mahagenco ele. scope

Maharashtra State Power Generation Co. Ltd,

Chandrapur STPS Expansion Project 2 x 500 MW, Balance of Plant Package

VOL-II, M0 SECTION-IV Page No.

MAHAGENCO

SPECIFICATION – M0

SECTION - IV

SCOPE OF SUPPLY AND SERVICES, TERMINAL POINTS AND EXCLUSIONS



VOL-II, M0 SECTION-IV

Page No. CONT-1 OF 1

MAHAGENCO VOLUME-II

SPECIFCATION M0 SECTION-IV SCOPE OF WORK AND TERMINAL POINTS CONTENTS

ITEM DESCRIPTION

A. WATER SYSTEM

B. COAL HANDLING PLANT & MILLS REJECT HANDLING SYSTEM

C. ASH HANDLING PLANT

D. FUEL OIL SYSTEM

E. FIRE PROTECTION SYSTEM

F. COMPRESSED AIR SYSEM

G. OTHER AUXILIARY SYSTEMS

H. ELECTRICAL SYSTEM I. CONTROL AND INSTRUMENTATION

J. CIVIL, STRUCTURAL AND ARCHITECTURAL

K. SERVICES

L. TERMINAL POINTS AND EXCLUSIONS




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VOLUME-II SPECIFCATION M0

SECTION-IV SCOPE OF WORK AND TERMINAL POINTS The scope of the Contractor under this specification shall comprise design, engineering, material selection, manufacturing, testing at works, supply to site, construction, installation, testing, commissioning, performance testing at site, and other related items of work for the Balance of Plant and equipment inclusive of all mechanical, electrical, instrumentation & control systems, civil, structural and architectural works, coordination with BHEL supplied Main Plant equipment for putting into commercial operation a highly reliable, safe, efficient and environmentally compliant power station comprising 2 x 500 MW Units on Engineering, Procurement & Construction basis (EPC – BOP), including but not limited to the following. The systems and equipment shall conform to the technical requirements specified in various Volumes and Sections of this Specification. Items not specifically mentioned here, but needed to complete the system and equipment and as required to meet the intent of the specification or required for operation of the equipment shall be deemed to be included in the scope of work of the Bidder unless otherwise specifically brought out under exclusions. The Bidders shall get themselves fully acquainted with the existing conditions at the site for the expansion project (Units 8 and 9) as well as for the existing 3 x 500 MW units (5, 6 and 7) for the purpose of assessing the quantum of work involved for supply of utilities from the existing units to the new units, as per Specifications. For detailed requirement of various equipment and systems (number, redundancy, capacity, technical parameters etc.), the respective Specifications and Sections for Mechanical, Electrical, Control & Instrumentation, Civil, Structural & Architectural works shall be referred. SL. NO.

ITEMS

A) WATER SYSTEM 1. Interconnection with the existing facilities at Units 5, 6 and 7 (3 x 500 MW) at Chandrapur

STPS by supply and installation of Ash Water Supply Pipeline including pipe-rack, Four (4) nos. Filtered Water Supply Pumps (to be located in the existing Filtered Water Reservoir and Pump House of Units 5, 6 and 7) and Filtered Water Supply Pipeline including pipe-rack, up to the new 2 x 500 MW Expansion Units.

2. A

Supply and Installation of One (1) new clariflocculator at the existing non-DM system area of units 5, 6 and 7, complete with rake mechanism (bridge type rake arm) along with drive and drive motors, flocculator mechanisms along with drive and drive motors, telescopic type continuous sludge discharge arrangement, intermittent timer operated main sludge disposal system, mechanically driven sludge scraper and collectors to remove the settled sludge etc. for the new clariflocculator. The unit shall be circular, center feed type, with concentric




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2 - B

flocculation zone and clarifier zone. The configuration and type shall be in line with the existing clariflocculators Interconnections from the existing flash mixers outlet to the new clariflocculator and from the effluent launder of the new clariflocculator to the common clarified water outlet channel.

Sampling of water from the new clariflocculator up to the existing sampling rack, for: Sludge water from the clariflocculator Clarified water from the clariflocculator outlet Filtered Water Reservoir of RCC construction and Filtered Water Pump House for Units 5, 6 and 7, to be located in the premises of the Expansion Units. CCW/ ACW System make-up supply pumps, Potable Water Pumps, Potable Water Chlorination System, Pumps for Air-conditioning and Ventilation System make-up supply located in the Filtered Water Pump House.

3. Fire Water Reservoir of RCC construction, and Fire Water Pump House, for Units 5, 6 and 7, to be located in the premises of the Expansion Units, with provision of connections from the basins of the Natural Draught Cooling Towers of Units 8 and 9 to the Fire Water Reservoir by gravity pipelines.

