TERMS OF REFERENCE FOR CONSULTANCY WORK FOR PREPARATION OF

FR, DPR, ENGINEERING AND PROJECT MANAGEMENT FOR DEVELOPMENT

AND FORMATION OF ASH MOUND ALONG WITH ASSOCIATED MATERIAL

HANDLING AND INFRASTRUCTURE WORKS FOR PATRATU SUPER THERMAL

POWER PROJECT, PHASE-I (3X800 MW), PATRATU, DIST. RAMGARH,

JHARKHAND

1.0 INTRODUCTION:

Patratu Vidyut Utpadan Nigam Limited (PVUNL), is a JV Company of NTPC

Limited and Jharkhand Bijli Vitaran Nigam Limited (JBVNL). JBVNL is state

owned company of Govt. of Jharkhand and NTPC is a leading power sector

company of India.

Patratu Super Thermal Power Project (PSTPP), Phase-I (3 x 800 MW) is being

set up near Patratu town in Ramgarh district of Jharkhand having ultimate

capacity of 4000 MW (Phase-I: 3x800 MW and Phase-II: 2x800 MW).

Project site is well connected through rail, road and air routes. The site can be

approached from Patratu Railway Station at about 4 km (located on Barkakhana-

Barwadih Railway line) and National Highway no. 33 & 23 (approx. 21 km) & NH-

75 (approx. 27 km). The nearest commercial airport is Ranchi (about 40 km).

2.0 OBJECTIVES:

Detailed study and complete system design for development and formation of

Ash mound along with associated material handling and infrastructure works for

dry ash disposal to be done for PATRATU STPP, Phase-I (3X800MW).

3.0 Intent of Consultancy

3.1 The intent of this consultancy is that consultant should carry out the feasibility /

viability study for ash mound system for Patratu STPP-I (3x800MW). Once the

viability/ feasibility is established, the consultant will be required to make

Detailed Project Report (DPR) establishing the mound planning and

development with design of all associated systems i.e. material handling

system, infrastructure system along with all associated electrical, Control &

instrumentation systems. Further, consultant is required to identify the

separate procurement packages for tendering equipment, system required to

start formation of ash mound and make it fully operational and development of

mound up to full height with landscaping and land reclaiming measures. It is

duty of consultant to identify each and every requirement associated with

mound formation & development and include the same in DPR and other

assigned works such as engineering and project management etc.

3.2 The consultants shall ensure design and engineering of the system for high

reliability, availability, efficiency, no harmful impact on the ecology and

environment of the area and optimum cost of the project consistent with the

latest and well proven practices in the world in this field. Over and above, the

services identified under scope of work, the work to be performed by the

consultant shall also include imparting of any necessary information, design

data, documentation drawings and specifications to the owner to enable the

owner's engineers to carry out the complete design and engineering of future

projects.

4.0 SCOPE OF WORK

The main scope of work is Preparation of Feasibility Report, Detailed Project

Report, preparation of tender documents of necessary equipment’s and system

associated with ash mound, assistance in bid evaluation, assistance in review

engineering during Detailed Engineering, supervision during erection and

commissioning of various packages (optional for consultant) for setting up Ash

mound facilities at Patratu STPP to handle ash generated from 3 x800MW units:

It is proposed to divide all the above works of the consultancy services into

following stages:

i) Stage-I: Viability and Feasibility study

ii) Stage-II: Detailed Project Report and scheme finalization

iii) Stage-III: Concept of Packaging & Preparation of Tender Documents

iv) Stage-IV: Review Engineering for all Packages after award

v) Stage-V (Optional): Supervision during erection and commissioning of ash

mound system

vi) Stage-VI (Optional): Expert assistance for implementation of scheme during

Operation and maintenance

4.1 Stage-I: Viability and Feasibility study

The broad scope of work under Stage-I study is as given below:

i. To study the viability of ash mound construction with dry ash disposal system

giving due consideration to the local geology, tropical climate & existing area

drainage pattern including conditions that will arise during the monsoon

period.

ii. Consultant shall prepare an inception report bringing out clearly the viability

of the ash mound construction with dry disposal system with typical design of

ash mound and associated systems.

iii. Consultant shall formulate programme of additional investigations and design

studies required if any, and shall execute these programmes by their own

experts and / or under their direct supervision and with involvement of NTPC

officials. The cost of such investigations/studies is deemed to have been

included in the quoted prices.

iv. Any other detail deemed necessary according to the Consultants/Owners.

