Thermal Power Plant (9,11,12)

Project Management I
Report on Feasibility study of Thermal Power Plant (Coal based)
1.0. INTRODUCTION A thermal power station is a power plant in which the prime mover is steam driven. Water is heated, turns into steam and spins a steam turbine which drives an electrical generator. After it passes through the turbine, the steam is condensed in a condenser and recycled to where it was heated; this is known as a Rankine cycle. The greatest variation in the design of thermal power stations is due to the different fuel sources. Some prefer to use the term energy center because such facilities convert forms of heat energy into electricity.[1] Some thermal power plants also deliver heat energy for industrial purposes, for district heating, or for desalination of water as well as delivering electrical power. A large part of human CO2 emissions comes from fossil fueled thermal power plants; efforts to reduce these outputs are various and widespread. 2.0. Efficiency The energy efficiency of a conventional thermal power station, considered as salable energy as a percent of the heating value of the fuel consumed, is typically 33% to 48%. This efficiency is limited as all heat engines are governed by the laws of thermodynamics. The rest of the energy must leave the plant in the form of heat. This waste heat can go through a condenser and be disposed of with cooling water or in cooling towers. If the waste heat is instead utilized for district heating, it is called co-generation. An important class of thermal power station is associated with desalination facilities; these are typically found in desert countries with large supplies of natural gas and in these plants, freshwater production and electricity are equally important co-products.
Submitted by: .
CP0911, CP1111 and CP1211, M-Tech CPM, Faculty of Technology, CEPT University, Ahmedabad, India
3.0.Components of thermal power plant 1. Cooling tower 10. Steam Control valve 11. High pressure steam 2. Cooling water pump turbine 3. transmission line (3-phase) 12. Deaerator 4. Step-up transformer (3-phase) 13. Feedwater heater 5. Electrical generator (3-phase) 14. Coal conveyor 6. Low pressure steam turbine 15. Coal hopper 7. Condensate pump 16. Coal pulverizer 8. Surface condenser 17. Boiler steam drum 9. Intermediate pressure steam 18. Bottom ash hopper turbine 19. Superheater 20. Forced draught (draft) fan 21. Reheater 22. Combustion air intake 23. Economiser 24. Air preheater 25. Precipitator 26. Induced draught (draft) fan 27. Flue gas stack
Typical diagram of a coal-fired thermal power station
Submitted by: .
3.1. Functions 1. COAL (fig. 1) Coal is transported from the mine to loading place Loading place into ships Ships to the port Unloaded at the Port Transported through conveyors into bunkers From bunkers into mills (Pulverizes) Powdered, put into furnace and burnt The heat generated is used to heat water, steam, air
(fig. 1)
2. CHP Coal handling plant (fig. 2) At the receiving location stock yard or sent to coal bunkers To make sure to generate electricity when you want to, you have to make sure the coal is in the right place at the right time Typically 15 days stock is maintained at site The stock yard stocks these and helps in times of lean supply from the mines or when transportation is not available
(fig. 2) 3. Coal Conveyor (fig. 2) Coal conveyors are used to move coal around efficiently. Coal arriving by train can be stocked for later use or taken straight to the coal bunkers CHP control room with remote control system helps to ensure that the conveyors take the coal to the right bunkers
Submitted by: .
4. Boiler Coal (fig. 3) Coal bunker supplies coal to pulverizing fuel mills. Each bunker can hold 1,000 tonnes of coal, and there may be six to eight bunkers per unit Power station coal is not as lumpy as coal used in the home. Typically around half of it is less than 12.5 millimeters across and 95% is less than 50 millimeters This when powdered is called 200 mesh cleared. That is the powdered coal passes through a sieve with so many holes in square inch area. It is better than the face powder in terms of size (fig. 3) 5. Stack and Reclaim (fig. 4) Machines are used to put coal out to the stockpile and reclaim coal from the stockpile Water is sprayed on coal to stop them from getting burnt when in storage yard due to internal heat up or sun heat Coal when powdered is heated and being lifted by hot air that is sent into the mills This goes and burns inside the furnace producing ash and converting the water in the pipelines into steam (fig. 4) 6. Coal Feeder (fig. 5) The variable speed coal feeder feeds coal from the bunkers to the mill It uses a conveyor to move coal through a fixed gap at a precisely controlled speed Varying the speed controls the amount of coal supplied to the boilers These are precision bits of equipment that have to move exact amounts of coal. They can move 40 tonnes of coal in an hour
(fig. 5)
Submitted by: .