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Condensate Polishing Units (CPU) for the Expansion Project consisting of 3 x 50% polisher vessels for each 500 MW unit, to be located in the STG building. Each Condensate Polisher Vessel shall be complete with condensate inlet and outlet connections, connections for resin transfer to and from vessels, bed support-cum-under drain system, inlet water distributors, resin traps at the outlet, all accessories and appurtenances etc. as required. Common External Regeneration Facilities for the CPUs including resin transfer, collection, separation and mixing vessels, Demineralised Water Tank for regeneration, 2 x 100% pumps with piping for resin transfer and condensate transfer for the CPUs of both 500 MW units. These facilities shall be located in a separate building close to the STG Building. Acid and alkali handling system, storage and measuring tanks and piping for regeneration of the CPUs Regeneration Effluent collection in a lined RCC neutralizing pit, chemical tanks and dosing system for neutralizing the effluent, 2 x 100% Effluent Transfer Pumps with recirculation arrangement, compressed air supply to the neutralizing pit and transfer of the neutralizing waste to the Effluent Treatment Plant All instruments, process switches, analyzers, control valves, solenoid valves, etc. as required operation and regeneration of the CPUs. Free Standing Control System with Programmable Logic Controller and CRT/Keyboard based operator console & engineering console for the control and safe regeneration of CP System.




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First fill of resins for all service vessels, mixed resins storage vessel and makeup resin hopper and also first fill of lubricants and grease. All drive motors / actuators associated with the system / equipment, MCC etc.

5. Interconnection with the existing facilities of Units 5, 6 and 7 (3 x 500 MW) at Chandrapur STPS for supply of demineralised water by additional pipelines from the existing Mixed Bed Outlet Header to the new Demineralised Water Storage Tanks Four Demineralised Water Storage Tanks (Carbon Steel construction) for the Expansion Project, with interconnecting piping and headers at inlet and outlet, located adjacent to the existing Demineraliser Plant. Four (2 x 100% for each unit) Demineralised Water Transfer Pumps for make-up supply to power cycle system of the 2 x 500 MW Expansion Units, to be located within the existing Demineraliser Plant Building.

6. Plant drains, transformer sumps / all equipment drain sumps and drain pumps for the entire plant, with piping up to the Effluent Treatment Plant for treatment and recycling and misc. pumps.

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Circulating condenser cooling water (CCW) and auxiliary cooling water (ACW) systems, including: a) Natural Draft Cooling Towers with cooling tower basins and accessories b) Cold Water Tunnels from the Cooling Towers up to CW / ACW Pump House c) CCW Pumps and ACW Pumps along with butterfly valves and expansion joints at pump

discharge. d) CCW / ACW Pump House with forebay, gates and screens e) Complete CCW piping and accessories up to the terminal points for BTG Contract near

STG building up to the Cooling Towers. f) ACW piping and accessories up to the Terminal Points for the Plate Heat Exchangers

for BTG (Boiler and Turbine-Generator) Contract at the inlet and outlet headers of the Plate Heat Exchangers, and for supply to the coolers for the Balance of Plant Equipment/ Systems,

g) CCW/ ACW System make-up water supply and Cooling Tower Basins draining

arrangement. Piping connections from the Cooling Tower Basins outlets to the Fire Water Reservoir for the Expansion Units.

h) ACW Recirculation pipeline from ACW Pumps header to the pumps sump along with

pneumatic control valve station. i) CW Blow down Piping up to the Effluent Treatment Plant




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j) CW System Chemical Conditioning and Treatment. Chlorination Plant and chlorine dosing system

k) On-line Condenser Tube Cleaning System and Debris Filter for the Condenser Cooling

Water System, to be incorporated in the CW inlet/ outlet lines of Condenser, complete with all accessories, piping, supports, instruments and controls as per specification and as required for trouble-free operation of the system.

8. Miscellaneous water systems such as: Service water covering all buildings and facilities within the plant includings supply of wash water for air preheaters, supply of service and drinking water up to the terminal points for BTG supplier, drinking water distribution for plant and other auxiliary water systems, including piping, pumps, storage tanks, etc. All pumps, piping, gates, screens, trash racks etc. for the complete system with handling arrangement. All piping, valves, strainers etc required for the water systems. Control, protection and monitoring system with necessary interfacing with centralized Distributed Control system (DCS)

B) B1) 1. 2. 3. 4. 5. 6. 7. 8. 9. 10

COAL HANDLING PLANT AND MILLS REJECT HANDLING SYSTEM Coal Handling Plant complete with: Coal wagons unloading system (with Rotaside wagon tipplers, side arm chargers and apron feeders). Coal crushing and screening plant with magnetic separators Two (2) nos. Coal stacker and reclaimer for four (4) crushed coal stock piles Coal conveyors (complete with galleries, tunnels, and transfer towers) from unloading station to crushing plant, to stock pile and to power house coal bunkers Motorized traveling trippers for coal bunkers. Complete dust control system, ventilation and air-conditioning system. Control, protection and monitoring system with necessary interfacing with centralized Distributed Control system (DCS) Coal wagon weigh bridges for weighing loaded and empty rail-wagons. Conveyor belt weigh scales upstream of coal crushers/stackers as well as downstream before entry to the powerhouse bunkers. Rain protection sheds with structures for wagon tipplers facilities




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Coal handling and storage area storm water drainage system, including the arrangement for collection, clarification, recycling and reuse of the drain water through Effluent Treatment Plant. Manually operated/ motor operated hoists as specified and as required. CHP Control cum Maintenance Building with 5 Te electric operated hoist and electrical equipment room and Loco Maintenance Shed with 25 Te EOT Crane Coal bunker shed. Auger type sampling system of coal from the raw coal wagons Crushed coal sampling units from the coal conveyors upstream of the coal bunkers Rails over wagon tippler table shall be in the scope of BOP Bidder. These rails shall match in all respect to railway lines designed by RITES. Also, the rail lines 12 meter on inhaul side and 12 meter on outhaul side will be in the scope of the BOP contractor. Manual coal picking arrangement along with hopper, discharge pipe up to ground and platform for picking arrangement.

