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PROJECT	: TALCHER TPP STAGE-III (2X660 MW)
PACKAGE NAME	: MAIN PLANT PACKAGE

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“Salient Technical Features of the equipment/systems/services covered in the Bidding Document No. CS-4540-001-2 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 Main Plant Package for Talcher TPP Stage-III (2X660 MW) is as follows:

Design, Engineering, Manufacture, Supply, Construction, Erection, Testing & Commissioning works for the Main Plant Package for Talcher Thermal Power Project Stage-III (2 X 660 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, Compressed air (instrument & service air) system, air conditioning & ventilation system for all buildings under Bidder’s scope of work, fire detection & protection System for entire power plant, all electrical systems, 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, 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)The complete Civil, structural and architectural works including detailed geotechnical investigation, topographical survey, site leveling, construction water for plant area, water supply and sanitation, infrastructure works including roads & drainage for plant, main plant area structures and foundations including turbine building, bunker building, boiler structure, ESP structure, service building, compressor house, coal conveying facilities in main plant area and Ash handling plant, chimney, pipe/cable galleries and pipe/cable trenches, duct banks, pedestals, transformer yard foundation, fuel oil handling system and fire protection system structures and foundations, bridges and culverts for crossing of roads / Rail Tracks inside plant area, Rain water harvesting, landscaping and other miscellaneous buildings and structures, Civil and structural works, CW system, Raw water reservoir etc.

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

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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

1.00.00Steam 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:

Capacity

Steam

Steam Flow

Temp.

Pressure Kg/cm2(a)

Generator

and

Rated

(T/Hr)

(Deg C)

Steam parameters:

i) At super-heater outlet

102%

of the

achieve

turbine

achieve

turbine

VWO

throttle

main

steam

throttle

steam

flow

temperature as indicated

pressure as indicated

requirement.

clause

5.02.00.

The

in clause 5.02.00. the

steam

temperature

steam

pressure

Superheater

outlet shall

superheater

outlet

atleast

3°C

higher

shall

be atleast

than

the

rated

main

kg/cm2

higher than

steam temperature at HP

the rated main steam

turbine inlet.

pressure

turbine inlet

ii) At re-heater outlet

To achieve reheat steam

---

temperature

at Turbine

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	Inlet	as indicated				in
	clause	5.02.00			of	this
	Sub-section. The steam
	temperature		at	reheater
	outlet	shall	be		atleast
	3oC	higher		than		the
	rated	reheat			steam
	temperature at IP turbine
	inlet.
iii) Feed Water Temp. at	To be	optimized			by	the
Economizer Inlet	bidder but not less than
	285oC

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 -			125oC (minimum)
		(Corrected) at 100 % TMCR load
1.05.00		Operating Requirements

	1.		Minimum load without oil support for	40% BMCR
			flame stabilization
	2.		Operation without HP heaters in	Steam generator shall be capable of
			service	operation with HP heaters out of
				operation. The		steam	generator	heat
				output under HP heaters out condition
				shall not be less than heat duty required
				for generating rated power output or
				design BMCR heat duty, whichever is
				lower. Steam generator shall also be
				capable of sustained operation with HP
				heaters out of operation so as to generate
				rated	power	output	or	output
				corresponding to design BMCR heat duty,
				whichever is lower.
	3.		Steam generator control range	The automatic control range of Steam
				Generator shall be from 50% TMCR to
				100% BMCR. Under the above control
				range, the steam temperatures at SH &
				RH outlets shall be maintained at their
				rated values.
	4.		Mode of Steam Generator Operation	The Steam Generators shall be designed
				for variable pressure operation. Thermal
				design of Steam Generator and the
				selection of materials shall be suitable for
				variable pressure operational modes.
	5		Rate of loading / unloading

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a)	Step load change	Minimum + 10% per minute
b)	Ramp Rate	(i)	Minimum + 3% per minute (30% to
			50% load)
		(ii)	Minimum + 5% per minute (50% to
			100% load)

1.06.00Coal/Ash data

The primary fuel for the main steam generator shall be coal.LDO shall be used for initial start-up, coal flame stabilization and low load operation of the steam generator while firing coal.

2.00.00 NOx Control System

2.00.01NOx Control System including Selective Catalytic Reduction (SCR) system or Hybrid( SCNR+SCR) along with ammonia unloading, Storage and Handling system , cyclone separators complete in all respects with all components and accessories etc. for two (02) steam generators each of 660 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.