4.2 Stage-II: Detailed Project Report (DPR) and scheme finalization

i. To design ash mound for maximum capacity of ash storage in the identified

340 acres of land. However, the capacity so developed shall not be less than

35 Million cum and shall be designed such that, there is no spill into

neighboring land.

ii. To carry out all additional topographical survey & geotechnical investigation

(if required) or any other investigation as required to finalize the design of ash

mound for ultimate height. Rainfall data may be obtained from Indian

metrological department (IMD).

iii. To carry out ground improvement ground improvement in the ash mound

area, if required, to achieve the ultimate height.

iv. Based on earlier experience of the owner, the ash disposal area may be

divided into (i) main ash mound area for bottom ash (BA) and fly ash (FA) (ii)

temporary ash storage yard area, (iii) emergency ash storage yard area and

(iv) balance area for peripheral drain, inspection road, filter lagoons and other

facilities etc.

v. To coordinate with vendor for ash handling system for inputs and interface

issues.

vi. Proven principles for mound design & construction to be used giving due

consideration to the local geology, climate & existing area drainage pattern

including conditions that will arise during the monsoon period.

vii. Stability and seepage analysis to be performed through appropriate method.

Analysis to be performed for both static & seismic conditions. Appropriate

safety factors to be ensured for the intermediate and ultimate height of ash

mound.

viii. Design of ash mound & the methodology proposed for its construction should

ensure stability of the mound at all times and ensure that pollution of the

atmosphere and ground water is minimized. Liner if required shall specify

suitable material.

ix. Appropriate drainage design to be provided for surface water runoff to

prevent pollution of adjacent natural drains/river and ground water. The slope

drain shall be provided with energy dissipater’s.

x. Ash mound design and its proposed methodology of construction to be

flexible as to allow the ash to be handled in all circumstances that are likely to

arise from climatic conditions, plant malfunction and different rates of ash

production. It shall ensure measures for control of fugitive dust both at

intermediate stages & final completion of ash mound.

xi. The design and proposed construction methodology for ash mound and civil

works to be done as per latest Indian Standards. Where a relevant Indian

Standard does not exist British, American, German or any other standard

may be used.

xii. To furnish appropriate landscape design for final surfaces of the ash mound

furnishing the recommended plant species to be planted on the surface to

provide protection and stability and good aesthetic look considering that the

ash mound is to be retained as a natural feature in the area during the life of

plant (25 years) and thereafter. Provision for a trial planting area and plant

nursery within the mound site shall be kept.

xiii. Methodology for safe extraction of ash directly from mound by users. It is

envisaged that there will be off take of ash from the mound in trucks/bulkers

for use by the industry. The same shall be considered in the design and

scheme & methodology for safe off take of the ash from mound for

prospective users, shall be furnished.

xiv. Design of all ancillary buildings like control and MCC/ switchgear buildings,

administrative building, pump houses, safety centre, rest rooms with drinking

water facilities, laboratory building, workshop etc. shall be provided for

regular servicing of plant & equipment working on the mound and for the

welfare and control of the personnel involved.

xv. The ash handling plant and proposed method of construction of the ash

mound shall be designed to control & minimize the extent of fugitive dust

emissions. The main area of likely dust nuisance are the belt conveyors, ash

moving equipment, Temporary & emergency yards, site traffic, wind erosion

etc. including the ash mound construction / operation stage. A

comprehensive dust control system/ scheme shall be provided.

xvi. To design Ash mound, the following Mechanical & associated works are also

to be included in DPR:

 All plant & equipment/ machines like conveyors (fixed, shiftable and

extendable or any other technology), boom spreaders, Stackers/

Reclaimers, dust suppression system, drainage pumps etc. required for

the development of ash mound including their number and capacities.

 Mobile and earth/ ash moving equipment like Soil compactors, Bull

dozers, Front loaders, Dumpers, Motor graders, Water bowsers, Hydras,

Excavators, Tractors or any other technology required for

construction/development of the Ash mound including their number and

capacities, based on the amount of ash to be handled on daily basis.

 Workshop along with equipment or special tools and tackles and facilities

required for maintenance of the Ash mound equipment including their

number and capacities.

 Scheme and functional layout of maintenance workshop for servicing and

maintenance of mobile/ earth/ash moving equipment required up to

ultimate stage.

 Water requirement and Dust suppression system at ash mound along with

its equipment and Pump houses and its locations.

 Development of the total scheme and layout of the Ash mound. Identifying

the ash transportation corridor from plant boundary to Ash mound. Also

indicate type of conveying system along with its capacity.

 Examine the option for pipe conveyor / trough conveyor w.r.t. capacity

and handling of ash.

 Suggestion for Commercial uses for stored ash in mound and future

recovery of bottom ash and fly ash separately from mound for utilization of

ash and also for Light weight aggregate etc.

 Ash mound, temporary and emergency storage system capacity & its

layout.

