PROJECT FEASIBILITY REPORT

2x660 MW COAL BASED SUPER CRITICAL POWER PLANT

MULVAD, BASAVANA BAGEWADI TALUK, BIJAPUR DISTRICT
KARNATAKA

INDEX
S.No

DESCRIPTION

Sheet
Nos.

PROJECT HIGHLIGHTS

01-04

1.0

INTRODUCTION

05-08

2.0

JUSTIFICATION OF THE PROJECT

09-16

2.1

National Electricity Policy

09

2.2

Power Scenario in Karnataka

10

2.3

Statutory and non-statutory clearances

13

3.0

PROJECT PROMOTERS

17-21

4.0

BASIC REQUIREMENTS AND SALIENT FEATURES

OF THE SITE

22-29

4.1

Basic Requirements to set up TPS

22

4.2

Salient features of Three sites

22

4.3

Proposed project site

27

5.0

TECHNOLOGICAL DEVELOPMENTS

5.1

Supercritical Technology

30

5.2

Unit rating & plant capacity

33

5.3

Equipment Manufacturers

34

6.0.0

TECHNICAL FEATURES OF MAIN PLANT STEAM

GENERATOR ,TURBINE & GENERATOR

6.1.0

Steam Generator and Auxiliary Systems

30-35

36-66
36

6.1.1

Steam Generator Configuration and Technical Features

36

6.1.2

Steam Generator - Auxiliaries

41

6.1.3

Technical Data

45

6.2.00

Steam Turbine and Auxiliaries

46

6.2.01

Power cycle

46

6.2.02

Steam Extraction system

47

6.2.03

Steam Turbine Plant

48

6.2.04

Turbine

48

6.2.05

Blades

49

6.2.06

Valves

50

6.2.07

Gland Steam Sealing System

50

6.2.08

Shaft Glands

51

6.2.09

Lubricating Oil System

51

6.2.10

Turbine Control Fluid System

52

6.2.11

Governing/Regulation Systems

52

6.2.12

Turbine Drain System

53

6.2.13

Bearings and Couplings

53

6.2.14

Turning Gear

53

6.2.15

Turbine protection system

54

6.2.16

Turbine stress controller

54

6.2.17

HP-LP Bypass Station

54

6.2.18

Condensing Plant

55

6.2.19

Design Features

55

6.2.20

Air Extraction

57

6.2.21

Condensate System

57

6.2.22

Condensate Pumps

58

6.2.23

Heaters Drip/Drain System

58

6.2.24

Turbine Drains

59

6.2.25

Regenerative Feed Heating Cycle

59

6.2.26

HP & LP Heaters

59

6.2.27

Deaerator

60

6.2.28

Boiler Feed System

60

6.2.29

Boiler Feed Pumps

61

6.2.30

Lube Oil Purification System

62

6.2.31

Steam Turbine - Typical Design Parameters

62

6.2.32

Auxiliary Steam System

63

6.2.33

Sampling system

64

6.3.00

Generator and Auxiliaries

64

6.3.01

Generator Typical specification

66

7.0.00

DESCRIPTION OF BALANCE OF PLANT SYSTEMS

7.1.00

Coal Handling system

67

7.1.01

Coal Transportation & Unloading facilities

67

7.1.02

Coal Handling Plant- Design Parameters

68

7.1.03

Crushing & Screening Facilities for Coal

70

7.1.04

Crushed Coal Storage/Reclaiming/Coal Bunker Feeding

Facilities

71

7.1.05

Coal Handling Plant - Auxiliaries

71

7.1.06

Electrical & Instrumentation

72

7.2.00

Coal mill rejects handling system

74

7.3.00

Fuel oil system

74

