2014 4 02 Apr 2014 1456559071FORM 1 ARS

Augmentation from 60 MW to 180 MW & Proposed Additional 300 MW
FORM 1
APPLICATION FORM
I Basic Information
Sl. No. Item Details
1. Name of the Project : ARS Metals Private Limited.
Coal Based Thermal Power Plant - Proposed
Augmentation/Expansion
2. S. No. in the schedule : 1 (d) – Category > 500 MW Coal based Power
Plant.
3. Proposed capacity / area/length/ : Existing Proposed Change /
tonnage to be handled /command Environmental Expansion
area/ lease area / number of wells Clearance
to be drilled 1 x 60 MW (Operating)
2 x 60 MW 1x60 MW Augmentation to
1x 180 MW
4. New/Expansion/Modernization : 1 x 300 MW (Additional)
5. Existing Capacity / Area etc. : Existing Land Proposed Additional
60 Acres 50 Acres
6. Category of Project ie. “A” or “B” : Category “A”
7. Does it attract the general : Yes, Tamil Nadu / Andhra Pradesh state
condition? If yes, please specify. boundary within 10 km radius.
8. Does it attract the specific : No.

condition? If yes, please specify.
9. Location
Plot/Survey/Khasra No. : Total Land Area : 110 Acres
S. Nos. _____________.
Village : Sithurnatham, Sirupuzhalpettai &
Eguvarpalayam
Tehsil : Gummidipoondi
District : Thiruvallur
State : Tamil Nadu
10. Nearest railway station/airport : Railway Station - Gummidipoondi – 5.2 km
alongwith distance in kms. Airport - Chennai- 53 km
11. Nearest Town, City, District : Town - Gummidipoondi - 6.1 km

Headquarters alongwith distance in District Headquarters – Thiruvallur – 39 km
kms.
Form 1 1 ARS, Gummidipoondi

12. Village Panchayats, Zilla Parishad, : Gummidipoondi

Municipal Corporation, Local Body
(complete postal addresses with
telephone nos. to be given).
13. Name of the applicant : ARS Metals Private Limited
14. Registered Address : D-109, 2nd Floor, LBR complex,

Annanagar (E). Chennai- 600102.
15. Address for correspondence : D-109, 2nd Floor, LBR complex,

Name : Rajesh Bhatia

Designation (Owner/Partner/CEO) : Director
Address D-109, 2nd Floor, LBR complex,
Annanagar (E). Chennai.
Pin Code 600 102.
E-mail rajesh@arsmetals.com
Telephone No. 044-43500687
Fax No. 044-43500597
16. Details of Alternative Sites : Not Applicable.
examined, if any. Proposed Expansion
Location of these sites should be
shown on a toposheet.
17. Interlined Projects : -
18. Whether separate application of : -
interlined project has been
submitted
19. If yes, date of submission : -
20. If no, reason : -
21. Whether the proposal involves : No

approval/clearance under:
(a) The Forest (Conservation) Act, 1980
(b) The Wildlife (Protection) Act,
1972
(c) The C.R.Z Notification, 1991
22. Whether there is any Government : No

Order / Policy relevant / relating to
the site?
23. Forest land involved (hectares) : No

24. Whether there is any litigation : Nil

pending against the project and / or
land in which the project is
proposed to be set up
(a) Name of the Court
(b) Case No.
(c) Orders/directions of the Court, if
any and its relevance with the
proposed project.
II Activity
1. Construction, operation or decommissioning of the Project involving actions,
which will cause physical changes in the locality (topography, land use,
changes in water bodies, etc.)
S. No. Information/Checklist Yes/No Details thereof (with approximate

confirmation quantities /rates, wherever possible)
with source of information data
1.1 Permanent or temporary No • Environmental Clearance
change in land use, land cover obtained for 2 x 60 MW.
or topography including • Of which 1 x 60 MW is under
increase in intensity of land use operation.
(with respect to local land use • The other 1 x 60 MW
plan) construction of which is yet to
start and is now proposed to
augment this capacity to 180
MW
• An additional 300 MW is also
proposed.
Copy of Environmental Clearance, &
Consent to Establish is enclosed in
Annexure I & Annexure II.
Hence, No Change in Land Use, Land
Cover or Topography.
1.2 Clearance of existing land, No -
vegetation and buildings?
1.3 Creation of new land uses? No -
1.4 Pre-construction investigations Yes Please refer Annexure-III
e.g. bore houses, soil testing?
1.5 Construction works? Yes Additional construction of shop floors etc
will be predominantly of steel structure.
1.6 Demolition works? No -
1.7 Temporary sites used for Yes There are a total of 40 – sheds constructed
construction works or housing with Brick Walls and Asbestos roofs with
of construction workers? facility for sanitation, bathing and also a
canteen facility.
The workers Quarters is also provided

with drinking water.

About 300 workers reside at site.

1.8 Above ground buildings, Yes Layout enclosed.
structures or earthworks
including linear structures, cut Please refer Annexure-IV
and fill or excavations.
1.9 Underground works including No -
mining or tunneling?
1.10 Reclamation works? No -
1.11 Dredging? No -
1.12 Offshore structures? No -
1.13 Production and manufacturing Yes Please refer Annexure – V
processes?
1.14 Facilities for storage of goods or Yes Please refer Annexure – IV
materials?
1.15 Facilities for treatment or Yes -
disposal of solid waste or liquid
effluents?
1.16 Facilities for long term housing No -
of operational workers?
1.17 New road, rail or sea traffic Yes Increase in no. of trucks resulting in
during construction or increased traffic.
operation? The present movement of coal is by road.
1.18 New road, rail, air waterborne Yes However, New rail route for
or other transport infrastructure transportation of coal from
including new or altered routes Gummidipoondi to Site is under process
and stations, ports, airports etc? wherein in principle approval has been
obtained.
1.19 Closure or diversion of existing No --
transport routes or
infrastructure leading to
changes in traffic movements?
1.20 New or diverted transmission Yes The proposed evacuation will be from
lines or pipelines? Thervoikandigai, which is 7 kms from site
and hence a new transmission line will be
erected.

1.21 Impoundment, damming, No -

culverting, realignment or other
changes to the hydrology of
watercourses or aquifers?
1.22 Stream crossings? Yes Arani River, which is 8.0 km in South
from the Plant Site.
1.23 Abstraction or transfers of Yes Water Consumption in KLD
water from ground or surface Existing For
waters? 1 x 60 MW 180 MW & 300 MW
48 250
• A Rain Water Reservoir constructed
for harvesting rainwater through
storm water drains.
• Capacity of reservoir is 70000 m³.
• Additional rain water reservoir
proposed to be constructed.
• However, Ground Water Clearance
has also been obtained for drawl upto
800 KLD. Copy of which is enclosed
in Annexure – VI.
1.24 Changes in water bodies or the No Proposed Expansion /Augmentation
land surface affecting drainage within/adjacent to the existing plant site.
or run-off? Enclosed is Drainage & Water bodies
Map in Annexure – VII.
1.25 Transport of personnel or Yes The existing transport facilities will be
materials for construction, made use of.
operation or decommissioning?
1.26 Long-term dismantling or No -
decommissioning or restoration
works?
1.27 Ongoing activity during No -
decommissioning which could
have an impact on the
environment?
1.28 Influx of people to an area in Yes About 200-Nos of workers will be
either temporarily or employed upon implementation of
permanently? expansion activity.
1.29 Introduction of alien species? No -
1.30 Loss of native species or genetic No -
diversity?
1.31 Any other actions? - -

2. Use of Natural resources for construction or operation of the Project (such as

land, water, materials or energy, especially any resources which are non-
renewable or in short supply):

2.1 Land especially undeveloped or No Proposed expansion / augmentation
agricultural land (ha) within/adjacent to the existing plant site.
2.2 Water (expected source & Yes • A Rain Water Reservoir constructed
competing users) unit: KLD for harvesting rainwater through
storm water drains.
• Capacity of reservoir is 70000 m³.
• Additional rain water reservoir
proposed to be constructed.
• However, Ground Water Clearance
has also been obtained for drawl upto
800 KLD. Copy of which is enclosed
in Annexure – VI.
Water Consumption in KLD
Existing For 180 MW & 300 MW Upon
1 x 60 MW Expansion
48 250 298
2.3 Minerals (MT) Yes Coal

Existing Proposed Proposed Upon
1x60MW 180 MW 300 MW Expansion
1000T/D 2571T/D 4107T/D 7678T/D
2.4 Construction material - stone, Yes Predominantly Steel Structures.

aggregates, sand / soil (expected
source – MT)
2.5 Forests and timber (source – MT) No -
2.6 Energy including electricity and Yes Auxiliary Power Requirement of the
fuels Plant will be met from its own generation.
(source, competing users) Unit:
fuel (MT), energy (MW)
2.7 Any other natural resources (use No -
appropriate standard units)

3. Use, storage, transport, handling or production of substances or materials,

which could be harmful to human health or the environment or raise concerns
about actual or perceived risks to human health.

