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2008

CONTENTS
STANDARD
PROPOSAL
1. INTRODUCTION
MODULE FOR 3x660
2. PROJECT MANAGEMENT PROCEDURES

MW COAL BASED
3. PLANT DESIGN BASIS
4. SCOPE OF WORK, TERMINAL POINTS AND EXCLUSIONS

THERMAL POWER
4.1 SCOPE OF WORK
4.2 TERMINAL POINTS
4.3 EXCLUSIONS
PLANT
5 TECHNICAL WRITE UP
BASED ON SUPERCRITICAL TECHNOLOGY
5.1 MAIN PLANT (STEAM GENERATOR & STEAM TURBINE
GENERATOR AND PIYUSH KUMAR SINHA
AUXILIARIES)
MBA Power Management
5.2 BALANCE OF PLANT- MECHANICAL
piyushkrsinha@gmail.com

5.3BALANCE OF PLANT – ELECTRICAL


5.4BALANCE OF PLANT CONTROL AND INSTRUMENTATION
5.5 CIVIL, STRUCTURAL AND ARCHITECTURAL WORKS
6 BASIS OF OFFER
7 TECHNICAL DATA SHEETS AS PER TENDER SPECIFICATIONS
8 DRAWINGS AND DIAGRAMS
Standard Proposal Module for 3x660 MW Coal based Thermal Power Project

EXECUTIVE SUMMARY

Power Crisis has been a long clamor in India and this seems to persist for the
coming decade or so. Beyond optimistic illusions, ground realities are too
fierce to be accepted.

Seeds of improvement are however being planted at all possible arenas


broadly Indicating: -
POWER SECTOR REFORMS

FIGURE – 1

The Project Idea springs from one of the reforms Viz. generation of Power.
To cater the accelerated need of the country Ultra Mega Power Plants
(UMPPs) have been proposed. These are giant power plants of 4000 MW at
one place. In addition to these, a number of Mega Power Projects (More than
1000 MW) are also being promoted. The unit size of power plants has also
experienced a supercritical shift in technology. Thus focus is on more efficient
supercritical units of 660 MW and 800 MW. However considering imported
coals as the main fuel, unit size can go up to 1000 MW. As the domestic coal

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Standard Proposal Module for 3x660 MW Coal based Thermal Power Project

available for power sector is having very high (40 to 45%) ash content
feasibility of higher size units are yet to be examined. Meanwhile after
500MW / 600 MW (subcritical) the next suitable supercritical size was
decided 660 MW or 800 MW for coal based thermal power plants.

This Project has been based on study and formulation of EPC proposal of
3x660 MW coal based thermal power plant (Super Critical Technology). It
also includes plant design basis, scopes of work different packages &
technical write up of main plant as well as Balance of Plants.

Cost estimation and percentage cost breakup of the Thermal power plant
spells out the brief overview of the EPC project cost.

2.0 INTRODUCTION

The study shall form the basis for the standard proposal module for the 660
MW project. As the gear of technology is experiencing a critical shift in
power sector, India is keen to welcome the Supercritical technology. The first
stage of capacity shift is seen to be 660 MW which is being adopted by NTPC
and other private sector players for several upcoming projects.

The assignment covers supply of complete main plant with BOP package on
Engineering, Procurement and Construction (EPC) basis and making standard
proposal module of this. EPC work can exclude civil works, coal handling
system, ash handling system, external raw water system and water intake
system depending upon the projects.

The power plant configuration considered for the project shall be having 3
identical units to generate gross power 1980 MW.

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Standard Proposal Module for 3x660 MW Coal based Thermal Power Project

Things to be included in the EPC Proposal

1. INRODUCTION

2. PROJECT MANAGEMENT PROCEDURES

3. DESIGN BASIS

4. SCOPE OF WORK, TERMINAL POINTS & EXCLUSIONS

5. BASIS OF OFFER

6. TECHNICAL DATA SHEETS

7. DRAWINGS & DIAGRAMS

8. SCHEDULE OF PRICES

9. TIME SCHEDULE

10. PERFORMANCE GUARANTEE SCHEDULE

11. COMMERCIAL BID

Brief Descriptions of these are as follows:-

1. INTRODUCTION

MAJOR EQUIPMENTS:-
3 units of steam generator, 3 units of steam turbine generator and other associated systems in line
with specific tender document taken as reference and as per the scope of work.

Besides this, FUEL DETAILS, WATER ARRANGEMENTS , L AYOUT , POLLUTION STANDARDS, LOGISTICS
PLANNING , POWER EVACUATION ARRANGEMENTS, WATER REQUIREMENTS , PLANT LAYOUT, POLLUTION ,
LOGISTICS ARRANGEMENT , LAND REQUIREMENTS(1.4 MW/Acre for indigenous coal and 0.53 for imported
coal including MGR & cooling tower) are given in introduction.

2. PROJECT MANAGEMENT & PROCEDURES

MANAGEMENT APPROACH
Define sequence of work and establish project organization.
Staff the organization, required communications & equipments.