7.4.00

Ash Handling system

76

7.4.01

Design Parameters

76

7.4.02

Bottom Ash System

76

7.4.03

Coarse Ash System

77

7.4.04

Fly Ash System

77

7.4.05

Ash Disposal System

79

7.4.06

Ash Disposal Water System

80

7.4.07

Electrical & Instrumentation for Ash Disposal

81

67-103

7.4.08

Ash Disposal Pump house

82

7.4.09

Emergency Ash Dyke

83

7.5.00

Plant Water System and Water Balance

84

7.5.01

Composite Water Balance

85

7.5.02

Raw Water System

86

7.5.03

Pre-treatment System

86

7.5.04

Condenser Cooling Water System

88

7.5.05

Bearing cooling Water System

88

7.5.06

Demineralization plant

89

7.5.07

Chemical Feed System

90

7.5.08

Station Effluent Treatment System

91

7.5.09

Condensate Polishing System

92

7.5.10

Chemical Laboratory

93

7.6.00

Compressed Air system

93

7.7.00

Air-conditioning & Ventilation Systems

94

7.7.01

Air-conditioning (AC) System

94

7.7.02

Ventilation System

95

7.08.0

Fire Protection System

97

7.09.0

Cranes and Hoists

100

7.10.0

Elevators

102

7.11.0

Hydrogen Generation Plant

102

7.12.0

Mechanical workshop

103

7.13.00

ELECTRICAL SYSTEM

103-125

7.13.01

Basic Design Concepts

103

7.13.02

Single Line Diagram

104

7.13.03

Power Evacuation

105

7.13.04

400 KV Switchyard

105

7.13.05

400 KV Switchyard Equipment

106

7.13.06

Generator Transformers (GTs)

107

7.13.07

Station Transformer

108

7.13.08

Unit Transformer

109

7.13.09

Start-up Power

109

7.13.10

Auxiliary Power for the Units & Common Auxiliaries

109

7.13.11

Unit/Station Service Transformers

109

7.13.12

Bus Ducts

110

7.13.13

Auxiliary Transformers -Coal/Ash Handing/ Water

System Pump House

110

7.13.14

11 KV & 3.3 KV Switchgear

111

7.13.15

415 V switchgear

111

7.13.16

Motor control Centers & Distribution Boards

111

7.13.17

Electric Drives

112

7.13.18

Metering

113

7.13.19

Protection

114

7.13.20

Control Rooms

116

7.13.21

Grounding

117

7.13.22

Lighting Protection System

118

7.13.23

Emergency Power Supply

118

7.13.24

Power and Control Cables

119

7.13.25

Plant DC System

120

7.13.26

Telephone and Inter-communication System

123

7.13.27

Illumination System

123

7.13.28

Electrical Laboratory

125

7.14.00

CONTROL & INSTRUMENTATION

7.14.01

125

7.14.02

Design Philosophy
Distributed Digital Control, Monitoring & Information
System(DDCMIS)

7.14.03

DDCMIS- System Description

132

7.14.04

Control System

139

125-180

128

7.14.05

Man-Machine Interface System and Plant Information

System (MMIPIS)

157

7.14.06

BOP Packages control system

168

7.14.07

Programmable Logic Controller (PLC)

168

7.14.08

24 V DC Power Supply

169

7.14.09

Uninterrupted Power Supply (UPS)

