plus any calibrating devices, special test instruments, etc. required to prepare for and conduct the Performance Tests. The Owner will available biomass, water supplies, and the electrical load. Owner will also deploy O&M staff for the Contractor’s use during the test period. The Contractor’s supervisory personnel shall conduct training sessions for the Owner personnel prior to and during this period and shall otherwise train them so that they will be

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able to operate and maintain the new equipment satisfactorily after acceptance by the Owner.

Tests-on-Commissioning

The Contractor shall perform all Tests-on-Commissioning before the start of Trial-Operation or at such other time as agreed by the Independent Engineer or authorized person of the Owner in accordance with the provision of the Contract and all such tests specified in the Contract, excerpt of the tests to be performed under the supervision of Independent Engineer appointed by Owner, and to be witnessed by the authorized representatives of the Power Purchaser, are mentioned below:Trial Operation

Following the issuance of the authorization to start Trial Operation, Trial Operation shall take place under the supervision and at the expense and risk of the Contractor.

The duration of the Trail Operation shall be 15 days. The Performance Tests shall be performed within the Trial Operation period or any such period mutually agreed. During the Trail Operation period the Contractor will perform the Reliability Run Test and the Capacity Test in accordance with the Tests procedures agreed and specified in the Contract. During the Trial Operation Tests if faults or defects interrupt operation within the Contractor’s responsibility, Trial Operation shall start again after remedy of the faults and defects. On successful completion of the Reliability Run Test the plant will qualify for Commercial Operation and Provisional Acceptance.

Tests under Power Purchase Agreement (PPA)

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The Contractor in addition to commissioning tests shall also carry out certain tests as required by the Power Purchaser prior to initial synchronization of the facility with the grid system. Owner will appoint Independent Engineer (the “Engineer”) prior to commissioning and testing of the plant, Engineer shall deliver to Owner and the Power Purchaser the Certificate of Readiness for synchronization. Prior to the delivery of the Certificate of Readiness for synchronization and the first synchronization of the unit, the Contractor shall carry out, or shall cause to carryout, in the presence of the Engineer, and authorized representatives of the Power Purchaser, the following tests:

a) Automatic voltage regulator setting and adjust in stand still condition and with the generator running at no load.

b) Turbine governor control checks, including over speed test.c) To verify the protection level settings for the following as agreed by

the power purchaser and owner. i. Stator earth faultii. Negative phase sequenceiii. Generator transformer over current and earth faultiv. 11KV bus bar protection

Tests after Synchronization of the Plant and Commercial Operation Tests

After first synchronizing the plant, initial operational testing of the plant shall be conducted by the Contractor. Once the Owner or Engineer is satisfied that the plant is capable of continued reliable operation, the Contractor shall request the Engineer or the Owner to issue the Certificate of Readiness. Upon the issuance of the Certificate of Readiness, the Contractor shall so notify the Power Purchaser and carry out the following tests (the “Commissioning Tests”), which if Plant satisfies the minimum performance criteria therefor, will result in the Plant being “Commissioned”

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and the Commercial Operations Date is establish in accordance with the provision of Power Purchase Agreement (PPA).

(a)Initial Capacity Test (b)Reliability run test(c) Automatic voltage regulator droop(d)Turbine governor operation(e)Reactive capability(f) Minimum load capability(g)Full load rejection

Automatic Voltage Regulator

The AVR Test is required to demonstrate the control of the generator voltage over the range of ±10 percent of the rated voltage.

Turbine Governor Operation

The operation of the speed governor is required to demonstrate control over its range, with the droop being adjusted from 2% to 8% with droop characteristics of ±0.5 percent.

Reactive Capacity

The reactive capacity test demonstrates the capability of the facility and the unit to operate at rated voltage and frequency at following power factors and reactive conditions as per generator manufacturer's reactive capability curve.

Power Factor 0.8lag/ 0.95 Lead100% MW output ____MVAR/____MVAR

Minimum Load Capacity

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The minimum load capacity test shall demonstrate the capability of the facility to be operated at 20 percent of gross rated output while the boiler, turbine, and auxiliaries remain in a stable and controlled condition.

Full Load Rejection The full load rejection tests will demonstrate the ability of the facility and its auxiliaries to withstand full and part load rejection and the facility must not trip and remain in a safe condition. This test is a prerequisite to performing the reliability run.

Reliability Run and Initial Tested Capacity

Successful completion of the reliability run is a pre-requisite to achieving Commercial Operation under the agreement with the power purchaser. The plant will operate continuously at full load during 72 hours, the output during the remaining 96 hours of the test will be as requested by the power purchaser. The reliability run test shall have been satisfactorily completed only if it continues without any interruption whatsoever for not less then 168 hours.

During the one hundred sixty-eight (168) hours period of the Reliability Run Test, the initial Tested Capacity of the Plant will be determined in the following manner:

i) The Plant shall be in operation at full output with auxiliaries in service and full colony load if connected directly to the Plant.

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ii) The Company will declare to the Power Purchaser the commencement of the test and will record the reading of the metering system.

iii) The test duration will be six (6) continuous hours and at the end of this period the Company will record the new reading of the metering system. The initial Tested Capacity as determined by such test shall be the difference between the reading taken at the end of the six (6) hours period and the reading taken at the beginning of such period, divided by six (6) and such result adjusted to Reference Condition if applicable.

Conditions: i. The Contractor shall at its own cost be responsible to carry out as

many as reliability run tests unless successful demonstration in accordance with the provision above.

ii. The Taking over Certificate (Provisional Acceptance) shall not be issued by the Owner unless the above tests are successfully performs by the Contractor duly certified by the Independent Engineer.

EPC Cost Annexure – A

Sr. No.

Description US $ x 1000

1 Mechanical Equipments 2 Electrical & Instrumentation 3 Civil Works4 Initial Spares 5 Sea Freight and Insurance 6 Port Clearance and Inland Transportation

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7Detail Engineering, Erection, Testing and Commissioning

8 Service Tax Total EPC cost

Detail of EPC Cost Annexure – B

Sr. No.

Particulars US $ x 1000

Mechanical Equipments1 Steam Boiler and Auxiliaries

2Steam Turbine–Generator and Auxiliaries, Condenser, and HP/LP Heaters

3 HP Piping with Valves and Pipe rack

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4 Water Treatment Plant and Auxiliaries 5 HVAC system6 Fire Protection System 7 Raw Water Pumps, CW Pumps, ACW Pumps8 Biomass Handling – Storage System9 Cooling Tower Equipment10 Compressed Air System11 Process Steam Pipe Works & LP Piping & Valve

Total Mechanical

Detail of EPC Cost Annexure – C

Sr. No.

Particulars US $ x 1000

Electrical & Instrumentation

111KV Bus with Switchgear, Protection and Metering System

2 Unit Auxiliary Transformer (3 MVA)

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3 Generator Circuit Breaker, 12KV4 LT Bus Duct + Switchgear 415 V 5 Cables and Cable Accessories 6 Emergency Diesel Set 7 NGT & NGR – 1 NO.8 Earthing and Lighting Protection9 Plant Lighting10 Plant Communication 11 DCS 12 DC – UPS System13 Miscellaneous Electrical

Total Electrical

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