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Standard Proposal Module for 3x660 MW Coal based Thermal Power Project

PROJECT COORDINATION
It is very important at all levels Viz. Engineering, Procurement, Construction, and Start Up.
Some Other Important aspects of project management are as follows:-

P LANNING & S CHEDULING M ANAGEMENT I NFORMATION S YSTEM

D OCUMENT C ONTROL & D ESIGN P ROCUREMENT & F IELD C ONTRACTING


S UBMISSIONS

P RODUCTION C ONTROL & M ANUFACTURE I NSPECTION & T ESTING

M ATERIAL C ONTROL Q UALITY A SSURANCE

C ONSTRUCTION M ANAGEMENT C OMMISSIONING & T ESTING

S TART U P D OCUMENTATION S ITE M ANAGEMENT & I NSURANCE


Table – 1

Project organization Structure - Office

FIGURE – 2

3. PLANT DESCRIPTION & DESIGN BASIS

This is mainly detailed description of all important equipments(Steam generator, Steam


turbine & generator, Water system, Fire protection system, Compressed air system, Fuel oil
handling system, Air condition & ventilation system etc) their technical specifications and
manufacturing parameters. Please go through main project report for more details.

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Standard Proposal Module for 3x660 MW Coal based Thermal Power Project

4. SCOPE OF WORK, TERMINAL POINTS & EXCLUSIONS

SCOPE OF S TEAM GENERATOR : - Followings equipments come under the scope of steam
generator. Boiler pressure parts (Economiser, Super Heater, Reheater), Boiler structure
Flues , Ducts, Fuel feeding system, Oil system, Combustion equipments( Pf Burners, Igniters,
Oil Burners), Boiler auxiliaries( FD , ID, PA – Fans, BCP, Air heaters), Cabling, control &
monitoring system, Electrical ( HT & LT Motors, Insulation, Refractory), ESP, Milling plant (
Coal Pulverizer)

SCOPE OF WORK : – MECHANICAL


Water system, CHP & AHP, Effluent treatment plant, Fire protection system, Air
conditioning & Ventilation system, Cranes & hoists, Turbine auxiliaries, Compressed air
system, Power cycle piping, Fuel oil systems, Chemical laboratory & equipment, Pumps,
Auxiliary boiler

SCOPE OF WORK : – E LECTRICAL


Evacuation & distribution system, Main generation system, Emergency power, Transformers
Switchyard, Isolators & circuit breakers, Cabling & illumination, Earthing & lightning
protection, Control protection & metering system, Plant communication system

SCOPE OF WORK : – CONTROL & INSTRUMENTATION


Distributed control system, Programming logic controllers, Control & instrumentation for
STG & auxiliaries, Steam water & analysis system, Continuous emission monitoring system,
Centralized vibration monitoring system, Plant security & surveillance system, Plant LAN
work, Testing & calibration system, Air & weather monitoring system.

TERMINAL POINTS: - This is the point of deliveries under mutual agreements between
contractor and owner. E.g. - Raw water, Coal, CW piping, Fuel oil, Civil works, Electrical
evacuation, Construction system, Construction power, Roads.

EXCLUSIONS: - This is mainly distinction of responsibilities, clarification of scope of works,


obligations, schedule of works.

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Standard Proposal Module for 3x660 MW Coal based Thermal Power Project

5. BASIS OF OFFER
This is mainly distinction of responsibilities, clarification of scope of works, obligations,
schedule of works, vendor list and quality manuals wish can be categorized under following
heads:

• Clarification to tender documents………………..……………..Doubts are made crystal clear

• Customer obligation………………………………………… Expectations from customer/ Owner

• Project schedule…………Detail anticipated project completion schedule are submitted

• Vendor list……………………………………………………………….………….Equipments Suppliers list

• Quality manual………………………………………..…..This shall be provided by the Contractor

6. TECHNICAL DATA SHEETS


These are all technical data of all equipments supplied and installed with their capacities.
Please go through main project for detailed technical specifications.

7. DRAWINGS & DIAGRAMS


All drawings are supplied wherever required. Namely … Plot Plan, PIDs (Process N
Instrumentation Diagrams), Turbine Cycle Scheme, Water & Steam System Scheme, Coal
Handling System Flow Diagram, Fly Ash Handling System, Bottom Ash Handling and Slurry
System etc.

8. SCHEDULE OF PRICES
Price Schedule (FOB/CIF plus duties & Taxes) is submitted which has details of followings:-

OFF SHORE SUPPLY CONTRACT: - Cost components of foreign & Indian rupees with
marine freight & Insurance, Custom Duty, other taxes & duties.

ON SHORE SUPPLY CONTRACT:- Includes Ex-works price of equipments including


design and engineering, packing and forwarding, Excise Duty, Central and State Sales Tax,
Transportation, entry tax & others.

ON SHORE SERVICES CONTRACT:- Includes Scope of services, mentioning design and


detail engineering, project management services, erection, testing and commissioning ,
clearing, forwarding of Offshore supply of goods at Indian port, transportation and transit
insurance, performance Guarantee tests, training and service tax & other duties.