3.1 Use of substances or materials, None This is a coal based power plant and hence
which are hazardous (as per does not include any chemicals listed in
MSIHC rules) to human health MSIHC rules.
or the environment (flora, fauna,
and water supplies)
3.2 Changes in occurrence of disease None -
or affect disease vectors (e.g.
insect or water borne diseases)
3.3 Affect the welfare of people e.g. Yes Betterment in the socio – economic
by changing living conditions? conditions of the areas surrounding the
plant site and improved availability of
power. General improvement in standard
of living.
3.4 Vulnerable groups of people None -
who could be affected by the
project e.g. hospital patients,
children, the elderly etc.,
3.5 Any other causes No -
4. Production of solid wastes during construction or operation or decommissioning

(MT/month)
S. No. Information/Checklist Yes/No Details thereof (with

confirmation approximate quantities /rates,
wherever possible) with source
of information data
4.1 Spoil, overburden or mine wastes No -
4.2 Municipal waste (domestic and or No -
commercial wastes)
4.3 Hazardous wastes (as per No -
Hazardous Waste Management
Rules)
4.4 Other industrial process wastes Yes The solid waste will be in the form of
Fly Ash & Bottom Ash.
Existing Proposed Proposed Upon
60MW 180MW 300MW Expansion
50T/D 155T/D 246.42T/D 451.42 T/D
4.5 Surplus product No -
4.6 Sewage sludge or other sludge Yes Dried Sewage Sludge from Filter
from effluent treatment Press of STP – 0.2 T/M

4.7 Construction or demolition wastes No -

4.8 Redundant machinery or No -
equipment
4.9 Contaminated soils or other No -
materials
4.10 Agricultural wastes No -
4.11 Other solid wastes - -
5. Release of pollutants or any hazardous, toxic or noxious substances to air

(Kg/hr)
S. No. Information/Checklist confirmation Yes/No Details thereof (with

approximate quantities /rates,
of information data
5.1 Emissions from combustion of fossil Yes Please refer Annexure – VIII
fuels from stationary or mobile
sources
5.2 Emissions from production Yes Please refer Annexure – VIII
processes
5.3 Emissions from materials handling Yes Please refer Annexure IX
including storage or transport
5.4 Emissions from construction Yes Emission from diesel operated
activities including plant and pumps, concrete mixers, vibrators
equipment and excavators. However these
equipments will be maintained
properly to ensure minimum
emissions, more-over construction
activity will be for a short duration
of period.
5.5 Dust or odours from handling of Yes This is a coal based power plant and
materials including construction hence will not have any odour
materials, sewage and waste nuisance, however dust suppression
by way of sprinklers etc., is
proposed as in Annexure – IX.
5.6 Emissions from incineration of waste No -
5.7 Emissions from burning of waste in No -
open air (e.g. slash materials,
construction debris)
5.8 Emissions from any other sources - -

6. Generation of Noise and Vibration, and Emissions of Light and Heat
S. No. Information/Checklist Yes/No Details thereof (with

confirmation approximate quantities /rates,
of information data
6.1 From operation of equipment e.g. Yes The main sources of noise in the
engines, ventilation plant, crushers Thermal Power Plant are noise
generated by the Turbine[93
dB(A)], Fans [85 dB(A)], Pumps
[90 dB(A)], Generators[70 dB(A)]
etc and loading/ unloading
activities of different power plant
processes for producing power and
all the noise generated will be
within the stipulations of the
OSHA standards.
6.2 From industrial or similar processes Yes Same as above.
6.3 From construction or demolition Yes During construction, operation of
construction equipments will result
in intermittent noise.
6.4 From blasting or piling No -
6.5 From construction or operational Yes Noise due to movement of trucks
traffic carrying raw materials/products.
6.6 From lighting or cooling systems No -
6.7 From any other sources - -
7. Risks of contamination of land or water from releases of pollutants into the

ground or into sewers, surface waters, groundwater, coastal waters or the sea
S.No. Information/Checklist Yes/No Details thereof (with approximate

7.1 From handling, storage, use No There are no hazardous materials used or
or spillage of hazardous generated.
materials
7.2 From discharge of sewage No
Waste Water Generation in KLD
or other effluents to water
Existing For Upon
or the land (expected mode 1 x 60 MW 180 MW Expansion
and place of discharge) & 300
MW
Boiler Blow Down 35 190 225
D.M. Plant 6 42 48
Regeneration Waste
Domestic Sewage 4.8 6.4 11.2
• Boiler Blowdown & DM. Plant

regeneration waste water is at present
treated in 2-stage RO Plant.
Upon Expansion,
• Daily water requirement will be 68 KLD.

• About 273 KLD will be recycled.

• Boiler Blow down & DM Plant
Regeneration Waste Water from
proposed Augmentation/ Expansion will
also be treated in 2-stage RO Plant.
• 230 KLD is used for boiler make-up
/D.M Plant and 43 KLD used for Ash
Quenching/ Coal Dust Suppression/
Greenbelt.
• Domestic Sewage is treated in Sewage
Treatment Plant & used for greenbelt.
Hence, resulting in Zero Discharge
7.3 By deposition of pollutants Yes Main fuel is Coal. The source of emission is
emitted to air into the land burning of fuel. These operations are provided
or into water with adequate height of stacks, ESP with
99.99% efficiency, Optimum air fuel ratio to
limit excess air for control of NOx emission,
Low sulphur and low ash content fuel,
greenbelt development etc. These measures to
have least impact on the ambient
environment, the details of various air
pollution control equipments are given in
Annexure X. Stack characteristics are given
in Annexure VIII.
7.4 From any other sources No -
7.5 Is there a risk of long term No -
build up of pollutants in the
environment from these
sources?
8. Risk of accidents during construction or operation of the Project, which could

affect human health or the environment
S.No. Information/Checklist confirmation Yes/No Details thereof (with

approximate quantities /rates,
of information data
8.1 From explosions, spillages, fires etc Yes HSD/FO used for start-up, which
from storage, handling, use or will be subject to requirements as
production of hazardous substances per Indian Explosive Act, HAZOP
Studies & Risk Assessment.
8.2 From any other causes Yes Details Enclosed in Annexure XI
8.3 Could the project be affected by Yes -
natural disasters causing environ-
mental damage (e.g. floods, earth-
quakes, landslides, cloudburst etc)?

9. Factors which should be considered (such as consequential development)

which could lead to environmental effects or the potential for cumulative
impacts with other existing or planned activities in the locality
S.No. Information/Checklist confirmation Yes/No Details thereof (with

approximate quantities / rates,
of information data
9.1 Lead to development of supporting Yes This is an existing operation, and
utilities, ancillary development or area is already well developed with
development stimulated by the supporting infrastructures, services
project which could have impact on etc.
the environment e.g.:
• Supporting infrastructure (roads, • Increase in local commerce.
power supply, waste or waste water • Increase in Ancillary
treatment, etc.) Services.
• housing development • Increased requirement for
• extractive industries housing etc.
• supply industries
• other
9.2 Lead to after-use of the site, which No -
could have an impact on the
environment
9.3 Set a precedent for later Yes Use of finfan coolers for Auxiliary
developments Cooling System.
100% utilization of Fly ash.
9.4 Have cumulative effects due to Yes -
proximity to other existing or
planned projects with similar effects
III Environmental Sensitivity
S.No. Areas Name/ Aerial distance (within 15

Identity Km.) Proposed project
location boundary
1. Areas protected under international Yes Pulicat Lake – 14 kms
conventions, national or local legislation
for their ecological, landscape, cultural
or other related value
2. Areas which are important or sensitive Yes Pulicat Lake – 14 kms
for ecological reasons - Wetlands,
watercourses or other water bodies,
coastal zone, biospheres, mountains,
forests
3. Areas used by protected, important or Yes Pulicat Lake – 14 kms
sensitive species of flora or fauna for
breeding, nesting, foraging, resting, over
wintering, migration

4. Inland, coastal, marine or underground Yes Araniyar River – 8.0 kms

waters
5. State, National boundaries Yes Tamil Nadu-Andhra Pradesh
border, which is 5.0 kms away in
North.
6. Routes or facilities used by the public Yes NH-5 - 5.2 Km - East
for access to recreation or other tourist, SH-52 – 3.5 Km – SW
pilgrim areas Southern Railway – 6.0 km East
7. Defense installations None -
8. Densely populated or built-up area None -
9. Areas occupied by sensitive man-made Yes Please refer Annexure –XII
land uses (hospitals, schools, places of
worship, community facilities)
10. Areas containing important, high Yes Palavakkam RF – 5.5 kms
quality or scarce resources (ground water Araniyar – 8.0 kms
resources, surface resources,
forestry, agriculture, fisheries, tourism,
minerals)
11. Areas already subjected to pollution or None -
environmental damage. (those where
existing legal environmental standards are
exceeded)
12. Areas susceptible to natural hazard None -
which could cause the project to present
environmental problems
(earthquakes, subsidence, landslides,
erosion, flooding or extreme or adverse
climatic conditions)
IV Proposed Terms of Reference for This application is requesting for