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Mills Reject Handling System complete with: Mill Discharge Spout with Pneumatically operated isolation gate and Pyrite Hopper. Pneumatic Conveying System of Mills Reject Material from Pyrite Hopper to Reject Storage Silos. Mills Rejects Conveying Piping, Bends, Fittings & Accessories. Mills Rejects Silos & Accessories. Air Receivers Compressed Air, Cooling Water and Drain – Piping, Valves, Fittings & Accessories. All structural works for steel silos, pipe racks, support including pyrite hoppers, support galleries/walk ways etc. Foundation for trestles, storage silos, air compressor, air receiver etc. Bag Filters Pneumatic Cylinder Operated & Manually Operated Plate Valves as required for the System. Necessary lifting devices for handling the Mills reject system equipment. Control, protection and monitoring system with necessary interfacing with centralized Distributed Control system (DCS)




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ASH HANDLING PLANT Ash Handling Plant Complete with bottom ash, coarse ash and fly ash conveying systems to intermediate storage or to silo directly and wet transportation system up to the ash dump area for each unit, including: Bottom Ash Water-impounded Hoppers (W-shaped) below Boilers, hydro-pneumatic gates, bottom ash clinker grinders, bottom ash transfer up to Ash Slurry Pond with Jet Pumps. Coarse ash collection system below hoppers i.e. feeder ejectors, surge tank, coarse ash jet pumps, piping for transporting the ash up to the ash slurry sump. Bottom ash slurry sump for collecting the bottom ash and coarse ash. Bottom Ash slurry Disposal Pumps and ash slurry piping up to the ash dyke. Miscellaneous pump sets like H.P. Seal Water Pumps, L.P. Seal Water Pumps, H.P. Ash Water Pumps, L.P. Ash Water Pumps, Refractory cooling water pumps, Slurry Drain Sump Pumps, B.A. Overflow transfer pumps, tube settler sludge pumps etc. as per specification. Drain sumps, B.A. Overflow sumps, sludge sumps, tube settler for B.A. Overflow recovery as per specification. Fly ash silos with ash outlets and collection arrangements, intermediate surge hoppers, dust extraction/ suppression systems, unloaders etc., and ash withdrawal system from both intermediate surge hoppers and fly ash silos. Dry fly ash handling system by pressure and vacuum mode, comprising of ash collecting hoppers outlet gates, ash piping up to the buffer vessels and to the intermediate/ final ash silos, Mechanical Exhausters (Vacuum Pumps), Transport Air Compressors, ESP Fluidizing Blowers, Ash Silos Aeration Blowers, rotary feeders and ash conditioner/ telescopic chutes for unloading fly ash from silos into trucks, vent filters with pulse jet cleaning facilities, drain sump and sump pumps. High Concentration Slurry Disposal (HCSD) system for fly ash including intermediate silos for collection of ash, rotary feeders, dosing screw feeders with ash conditioning, agitated retention tanks, HCSD Pumps, HCSD piping up to the ash dump area along with inspection/ service road for Ash Disposal. Control, protection and monitoring system with necessary interfacing with centralized. Distributed Control system (DCS). Dedicated Air Compressors, Air Dryers and Air receivers for instrumentation of Air Handling Plant with interconnection from plant compressed air system. Supports & Roads / Rail crossing for ash disposal piping including tunnels, culverts etc.

D)

FUEL OIL SYSTEM




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Interconnection with the existing facilities at Units 5, 6 and 7 (3 x 500 MW) at Chandrapur STPS for supply and installation of Fuel Oil System Pumps and Pipelines for the new 2 x 500 MW Expansion Units. Pipe-rack for interconnecting pipeline from existing fuel oil system to the proposed expansion units. Conversion of two existing LSHS Storage Tanks into two HFO Storage Tanks and conversion of one existing LSHS Storage Tank into one LDO Storage Tank for the new 2 x 500 MW Expansion Units. All associated renovation work including painting shall be included in the scope of BOP package. Supply and installation of new LDO Transfer Pumps (2 x 100%), to be located in the existing Fuel Oil Pump House, for the Expansion Project. Interconnection of existing LDO unloading header with the existing LSHS Storage Tank-4 which will be converted to LDO Storage Tank for the Expansion Project. Interconnection of the new LDO Transfer Pumps with the existing LSHS Storage Tank-4 outlet as well as the existing LDO Storage Tank outlet. HFO transfer piping from the existing LSHS Pumps discharge header and LDO transfer piping from the new LDO Transfer Pumps discharge header, up to the respective day tanks for the Expansion Units. Electrical tracing system and insulation for HFO piping and day tanks for 2 x 500 MW Expansion Units. HFO and LDO day tanks for the Expansion Units along with necessary dyke, collection of run-off and spillage etc. from the dyke area drain collection sumps with sump pumps and transferring the same to the Effluent Treatment Plant for separating the oil and reusing the water. Providing necessary level and temperature instrumentation for the existing fuel oil storage tanks as well as the new day tanks and providing the necessary Control, protection and monitoring of the system with required interfacing with centralized DCS. Air- conditioned Control room near the existing fuel oil system for the accommodating PLC based control panel and work station. Drain collection sump with sump pumps for the day tanks area. Service air receiver, piping, etc. and instrument air piping, as required. All foundations for new equipment in the fuel pump house in the existing facility as well as in the new facilities, including those for HFO heater, LDO/ HFO pressurizing pumps of BTG system. (Pressurizing pumps and heaters shall be supplied by BTG Vendor.)

