btg scope aug 29

EMCO Energy Ltd.

SCOPE OF WORK AND TERMINAL POINTS SECTION - G3

2 X 135 MW THERMAL POWER PROJECT

AT WARORA, MAHARASHTRA

CONTRACT DOCUMENT FOR COAL BASED THERMAL POWER PROJECT

VOLUME II

SECTION – G3

SCOPE OF WORK AND TERMINAL POINTS

2 x 135 MW Coal basedPower Generation Project CONTRACT DOCUMENT

VOL-II, SECTION-G3

PAGE

EMCO Energy Ltd.


VOLUME-II

SECTION-G3


CONTENTS

ITEM DESCRIPTION

A. BOILER ISLAND

B. STEAM TURBINE ISLAND

C. POWER CYCLE AND AUXILIARY PIPING

D. WATER SYSTEM

E. COAL HANDLING PLANT

F. ASH HANDLING PLANT

G. FUEL OIL SYSTEM

H. FIRE PROTECTION SYSTEM

I. OTHER AUXILIARY SYSTEMS

J. ELECTRICAL SYSTEM

K. CONTROL AND INSTRUMENTATION

L. CIVIL, STRUCTURAL AND ARCHITECTURAL

M. SERVICES AND GENERAL ITEMS

N. TERMINAL POINTS


VOL-II, SECTION-G3

PAGE1 OF 16

EMCO Energy Ltd.


SECTION – G-3


The scope of work shall comprise the engineering, design, material selection, fabrication, manufacturing, testing at works, supply at CIF port Mumbai, marine insurance, design and engineering of Civil, Structural and Architectural works related with BTG island, testing, commissioning, trial operation, performance testing at site, supervision of erection, supervision of civil, structural, architectural work and other related items of work for entire BTG island, necessary for a complete working power station, including but not limited to the following:

SL.NO.

ITEMS SPECIFICATION

REQUIREMENT

BIDDER’S RESPONSE （CNAICO）

Item classified

in

Remarks

A. BOILER ISLAND

1. Complete steam generating unit with milling and draught plant for pulverised coal firing system, alongwith ignition and support firing system and low Nox burner; refractories and insulation as required.

Yes Yes A,B Refractory and insulation is included in extra scope B

2. Particulate extraction equipment (Electrostatic Precipitator having total seven field with six active fields and one spare field to meet SPM level of 75mg/Nm3 with worst coal firing at BMCR.) and one field out condition

Yes 75 mg/nm3 A We have agreed for 5 working fields and one stand by

field

3. Chimney (single , twin flue chimney of height 220m common for both units)

No Only design basis

We give only design input like gas

temperature and flow4. One Goods-cum-Passenger Elevator for

approach to boiler galleries Yes Yes C This is new

requirement given on 29-08-08. Price to worked and given

later5. Elevator for the maintenance of the

chimney No No

6. Boiler cleaning system, soot blowing system for the furnace and air pre-heaters

Yes Yes A Soot blowing system is included. No other cleaning is considered

7. Raw coal bunkers and the coal feed Yes Yes C This is new


VOL-II, SECTION-G3

PAGE2 OF 16

EMCO Energy Ltd.


SL.NO.

ITEMS SPECIFICATION

REQUIREMENT


Item classified

in

Remarks

system requirement. Price will be worked out and given later

8. Auxiliary boilers, if required by the Bidder.

Yes Not required

9. Coal mill reject handling system, as applicable.

Yes No

10. Raw coal bunker emergency emptying system.

Yes Yes C This is new requirement along with bunker. Price will be given later

11. Air pre-heater and coal mill fire fighting system

Yes Yes A

12. Chemical dosing system Yes Yes A

13. Blow down system (continuous, with steam recovery, and also intermittent)

Yes Yes A

14. Fuel Oil Support system Yes Yes A

15. Boiler structural steelwork with all necessary stairs, galleries with roofs and side covers.Interconnecting platform between Boiler and Bunker bay

Yes Yes B Side cladding is al-ready considered given in extra price.

16. Pent house on furnace roof with weatherproof enclosure and pressurised ventilation

Yes Yes A

17. Coal sampling system at mill outlet. Yes Yes A

18. Air-flow measurement system at mill inlet.

Yes Yes A

19. Any other accessories as required Yes Yes A

B. STEAM TURBINE ISLAND

1. Steam turbines with emergency stop and governing valves, gland sealing system, extraction steam systems, HP-LP bypass, all control, protection and

Yes Yes A


VOL-II, SECTION-G3

PAGE3 OF 16

EMCO Energy Ltd.