7. Primary Air Fan (fig. 6) Air to blow the coal from the mill to the boiler, called the primary air, is supplied by a large fan driven by a variable speed motor When mixed with a stream of air the powdered coal behaves more like a gas than a solid Primary air does two jobs heating the coal powder and secondly lifting it into the furnace through pipelines (fig. 6) 8. Boiler light-up (fig. 7) Spark plug provides the initial ignition. Light Diesel oil is then fed to the burner and it catches fire This is followed by heavy furnace oil (HFO) Once a stable flame is established the coal/air mix is blown through the burner where it lights spontaneously The oil are then shut off. Burner position, coal flow and air flow are controlled to achieve desired output of temperature, pressure and flow and hence the electricity At full output 4,000 MW power station can burn more than 50,000 tons of coal a day (fig. 7) 9. Boiler (fig. 8) To produce steam each boiler converts energy, in the form of coal, into steam The boiler is lined with steel tubing in which pure boiler feed water is turned to steam by the heat created from the burning of coal Each boiler is as high as 60 mts and weighs about 40,00,000 kg (4000 T) Inside the boiler there is enough steel tubing to stretch the 500 kilometers and they are joined together by about 20,000 joints Pressure inside the tubes could be about hundred times that of cars wheel pressure
(fig. 8)
Submitted by: . CP0911, CP1111 and CP1211, M-Tech CPM, Faculty of Technology, CEPT University, Ahmedabad, India
10. Forced Draught (FD) Fan (fig. 9) Each unit shall have two forced draught fans The fans draw warm air from the top of the boiler house through large air heaters becoming the primary and secondary air used for the boiler combustion process The air heater warms the incoming air by transferring heat energy from the outgoing flue gases. (fig. 9) 11. Air Pre-Heater (APH) The air heaters use the remaining heat energy in the flue gas to heat up the combustion air for the boiler Efficiency is increased by using this heat that would otherwise go up the chimney. The air temperature leaving the air heaters is at 300C The air heaters use the remaining heat energy and efficiency is increased by using this heat that would otherwise go up the chimney 12. Electro-Static Precipitator (fig. 11) Each boiler has 4 passes with 7 fields each containing high voltage electrodes These attract the dust or ash from the flue gases At regular intervals the electrodes are rapped with motordriven hammers and the PFA falls into hoppers below In a year 1,000 MW station may generate 1.5 million ton of ash (fig. 11) This is one of the ways to clean up the flue gases or smoke sent up the chimney Secondly this ash is used by construction industry for use in building materials (bricks !!, Cement Fillers)
13. Induced Draught (ID) Fan Two induced draught fans draw gases out of the boiler The gas has already passed through the air heaters and precipitators before it has reached these fans The heat from the flue gases or smoke is used in the air heaters to heat up the primary and secondary air
Submitted by: .
14. Chimney (fig. 12) The chimney is 275 meters' high and 50,000 tonnes of reinforced concrete were used to make it It consists of flues each of which serve typically two or three boilers (two units) (fig. 12) 15. Super heater (fig. 8) The steam produced in the boiler goes to the steam drum and is then piped through the primary, platen and final super-heaters where it reaches the outlet temperature of 560C and 160 ksc pressure At this point in the process they have now turned the water into a very powerful source of energy This rotates the turbine to which generator is on the other end From rotating generator electricity is produced 16. High Pressure Turbine (fig. 13) High pressure steam at 560C and 160 ksc pressure passes through the high pressure turbine. The exhaust steam from this section is returned to the boiler for reheating before being used in the next section of the turbine set. The blades in the high pressure turbine are the smallest of all the turbine blades, this is because the incoming steam has very high energy and occupies a low volume. The blades are fixed to a shaft and as the steam hits the blades it causes the shaft to rotate 17. Boiler Reheater (fig. 14) After expanding through the high pressure turbine the exhaust steam is returned to the boiler at 360C and 40 ksc pressure for reheating before being used in the intermediate pressure turbine The Reheater reheats the steam from a temperature of 360C back to 560C (fig. 14) 18. Intermediate Pressure Turbine On leaving the boiler Reheater, steam enters the intermediate pressure turbine at 560C and 40 ksc pressure (1 ksc = 14.22 psi ) From here the steam goes straight to the next section of the turbine set The steam has expanded and has less energy when it enters this section, so here the turbine blades are bigger than those in the high pressure turbine The blades are fixed to a shaft and as the steam hits the blades it causes the shaft to rotate
19. Low Pressure Turbine (fig. 15) From the intermediate pressure turbines, the steam continues its expansion in the three low pressure turbines. The steam entering the turbines is at 300C and 6 ksc pressure To get the most work out of the steam, exhaust pressure is kept very low, just 50 mille-bar above a complete vacuum The tip speed of the largest blades with the shaft spinning at 3,000 revolutions per minute is 2,000 kmph
(fig. 15)
20. Rotor (fig. 16) The shaft that runs through the turbines is coupled to the rotor, which is a large electromagnet inside a cylinder of copper windings called the stator The rotor weighs 100 tonnes and rotates at 3,000 revolutions per minute (fig. 16) 21. Stator As the electromagnet rotates inside the copper windings, a magnetic field is created which induces a three phase alternating electric current (AC) in the stator windings Together the rotor and stator are known as the generator. The stator weighs 300 tonnes electricity is generated at over 80 times the voltage in our homes This is stepped up to about 4,00,000 volts and then transmitted