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FIRE PROTECTION SYSTEM Complete fire detection and fire protection system for the entire power station, including Main Plant BTG Package, all buildings, transformers, HT / LT Switchgears coal handling




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and fuel oil handling systems, coal stockpile, open yard storage, portable fire extinguishers etc. as detailed below. Motor driven and diesel engine driven fire water pumps for hydrant systems. Motor driven and diesel engine driven fire water pumps for spray systems. Motor driven and diesel engine driven Booster pumps for fire fighting for boiler areas. Jockey pumps, hydro pneumatic tank and air compressors for fire water pressurizing system (common for hydrant system and spray system). Fire hydrant system network with hydrants, monitors and piping covering the whole power station buildings and plants, as per specification. Automatic high velocity water spray system for oil filled transformers, turbine oil tanks etc. as per specification. Nitrogen blanketing system for oil filled transformers Automatic medium velocity water spray system for cable galleries/ spreader rooms, coal conveyors etc. as per specification. Inert gas flooding system for control rooms, control equipment rooms, programmer’s rooms, data storage rooms, UPS and Inverter rooms etc. as per specification. Foam type fire fighting system for fuel oil day tanks. Automatic fire detection and alarm system for the power station, as per specification. Fire hydrant system accessories like fire hose stations, hosepipes, nozzles and couplings, at various locations, as per specification. Portable and mobile fire extinguishers – dry chemical, CO2, Pressurized Water, Foam type – as per specification. Fire hydrant system for switchyard. Shed for deluge valves.

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COMPRESSED AIR SYSTEM Separate set of instrument air compressors and service air compressors as per specification. Shell and tube type water-cooled Inter-coolers and After-coolers with moisture separators and drain traps for each air compressor. Suction filter and silencer for each air compressor. Air Drying Plants with accessories as per specification




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All instruments and controls as per specification and as required for trouble-free operation of the equipment and systems. Air receivers complete with supporting structure, pressure gauges and switches, safety valves, drain traps etc. as per specification PLC based control panel for control and monitoring of the Compressed air system, field instruments, control cables, etc. All interconnecting Piping, distribution piping valves, fitting and other accessories.

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OTHER AUXILIARY SYSTEMS Auxiliary system piping. (e.g. compressed air, fuel oil, drinking water, service water, effluent treatment and recycling etc.). Pipe-rack for carrying ash water, DM water and fuel lines from existing system to proposed expansion units. Pipe supports and associated civil/ structural works, including pipe and cable racks, structural beams for BTG system piping in STG Building, miscellaneous trestles and trenches etc. as required including all temporary frames for transport and erection. All lifting and handling equipment to facilitate the handling and transportation of all plant and equipment under BOP Package (heavier than 1000 kg) that may need maintenance/ overhaul during the plant's life time. This shall include the EOT cranes on rails for –(a) Power House Building, (b) CW/ACW pump house, (c) Filtered water pump House, (d) Loco Maintenance Shed, (e) DG and Air Compressors Building, (f) AHP pump houses and vacuum pumps/ transport air compressors/ instrument air compressors buildings etc. Hoists, trolleys and monorails for other plants and equipment such as portion of Power House Building outside the range of EOT Crane, Coal Handling Plant, Ash Handling Plant, Fuel Oil Pump House, fire water pump house, CW & ACW Pump House etc. Slide rails and pulling systems required for equipment handling wherever applicable.

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a) Effluent collecting, sampling, monitoring, treatment, recirculation and reuse avoiding any liquid effluent discharge. b) All necessary equipment for testing, monitoring and control of pollution from within the plant to the environment for meeting stipulations, as required. Hydrogen Cylinders duly filled with respective gases as per statutory norms and their storage, handling as per specification. Nitrogen Cylinders duly filled with respective gases as per statutory norms and their storage, handling for preservation purpose, as per specification. Carbon-di-oxide Cylinders duly filled with respective gases as per statutory norms and their storage, handling as per specification




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Laboratory for testing coal, fuel oil, ash, ambient air quality, stack emission, & other effluents, water analysis etc. (including Precision Laboratory for WTP) as specified Ventilation and Air conditioning systems as required, for powerhouse and other auxiliary buildings. Diesel generator set(s) as required for the safe coasting down of the unit. Passenger cum goods lift for power house. Passenger cum goods lift for service building.

13. Raw coal bunkers

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Miscellaneous Pumps and sump pumps as required.

15. Supply and application of paints and thermal/acoustic insulation as required for the entire power station.

16. Gunniting, Coating and Wrapping of underground piping.

17. Design and Construction of foundation for Stator lifting.

18. Complete rails in the transformer yard required for the handling of transformers/stators.

19. Rails embedded in concrete in Loco shed, STG building, Wagon tippler complex. Two rail tracks near ‘A’ grid of STG Building for Stator and transformer movement upto Site Grid W-22 (Refer Plot Plan). The rail track beyond Grid W-22 is exluded from BOP Bidder scope.