SL.NO.

ITEMS SPECIFICATION

REQUIREMENT


Item classified

in

Remarks

monitoring devices, lubricating and governing/control oil systems etc.

2. Boiler feed pump sets with drive units, (motor drive) booster pumps (if required).

Yes Yes A

3. Regenerative feed water heating system including feed water heaters and deaerator, chemical dosing, condensate make-up and dump, reserve feed water tank etc.

Yes Yes A

4. Condenser with air evacuation system, condensate extraction pumps, continuous tube cleaning system, etc.

Yes Yes A

5. Turbine oil receiving, storage, transfer and purification system.

Yes Yes for cen-trifuges and integral sys-

tem. Only de-sign for cen-tral lube oil

system.

A

C. POWER CYCLE AND AUXILIARY PIPING

Complete Power Cycle piping, valves etc. as well as all auxiliary system piping, valves with hangers and supports etc. as required for the boiler and steam turbine islands and connected systems.

Yes Yes A

D WATER SYSTEM(CW,ACW,DM ETC)

a) DM water : From outlet filling connection of Condensate Storage Tanks

CW/ACW : Tapping from two meters distance away from power house building including piping inside TG hall/user point

Yes Yes B CCCW System price is given as extra

scope under item B


VOL-II, SECTION-G3

PAGE4 OF 16

EMCO Energy Ltd.


SL.NO.

ITEMS SPECIFICATION

REQUIREMENT


Item classified

in

Remarks

Fire water & Drinking water: Tapping from two meters distance away from power house building and distribution as per approved drawing

b) Heat exchangers with closed cycle DM water primary cooling system and secondary circuit auxiliary cooling water pumps for each unit.

Yes Yes B CCCW System price is given as extra

scope under item B

c) Boiler filling system (pumps, piping etc.) Yes Yes B Boiler fill pumps are given as extra scope

E. COAL HANDLING PLANT

Scope of BTG vendor starts from inlet to Coal bunkers

Yes Yes C Coal Bunkers are extra in scope. Extra Price to be given separately

F. ASH HANDLING PLANT

Fly ash : From the outlet flange of ESP, air heater, economiser and chimney bottom hopper including companion flanges.

Bottom ash : At the seal plate of boiler furnace bottom

Yes Yes A

G. FUEL OIL SYSTEM

Pumps, motors, piping, valves etc. from outlet connection of fuel oil storage tanks

Steam line for heating etc. – Complete system

Yes Yes C New requirement. Extra price to be given separately

H. FIRE PROTECTION SYSTEM

Complete fire detection and fire protection system for the protection of the BTG island. Fire detection panels with all provisions in central control room.

No Only design


VOL-II, SECTION-G3

PAGE5 OF 16

EMCO Energy Ltd.


SL.NO.

ITEMS SPECIFICATION

REQUIREMENT


Item classified

in

Remarks

I. OTHER AUXILIARY ITEMS

Compressed air (service air/instrument air) piping from one point at two meter distance from boiler/TG building (throughout the BTG area) etc.

Auxiliary system piping. (e.g. fuel oil, drinking water, effluent etc.) from one point near boiler/TG area

Pipe supports and associated civil/structural works, including pipe racks, trestles, trenches etc. as required including all temporary frames for transport and erection in BTG area.

All lifting and handling equipment to facilitate the handling and transportation of all plant and equipment (heavier than 500 kg) that may need maintenance/overhaul during the plant's life time. This shall include the cranes on rails for - a) TG Hall EOT Crane, b) Boiler feed pump, feed heater bay (if applicable), etc., as also hoists, trolleys & monorails for other plant and equipment such as mills, ID, FD & PA fans etc. Also, slide rails and pulling systems required for equipment handling where applicable and trolleys for

Yes Yes

C

B

EOT Crane in TG hall is extra. This shall be quoted separately.

Maintenance tools and tackles are quoted as extra

5. a) Effluent collecting, sampling, monitoring, treatment, recirculation and discharge system (only minimum discharge and maximum recycling and reuse is accepted) meeting environmental and other statutory requirements.

No No

b) All necessary equipment for testing, monitoring and control of pollution from within the plant to the environment for meeting stipulations, as required.