EIA studies Amendment
“I hereby given undertaking that the data and information given in the application and
enclosures are true to the best of my knowledge and belief and I am aware that if any
part of the data and information submitted is found to be false or misleading at any
stage, the project will be rejected and clearance give, if any to the project will be revoked
at our risk and cost”.
For ARS Metals Pvt. Ltd.,
Date : 13/02/2014
Place : Chennai
Rajesh Bhatia,
Director.
ARS Metals Pvt. Ltd.
D-109, 2nd Floor, LBR complex,
Signature of the applicant

With Name and Full Address
(Project Proponent / Authorised Signatory)

List of Annexures
Annexure I Copy of Environmental Clearance
Annexure II Copy of Consent to Establishment
Annexure III Soil Investigation Report
Annexure IV Plant Layout
Annexure V Process Description
Annexure VI Copy of CGWA Clearance &

Water Balance Diagram
Annexure VII Drainage and Water Bodies Map
Annexure VIII Stack Emission Characteristics
Annexure IX Fugitive Emission Control
Annexure X Air Pollution Control
Annexure XI On-site & Off-site Emergency Plan
Annexure XII Administrative Set-up Map
Annexure 13 ARS, Gummidipoondi

ANNEXURE – I
COPY OF ENVIRONMENTAL CLEARANCE









ANNEXURE – II
COPY OF CONSENT TO ESTABLISHMENT

Consent to Establish












ANNEXURE – III
SOIL INVESTIGATION REPORT

PARAMETER LOCATION : POWER PLANT SITE REMARKS

NW SIDE SW SIDE
pH 7.5 7.2 Normal
EC MS/Cm 0.15 0.13 Normal
Available N (Kg/Acre) 63 60 Low
Available P205 (Kg/Acre) 7 6 Low
Available K20 (Kg/Acre) 60 55 Medium
Physical Characteristics
Colour Red Red -
Drainage Good Good -
Soil Texture Loamy sand Loamy sand -
Clay % 10 11 -
Silt % 7 6 -
Sand % 83 85 -
Organic Carbon % 0.14 0.15 Very Low
Organic Matter % 0.31 0.28 Very Low
Micronutrient Status
Copper PPM 2.7 2.5 High
Manganese PPM 8.6 8.8 High
Zinc PPM 0.84 0.86 High
Iron PPM 13.8 13.5 High

ANNEXURE – IV
PLANT LAYOUT

Plant Layout

ANNEXURE – V
PROCESS DESCRIPTION

Process Description
The details of equipments are as follows
1 Boiler 1 x 235.13 TPH (Existing 1 x 60 MW)

1 x 563 TPH (from 60 MW to 180 MW)
1 x 950 TPH (Proposed 300 MW)
CFBC/Pulverized Coal fired, natural
circulation boilers.
2 Steam Turbine 1 x 60 MW, 1 x 180 MW & 1 x 300 MW
condensing Steam Turbine.
3 Electrical Generator There will three generator with rated 60
MW, 11KV, 50 Hz, 3 ph and 0.8 PF
180MW,
300MW,
4 Coal Handling Ground hoppers, stacker reclaimers and

double stream conveying system.
5 Electro-Static Precipitator 6 Stage ESPs for each Boiler
6 Ash Handling Dry Ash Collection
7 Condenser Air Cooled Condenser
8 Auxiliary Cooling System Finfan coolers for cooling of turbine,
generator and boiler auxiliaries
9 Chimney Single chimey of 145 m height for 60 MW
& 180 MW & 132 m height for 300 MW
10 HFO/LDO Storage Tanks 2 x 300 KL HFO tanks and 2 x 150 kL LDO
tanks
11 Switchyard, Generator 230 KV System
Transformer and Station
Transformer
The power plant would use coal as fuel in its boilers. The plant would consist of
235.13 TPH (Existing), 593 TPH & 950 TPH (Proposed) CFBC/pulverized Coal
fired natural circulation boiler producing superheated steam at 93 Kg/cm2 and at
540ºC together with associated auxiliaries.
The steam turbine unit consists of 540 MW (Gross) [60 MW Existing, 180 MW &
300 MW Proposed] condensing steam turbine generator together with Air cooled
condenser and associated auxiliaries. Based on average gross calorific value of
coal as 4000 Kcal/kg, the plant would require about 7678 TPD of Imported Coal,

The steam generators of the proposed Thermal Power Plant will be of

CFBC/pulverized fuel firing with Imported coal. The steam generator will
consist of Air cooled furnace, radiant, convection super heaters, economizer, air
pre heaters etc. Soot blowers will be provided at strategic locations and will be
designed for sequential fully automatic operation from the Unit Control Room.
The steam generator will be provided with coal mills along with individual raw
coal feeders and coal bunkers. The steam generators will be equipped with
facilities for Heavy Furnace Oil / LDO firing for start-up and for flame
stabilization at low loads. Electrostatic precipitator (ESP) with fly ash hoppers
will be provided for the collection of fly ash. The steam turbine will drive the
turbo generator at 3000 rpm. The steam generators will be designed as semi –
outdoor equipment while the turbine generator set with all auxiliary and feed
cycle equipment will be located indoors. The Figure below shows the simplified
process flow diagram of the proposed Thermal power plant.

Proposed Flow Diagram of Thermal Power Plant
COAL
WATER
POWER
MILL
BOILER TURBINE GENERATOR
ESP
AIR COOLED
CONDENSOR
SILO
CHIMNEY SALE /
DISPOSAL

Furnace
The furnace will be designed such that the heat release rates will be optimum at
100% steam generator maximum continuous rating (SGMCR) condition. The
configuration of the furnace will be such that flame impingement on any section
of the furnace is avoided over the entire load range.
The furnace will have hopper bottom with stainless steel seal plates which will be
suitable for connection to a water impounded ash hopper. A suitable sealing
arrangement for connecting to the water impounded ash hopper will also be
provided.
The circulation system will ensure adequate circulation ratio during rapid start-
ups and load changes to prevent overheating of the water wall tubes with
maximum possible heat flux in the furnace. Suitable allowances will be provided
for all the water wall tubes to counter the erosion conditions.
Boiler
The boiler will be CFBC/pulverized coal fired, single drum, with membrane wall
construction, balanced draft boiler natural circulation semi outdoor type.
Superheat of the steam is controlled by inter-stage spray water attemperation.
The final superheated steam at a pressure of 93 Kg/cm2 and at 540ºC is supplied

to steam turbine unit through HP steam piping.
Steam Turbine Generator
The steam turbine will be designed to meet the requirements of the latest IEC
standard. It will be designed for quick start-up rates and to withstand rapid load

fluctuations without causing undue thermal stresses and strains in the

components of steam turbine. Suitable rotor and casing heating devices to meet
this requirement if required will be provided. Steam turbine will be provided
with aesthetic and acoustic enclosure. The Steam Turbine will have the following
systems for its optimum performance and safe operation;
• Steam admission valves

• Turning gear
• Steam turbine gland steam sealing system
• Steam turbine lubricating system
• Oil coolers
• Steam turbine governing system and accessory equipment
• Emergency over speed trip device
• Steam turbine protection system
• Initial pressure regulator
• Protection against water induction and over speeding
• Exhaust temperature limiting equipment
• Pressure relief diaphragms
• Vacuum breaker valves
• Steam turbine supervisory equipment
• Automatic Turbine Run-up System (ATRS)
• Steam Turbine By-pass System
• Air cooled Condensor
• Condensate Extraction Pumps and Accessories
• Closed Feed Water Heaters and Accessories
• Boiler Feed Pumps

ANNEXURE – VI
GROUND WATER CLEARANCE
&
WATER BALANCE DIAGARA


WATER BALANCE
All Values are in KLD
36 Boiler Make-up 35
1 x 60 MW
Ground Water
/Rain Water
Reservoir 200 Boiler Make-up 190
1 x 180 MW &
68 1 x 300 MW 225
Raw
Cooling Pond I
Water 298
Cooling Pond II
225
230
6 DM PLANT 6
1 x 60 MW
48 Neutralization
Pit
42 DM PLANT 42
1 x 180 MW & 273
1 x 300 MW
Guard Pond
6 Domestic Consumption 4.8
1 x 60 MW
STP
1 x 180 MW &
1 x 300 MW Greenbelt
230 RO Plant
43
Ash Quenching/
Coal Dust Suppression/ 43 RO
REJECT
Greenbelt

ANNEXURE – VII
DRAINAGE & WATER BODIES MAP


ANNEXURE – VIII
STACK EMISSION CHARACTERISTICS

Stack Emission Characteristics
Stack No 1 1
Material of Construction RCC RCC
Stack attached to 1 x 60 MW & 1 x 300 MW
1 x 180 MW
Stack height (m) 145 132
Stack diameter (mm) approx.. 5250 6000
Volume Flow Rate (m3/s) 475.45 593.74
Velocity of flue gas (m/s) 22.0 21.0
Temperature of flue gas (°C) 140 140
Flue gas specific volume ( kg / Nm³) 1.3 1.3
Fuel Consumption (Kg/s) 42.71 47.92
Sulphur content (% w/w) 0.5 0.5
Emission rate – NOx (g/s) 384.38 427.81
Emission rate – SO2 (g/s) 427.08 475.35
Emission rate – SPM (g/s) 21.5 29.69
Existing Stack - 145 m (60 MW & 180 MW)
Stack Height Calculation for 1 x 300 MW
The daily consumption of coal is around 4107 Tonnes

The rate of SO2 emission due to usage of coal is calculated as given below
Sulphur content = 0.5%
S = (4107 x 0.5/100) = 20.535 T/D
SO2 = 20.535 x 2 T/D
= 41.07 T/D = 1711.25 kg/hr
SO2 emission = 1711.25 kg/hr = 475.35 g/s
Stack height calculation:
H = 14 Q0.3
Where,
H = height of the Stack
Q = SO2 Concentration in Kg/hr.
Hence
H = 14 x (1711.25)0.3 = 14 x 9.332 = 130.65 m
The stack height proposed is 132 meters.