22. Generator Transformer (fig. 17) From the generator the electricity then goes to a transformer where the voltage is increased to 4,00,000 volts before sending it via cables to the Grid for distribution Each 1 MW generates about 8 million units and gives about Rs 2 crores revenue every year . This generates enough electricity to power around 5,000 avg. homes
(fig. 17)
(fig. 17)
Submitted by: .
23. Condenser (fig. 18) With its useful energy spent in the turbines the steam then passes to condensers Here it is condensed back into water and pumped back to the boiler This happens via a series of low pressure and high pressure feedheaters (fig. 18) 24. Condensate Extraction Pump (fig. 19) (fig. 18) The condensate water is drawn from the condenser by the extraction pump and sent to the low pressure feed heaters
25. Low Pressure Feed Heaters Feedwater from the condensate extraction pumps passes through low pressure feed heaters. Steam is used to heat the feedwater After the last feedheater, the feedwater is at around 160C.
(fig. 19) 26. Deaerator (fig. 20a) From the low pressure feed heaters the water passes through the deaerator before going to the high pressure (HP) feed heaters. (fig. 20a) 27. Boiler Feed Pump The boiler feed pump pumps water into the boiler, overcoming the boiler pressure of 160 bar to achieve it The pump is driven by a steam turbine or an electric motor It runs at 7,000 revolutions per minute
Submitted by: .
10
28. High Pressure Feed Heaters (fig. 20b) With a similar purpose to the low pressure feed heaters, the high pressure feed heaters are the last stage of feedwater heating before the feedwater enters the boiler system at the economizer Feedwater leaving these heaters is at 250C
(fig. 20b)
29. Cooling Tower (fig. 21) The warm river water is taken from the condenser tubes to about a quarter of the way up the 100 metre high cooling tower where it is dropped through honeycombed plastic packing This breaks the water up into a very fine spray, increasing the surface area of the water droplets making it easier to cool The cooling tower is designed as a natural draught chimney, drawing cold air from outside through the falling water Cool water is collected in pond at the bottom of the cooling tower (fig. 21) From here it is pumped back to the condensers 30. Circulating Water Pumps (fig. 22) The circulating water pumps are used to circulate the water from the cooling tower to the condenser and back again (fig. 22) 31. Circulating Water Make-Up Pumps (fig. 23) These pumps are used to supply water for make-up purpose Before going to the cooling Tower the silt is removed in large sedimentation tanks 32. FGD After passing through the electrostatic precipitators, the boiler flue gas is increased in pressure and then cooled from between 115C-130C to 80C
Submitted by: .
11
It enters the lowest part of the absorber and is further cooled by water used to wash the inlet duct to prevent a build up of solids The main SO2 absorption process, and the washing out of any remaining pulverized fuel ash, occurs as the gas is scrubbed by the re-circulating limestone slurry This is taken from the bottom of the absorber and is sprayed downwards from nozzles arranged at five separate levels in the absorber tower As a result of the process chemistry, the recirculation slurry becomes predominantly gypsum and a portion is continuously pumped away for gypsum separation and the removal of water using a hydro-cyclone system A waste water treatment plant ensures any water from the FGD process returned to the river meets quality standards set by the regulatory authority The cleaned flue gas is discharged up the 275 metre high chimney which has been lined with steel plates/brick lining. The generated power stepped up to 4 lakh volts is transmitted and handed over to distributors at lower voltages Finally it is supplied to households at 230 volts and to industries at little higher voltages.
4.1. ADVANTAGES The fuel used is quite cheap. Less initial cost as compared to other generating plants. It can be installed at any place irrespective of the existence of coal. The coal can be transported to the site of the plant by rail or road or sea It requires less space as compared to Hydro power plants. Cost of generation is less than that of diesel power plants. This plants can be quickly installed and commissioned and can be loaded when compare to hydel power plant It can meet sudden changes in the load without much difficulty controlling operation to increase steam generation Capital cost in Rupees per Mega watt installed is about 4 crores for hydro, 5.0 crores for thermal and 5.5 crores for nuclear. Maintenance and lubrication cost is lower
Submitted by: .
12
4.2. DISADVANTAGES
It pollutes the atmosphere due to production of large amount of smoke and fumes. However, this could create more jobs for a lot of people thus increasing in a good way our current economic situation which by is failing miserably. Over all capital investment is very high on account of turbines, condensers, boilers re-heaters etc .maintenance cost is also high on lubrication, fuel handling, fuel processing. It requires comparatively more space and more skilled operating staff as the operations are complex and required precise execution A large number of circuits make the design complex. Starting of a thermal power plant takes fairly long time as the boiler operation and steam generation process are not rapid and instantaneous
Submitted by: .
13
CASE STUDY
On 2 x 500 MW Coal based thermal power plant near Pipavav, Gujarat, India
Submitted by: .
14
5.0. LOCATION
Submitted by: .
15
