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“Salient Technical Features of the equipment/systems/services covered in the Bidding Document No. CS-9585-001-2 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 equipment/ systems/ services covered in the Bidding Documents. Detailed provisions in regard of scope of work and technical features/ specification of equipment/ systems/ services, contained in the Bidding Documents shall be final and binding.”
ABRIEF SCOPE OF WORK
The Brief scope of work for the subject EPC Package for Patratu STPS (3X800 MW) is as follows:
Design, Engineering, Manufacture, Supply, Construction, Erection, Testing & Commissioning works for the EPC Package for Patratu Super Thermal Power Station (3 X 800 MW), on the basis of single point responsibility, completely covering the
following activities and services in respect of Steam Generator, Steam Turbine Generator, Electrostatic Precipitator, NOx Control System, Flue Gas Desulphurization System, all Balance of Plant (BOP) systems, Make-up water system , Ash Mound, Railway siding & Township, all Electrical systems including Switchyard, complete Control & Instrumentation, complete simulator system and complete Civil, Structural and Architectural works and Solar PV Plants at roof-top covered under the specifications:
a)Basic Engineering of the plant including preparation of Plant Definition Manuals;
b)Detailed design of all the equipment and equipment system(s) including civil, structural & 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)The complete Civil, structural and architectural works including topographical survey, site leveling, construction water, water supply and sanitation, infrastructure works including roads & drainage, Effluent & sewage treatment facility, main plant area structures and foundations including turbine building, bunker building, boiler structure, ESP structure, service building, compressor house, complete coal handling plant and Ash handling plant, chimney, pipe/cable galleries and pipe/cable trenches, duct banks, pedestals, cooling towers, balance of plant buildings including ACW system, make-up water system, PT, DM and ETP system, offsite structures and buildings, transformer yard structures, switchyard structures, fuel oil handling system and fire protection system structures and foundations, bridges and culverts for crossing of roads / Rail Tracks inside plant area, landscaping and other miscellaneous buildings and structures.
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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, in case of foreign Bidders;
m)Satisfactory conclusion of the Contract;
n)Insurance and other requirements
Detailed scope of work has been specified in the bidding documents.
BSALIENT TECHNICAL FEATURES
1.00.00Steam Generator
1.01.00Type
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.
1.02.00Other 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.
1.03.00Rating of Steam Generator(s)
Steam Generator shall be designed to cater to duty requirements at Boiler Maximum Continuous Rating (BMCR) specified below:
1.04.00Limiting 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:
100% load)
1.06.00Coal/Ash data
The primary fuel for the main steam generator shall be coal. Heavy Fuel Oil (HFO) shall be used for start-up, coal flame stabilization and low load operation of the main Steam Generator(s). Light Diesel Oil (LDO) shall be used for cold start up and Black startup.
2.00.00 NOx Control System
2.00.01NOx Control System including Selective Catalytic Reduction (SCR) system along with ammonia unloading, Storage and Handling system , cyclone separators complete in all respects with all components and accessories etc. for three (03) steam generators each of 800 MW capacity shall be provided.
2.00.02Each SCR system serving one (01) steam generator, shall have two (02) numbers of independently operated SCR reactors along with catalyst modules housed in SCR reactor casing shall be provided. Each SCR reactor shall have three (03) working catalyst layers and one (01) spare (future) catalyst layer.
2.00.03Two (02) nos. of independently operated cyclone separators housed in independent casing shall be provided including ash hoppers. One (01) cyclone separator shall be provided in each stream of flue gas duct from economizer outlet to SCR reactor inlet.
3.00.00 Electrostatic Precipitator (ESP)
3.01.00 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.
3.02.00 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 stablisation of Steam Generator. 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.
4.00.00 Flue Gas Desulphurization System:
4.00.01Flue Gas Desulphurization (FGD) System and its auxiliaries shall be supplied for three (03) number of steam generators each of 800 MW capacity. The FGD system shall be based on wet limestone FGD technology and is intended to reduce the emissions of sulphur dioxide in flue gas produced by coal being fired in boiler to the specified limits.
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4.00.02The FGD system shall have an independent absorber for each unit, common limestone milling systems for the three units, common gypsum dewatering system for the three units along with associated limestone and gypsum handling and storage system.
5.00.00Steam Turbine
5.01.00Type
The steam turbine shall be tandem compound, single reheat, regenerative, condensing, multi-cylinder design with separate HP, separate IP and separate LP casing(s) OR combined casing for HP-IP and separate casings for LP Turbine directly coupled with generator suitable for indoor installation.
5.02.00Rating
The steam turbine generator unit shall conform to the following design and duty conditions:
5.03.00Other Features
(a.) Turbine shall be capable of operating continuously with valves wide open (V.W.O.) to swallow at least 105% of EMCR steam flow to the turbine at rated main steam and reheat steam parameters and also the corresponding output shall not be less than 105% of rated load with 3% make up and 160 mm Hg (abs) condenser pressure.
(b.) The steam turbine shall have minimum seven uncontrolled extractions for regenerative feed heating based on optimised cycle and shall be suitable for satisfactory operation under tropical conditions.
6.00.00Generator
6.01.00Type
Three phase, horizontal mounted, indoor installed, two-pole, class-F winding insulation, Stator water/ hydrogen cooled, cylindrical hydrogen cooled rotor type.
6.02.00Rating
Generator and its excitation system shall have a capability at least matching the declared maximum continuous rated output of the associated steam turbine (for the designed secondary cooling water temperature) at all power factors between 0.85
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lagging and 0.95 leading with +3% to -5% frequency variation, terminal voltage variation of +/- 5% and combined voltage & frequency variation of 5%. It shall be ensured that when the Generator is working at this capability and design cooling water temperature, no part of the Generator shall attain a temperature in excess of the temperature limits specified for class-B insulation as per IEC-60034.