ANNEXURE – IX
FUGITIVE EMISSIONS CONTROL
&
ANNEXURE – X
AIR POLLUTION CONTROL

Fugitive Emissions
To control fugitive emissions from process units in the plant, the following
measures are already in place.
• Tarring of roads inside the factory.
• Preventive maintenance of valves and other equipments.
• Green belt on all sides within the project boundary, and community
plantation around the unit with help of local area development authorities
have already been done.
• Ambient air quality and stack/fugitive emissions monitored regularly.
• In-plant training provided to the plant personnel on operation and
maintenance of dust collectors, techniques of dust emission measurements,
particle size analysis etc.
• Effective operation and maintenance of pollution control system is ensured to
contain the emissions/keep them within the CPCB limits
• A good house keeping consisting of simple, obvious task of cleaning up spills,
removing accumulations around processing equipment and in general
keeping things neat and clean form a part of normal operation and
maintenance procedure
Measures for arresting fugitive dust emissions along with the envisaged
pollution control equipments are adequate and will help to have a healthy and
cleaner environment inside the plant thereby improve the productivity and the
efficiency of the workers as well as that of plant machinery.

Air Pollution Control Devices
The following environmental protection or pollution control systems have

already been considered for mitigation of impacts on Air Environment.
• 145 m & 132 m tall stacks for flue gas emission.

• Space provision for retrofitting FGD (Flue Gas Desulfurization) systems.
• High efficiency ESPs to reduce SPM level in the exhaust gas to
<50mg/Nm³.
• Dust suppression and extraction system at Handling Plant area to Control
Fugitive Emission.
• Green belt development and afforestation in the plant and ash disposal
areas.
• A minimum water depth will be maintained in the ash pond to prevent
fugitive dust emission.
• Use of bag filters at all transfer points.
• Use of limestone to limit SO2 emission.
High efficiency Electrostatic Precipitator of 99.9% are provided for limiting SPM
concentration in the flue gas to less than 50 mg/Nm³. The tall stack of 145 m &
132 m height based on maximum SO2 concentration in the flue gas is provided
for natural dispersion at high elevation so that ground level concentration are
within acceptable limits.
The emission of NOX, is reduced by burning fuel at a lower temperature and

shortening the throughput time of the fuel. NOX is also controlled by operating at
low excess air.

Coal Handling and Feeding System
Coal is received in Trucks and unloaded using Truck tipplers. The coal handling system
is capable of handling coal at the rate of 200 tonnes/hr from tippler to coal stockyard in
single streams of conveyors. The coal handling system beyond coal stockyard is of single
streams of conveyors, which has a capacity of 200 tonnes/hr. It is designed considering
that coal of maximum 200 mm size can be received at the site. Therefore, single stage
crushing is employed to crush the coal to a size of 25 mm as feed to the mills of steam
generators.
Reclaiming, Crushing and Bunker Feeding System
Coal from the stock yard will be reclaimed on to the reclaim conveyor using Reclaimers.
coal will be conveyed to the boiler bunkers.
Ash Handling System
The fly ash collected at the air preheater hoppers, economiser hoppers, ESP hoppers and
stack hopper shall be gravity fed into individual transmitter vessels provided below
each hopper. On initiation of dry fly ash collection system, the inlet valve shall open
and allow the fly ash to be fed into the transmitter vessel for pre-determined time after
which the inlet valve shall close. Afterwards, the compressed air shall be allowed to
flow into the transmitter vessel by opening the air inlet valve. Once the desired
conveying pressure is reached inside the vessel, the fly ash shall be conveyed to the fly
ash storage silo through transport piping. The hoppers are connected to a common
conveying line along the gas path for the easy clearing. The clearance from any hopper
shall continue cycle after cycle till ash in the hopper reaches to low level. Removal of fly
ash from any particular hopper shall be initiated whenever the level of ash in that
hopper reaches predetermined level. This level is fixed in such a way that the volume of
ash collected will be adequate for conveying in one cycle. Thus in this system, the fly
ash hoppers are always kept empty. Therefore the removal and conveying of fly ash to
the fly ash silo shall be done in cyclic manner on a continuous basis. The dry fly ash
collected in storage silo will be disposed into closed containers through

conditioner/retractable chute in dry form for utilization in nearby cement plants. Fly
ash silo and disposal equipment are common for both the units.
Two reciprocating compressors, one standby, one operating for two units during normal
operation and both operating for both units during rapid evacuation will be provided to
meet the conveying air requirements of fly ash handling system of 540 MW power plant.
Ash handling system equipment will be designed considering maximum ash content of
45%. The ash handling system proposed envisages scraper chain conveyor system for
bottom ash disposal from steam generator and pneumatic type system for fly ash
removal from ESP, economizer and air pre-heater hoppers. Dry collection of fly ash and
bottom ash in separate ash silos has been planned. Fly ash to the maximum extent
possible will be utilized. Bottom ash and balance fly ash will be transported by trucks to
ash disposal area.
Bottom ash Storage Silo

There will be individual bottom ash storage silo. Bottom ash collected in the silo will be
loaded into trucks through feeder for further process.
Fly ash storage silo
There will be one fly ash silo each for 1 x 60 MW, 1 x 180 MW & 1 x 300 MW. Each Fly
ash silo will be provided with two outlets. First outlet will be used to load ash into the
open trucks in conditioned form for further disposal. For this purpose a rotary feeder
and ash conditioner will be provided. The other outlet will be used to dispose ash in
closed containers for utilization. This outlet will be provided with rotary feeder and a
motor operated retractable chute.

ANNEXURE – XI
ON-SITE & OFF-SITE EMERGENCY PLAN

On-Site & Off-Site Emergency Plan
At ARS Power Plant 60 MW emergency has been categorized in three level i.e.
LEVEL - 1
The level of emergency which is controllable within the plant / area.
Emergency may be due to:
a) Small spot of fire in the plant.
b) Collapse of small equipments.
LEVEL – 2
The emergency which is confinable within the Plant premises.
Emergency may be due to:
a) Big fire in factory premises
b) Medium scale explosion
LEVEL- 3
Likelihood of vapor cloud with formation of toxic / flammable gases
Drifting and affecting the general public (i.e. outside of plant premises).
This type of emergency arises out of:
a) Explosion in Coal Mills / bunker / feeder/ TG Area /APH / Lube Oil

Tanks/Tunnel/ high pressure vessels.
b) Fire in Lube Oil Storage Area/PLANT/STORES/chemical lab/HFO, LDO storage/

MOT/ Electrical fires (DG sets/cable gallery/MCC/switch gear/switch
yard/transformer/cable trays).
List of the key personnel of ARS.
NAME & DESIGNATION OFFICE CONTACT NO RESIDENCE PHONE

Mr. A. Xavier-VP(Project) 9566000624
Mr.Hari prasanna(O&M-Mgr) 9944481832
Mr.Saravanan(HOD-Mech) 9500062118
Mr.Gnanagiri(DM-Mech) 9790817901
Mr.Jeyachandran(DM-Elect) 9952973962
Mr.Niranjan(HOD-C&I) 9500058326
Mr.A.K.JHA(Manager-WTP) 9840268411
Mr.Santhosh(HOD-CIVIL) 9551687171
Mr.Sahil sethi (HOD-Weighment) 9566199951
Mr.V.K.Raja(HOD-Coal logistics) 8939852217
Mr.Venkata Raghavan-(Store Mgr) 9840295985
Mr.Arul Jothi ASSTT. MANAGER 9840076941
Mr.Balu Mahendran(HR&Admin) 9840939417
Mr.Karthik(EHS Officer) 9626156399

List of the key personnel of OEG (O&M).
NAME & DESIGNATION OFFICE CONTACT NO RESIDENCE PHONE

Mr. Saravanan-DM 9840664978
Shift in charge 9840665493
Mr.Ravindran(Mech Mgr) 9840667564
Mr.Rajavel(Elect Mgr) 9840668965
Mr.Stallin(C& I Head) 9840664582
EMERGENCY PREPAREDNESS and RESPONSE PLAN

REVIEW ON ROLE & RESPONSIBILITIES OF EMERGENCY
COORDINATORS:
• Incident Evaluation and Classification of On-Site Emergency Declaration.