5.1. PROJECT AT GLANCE GENERAL The project Owner Location 2 x 500 MW Coal based thermal power plant near Pipavav in Gujarat GPCL, Ahmedabad, Gujarat The site is located near Pipavav in Amreli District of Gujarat state. Latitude 20 54 N and longitude 71 26 E
INPUTS Main fuel Auxiliary Fuel Fuel Transportation Coal: About 2.26 MTPY of coal from overseas sources. HFO/LDO from nearby port Coal will be received in shiploads from SA, Aus., Indo. At Pipavav port. From port, conveyors would be used to transport the coal to the plant. HFO/LDO would be transported to the plant by road tankers. Water will be drawn for sea (gulf of khambat). An intake of pump house located beyond high water limit would supply water to the power plant through a 4kms long MS, concrete lined pipeline.
Water
5.2. LAND About 479.5 Ha of land used for proposed power station including all including facilities. 5.3 MANPOWER Direct employment of about 800 persons during power plant operation 5.4. REHABILITATION None 5.5 SUPPORTING INFRASTRUCTURE Road access Land development Township The site is located near the SH-34. A double lane access would connect the site with the above highway. There is no railway connection. Plant will be laid at about 20m level above MSL. The designated area is above HFL. 640 dwelling units based on 80% satisfaction level will be provided
Submitted by: .
16
5.6. PROJECT COST & COST OF GENERATION Capital cost Overall project cost Project cost with interest Cost of generation Power Plant : Rs. 3333.28 Cr Port Facility : Rs. 146.32 Cr Rs. 3479.60 Cr Rs. 4220.83 Cr Tariff Rs. 2.76/kWh
6.0. MARKET FEASIBILITY 6.1. PROJECT GENESIS The state of gujarat was 8th in the list of industrialised state till 1960, it now occupies 2nd position in terms of output in manufacturing sector. Due to rapid development power demand has outstripped supply in gujarat. Gujarat industrial development was concentrated in ahmedabad-baroda-surat belt. Focus is now shifting to saurashtra region owing to increased power requirement.
6.2. SECTOR-WISE TREND OF POWER CONSUMPTION / DEMAND
Submitted by: .
17
6.3. EXISTING POWER SCENARIO IN GUJARAT DEMAND / SUPPLY POSITION OF POWER IN GUJARAT INSTALLED CAPACITY DEMAND AVAILABILITY DEFICIT REQUIRED INSTALLED CAPACITY TO MEET DEMAND 7516 8573 9778 11133
YEAR
1994-95 1996-97 1998-99 2000-01
6190 6390 7408 8407
4810 5487 6258 7125
3616 4303 4757 5376
1326 2183 2372 2726
NOTE : ALL CAPACITIES IN MW & MAX. EFFICIENCY OF PLANT = 0.64 6.4. DEMAND vs. SUPPLY TREND IN GUJARAT
Submitted by: .
18
6.5. PROJECT JUSTIFICATION Deficit of 2726 mw requires additional power generation capacity. Trend of growth in demand ensures that plant utilisation factor will be more than 64%. Use of imported coal through a dedicated port facility ensures higher plant availability for generation. Since coal is imported through sea route, no pressure on already strained railway system. The regional grid is capable of additional power from the project. Project may be implemented through private / jv participation.
6.6. UNIT SIZE SELECTION Frequently used unit sizes are: 4 x 250 mw , 3 x 330 mw & 2 x 550 mw. Selection of unit size depends upon: o Efficiency , grid capability, operating experience, o Reliability & cost effectiveness, To take advantage of economy of scale, smaller unit sizes are normally not recommended. With higher unit sizes, capital cost & cost of generation is comparitively lower. The manpower required to maintain & operate the same is low. Availability of vendors, skilled labour & auxillary support indigenously favours the higher unit sets of 500 mw. Existing geb grid is capable of receiving power from 500 mw units. Hence 2 units of 500 mw are proposed.
Submitted by: .
19
7.0. TECHNICAL FEASIBILITY 7.1. Land requirement Plant area Ash disposal area Township area Intake pipe route Other requirement - 300 ha. - 135 ha. - 30 ha. - 4.5 ha. - 10 ha. - 479.50 Ha.
Total land requirement 7.2. WATER REQUIREMENT & AVAILABILITY Water required for : cooling water for team condenser cooling of electrical and mechanical equipment make-up water for power cycle ( boiler feed) fire fighting, air conditioning and sanitation potable water for plant & township
There is scarcity of sweet water in the area as ground water is brackish & no river is availabile, hence proposed to adopt recycling and use of sea water for major use.
Sea water shall be used in proposed desalination plant (2 x 1.5 mgd)
7.3. FUEL REQUIREMENT & AVAILABILITY Primary fule coal is required at the rate of 8850 mt per day Coal shall be imported from s.africa/ australia / indonesia through pipavav port. Pipavav port facilitates navigation of 60000 dwt ships & has unloading facility of 1500 t/hr. Coal transportation to plant site through twin conveyor belt system. Back up storage of 30 days is proposed at power plant. Daily requirement of start up & stabilization fuel (hfo) is 80000 lt.
Submitted by: .
20
7.4. INFRASTRUCTURAL FACILITY Existing facility Distance from railway station : 40 km Distance from nearest state highway (sh-34) : 2.5 km
Proposed facilities 2 lane road from highway to plant site. Township for accomodating 800 employees equipped with market, school, hospital, post office etc.
7.5. POWER EVACUATION Power generated at the plant shall be evacuated through existing power grid of geb. Geb grid will be connected through 22o kv lines to jetpur substation & sevarkundla lines. Detailed scheme foe evacuation of exportable power about 915 mw would be drawn up by geb for which agreement is signed with geb.
7.6. SITE SELECTION Following three sites were indentified for proposed plant :
1. NEAR MUNDRA 2. NEAR VERAVAL 3. NEAR PIPAVAV
*- comparison of salient features of three sites is given in following table