Yes Yes B CEMS is quoted as extra in part B

6. Nitrogen bottles (adequate number for Yes Yes C Total Nitrogen sys-


VOL-II, SECTION-G3

PAGE6 OF 16

EMCO Energy Ltd.


SL.NO.

ITEMS SPECIFICATION

REQUIREMENT


Item classified

in

Remarks

refilling) storage, handling and distribution system for preservation purpose.

tem. Earlier offer contains only piping and manifolds

7. Carbon-di-oxide bottles (adequate number for refilling) storage, handling and distribution system.(For fire fighting system)

Yes Yes C Total Co2 system. Earlier offer contains only piping and manifolds

8. Laboratory for testing coal, fuel oil, turbine oil, transformer oil, ash, & other effluents; also steam and water analyzing and sampling units.

Yes Yes B Lab equipment can not be included in the scope of work. This is excluded.SWAS price is given under item B

9. Ventilation and Air conditioning systems as required, for power house and other auxiliary buildings.

Yes Only design for BTG area

10. Diesel generator set(s) as required for the safe coasting down of the units.

No. Only re-quirement to be given by CNAICO

11. Passenger lift for Administrative building (One number) and one number lift for service building.

No No

12. Plant maintenance workshop equipped with necessary equipment & facilities for best up keeping of the entire plant. Bulldozer and other Vehicle maintenance shop.

No No

13. Supply and application of paints and thermal/acoustic insulation as required for the BTG .

Yes Yes B Only shop painting.Thermal Insurance is given as extra scope

14. Coating, Wrapping and cathodic protection (if required) of underground piping for BTG

Yes Yes A

15 Drive motors (or, steam-turbines, if applicable) with gear reducer and coupling for all equipment wherever

Yes Yes A


VOL-II, SECTION-G3

PAGE7 OF 16

EMCO Energy Ltd.


SL.NO.

ITEMS SPECIFICATION

REQUIREMENT


Item classified

in

Remarks

required.

16. Any other supply items not specifically mentioned but deemed necessary for safe, reliable & satisfactory operation of the plant.

Yes Yes A

J. ELECTRICAL SYSTEM

1. Main Generators (2 nos.) with ExcitaitonExcitation system, Automatic Voltage Regulation, Surge Protection and Neutral Grounding Equipment and necessary control/protection panels and required CTs & VTs for protection also.

Yes Yes B This is quoted as extra price under B

2. Generator Transformers (2 nos.) with required tap-changer and all other fittings & accessories and Lightning Arrestors.

No Provide Specification

& requirement

Only Design put as applicable from BTG

3. Station Transformers (2nos) and Unit Transformer (2 nos.) with required tap-changers and all other fittings & accessories and neutral grounding resistors and Lightning Arrestors.


& requirement


4. Auxiliary Distribution Transformers (oil filled / dry type complete with all fittings and accessories and required tap changer.


& requirement


5. Generator Bus duct of isolated phase design, consisting main and tap-off sections complete with associated equipment.

Yes Yes B Qouted separately as extra price B

6. MV and LV Busducts. No Provide Specification

& requirement


7.A MV and LV Switchgears/Power Control Centres, Emergency Switchboard, Motor Control Centres, Distribution


&



VOL-II, SECTION-G3

PAGE8 OF 16

EMCO Energy Ltd.


SL.NO.

ITEMS SPECIFICATION

REQUIREMENT


Item classified

in

Remarks

7B

Boards, Starters for AC, Fuse Boards etc.

Starter of DC drive motorYes

requirement

Yes A

8. 220V DC systems each consisting of 2x100% capacity Battery with 2x100% Float cum boost Charger and DC Supply Distribution system complete with interconnection facility for both the unit and switchyard.


& requirement


9. a) Unitized 240V AC UPS system for BTG

b) UPS system for Common Electrical system & SCADA

c) UPS for each BOP systemd) UPS for Plant Intercommunication

System


& requirement


10. Illumination system of whole plant including Non-plant buildings with accessories and dry type lighting transformers.

No Only design for BTG area

11. Control, protection and metering systems for generator

Yes Yes A

12. All Local panels, local P.B. stations, Local Control Stations for BTG island.

Yes Yes A Only Local push buttons

13. 220 kV switchyard complete with all equipments, safety features, protective relaying, controls, metering, PLCC equipments, etc.