• Off-site and External Agency Notification (When required)
• Implementation of On-site Response Actions
• Implementation of Protective Actions and Evacuation.
• Coordination of Response Actions with External Agencies.
• Management of Emergency Resources
Responsibilities of On-site Emergency co-ordinators

Site Chief Incident Controller: Head (O&M)
Succession: Manager – WTP
Responsibilities:
The Site
Chief Controller will assume the overall responsibility for the factory
site and its personnel.
Assigned resposibilities are :
• Over all controller of the emergency
• Liaise with other coordinators
• Activate evacuation if required
• Inform MD/ED about action plan and actions
• Inform district collector about the emergency if needed
• Release information to media in coordination with the welfare,
media and transport coordinators
• Declare off-site emergency when the effects of emergency
threatens to enlarge
INCIDENT CONTROLLER: Shift In-charge

• Interact with other coordinators and get first hand information for
constant review and continuous updating.
• Activate emergency plant shutdown if required
• Ensure implementation of evacuation plan at site if activated

• Liaise with coordinators of emergency services (First aid, Security, Fire

and safety)
• Liaise with external agencies like TNEB/Metro water for uninterrupted
power and water supply
• Liaise with port authorities to stop coal receipt
• Ensure stoppage of all hot works
• Coordinate with chief incident controller to shutdown / isolation of units
/sections
• Coordinate for head count at the assembly points for safe evacuation
• Ensure adequate water availability in both fire water storages
• Ensure uninterrupted power supply for handling emergency – fire water
pumps and plant site lighting
• Liaise with nearby available fire fighting bodies for help if needed
• Evacuate all non essential personnel from affected area
• Keep Site Chief Controller informed about the situation on continuous
basis
External Resources and Communication Coordinator: Manager –

Administration
Succession Coordinator : Senior Engineer - Instrumentation
Responsibilities:
• Ensure catering facilities, transport facilities and resting facilities
for employees and emergency crew
• Arrange to inform family members of employees as required
• Liaise with press/media in consultation with chief site controller
• Liaise with state , central govt and statutory bodies including
police in respect of the nature and magnitude of the incident etc
in consultation with site chief controller
• Arrange transportation for emergency use if required
• Arrange for vehicles to evacuate people from assembly points if
evacuation declared
• Liaise with district / state transport authorities if required
• Arrange for refuelling of vehicles
• Liaise with medical coordinator for effective handling of medical
emergencies
Security coordinator:
• Prevent entry of unauthorised persons
• Release security personnel to assist fire marshal
• Direct the mutual aid vehicle to scene of fire
• Control traffic at the site
• Cordon off the incident site
• Arrange to remove all parked vehicles out of site premises
• Inform all key persons about the incident location

ENGINEERING COORDINATOR : MECHANICAL/ELECTRICAL /

INSTRUMENTATION/STORES
Senior Engineer – Electrical
Succession – Stores in-charge
Responsibilities:
• Ensure availability of materials required by the incident
controller
• Enact emergency procurement from neighbouring industries or
local dealers as required
• Arrange to man material issue counter
• Arrange to stop all hot works and height works
• Arrange to depute a team from mechanical to assist incident
controller
• Arrange to provide necessary mechanical and electrical
assistance as required
• Ensure all contract workers and employees not involved in fire
fighting, moved to the designated assembly point
• If evacuation is declared ensure head count of people evacuated
and coordinate with welfare / media / transport coordinates for
smooth boarding and drop of people to designated rallying post
• Ensure uninterrupted availability of proper communication
facilities like telephone,UHS,hand sets
• Mobilise additional UHF handsets for emergency use
Safety coordinator: Manager – Safety
Responsibilities:
• Monitor all fire fighting operations
• Liaise with Fire Marshall for effective control
• Liaise with nearby available fire fighting bodies for help if
required
• Ensure turn out of mutual aid at site
• Organise relieving groups for fire fighting through shift
coordinator
• Ensure adequate resources for fire fighting
MEDICAL SERVICES coordinator: Doctor

Responsibilities:
• Arrange first aid medical equipments at field as per site
coordinator instruction
• Ensure adequate medical facilities at emergency centre
• Organise first aid team, using the trained personnel
• Liaise with administration coordinator for seeking hospital
services and transport of victims

PROJECT HEAD: VP – Projects
Responsibilities:
• Coordinate all emergency management activities if project sites
are involved in the emergency
• Liaise with different project contractors
• Ensure stoppage of all hot and height works
• Ensure all personnel are assembled at the proper designated
location
• Ensure closing of all fire water consumption points other than
used for fire fighting
• If evacuation is declared ensure head count of people evacuated
and coordinate with welfare/media/transport coordinator for
smooth boarding and drop of people to designated rallying post
Telephone Operator On Duty:
• He/she will follow the instructions given by

administration coordinator, time to time
HEAD – FIRE CREW : HOD - Mechanical

Succession : Manager - Safety
Responsibilities:
• Mobilise fire fighting team to the scene of fire
• Advise on safe fire fighting distance
• Advise on fire fighting based on wind direction and severity
of fire
• Coordinate with incident controller , to effect isolation of fire
source / equipment/other equipment
• Organise standby crew for fire fighting and releiving
arrangements
• Coordinate and implement the instructions given by site chief
controller / incident controller
• Organise and advise the state / mutual aid fire team on arrival
at site
• Responsible to bring the emergency situation under control
• inform site chief controller / incident controller on fire
fighting needs
• responsible for the safety of his fire crew during fire fighting
operation
AMBULANCE DRIVER:
Responsibilities:
• follow the instructions and direction given by site chief
controller
• at the scenario, keep the engine running and do not switch-off
the engine as it may be the potential ignition source
• Always be ready with the vehicle anticipating emergency
services

SITE CHIEF INCIDENT CONTROLLER: BROADER SCOPE
• Analyze the emergency and decide on the emergency level warning.

• Direct, coordinate and supervise the emergency response activities
• Direct the shutdown (whole plant area, a particular unit/operation, as required),
isolation of valves, evacuation, shutting down of operations like unloading,
transfer, etc. through Incident Controller and if required, take any other
appropriate action that may be necessary for the emergency response.
• Ensure accountability of On-site and Off-site personnel for protection, safety etc.
• Ensure that the casualties if any are given medical attention and that the relatives
are informed, if necessary.
• Arrange for relief of personnel when emergency is prolonged.
• Liaison with the off-site emergency response govt departments and organizations
such as fire and police officials and other statutory bodies and advise them of all
likely effects of the incident - outside the complex.
• Ensure that the security staff at all the gates regulates traffic movement within the
facility.
• Issue authorized statement to the news media, if required.
• Ensure preservation of evidence for inquiries to be conducted by statutory
authorities. He should consider and take photographs to preserve the evidence and
first incident record.
• Also once the emergency is over then it should be ensured that the whole site is
first videotaped and then fill in the Incident First Information report. This would
not only help in identifying and preserving the evidence in a film but would also
be of a great help to the investigating agencies and clean up agencies.
• Authorize the termination of emergency situation by sounding of ‘All Clear’
siren, which will be a continuous, long siren for two minute.
INCIDENT CONTROLLER: BROAD SCOPE
• Typically the person fulfilling this function should have good operational
familiarity with the facility and its response organization - the shift in charge.
• When deemed appropriate, the incident controller position may coincide with the
site chief incident controller function and both positions assigned to just two
person.
He shall
• Take immediate charge of the incident site and arrange all rescue operation to
control the emergency situation.
• Be in constant communication with site chief incident controller and accordingly
organize and direct the emergency response activities keeping in mind the safety
of personnel and minimizing loss and damage to installation.
• Formulate strategies and advise the site chief incident controller of the actions to
be taken to mitigate the consequences of the accident.
• Maintain direct communications with the members of the emergency response
Coordinators team.