21
7.7. COMPARISON FOR SITE SELECTION FOR PROPOSED PLANT

Sr. No. 1. 2. Features Nearby town Nearest highway Mundra Bhuj : 62 km Nh 8a : 82 km Sh 31 : 22 km 3. New access road to site 7 km Kandla port : 80 km 9 km Gulf of kutch : 9 km Moderate 7. Wind/ current Red zone @ 50 m/sec Through desalination plant 1 km Porbandar : 230 km 4.8 km Arabian sea : Arabian sea 3.5 km 3 km Moderate Red zone @ 50 m/sec Through desalination plant Moderate Red zone @ 50 m/sec Desalination plant + water from narmada & Dhratrawadi. Indonesia, 9. Source of coal South africa Australia 10. 11. Distance of 400 kv substation & its distance from plant Cooling water system & gravity head Limbdi @ 225 km Indirect cooling with 8 m head. Indonesia, South africa Australia Jetpur @ 200 km Direct circulation with 6 km head Lodhva : 1km Dhamrej : 1 km Indonesia, South africa Australia Jetpur @ 125 km Indirect cooling with 22 m head Kovya reserve : 3 km Sh 34 : 2.9 km 2.5 km Pipavav port : 40 km 7 km Veraval Veraval : 27 km Nh 8b :144 km Pipavav Jafrabad : 8.5 km Nh 8a : 293 km
4.
Equipment unloading point
5.
Coal conveyor length to site
6.
Nearest intake location for sea water
8.
Source of sweet water
12.
Nearest forest boundary
Jetpur reserve forest : 2 km
13.
Land use
Private land
Private land
Private land marginally cultivated.
Submitted by: .
22
7.8. COST COMPRISON FOR SITE SELECTION *-note: all figures in crores SR. NO. 1. FEATURES Harbour facility Cost of conveyor 2. From port to plant @6 cr / km 3. 4. 5. 6. Cooling system Roads Land aquisition Cost 400 kv transmission line Total cost involved 143.4 1.3 6.0 450 756.45 67.0 0.2 7.2 200 583.65 91.4 2.2 12.0 250 422.40 55.8 28.8 43.8 MUNDRA 100.05 VERAVAL 280.04 PIPAVAV 22
7.9. SITE SELECTION (FINALIZATION) Based on techno commercial feasibility site near pipavav has been selected for construction of proposed 1000 mw power plant.
Submitted by: .
23
8.0. ENVIRONMENTAL ASPECTS Main sources of pollution in power plant: Stacks : discharging particulate matter, toxic gases & heat. Circulating water blown down from condensercooling circuit- discharging heat, water with higher salt & chemical concentration added for treatment. Coal handling plant : coal dust & particulate matter. Concentrated brine from de salination plant.
8.1. ENVIRONMENTAL MANAGEMENT PLAN Installation of dust trapping arrangement through electrostatic precipitator with suitably designed stack for proper dispersal. Installation of tall chimneys for dispersion of toxic gases & particulate matter. It also reduces the heat pollution. Ash/ solid waste disposal : gainful use of ash in the making of cement & building industry shall be ensured. Besides 13o ha. Has been earmarked to disposal of flyash. Etp installation for treatment of effleunt generated within the plant. Total cost of pollution control measure : 81.45 cr & recurring cost : 3.55 cr.
Submitted by: .
24
9.0. TECHNICAL FEASIBILITY (Port) .1. HARBOUR PLANNING AND LAYOUT The harbour is proposed to be constructed along a bay/waterway spanning along N-E. The available water depth is of the order of 10m. The average width of the channel bounded by the 10m contour line is of the order of 400m. The length of the channel from the entry point up to the turning circle is of the order of 2000m The wind direction is predominantly western and most of the wind energy is concentrated within the band of 45deg. Between W and N-W. The mean tidal range is expected to be 2.7m and the mean lower tidal range is expected to Be 1.2m Average current of site will be of the order of 1.1knots to 1.3 knots which at high spring might attain a speed of 3 knots SIZE and SHAPE of HARBOUR and TURNING BASIN Location and width of entrance to harbour Number and orientation of location and docks Shore connectivity of marine terminal
Submitted by: .
25
2. HARBOUR LAYOUT AND COMPONENTS 3. SELECTION OF DOCK TYPE 4. BERTHING OF SHIP 5. MOORING OF SHIP 6. COAL UNLOADING AND CONVEYANCE 7. UTILITIES AND SERVICES 8. MAINTAINENCE OF BERTHING DOCK AND HARBOUR ZONE
9.1. PROCESS FLOW DIAGRAM AND POWER GENERATION (proposed)
Submitted by: .
26
10.0. CIVIL and STRUCTURAL ASPECTS 1. Plant Level The general grade of plant level of the plot is approximately 20m above MSL with a gentle Slope from North to South (The exact grade level will be decided on completion of site survey) By visual investigation, a single terraced level land of the power plant has been considered At an elevation of 20m above MSL. An average of 0.5m cutting/filling has been considered for grading
2. Soil Characteristics Soil investigation has not been done yet. Based on the soil characteristics of adjoining Area in raft/spread footings in foundation have been considered for major plant. Equipment and the project cost is estimated on basis of this available data
