‘STEAM GENERATOR ISLAND’ PACKAGE

FOR

PUDIMADAKA SUPER THERMAL POWER PROJECT (4X1000 MW)

BIDDING DOCUMENT NO. : CS-9590-101-2

Salient Technical Features of the Equipments/ Systems/ Services covered in NIT/IFB No. 40036362 dated 23.03.2014, Bidding Document No. CS-9590-101-2 are mentioned below.

These Salient Technical Features are mentioned only to facilitate the prospective Bidders to prima-facie understand the requirements under the tender and shall not in any way limit or alter the Scope of Work and Technical Features/ Specification of Equipments/ Systems/ Services covered in the Bidding Documents. Detailed provisions in regard of Scope of Work and Technical Features/ Specification of Equipments/ Systems/ Services, contained in the Bidding Documents shall be final and binding.

A. Brief Scope of Work:

The brief Scope of Work for the subject Steam Generator Island Package for Pudimadaka STPP (4x1000 MW) is as follows:

Design, Engineering, Manufacture, Supply, Construction, Erection, Testing & Commissioning works for the Steam Generator Island Package for Pudimadaka Super Ther­mal Power Project (4x1000 MW), on SG island basis, covering the following activities and services in respect of Steam Generator and Electrostatic Precipitator, Ash Handling, Coal Conveying facilities, Auxiliary Boiler, Electrical Systems, associated Control & Instrumentation and Civil, Structural and Architectural works and Solar PV Plants at roof-top covered under the specifications:

a) Basic Engineering of the Plant;

b) Detailed Design of all the Equipment and Equipment System(s) including Civil, Structure Steel & Architectural works included in Bidder's scope.

c) Providing Engineering Drawings, Equipment Sizing & Performance Data, Instruction Manuals, ‘As Built drawings’ and other information;

d) Compliance with statutory requirements and obtaining clearances from statutory authorities, wherever required;

e) Complete Manufacturing including Shop Testing/Type Testing;

f) Civil, Structural and Architectural works including Site Leveling in BTG area, underground facilities like drainage, sewerage, trenches, earthing mat/grounding for SG, ESP, SG area structures and foundations including Bunker Building, Boiler Structure, ESP Structure, Compressor House, Coal Conveying facilities, Ash Handling Plant, Chimney, Pipe/Cable Galleries and Pipe/Cable trenches, Duct Banks, Pedestals, other buildings and structures, Fuel Oil Handling System, other miscellaneous buildings and structures, approach road for building included in the package. Civil works associated with Air-Conditioning and Ventilation System.

g) Packing and transportation from the manufacturer’s works to the site including logistic studies, insurance, customs clearance & port clearance, port charges, if any.

h) Receipt, storage, preservation, handling and conservation of equipment at the Site;

i) Fabrication, Pre-Assembly, if any, Erection, Insurance, Testing, Commissioning and Completion of Facilities including putting into satisfactory operation all the equipment including successful completion of initial operation;

j) Performance and Guarantee Tests after successful completion of initial operation;

k) Supply of spares on FOR site basis;

l) Reconciliation with Customs Authorities;

m) Satisfactory conclusion of the Contract;

n) Insurance and other requirements.

Detailed Scope of Work has been specified in the Bidding Documents.

B. Salient Technical Features:

1.00.00 Steam Generator

1.01.00 Type

The Steam Generator shall be of single pass (Tower type) or two pass type using either spiral wall (inclined) or vertical plain / rifled type water wall tubing.

1.02.00 Other Features of Steam Generator Design

The Steam Generator shall be direct pulverized coal fired, top supported, single reheat, radiant, dry bottom, with balance draft furnace and shall be suitable for outdoor installation. The evaporator of Steam Generator shall be suitable for variable pressure operation from subcritical to supercritical pressure range.

1.03.00 Rating of Steam Generator(s)

Steam Generator shall be designed to cater to duty requirements at Boiler Maximum Continuous Rating (BMCR) specified below:

1.04.00 Limiting Parameters for Steam Generator Design

The Steam Generator design shall comply with the following limiting parameters with ‘design coal’ firing, under stipulated ambient air condition i.e. 27 degree Celsius temperature and 60 % relative humidity:

Flue gas temperature at air-heater outlet - 125^oC (minimum)

(Corrected) at 105% TMCR & 100 % TMCR load

1.05.00 Operating Requirements

1.06.00 Coal data/Fuel Oil System

The primary fuel for the main steam generator shall be imported coal. Light Diesel Oil (LDO) & Heavy Fuel oil (HFO) shall be used for start-up, coal flame stabilization and low load operation of the main Steam Generator(s). Further, LDO shall also be used to facilitate black start of units when no auxiliary steam is available from external source.

2.00.00 Electrostatic Precipitator (ESP)

2.01.00 System Description:

The Electrostatic Precipitators shall be of outdoor type and installed on the cold end side of regenerative air preheaters. The flue gas shall be drawn from air preheater outlets of the balanced draft, pulverized coal fired Steam Generator and guided through adequately sized duct work into the specified number of independent gas streams of each ESP. Similarly, the flue gas after the Electrostatic Precipitators shall be led to the suction of the induced draft fans.

2.02.00 Service Conditions

The Steam Generators are designed to burn pulverised coal. HFO & LDO shall be used during startup and at low loads for warm up and flame stabilization of Steam Generator. Further, Light Diesel Oil (LDO) shall be used to facilitate black start of units when no auxiliary steam is available from external source. The ESP shall be designed to remove fly ash particles (to meet the stipulated ESP emission levels) from the flue gas generated in the Steam Generator with pulverized coal firing.