• Coordinate the activities aimed at organizing, requesting, and obtaining additional

resources (both as equipment and personnel) to support the field operations.
• Check for casualties.
• Arrange for rescue of trapped workers and those in a state of shock.
• Get all non essential workers safely evacuated after stopping all those jobs, which
are not required during an emergency and instruct them to reach appropriate
assembly point.
• Direct the shutting down of plant, unit, material handling operations (enclosing of
valves, conveyors, etc.) and evacuation from the plant and call outside emergency
service, if necessary.
• Allocate predetermined and additional job to members of the emergency squad.
• Report all developments to the site chief incident controller.
• Preserve all evidence for use in the subsequent inquiry.
ADMINISTRATION COORDINATOR:
• Immediately proceed to the Emergency on learning about the incident or on
hearing the emergency siren.
• Immediately take out the list of all the people present in the plant (including
contractor people) department wise.
• Issue department wise list to all the sub departmental heads and ask for a head
count.
• Make a list of all the missing people, if any.
• Generate a list of all the emergency response team members in the plant and keep
it on standby to make it available to site chief incident controller, if and when
needed.
• Work as a liaison officer during the emergency and liaison with police, district
administration, surrounding industries, factory directorate, and general public.
• Arrange refreshment, lunch, dinner etc. for emergency team
• Under the direction of the site chief incident controller handle police, press and
other inquiries, receive reports of roll call from emergency assembly areas and
pass on the absenteeism information to the incident controller.
• Ensure that casualties receive adequate and immediate medical attention.
• Inform the nearby hospitals and call for ambulance, if required.
• Maintain prior agreed inventory of emergency equipment in the plant and make
up for shortages.(coordinate with engineering coordinator)
• In addition, this function has the important task of keeping chronological records
of what is happening during the emergency, and preparing reports for the site
chief incident controller and his staff. This includes.
1. Recording any change in the emergency action level status.
2. Keeping track of all external agencies notified.
3. Keeping track of emergency personnel intervening.
4. Keeping track of emergency personnel notified and arriving at the scene.
5. Keeping a record of all events affecting the emergency.
6. Keeping a record of all of the decisions made and emergency actions taken during
the emergency operations.

7. Updating maps and wall charts displaying the spreading of the emergency (e.g.
units affected by fire, areas affected by evacuation orders), and maintaining a
record of them.
8. Recording the arrival of special emergency materials or equipment (this may be
especially important for later financial accountability).
9. Recording any fact of relevance occurring during the emergency.
PERSONNEL OF THE AFFECTED AREA

They shall:
• Continue to handle the emergency as per the laid down procedures and as guided
by the incident controller.
• Avoid crowding of the affected area by unwanted personnel.
• Stop all non essential jobs/unwanted operations.
• Remove unwanted persons from the area to a “Safe Assembly Point”.
PERSONNEL OF NON AFFECTED AREAS
They shall:
• Promptly relieve the members of the team and direct them to rush to the scene of
incident.
• Those employees who may be in the canteen or toilet or any other place, on
hearing the alarm, shall immediately rush back to the department/facility.
• Act as per the instructions of the incident controller or your own plant shift
engineer.
• All the employees shall confine themselves at the place of work and wait for
further instructions.
• The personnel of the non affected area shall take adequate steps to safe guard
important documents if the area is likely to be affected.
• Contractor employees shall stop their work and report at the safe assembly points
POSSIBLE TYPES OF MAJOR INCIDENTS

The possible types of accidents/emergencies that could occur in the plant are :
a) Boiler / TG Area / APH
Fire & Explosion in the Boiler
Fire in Coal Mills / bunker / feeder
Fire in TG Area /APH / Lube Oil Tanks
b) CHP Area
Fire & explosion in tunnel
Fire in Coal conveyors
Fire in coal at coal yard
c) Other Services Department
Fire in Lube Oil Storage Area/PLANT/STORES/chemical lab/HFO, LDO storage/
MOT/
Electrical fires (DG sets/cable gallery/MCC/switch gear/switch yard/transformer/cable
trays)
d) Bush fire.
“DONOT ATTEMPT ANY HEROIC EFFORT” – be an ARS team.

ANNEXURE – XII
ADMINISTRATIVE SET-UP MAP


ARS Metals Pvt. Ltd.
PRE-FEASIBILITY REPORT
ON
ENVIRONMENTAL ASPECTS
OF
PROPOSED
AUGMENTATION OF CAPACITY
from 1 x 60 MW to 1 x 180 MW &

installation of additional 1 x 300 MW
within/adjacent to the Existing 2 x 60 MW Plant Site
at
Sithurnatham, Sirupuzhalpettai & Eguvarpalayam Villages,

Gummidipoondi Taluk, Thiruvallur District, Tamil Nadu.
February 2014
CONTENTS
1.0 EXECUTIVE SUMMARY ................................................................................ 1

2.0 INTRODUCTION ............................................................................................ 3
3.0 ABOUT PROJECT PROPONENT.................................................................. 3
4.0 THE PROPOSED PROJECT............................................................................ 3
5.0 PROJECT LOCATION .................................................................................... 4
6.0 LAND USE/LAND CLASSIFICATION ....................................................... 7
7.0 RAW MATERIALS CONSUMPTION .......................................................... 7
8.0 FUEL TRANSPORTATION............................................................................ 7
9.0 PROCESS DESCRIPTION............................................................................... 8
10.0 RAW WATER REQUIREMENT .................................................................. 13
11.0 ENERGY CONSUMPTION .......................................................................... 15
12.0 WORK FORCE ............................................................................................... 15
13.0 WASTE & WASTE MANAGEMENT ......................................................... 15
13.1 Air Pollution ......................................................................................... 15
13.2 Waste Water Management .................................................................... 18
13.3 Solid Waste Management ..................................................................... 19
14.0 SITE ANALYSIS, PLANNING & REHABILITATION AND
RESETTLEMENT ...................................................................................................... 19
15.0 PROJECT SCHEDULE & COST ESTIMATION ........................................ 19
16.0 CONCLUSION ............................................................................................... 20
Fig 1.0 Project Location .………………………………………………………….5

Fig 2.0 Plant Layout ………………………………………………………………6
1.0 EXECUTIVE SUMMARY
The Proposed activity is Augmentation from 60 MW to 180 MW and proposed

additional 1 x 300 MW coal based thermal power plant within the existing operating
plant site, wherein 1 x 60 MW is already in operation.
Project Location
The location of the project is at Sithurnatham, Sirupuzhalpettai & Eguvarpalayam Villages,
Gummidipoondi Taluk, Thiruvallur District, Tamil Nadu. The plant site is devoid of any
forest land. There are no areas of ecological sensitivity or notified bio diversity area
or wildlife sanctuary etc. within 10 kms radius of the plant site.
Project Proponent
ARS Metals Private Limited is a major producer of TMT bars in South India. Now it
has proposed to augment the existing 1 x 60 MW to 1 x 180 MW and additionally
proposed to install 1 x 300 MW coal based power plant within/adjacent to the
existing plant site, wherein 1 x 60 MW is already in operation.
The purpose of proposed expansion is to meet its captive requirement and the excess
power is given to state Grid.
Products & Capacity

Augmentation of Thermal Power generation using coal from 60 MW to 180 MW and
proposed addition of 1 x 300 MW within/adjacent to the existing operation of 1 x 60
MW power plant site.
Pre-feasibility Report 1 ARS - Gummidipoondi

Raw Material Requirement

The raw material used will be Imported Coal.
The details of coal consumption are as follows
Existing Augmentation Proposed Addition Upon Expansion

1 x 60MW from 1 x 60 MW to 1 x 300 MW
1 x 180 MW
1000 T/D 2571 T/D 4107 T/D 7678 T/D
Raw Water Requirement & Source

Main Condensate is based on Air Condensate Cooling. The water requirement are as
follows:
Existing For Upon Expansion

1 x 60 MW 180 MW & 300 MW
48 KLD 250 KLD 298 KLD
The source of water is met from Harvested Rain Water. Reservoir with the capacity
of 70000 m³ has already been constructed to store the harvested rain water. Also
Ground water clearance for 800 KLD already obtained. It is proposed to construct
additional reservoir for rain water harvesting.
Solid Waste Generation & Method of Disposal

The details of total Ash generation are as follows.
Existing 60MW Proposed 180MW Proposed 300MW Upon Expansion

50T/D 155T/D 246.42T/D 451.42 T/D
Fly ash is being completely disposed & Bottom ash is stored in ash dyke.
Man Power
The existing man power is 150 and upon expansion, the man power will increase to
350.
Project Cost
The project cost for expansion will be Rs.2400/- Crores.
2.0 INTRODUCTION
India's Electricity Act 2003 introduced structural changes to the power industry,
permitting private investment for the first time since 1948. This allowed power
producers to sell power directly to industrial consumers under the Group Captive
model.
ARS has been a pioneer in developing the Group Captive model which allows the
flexibility to choose between two market routes. Key features of the Group Captive
and Merchant model are
Group Captive Merchant

Bilateral arrangements with consumers / Sales with traders directly
traders / utilities
Flexibility and risks of spot pricing
Offering reliable, consistent power supply,
even during peak periods Returns dependent on available
pricing
Attractive prices relative to alternative
tariffs Limited to one day future trading
3.0 ABOUT PROJECT PROPONENT
ARS Metals Private Limited is a major producer of TMT bars in South India.
4.0 THE PROPOSED PROJECT
The proposed augmentation from 160 MW to 180 MW and proposed addition of 1 x

300 MW is coal based thermal power plant within/adjacent to the existing plant
premises, wherein 1 x 60 MW is already in operation. The Plant is based on Air
Cooled main condensate cooling, finfan auxiliary cooling. The fuel used is imported
coal.