3.0 Seismic considerations The power station is located under Zone-IV as per IS: 1893, for which the basic horizontal Seismic co-efficient is 0.05. Analysis and design structures to resist the seismic forces are to be carried out as per the Provisions of IS: 1893 The applicable importance factors would be duly considered in the detail design
Submitted by: .
27
4.0. Wind Loading The maximum wind pressure including winds of short duration as specified in IS code No. 875-1987, for the zone where the power plant is located, will be adopted in design The site is located in the red zone as per above standard with wind speed of 50m/sec And the basic wind pressure for short duration is 150kg/sq.m. The basic wind pressure along with it variation with heights and with appropriate Coefficients for shape of the structures will be considered for design
Submitted by: .
28
10.1. Power House building superstructure The power house building superstructure will be in fabricated structural steelwork. All components will be of welded fabrication and the field connections will be with high-tensile bolts or welding as determined in designed stage The transverse frames will be of rigid type In the longitudinal direction these rigid transverse frame will be braced of to resist horizontal forces.
10.2. Civil works for Plant Water System Circulating cooling water system using cooling tower is considered for condenser as well As auxiliary cooling of the proposed station using sea water from the gulf of khambat The sea water intake structure will be located about 3.5kms south of plant size above HFL. The pump house forebay will be fed by a set of RCC submarine pipe laid on sea bed. The intake point would be 4/5m above sea bed level and 4/5m below MLLW to ensure receipt of comparative clean water The submarine pipe would be suitably covered with ballasts. The intake point of water in sea should be complete without marking buoys. The intake structure shall be of RCC construction and will house forebay sump chamber, a suitable sand trap, pump room and electrical room The Discharge line from intake pump house will be buried mild steel gunited line upto the plant The discharge line shall also have a pressurized flow in order to achieve a minimum velocity of 1.2m/sec to prevent marine growth. The discharge pipe shall have a diffuser system at the end.
Submitted by: .
29
10.3. Civil works for Coal Handling Plant Coal from the port will be transported by mean of conveyor This conveyor would be constructed owned and operated by the station Conveyor galleries, supporting trestles, superstructures of transfer houses shall be fabricated structural steelwork All components will be of welded fabrication with bolted/welded joints for erection and Assembly in the field Roofing will be of AC sheets. Intermediate floors in transfer houses will be reinforced concrete supported on structural steel framing Side cladding will be of AC sheets and necessary windows/louvers will be provided for natural lighting and ventilation
10.4. CONSTRUCTION FACILITIES AND GENERATING PLANT OPERATIONS 10.4.1 Construction of roads The proposed site is located near the SH-34. The road is proposed to be built connecting this highway to the plant site. This road access to the plot is shown in the following figure would form priority for taking up the project The nearest railway station heads namely at Rajula (14kms) and Pipavav port (140kms) are connected by meter gauge railway line of the western railways No provision has been kept for use of the railway system in the present project Plant machineries and equipment would be transported by sea and road
10.4.2 Construction of building About 2000 sq. m. of construction office space and 4000 sq. m. of covered storage is proposed to be provided In addition, open storage spaces, a small garage, yard, toilets etc. along with hostels and residential units for the staff
Submitted by: .
30
10.4.3 Construction water The maximum requirement of water is estimated at 80cum/hr for potable and service purposes. This may be created to by digging tube-wells and having an overhead steel tank during construction period
10.4.4 Construction power A GEB distribution is expected to be in operation at site before the beginning of site activities In case of delay in obtaining supply from GEB for construction power, arrangements for providing diesel generating sets of adequate size will be made
10.4.5 Construction Equipments A number of equipments namely bulldozer, road-roller, crawler and tyre-mounted cranes, tractor-trailors, winches, lifting-tackles etc. are proposed to be arranged by the project authorities. The above may be rented to the contractors as found necessary An ambulance and fire Bridget vans are made must to be available on the site all the time