6.03.00Also the generator and its excitation system shall be capable of continuous stable operation without any excessive temperature rise at the peak output of the associated steam turbine under VWO & HP heater out condition, etc. as available for the designed secondary cooling water temperature, at all power factors between 0.85 lagging and 0.95 leading with +3% to -5% frequency variation, terminal voltage variation of +/- 5% and combined voltage & frequency variation of 5%. Temperature of different parts may exceed those permissible for class-B insulation under such operating conditions, but shall be lower than those permissible for class-F insulation as per IEC-60034.
6.04.00 Rated Parameters
7.00.00Coal Handling Plant
Coal Handling Plant shall be designed based on specified Indian Coals. Rated capacity of CHP shall be as specified in the technical Specification.
The design capacity of the conveyors shall be 110% of the rated capacity.
Wagon tippler shall be side-discharge type (Rotaside) and shall conform to RDSO G-33 Rev. 1. Track Hopper is also envisaged.
8.00.00Ash Handling Plant
Ash handling system consists of the following sub systems:
a)Bottom Ash Handling System
A complete dry bottom ash removal system involving mechanical conveying, crushing and storing of Bottom Ash into Bottom Ash Silo.
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 up to buffer hoppers. i.e. vacuum conveying system or pressure conveying system
i)Vacuum Conveying System
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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 main hoppers in each unit shall be transported to storage silos. The user industries shall take the dry fly ash from storage silos either in closed tankers or in open tankers.
d)Ash Disposal System
Bottom Ash and Fly Ash shall be transported through series of belt conveyors/ pipe conveyors to Ash Mound.
7.00.00ACW with its Cooling Towers and Make up water system
ACW System along with its Cooling towers and make up water system shall be provided as per the scope of technical specifications.
8.00.00Fire protection system, Air compressors, AC and ventilation system, H2 generation system shall be as per the scope of technical specification.
9.00.00WATER TREATMENT SYSTEM
Water treatment system covers pre-treatment, chlorination, Liquid Effluent Treatment, De- mineralization system & condensate polishing system.
10.00.00Electrical Systems
The electrical items shall cover following:
∙Generator, Excitation System and its Auxiliary Systems
∙Motors, Electric Actuators
∙Generator Busducts, MV Busducts and Generator Circuit Breaker.
∙Power Transformers, Auxiliary Oil Filled Transformers, Indoor Transformers
∙MV Switchgears, LV Switchgears and LV Busducts, Numerical Relay Networking, DC System, Battery and Battery Charger
∙HT Power Cables, LT Power and Control Cables, Cabling, Earthing and Lightning Protection, Lighting, DG Sets
∙400 kV GIS/ 765 KV GIS.
∙Control & Protection of EHV system and Generator Relay Panels, Substation Automation System (SAS) based on IEC 61850 protocols.
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∙Construction Power facilities
∙Complete Electricals for Offsite Areas etc.
∙Type Testing and Mandatory Spares as specified.
11.00.00C & 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.
The integral control & protection of Steam Turbine Generator including Electro-hydraulic control & Turbine Protection system.
Modulating controls of the Steam Generator (SG) {Combustion Control- Fuel Flow/Air Flow; Furnace Draft Control, FW flow control etc.}.
Modulating controls of Feedwater & Condensate Cycle {Hotwell level control, Deaerater Level control, Heater Level Control, etc.}.
Binary control of auxiliaries of Steam Generator (SG) {Forced draft (FD) fan, Induced Draft (ID) Fan, Primary Air (PA) Fan etc.}.
Binary control of auxiliaries of Turbine Generator (TG) {Boiler Feed Pump (BFP), Condensate Extraction Pump (CEP) etc.}.
Electrical Breaker including synchronization circuits.
Coal Handling Plant.
Water System (PT Plant, DM Plant, Cooling Tower etc.).
ACW System.
Air Conditioning and Ventilation systems.
Ash Handling Plant.
Make-up water System.
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, Turbine stress control /
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evaluation system, Turbine supervisory and diagnostic 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.
A plant-wide CCTV system based on IP technology is included in this package for surveillance of plant equipment as an aid to the operation.
Complete Simulator system is included in this package for training through simulation.
Apart from above, an on-line Steam & Water analysis system (SWAS), PA system, Operator control desks, panels, shielded twisted pair cables as well as optical fiber cables for system interconnection and all types of Instrumentation Cables are also included in this package.
12.00.00Civil Works
The site for Plant and offsite areas comprises of layers of silty clay / clayey silt and sand/weathered rock layer at deeper depths. Open foundation and pile foundation are envisaged for major structures. The steel structures shall be pre-fabricated in factory and shall have bolted field connections. Ash Mound shall be provided. Railway siding system for transportation of coal, lime, POL, Gypsum and Fly Ash shall be provided
13.00.00 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.
14.00.00LOCOMOTIVES
Co-Co diesel electric locomotive of specified numbers for the 1676 mm gauge having gross installed capacity of approximately 3100 HP WDG3A type each under UIC conditions, complete in all respects, duly painted at manufacturer’s works shall be supplied on FOR site basis, thereafter supervision of all other activities, such as handling, storing, cleaning, commissioning and testing at site, of the equipment shall be provided.
15.00.00 TOWNSHIP
Township shall be complete in all aspects. Main Buildings covering residential, non- residential buildings and related bulk services. All the works shall be designed and executed as per relevant IS codes/ CPWD as per the scope of technical specification.
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