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

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ELECTRICAL SYSTEM SCOPE: - (In case of any deviation in the scope of Electrical System indicated below, details given in the respective Section & E0 of the specification shall prevail and shall supersede the details indicated below.) All Electrical Installation Works of the equipment & Panels supplied under BOP Package & interfaced with the BTG Package Equipment. Electrical equipment to be covered under BOP package shall comprise of following: - 415V switchgears & MCC’s except 415V ESP switchgear & soot blower MCC. 415 V ACDB’s except for Turbine and Boiler Valves and Dampers and 220 V DCDB’s LT Dry Type Auxiliary Transformer of 11/0.433kV & 6.6/0.433kV of various ratings.




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11kV, 6.6kV UE grade HT, 1.1kV grade LT Power Cables & Control Cables, instrumentation cables and any other special cables. 6.6kV & 415V Motors and Motor Actuators (excluding those related to BTG) Cable trays with accessories and cabling accessories like joining kits, end termination kits, glands, lugs, etc. LT Bus duct (Non phase segregated type) Earthing grid of entire power plant (BTG + BOP) and establishing earthing connections of different equipment under BOP package. Four (4) number Oil filled 11/ 6.9kV Auxiliary Transformers of adequate rating along with Four (4) numbers Oil filled earthing transformer of adequate capacity with loading resistors for CHP and AHP. Local Control Panels, DB cum Local Control Panel & Local Push Button Stations as required 220V Battery (Lead acid Plante / Ni-cd) along with Battery chargers for entire plant (BTG + BOP). DG sets with DG board. Smart Illumination System of entire plant including area lighting. Fire Stop Mortar Seal/ Fire Retardant coating system as detailed in specification. The supply, laying and termination of control cables for the purpose of indication, control, protection and metering from the 400 kV switchyard CTs, PTs, switchyard bay equipment cubicles, marshalling boxes, JBs of two (2) Generator bay, two (2) Station Transformer bays and one (1) Bus Transfer bay shall be under the scope of BOP Contractor’s scope. The supply & erection of cable trays and cabling accessories for the above mentioned cables shall also be under the BOP Package Contractor’s scope. VFD except for ID Fans. Lightning protection system for entire plant (BTG + BOP). Supply and installation of lighting arrestor for generator transformers and station transformers. Supply, installation and foundation arrangement of Bus post insulator for connection of overhead conductor with lighting arrestor for generator transformer and station transformers.




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CONTROL AND INSTRUMENTATION SYSTEM Complete control, monitoring and protection system of all auxiliary systems and offsites like Coal Handling plant, Ash Handling Plant, Fuel oil system, Compressed Air Plant, DG package, Effluent Treatment Plant etc. with facility to interface with main DCS. Microprocessor based Programmable Logic controller (PLC) for various BOP systems comprising closed loop and open loop controls, data highways, gateways for connecting various control systems, operator stations with Visual Display Units and control devices, printers, engineering work station, historical storage unit, necessary application, documentation, diagnostic and engineering software. Interfacing between PLC and max DNA DCS (Including Termination at max LINK station) All local panels, supervisory control panels / consoles. All primary sensors like Flow elements, Temperature sensors etc. All field instruments - process switches, transmitters, local gauges etc. All final control elements like Control valves, dampers / gates etc. with actuators. All field cables, field to local / Main control room cables and interfacing to BHEL’s BTG package. Scope also includes even one end in BTG package scope. All junction boxes, cubicles, enclosures, local panels, marshalling panels, pneumatic and process hook up hardware, cables and other erection materials and accessories. Telephone system for entire plant (BTG + BOP) UPS with ACDB

J) CIVIL, STRUCTURAL AND ARCHITECTURAL

The scope of civil, structural and architectural works inside the plant battery limits shall cover following:




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I. Basic & detail Engineering, Analysis, Design and Preparation of Execution Drawings.

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Preparation of a project design manual containing design data and detailed criteria for construction & construction material specifications, and criteria for design & durability of the foundations and structures for Plant and non-plant buildings based upon a correct evaluation of the existing geo-technical / environmental/ topographic conditions and other relevant site-specific parameters. Preparation of drawings showing loading data for foundations, floors and supporting structures of all the equipments and systems in the Power Plant. Preparation of conceptual & detail architectural design & drawings showing floor plans, elevation, sections, schedules for finishes; schedules for doors, windows & hardware; false floor / false ceiling details; sanitary, plumbing & water supply pipe lines details in buildings; colour schemes for all buildings and facilities including coloured 3-D drawings for main plant building. Detail analysis and design of the structures/ foundations, preparation of the excavation drawings, civil construction drawings with bar bending schedule, structural steel design drawings, fabrication drawings with bill of material, preparation of the erection drawings/scheme, preparation of a schedule of inserts/embedment/sleeves and a schedule of finishes required for the different structures under the scope including special protective paints if any and preparation of “As built” drawings after completion of works. Embedded parts for BTG system, and structural beams for pipe supports for BTG system as per drawings/ documents from BTG supplier. Preparation of specifications for construction and construction material, quality assurance plan (QAP), field quality plan (FQP), testing and acceptance criteria, structure wise Bill Of Quantity (BOQ) including the items of architectural works.