No Provide design input

data for generator

14. Cables and cable raceway system with necessary fire barriers, fire proof sealing and coating systems for in BTG islandAll HT & LT cables from equipment to switch gear, LPB to switch gear andDCS to switch gear.

Yes Yes C This is new requirement. Separate price to be given separately

15. Grounding and Lightning protection systems


&

Only design input


VOL-II, SECTION-G3

PAGE9 OF 16

EMCO Energy Ltd.


SL.NO.

ITEMS SPECIFICATION

REQUIREMENT


Item classified

in

Remarks

requirement16. Electrical laboratory equipments No No

17. 3x50% DG set with AMF Panel for emergency power supply.100 % specify requirement of total plant with Two units.


& requirement

Only Design input

18. Neutral Grounding Resistors for generators

Yes Yes A

19. AC Motors, DC Motors & Motors Actuators with termination accessory for HT motors.

Yes Yes A

K. CONTROL AND INSTRUMENTATION SYSTEM for BTG

1. Distributed Control System (DCS) comprising data acquisition sub-system, closed loop and open loop controls, data highways, gateways for connecting packaged control systems, operator stations with Visual Display Units (VDU) and control devices, printers, engineering work station, historical storage unit, Large video screen (LVS), Sequence of Events (SOE) recording, master clock system necessary application, documentation, diagnostic and engineering software.

Yes Yes A

2. Control room panels and racks including supervisor's console.

Yes Yes A

3. All primary sensors like Flow elements, Temperature sensors etc.

Yes Yes A

4. All field instruments - process switches, transmitters, local gauges etc.

Yes Yes A

5. All final control elements like Control valves and drives.

Yes Yes A

6. Steam and Water Analysis System (SWAS).

Yes Yes B Price given as extra scope

7.a. Continuous emission monitoring (CEM) system.

Yes Yes B Price given as extra scope

7.b. Ambient Air Monitoring system Yes Yes A


VOL-II, SECTION-G3

PAGE10 OF 16

EMCO Energy Ltd.


SL.NO.

ITEMS SPECIFICATION

REQUIREMENT


Item classified

in

Remarks

8. Machinery Monitoring System. Yes Yes A9. All boiler integral instrumentation

including Furnace Safeguard Supervisory System (FSSS), Flame monitoring system, Soot blower control system (SBC) etc. with connectivity to DCS.

Yes Yes A

10. All turbine integral instrumentation like Turbine supervisory instruments, Automatic Turbine Run up System (ATRS), Turbine Stress Control (TSC), Electro-hydraulic Governor Control (EHG), Automatic Turbine Testing System (ATT), Turbine Protection system, HP-LP bypass system etc. and interface with DCS.

Yes Yes A

11. All junction boxes, cubicles, enclosures, local panels, marshalling panels, pneumatic and process hook up hardware, cables, cable-trays and any other erection materials and accessories.

Yes Yes A

12. Performance calculation & optimisation system

Yes Yes A

13. C&I Lab Equipment YES NO14 UNITISED UPS complete with batteries

and Power distribution boards for C&I system as per EMCO specifications

YES YES UPS only for UPS

15 Earthing pits & Earthing cables for C&I electronic & protection & screen grounding

YES YES


VOL-II, SECTION-G3

PAGE11 OF 16

EMCO Energy Ltd.


L.

1.

2.

3.

4.

5.

6.

7.

8.

9.

10.

CIVIL, STRUCTURAL AND ARCHITECTURAL

Engineering, Design, Construction purpose drawings / documents related to main power plant equipments, power house and auxiliaries

Construction, including supply of all materials and labour of all civil, structural and Architectural works related to power plant.

Supervision of construction activities for 1 & 2 above

Engineering, Design, Construction purpose drawings / documents related to Miscellaneous non-plant building and structures, such as, Administrative buildings, Service building, Gate office, Time office, Weigh bridge, Stores buildings, Open store yard, Rest room, Security buildings, Car park, Cycle shed, Scooter shed, Petrol Pumps etc.

Construction, including supply of all materials and labour of all civil, structural and Architectural works related to Miscellaneous non-plant building and structures, such as, Administrative buildings, Service building, Gate office, Time office, Weigh bridge, Stores buildings, Open store yard, Rest room, Security buildings, Car park, Cycle shed, Scooter shed, Petrol Pumps etc.