170

7.14.10

Unit Control Panel / Desk

171

7.14.11

Steam & Water Analysis System

172

7.14.12

Field Instrumentation

176

7.14.13

Control Valves

178

7.14.14

Instrumentation Cables

179

7.14.15

Erection Hardware

180

7.14.16

Maintenance and Calibration Equipment

180

8.00.00

CIVIL AND STRUCTURAL ENGINEERING ASPECTS

8.01.01

Basic Design considerations

8.01.02

Wind speed

181
181

8.01.03

Temperature

181

8.01.04

Relative Humidity

181

8.01.05

Seismicity

181

8.01.06

Soil characteristics

182

8.01.07

Site grading and leveling

182

8.02.00

Main plant -Power plant Building Superstructure

182

8.03.00

Plant Area civil works

183

8.04.00

Roads & culverts

186

8.05.00

Liquid retaining structures

186

8.06.00

Natural draft cooling towers

186

8.07.00

Water system

187

8.08.00

Coal Handling Works

187

8.09.00

Ash Handling Plant civil works

188

181-192

8.10.00

Emergency Ash Dyke

188

8.11.00

Waste Water Management

189

8.12.00

Switchyard

189

8.13.00

Chimney

189

8.14.00

Railway Siding

190

8.15.00

Auxiliary Buildings

190

8.16.00

Colony

191

9.00.00

PLOT PLAN AND GENERAL ARRANGEMENT

9.01.00

CEA Guidelines

193

9.02.00

Plot Plan

194

9.03.00

General Plant Layout

196

9.04.00

Switchyard

196

9.05.00

Layout of Steam Generator and Auxiliaries

196

9.06.00

Layout of Machine Room Building with Annex

197

10.00.000 ENVIRONMENTAL CONSIDERATIONS

193-199

200-208

10.01.000 Air Pollution Control System

201

10.02.000 Water Pollution Control System

201

10.03.000 Noise Pollution

203

10.04.000 Solid Waste Management

204

10.05.000 Resettlement & Rehabilitation

207

10.06.000 Post Operational Monitoring Programme

208

10.07.000 Institutional Set-up

208

11.00.0

EXECUTION AND MANAGEMENT

209-214

11.01.0

Infrastructure Facilities for Construction

209

11.02.0

Construction and Execution

211

11.03.0

Quality Assurance

211

11.04.0

Operation and Maintenance

212

11.05.0

Construction Management Organization

212

11.06.0

Spare Part Management & Inventory Control System

213

11.07.0

Training

213

11.08.0

Completion Schedule

214

12.00.0

PROJECT COST ESTIMATES AND FINANCIAL

ANALYSIS

12.01.0

Mega power policy Guidelines

215

12.02.0

Cost Estimates

216

12.03.0

CERC Tariff Regulations - 2009

218

12.04.0

Other input Parameters

218

12.05.0

Financing Structure

219

12.06.0

Interest During Construction

219

12.07.0

Working Capital

219

12.08.0

Cost of Generation

219

LIST OF ANNEXURES

215-219

LIST OF ANNEXURES
1.

Karnataka State Map

2.

Alternate Sites- Topo map

3.

Proposed site - Topo map

4.

Railway Map

5.

Power Grid corporation of India Ltd. grid Map

6.

Coal Analysis.

7.

Raw water analysis

8.

Climatological data

9.

Drawings.

10.

a)

Plot Plan

b)

Heat Balance Diagram

c)

Coal Handling system

d)

Mill reject handling arrangement

e)

Fuel oil system

f)

Bottom Ash Handling system

g)

Fly Ash Handling system

h)

Composite water Scheme

i)

Waste water management system

j)

Compressed Air scheme

k)

Key Single Line diagram of Electrical system

l)

Control System configuration

Project Construction Organization Chart.

11. O&M Staff Organization Chart

12. Project schedule
13. Approvals/Clearances/Statutory requirements
a)

Certificate of incorporation

b)

Government of Karnataka, through its 22nd State High Level

Clearance Committee meeting held on 24.05.2010, accorded
approval vide GO No: CI 185 SPI 2010, Bangalore, dated
02.06.2010.

c)

Application submitted to Coal India for Coal Linkage on

01.9.2010.

d)

Ministry of Environment & Forest Notification-14.09.2006

e)

Ministry of Environment & Forest Notification-S.O 2804(E) dt.

03.11.2009

f)

Thermal power plants - stack height/limits

g)

Indian National Ambient Air Quality Standards

h)

Thermal Power Plants - Standards For Liquid Effluents

i)

Indian General Standards for Discharge of Environmental

Pollutants : Effluents

j)

Indian Standards for Ambient Noise

ANNEXURES

LIST OF ANNEXURES
ANN. NO
1.
2.
3.
4.
5.
6.
7.
8.
9.
A
B
C
D
E
F
G
H
I
J
K
L

10.
11.
12.
13.
A
B

DESCRIPTION

Karnataka State Map

Alternate Sites- Topo map
Proposed site - Topo map
Railway Map
Power Grid corporation of India Ltd. grid Map
Coal Analysis.
Raw water analysis
Climatological data
Drawings.
Plot Plan
Heat Balance Diagram
Coal Handling system
Mill reject handling arrangement
Fuel oil system
Bottom Ash Handling system
Fly Ash Handling system
Composite water Scheme
Waste water management system
Compressed Air scheme
Key Single Line diagram of Electrical system
Control System configuration
Project Construction Organization Chart.
O&M Staff Organization Chart
Project schedule
Approvals/Clearances/Statutory requirements
Certificate of incorporation
Government of Karnataka, through its 22nd State High Level
Clearance Committee meeting held on 24.05.2010, accorded
approval vide GO No: CI 185 SPI 2010, Bangalore, dated
02.06.2010.
Application submitted to Coal India for Coal Linkage on
01.9.2010.

D
E
F
G
H
I
J

Ministry of Environment & Forest Notification-14.09.2006

Ministry of Environment & Forest Notification-S.O 2804(E) dt.
03.11.2009
Thermal power plants - stack height/limits
Indian National Ambient Air Quality Standards
Thermal Power Plants - Standards For Liquid Effluents
Indian General Standards for Discharge of Environmental
Pollutants : Effluents
Indian Standards for Ambient Noise