II. Infrastructure Works

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Leveling and grading of the entire land within the plant boundary up to FGLs as per Plot Plan, including slopes protection as per civil specifications wherever required except for the switchyard area. Additional soil investigation and other tests if required for foundation designs of structures / building for power plant. Site clearing as required, as per civil specifications. Demolishing / removal of debris for any existing structure / foundations / paving etc. as per civil specifications. Culverts and storm water drains and manholes, internal construction water supply scheme, associated civil works for construction power supply etc within the plant boundary. Store yard for Bidder.




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Plant internal roads including permanent and temporary roads for complete plant area. Sewage treatment & disposal system for the complete plant with internal sewage system for all the buildings. Lighting masts. Plant storm water / oily water drainage (with oil separation/ recovery arrangement) system up to terminal points Final dressing and grade finishing after finishing of construction.

III. Construction, Erection & Execution of Civil/ Structural & Architectural works in the Power Block area

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Piling, if required. Boiler foundations, TG foundation, Power House foundations along with earth mat and its superstructure in structural steel. All equipment foundations for BTG area including transformer foundations along with earth mat. Vibration isolation system: Steel springs/ Viscous dampers for Steam Turbine Generator (STG), Boiler Feed Pumps, ID, FD, PA fans, Coal mills and Crushers Foundation. ESP foundations along with earth mat and ESP control room building, Cable trestle between ESP to ESP control room & ID fans. Mill foundations, complete structure for the Mills, Bunker including stainless steel lining to conical inside surface of bunker hopper and bunker bay structure and its foundations along with earth mat. Flue gas duct foundations. All Fire Barrier Walls as required. Multi Flue Chimney (steel flues with RCC wind shield) with Elevator having ground + Six (6) landings Pipe/Cable rack foundations and structures. All Cable trenches for complete plant. Pipe trenches. RCC paving in power block (BTG area) or any other area as required including plinth protection of all the buildings. Gravel filling in the transformer area along with the anti-weed treatment of the top layer of




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the soil. Chain link / barbed wire fencing as per civil specifications. All structural steel work except for steel work of boiler, ESP, Auxiliary structures for pipe and duct supports. Electrical Grounding. Rail tracks (embedded in concrete pavement and/ or roads) in transformer yard for movement of transformers and for movement of generator stator in front of A-axis of Power house, power house unloading bay, CHP maintenance building and locomotive maintenance shed.

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Transformer oil collection drain pits with sump pumps & intermediate pits, as per requirement of BTG contractor. Foundation arrangement for gantry for supporting overhead conductors between transformer yard and switchyard. RCC Pads and Foundations required for handling of Generator Stators and RCC pedestals and foundations for Stator Lifting Crane. Enabling works required like ramps, backfilling to increase ground level, compaction, finishing work etc. required for other erection agencies (BTG contractor etc.) are also included in scope of BOP Bidder.

IV. Construction, Erection & Execution of Civil / Structural & Architectural Works for Balance of Plant

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Piling, if required. All Civil/ Structural works related with the interconnection with the existing facilities at units 5, 6 and 7, as specified elsewhere. Superstructure and foundations for the additional one (1) clariflocculator to be installed in the existing Pre-water Treatment areaof units 5, 6 and 7. Filtered water storage reservoir in RCC and Filtered Water Pump House with pumps, switch gear / MCC rooms, equipment foundation along with earth mat. Fire water storage tanks and fire water pump house with pumps, switch gear / MCC rooms, equipment foundation along with earth mat. DM water storage tanks and foundations, DM water Transfer Pumps, Chlorination plant, equipment foundations along with earth mat etc. CW make-up supply system, potable and service water system and Air Conditioning/ Ventilation make up water system including potable water tanks. Condensate Polishing Units including CPU Regeneration building, Equipment foundations




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9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

22.

23.

24.

25.

26.

27.

28.

29.

along with earth mat, neutralization pit, etc. Cooling water pump house including covered approach channel and forebay, gates and screen, maintenance facilities, switch gear/ MCC rooms, equipment foundations along with earth mat etc. CCW and ACW pump foundations and all other equipment foundations along with earth mat in the scope of power block (BTG) Cooling water supply and discharge pipes/ducts including their supports and foundations, thrust blocks, RCC encasing of pipes where ever required etc. N D Cooling towers, cold-water basin cold water tunnel up to CCW pump house forebay. Fuel oil handling system including fuel oil day tanks, pumps and tanks foundations, dyke and dyke walls, fencing, pump house etc. Liquid fuel forwarding station including room for foam preparation unit. Complete Compressed Air system with Air compressors & DG building and equipment foundations. Service building with central air conditioning system. Transformer Yard including foundations and other civil/structural works. Effluent treatment plant. Complete oil water separator system Gas Cylinder Storage Building. Chemical Lab and Coal Testing Lab Complete fire fighting system Duct foundations All Cable trenches/trestles, as required for complete plant. Pipe trenches/trestles/racks with maintenance walkway, as required. RCC paving in BOP area including plinth protection of all the buildings. Electrical and C&I Lab (Part of STG Building). Plant wastewater drainage system. Fencing with gates wherever required




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30.

31.

32.

33.

34.