5.0 PROJECT LOCATION
The proposed augmentation / expansion is located within/adjacent to the existing

plant premises at Sithurnatham, Sirupulalpettai & Eguvarpalayam Villages,
Gummidipoondi Taluk, Thiruvallur District, Tamil Nadu.
The project location is as shown in Fig.1.0 and the Plant Layout of the project is as
shown in Fig 2.0.

Fig 1.0 Location Map

Fig 2.0 Plant Layout

6.0 LAND USE/LAND CLASSIFICATION
The Augmentation of Capacity ie from 60 MW to 180 MW and proposed

addition of 1 x 300 MW is within/adjacent to the exiting plant site, wherein 1
x 60 MW is already under operation.
7.0 RAW MATERIALS CONSUMPTION
The main raw material is coal which is imported from Indonesia.

The details of coal consumption are as follows
Existing Augmentation Proposed Addition Upon Expansion

1 x 60MW from 1 x 60 MW to 1 x 300 MW
1 x 180 MW
1000 T/D 2571 T/D 4107 T/D 7678 T/D
Station Heat Rate : 2300 & 2400 Kcal/KWh.

Characteristics of Coal
S. Particulars Imported Coal

No.
1 Gross Calorific Value 4000 k cal/kg
2 Moisture 25 %
3 Ash 10%
4 Fixed Carbon 37%
5 Sulphur 0.5%
6 Volatile Matter 38 %
8.0 FUEL TRANSPORTATION
The existing road, viz. NH-5, SH-52 will be used for coal transportation.
Imported Coal will be shipped by sea and unloaded at Ennore Port and then
will be transported by road by 40T capacity container.
It is also proposed to explore the possible of rain transportation, although at

present, there is no, rail route connecting Gummidipoondi Railway Station to
Plant Site.

9.0 PROCESS DESCRIPTION
The details of equipments are as follows
1 Boiler 1 x 235.13 TPH (Existing 1 x 60 MW)

1 x 563 TPH (from 60 MW to 180 MW)
1 x 950 TPH (Proposed 300 MW)
CFBC/Pulverized Coal fired, natural
circulation boilers.
2 Steam Turbine 1 x 60 MW, 1 x 180 MW & 1 x 300 MW
condensing Steam Turbine.
3 Electrical Generator There will three generator with rated 60
MW, 11KV, 50 Hz, 3 ph and 0.8 PF
180MW,
300MW,
4 Coal Handling Ground hoppers, stacker reclaimers and

double stream conveying system.
5 Electro-Static Precipitator 6 Stage ESPs for each Boiler
6 Ash Handling Dry Ash Collection
7 Condenser Air Cooled Condenser
8 Auxiliary Cooling System Finfan coolers for cooling of turbine,
generator and boiler auxiliaries
9 Chimney Single chimey of 145 m height for 60 MW
& 180 MW & 132 m height for 300 MW
10 HFO/LDO Storage Tanks 2 x 300 KL HFO tanks and 2 x 150 kL LDO
tanks
11 Switchyard, Generator 230 KV System
Transformer and Station
Transformer
The power plant would use coal as fuel in its boilers. The plant would consist
of 235.13 TPH (Existing), 593 TPH & 950 TPH (Proposed) CFBC/pulverized
Coal fired natural circulation boiler producing superheated steam at 93
Kg/cm2 and at 540ºC together with associated auxiliaries.
The steam turbine unit consists of 540 MW (Gross) [60 MW Existing, 180 MW
& 300 MW Proposed] condensing steam turbine generator together with Air
cooled condenser and associated auxiliaries. Based on average gross calorific

value of coal as 4000 Kcal/kg, the plant would require about 7678 TPD of
Imported Coal,
The steam generators of the proposed Thermal Power Plant will be of

CFBC/pulverized fuel firing with Imported coal. The steam generator will
consist of Air cooled furnace, radiant, convection super heaters, economizer,
air pre heaters etc. Soot blowers will be provided at strategic locations and
will be designed for sequential fully automatic operation from the Unit
Control Room. The steam generator will be provided with coal mills along
with individual raw coal feeders and coal bunkers. The steam generators will
be equipped with facilities for Heavy Furnace Oil / LDO firing for start-up
and for flame stabilization at low loads. Electrostatic precipitator (ESP) with
fly ash hoppers will be provided for the collection of fly ash. The steam
turbine will drive the turbo generator at 3000 rpm. The steam generators will
be designed as semi –outdoor equipment while the turbine generator set with
all auxiliary and feed cycle equipment will be located indoors. The Figure
below shows the simplified process flow diagram of the proposed Thermal
power plant.

Proposed Flow Diagram of Thermal Power Plant
COAL
WATER
POWER
MILL
BOILER TURBINE GENERATOR
ESP
AIR COOLED
CONDENSOR
SILO
CHIMNEY SALE /
DISPOSAL

Furnace
The furnace will be designed such that the heat release rates will be optimum
at 100% steam generator maximum continuous rating (SGMCR) condition.
The configuration of the furnace will be such that flame impingement on any
section of the furnace is avoided over the entire load range.
The furnace will have hopper bottom with stainless steel seal plates which will
be suitable for connection to a water impounded ash hopper. A suitable
sealing arrangement for connecting to the water impounded ash hopper will
also be provided.
The circulation system will ensure adequate circulation ratio during rapid
start-ups and load changes to prevent overheating of the water wall tubes
with maximum possible heat flux in the furnace. Suitable allowances will be
provided for all the water wall tubes to counter the erosion conditions.
Boiler
The boiler will be CFBC/pulverized coal fired, single drum, with membrane
wall construction, balanced draft boiler natural circulation semi outdoor type.
Superheat of the steam is controlled by inter-stage spray water attemperation.
The final superheated steam at a pressure of 93 Kg/cm2 and at 540ºC is

supplied to steam turbine unit through HP steam piping.
Steam Turbine Generator
The steam turbine will be designed to meet the requirements of the latest IEC
standard. It will be designed for quick start-up rates and to withstand rapid

load fluctuations without causing undue thermal stresses and strains in the
components of steam turbine. Suitable rotor and casing heating devices to
meet this requirement if required will be provided. Steam turbine will be
provided with aesthetic and acoustic enclosure. The Steam Turbine will have
the following systems for its optimum performance and safe operation;
• Steam admission valves

• Turning gear
• Steam turbine gland steam sealing system
• Steam turbine lubricating system
• Oil coolers
• Steam turbine governing system and accessory equipment
• Emergency over speed trip device
• Steam turbine protection system
• Initial pressure regulator
• Protection against water induction and over speeding
• Exhaust temperature limiting equipment
• Pressure relief diaphragms
• Vacuum breaker valves
• Steam turbine supervisory equipment
• Automatic Turbine Run-up System (ATRS)
• Steam Turbine By-pass System
• Air cooled Condensor
• Condensate Extraction Pumps and Accessories
• Closed Feed Water Heaters and Accessories
• Boiler Feed Pumps

10.0 RAW WATER REQUIREMENT
Main Condensate is based on Air Condensate Cooling, and Auxiliary Cooling

is Finfan Cooling.
The details of Water Requirement are as follows
Existing For Upon Expansion

1 x 60 MW 180 MW & 300 MW
48 KLD 250 KLD 298 KLD
Source of Water
The total water requirement will be met from harvested rain water.
A Rain Water Reservoir constructed for harvesting rainwater through storm

water drains. Capacity of reservoir is 70000 m³.
Additional rain water reservoir proposed to be constructed.
However, Ground Water Clearance has also been obtained for drawl upto 800
KLD.
Water Balance Diagram is as follows:

WATER BALANCE
All Values are in KLD
36 Boiler Make-up 35
1 x 60 MW
Ground Water
/Rain Water
Reservoir 200 Boiler Make-up 190
1 x 180 MW &
68 1 x 300 MW 225
Raw
Cooling Pond I
Water 298
Cooling Pond II
225
230
6 DM PLANT 6
1 x 60 MW
48 Neutralization
Pit
42 DM PLANT 42
1 x 180 MW & 273
1 x 300 MW
Guard Pond
1 x 60 MW
STP
1 x 180 MW &
1 x 300 MW Greenbelt
230 RO Plant
43
Ash Quenching/
Coal Dust Suppression/ 43 RO
REJECT
Greenbelt

11.0 ENERGY CONSUMPTION
It is a proposed augmentation of power generation facility and hence the

auxiliary power requirement will be met internally.
12.0 WORK FORCE
The existing man power is 150 and upon expansion, the man power will
increase to 350.
13.0 WASTE & WASTE MANAGEMENT
13.1 Air Pollution
The Stack height will remain the same at 145 Metres for 1 x 60 MW and
1x180 MW.
A Stack proposed to construct with a height of 132m for 1 x 300, the

calculation of which is as follows.
Stack Height Calculation for 1 x 300 MW
The daily consumption of coal is around 4107 Tonnes