Hybrid system will consist of SCR and SNCR system for reduction of desired NOx. SCR system alongwith the cyclone separator will be same as SCR system alone except the following changes:-

i)SCR system of Hybrid system will have one catalyst layer less than SCR system alone

ii)SNCR system shall be provided in order to compensate NOx reduction done by one layer of catalyst of SCR

iii)Hybrid system shall use the Urea. SNCR system shall be injected urea solution and Urea will be converted to ammonia for injection in SCR system

iv)DM water shall be used for making urea solution and dilution of urea solution

3.00.00 Electrostatic Precipitator (ESP)

3.01.00 System Description:

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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. 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 two(02) number of steam generators each of 660 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.

4.00.02The FGD system shall have an independent absorber for each unit, common limestone milling systems for the two units, common gypsum dewatering system for the two units along with associated limestone and gypsum handling and storage system.

5.00.00 Steam 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:

1.	Output under	economic	maximum	:	660 MW
	continuous rating	(EMCR)	(guaranteed
	output load) at generator terminals
2.	Turbine throttle steam pressure			:	270 Kg/cm2 (abs)
3.	Turbine throttle main steam temp.			:	600 oC
4.	Reheat steam temp. at turbine inlet			:	600 oC
5.	Condenser pressure			:	77 mm Hg (abs)
6.	Turbine speed			:	3000 rpm
7.	Frequency variation range around rated			:	+ 3% to - 5% (47.5 Hz to 51.5
	frequency of 50 Hz				Hz)

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5.03.00 Other 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 77 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.

6.00.00 Generator

6.01.00Type

Three phase, horizontal mounted, indoor installed, two-pole, class-F winding insulation, Stator water/ hydrogen cooled, cylindrical hydrogen/water 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 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.

6.04.00Rated Parameters

1.	Power Factor	-	0.85 (lag)
2.	Terminal voltage	-	In the 18 to 28 kV range
3.	Frequency	-	50 Hz
4.	Speed	-	3000 rpm
5.	Short circuit ratio	-	Not less than 0.48 (without any
			tolerance)

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c)Dry Fly Ash Transportation system

The dry fly ash from the buffer 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

The bottom ash slurry and fly ash slurry of each unit shall be taken to the ash slurry sump of the combined ash slurry disposal pump shed for further pumping the slurry to mine void.

e)AWRS System

Ash water recirculation system shall be provided to back decanted water in to plant area from mine void by Barge mounted pumps.

9.00.00 CW SYSTEM

CW System shall be provided as per the scope of technical specifications.

10.00.00Fire detection & protection system, Compressed air(instrument & service air) system, A/C and ventilation system,shall be as per the scope of technical specification.

11.00.00 WATER TREATMENT FACILITIES

Condensate polishing system and Portable DM Plant .

12.00.00Electrical Systems

The electrical items shall cover following:

∑Generator, Excitation System and its Auxiliary Systems

∑Motors, Electric Actuators

∑Generator Busducts, MV Busducts .

∑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

∑Construction Power facilities

∑Type Testing and Mandatory Spares as specified.

13.00.00 C & I Systems

All the systems/equipment being supplied under this package shall be monitored and controlled from DDCMIS in this package. Some systems/equipment are also being procured by Employer under separate packages (e.g. CHP excluding coal conveying facilities near main plant area, DM Plant, PT Plant, Raw Water system, Make up water system etc) shall also be monitored and controlled from DDCMIS being procured in this package.

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

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

ÿThe integral control & protection of Steam Turbine Generator including Electro-hydraulic control & Turbine Protection system.

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

ÿModulating controls of Feedwater & Condensate Cycle {Hotwell level control, Deaerater Level control, Heater Level Control, etc.}.

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

ÿBinary control of auxiliaries of Turbine Generator (TG) {Boiler Feed Pump (BFP), Condensate Extraction Pump (CEP) etc.}.

ÿElectrical Breaker including synchronization circuits.

ÿCoal Handling Plant.

ÿWater System (PT Plant, DM Plant, Cooling Tower etc.).

ÿCW System.

ÿAir Conditioning and Ventilation systems.

ÿAsh Handling Plant.

ÿMake-up water System.

ÿFGD System

ÿFOPH 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 / evaluation system, Turbine supervisory and diagnostic system etc are also procured through this package.

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