Electrical Grounding/Earthing. Boundary wall. All buildings, foundations and structures, bridges/culverts for crossing of roads/canals/rivers/nallahs. All building, transfer towers, equipment foundations, handrails, staircase, walkways, coal unloading system hoppers and foundations, paint house, underground tunnels, rails forming part of wagon tippler complex, RCC foundation for rails of wagon tippler complex inhaul and outhaul. All pipe and cable racks inside the plant as well as for interconnection between the existing units (Units-5,6 & 7) and new units (Unit-8 & 9).

V Construction, Erection & Execution of Civil, Structural & Architectural Works for Non Plant Buildings

1.

2.

3.

4.

5.

6.

7.

8.

9.

Piling wherever required First aid station. Fire station. Canteen. Miscellaneous Works. Security/Time office Building Car/Scooter & Cycle sheds Coal sampling room in CHP area Watch Towers and watch man cabins.

K) 1.

2.

3.

4.

5.

SERVICES Statutory / Regulatory clearances / approvals from concerned government agencies regarding the BOP systems of the project. Complete design & engineering for BOP systems as per relevant specifications. Packing & transportation, custom/port clearances as required, receiving and unloading at site. Co-ordination with Owner, BTG and other contractors at site and Project Management. Shop tests & Quality Assurance.




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6.

7.

8.

9.

10.

11.

12.

13.

14.

15.

16.

17.

18.

19.

20.

21.

Site temporary services (telecom, water, power, security, cleanliness etc.) during construction period. Complete Civil Construction including supply of cement, rebar, structural steel along with other materials and labour, construction of site office, canteen, construction stores, residential accommodation of contractor's staff and labour etc. Fabrication, Erection, chemical cleaning, Trial run, Commissioning and Testing of entire BOP Plant. Interfacing joints at terminal points. Supply of lubricants / consumables, spares and all temporary provisions till handing over of the plant including supply of Nitrogen, hydrogen & carbon dioxide gas etc. Supply of Mandatory spares as specified. Spare parts as required for the Balance of Plant during defects liability period. Tools and tackle including all special tools and tackle, calibration and testing instruments etc. as required, for the Balance of Plant. After Sales Services during & after warranty period. Plant stores for consumables and spares. Furnishing all documents, drawings, design basis reports, design calculations, data sheets, quality assurance plans, testing procedures, operating and maintenance instruction manuals, commissioning documentation etc. including "As-built" drawings. Training of the plant Owner's personnel on plant operation and maintenance. Provision of compound/ boundary wall. Submission of requisite number of soft copies on CDs and hard copies of each of the documents and drawings prepared above including “As Built” drawings. Attending meetings with Owner at any venue fixed by Owner as and when required for review, discussions and coordination of any work under the scope. The service shall also include setting up by the Bidder a complete testing laboratory in the field to carry out all relevant tests required for the civil/structural works for the project. Approval for overhead structures crossing rail track from Railway authority (CTPM) central railway, Mumbai. NOTE: The above list of work is not exhaustive. Any additional works, whether or not specifically




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described in this bid document, incidental to complete the BOP systems in all respects shall be deemed to be in the scope of work of the EPC Contractor.

L)

1.

2.

3.

4.

5.

TERMINAL POINTS / EXCLUSION Following shall be provided by the Owner.

a) Approach road to project area upto plant boundary.

b) Chain link fencing between existing power house area and project premises for security purpose.

c) Rail tracks with Railway siding as shown on the Plot Plan except for the rail tracks

embedded in concrete in the Main Plant in transformer area, unloading bay and loco maintenance shed including track electrification.

d) Raw water supply to the Raw Water Reservoir, raw water reservoir, raw water

piping.

e) Construction water and drinking water supply at one point near plant boundary. f) 11 kV power supply at one point near plant boundary for construction purposes.

g) Ash bund.

h) Rail Wagons

i) Tools & Plants for Coal Handling Plant such as Locomotives, Mobile Crane,

Bulldozers, Forklift, Fire Tender etc.

j) Statutory Permission from authorities related to laying and routing of Ash Disposal Piping. Necessary assistance for this purpose shall be provided by the Bidder.

k) Third Party Inspection of Plant Equipment.

Cooling Water – CW and ACW piping (supply & return) 2m away from Grid-A of TG building, Ash Water Pipeline from the existing Ash Water Pumps header with interconnection as defined in the Tender Drawing. Complete filtered water pumps (to be located in the existing Filtered water Pump House and Storage Tank of Units 5, 6, 7) and filtered water piping up to the new Filtered Water Storage Reservoir (in the premises of the Expansion Project) is included in the Scope of the BOP Bidder. New Demineralised Water line to be connected with the existing Mixed Bed outlet header of the DM Plant of Units 5, 6, 7 as defined in the tender drawing, up to the new Deminealised




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6.

7.

8.

9.

10.

11.

12.

13.

14.