The rate of SO2 emission due to usage of coal is calculated as given below
Sulphur content = 0.5%

S = (4107 x 0.5/100) = 20.535 T/D
SO2 = 20.535 x 2 T/D
= 41.07 T/D = 1711.25 kg/hr
SO2 emission = 1711.25 kg/hr = 475.35 g/s

Stack height calculation:
H = 14 Q0.3
Where,
H = height of the Stack
Q = SO2 Concentration in Kg/hr.
Hence
H = 14 x (1711.25)0.3 = 14 x 9.332 = 130.65 m
The stack height already constructed is however 132 meters, which is

adequate.
Stack Emission Characteristics
Stack No 1 1
Material of Construction RCC RCC
Stack attached to 1 x 60 MW & 1 x 300 MW
1 x 180 MW
Stack height (m) 145 132
Stack diameter (mm) approx.. 5250 6000
Volume Flow Rate (m3/s) 475.45 593.74
Velocity of flue gas (m/s) 22.0 21.0
Temperature of flue gas (°C) 140 140
Flue gas specific volume ( kg / Nm³) 1.3 1.3
Fuel Consumption (Kg/s) 42.71 47.92
Sulphur content (% w/w) 0.5 0.5
Emission rate – NOx (g/s) 384.38 427.81
Emission rate – SO2 (g/s) 427.08 475.35
Emission rate – SPM (g/s) 21.5 29.69
The following environmental protection or pollution control systems have

already been considered for mitigation of impacts on Air Environment.
• 145 m & 132 m tall stacks for flue gas emission.

• Space provision for retrofitting FGD (Flue Gas Desulfurization)

systems.
• High efficiency ESPs to reduce SPM level in the exhaust gas to
<50mg/Nm³.
• Dust suppression and extraction system at Handling Plant area to
Control Fugitive Emission.
• Green belt development and afforestation in the plant and ash disposal
areas.
• A minimum water depth will be maintained in the ash pond to prevent
fugitive dust emission.
• Use of bag filters at all transfer points.
• Use of limestone to limit SO2 emission.
High efficiency Electrostatic Precipitator of 99.9% are provided for limiting

SPM concentration in the flue gas to less than 50 mg/Nm³. The tall stack of
145 m & 132 m height based on maximum SO2 concentration in the flue gas is
provided for natural dispersion at high elevation so that ground level
concentration are within acceptable limits.
The emission of NOX, is reduced by burning fuel at a lower temperature and

shortening the throughput time of the fuel. NOX is also controlled by
operating at low excess air.
Fugitive Emissions
To control fugitive emissions from process units in the plant, the following
measures are already in place.
• Tarring of roads inside the factory.

• Preventive maintenance of valves and other equipments.
• Green belt on all sides within the project boundary, and community
plantation around the unit with help of local area development authorities
have already been done.
• Ambient air quality and stack/fugitive emissions monitored regularly.
• In-plant training provided to the plant personnel on operation and
maintenance of dust collectors, techniques of dust emission
measurements, particle size analysis etc.
• Effective operation and maintenance of pollution control system is
ensured to contain the emissions/keep them within the CPCB limits
• A good house keeping consisting of simple, obvious task of cleaning up
spills, removing accumulations around processing equipment and in
general keeping things neat and clean form a part of normal operation and
maintenance procedure
Measures for arresting fugitive dust emissions along with the envisaged
pollution control equipments are adequate and will help to have a healthy
and cleaner environment inside the plant thereby improve the productivity
and the efficiency of the workers as well as that of plant machinery.
13.2 Waste Water Management
The quantity of waste water generation are given below
Waste Water Generation in KLD

Existing For Upon
1 x 60 MW 180 MW & 300 MW Expansion
Boiler Blow Down 35 190 225
D.M. Plant 6 42 48
Regeneration Waste
Domestic Sewage 4.8 6.4 11.2
Boiler Blowdown & DM. Plant regeneration waste water is at present treated
in 2-stage RO Plant.

Upon Expansion,
Daily water requirement will be 68 KLD. About 273 KLD will be recycled.
Boiler Blow down & DM Plant Regeneration Waste Water from proposed
Augmentation/ Expansion will also be treated in 2-stage RO Plant.
230 KLD is used for boiler make-up /D.M Plant and 43 KLD used for Ash
Quenching/ Coal Dust Suppression/ Greenbelt.
Domestic Sewage is treated in Sewage Treatment Plant & used for greenbelt.
Hence, resulting in Zero Discharge.
13.3 Solid Waste Management
The details of total Ash generation are as follows.
Existing Augmentation from 60 Proposed Upon Expansion

60MW MW to 180MW 300MW
50 T/D 155 T/D 246.42 T/D 451.42 T/D
Fly ash is being completely disposed & Bottom ash is stored in ash dyke.
14.0 SITE ANALYSIS, PLANNING & REHABILITATION AND

RESETTLEMENT
The augmentation of the capacity 60 MW to 180 MW & proposed addition of

1 x 300 MW is within/adjacent to the exiting the plant site wherein 1 x 60 MW
is already under operation.
15.0 PROJECT SCHEDULE & COST ESTIMATION
The construction of 180 MW & 300 MW power plant is proposed to start upon
obtaining Clearance from MoEF/Consent from TNPCB, and scheduled to be
commissioned in 18 months from obtaining clearance.
The project cost for expansion will be Rs.2400/- Crores.

16.0 CONCLUSION
The proposed augmentation/expansion will result in better utilization

without any modification to the majority of existing environment.
Adequate measures already proposed to mitigate negative impacts, and thus

aid positive impacts on environment due to the proposed augmentation /
expansion.

2014 4 02 Apr 2014 1456559071FORM 1 ARS

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Augmentation from 60 MW to 180 MW & Proposed Additional 300 MW

8. Does it attract the specific : No.

11. Nearest Town, City, District : Town - Gummidipoondi - 6.1 km

Form 1 1 ARS, Gummidipoondi

12. Village Panchayats, Zilla Parishad, : Gummidipoondi

14. Registered Address : D-109, 2nd Floor, LBR complex,

15. Address for correspondence : D-109, 2nd Floor, LBR complex,

Name : Rajesh Bhatia

21. Whether the proposal involves : No

22. Whether there is any Government : No

Form 1 2 ARS, Gummidipoondi

24. Whether there is any litigation : Nil

S. No. Information/Checklist Yes/No Details thereof (with approximate

The workers Quarters is also provided

Form 1 3 ARS, Gummidipoondi

About 300 workers reside at site.

Form 1 4 ARS, Gummidipoondi

1.21 Impoundment, damming, No -

Form 1 5 ARS, Gummidipoondi

2. Use of Natural resources for construction or operation of the Project (such as

S. No. Information/Checklist Yes/No Details thereof (with approximate

2.3 Minerals (MT) Yes Coal

2.4 Construction material - stone, Yes Predominantly Steel Structures.

Form 1 6 ARS, Gummidipoondi

3. Use, storage, transport, handling or production of substances or materials,

S. No. Information/Checklist Yes/No Details thereof (with approximate

4. Production of solid wastes during construction or operation or decommissioning

S. No. Information/Checklist Yes/No Details thereof (with

4.5 Surplus product No -

Form 1 7 ARS, Gummidipoondi

4.7 Construction or demolition wastes No -

5. Release of pollutants or any hazardous, toxic or noxious substances to air

S. No. Information/Checklist confirmation Yes/No Details thereof (with

Form 1 8 ARS, Gummidipoondi

6. Generation of Noise and Vibration, and Emissions of Light and Heat

S. No. Information/Checklist Yes/No Details thereof (with

7. Risks of contamination of land or water from releases of pollutants into the

S.No. Information/Checklist Yes/No Details thereof (with approximate

• Boiler Blowdown & DM. Plant

Form 1 9 ARS, Gummidipoondi

• About 273 KLD will be recycled.

8. Risk of accidents during construction or operation of the Project, which could

S.No. Information/Checklist confirmation Yes/No Details thereof (with

Form 1 10 ARS, Gummidipoondi

9. Factors which should be considered (such as consequential development)

S.No. Information/Checklist confirmation Yes/No Details thereof (with

III Environmental Sensitivity

S.No. Areas Name/ Aerial distance (within 15

Form 1 11 ARS, Gummidipoondi

4. Inland, coastal, marine or underground Yes Araniyar River – 8.0 kms

IV Proposed Terms of Reference for This application is requesting for

Signature of the applicant

Form 1 12 ARS, Gummidipoondi

Annexure I Copy of Environmental Clearance

Annexure II Copy of Consent to Establishment

Annexure III Soil Investigation Report

Annexure IV Plant Layout

Annexure V Process Description

Annexure VI Copy of CGWA Clearance &

Annexure VII Drainage and Water Bodies Map

Annexure VIII Stack Emission Characteristics

Annexure IX Fugitive Emission Control

Annexure X Air Pollution Control