9. TIME SCHEDULE
Time schedule are given for design, manufacture, delivery at site (FOB portion and Ex-Works
portion), equipment erection, commissioning, performance guarantee tests Start and finish.

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Standard Proposal Module for 3x660 MW Coal based Thermal Power Project

10. PERFORMANCE GUARATEE SCHEDULE

This has to be given for all units of power plant and auxiliaries in respect of all items based
on specified design and parameters mainly specifying the followings:-

PERFORMANCE GUARANTEE UNDER LIQUIDATE DAMAGE: - Value inclusive design,


manufacture & other tolerances with required clarifications. (Gross STG Power Output,
Total Auxiliary Power Consumption, Gross unit heat rate, Station Heat rate, SGMCR etc.)

PERFORMANCE GUARANTEE UNDER CORRECTION:- This contains Value inclusive


design, manufacturing and other tolerances including measurement uncertainty with
required clarifications(BMCR & TMCR Ratings, Noise Level, Vibration level, other
systems as per tender specifications)

11. COMMERCIAL BID

Letter of Submission, Company profile, Bid security, Power of Attorney/Letter of Authority,


Information forms, Application for bidding, Statement of bidders, Experiences & references,
Financial data, Schedules, Un-price, Clarification / Deviation schedule to general conditions
of contract & Letter of submission have to be specified in this.

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Standard Proposal Module for 3x660 MW Coal based Thermal Power Project

COST ESTIMATION & CLEARANCES FOR 3x660 MW TPP


Sr. COST
No
Preliminary cost Estimate for 3x 660 MW TPP % Cost
( Crore )
100 Preliminary investigation & survey 2.5 0.04%
200 Civil Works 800.0 11.40%
300 Mechanical Works 5367.4 76.46%
401 Main Plant 3900.0 55.56%
401 Steam generator with associated auxiliaries 2500.0 35.61%
401 Turbo generator with associated auxiliaries 1400.0 19.94%
402 Coal handling Plant 480.0 6.84%
403 Ash Handling Plant 260.0 3.70%
404 Water System 540.0 7.69%
404 Sea Water Intake including intake piping and outfall 200.0 2.85%
404 Water treatment plant( Desalination & DM) 180.0 2.56%
404 Cooling tower including pumps 160.0 2.28%
405 LP & CW piping including valves, specialities and fittings 65.0 0.93%
406 Air conditioning system and ventilation system 20.0 0.28%
407 Fire protection system 60.0 0.85%
408 Cranes/ Hoisting Equipments 10.0 0.14%
409 Compressed air System 13.0 0.19%
410 Miscellaneous Equipments, tanks, Piping, Insulation etc 19.4 0.28%
411 Sub Total 5367.4 76.46%
GRAND TOTAL MECHANICAL 5367.4 76.46%
500 Electrical Works 350.0 4.99%
501 Electrical cost AS PER ROW 300.0 4.27%
Cost of transmission line & plant instrument & control
505 Lumpsum 200.0 2.85%
600 Total works Cost ( Prelims+ civil + mech+ elec+ C& I) 7019.9 100.00%
700 EPC Project Cost 7019.9 100.00%

COST % Total cost


COST BREAK UP
( Crore) (9023 Crores)
Supply Of Main Plant Equipment System 3900.0 43%
Supercritical Boiler Including Auxiliaries 2500.0
Supercritical STG & Auxiliaries 1400.0
Supply of BOP Equipment System 2317.4 26%
Other mechanical Equipment System 1467.4
Electrical Equipment System and C&I 850.0
Engineering & Project management 351.0 4%
Erection & commissioning 352 4%
Civil Works 800 9%
Total 7720.5 86%

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Standard Proposal Module for 3x660 MW Coal based Thermal Power Project

LIMITATIONS

There were some limitations with respect to the analysis and data that may
affect the accuracy of the results:
EPC Proposal depends largely on Bid Requirements so may be some
sections may not be as applicable.
This is only a rough cost estimate and may differ from prevailing market
conditions.
As EPC has three models BTG+BOP, Total EPC, STG+BOP, hence
scope of work and cost estimation can vary from project to project.
Some costs components like Land, Transportation etc. can vary
depending on site location.

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Standard Proposal Module for 3x660 MW Coal based Thermal Power Project

Suggestions & Recommendations

Growing economies always need a proportional need for power. Country like
India has a required growth in power sector close to 15 %. In order to match
the accelerated need of country, there is urgent need is to take the challenge to
squeeze the time and cost required to complete a coal based power project. If
some more R&Ds could fetch some reductions in total EPC costs and could
increase operating efficiencies, it would be a great relief to fund hungry power
projects.

We should go for large size projects which are more efficient and less
polluting than several smaller units. One more field which needs to be
prioritized is Risk management and project management that play a very
crucial role in carrying out such big projects.

BIBLIOGRAPHY

www.cea.nic.in , Report on land Requirement

http://powermin.nic.in/, Report on Generation

www.ntpc.co.in , Generation & Plants

http://www.worldenergy.org/ ,

www.bhel.com

www.power.alstom.com

www.google.com

http://en.wikipedia.org/

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