Water Storage Tanks and new Deminealised Water Transfer Pumps. Demineralised Make-up water to Condensate Storage Tank, at inlet to the motor operated isolation valve to the Condensate Storage Tank for each unit, The following terminals to be considered for the additional clariflocculator to be provided by the BOP Bidder in the existing Pretreatment Plant area of units 5, 6 and 7. a) Connection for inlet to the new clariflocculator from the existing Flash Mixer (for non- DM system) outlet b) Clarified Water outlet from the new clariflocculator up to the existing carified water channel at a suitable point c) Sludge outlet connection to the existing sludge sump Counter-flanges and nuts, bolts, gaskets at the terminal points by BOP Contractor. Coal Mills reject - at pyrite hopper outlet flange of the Mills. Raw coal bunkers outlet flange (The bunkers are included in the scope of BOP Package.) Chimney flue inlet flange. (The flue gas ducting up to the RCC chimney inlet flanges is included in the scope of the BTG Package Contractor.) The steel flues inside the RCC chimney is under the scope of BOP contractor. Bottom Ash Hopper below furnace. The seal plate and shield plate shall be supplied by the BTG Package Contractor. Fly ash and coarse ash hoppers outlet flanges. The hoppers shall be provided by the BTG Contractor Grouting for BTG Equipment foundations. Fuel Oil System: - At the existing LDO unloading header for units 5, 6, 7 - for connection with the existing LSHS Tank-4. - At the existing LSHS Tank-4 outlet piping, for connection with the new LDO Transfer Pumps - At the existing LDO Tank outlet piping, for connection with the new LDO Transfer Pumps - At the existing LSHS Pumps Discharge header spare valve outlet for units 5, 6, 7 - for supply of HFO to the new Expansion Units. - At the existing LDO Pumps Discharge header spare valve outlet for units 5, 6, 7 - for interconnection with new LDO pipeline to the new Expansion Units. - At the inlet to the Pressurizing units for HFO and LDO supply system of the BTG Package,




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15.

16.

17.

18. i)

ii)

iii)

iv)

v)

vi)

vii)

viii)

ix)

x)

xi)

xii)

located near the Fuel Oil Day Tanks area. - Fuel oil return piping from Steam Generator, at the HFO/ LDO storage tanks return oil flanges. BOP Contractor shall provide the counter flanges with nuts, bolts, and gaskets. Service air and instrument air piping at one point each near boiler area and turbine area with isolation valves, counter flanges, nuts, bolts and gaskets Carbon dioxide and hydrogen cylinders outlet. The manifolds and subsequent distribution are under the scope of the BTG Contractor. ELECTRICAL EXCLUSION Generators complete with its auxiliary system. Isolated phase bus duct of generator inclusive of CT’s, LAVT, SC, NGTR, LR Generator Transformers, Station Transformers and Unit Auxiliary Transformers. Neutral Grounding resistor/transformer for earthing of Generators and ST and UAT Transformers. 11kV and 6.6kV switchgear complete with Bus Transfer Scheme. 11kV and 6.6 kV bus ducts. Control, Protection, Monitoring & Metering system for Generator, GT, ST and UAT. Electrical Control Panel for remote control of 6.6 kV and 11kV circuit breakers, transformer (ST/UAT) taps changer. ESP – LT Dry type Auxiliary indoor transformer along with its non-segregated phase bus duct, PCC, MCC. Electrical items of BTG like Motors, Actuators, VFD’s for ID Fan, DC Starter Panel, Local Panels, Control Panels, Local Control Stations, Soot blower MCC’s. Laying and termination of Power Cables including cable trays and accessories from – (a) VFD panels to ID Fans (b) ESP switchboard to all down stream equipment & all cable trestles for cable tray racks in BOP scope. Laying and termination of all Power Cables down stream of soot blower MCC. However, the main Cable Tray running from soot blower MCC before branching for respective soot blower shall be in BOP bidder’s scope. Only branch trays shall be fabricated and installed by BTG Package Contractor.




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xiii)

xiv)

xv)

18.

19.

20.

21.

22.

Supply, laying and termination of control cables and C&I cables wherever both end equipment are in BTG package. However, supply & installation of cable trays shall be in the scope of Balance of Plant package. ACDB’s for Turbine & Boiler Valves actuators and Dampers and the power cable between the same are in BTG scope of supply. Switchyard Equipment for Power Evacuation System. 24V Battery (Ni–Cd) along with Battery chargers for BTG package. ELECTRICAL TERMINAL POINTS a) 6.6kV Unit Switchgear, 6.6 kV Station Switchgear and 11kV Station Switchgear

outgoing feeder modules. b) Incoming and Outgoing feeder terminals of 6.6kV Coal Handling, 6.6 kV Ash

Handling Switchgears. c) Primary side (6.6 kV) bushing of Dry Type transformers for ESP. d) ID Fan VFD 6.6 kV transformer input terminals e) Incomer of soot blower MCC f) Incomers for Chargers of 24V Battery. g) Incomer of ACDB’s for Turbine & Boiler Valve Actuators and Dampers. h) Pigtails at BTG island area for equipment earthing i) Motor Terminal block of all motors under BTG contractor. j) Construction Power – HT supply at a single location near plant boundary. C & I INTERFACING WITH BTG PACKAGE: - Cooling Water System Control/ C&I – max link station of DCS/BTG cabinet PLC’s for CHP, AHP, Compressor, AC System, Fuel Oil system, other non-PLC system etc. – max. LINK station of DCS / BTG cabinet. CIVIL EXCLUSIONS

a) Land acquisition & preliminary works, Land Development of Switchyard portion

b) Staff quarters with associated Sewage Treatment Plant

c) Site Leveling outside Plant Boundary




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d) Drainage beyond battery limits.

e) Dismantling of existing boundary wall as per site requirements and provision Chain

link fencing between existing power house area and project premises for security purpose.

f) Ash Bund

Land - in as acquired condition for plant area would be made available to the BOP contractor.

mahagenco ele. scope

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