10.4.6 Construction Materials Stone aggregates: Quarries for stone aggregates are available in adjacent areas not far from the power station site and the aggregate can be transported by road. Sand: Coarse to medium sand is available from the river bed within a radius of 15kms from the site and may be transported by road Bricks: There are number of brick manufacturing agencies in the nearby areas and hence there should not be any difficulty in getting sufficient quantity of bricks
Submitted by: .
31
11.0. PROJECT IMPLEMENTATION AND MONITORING
Submitted by: .
32
Some of the major packages such as coal handling, Ash Handling, Fuel oil handling system, Cooling towers etc. would be undertaken on a turnkey basis. The contractors would be entrusted with the design, engineering, manufacture, supply, erection, testing and commissioning for these packages. Experiences engineers will be deputed on site at every stage of progress right from excavation or finishing to ensure quality and accuracy or work
11.1. TESTING AND COMMISSIONING A testing and commissioning group including operation and maintenance personnel would be deputed for pre-commissioning checks and final commissioning of various plant and equipment. A commissioning network and procedure would be prepared jointly with all concerned which would guide the team for execution of commissioning activities. Proper documentation of the commissioning activities would be made for safety and orderly commissioning of the plant.
12.0. PROJECT MONITORING CO-ORDINATION AND CONTROL 12.1. PROJECT MONITORING INFORMATION SYSTEM: Progress of each activity at every stage would be physically monitored by respective supervising engineers.
Submitted by: .
33
All detailed information would be passed on to the central monitoring cell to keep track of the work progress. Similarly, costing of individual items would be monitored and recorded preferably with the help of software. Central monitoring cell would monitor the progress and report to the senior executives for information and necessary actions
12.2. CO-ORDINATION Regular meetings would be held at the site amongst representatives of the contractors, consultants and engineers of the respective depts. Accordingly identification of progress, corrective measure if any, material constraints etc. would be done, sorted out and leveled up
12.3 REPORTING Various reports would be generated in regard to the physical and financial progress of the project on monthly, quarterly and yearly basis for forwarding to the various Government Departments. Financial institutions as well as for the internal use Daily progress report of the major items of work, along with their monthly targets, would be reported to the project head.
12.4. FINANCIAL CONTROL Actual cost records would be regularly monitored against forecasts which would be forwarded to Finance department by the project department on monthly, half-yearly and yearly basis, depending on the actual progress of delivery and erection/construction.
Submitted by: .
34
13.0. FINANCIAL FEASIBILITY and ASPECTS Foreign loans of the order of 50% of the loan amount of the project cost attract an overall Interest rate of 12.6% per annum and Indian currency load of equivalent amount will attract Interest @ 18.5% Interest during the construction will be capitalized Equity to be raised from promoters, contribution /public issue/right issues etc. Debt to be sourced from All India financial institutions and overseas sources Total borrowing from the AIFI not to exceed to 40% of the project cost The rate of interest on working capital load would be 18.5% p.a. Terms of repayment of loan with 10th operating years with no moratorium Price of coal would be Rs. 1683.03/MT. Cost of fuel has been estimated by considering a station heat rate of 2500kCAL/kWh and designed GCV of fuel as 6720Kcal/kg The delivered cost of fuel oil would be Rs. 7000/KL Working capital to be estimated as per guidelines of CEA The plant load factor to be 68.49%. The annual working hours to be 6000 hours The auxiliary consumption to be 8% & M cost expenses to be @ 2.5% Depreciation would be provided @ 7.84% as per guidelines of CEA for estimation of book profit and as per WDV method of calculating tax liability Project Cost Preliminary investigation Land Civil works Mechanical works Electrical works Preliminary capital issues expenses Overhead works construction cost Contingencies Total Amount (Million) 2.0 2.0 527.1 737 420 260 877 39.1 1463.20
Submitted by: .
35
13.1. Estimation cost of generation: Estimation cost of generation and interest during construction period Project Cost Preliminary investigation Land Civil works Mechanical works Electrical works Instrumentation Preliminary and capital issues expenses Other works cost, construction, management etc. Contingencies Capital Expenses (Power Plant) Capital Expenses (Port facilities) Overall project cost Amount (Million) 15 119.90 3018.80 23675.05 1915.50 585.60 620.00 1916.50 1466.40 33332.80 1463.20 34796.00
13.2. MEANS OF FINANCING