Engineering, Design, Construction purpose drawings / documents related to Site grading including construction roads and drains for BTG area.

Construction, including supply of all materials and labour of all civil, structural and Architectural works related to Site grading including construction roads and drains.


Engineering, Design, Construction purpose drawings / documents related to Drainage system with required segregation of clear water drains from contaminated

Yes

No

Yes

No

No

No

Yes

No

Yes

Yes

Civil design is not considered by us.

Supervision of civil design can not be

accepted by us

This is not part of civil design also. This is total plant civil design

We will not accept supervision for civil even at extra cost


VOL-II, SECTION-G3

PAGE12 OF 16

EMCO Energy Ltd.


11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

water drains for BTG area (such as oily water, sanitary Sewer, effluents from water treatment plant etc) .

Construction, including supply of all materials and labour of all civil, structural and Architectural works related to Drainage system with required segregation of clear water drains from contaminated water drains (such as oily water, sanitary Sewer, effluents from water treatment plant etc).


Engineering, Design, Construction purpose drawings / documents related to Roads and Paving within BTG island

Construction, including supply of all materials and labour of all civil, structural and Architectural works related to Roads and Paving


Engineering, Design, Construction purpose drawings / documents related to Boundary wall and fencing with gates.

Construction, including supply of all materials and labour of all civil, structural and Architectural works related to Boundary wall and fencing with gates


Demolishing/removal of debris for any existing structure/foundations

Breaking/clearing of any existing concrete/paving etc.

Landscaping including green belts

Topographical survey.

Geo-Technical Investigation

No

Yes

Yes

No

Yes

No

No

No

No

No

No

No

No

This is not possible

M.

1.

2.

SERVICES & GENERAL ITEMS

Obtaining statutory/Regulatory clearances/approvals from concerned government agencies regarding the project. (only IBR for boiler, pressure parts )

Consents, licenses and permissions other than those to be obtained by the Owner. (Iianglian shall obtain all necessary licenses/approvals by Chinese

Yes

Yes

IBR approval is quoted extra in B


VOL-II, SECTION-G3

PAGE13 OF 16

EMCO Energy Ltd.


3.

4.

5.

6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17

Government.)

Complete design & engineering.

Packing & transportation (ocean and China inland), CIF Mumbai India. Supervision for unloading and storage at site.

Co-ordination & Project Management.

Shop tests & Quality Assurance.

Site temporary services (telecoms, water, power, discharges etc.) during construction period.

Complete Civil Construction (including supply of material and labour, construction of site office, canteen, construction stores, residential accommodation of contractor's staff and labour etc.),

Supervision of Fabrication, Erection

Provide specification, quantity requirement for lube oil and other consumables during commissioning and upto handover of BTG.

Spare parts, as required, for the entire plant for three (3) years (covering defects liability period) as per list.

Tools and tackle including all special tools and tackle, calibration and testing instruments etc. as required, for the entire BTG equipment.

After Sales Services during & after warranty period.

Plant stores for consumables and spares.

Water and power supply for the colony.

Development of green belt around power plant, ash dump area and township

Furnishing all documents, drawings, design basis reports, optimization study reports, design calculations, data sheets, quality assurance plans, testing procedures, operating and maintenance instruction manuals, commissioning documentation etc including "As-built" drawings.

Yes

Yes

Yes

Yes

No

No

Yes

Yes

Yes

Yes

Yes

NoNo

No

Yes

This will be quoted extra

18. Training of the plant Owner's personnel (20 Yes


VOL-II, SECTION-G3

PAGE14 OF 16

EMCO Energy Ltd.


19.

N.

1.

2.

3.

4.

5.

6

7

manmonths in China) and at site.Carrying out raw water analysis

NOTE :The above list of work is not exhaustive. Any additional works, whether or not specifically described in this bid document, incidental to complete the package in all respects shall be deemed to be in the scope of work of the Contractor.

TERMINAL POINTS

Rail - rail-track with railway siding will be provided by the Owner.

Treated Effluent- At plant boundary

Flue gas - At the inlet to chimney including expansion bellows & matching flanges

Drains: In nearby drain channel / canal

Vents : To the atmosphere at safe elevation (plus 2 m elevation above building roof).

Sewerage system : Upto nearest network

Roof water for rain water harvesting : Upto 10m from power house building

No

This is not applicable for BTG


VOL-II, SECTION-G3

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btg scope aug 29

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