3.00.00 Ash Handling Plant

Ash handling system consists of the following sub systems:

a) Bottom Ash Handling System

i) Jet pump and Water Impounded Hopper System – An intermittent system consisting of water impounded hoppers, clinker grinders, jet pumps, etc.

OR

ii) Submerged Scrapper Conveyor and dry type hopper System – A continuous system consisting of dry type Bottom Ash hoppers, submerged scrapper conveyors, clinker grinders, bottom ash slurry trench, slurry transportation pumps, etc.

OR

iii) Completely dry type bottom ash/Economiser Ash removal system comprising mechanical conveying and crushing and storage of Bottom ash/Economiser Ash.

b) Dry Fly Ash Conveying system

Two alternatives for pneumatic conveying system are specified for conveying of fly ash in dry form from ESP hoppers upto buffer hoppers. i.e. vacuum conveying system or pressure conveying system

i) Vacuum Conveying System

It shall consist of liquid ring vacuum pumps, material handling valves, cast iron and MS pipes, instrument air compressors etc.

OR

ii) Pressure Conveying System

It shall consist of screw compressors, air lock/pump tanks, ash intake & discharge valves, CI , MS pipes, instrument air compressors etc.

c) Dry Fly Ash Transportation system

The dry fly ash from the buffer hoppers in each unit shall be transported main Fly Ash storage silos for disposal of fly ash through HCSD system. The user industries shall take the dry fly ash from storage silos either in closed tankers or in open tankers.

d) Ash Disposal System

i) Bottom ash, economizer ash and air preheater ash shall be disposed off from ash slurry sump to ash disposal area by bottom ash slurry disposal pumps.

ii) The fly ash i,e. ESP Ash and Air preheater Ash/Duct hoppers Ash shall be disposed off by high concentration slurry disposal (HCSD) system. In high concentration slurry disposal (HCSD), fly ash shall be mixed with water in suitable proportions to form high concentration slurry. The slurry shall be pumped to the disposal area by means of positive displacement pumps.

4.00.00 Coal Conveying facilities, Fire Detection & Protection System, Compressed Air System, A/C and Ventilation System, Condensate Polishing System etc. shall be as per the scope of Technical Specification.

5.00.00 Electrical Systems

The electrical items shall cover following:

· Motors, Electric Actuators

· LV Switchgears and LV Bus ducts, Numerical Relay

· LT Power and Control Cables, Cabling, Earthing and Lightning Protection

· Type Testing and Mandatory Spares as specified.

6.00.00 C & I Systems

The control system, called Distributed Digital Control Monitoring & Information system (DDCMIS) is envisaged to be procured under this package for control and operation of

· Integral control & protection of boiler including Burner Management System and Boiler protection system.

· Modulating controls of the Steam Generator (SG) {Combustion Control- Fuel Flow/Air Flow; Furnace Draft Control, FW flow control etc.}.

· Binary control of auxiliaries of Steam Generator (SG) {Forced draft (FD) fan, Induced Draft (ID) Fan, Primary Air (PA) Fan etc.}.

· ESP Air Conditioning and Ventilation systems.

· Ash Handling Plant.

· Fuel Oil Pump House including Unloading System

· Auxiliary Boiler

Human Machine Interface & Plant Information System (HMIPIS) is based on Large Video Screen (LVS) displays supported by TFT monitor based Operator Work Stations (OWS). These devices through customized user-friendly displays, soft alarm facia and pop-up displays are used for giving fast pin-pointed faults/ status to the operator. Local ON/OFF operation of equipments is envisaged through Graphical Interface Unit (GIU). The total system is networked through a Station-Wide LAN for use of real time data of various plant areas by other users like maintenance, planning, efficiency enhancement groups etc.

The sequence of events recording & alarm annunciation are also implemented as a part of DDCMIS system. A GPS based master and slave clock system is to be provided for uniform and synchronized timing signals throughout the entire station.

The power supply for the control system is based on 24V DC provided through microprocessor based modular charger system and for the peripherals and other subsystem through 230V Single Phase UPS.

Main Equipment related instruments like Flame Monitoring system, Coal Bunker Level measurement system, gravimetric feeder control system, Acoustic Pyrometer, Acoustic Steam Leak detection system, Furnace and Flame viewing system, etc are also procured through this package.

Field instruments like pressure, DP, flow & level transmitter, analyzers along with their process connection & piping as well as measurement systems like vibration monitoring system etc are also procured through this package.

7.00.00 Civil Works

The site for Plant and offsite areas comprises of layers of silty clay / silty sand / ash followed by fractured / soft disintegrated rock which is underlain by medium to slightly weathered ferruginous sandstone. Open foundations are envisaged for all structures. The steel structures shall be pre-fabricated in factory and shall have bolted field connections (except chimney flue liners which may be fabricated and welded at site).

8.00.00 SOLAR P.V Plants

Solar Photo-voltaic plants to be supplied under the package shall be grid-connected rooftop SPV plants including all auxiliaries. The SPV modules must conform to latest edition of IEC 61215 / IS 14286 for crystalline silicon Terrestrial PV Modules design qualification and type approval. In addition, the modules must also conform to IEC 61730 part 1 & Part 2 or equivalent IS for construction & testing requirements respectively.