 A layout plan of the Ash mound facilities proposed including the Ash

Handling system with respect to the ‘grid system’ of the Patratu Power

Project including approach corridor along with roads has to be provided.

xvii. Assessment of infra-structure, O&M and other facilities required for handling

of ash in Ash mound area and preparation of detailed plan of the complete

system.

xviii. The scope also includes furnishing operational manual covering the aspects

of construction and maintenance for the ash mound, safety instructions,

testing & maintenance of records on short & long term basis, emergency/

disaster management plan etc.

xix. Preparation and submission of report incorporating above details to obtain

approval from NTPC. This should include consultant’s recommendation

clearly bringing out tangible/intangible benefit to NTPC on the subject.

xx. The study also involves facilities to be developed at the proposed Ash mound

for take-off of fly ash/bottom ash by road.

xxi. The study shall include schemes of the Ash Mound planning to ultimate

height with progressive placement of shiftable and extendable conveyors and

uses of various other equipment and earth moving equipment in various

stages of mound development.

xxii. Identification of all the equipment including earth moving equipment with

capacity and numbers required for the Ash mound development.

4.3 Stage-III: Concept of Packaging & Preparation of Tender Documents

4.3.1 The entire work related to the Dry Ash Transportation from Transfer point (near

main ash Silo area at plant boundary) to Ash mound including the Ash mound

formation, is proposed to be carried out by the consultant. The activity of

contracting and procurement should be carried out in separate procurement

packages preferably as identified below:

i. Ash Disposal system package (beyond Transfer Point near plant

boundary):-

 Ash Conveyor System from Transfer Point (near main ash silo area at plant

boundary) up to Ash Mound

 Dry ash transportation system from the ash conditioner outlets at silo to the

Ash mound area by means of belt conveyors. Material handling and earth

moving equipment like moveable conveyors, boom stackers, Reclaimers, etc.

required at the disposal site for creating the ash mound.

 Battery of mobile equipment like Soil compactors, Bull dozers, Front loaders,

Dumpers, Motor graders, Water bowsers, Hydras, Excavators, Tractors or any

other technology required for construction/development of the Ash mound.

 Workshop & Workshop equipment, Laboratory & laboratory equipment if

required.

 All associated civil, architectural & structural works this shall include all

equipment foundations, supports, trenches, conveyor galleries, trestle and

their foundations, control room, pump house etc.

 Other equipment such as pumps & piping system for dust suppression,

drainage system etc.

ii. Civil / Architectural works including ash mound formation

 Civil works related to spreading, rolling and compaction for creation of ash

mounds. Civil works in the ash mound area like drains, roads, workshops,

garage, laboratory (if necessary), etc. as required to facilitate proper

implementation.

 Work like drainage of ash mound area, slope protections/covering of ash

mound, treatment and disposal of mound, settling tank (if required) and all

works to prevent environmental pollution, erection and sedimentation control

etc.

iii. Nursery & landscaping of ash mound

 Landscaping work i.e. covering mound with earth layer and plantation of

specific plant species or converting it into agricultural land/ etc.

4.3.2 Preparation of package list, technical specification/detailed system design,

BOQ, tender drawings, cost estimates, suggestive qualifying requirements,

assistance during technical evaluation of bids including resolution of issues

raised by bidder’s for Mechanical, civil & associated works for Ash mound

package consists:

 All plant & equipment/ machines like conveyors (fixed, shiftable and

extendable or any other technology), boom spreaders, Stackers/ Reclaimers,

dust suppression system, drainage pumps etc required for the development of

ash mound including their number and capacities.

 Mobile and earth/ ash moving equipment like Soil compactors, Bull dozers,

Front loaders, Dumpers, Motor graders, Water bowsers, Hydras, Excavators,

Tractors or any other technology required for construction/development of the

Ash mound including their number and capacities, based on the amount of

ash to be handled on daily basis.

 Workshop along with equipment or special tools and tackles and facilities

required for maintenance of the Ash mound equipment including their number

and capacities.

 Preparation of scheme and functional layout of maintenance workshop for

servicing and maintenance of mobile/ earth/ash moving equipment required

up to ultimate stage.

 Drawings for layout of control rooms, cabins and foundations related to the

installation of Ash transportation system works and other associated facilities

of Ash mound system.

 Submission of list of spares, tools and plants and maintenance schedule.

 Water requirement and Dust suppression system at ash mound along with its

equipment and Pump houses and its locations.

 Development of the total scheme and layout of the Ash mound. Identifying the

ash transportation corridor from plant boundary to Ash mound. Also indicate

type of conveying system along with its capacity.

 Examine the option for pipe conveyor / trough conveyor w.r.t. capacity and

handling of ash.

 Suggestion for Commercial uses for stored ash in mound and future recovery

of bottom ash and fly ash separately from mound for utilization of ash and also

for Light weight aggregate etc.