Source Equity Forex loan Rupee loan Project cost Total equity Total debt Debt equity ratio Amount 12240.00 14777.28 15190.99 42208.28 12240.00 29968.28 2.33:1 Share of project cost 29% 35% 36% 100% 29% 71% -
Submitted by: .
36
14.0. CONCLUSION The site selected for construction of a dedicated berth inside the proposed Pipavav Pot harbour zone satisfies all the requirements. However, capital dredging and subsequent maintenance dredging have to be undertaken to cater the need for the design vessel. Since the desired depth of natural water level is not sufficient. The harbour may not be available for all weather operations. Amenities such as electricity and water supply are important challenges to be met prior to the construction phase. Inspite of these issues the GPPL has shown green signal for this project and agreed to accommodate the above requirements.
Submitted by: .
37
15.0. REFERENCE 1. GPCL Gujarat Power Corporation Ltd., Ahmedabad, Gujarat. 2. GEB Gujarat Electricity Board 3. Development Consultants Ltd., Ahmedabad, Gujarat. 4. GPCB - Gujarat Pollution Control Board, Gandhinagar. 5. GIDB Gujarat Infrastructure Development Board
Submitted by: .

Thermal Power Plant (9,11,12)

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

Thermal Power Plant (9,11,12)

Caricato da

Copyright:

Formati disponibili

Project Management I

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Typical diagram of a coal-fired thermal power station

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

6.2. SECTOR-WISE TREND OF POWER CONSUMPTION / DEMAND

Report on Feasibility study of Thermal Power Plant (Coal based)

1994-95 1996-97 1998-99 2000-01

6190 6390 7408 8407

4810 5487 6258 7125

3616 4303 4757 5376

1326 2183 2372 2726

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Sea water shall be used in proposed desalination plant (2 x 1.5 mgd)

Report on Feasibility study of Thermal Power Plant (Coal based)

1. NEAR MUNDRA 2. NEAR VERAVAL 3. NEAR PIPAVAV

*- comparison of salient features of three sites is given in following table

Report on Feasibility study of Thermal Power Plant (Coal based)

7.7. COMPARISON FOR SITE SELECTION FOR PROPOSED PLANT

Equipment unloading point

Coal conveyor length to site

Nearest intake location for sea water

Source of sweet water

Nearest forest boundary

Jetpur reserve forest : 2 km

Private land marginally cultivated.

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

9.1. PROCESS FLOW DIAGRAM AND POWER GENERATION (proposed)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

11.0. PROJECT IMPLEMENTATION AND MONITORING

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

13.2. MEANS OF FINANCING

Report on Feasibility study of Thermal Power Plant (Coal based)

Report on Feasibility study of Thermal Power Plant (Coal based)

Potrebbero piacerti anche