 Ash mound, temporary and emergency storage system capacity & its layout.

 A layout plan of the Ash mound facilities proposed including the Ash Handling

system with respect to the ‘grid system’ of the Patratu Power Project including

approach corridor along with roads has to be provided.

 Assessment infra-structure, O&M and other facilities required for handling of

ash in Ash mound area and preparation of detailed plan of the complete

system.

 Preparation and submission of report incorporating above details to obtain

approval from NTPC. This should include consultant’s recommendation clearly

bringing out tangible/intangible benefit to NTPC on the subject.

4.4 Stage-IV: Review Engineering for all Packages after award

 Review Engineering of Mechanical, civil & associated works for Ash mound

package. This covers all Ash mound related facilities such as Shiftable and

extendable conveyors, Ash conveyors, transfer points, Ash mound and its

associated infrastructure equipment, roads & culverts, bridges, buildings,

control rooms, workshops etc.

 To coordinate with Main plant EPC vendor and different vendors working in

Ash mound for inputs and interface issues.

4.5 Stage-V (Optional): Supervision during erection and commissioning of ash

mound system

i) Consultant shall be responsible for successful implementation of Quality

Assurance Plan for the entire works till commissioning. Consultant shall submit

comprehensive documents on Quality Assurance covering services under Civil,

Mechanical, Electrical, Control & Instrumentation works.

ii) Consultant shall include in his offer a detailed man power deployment schedule

for quality assurance purposes along with complete man-hour estimate.

iii) Construction supervision of the works shall be done by NTPC executives at site

and role of consultant's experts at site will be advisory. Consultant shall have his

experts posted at site during construction, erection and commissioning

particularly in following critical areas-:

a) Translating the total layout of the scheme on the ground.

b) Construction of Ash Mound

c) Erection, Testing& commissioning of Mechanical works

d) Any other area which is not covered above however required consultant’s

involvement in the opinion of employer shall be dealt by the consultant.

iv) Advisory role of consultant will also cover advise on technical problems arising at

site on all issues for which engineering is in the scope of consultant.

v) Consultant shall indicate the estimated man-days required for each activity

identified in the bar chart of the scheme furnished by them identifying their

categories of experts.

vi) In case actual deployment exceeds the estimates, the cost of additional man-

days spent will be deemed to have been included in the lump sum quoted price.

However, if the owner concludes that services of any expert/ specialist in any

particular area under 4.4 is no longer required, the owner reserve the right to

request the consultant to withdraw the expert and payment for consultant’s

advising services shall be proportionately reduced. Similarly, there will be a

downward adjustment in case entire services as referred at para 4.2 is not

availed.

vii) The scope also includes furnishing operational manual covering the aspects of

construction and maintenance for the ash mound, safety instructions, testing &

maintenance of records on short & long term basis, emergency/ disaster

management plan etc.

4.6 Stage-VI (Optional): Expert assistance for implementation of scheme

during Operation and maintenance

4.6.1 The scope includes providing expert assistance during actual operation &

construction of ash mound and associate system after commissioning of unit-1

to 12 month beyond the commissioning of 3

unit of Patratu STPP on monthly

price basis.

Submission of EOI Consultancy Work for detailed study and system design for development and

formation of ash mound

(TO BE PRINTED ON THE LETTER HEAD OF THE INTERESTED PARTY/AGENCY AND SIGNED)

(This is only an enquiry for short listing of agencies towards enlistment for Consultancy Work for detailed

study and system design for development and formation of ash mound of Patratu Super Thermal Power

Project Phase – I (3X800 MW) project. Duly filled and signed form in original to be sent by post or handed

over in person, before two weeks from date of publication)

------------------

Dear Sir,

We are interestedin Consultancy Work for detailed study and system design for development and formation

of ash mound for PatratuSTPP. We submit the following details of our firm and requirement.

Name of the Company and Address

Whether the company is Govt.firm /Private /PSU/Listed

Co./Indian Subsidiary/ Jvs/ Foreign Co.

Do you have any previous experience of detailed Feasibility

Report (FR) and/or Detailed Project Report (DPR)study and

design for development of ash mound?

Yes/No

Name of the plant& Year of Commissioning of the Plant, if

known

Date of commissioning

and start of operation

of ash mound

Ash mound Capacity (Cu.m)

Base diameter/Perimeter, Base area and height of ash mound

Is the mound for only fly ash or both fly and bottom ash?

Brief scope of works (P.O copy & date, completion certificate

from employer along with specifications/ drawings to be

attached)

Brief details of material handling system for conveying and

discharge to mound.

Name and Designation of the contact person

Address

Contact Number

E-Mail Address

Any other relevant information

Place:

Date:

(Seal of the company)

(Authorised Signatory)